Abstract:
A connector assembly comprising a housing having a jack interface that has a receptacle jack therein, which is configured to receive a plug. The connector assembly also includes a sensor bezel removably attachable to said jack interface. The sensor bezel includes an outer frame configured to engage the jack interface. The sensor bezel also includes jack cavities extending therethrough to allow passage of a plug when inserted into said receptacle jack. A sensor array is secured to the outer frame proximate the jack cavities. The sensor array comprises a sensor contact overlaying the jack interface. The sensor contact is aligned with, and configured to engage, a sensor probe associated with a plug insertable into the receptacle jack.

Description:
BACKGROUND OF THE INVENTION 
     The present invention generally relates to a connector that connects electronic components in a network and more particularly relates to an interconnect module or cassette that connects network components to a sensor component. 
     In order to better operate large electronic networks, sensor systems have been developed to monitor connections between components within the network. The sensor system typically includes an interconnect module that is retained in a patch panel, or any number of other network structures, and interconnects two separate network components. The interconnect module includes receptacle jacks, such as modular jacks, at a mating face. These jacks receive patch cords that in turn are connected to a first network component. Each patch cord includes an electrical cable comprised of signal wires connected to a plug at one end. The plug is received within a corresponding receptacle jack such that the signal wires in the electrical cable are electrically connected to signal contacts extending from a rear side of the interconnect module. The signal contacts are in turn connected to a second set of signal wires that extend to a second network component. Thus, the interconnect module electrically interconnects the first and second network components. 
     Conventional interconnect modules are joined with separate sensor configurations that enable the network to determine when a plug is joined with a receptacle jack. FIGS. 5 and 6 illustrate a conventional interconnect module  600  in combination with a conventional sensor configuration. The sensor configuration includes a separate flexible etched circuit (FEC)  602  containing several sensor contacts  604  arranged on a strip  606 . The strip  606  is glued to the face plate  608  near the receptacle jacks  610 . Traces extend from each sensor contact  604  along the length of the FEC  602  across the front of the face plate  608  to a first connector  612  that extends from a side of the interconnect module  600 . The first connector  612  is then connected to a second connector (not shown) that is connected to a sensor component (not shown). Alternatively, the first connector  612  may be positioned to extend from the rear side of the interconnect module  600  instead of from the front side. 
     Each plug includes a sensor probe connected to a sensor wire that carries signals between the sensor probe and an associated network component. When the plugs are fully inserted into the receptacle jacks the sensor probes contact and electrically engage the sensor contacts  604  on the FEC  602  to create a sensor circuit. The sensor component may then be used to monitor and record the connections of network components throughout the network. For example, if one network component is connected to the wrong server, a network shutdown or outage may occur which could be very costly. The sensor component determines where the faulty connection is located and determines how long it has existed in order that the outage may be quickly remedied. Additionally, the sensor component may be used to determine whether unauthorized parties are connected to a component within the network and thus improve network security. 
     However, the conventional interconnect module  600  suffers from several drawbacks. The FEC  602  is expensive and attaching the FEC  602  to the interconnect module  600  requires the use of adhesives and registration of the sensor contacts  604  proximate each receptacle jack  610 . The process of installing the FEC  602  is thus time consuming and difficult, especially when the interconnect module  600  is located in a space-constrained network structure. Also, the first connector  612  is typically connected to the FEC  602  while the FEC  602  is attached to the interconnect module  600 . The second connector hangs from the front side of the interconnect module  600  and is thus easily damaged during installation and use. Also, the second connector takes up a great deal of space which renders the interconnect module  600  difficult to install in space-constrained network structures. The interconnect module  600  requires cables and a second connector to connect the first connector  612  to the sensor component. The connectors and cables take up space and increase the risk of an unintentional disconnection and also limit the adaptability of the interconnect module  600  by presenting a more complicated structure of components to consider when adding or changing connections. In addition, the cables preferably should be selected at the time of installation of the FEC  602  to have a fixed length in order that loops of extra cable are not situated at the patch panel. Further, if any receptacle jack  610  needs to be removed or added, the entire FEC  602 , which covers a portion of the receptacle jacks  610 , has to be removed and replaced. Also, positioning the first connector  612  to extend to the rear side of the interconnect module  600  requires a difficult and expensive mechanical routing process that requires removal or modification of components already on the rear side of the interconnect module  600 . 
     A need remains for an interconnect module that overcomes the above problems and addresses other concerns experienced in the prior art. 
     BRIEF SUMMARY OF THE INVENTION 
     Certain embodiments of the present invention provide a connector assembly comprising a housing having a jack interface that has a receptacle jack therein, which is configured to receive a plug. The connector assembly also includes a sensor bezel removably attachable to said jack interface. The sensor bezel includes an outer frame configured to engage the jack interface. The sensor bezel also includes jack cavities extending therethrough to allow passage of a plug when inserted into said receptacle jack. A sensor array is removably or permanently secured to the outer frame proximate the jack cavities. The sensor array comprises a sensor contact overlaying the jack interface. The sensor contact is aligned with, and configured to engage, a sensor probe associated with a plug insertable into the receptacle jack. 
     The sensor bezel may be snapably secured to the jack interface without glue or adhesive material. Optionally, the sensor bezel may be secured through the normal force of the bezel pins within the pin receptacles of the connector. The sensor array may be is a flexible circuit, a printed circuit, a lead frame, or separate and distinct contacts that may be integrally formed with, or removably secured within, the sensor bezel. 
     The sensor bezel comprises sensor strip pins extending outwardly from a rear surface of the sensor bezel. The strip pins are electrically connected to the sensor strip, and are configured to be received and retained within sensor strip receptacles formed within the jack interface of the housing. The sensor strip is electrically connected to sensor pins of the sensor bezel through traces. The sensor pins are configured to be mated with sensor pin receptacles formed within the housing. The housing may be an interconnect cassette comprising signal and sensor input/output (I/O) interfaces located on a front or rear surface of the interconnect cassette. The signal and sensor I/O interfaces electrically connect to the receptacles jacks and the sensor strip, respectively. 
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 illustrates a front isometric view of an interconnect cassette configured to be mated with a sensor strip assembly according to an embodiment of the present invention. 
     FIG. 2 illustrates a side sectional view of a portion of a patch cord formed in accordance with an embodiment of the present invention. 
     FIG. 3 illustrates a rear isometric view of an interconnect cassette according to an embodiment of the present invention. 
     FIG. 4 illustrates a rear isometric view of an interconnect cassette according to an alternative embodiment of the present invention. 
     FIG. 5 illustrates a front view of a conventional interconnect module with a flexible etched circuit mounted thereto. 
     FIG. 6 illustrates a front view of a conventional flexible etched circuit. 
    
    
     The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 illustrates a front isometric view of an interconnect cassette  300  configured to be mated with a separate and discrete sensor bezel  302  according to an embodiment of the present invention. The interconnect cassette  300  includes a housing  304  defined by side walls  306 , a top surface  308 , a base  310 , a rear wall  312  and a jack interface  314 . The jack interface  314  includes a plurality of receptacle jacks  370  and sensor strip pin receptacles  316  positioned to the side of the receptacle jacks  370 . The receptacle jacks  370  each have a channel  386  along one side thereof and are configured to receive plugs  18  (as shown in FIG. 2) on patch cords  10 . 
     FIG. 2 illustrates a side sectional view of a portion of a patch cord  10  formed according to an embodiment of the present invention. The patch cord  10  includes an insulated cable  14  and a plug  18  retained in a boot  22 . The cable  14  extends to a first network component (not shown) that, by way of example only, may be a server, interconnect module or another interconnect cassette  300 . The cable  14  contains several signal wires (not shown) that may, by way of example only, be shielded or unshielded and made of fiber optics or copper. A probe wire  26  extends from the cable  14  to a sensor probe  30 . The sensor probe  30  may be positioned generally parallel to a longitudinal axis of the plug  18 . The sensor probe  30  has a probe head  98  extending outward from the boot  22 . A flexible prong  38  extends from a front end  42  of the plug  18  rearward at an acute angle with respect to a bottom surface  36  of the plug  18  and is configured to retain the plug  18  within the interconnect cassette  300 . 
     Referring again to FIG. 1, the receptacle jacks  370  are arranged in two rows (A and B) each having six receptacle jacks  370 . Rows A and B of receptacles jacks  370  are stacked. Optionally, the jack interface  314  may have more or less than two rows of receptacle jacks  370 . Further, more or less than six receptacle jacks  370  may be included within each row. Additionally, the sensor strip pin receptacles  316  may be positioned above or below the rows A and B of receptacle jacks  370  depending on the location of the sensor strip pins  342  on the sensor bezel  302 . 
     The interconnect cassette  300  may be connected to a network connection component such as a patch panel, a wall mounted box, a floor box, or any number of other network connection structures (not shown). Mounting features, such as fastener holes  343 , are provided in the jack interface  314  to allow the interconnect cassette  300  to be mounted into a rack unit (not shown) or other such organizational and support structure. The interconnect cassette  300  connects the receptacle jacks  370  to corresponding wires, a printed circuit board, a flexible circuit, a lead frame, or the like within the housing of the interconnect cassette  300  as opposed to directly connecting each receptacle jack  370  to a corresponding structure within another network connection. The wires electrically connected to the receptacle jacks  370  may be bundled inside the interconnect cassette  300  and electrically connected to a signal input/output (I/O) interface  320  (as shown below with respect to FIGS.  3  and  4 ). The signal I/O interface  320  may then be connected to a cable or other connection route (such as cable  311 ), which in turn is electrically connected to a network component or connection  313 , such as a patch panel. Because the wires from the receptacle jacks  370  are bundled within the interconnect cassette  300  and subsequently routed to corresponding features in the signal I/O interface  320  within the interconnect cassette  300 , there is no need to route numerous cables and wires from the interconnect cassette  300  to the network component  313 . Rather, a single cable, such as cable  311 , may house a plurality of wires and connect the interconnect cassette  300  to the network connection  313 . Optionally, the receptacle jacks  370  may be electrically connected to a flexible or printed circuit board (not shown) within the interconnect cassette  300  that is, in turn, electrically connected to a signal input/output interface  318  located at the front or rear of the interconnect cassette  300 . 
     The sensor bezel  302  includes a frame  324  defined by horizontal frame members  326  formed integrally with vertical frame members  328 . The frame  324  includes a front face  330 , a cassette interface surface  332  and a column of strip pins  342  located on one of the vertical frame members  328 . Portions of the cassette interface surface  332  (for example, the edges of the cassette interface surface  332 ) may be beveled, notched or ribbed such that the cassette interface surface  332  engages corresponding structures in the jack interface  314  to allow the sensor bezel  302  to be snapably, latchably, removably, or otherwise securably retained by the jack interface  314  of the interconnect cassette  300 . Optionally, the sensor bezel  302  may be securably retained by the interconnect cassette  300  without the use of glue or other such adhesives. 
     The strip pins  342  extend outwardly from the cassette interface surface  332  and may optionally be formed on one of the horizontal frame members  326  (as a row) or on the other vertical frame member  328 . Also, optionally, strip pins  342  may be positioned on more than one of the vertical and horizontal frame member  328  and  326  (so long as they correspond to strip pin receptacles formed within the interconnect cassette  300 ). A sensor strip  334 , attached to each vertical frame member, spans longitudinally across the sensor bezel  302  in a parallel relationship with the horizontal frame members  326 . The sensor bezel  302  may be molded with, stamped onto, or otherwise integrally formed with the frame  324 . Alternatively, the horizontal frame members  328  may include slots configured to receive and retain support tabs formed as terminal ends of the sensor strip  334 . That is, the sensor strip  334  may be removable from the frame  324 . Two open jack cavities  336  are defined between the horizontal frame members  326  and the sensor strip  334  and are configured to allow plugs  18  to pass therethrough. The jack cavities  336  allow plugs  18  of the patch cords  10  to mate with the receptacle jacks  370  as described below. 
     As shown in FIG. 1, the sensor strip  334  is a flexible circuit having conducting pads or sensor contacts  340 , as commonly used as a connection sensor with interconnect modules (such as interconnect module  600  shown in FIG.  5 ). The sensor contacts  340  are electrically connected to corresponding strip pins  342  extending outwardly from the cassette interface surface  332 . The sensor contacts  340  may be electrically connected to the corresponding strip pins through traces (an exemplary trace, which is under the surface of the sensor strip  334  and vertical member  326 , is shown by line  341 ) that may be formed within or on the sensor strip  334  and the frame  324 . 
     The sensor bezel  302  is received and retained by the interconnect cassette  300 . The interconnect cassette  300  includes features that allow the strip assembly  302  to snapably, latchably or otherwise securably mount to the jack interface  314  of the interconnect cassette  300 . The sensor bezel  302  is mounted to the interconnect cassette  300  without the use of glue or other such adhesives. The sensor bezel  302  may be quickly and efficiently mounted to (and removed from) the interconnect cassette  300  through snapable, latchable or other such matable engagement between the jack interface  314  and the cassette interface surface  332 . Also, the strip pins  342  may be securably retained by the strip pin receptacles  316  so that the strip assembly  302  is securably positioned on the jack interface  314  of the interconnect cassette  300 . As the sensor bezel  302  is mounted to the jack interface  314  in the direction of the dashed lines, the strip pins  342  are received and retained by the strip pin receptacles  316 . The strip pins  342  are then electrically connected to contacts (not shown) within the strip pin receptacles  316 , which are in turn electrically connected to a sensor input/output (I/O) interface  318  or insulated displacement contact (IDC) assembly  322  (as discussed below with respect to FIGS. 3 and 4) through internal traces, wires, or the like. The sensor I/O interface  318  or IDC assembly  322  may then be in electrical communication with a sensing component  317  within or discrete from the network component  313  through a cable  315  or other such electrical path. 
     When the sensor bezel  302  is securably mounted to, and consequently in operative connection with, the interconnect cassette  300 , the receptacle jacks  370  may receive the plugs  18  of the patch cords  10  such that the flexible prongs  38  are retained in the channels  386  and biased toward the bottom surface  36  of the plugs  18 . The resistance of the flexible prongs  38  against the channels  386  retains the plugs  18  within the receptacle jacks  370 . Optionally, the flexible prongs  38  may include a latch feature that joins a corresponding latch feature in the channel  386 . When the plugs  18  are fully received in the receptacle jacks  370 , the probe heads  98  contact and electrically engage corresponding sensor contacts  340 . When the plugs  18  are inserted into corresponding receptacle jacks  370 , the sensor probes  30  align with and engage corresponding sensor contacts  340  on the sensor strip  334 , thereby enabling sensor signals to pass in either direction between the plug  18  and interconnect cassette  300 . 
     Optionally, instead of a pin and socket configuration, the sensor bezel  302  may be compressibly connected to the interconnect cassette  300 . For example, instead of the pins  342  and the receptacles  316 , the sensor bezel  302  may include an array of insulators and conductors. The insulators may be longer or higher than the conductors. When the array is sandwiched between the sensor bezel  302  and interconnect cassette  300 , however, the insulators may be compressed to the length or height of the conductors. 
     When the sensor strip  334  is operatively connected to the interconnect cassette  300 , a pin or other such element, such as the sensor probe  30 , on the plug  18  or patch cord  10  contacts the sensor strip  334  if the plug  18  is fully mated into a corresponding receptacle jack  370 . In particular, the sensor probe  30  of the plug  18  contacts a sensor contact  340  when the plug is fully mated into the receptacle jack  370 . Upon full mating of the plug  18  into the receptacle jack  370 , an electrical circuit is formed between the plug  18  and the sensor contact  340  by virtue of the sensor probe  30  contacting the sensor contact  340 . The sensing component  317  detects this electrical circuit as a connection between the plug  18  and its corresponding receptacle jack  370 . If, however, the plug  18  becomes dislodged from its corresponding receptacle jack  370 , the sensor probe  30  no longer contacts the sensor contact  340 . Thus, the electrical circuit is broken and the sensing component  317  senses that a connection is not present between the plug  318  and its corresponding receptacle jack  370 . The information regarding connections is relayed to a processing unit (not shown), which in turn may display connection information to an operator or overseer. 
     FIG. 3 illustrates a rear isometric view of an interconnect cassette  300  according to an embodiment of the present invention. The rear wall  312  of the interconnect cassette  300  includes a sensor input/output (I/O) interface  318  and a signal input/output (I/O) interface  320 . The sensor I/O interface  318  electrically connects to the strip pin receptacles  316  through electrical traces, cables, wires, circuit boards or the like. Similarly, the signal I/O interface  320  electrically connects to the receptacle jacks  370  through electrical traces, cables, wires, circuit boards or the like. Thus, the interconnect cassette  300  may connect to a patch panel, or other network connection structure, such as network component  313 , through an electrical cable, such as cable  311 , that bundles a plurality of signal wires and connects them to an I/O interface on the network component  313 . Similarly, sensor information is relayed to a sensing component  317  through a cable  315  that connects the sensor I/O interface  318  to an interface on the sensing component  317 . 
     FIG. 4 illustrates a rear isometric view of an interconnect cassette  300  according to an alternative embodiment of the present invention. Instead of the sensor I/O interface shown in FIG. 9, the interconnect cassette  300  may include an IDC assembly  322  that may communicate with a corresponding assembly of a sensing component  317 . 
     United States Patent Application entitled “Receptacle and Plug Interconnect Module With Integral Sensor Contacts,” filed Jun. 18, 2002, attorney docket 17862US1 (MHM No. 13761US01), listing Pepe et al. as inventors (“the Pepe application”), discloses a connector assembly having sensor contacts integrally formed with a housing of the connector assembly. The Pepe application is incorporated by reference herein in its entirety. The Pepe application discloses an interconnect module having a plurality of sensor contacts integrally formed thereon. The sensor strip  334  shown above with respect to FIG. 1 may include the sensor contacts shown in the Pepe application, instead of the flexible strip  338 . Each contact sensor, or conducting pad of the contact sensor, is electrically connected to the strip pins  342  by way of traces  341  or similar electrical paths. 
     In an alternative embodiment of the present invention, the sensor strip  334  and the sensor I/O interface  318  or the IDC assembly  322  may be connected together by a printed circuit board that extends through the housing  304  of the interconnect cassette  300 . The printed circuit board has electronic traces that extend along the length thereof and that are connected to the sensor strip receptacles  316 . The printed circuit board may include signal conditioning circuits, an identification ID code unique to each receptacle jack  370 , and/or processing components that analyze and identify the type of plug inserted. 
     The interconnect cassette  300  and separate sensor bezel  302  confer several benefits. First, the interconnect cassette  300  utilizes individual sensor contacts  340  positioned proximate each receptacle jack  370 . The sensor contacts  340  are retained individually within the front face of the sensor bezel  302  and are connected to the sensor pins  316  through traces  341 , or the like. Thus, the sensor contacts  340  directly connect to the sensor probes of the plugs  18 . The sensor contacts  340  are separate and discrete from one another thereby allowing easy removal and replacement of the plugs  18  from the receptacle jacks  370  without disconnecting other plugs  18  from receptacle jacks  370  that are not being replaced/removed. That is, only the sensor strip  334  needs to be removed, while the sensor bezel  302  and the plugs remain in place. Also, if sensor contacts  34 - are faulty, only the sensor bezel  302  needs to be replaced (as opposed to the entire interconnect cassette  300 ). Further, the sensor strip  334  of the sensor bezel  302  may be removable so that only the sensor strip  334  or individual sensor contacts  340  needs to be replaced. Finally, the sensor contacts eliminate the need for fixed lengths of cable and multiple connectors to connect sensor pads to the sensor wires, thus saving time and space. 
     Embodiments of the present invention may be used with various applications including modular jacks. For example, the present invention may be used to electrically or fiber optically connect components. 
     While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.