Modular plug with locking member

A modular plug includes a mating portion having a latch for engaging a jack and a slidable housing having a first end and a second end. The slidable housing receives the mating portion at the first end and the slidable housing is adapted to slide along the mating portion and engage the mating portion. A a cable is connected to the mating portion and extends through the second end of the slidable housing. A locking member is in operable communication with both the slidable housing and the cable.

BACKGROUND OF THE INVENTION

Many prevalent network systems, i.e., Ethernet, etc., require the use of a common modular plug. The modular plug includes opposing first and second ends. The first end is terminated with a cable. The second end is connected to a modular connector, thus forming a modular connection interface. The modular plug connects to a modular jack. The existing manner in which the modular plug is connected to the jack is through the use of a snap latching system, which is illustrated inFIG. 44. The user is required to push down on the latch to disengage the modular plug from the jack. When there are a number of modular plugs in close proximity (e.g., in a patch panel), each of the modular plugs are located next to each other and it is difficult for the user to reach the latch and disengage a specific modular plug.

SUMMARY OF THE INVENTION

A modular plug includes: a mating portion having a latch for engaging a jack; a slidable housing having a first end and a second end, the slidable housing receives the mating portion at the first end and the slidable housing is adapted to slide along the mating portion and engage the mating portion; a cable that is connected to the mating portion and extends through the second end of said slidable housing; and a locking member in operable communication with both the slidable housing and the cable.

DETAILED DESCRIPTION

Referring toFIG. 1, a modular plug10is illustrated. Plug10includes a slidable housing12and a mating portion14. Mating portion14is partially received into housing12. The mating portion14is attached to a cable30using known techniques (seeFIG. 19).

Referring now toFIGS. 1–5, housing12has a first end16, an opposing second end18, and a middle portion20. Both first end16and second end18have openings22and24, with a chamber26disposed therebetween. Chamber26provides a pathway from first end16to second end18. First end16is elongated to allow an operator to grasp housing12. Opening22is sized to receive cable30.

Second end18is sized to receive mating portion14. Second end18has a first side32, a second side34, and a third side36. First side32is approximately parallel to third side36, with second side34located approximately perpendicular to both first side32and third side36.

Housing12includes contoured surfaces, which are located within chamber26and which engage mating portion14. The contoured surfaces are as follows. A first stepped edge38is located at a corner of first side32and second side34and a second stepped edge40is located at a corner of second side34and third side36. First stepped edge38mirrors second stepped edge40so as to form a cut out section42located at opening24and along second side34. A first wedge44and a second wedge46are located within chamber26and directly behind first stepped edge38and second stepped edge40, respectively. Both first side32and third side36have slots50. Housing12generally tapers from second end18to first end16, with second end18being larger than first end16.

Second end18also has a sloped extension58, which provides for a smooth transition from second end18to middle portion20and helps to prevent plug10from snagging as plug10is drawn through cabling areas.

Referring to FIGS.1and6–10, mating portion14has a main body70with a first end72and an opposing second end74. Main body70also has a first side76, a second side78, and a third side79. First side76is approximately parallel to third side79, with second side78located approximately perpendicular to both first side76and third side79. Both first side76and third side79have indented portions82. A plug stop84is located at second end74on both first side76and third side79at indented portions82.

Mating portion14includes a latch80that is connected to first end72at a base90. Latch80includes two fingers92and94that extend from base90over second side78. Fingers have opposing sloped sides96and98. Fingers92and94are located closest together at first end72and move apart from one another as fingers92and94extend away from base90over second side78to terminal ends102and104. There is a gap109located between fingers92and94and second side78. Accordingly, because fingers92and94are only attached at base90and merely extend over second side78, fingers92and94can be pushed together in a scissors-like manner with the most movement occurring at terminal ends102and104.

Fingers92and94also have top sides106and108, which have cavities110and112that located at approximately a mid-section114of fingers92and94. Cavities110and112include latch surfaces116and118, which are generally perpendicular to top sides106and108of fingers92and94. Terminal ends102and104of fingers92and94have outer surfaces120and122and sloped surfaces124and126.

Referring toFIGS. 1–11, plug10is assembled as follows. Second end74of mating portion14is received into opening24of housing12. Main body70slides into opening24until plug stops84are received into slots50. Plug stops84have a sloped surface130and a tab side132. Plug stops84will slide into opening24along sloped surface and then hook into slot50at tab side132. When plug stops84are received into slots50, terminal ends102and104are received into cut out section42. This is the unlatched position, as indicated inFIG. 1.

Plug stops50keep mating portion14movably secured to slidable housing12. In other words, mating portion14can slide within slidable housing12; however, plug stops50ensure that mating portion14does not come apart from slidable housing12when the user disengages modular plug10from the jack.

As main body70continues to slide into opening24and into chamber26, plug stops84slide along slots50. In addition, fingers92and94slide along wedges44and46. As sloped surfaces124and126engage with wedges44and46, respectively, fingers92and94begin to move in an outward direction so that fingers92and94separate away from each other. Thus, the shape of wedges44and46and the shape of terminal ends102and104cause fingers92and94to move laterally in an outward direction towards first side76and third side79, respectively.FIG. 11indicates the latched position of plug in which housing12completely encloses indented portions82and fingers92and94are forced apart.

Referring toFIGS. 1–13, plug10operates as follows. When plug10is in the unlatched position, as indicated inFIG. 1, the user grasps cable30at first end16of housing12and pushes mating portion14into a jack140(seeFIG. 13). Jack140includes a RJ-45 jack. Once mating portion14has been inserted into jack140, the user releases cable30and continues to grasp first end16. The user pushes first end16towards jack140. Housing12slides towards jack140so that plug stops84slide in slots50and fingers92and94slide into cut out section42. As explained above, when fingers92and94slide into cut out section42, wedges44and46engage sloped surfaces124and126, which pushes fingers92and94in an outward lateral direction, as indicated inFIG. 11. This is the latched position. When this happens, latch surfaces116and118engage with the surfaces in jack140and lock plug10into jack140. Thus, if the user releases housing12and grasps only cable30and pulls cable away from jack140, plug10will not release from jack140.

Plug10can be disengaged and released from jack140when the user grasps first end16and pulls in an outward direction, away from jack140. When the user pulls on first end16, terminal ends102and104slide along wedges44and46, which pushes fingers92and94together. When fingers92and94are pushed together, latch surfaces116and118disengage from the surfaces of the jack140, thereby releasing plug10from jack140. This is the unlatched position.

Accordingly, when multiple cables are grouped together, an operator can grasp first end16of housing12and pull housing12so that it slides away from jack140. When housing12is pulled away from jack140, latch80disengages from jack140and releases mating portion14from jack140.

Referring toFIGS. 14–16, an alternative embodiment of slidable housing12is illustrated. In this embodiment, first end16is removed and the user would grasp middle portion20to insert plug10(seeFIG. 1) into jack140(seeFIG. 13). In addition, middle portion20includes two sides150and152that swing away from each other. This type of housing allows for slidable housing12to clamp over cable30(seeFIG. 1) in an easy manner. Sides150and152connected at a plurality of snap latches154. Snap latches154include an extension156at sides150and152that hooks onto recess areas158at sides150and152.

Referring toFIGS. 17–25, an alternative embodiment of modular plug10is illustrated. As with the first embodiment, plug10includes housing12and mating portion14. Housing12includes first end16, opposing second end18, and middle portion20. Second end18includes opening24and is sized to receive mating portion14.

Housing12is similar to the first embodiment except for the differences set forth herein. As such, when describing this embodiment, all of the parts that remain the same have the same part numbers as with the first embodiment. Second end18has first side32, second side34, and third side36. First side32is approximately parallel to third side36, with second side34located approximately perpendicular to both first side32and third side36. Second side34includes an opening202and a cover204. Second end18also has an end face216, which includes a rectangular slot220. Cover204includes a gripper edge206, two projections208, and a stop209(shown inFIG. 24). Two projections208slide under a first edge210of opening202and gripper edge206hooks under a lip212of an opposing second edge214of opening202. In addition, sides32and36do not have slots50as with the first embodiment, but rather have a sloped edge222.

In addition, mating portion14is similar to the first embodiment except for the differences set forth herein. Mating portion14has main body70with first end72and opposing second end74. Main body70also has first side76, second side78, and third side79.

In this embodiment, latch80is connected to second end74at base90. Latch80includes two fingers230and232that extend from base90over second side78. Fingers230and234are generally parallel and extend away from base90over second side to terminal ends236and238. While this embodiment depicts fingers230and234disposed in a generally parallel manner, fingers230and234are not required to be parallel in order for fingers230and234to function properly. In addition, because fingers230and234are only attached at base90and merely extend over second side78, fingers230and234can be pushed together in a scissors-like manner with the most movement occurring at terminal ends236and238.

Fingers230and234also have top sides240and242, which have sloped surfaces244and246leading to top sides248and250. As such, terminal ends236and238are thicker than fingers230and234at base90. Top sides248and250have cavities260and262that located near terminal ends236and238. Cavities260and262include latch surfaces264and266, which are generally perpendicular to top sides248and250. In addition, cavities260and262mirror each other on each finger230and236.

Cover204includes stop209, which is located between fingers230and236when cover204is attached to housing12. Stop209extends into a cavity211, which is formed by fingers230and236, wall211, and the back end of fingers230and236. Cavity211is set into second side78of mating portion14. Stop209can slide within cavity211, as shown inFIGS. 24 and 25. Stop209has the same function as plug stops84. Stop209keeps mating portion14movably secured to slidable housing12. In other words, mating portion14can slide within slidable housing12; however, stop209ensures that mating portion14does not come apart from slidable housing12when the user disengages modular plug10from the jack.

Fingers230and234also have cam surfaces270and272, which are located at about a mid-point along the outer side of fingers230and234.

Once cover204is in place, cover204can slide in the direction of arrow280. When cover204slides towards second edge214, projections slide along cam surfaces270and272until projections208are at the edge of cam surfaces270and272, as shown inFIG. 25. As projections208slide along cam surfaces270and272, fingers230and234are pressed together. This is the unlatched position of modular plug10.

Referring to FIGS.13and17–25, plug10operates as follows. To mate the plug10with a jack, the plug may be placed in the unlatched position as shown inFIG. 25, inserted in the jack and then placed in the latched postion shown inFIG. 24. Alternatively, when plug10is in the latched position, as indicated inFIG. 24, the user grasps first end16of housing12and pushes mating portion14into a jack140(seeFIG. 13). Mating portion14slides into jack140until latch surfaces264and266engage with the surfaces in jack140and lock plug10into jack140.

Plug10can be disengaged and released from jack140when the user grasps first end16, and slides cover204away from the first end72of mating portion14. As cover204slides toward second edge214, fingers230and234press together and release the jack surfaces from latch surfaces264and266so that mating portion14is no longer engaged with jack140, thereby releasing plug10from jack140. This is the unlatched position of the modular plug10. Thus, in this embodiment, only the cover204of housing12slides to disengage plug10from jack140.

Referring toFIGS. 26–35, an alternative embodiment of slidable housing12is illustrated. In this embodiment, slidable housing12opens so that there is a top side402and a bottom side404. In addition, there is no separate cover (seeFIG. 18with separate cover204) and stop209extends from top side402. Top side402may be connected to bottom side by a hinge406. Top side402is secured to bottom side404by snap hooks410,412, and414, all of which extend from top side402, however, they could also extend from bottom side404. Snap hooks are received into openings416,418, and420, which are all sized to received the corresponding snap hooks and are disposed on bottom side404. In addition, bottom side has a connector424, which extends from bottom side404and is received into an opening426, which is located on top side402.

When assembling slidable housing12with mating portion14, mating portion14is placed into bottom side404and top side402is closed over mating portion14. Once top side402is secured to bottom side404, mating portion cannot slide out of slideable housing12because stop209prevents mating portion14from sliding out of slideable housing12. This embodiment of slideable housing12operates in the same manner as described above with respect to FIGS.13and17–25.

FIGS. 36 and 37show an alternative embodiment of modular plug10. In this embodiment, mating portion14has latch502extending from base90. Latch502has a bend location504so that latch502bends away from second side78of mating portion. Latch502extends to an end506. Slidable housing12has a window508that receives end506of latch502.

Modular plug10, which is shown inFIGS. 36–37, is assembled in the following manner. Mating portion14is received into chamber26of slidable housing12by sliding mating portion14into chamber26. End506slides through window508. Once end506is located in window508, but before a front face510of slidable housing12reaches bend location504of latch502, modular plug10is in the unlatched position. The modular plug10is now ready to be mated with a jack. Mating portion14is inserted into the jack and the user continues to slide slidable housing12continues to over mating portion14until front face510reaches bend location504. This is the latched position. Once modular plug10is in the latched position, the user would then grasp slidable housing12and slide housing12in the opposite direction. As the user pulls the slidable housing12a cam surface512of window508pushes down on latch502, which disengages mating portion14from the jack. In addition, slidable housing12includes slots50, which engage plug stops84.

The mating portion shown in the drawings is an RJ-45 plug having eight contacts, preferably used with cable having four twisted pairs of copper wire. One of the advantages of the axial latch actuator is that it can be mated with a standard outlet, which has not been modified. In other words, a face of the jack is flush with the opening of the jack so that the modular plug directly abuts the face of the jack. SeeFIG. 13. It is also understood that the mating portion may be altered to mate with non RJ-45 jacks and may be used with a variety of cable types such as coaxial cable, single fiber, duplex fiber, etc. Thus, embodiments of the invention are not limited to RJ-45, copper wire installations.

FIGS. 38–39illustrate an exemplary embodiment of a locking member600andFIG. 40illustrates the locking member600engaged with the slidable housing12. In this embodiment, the locking member has a main body602, such as a ring that is slid over the cable30and abuts an end603(FIG. 40) of the slidable housing12. The main body602is then tightened so that the locking member600is held in place at the cable30, which in turns holds the slidable housing12in place so that the slidable housing12cannot move along the cable30. In addition, it is also contemplated that the main body602is slid over the cable30and the end603of the slidable housing so that both the slidable housing12and the cable are gripped together. In either event, the locking member is engaged with the slidable housing12and the cable30so that the slidable housing12does not move along the cable30.

In this embodiment, the main body602has an arm604that extends around an outside wall606of the main body602. Both the arm604and the main body602have teeth610that engage and grip the arm604to the main body602. The arm604can extend further along the outside wall606to provide a tighter grip. The locking member600is disengaged from the cable30by lifting the arm604so that the teeth610of the arm604disengage from the teeth610of the outside wall606. Once the arm604is disengaged from the outside wall606, the arm604is pushed in a direction612so as to loosen the grip and remove the locking member600from the cable30.

FIG. 41is an exemplary embodiment of another locking member700andFIG. 42illustrates the locking member700on a slidable housing12. The locking member700is a seal having a main body702that is cylindrical in shape and long enough to extend over both the slidable housing12and the cable30. An inside wall704of the main body is coated with an adhesive. The main body702also includes at least one row of perforations708, and in an exemplary embodiment, there are two rows of perforations708. The rows of perforations708facilitate the removal of the locking member700in that a section710between the two rows of perforations708can be lifted and torn off, thereby easily removing the locking member from the slidable housing12and the cable30. An outside wall712of the main body702may be color coded to indicate the importance of the plug remaining engaged with the jack.

The locking member700is extended over the cable30in such a way so that the cable does not touch the inside wall704of the locking member700. The locking member700is moved along the cable30until approximately half of the main body702extends over the slidable housing12and half of the main body702extends over the cable30. The user then presses the locking member to the slidable housing12and the cable30.

FIG. 43illustrates the locking member600and the locking member700engaged with the slidable housing12. In an exemplary embodiment, the plug may include two locking members. First, the locking member600is engaged with the slidable housing12and the cable30. Then the locking member700is placed over the slidable housing12and the locking member600. In addition, the locking member700may extend over both the housing12and the cable30, as shown inFIG. 42, at the same time as the locking member600is engaged on the housing12. By having two locking mechanisms, the security of the plug is further enhanced.

The locking members600and700have a number of advantages. First, the locking members600and700may be placed on certain plugs that the user does not want being disconnected from the jack, except in very special circumstances. Second, the locking members600and700help to prevent tampering with the plug.

In field applications, plugs are sometimes inadvertently disconnected from jacks. For example, a plug connected to a switch is part of an application that should not be disconnected without some approval protocol. Because the plug density at a swtich can be high, this may cause confusion and a person may accidentally unplug the wrong plug during routing work. By having either locking member600or700attached to the slidable housing, a person would go through proper protocol and make sure that the correct plug is being unplugged. Moreover, when both locking members600and700are used, this can indicate a more critical plug, which would require a higher protocol in order to unplug the plug.

The entire disclosure of U.S. patent application Ser. No. 10/408,976, filed on Apr. 8, 2003, including specification, drawings, and claims, is incorporated by reference in its entirety.