Adapter configured with both optical and electrical connections for providing both optical and electrical communications capabilities

An adapter is provided that has both an electrical coupling configuration that complies with the RJ-45 wiring standard for electrical communications and an optical coupling configuration for optical communications. The adapter is configured as an interface for at least two modular connector assemblies to enable the modular connector assemblies to communicate with each other either optically or electrically, depending on whether the plugs of the assemblies are configured to have optical or electrical communications capabilities.

TECHNICAL FIELD OF THE INVENTION

The invention relates to adapters for interfacing modular connector assemblies of the type that comply with registered jack-45 (RJ-45) wiring standards. More particularly, the invention is directed to an adapter having both an electrical coupling configuration that complies with the RJ-45 wiring standard and an optical coupling configuration that provides the assembly with optical communications capabilities.

BACKGROUND OF THE INVENTION

A variety of modular connector assemblies are used to electrically couple electrical signals between the ends of electrical conductors contained in electrical cables and electrical contacts of electrical circuitry of terminal equipment connected to the ends of the cables. A modular connector assembly has a plug that terminates the end of the electrical cable and a jack that mates with the plug. The exterior surface of the plug and the interior surface of the jack have mating features located on them that mate with each other to removably interlock the plug inside of the jack. When the plug is interlocked in a mating relationship with the jack, respective electrical contacts of the plug are in contact with respective electrical contacts of the jack. The electrical contacts of the plug are electrically coupled with the ends of respective electrical conductors of the cable. Similarly, the electrical contacts of the jack are electrically coupled with respective electrical contacts of electrical circuitry of the terminal equipment. Through all of these electrical connections, electrical signals being carried on the electrical conductors of the cable are electrically coupled to the electrical circuitry of the terminal equipment, and vice versa.

One type of modular connector assembly that is well known in the communications industry is an eight position, eight contact (8P8C) modular connector assembly. The 8P8C modular connector assembly is often used with twisted copper pairs to communicate electrical data signals over Ethernet-based communications networks. In Ethernet-based communications networks, the electrical contacts and other circuitry of the 8P8C connector assembly are configured to comply with the RJ-45 wiring standards, which are called the T-568A and T-568B wiring standards. Because these types of modular connector assemblies are made to comply with the RJ-45 wiring standards when they are manufactured for use in Ethernet-based communications networks, they are often referred to as RJ-45 connectors.

FIG. 1illustrates a perspective view of a known 8P8C plug1of a known 8P8C modular connector assembly. The plug1is configured to mate with a known jack (not shown for purposes of clarity) of the known 8P8C modular connector assembly. The 8P8C plug1includes electrical wiring that complies with one of the RJ-45 wiring standards, i.e., either the T-568A or T-568B wiring standard. The plug1has a plug housing2, a latch mechanism3formed on a top portion of the plug housing2, and a plurality of insulation displacement contacts4disposed on a bottom portion of the plug2. The latch mechanism3has a locking feature3athereon that engages a locking feature of the jack (not shown) when the plug1is mated with the jack. The insulation displacement contacts4pierce the insulating jackets of twisted copper pair wires of a cable (not shown for purposes of clarity) when the plug1is installed on the end of the cable. The cable that is used with the plug1is typically a Category 5 (CAT 5) or a Category 6 (CAT 6) cable as defined by the Electronic Industries Association and Telecommunications Industry Association (EIA/TIA).

Ethernet-based communications networks currently have the capability of carrying electrical data signals at data rates in excess of 1 gigabits per second (Gb/s). Although optical communications links are currently capable of operating at date rates of 10 Gb/s over distances of up to about 100 meters (m), the use of such optical links generally has not spread into areas occupied by high-speed Ethernet-based networks. One reason that the use of optical links has not spread into this space is that the costs of manufacturing pluggable optical modular connector assemblies that can operate at these data rates are much higher than the costs of manufacturing 8P8C modular connector assemblies that operate at these data rates. Another reason that the use of optical links has not spread into this space is that there are currently no optical solutions that have backwards compatibility to the existing electrical Ethernet solutions. Although it is possible to design electrical connections that operate at data rates higher than 1 Gb/s using 8P8C modular connectors that implement the RJ-45 wiring standard, such connections would consume much more power than optical connections operating at the same data rate. In addition, the complexity of the design for such high data rate electrical connections would result in the connections being significantly more expensive than those that operate at 1 Gb/s. Furthermore, a new cabling scheme with higher costs would be required to propagate the data signals at data rates higher than 1 Gb/s over distances of about 100 meters (m).

Adapters currently exist that enable two 8P8C modular connector assemblies to be interfaced together. The existing adapter has an 8P8C jack formed in opposite ends thereof for mating with respective 8P8C plugs of the type shown inFIG. 1. When the respective 8P8C plugs are mated with the respective 8P8C jacks, the electrical wiring of the adapter electrically interconnects the two plugs. Through this electrical interconnection between the two plugs, respective wires of the cables that are terminated by the plugs are electrically interconnected, thereby allowing electrical signals being carried on the wires of one of the cables to be coupled onto the wires of the other cable.

Although the adapter described above is useful for interconnecting electrical cables that are terminated with 8P8C plugs, it cannot be used to interconnect optical cables that are terminated with optical plugs or to interconnect an electrical cable terminated with an 8P8C plug with an electrical or hybrid cable terminated with a plug that has both electrical and optical communications capabilities. A need exists for an adapter that is capable of interconnecting optical cables terminated with optical plugs, interconnecting electrical cables terminated with 8P8C plugs, or interconnecting an electrical cable terminated with an 8P8C plug with an electrical or hybrid cable terminated with a plug that has both electrical and optical communications capabilities.

SUMMARY OF THE INVENTION

The invention is directed to an adapter having multiple jacks for mating with multiple respective plugs that terminate multiple respective cables, and an adapter assembly that includes the adapter and the plugs mated with the respective jacks of the adapter. The adapter comprises an adapter housing, an optical coupling system, and an electrical conductor configuration. The adapter housing has first and second jacks formed therein and a shared partitioning member that partitions the first and second jacks from each other. The first jack comprises a first plug opening formed in a first end of the adapter and configured to receive a first plug, and a first electrical contact configuration that complies with a RJ-45 wiring standard. The second jack comprises a second plug opening formed in a second end of the adapter and configured to receive a second plug, and a second electrical contact configuration that complies with a RJ-45 wiring standard. The optical coupling system is formed in or is secured to the shared partitioning member of the adapter housing. The optical coupling system is configured to optically couple optical signals between a first side of the rear partitioning member and a second side of the rear partitioning member. The electrical conductor configuration interconnects the first and second electrical contact configurations for electrically coupling electrical signals between the first and second electrical contact configurations.

The adapter assembly comprises the adapter, first and second plugs mated with the first and second plug openings, respectively, and first and second cables terminated by the first and second plugs, respectively.

These and other features and advantages of the invention will become apparent from the following description, drawings and claims.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

The invention is directed to an adapter having both an electrical coupling configuration that complies with the RJ-45 wiring standard for electrical communications and an optical coupling configuration for optical communications. The adapter is configured as an interface for at least two modular connector assemblies to enable the modular connector assemblies to communicate with each other either optically or electrically, depending on whether the plugs of the assemblies are configured to have optical or electrical communications capabilities. In other words, the adapter will operate as either: (1) an interface for two typical electrical-only RJ-45 plugs; (2) an interface for two plugs of the invention described below that can operate optically or electrically; or (3) an interface for a typical electrical-only RJ-45 plug and the plug of the invention described below that can operate optically or electrically. Thus, the adapter has backwards compatibility with electrical-only 8P8C plugs that implement the RJ-45 wiring standard, but can also be used with the plugs of the invention that operate optically or electrically. Thus, the adapter may be used to interface modular connector assemblies that communicate optical data signals at higher data rates (e.g., 10 Gb/s and higher) or that communicate electrical data signals at lower data rates (e.g., 1 Gb/s).

Prior to describing illustrative embodiments of the adapter of the invention, illustrative embodiments of the plug and jack of the invention that together form a modular connector assembly will be described with reference toFIGS. 2A-14. Then, illustrative embodiments of the adapter will be described with reference toFIGS. 15-21.

FIGS. 2A-2Cillustrate, respectively, perspective top right front, top left front and bottom right front views of the plug10of the modular connector assembly in accordance with an illustrative embodiment. The plug10is similar in many respects to the typical 8P8C plug1shown inFIG. 1used for Ethernet communications in that the plug1includes electrical wiring that complies with one of the RJ-45 wiring standards, i.e., either the T-568A or T-568B wiring standard. The plug10has a plug housing12, a latch mechanism13formed on a top portion of the plug housing12, an optical interface comprising openings11aand11bformed in a front portion of the plug housing12, and a plurality of insulation displacement contacts14disposed on a bottom portion of the plug10. The latch mechanism13has a locking feature13athereon that engages a locking feature of the jack when the plug10is mated with a jack, as will be described below in more detail with reference toFIGS. 8-11B.

As with a typical 8P8C modular connector assembly plug of the type shown inFIG. 1, the insulation displacement contacts14pierce the insulating jackets of twisted copper pair wires of a cable (not shown for purposes of clarity) when the plug10is installed on the end of the cable. The cable that is used with the plug10will typically be a Category 5 (CAT 5) or a Category 6 (CAT 6) cable as defined by the Electronic Industries Association and Telecommunications Industry Association (EIA/TIA), an optical fiber cable, or a hybrid cable. The CAT 5 and CAT 6 cables are electrical Ethernet cables. There are a variety of optical fiber cables used in the industry today, but the optical fiber cable that may be terminated with the plug10will typically be a rounded cable having a transmit optical fiber, a receive optical fiber a strength membrane, and protective jacket. It should be noted, however, that the invention is not limited with respect to the type of cable that is used with the plug10.

In accordance with an embodiment, a hybrid cable that may be terminated by the plug10is a cable that includes electrical wires similar or identical to those contained in, for example, a CAT 5, CAT 5e, CAT 6a, or CAT 7 cable, and that also includes a transmit optical fiber and a receive optical fiber. Such a hybrid cable provides the option of communicating with either electrical Ethernet data signals or optical data signals. The hybrid cable typically comprises eight insulated copper wires, at least one transmit optical fiber, at least one receive optical fiber, and a cable jacket. If the cable is one of the aforementioned known cables, such as a CAT 5, CAT 5e, CAT 6a, or CAT 7 cable, the transmit and receive optical fibers may be embedded within the main cable jacket or they may be external to the main cable jacket and embedded in one or more optical fiber cable jackets. In the latter case, the two cable jackets may be attached to one another by some suitable attachment mechanism. At the end of the cable that attaches to the plug10, the loose ends of the insulated copper wires are inserted into a wire and optical fiber (WOF) guide device (not shown for purposes of clarity) of the plug10in accordance with the RJ-45 wiring standard, as will be described below in more detail with reference toFIG. 12. The loose ends of the optical fibers can be stripped of their protection jackets and buffers and polished, as is commonly performed for fiber termination. The polished ends would then be inserted into respective ferrules (not shown for purposes of clarity) that are then guided through the aforementioned WOF guide device such that the ferrules are disposed within the respective openings10aand10bthat provide the optical interface of the plug10, as will be described below with reference toFIG. 12.

The openings10aand10bare disposed adjacent the right and left sides of the plug10in a proximal end face18of the plug10. As will be described below in more detail below with reference toFIGS. 9-11B, ferrule-type elements (not shown for purposes of clarity) of optical-to-electrical (OE) and electrical-to-optical (EO) conversion modules (not shown for purposes of clarity) are partially received in the openings10aand10b, respectively. Inside of the respective openings10aand10b, the ends of the ferrule-type devices abut respective optics systems (not shown for purposes of clarity) of the plug10, which, in turn, are optically coupled with the respective ends of a receive optical fiber and a transmit optical fiber, as will be described below in more detail with reference toFIGS. 11B and 12. This optical arrangement provides an optical coupling interface for optically coupling light between the OE and EO conversion modules and the receive and transmit optical fibers, respectively.

The plug housing12has a tiered surface11formed in the front portion of the plug housing12adjacent the proximal end face18. The tiered surface comprises an upper tier surface11aand a lower tier surface11bsuch that a first distance, D1, between a lower surface12aof the plug housing12and the upper tier surface11ais greater than a second distance, D2, between the lower surface12aof the plug housing12and the lower tier surface11b. This difference between the first and second distances D1and D2operates in conjunction with the locking feature13aformed on the latch mechanism13and in conjunction with complimentary features formed in the jack (not shown for purposes of clarity) to allow the plug10to be interlocked with the jack in either a first or a second interlocking position, as will be described below in detail with reference toFIG. 9-11B. Although the tiered surface12is not required, it provides one of many possible solutions for providing the plug10with both electrical and optical capabilities while also enhancing the versatility of the plug10. In addition, providing these two different interlocking positions is one way in which the system in which the modular connector assembly is used to automatically differentiate between when it is operating in the electrical Ethernet mode and when it is operating in the optical mode. In addition, because the jack has features that are complimentary to the tiered surface11, existing 8P8C plugs of the type shown inFIG. 1that are configured to comply with the RJ-45 wiring standard may be interlocked inside of the jack in the normal manner. These features are described in more detail below with reference toFIGS. 7-9.

FIG. 3illustrates a front perspective view of the jack20of the modular connector assembly that mates with the plug10shown inFIGS. 2A-2Cin accordance with an illustrative embodiment. The jack20has a jack housing22that has a front opening23formed therein. The front opening23is configured to receive an 8P8C plug such as the plug10shown inFIGS. 2A-2Cor a convention 8P8C plug of the type shown inFIG. 1. A plurality (e.g., eight) of electrical contacts24are disposed inside of the opening23for making contact with respective insulation displacement contacts4or14shown inFIG. 1or inFIGS. 2A-2C, respectively, when the plug1or10is locked inside of the jack20. The electrical contacts24are electrically coupled to other electrical circuitry (not shown for purposes of clarity) external to the jack20. The jack housing22has a back cover25secured to a back portion of the jack housing22. The back cover25has a door26that is in a hinging relationship with the cover25. The cover25has openings27formed therein through which the aforementioned ferrule-type elements (not shown for purposes of clarity) of the OE and EO conversion modules (not shown for purposes of clarity) extend when the OE and EO conversion modules are installed in the jack housing22, as will be described below in more detail with reference toFIGS. 4-6. Alternatively, in an embodiment in which the OE and EO conversion module or modules are installed on an external circuit board (not shown for purposes of clarity) on which the jack housing22resides, respective ends of respective optical fibers extend into the respective openings27to optically couple the external EO and OE conversion module(s) to the jack20, as will be described below in more detail with reference toFIG. 14.

FIG. 4illustrates a back perspective view of the jack20shown inFIG. 3having the cover25attached thereto with the door26in the opened position to reveal locations in the cover25at which the OE and EO conversion modules (not shown for purposes of clarity) will be installed.FIGS. 5A and 5Billustrate front and back perspective views, respectively, of the EO or the OE conversion module30. In accordance with this illustrative embodiment, the OE and EO conversion modules30are formed on separate substrates. It should be noted, however, that the OE and the EO conversion modules30could be integrated on the same substrate. For ease of illustration and in the interest of brevity, the latter approach is not shown in the drawings because its appearance is very similar to that of placing the EO and OE conversion modules30shown inFIGS. 5A and 5Bside by side.

The EO conversion module30includes a substrate30aand an EO module housing30b. The EO module housing30bincludes the aforementioned ferrule-type element, which is identified inFIGS. 5A and 5Bby reference numeral30b′. The ferrule-type element30b′ has an optics system (e.g., a lens)30b″ disposed therein. Inside of the EO module housing30b, an EO conversion device, which is typically a laser diode (not shown for purposes of clarity), and a corresponding laser diode driver integrated circuit (IC) (not shown for purposes of clarity) are mounted on and electrically coupled to the substrate30a. Electrical contacts30cdisposed on the PCB30acome into contact with respective electrical contacts28(FIG. 4) disposed on the back cover25when the EO conversion module30is installed in the back cover25of the jack20. The electrical contacts28are electrically coupled by other electrical conductors (not shown for purposes of clarity) to electrical circuitry that is external to the jack20, as will be described below in more detail with reference toFIG. 13. Alternatively, the EO and OE conversion modules, or a combined EO/OE conversion module could be mounted on an external system board on which the jack housing22resides, in which case a ferule-type element similar or identical to the ferrule-type elements30b′ has a fiber end attached to it such that a fiber pigtail disposed on the opposite end of the fiber extends from the EO/OE conversion module into hole27, as will be described below in more detail with reference toFIG. 14. In such an alternative implementation, the electrical contacts28and29disposed on the jack housing are unnecessary.

The OE conversion module (not shown for purposes of clarity) is identical in construction to the EO conversion module30shown inFIGS. 5A and 5Bwith the exception that instead of a laser diode and driver IC, the OE conversion module has an OE conversion device, which is typically a P-I-N photodiode (not shown for purposes of clarity), and a receiver IC (not shown for purposes of clarity). The visible components of the OE conversion module will be described with reference toFIGS. 5A and 5B. Although they are not visible inFIGS. 5A and 5B, the P-I-N photodiode and the receiver IC are mounted on and electrically coupled to the substrate30a.

When an optical cable or hybrid cable is terminated by the plug1shown inFIGS. 2A-2C, light generated by the laser diode is coupled via the optics system30b″ into an end of a transmit optical fiber (not shown for purposes of clarity) of the cable. Conversely, light passing out of the end of a receive optical fiber of the cable is coupled via the optics system30b″onto the P-I-N photodiode, which converts the light into electrical signals. The electrical signals are then electrically coupled via the electrical contacts29(FIG. 4) disposed on the back cover25to electrical circuitry that is external to the jack20, as will be described below in more detail with reference toFIG. 13. As indicated above, instead of the OE and the EO conversion modules residing on two separate substrates as shown inFIGS. 5A and 5B, the laser diode, the P-I-N photodiode, the laser diode driver IC, and the receiver IC may be integrated on a single substrate. Alternatively, the laser driver and the receiver may be integrated into the same IC, which would then be integrated onto a single substrate on which the ferule-type elements30b′ and optics systems30b″ are also integrated on the substrate. In the latter case, the optics systems30b″ may be housed in the same module housing30bor in separate module housings and the ferule-type elements30b′ may be part of the same module housing or parts of separate module housings.

FIG. 6illustrates a back perspective view of the jack20shown inFIGS. 3 and 4after the OE and EO conversion modules30have been installed in the back of the jack20, but prior to the door26being closed.FIG. 7illustrates a front perspective view of the jack20shown inFIG. 6after the OE and EO conversion modules30have been installed in the back of the jack20and the door26has been closed. The end of one of the ferrule-type elements30b′ can be seen positioned within one of the openings27formed in the back cover25. The locations in the cover25at which the EO and OE conversion modules30are secured to the cover25are shown inFIG. 4as cutaway regions where respective rectangular portions of the cover25have been removed to accommodate the shapes of the module housing30band the substrate30a. The invention is not limited with respect to the manner in which the EO and OE conversion modules30or the cover25are shaped or with respect to the manner in which the modules30attach to the cover25. For example, the entire module housing30bmay extend through the cover25into the front opening23, as will be described below with reference toFIGS. 10-11B, or, alternatively, only the ferule-type elements30b′ may extend through the cover25into the front opening23, as shownFIG. 7.

FIG. 8illustrates a perspective view of the modular connector assembly40of the invention comprising the plug10shown inFIGS. 2A-2Cand the jack20shown inFIGS. 3,4,6, and7mounted on a system printed circuit board (PCB)42. InFIG. 8, the plug10and the jack20are shown interlocked.FIG. 9illustrates a cutaway view of the assembly40shown inFIG. 8with a portion of the jack20removed to show the manner in which the plug10is removably secured to the jack20.FIG. 10illustrates a cutaway view of the jack20with the plug10removed to reveal locking features45and46of the jack20. One of the locking features45and46of the jack20engages the locking feature13aof the latch mechanism13when the plug10is inserted into the opening23formed in the front of the jack20.FIG. 11Aillustrates a cutaway view of a modular connector assembly comprising the jack20shown inFIG. 3and the standard electrical-only RJ-45 plug1shown inFIG. 1interlocked with the jack20in the aforementioned first interlocking position for electrical Ethernet communications.FIG. 11Billustrates a cutaway view of the modular connector assembly40shown inFIG. 8with the plug10shown inFIGS. 2A-2Cinterlocked with the jack20in the aforementioned second interlocking position for either optical communications or Ethernet electrical communications as dictated by the Ethernet Controller and Physical Layer IC shown inFIGS. 13 and 14, as will be described below in detail. The manner in which the plug10and the jack20are interlocked with each other will now be described with reference toFIGS. 10-11B.

As can be seen inFIG. 10, there are first and second locking features45and46inside of the opening23formed in the front portion of the jack20. The first and second locking features45and46are first and second openings, respectively, formed in an upper portion of the jack20. The first and second locking features45and46have shapes that are complementary to the shape of the locking feature13aof the latch mechanism13. When the plug10shown inFIGS. 2A-2Cis inserted into the opening23formed in the front of the jack20, one of the locking features45and46of the jack20engages the locking feature13aof the latch mechanism13, depending on how far the plug10is inserted into the jack20in the direction represented by arrow47inFIG. 8. Depressing the latch mechanism13in the downward direction toward the system PCB42unlocks the latch mechanism13to allow it to be removed from the jack20. If the plug10is inserted into the jack20far enough for the locking feature13aon the latch mechanism13of the plug10to be received in locking feature45, the plug10will be interlocked with the jack20in the aforementioned first interlocking position. If the plug10is inserted into the jack20just far enough for the locking feature13aof the latch mechanism13of the plug10to be received in locking feature46, the plug10will be interlocked with the jack20in the aforementioned second interlocking position.FIGS. 11A and 11Bshow the standard electrical-only RJ-45 plug1ofFIG. 1and the plug10ofFIGS. 2A-2C, respectively, in the first and second interlocking positions, respectively, inside of the jack20.

Electrical contacts48on the underside of the jack20are in contact with electrical contacts (not shown for purposes of clarity) on the system PCB42. The electrical contacts48are distal ends of the electrical contacts24disposed in the opening23of the jack20shown inFIGS. 3 and 7. In the first interlocking position shown inFIG. 11A, the insulation displacement contacts4of the standard electrical-only RJ-45 plug1shown inFIG. 1are electrically coupled via the electrical contacts24(FIG. 7) of the jack20to the electrical contacts (not shown for purposes of clarity) located on the system PCB42beneath the jack20. This electrical coupling configuration that exists in the first interlocking position enables electrical Ethernet communications to be performed. In the second interlocking position shown inFIG. 11B, optical interfaces are created between the optics systems30b″ of the ferrule-type elements30b′ (FIGS. 5A and 5B) of the OE and EO conversion modules30and the ends of the receive and transmit optical fibers, respectively, (not shown for purposes of clarity). As mentioned above, a WOF guide device60(FIG. 11B) secured within the plug housing12functions as a mechanical guide for mechanically guiding electrical wires of a hybrid cable (not shown for purposes of clarity) and the ferrules on the ends of the optical fibers of the hybrid cable (not shown for purposes of clarity) within the openings10aand10bformed in the plug housing12, as will be described below in more detail with reference toFIG. 12. In the second interlocking position shown inFIG. 11B, the tiered surface11of the plug10(FIGS. 2A-2C) abuts a complementarily-shaped surface49(FIG. 10) formed in an upper portion the jack20. The optical coupling configuration that exists in the second interlocking position enables optical communications to be performed in addition to, or in lieu of, the electrical communication provided through contacts48to the system board42. As will be described below in more detail with reference toFIG. 13, other components that communicate with the OE and EO conversion modules30and/or with the RJ-45 wiring of the jack20are mounted on the system PCB42and electrically connected via conductors of the system PCB42to the electrical contacts48of the jack20.

FIG. 12illustrates a perspective view of the WOF guide device60shown inFIG. 11B. When the WOF guide device60is installed inside of the plug housing12, locking features61on the sides of the guide device60are received in openings (not shown for purposes of clarity) formed in the plug housing12to interlock the WOF guide device60with the plug housing12. The WOF guide device60has openings63aand63bformed therein in which ferrules64and65are disposed, respectively. Each of the ferrules64and65has a compression spring66and67, respectively, disposed thereon that has a diameter that is slightly larger than the diameter of the respective openings63aand63b. The ferrules64and65have flange portions64aand65a, respectively, each having an outer diameter that is larger than an outer diameter of the ferrules64and65, respectively, and that is about the same size as the outer diameter of the compression springs66and67, respectively. The ferrules64and65have inner diameters64band65b, respectively, that are about the same size as the outer diameters of receive and transmit optical fiber (not shown for purposes of clarity). When the receive and transmit optical fibers are guided inside of the respective ferrules64and65, the ends of the respective fibers abut respective lenses64cand65cformed inside of the respective ferrules64and65.

With reference toFIGS. 2A,5A,10,11B, and12, when the plug10is inserted into the opening23formed in the jack20and interlocked with the jack20in the aforementioned second interlocking position, respective ends64dand65dof the respective ferrules64and65are received inside of the respective ends of the ferrule-type elements30b′ of the respective OE and EO conversion modules30such that the respective ends64dand65dinterface with the respective optics systems30b″ of the respective ferrule-type elements30b′. As the plug10is inserted into the opening23formed in the jack20and the respective ends64dand65dof the ferrules64and65come into contact with the respective optics systems30b″, the force in the direction of insertion of the plug10causes the ferrules64and65to retract into the openings63aand63b, respectively, formed in the WOF guide device60. Once the locking feature13aof the latch mechanism13of the plug10interlocks with the locking feature46formed on the jack housing22, retraction of the ferrules64and65ceases. The compression springs66and67exert forces that maintain the ends64dand65din abutment with the respective optics systems30b′. The resulting coupling of optical signals between the ends64dand65dof the respective ferrules64and65and the respective optics systems30b″ occurs with very little, if any, optical loss. The ends64dand65dare lenses with the focal points at the ends of the fibers.

FIG. 13illustrates a block diagram of the system PCB42shown inFIGS. 8 and 9having the modular connector assembly40and additional components mounted thereon. In the illustrative embodiment described above with reference toFIGS. 2A-12, the OE and EO conversion modules30, which are labeled with reference numerals30′ and30″ inFIG. 13, are integrated into the jack20. When the OE and EO conversion modules30′ and30″ are installed in the jack20in the manner described above with reference toFIG. 6, the electrical contacts30c(FIG. 5A) of the modules30′ and30″ are in contact with the respective electrical contacts28and29of the cover25(FIG. 4), which are, in turn, in contact with respective electrical connections (not shown for purposes of clarity) disposed on the system PCB42(FIGS. 8 and 9). With reference toFIG. 13, electrical traces71aand71belectrically couple the OE and EO conversion modules30′ and30″ to an Ethernet Controller and Physical Layer (ECPL) IC80. Electrical trace group73aand73bcarry electrical Ethernet signals to and from the electrical contacts48of the jack20to and from the ECPL IC80. As will be described below in more detail, the EPCL IC80has the capability of performing auto-negotiation with a corresponding IC (not shown for purposes of clarity) located at the end of the link opposite the end of the link to which the modular connector assembly40is installed in order to choose whether to carry out electrical or optical communications.

When optical signals are to be transmitted from the system PCB42over the cable72, which is either an optical cable or a hybrid cable, electrical signals are transmitted from the EPLC IC80over the electrically conductive traces71ato the EO conversion module30′. The EO conversion module30′ converts the electrical signals into optical signals and couples the optical signals into an end of a transmit optical fiber (not shown for purposes of clarity) of the cable72. When optical signals received over a receive optical fiber (not shown for purposes of clarity) of the cable72are coupled from the end of the receive optical fiber into the OE conversion module30″, the OE conversion module30″ converts the optical signals into electrical signals and couples the electrical signals onto the electrically conductive traces71bfor transmission to the EPLC IC80. The EPLC IC80communicates via electrically conductive traces92with the system controller IC100.

When electrical Ethernet signals are to be transmitted from the system PCB42over the cable72, which is either an Ethernet cable or a hybrid cable, electrical signals are transmitted from the EPLC IC80over the electrically conductive traces73ato RJ-45 electrical circuitry (not shown for purposes of clarity) within the jack20and plug10. The electrical signals are then electrically coupled from the RJ-45 electrical circuitry within the jack20and plug10onto one or more electrical wires of the cable72. When electrical Ethernet signals are received over one or more electrical wires of the cable72, the electrical signals are coupled via the RJ-45 electrical circuitry of the plug10and jack20from the ends of the electrical wires of the cable72onto the electrically conductive traces73b, which carry the electrical signals to the EPLC IC80.

As an alternative to the illustrative embodiment described above with reference toFIG. 13, the OE/EO conversion modules may be external to the jack20and mounted on the system PCB42, as will now be described with reference toFIG. 14.FIG. 14illustrates a block diagram of the system PCB42having the modular connector assembly40shown inFIGS. 8 and 9and additional components mounted thereon, including an EO and OE (EO/OE) conversion module110. In accordance with this embodiment, the EO/OE conversion module110is external to the jack20. The jack20may be identical to the jack shown inFIGS. 3,4and6except that the OE and EO conversion modules30shown inFIGS. 5A and 5Bhave been removed from the jack20. Two optical fibers94aand94boptically couple the EO/OE conversion module110to the jack20. The ends of the optical fibers94aand94bthat are to be inserted into the jack20may have ferrules on them that are similar or identical to the ferrules64and65shown inFIG. 12or to the ferrule-type elements30b′ shown inFIG. 10. These ends having the ferrules or ferrule-type elements on them are inserted into the back of jack20through the holes27shown inFIG. 4. The ports of the EO/OE conversion module110may have ferrule-type elements that are similar to the ferrule-type elements30b′ shown inFIG. 10.

When optical signals are to be transmitted from the system PCB42over the cable72, electrical signals are transmitted from the EPLC IC80over the electrically conductive trace93ato the EO/OE conversion module110. The EO/OE conversion module110converts the electrical signals into optical signals and couples the optical signals into the end of the optical fiber94aconnected thereto. The optical signals carried on the optical fiber94aare optically coupled via a lens element95ainto an end of a transmit optical fiber (not shown for purposes of clarity) of the cable72. When optical signals are received in the jack20over a receive optical fiber (not shown for purposes of clarity) of the cable72, the optical signals are coupled via lens element95binto the end of the optical fiber95bconnected thereto, which carries the optical signals to the EO/OE conversion module110. The optical signals are optically coupled out of the opposite end of the optical fiber95binto the EO/OE conversion module110, which converts the optical signals into electrical signals. The electrical signals are then communicated via electrically conductive trace93bto the EPLC controller IC80.

When electrical Ethernet signals are to be transmitted from the system PCB42over the cable72, electrical signals are sent from the EPLC IC80over the electrically conductive traces73ato the RJ-45 electrical circuitry (not shown for purposes of clarity) within the jack20and plug10. The electrical signals are then electrically coupled from the RJ-45 electrical circuitry within the jack20and plug10onto one or more electrical wires of the cable72. When electrical Ethernet signals are received over one or more electrical wires of the cable72, the electrical Ethernet signals are coupled via the RJ-45 electrical circuitry of the plug10and jack20from the ends of the electrical wires of the cable72onto the electrically conductive traces73b, which carry the electrical signals to the EPLC IC80.

The manner in which the aforementioned auto-negotiation process is performed will now be described. As indicated above, the EPLC IC80automatically selects whether to use optical or electrical communications. This can be achieved in a manner similar to the auto-negotiation function defined in Clause 28 of, for example, the 802.3a Ethernet standards, in which the data rate capabilities of the Ethernet stations involved in the network are made known and a fixed data rate is selected through the defined exchange of electrical pulse sequences. In accordance with the invention, the auto-negotiation process is carried out on the electrical Ethernet path (1000 megabits per second (Mbps), or 10 Mbps, or 1 Mbps) to determine whether optical paths are shared among the stations in the network and therefore to be activated as the mode of communication; a specific value of the 7-bit field in the auto-negotiation base page can be defined to indicate the optical capability of a station configured similar to that depicted in either ofFIG. 13or14. With reference toFIGS. 13 and 14, the EPLC IC80performs the auto-negotiation process with one or more similar or identical controller ICs located at one or more opposite ends of the link to determine whether electrical or optical communications are to be performed and then selects the appropriate mode of operations. Typically, if the opposite end of the link is configured to perform optical communications, the EPLC IC80will select the optical mode of operations due to the fact that they can be performed at a higher data rate; otherwise, the EPLC IC80will select the electrical mode of operations.

As indicated above, the plug10and jack20are backwards compatible with existing 8P8C modular connector assembly jacks and plugs. In other words, the jack10and plug20of the modular connector assembly can be mated with a jack and plug, respectively, of a typical 8P8C modular connector having typical RJ-45 wiring configurations. Thus, if a typical 8P8C plug having a typical RJ-45 wiring configuration, such as that shown inFIG. 1, for example, is mated with the jack of the invention, the modular connector assembly will operate as a typical 8P8C modular connector assembly. Similarly, if the plug of the invention is mated with a jack of a typical 8P8C modular connector assembly, the 8P8C modular connector assembly will operate in the typical manner. If, however, an optical cable or hybrid cable plug having the configuration shown inFIGS. 2A-2Cis connected to a jack having the configuration shown inFIGS. 3,4and6, the resulting modular connector assembly can be operated either in the optical mode or in the electrical Ethernet mode, as described above with reference toFIGS. 13 and 14. These features allow high-speed electrical or optical operations to be performed and provide the modular connector assembly with great versatility.

As will now be described with reference toFIGS. 15-21, the invention is directed to an adapter that provides an interface of at least two of the modular connector assemblies described above with reference toFIGS. 2A-12.FIGS. 15-21depict an illustrative, or exemplary, embodiment of the adapter. The adapter interfaces the plugs together to allow the signals being carried on a cable (not shown for purposes of clarity) terminated by one of the plugs to be communicated onto and carried by a cable (not shown for purposes of clarity) terminated by the other of the plugs.FIG. 15illustrates a cross-sectional perspective side view of the adapter200in accordance with an illustrative embodiment.FIG. 16illustrates a bottom perspective view of the adapter200shown inFIG. 15.FIG. 17illustrates a front perspective view of the adapter200shown inFIG. 15.FIG. 18illustrates a top perspective view of the adapter200shown inFIG. 15having plugs10of the type shown inFIGS. 2A-2Cmated therewith.FIG. 19illustrates a side cross-sectional view of the adapter200shown inFIG. 15having plugs10of the type shown inFIGS. 2A-2Cconnected to the jacks20aand20bof the adapter200.FIG. 20illustrates a side cross-sectional view of the adapter200shown inFIG. 15having typical electrical-only RJ-45 plugs1of the type shown inFIG. 1connected to the jacks20aand20bof the adapter200.FIG. 21illustrates a side cross-sectional view of the adapter200shown inFIG. 15having a plug10of the type shown inFIGS. 2A-2Cconnected to the jack20aof the adapter200and having an electrical-only RJ-45 plug1of the type shown inFIG. 1connected to the jack20bof the adapter200. The adapter200and its operations will now be described in detail with reference toFIGS. 15-21.

Like reference numerals inFIGS. 1-21identify like elements or features. The adapter has jacks20aand20bformed in opposite ends thereof that receive respective plugs, such as, for example, the plug10shownFIGS. 2A-2Cor a typical 8P8C plug of the type shown inFIG. 1having a typical RJ-45 configuration. The first and second jacks20aand20bhave the same configuration as the jack20described above with reference toFIGS. 3,4, and6-12except that the back cover25shown in those figures is replaced inFIGS. 15-21by a rear partitioning member210that is shared by the first and second jacks20aand20b. The shared rear partitioning member210has an optical coupling system220aand220bformed therein or otherwise secure thereto. In accordance with this illustrative embodiment, the first and second optical coupling systems are first and second sets of ferrules disposed on opposite sides210aand210bof the shared rear partitioning member210. The ferrules220aof the first set extend into the first jack20aand the ferrules220bof the second set extend into the second jack20b.

In addition to the shared rear partitioning member210, the jacks20aand20bshare the adapter housing222. The electrical contacts24disposed inside of each of the jacks20aand20bare interconnected by the electrical conductors223disposed on the underside of the adapter housing222. The plugs10mate with the respective jacks20aand20bin the manner described above with reference toFIGS. 9-11B. In particular, as indicated above, there are first and second locking features45and46formed in the jacks20aand20b. The first and second locking features45and46are first and second openings, respectively, formed in an upper portion of the adapter housing222. The first and second locking features45and46have shapes that are complementary to the shape of the locking feature13aof the latch mechanism13of the plug10. If the plugs10are inserted into the jacks20aand20bjust far enough for the locking features13aon the latch mechanisms13of the plugs10to be received in locking features45, the plugs10will be interlocked with the jacks20aand20bin the aforementioned first interlocking position. If the plugs10are inserted into the jacks20aand20bfar enough for the locking features13aof the latch mechanisms13of the plugs10to be received in locking features46, the plugs10will be interlocked with the jacks20in the aforementioned second interlocking position.

InFIG. 19, two of the plugs10shown inFIGS. 2A-2Care mated in the second interlocking position. As indicated above with reference toFIG. 11B, in the second interlocking position, either electrical or optical communications can be performed. If both of the plugs10terminate optical cables, then transmit and receive optical fibers of the cable terminated by the plug10that is mated with jack20aare optically coupled, via the ferrules220aand220b, with receive and transmit optical fibers, respectively, of the cable terminated by the plug10that is mated with jack20bto provide optical communications. If both of the plugs10terminate electrical Ethernet cables, then electrical wires of the Ethernet cable terminated by plug10mated with jack20aare electrically coupled with respective electrical wires of the Ethernet cable that is terminated by plug10mated with jack20bfor electrical Ethernet communications. Both plugs10could also provide electrical Ethernet communications by being mated with the jacks20aand20bin the first interlocking position.

InFIG. 20, two standard electrical-only RJ-45 plugs1of the type shown inFIG. 1are mated with the jacks20aand20bin the first interlocking position. As indicated above with reference toFIG. 11A, in the first interlocking position, the plugs1are connected to provide electrical Ethernet communications. In particular, electrical wires of the Ethernet cable (not shown for purposes of clarity) that is terminated by the plug1mated with jack20aare electrically coupled with respective electrical wires of the Ethernet cable (not shown for purposes of clarity) that is terminated by the plug1mated with jack20b.

InFIG. 21, a plug10of the type shown inFIGS. 2A-2Cis mated with jack20ain the second interlocking position and an electrical-only RJ-45 plug1of the type shown inFIG. 1is mated with the jack20bin the first interlocking position. Because the plug1is only capable of performing electrical Ethernet operations, the plug1will operate in the electrical mode. Although the plug10is shown mated with the jack20ain the second interlocking position, the plug10can operate in the electrical mode when mated with the jack20ain either the first or second interlocking position. Respective ones of the electrical contacts24disposed inside of each of the jacks20aand20bare electrically connected to each other via the electrical conductors223disposed on the underside of the adapter housing222. In this way, the electrical 8P8C contact configuration of the plug10is electrically coupled with the electrical 8P8C contact configuration of the plug1.

It can be seen fromFIGS. 15-21that the adapter200enables optical signals carried on optical cables to be coupled from one cable onto the other, and enables electrical signals carried on Ethernet or hybrid cables to be coupled from one such cable onto another such cable. In essence, each side of the adapter200is a modular connector assembly comprising a jack and either the plug10shown inFIGS. 2A-2Cor some other plug, such as a typically electrical-only RJ-45 plug1of the type shown inFIG. 1. The optical coupling system220a/220boptically couples the modular connector assemblies together whereas the electrical conductor configuration223electrically couples the modular connector assemblies together. It can be seen that the adapter200has backwards compatibility with existing Ethernet cables terminated by electrical-only RJ-45 plugs of the type shown inFIG. 1. These features of the adapter200enable it to provide great diversity and versatility with respect to the types of signals that are communicated between the assemblies, which, as will be apparent to those skilled in the art, is useful in many applications and environments.

It should be noted that the invention has been described with reference to a few illustrative, or exemplary, embodiments for the purposes of demonstrating the principles and concepts of the invention. It will be understood by persons skilled in the art, in view of the description provided herein, that many modifications may be made to the adapter200described herein without deviating from the principles of the invention. For example, instead of having first and second locking features45and46formed on the adapter housing222and a single locking feature3aformed on the latch mechanism13of the plug10, a single locking feature45or46may be formed on the housing222and multiple, spaced apart locking features13amay be formed on the latch mechanism13of the plug10. Other modifications may also be made to the adapter200, as will be understood by those skilled in the art. As will be understood by those skilled in the art, all such modifications are within the scope of the invention.