Modular plug with automatically staggered wires

A modular plug connector that achieves category 5 cross talk performance is constructed with substantially parallel conductor positioning channels situated in a pair of spaced apart planar arrays to position individual conductors for termination by a plurality of flat insulation displacement contacts. A plurality of conductor guide ramps are formed such that upon insertion of the individual conductors, alternating conductors will be guided into their respective spaced apart array.

TECHNICAL FIELD 
The present invention relates generally to modular communication plug 
connectors for electrically terminating and connecting conductors of 
communication cables, and more specifically to a modular plug connector 
having an improved wire conductor insertion and positioning design. 
BACKGROUND OF THE INVENTION 
A wide variety of modular plugs of generally similar outward configuration, 
necessitated by the requirement of mating with a standard modular jack, 
are known in the communication industry. Modular plugs are relatively 
small in size, and terminate ends of communication cables whereby the 
individual wires are in close proximity thus inducing cross talk between 
different signal pairs. However, with the increase in data transmission 
rate requirements, the use of modular communication plugs and jacks to 
connect twisted pair cables in computer networks has resulted in a need to 
reduce the cross talk between signal transmitting wire pairs of the 
modular communication connectors. One method of reducing cross talk is 
achieved by staggering adjacent pairs of individual wires and minimizing 
the distance of the parallel runs. 
The relatively small size of the plugs and conductors requires careful 
manipulation of the individual insulated conductors in arranging the order 
of the conductors relative to the contacts in the modular plug and for 
holding the conductors in the proper arrangement within the plug prior to 
being terminated. Typically, eight individual insulated conductors must be 
arranged and terminated to eight contacts in the plug. Providing the 
individual wires in a pair of spaced apart planes with alternating 
conductors being in alternating planes and situated such that the adjacent 
conductors have minimized parallel runs to reduce cross talk can be 
difficult to assemble. The individual conductors must either be preformed 
and carefully inserted into the individual channels or else initially 
positioned in a single planar array and forced into a staggered 
relationship. 
Therefore, there is need for improvement in the art for a modular plug 
connector that can be easily terminated while reducing the cross talk 
induced by the connector in terminated wire pairs. 
SUMMARY OF THE INVENTION 
It is an object of the present invention to provide an improved modular 
plug connector that reduces cross talk between the conductor pairs 
terminated in the connector. 
It is also an object of the present invention to provide an improved 
modular plug connector that provides for easier wire insertion of the 
individual wires into an improved relationship. 
In general, a modular plug according to the present invention includes a 
connector for terminating a plurality of conductors of a plurality of 
conductor pairs, comprising a connector housing having a rear cable 
receiving opening formed by a top wall, a bottom wall and a pair of 
opposing side walls, a plurality of conductor positioning channels formed 
in a pair of offset planar arrays, and guide means for guiding the 
plurality of conductors into the pair of offset planar arrays of conductor 
positioning channels.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
A modular communication plug connector embodying the concept of the present 
invention is designated generally by the reference numeral 10 in the 
accompanying drawings. Modular plug 10 is formed of a thermoplastic 
material and is designed to terminate a plurality of insulated conductors 
of a twisted pair cable. 
Generally, the insulated conductors in signaled pairs are twisted together 
along their length within the cable to reduce cross talk between 
conductors 42 and are enclosed within a protective sheath 44 of cable 40. 
The cable 40 generally is stripped of its sheath 44 exposing four twisted 
wire pair conductors. These eight conductors 42 are then arranged into the 
proper color sequence, parallel to one another, and inserted into the 
housing as shown in FIG. 1. Connector 10 can also be used to terminate 
untwisted pair cable, flat cable or any other cable, the conductors of 
which are formed or can be formed into a planar array. 
Modular plug 10 having a latch 30 is formed as a housing having a front 
face 20, and a rear cable receiving channel 28 defined by a top wall 12, 
first and second sidewalls 16, 18, and a bottom wall 14 as can be seen in 
FIGS. 2 and 3. As seen in FIG. 4, Channel 28 communicates with an array of 
eight conductor positioning channels 22 extending to the front face 20. 
The conductor positioning channels 22 are separated into an upper plane 24 
and a lower plane 26. It is to be noted that as shown in FIG. 2, due to 
manufacturing constraints the far left conductor of the upper plane is 
slightly lower. As can be seen in FIGS. 3, 4, 6 and 7, a plurality of 
integrally formed ramp surfaces 34, 36 are situated within the cable 
receiving channel 28 so as to automatically receive and accurately 
position individual conductors 42 therebetween in the preferred spaced 
apart two-plane relationship. Upon sufficient insertion of the conductors 
42 as shown in FIGS. 8 and 9, the top ramp surfaces 34 cause alternate 
conductors 42 to be deflected downward into the lower plane of conductor 
positioning channels 26. The bottom ramps 36 are positioned so as to 
automatically realign any stray conductors 42 back into the upper plane of 
conductor positioning channels 24. 
As shown in FIG. 4, when terminating a cable 40 to the connector 10 the 
stripped and aligned conductors 42 are initially inserted against the top 
interior wall surface 12 which includes a plurality of guide troughs 32 
that keep conductors 42 separated and in their proper order. Further 
insertion guides the conductors 42 to the respective ramp and 
corresponding conductor positioning channel 22. As can be seen in FIGS. 8 
and 9 as the conductors 42 reach the guide ramps 34, 36, upper ramps 34 
deflect the alternate conductors 42 downward and into the lower plane 26 
of conductor positioning channels 22. After cable 40 and conductors 42 
have been fully inserted, conductors 42 can be terminated by the contact 
blades 38 inserted through a plurality of corresponding contact slots 48 
and the strain relief 46 applied to the cable 40 within the connector 10 
as shown in FIGS. 11 and 12. 
It is to be noted that channel 26 extends into connector 10 as far as 
practicable since having a smaller parallel run of adjacent conductor 
pairs reduces cross talk. However, a sufficient length of the stripped end 
of the wires must be maintained to have enough rigidity to be inserted. 
When used to terminate shielded or unshielded 100 ohm cable twisted pair 
category 5 cable meeting EIA/TIA TSB-36, the final staggered disposition 
of the distal ends of conductors provides a plug connector that has been 
found to reduce cross talk induced by the connector an amount sufficient 
to consistently exceed category 5 cross talk performance as specified by 
the Electronics Industries Association and the Telecommunication Industry 
Association, EIA/TIA in specification SP-2840, with the plug and cable 
tested under TSB-67 certification test equipment for category 5 compliance 
and the plug alone tested under TSB-40 termination component requirements 
while providing a connector that can be economically manufactured and 
easily terminated, without the use of a separate wire loading bar, merely 
by inserting a planar array of conductors into the connector and 
terminating the plug connector. 
Although the present invention has been described as used in a modular plug 
connector, it is to be understood that the present invention would be 
useful in any type of connector to reduce cross talk in a connector where 
it is desirable to initially position a substantially planar array of 
conductors in the connector for termination. 
While the particular preferred embodiment of the present invention has been 
shown and described, it will be obvious to those skilled in the art that 
changes and modifications may be made without departing from the teachings 
of the invention in its broader aspects. The matter set forth in the 
foregoing description and accompanying drawings is offered by way of 
illustration only and not as a limitation. The actual scope of the 
invention is intended to be defined in the following claims when viewed in 
their proper perspective based on the prior art.