Patch cords for reduced-pair ethernet applications having strain relief units that resist rotational loads and related strain relief units and connectors

Reduced-pair Ethernet patch cords include a twisted pair cable that has a pair of insulated conductors that are contained within a cable jacket. A connector is mounted on a first end of the cable. The connector includes a connector housing and a strain relief unit that is mounted on the cable at the interface between the cable and the connector housing. The strain relief unit includes a plurality of internal protrusions that contact the cable jacket.

FIELD OF THE INVENTION

The present invention relates generally to communications systems and, more particularly, to patch cords for reduced-pair Ethernet applications.

BACKGROUND

The use of electronic devices that transmit and/or receive large amounts of data over a communications network such as cameras, televisions and computers continues to proliferate. Data may be transferred to and from these devices by hardwired or wireless connections, or a combination thereof. Devices that are connected to a communications network via a hardwired connection often use so-called Ethernet cables and connectors as these cables and connectors can support high data rate communications with a high level of reliability. Various industry standards such as, for example, the ANSI/TIA-568-C.2 standard, approved Aug. 11, 2009 by the Telecommunications Industry Association (referred to herein as “the Category 6a standard”), set forth interface and performance specifications for Ethernet cables, connectors and channels. Ethernet connectors and cables are routinely used in office buildings, homes, schools, data centers and the like to interconnect computers, fax machines, printers and other electronic devices in hardwired, high-speed communications networks.

As is well known in the art, Ethernet cables and connectors typically include four pairs of conductors that may be used to transmit four differential signals. Differential signaling techniques, where each signal is transmitted over a pair of conductors, are used because differential signals may be impacted less by external noise sources and internal noises sources such as crosstalk as compared to signals that are transmitted over a single-conductor. In Ethernet cables, the insulated conductors of each differential pair are tightly twisted about each other to form four twisted pairs of conductors, and these four twisted pairs may be further twisted about each other in a so-called “core twist.” A separator may be provided that is used to separate (and hence reduce coupling between) at least one of the twisted pairs from at least one other of the twisted pairs. The four twisted pairs and any separator may be enclosed in a protective jacket.

While hardwired Ethernet cables and connectors can support high data rates with excellent reliability in home, office and data center applications, Ethernet cables and connectors may be less well-suited for automotive, industrial and other applications that may involve harsher environments. Accordingly, Ethernet cables and connectors have typically not been used in these environments.

One relatively harsh environment where hardwired communications networks may be used is in automobiles and other types of vehicles, including planes, boats, etc. Communications connectors and cables that are used in automobiles are routinely subjected to high levels of vibration, wide temperature swings, and mechanical shocks, stresses and strains. Typically, single-ended communications channels that use non-Ethernet connectors and cabling are used in such environments, and the cables and connectors may be rather large and heavy. For example, pin connectors and socket connectors are sometimes used in automotive applications to detachably connect two communications cables and/or to detachably connect a communications cable to a printed circuit board or electronic device, as pin and socket connections can typically maintain good mechanical and electrical connections even when used for long periods of time in harsh environments.

SUMMARY

Pursuant to embodiments of the present invention, reduced-pair Ethernet patch cords are provided that include a twisted pair cable that has a pair of insulated conductors that are contained within a cable jacket. A connector is mounted on a first end of the cable. The connector includes a connector housing and a strain relief unit that is mounted on the cable at the interface between the cable and the connector housing. The strain relief unit has a plurality of internal protrusions that contact the cable jacket.

In some embodiments, the internal protrusions may be generally longitudinally aligned with a longitudinal axis of the connector. The strain relief unit may include a cable-gripping member that engages the cable and a compression member that is configured to apply a radially compressive force on the cable-gripping member. The compression member may be fixed relative to the connector housing. The protrusions may be, for example, teeth that are provided on an interior surface of the cable-gripping member. The protrusions may create respective depressions in the cable jacket. A stop may be provided in the connector housing that fixes the longitudinal position of the cable-gripping member within the connector housing. The twisted pair cable may include only a single pair of insulated conductors. The internal protrusions may contact the cable jacket to resist against rotational forces applied to the cable.

Pursuant to further embodiments of the present invention, patch cords are provided that include a cable that has a cable jacket that has at least one twisted pair of insulated conductors disposed therein, a connector that has a housing mounted on a first end of the cable. The connector includes a strain relief unit positioned at least partly within the housing. The strain relief unit includes a cable-gripping member that is mounted on the cable, the cable-gripping member including at least one uneven surface that is positioned to contact the cable jacket, and a compression member that is configured to apply a compressive force against the cable-gripping member when the compression member and cable-gripping member are installed within the connector.

In some embodiments, the compression member may be configured to apply a radial force to the cable-gripping member. The uneven surface may be configured to create a plurality of depressions in the cable jacket. The compression member may further include a cap that is mounted on a rear end of the housing. The cable-gripping member may include a plurality of cantilevered arms, and uneven surfaces may be provided on each of the cantilevered arms. In some embodiments, the interior surface of each of the cantilevered arms comprises an arcuate surface, and the uneven surface on each of the plurality of cantilevered arms comprises a plurality of teeth projecting from the interior surface thereof. The compression member may include a plurality of wedge shaped arms that are configured to apply a radially compressive force on respective ones of the cantilevered arms when the compression member and the cable-gripping member are installed within the housing. The patch cord may include at least one and no more than three twisted pairs of conductors.

Pursuant to still further embodiments of the present invention, methods of connectorizing a cable are provided in which first and second conductors of a twisted pair of conductors of a communications cable are terminated into respective first and second contacts. End portions of the terminated first and second conductors and the first and second contacts are inserted into a connector housing. A strain relief unit is slid along the communications cable and into a rear opening of the connector housing. A cable-gripping member of the strain relief unit may then be compressed onto the communications cable. The cable-gripping member has at least one protrusion that is positioned to engage a jacket of the communications cable when the strain relief unit is installed in the connector housing so as to resist angular rotation of the cable.

In some embodiments, the cable-gripping member may be at a fixed longitudinal position within the connector when it compresses onto the communications cable. The cable-gripping member may be compressed onto the communications cable by sliding a compression member of the strain relief unit onto the cable-gripping member.

DETAILED DESCRIPTION

Ethernet communications channels that connect a first electronic device to a second electronic device often includes more than one cable segment. Inline connectors such as, for example, communications jacks, are used to connect a first cable segment to a second cable segment to form the end-to-end communications channel between the two electronic devices. In many cases, one or both ends of each cable segment will be terminated with a connector such as a communications plug that may be releasably mated with the inline connector. Herein, a cable segment that includes a communications connector such as, for example, a plug on at least one end thereof is referred to as a “patch cord.” Most typically, a patch cord will have plug connectors on one or both ends thereof, but it will be appreciated that other types of connectors (e.g., jack connectors or non-plug-jack connectors) may be used.

An Ethernet patch cord plug typically has eight output terminals in the form of plug blades that are electrically connected to the respective conductors of the cable segment. This plug may be inserted into a mating jack so that the plug blades electrically connect to respective input terminals of the jack, which are often implemented as eight jackwire contacts. The jack may be mounted on an electronic device or may be electrically connected to another communications cable segment that is typically terminated into wire connection terminals provided in the back portion of the jack. The plug and jack can be readily connected and disconnected from each other in order to facilitate future connectivity changes.

A potential problem with conventional Ethernet patch cords is that forces may be applied to the cable segment of the patch cord that may cause the cable (or some of the conductors therein) to pull away from the plug blades or to even pull out of the plug. These forces may arise, for example, because individuals accidentally pull on the cable or because excessive forces are applied to the cable when the plug is removed from a mating jack. Such forces can degrade the performance of the patch cord, or render it unusable, as the connections between the conductors of the cable segment and the plug blades (or other terminals) may be loosened or disconnected as a result of the pulling forces on the cable. Axial pulling forces are of particular concern (i.e., a generally “straight pull” along the longitudinal direction of the plug), but “side pulls” may also cause problems where the pulling force is at an angle to the longitudinal axis of the plug. In order to reduce the impact of such pulling forces, prior art patch cords include strain relief mechanisms. For example, one prior art strain relief mechanism uses an anchoring member that is disposed in the plug housing, and another part of the housing pressures the cable against the anchoring member in order to securely lock the cable in place. Another known type of strain relief mechanism is a compression ring that fits around the cable that is forcibly inserted within a tapered portion of a bore through the plug housing so that the ring gradually compresses around and tightly grips the cable. The compression ring may include one or more latching projections that mate with latch openings in the plug housing at a point where the ring is near maximum compression to lock the compression ring in place. Thus, the compression ring, gripping the cable, is held within the bore of the plug, and resists pulling stresses that may be applied to the cable.

So-called “reduced-pair Ethernet” cables and connectors are now under development that include less than four differential pairs of conductors. Of particular interest are single-pair cables that include a single twisted pair of insulated conductors in a jacket (with no separator since only a single-pair is used) and single-pair patch cords that are connectorized versions of such cables. Single-pair patch cords may be joined to a mating single-pair connector or may be joined to a multi-pair connector that is designed to connect a plurality of single-pair patch cords to corresponding cables or patch cords. Two-pair and three-pair reduced-pair Ethernet cables, patch cords and connectors are also under consideration.

In reduced-pair Ethernet applications, the patch cords may be implemented, for example, using plug connectors, jack connectors or a plug connector on one end and a jack connector on the other end. In the discussion that follows, the patch cords will be described as having plug connectors, and the patch cords are mated with inline jack connectors (e.g., a connector that has two jacks arranged back-to-back) that may be used to electrically connect a first patch cord to a second patch cord. However, it will be appreciated that in other embodiments of the present invention patch cords that include jack connectors may be used instead, and it will also be appreciated that jacks other than inline jacks may be used such as, for example, jacks that electrically connect a patch cord to a printed circuit board.

In order to reduce the effects of crosstalk, the conductors of the twisted pairs of an Ethernet patch cord cable may be kept twisted right up to the point where the conductors are terminated into mating structures in the plug (e.g., insulation piercing contacts that may be included at the back of each plug blade or on a printed circuit board or metal-plated apertures on a printed circuit board). The same is true with respect to reduced-pair Ethernet patch cords, in order to reduce crosstalk between the twisted pairs within a single cable (in applications having at least two pairs per cable) and/or to reduce “alien” crosstalk that may arise between adjacent reduced-pair Ethernet cables and connectors. Additionally, in both standard and reduced-pair Ethernet applications, the patch cords and connectors may be designed to cancel out any crosstalk that is expected to arise in the connectors in order to keep crosstalk at a minimum. As a result, any variation from a design goal regarding the amount (if any) that a twisted pair of a patch cord is untwisted proximate its termination point within a connector can result in increased crosstalk (e.g., with another twisted pair in the cable or with a twisted pair in an adjacent cable) that can degrade the data transmission performance of the patch cord.

Unfortunately, if a single-pair Ethernet patch cord is twisted (i.e., the cable is rotated about its longitudinal axis with respect to the plug connector), the twisted pair contained within the cable may be either partially untwisted or over-twisted, depending upon the direction of rotation. In particular, when a rotational force (torque) is applied to the twisted pair that is opposite the direction of the original twist, the twist for a portion of the twisted pair may tend to loosen. This may degrade the crosstalk and/or return loss characteristics of the patch cord. Similarly, when a rotational force is applied to the twisted pair that is in the same direction as the original twist, a portion of the twisted pair may become over-twisted. This may also degrade the crosstalk and/or return loss characteristics of the patch cord. It is also possible for twisted pair cable to be compressed axially inside the connector during assembly of the connector. This compression may occur, for example, when the strain relief member is inserted into the rear of the connector and is pressed into the connector body to latch in place. This action may compress the cable inside the connector housing between the stain relief member and fixed terminals and can cause the conductors of the twisted pair to be forced apart forming “open loops” in the communications cable. These open loops may degrade the crosstalk and/or return loss characteristics of the patch cord.

Pursuant to embodiments of the present invention, patch cords are provided that have connectors with strain relief units that may resist rotation of a cable of the patch cord relative to the connectors thereof in response to a rotational force. The strain relief units may also protect against axial loads or side loads that are applied to the cable thereof. The strain relief units used in the patch cords according to embodiments of the present invention may facilitate providing patch cords with better and more consistent data transmission performance.

In some embodiments, the patch cords may comprise single-pair patch cords that include a cable having a single twisted pair of insulated conductors that is surrounded by a protective jacket. In other embodiments, the patch cord cables may include more than a single-pair of twisted conductors, such as two pairs of twisted conductors. The patch cords may also be implemented with cables in which more than two insulated conductors are twisted together, such as in patch cords implemented with so-called “twisted-quad” shielded cables that have four insulated conductors that are twisted together.

In some embodiments, the strain relief unit may comprise a two-piece unit that is mounted in a rear portion of the connector housing. Such strain relief units may include a cable-gripping member that is configured to engage an exterior surface of the cable of the patch cord and a compression member which is configured to compress the cable-gripping member against the cable. In some embodiments, the cable gripping member may comprise a collar that is mounted on the cable and the compression member may comprise a cap that both closes off the back portion of the connector housing and imparts a compressive force on the collar so that the collar securely locks the cable within the housing and resists axial, side-pull and rotational forces or loads. The cable-gripping member may include a plurality of teeth or other projections on an interior surface thereof that “bite” into the exterior surface of the cable and hence resist rotation of the cable of the patch cord relative to the connector. At least some of these teeth or other projections may be generally aligned along a longitudinal directional of the connector to better resist against twisting of the cable relative to the connector.

In some embodiments, the strain relief unit may only include a cable-gripping member, and features on the connector housing may be used to compress the cable-gripping member against the cable.

The patch cords, connectors and strain relief units according to embodiments of the present invention may be used in various applications such as automotive, industrial and other applications which may comprise harsher environments that are not well-suited to traditional Ethernet cables and connectors. In some embodiments, the patch cords may be terminated with pin connectors or socket connectors. The twisted pair(s) in the cable of the patch cord may maintain their twist right up to the point at which the conductors of the cable terminate into the appropriate termination in the connector (e.g., into a respective sockets of the connector or into a printed circuit board of the connector).

Certain embodiments of the present invention will now be described with reference to the drawings, in which example implementations of the present invention are depicted.

Referring toFIG. 1, two reduced-pair Ethernet cables are shown, namely a first cable10and a second cable20. The first cable10includes first and second conductors12,14that are twisted together to form a single twisted pair16. The conductors12,14are enclosed by a protective jacket18. The second cable20includes first through fourth conductors22,24,26,28. Conductors22and24are twisted together to form a first twisted pair30, and conductors26and28are twisted together to form a second twisted pair32. The twisted pairs30and32are separated by a separator34, and are encased in a protective jacket36.

FIGS. 2-8illustrate a patch cord100according to embodiments of the present invention that includes a cable110and a connector120on at least one end thereof.FIG. 2is an exploded perspective view of an end portion of the patch cord100.FIG. 3is an enlarged view of the cable110with a strain relief unit160of the connector120mounted thereon.FIG. 4is a partially cut-away side view of the connector120with the contact carrier thereof omitted.FIG. 5is a cross-sectional view of the connector housing and strain relief unit of the patch cord100.FIG. 6is a cross-sectional view of the connector120that illustrates the contact carrier and one of the contacts thereof.FIG. 7is an enlarged perspective view of a cable-gripping member of the strain relief unit of the connector120.FIGS. 8A-8Dillustrate the contacts of the connector120and show how they may mate with the contacts of a mating inline connector to electrically connect a first patch cord100to a second patch cord100.

Referring toFIG. 2, the patch cord100comprises a cable110and a connector120. The cable110may be identical to the cable10discussed above with reference toFIG. 1, and may include first and second conductors12,14that are twisted together to form a twisted pair16, and a protective jacket18. InFIGS. 2-6, only the cable jacket18of cable110is illustrated to simplify the drawings.

The connector120includes a connector housing130, a contact carrier140(seeFIG. 6) that includes a pair of contacts142,144(FIGS. 6 and 8A-8D) and a strain relief unit160. The housing130has a front end132, a rear end134and side surfaces136. A bore138extends longitudinally through the housing130. A rear portion of the bore138comprises a cable-receiving cavity139(seeFIGS. 5-6). Windows137are provided in the respective side surfaces136. The cable110is received through an opening in the rear end134of housing130and extends into the cable-receiving cavity139of the bore138. As shown inFIG. 6, the contact carrier140resides in a front portion of the bore138. The jacket18of cable110may extend into the bore138up to the rear end of the contact carrier140. The insulated conductors12,14of cable110(seeFIG. 1) may extend farther forwardly than the jacket18in order to make mechanical and electrical connections to their respective contacts142,144. The insulation may be removed from the end of insulated conductors12,14, and the exposed conductors thereof may be inserted within (or otherwise mated to) the respective contacts142,144. The housing130may comprise a dielectric housing, and may include various features that allow the connector120to be releasably joined to a mating connector (not shown). In the embodiment ofFIGS. 2-8, the connector120comprises a plug that is configured to be received within the plug aperture of a mating jack.

Referring toFIGS. 2-3 and 7, the strain relief unit160comprises a two-piece unit that includes a cable-gripping member170and a compression member180. Both pieces170,180may be made of, for example, a flexible material such as a plastic material (e.g., polycarbonate). In some embodiments, the cable-gripping member170may comprise a generally cylindrical member that has a generally circular bore extending therethrough that may be dimensioned to receive the cable110. In some embodiments, the cable-gripping member170may extend a full 360 degrees around the circumference of the cable110, while in other embodiments, the cable-gripping member170may extend less than 360 degrees around the circumference of the cable110as would be the case, for example, with a generally C-shaped cable-gripping member170(seeFIG. 9). The cable-gripping member170may be designed to engage the jacket18of cable110and to resist rotation of the cable110with respect to the connector housing130of patch cord100.

In the exemplary embodiment depicted inFIGS. 2-7, the cable-gripping member170has an annular base172and four generally wedge-shaped cantilevered arms174that extend forwardly from the annular base172. Gaps176are provided between adjacent ones of the cantilevered arms174. In the depicted embodiment, each cantilevered arm174has a generally arcuate interior surface that is designed to generally mimic the contour of the exterior surface of the jacket18of cable110. Moreover, a plurality of protrusions178(seeFIG. 7) extend from the interior surface of each cantilevered arm174in the form of longitudinally extending teeth178. Each cantilevered arm174tapers from its distal end toward the base172so that a circle defined by the distal ends of the four cantilevered arms174may have a diameter that is greater than the diameter of the annular base172. Because the arms174are both cantilevered and formed of a flexible material, they may be pressed inwardly if subjected to a radially compressive force. In the depicted embodiment, the cable-gripping member170comprises a collar that may be inserted over an end portion of the cable110, as is best shown inFIG. 3. Thus, member170is referred to herein as both a “collar” and as a “cable-gripping member.” As discussed below, in other embodiments, the collar may not act as a cable-gripping member. As shown inFIGS. 4-6, the collar170ultimately is received within the cable-receiving cavity139when the patch cord100is fully assembled.

As shown inFIGS. 2-3, the compression member180has a base182that has a flat rear surface. Four compression wedges184and two cantilevered latches186extend forwardly from the base182. As shown in the figures, the compression member180is mounted on the cable110rearwardly of the cable-gripping member170. The forwardly-extending compression wedges184are radially disposed about the base182, and each compression wedge184may be longitudinally aligned with a respective one of the cantilevered arms174of the cable-gripping member170. The compression wedges184may define a cylinder having a diameter that is greater than the diameter of the base172of the cable-gripping member170. Each latch186has a tab188at its distal end that slopes outwardly from the distal end of the latch176. The rear surface of each tab188forms a stop190. The latches186are spaced apart in the transverse dimension a distance that is slightly greater than the width of the rear opening into the housing130. In the depicted embodiment, the compression member180comprises a rear cap for the housing130that allows the cable110access into the bore138of the housing130while covering the remainder of the opening into the rear end134of the housing130. Thus, member180is referred to herein as both a “cap” and as a “compression member.” As discussed below, in other embodiments, the cap may not act as a compression member.

The strain relief unit160may operate as follows. The cap180and the collar170may be slid over the end of the cable110as is shown inFIG. 2, with the bases172,182being slid onto the cable110first so that the compression wedges184and the cantilevered arms174point forwardly toward the end of the cable110. The conductors12,14of cable110may be terminated into a pair of contacts142,144of the connector120(the contacts are shown inFIGS. 8A-8D, discussed infra). The contacts142,144may be mounted in the contact carrier140when the conductors12,14are terminated into the contacts142,144, or the contacts142,144may be terminated onto their respective conductors12,14and then installed into the contact carrier140. In some embodiments, the conductors12,14may remain twisted together essentially all the way up to the point where the conductors12,14terminate into their respective contacts142,144. Depending on the contact design, it may or may not be necessary to strip the insulation off of the end portion of each conductor12,14prior to terminating the conductors12,14onto the contacts142,144.

Next, the contact carrier140is inserted into the connector housing130via the rear opening into bore138. At this time, the collar170and the cap180may still be positioned some distance down the cable110from the connector housing130, as is shown inFIG. 2. As shown inFIGS. 5-6, the rear portion of bore138comprises a cable-receiving cavity139. The rear portion of cable-receiving cavity139has sloped walls135(e.g., a frusto-conical opening) that reduce the cross-sectional size of the cable-receiving cavity139so that the rear opening into the cable-receiving cavity139has a greater cross-sectional area than the middle and forward portions of the cable receiving cavity139. As is readily apparent fromFIGS. 5-6, the enlarged rear opening provided by the outward taper of walls135allows the collar170to be slid into position inside the connector housing130such that one or more stop features173that protrude from the base172of collar170(in the depicted embodiment the stop features173comprise a pair of rectangular protrusions that extend from the top and bottom of the annular base172that can be seen inFIG. 7) engage mating features175inside the cable-receiving cavity139(in the depicted embodiment the mating features175comprise recesses in the top and bottom of the cable-receiving cavity139), thereby preventing the collar170from rotating inside the connector housing130. The cap180can then be slid into position, and the compression wedges184and latches186of cap180may readily slide into the cable receiving cavity139. However, as the cap180is slid farther forwardly, the decreasing cross-sectional area of the cable-receiving cavity139forces the cantilevered arms174, latches186and compression wedges184radially inwardly. As shown inFIGS. 4-6, the compression wedges184overlap the cantilevered arms174, and thus both the decreasing cross-sectional area of the cable-receiving cavity139and the compression wedges184act to force the cantilevered arms174radially inwardly, which can increase the radial force on the cantilevered arms174. As a result, the teeth178on the interior surfaces of the respective cantilevered arms174may be firmly forced against the jacket18of cable110. The jacket18may be made of a relatively soft plastic material such as polyvinyl chloride (“PVC”). As shown inFIG. 11, the teeth178may create depressions112in the jacket18and the teeth178may lock into place within those depressions112.

Once the collar170and the cap180are fully received within the plug-receiving cavity139, the tabs188may reach their respective windows137in the housing130, thereby releasing the radially inward force on the latches186which allows the tabs188to extend through their respective windows137. The stops190on the tabs188lock the latches186in place, thereby firmly locking the cap180and collar170within the plug-receiving cavity139. While cantilevered latches186having tabs188with stops190and mating windows137in the housing130are used to lock the strain relief unit160in place within the connector housing130in the depicted embodiment, it will be appreciated that a wide variety of other means may be used to secure the strain relief unit160within the housing130.

Once in place, the strain relief unit160may resist a variety of loads. For example, if a pulling force such as a straight pull (e.g., a force applied in the longitudinal direction away from the connector120) or a side pull (e.g., a force applied at an angle to the longitudinal direction such as a 45 degree angle in a direction away from the connector120) is applied to the cable110, then the radial compression force applied by the collar170against the cable jacket18will act to reduce or prevent any tendency for this force to pull the cable110out of the connector120and/or to pull the conductors12,14of cable110out of their terminations to their respective contacts142,144. Thus, the strain relief unit160may provide conventional strain relief properties. Additionally, the position of the cap180is fixed with respect to the connector housing130, and the position of the collar170is fixed with respect to the connector housing130. Moreover, the longitudinally-extending teeth178that are lodged within depressions112in the cable jacket18(seeFIG. 11) resist rotation of the cable110with respect to the collar170. Consequently, even if a twisting or rotational force is applied to the cable110(in either direction), the cable110will resist rotating with respect to the connector120. Thus, the strain relief unit160may help reduce the likelihood that a rotational force applied to the cable110may negatively impact the twist of the twisted pair16by either loosening or over-tightening the twist. Longitudinally-extending teeth178or protrusions may be particularly effective in resisting against rotational forces that are applied to the cable110.

FIGS. 8A and 8Bschematically illustrate the contacts142,144of the connector120. In particular,FIG. 8Ais a perspective view of the two contacts142,144, whileFIG. 8Bis a perspective view of the two contacts142,144that illustrates how they mate with the contact structures210,220of a mating inline jack connector200.FIGS. 8C and 8Dare a perspective view and top view, respectively, that show how the contacts142,144of two different connectors120may be electrically connected via the contacts of an inline jack connector200. Note that only the contacts210,220of inline connector200(and not the remainder of the connector200) are shown in order to simplify the drawings.

As shown inFIGS. 8A and 8B, the contacts142,144are implemented as socket contacts and include a tip contact142and a ring contact144. Each contact142,144comprises a hollow cylinder having a rear end146and a front end148. The internal diameter of the rear end146of each contact142,144may be sized to receive a respective one of the insulated conductors (with the insulation removed) with an interference fit that provides a good mechanical and electrical connection. In other embodiments, the conductors12,14may be soldered into the rear ends146of their respective contacts142,144, or the socket contacts142,144may be crimped onto a bare end portion of their respective conductors12,14. The front end148of each contact142,144may be sized to receive the pin contacts of a mating connector, and may include one or more longitudinal slits150.

As shown inFIG. 8B, the contacts210,220of the inline jack connector200comprise a pair of double-sided crossover tip and ring pin contacts210,220. The tip contact200includes a first pin212, a second pin214and a crossover segment216that connects the first pin212to the second pin224. The ring contact220includes a first pin222, a second pin224and crossover segment226that connects the first pin220to the second pin224.

As shown inFIGS. 8C and 8D, the tip pin212on a first side of the inline connector200is received within the tip socket142of a first connector120-1, and the ring pin214on the first side of the inline connector200is received within the ring socket144of the first connector120-1. Likewise, the tip pin222on a second side of the inline connector200is received within the tip socket142of a second connector120-2, and the ring pin224on the second side of the inline connector200is received within the ring socket144of the second connector120-2.

Pin contacts212and214may each reside in a first horizontally-oriented plane, and pin contacts222and224may each reside in a second horizontally-oriented plane that is beneath the first horizontally-oriented plane and parallel thereto. Pin contacts212and214are each tip pin contacts that form a tip conductive path through the inline connector200. Pin contacts222and224are each ring pin contacts that form a ring conductive path through the inline connector200. Thus, the inline connector200may be used to electrically connect tip socket contact142of a first connector120-1to the tip socket contact142of a second connector120-2, and to electrically connect the ring socket contact144of connector120-1to the ring socket contact144of connector120-2. By staggering the tip and ring pin contacts in two vertical rows and by providing the crossover in the middle of the inline connector200, the inline connector200may exhibit reduced differential and common mode crosstalk between adjacent inline connectors when a plurality of inline connectors are arranged side-by-side in a row.

FIG. 9is a perspective view of a cable-gripping member270according to further embodiments of the present invention. The cable-gripping member270may be used, for example, in place of the cable-gripping member170that is discussed above with reference toFIGS. 2-7. As shown inFIG. 9, the cable-gripping member270comprises an annular ring272that has a portion of its circumference omitted to form a generally C-shaped ring having an opening280. The interior surface of the C-shaped ring272includes a plurality of protrusions278. In the depicted embodiment, the protrusions278comprise generally longitudinally extending teeth. However, it will be appreciated that any appropriate protrusions may be used that resist twisting forces that are applied to the cable of the patch cord in which cable-gripping member270is used. The exterior surface of the ring272may include a stop feature273that resists rotation of the ring272with respect to, for example, the connector housing.

The cable-gripping member270ofFIG. 9may be placed on the cable of a patch cord, and may be slid into the housing of the connector of the patch cord once the conductors of the cable are terminated into the contacts of the connector. The cable-gripping member270may be compressed tightly onto the cable so that the protrusions278make depressions in the cable jacket and resist rotational forces based on both the compression force and the protrusions that are lodged in the depressions in the cable jacket. The cable-gripping member270may be compressed onto the cable using a compression member such as the cap180of the embodiment ofFIGS. 2-7(modified appropriately to cooperate with the cable-gripping member270). Alternatively, the cable-gripping member270may be compressed by features within the housing that compress the cable-gripping member270as the cable-gripping member is inserted into the connector housing. In either case, as the cable-gripping member270is compressed, the opposed ends274,276of the C-shaped ring272that define the opening280of the “C” are pressed together. Thus, the opening in the “C” allows the cable-gripping member270to evenly compress around the cable. As shown, in some embodiments, the protrusions278may (optionally) only be provided on the interior portions of the C-shaped ring272that are opposite the opening280to allow the ring to more evenly compress around the cable. The stop feature273may mate with a mating feature (not shown) in the interior of the connector housing to resist rotation of the cable-gripping member270with respect to the connector housing.

While embodiments of the cable-gripping member that include cantilevered arms and a C-shaped ring are described above, it will be appreciated that other cable-gripping members may be used. Preferably, the cable-gripping member will apply a generally radial compression force on the cable as opposed to only applying a force to, for example, one side of the cable, in order to reduce or minimize the amount that the strain relief unit deforms or changes the relative positions of the conductors within the cable as such changes may negatively impact the electrical performance of the cable.

It will also be appreciated that a wide variety of uneven surfaces or protrusions may be used in the cable-gripping members according to embodiments of the present invention. By way of example,FIGS. 10A-10Dare schematic plan views that illustrate additional example protrusion patterns that may be used on the cable-gripping members according to further embodiments of the present invention.

For example,FIG. 10Aillustrates a protrusion pattern300in which the teeth178included on the collar170ofFIG. 7are replaced with an array (or other pattern) of small square protrusions302. It will be appreciated that shapes other than squares may be used in further embodiments.FIG. 10Billustrates a protrusion pattern310in which the rectangular teeth178included on the collar170ofFIG. 7are replaced with triangular teeth312.FIG. 10Cillustrates a protrusion pattern320in which the longitudinally-extending teeth included on the collar170ofFIG. 7are replaced with teeth322that extend at various angles from the longitudinal direction.FIG. 10Dillustrates a protrusion pattern330in which the rectangular teeth included on the collar170ofFIG. 7are replaced with V-shaped protrusions332. It will also be appreciated that a variety of different types of protrusions may be included on the same cable-gripping member.

In some embodiments, such as the embodiment ofFIGS. 2-8, the cable-gripping member170may be in a fixed longitudinal position when the cable-gripping member170is compressed onto the cable110. For example, as shown inFIGS. 5-6, a stop133is provided within the cable-receiving portion139of bore138. The stop133prevents the collar170from being moved any farther forwardly into the bore138, thus fixing the longitudinal position of the collar170within the housing130when the cap180is applied to compress the collar170around the cable110. If the cable gripping member170were to move longitudinally during the compression process (as opposed to just squeezing down on the cable110), the longitudinal movement of the cable gripping member170could push the cable110further into the connector120, which could distort the arrangement of the twisted pair16and degrade the electrical performance of the patch cord100. Accordingly, in some embodiments, the connector120may include stops such as the stops133that fix the longitudinal position of the cable-gripping member170during the installation of the strain relief unit160.

In still further embodiments of the present invention, the cap180and collar170of the embodiment ofFIGS. 2-8may be modified so that the cap180acts as the cable-gripping member and the collar acts as the compression member. In such embodiments, the compression wedges184of the embodiment ofFIGS. 2-8may be redesigned to define a circle that has a diameter slightly larger than the diameter of the cable110, and teeth or other protrusions may be provided on the interior surfaces of the wedges184. The collar170may likewise be designed to fit over the wedges of the cap to compress the wedges of the cap against the cable when the cap is inserted into the rear of the connector housing130. In some embodiments, the collar could be replaced with interior features in the connector housing that compress the wedges of the redesigned cap against the cable.

In automotive and other vehicle applications, a hardwired cabling connection between two devices such as a processor and a door-mounted camera may need to extend through one or more connection hubs. The patch cords according to embodiments of the present invention may be used to provide connections between these end devices and the connection hubs or between two connection hubs.

It will also be appreciated that aspects of the above embodiments may be combined in any way to provide numerous additional embodiments. These embodiments will not be described individually for the sake of brevity.

While the present invention has been described above primarily with reference to the accompanying drawings, it will be appreciated that the invention is not limited to the illustrated embodiments; rather, these embodiments are intended to fully and completely disclose the invention to those skilled in this art. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present invention. It will also be understood that the terms “tip” and “ring” are used to refer to the two conductors of a differential pair and otherwise are not limiting.

Well-known functions or constructions may not be described in detail for brevity and/or clarity. As used herein the expression “and/or” includes any and all combinations of one or more of the associated listed items.

Herein, the terms “attached”, “connected”, “interconnected”, “contacting”, “mounted” and the like can mean either direct or indirect attachment or contact between elements, unless stated otherwise.