COMMUNICATION CONNECTOR

The present invention generally relates to the field of telecommunication, and more particularly, to the field of connectors such as plugs and/or jacks used to interconnect electronic equipment. In an embodiment, the present invention is a shielded RJ45 network jack with an inter-jack connection method that has an electrical disengagement point outside of any electrical mating points, while still allowing for a relatively short distance to compensation from the plug/jack mating interface.

FIELD OF INVENTION

The present invention generally relates to the field of telecommunication, and more particularly, to the field of connectors such as plugs and/or jacks used to interconnect electronic equipment.

BACKGROUND

It is common practice to use modular (e.g., RJ45) plugs and jacks in combination with twisted pair cabling to interconnect electronic equipment. While the primary purpose of this type of connectivity is to enable the flow of data, it is also possible to use the same medium to transmit limited amounts of power. This is generally referred to as Power over Ethernet (PoE).

PoE allows a single cable to provide both electrical power and data connections, which may eliminate the need for additional power cables and devices such as transformers and AC outlets. Some non-limiting examples of PoE devices include Voice over Internet Protocol (VoIP) phones, wireless access points, network routers, switches, industrial devices (controllers, meters, sensors, etc.), nurse call stations, IP security cameras, televisions, LED lighting fixtures, remote point of sale kiosks, and physical security devices. PoE was launched into the market in 2003, standardized under IEEE 802.3af, and allowed for a power draw of 12.95 W and 350 mA per pair (Type 1). POE+ was launched into the market in 2009, standardized under IEEE 802.3at, and allowed for a power draw of 25.5 W and 600 mA per pair (Type 2). As the need for more and more power becomes apparent, non-standard applications, such as Cisco's Universal Power over Ethernet (UPoE) at 60 W and Power over HDBaseT (100 W), with 1000 mA per pair of current capacity, have arisen. As of 2015 there is a proposal for an IEEE 802.3bt (PoE++) standard with 49 W (Type 3) to 100 W (Type 4) of power draw and 600 mA (Type 3) to 1000 mA (Type 4) per pair of power, and other potential future applications may require a current capacity of 1500 mA per pair or more.

While the earlier-designed connectors could withstand the rigors of the relatively low power required for earlier PoE applications, these connectors lack the design for durability needed to sustain the ever-increasing power demands. One particular issue is the need to reduce damage that occurs to the plug and/or jack during the mating and disconnection.

In a PoE application, upon disconnection (and/or insertion) of the plug and jack connector combination there is an electrical discharge that can damage the plug and jack mating interfaces. This electrical discharge can be an electrical arc (spark) or a corona discharge. A spark is a fast single event that is time independent and may cause a large distinct crater on the plug contacts of the plug, the plug interface contacts (PICs) of the jack, or both. A corona discharge is a relatively slower event that is time dependent, has multiple events, and causes many shallow craters or pits that erode the plug contacts, PICs, or both. These effects are worsened after multiple insertions as erosion caused by mechanical abrasion also damages the plug/jack mating interfaces of both the plug contacts and the PICs. IEC 60603-7 requires a minimum of 750 plug insertions into a jack module. Many vendors test to a higher amount of insertion cycles as for some applications 750 plug insertions is relatively low. The effects of this damage can be seen in the form of physical damage, electrical interface degradation, and, over time, corrosion of the contacts.

Additional constraints on the design are imposed by the need of the connectors to handle a certain amount of bandwidth while at the same time meeting particular parameters such as, for example, near end crosstalk (NEXT), far end crosstalk (FEXT), return loss, and insertion loss requirements. As such, these and other design concerns give rise to the need for robust connectors designed to withstand current and future demands of PoE.

SUMMARY

Accordingly, at least some embodiments of the present invention are directed towards devices, systems, and methods which are related to connectors designed to withstand current and future PoE demands.

In an embodiment, the present invention is a shielded RJ45 network jack with an inter-jack connection method that has an electrical disengagement point outside of the plug/jack mating point, while still allowing for a relatively short distance to compensation from the plug/jack mating interface.

In another embodiment, the present invention is an RJ45 plug assembly with an inter-plug connection method that has an electrical disengagement point outside of preferred mating points.

In yet another embodiment, the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a printed circuit board (PCB), the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion; and a plurality of third contacts, each of the third contacts having a mating section configured to interface with one of the mating portions and a disconnect section configured to interface with one of the disconnect portions.

In still yet another embodiment, the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a PCB, the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion, and a plurality of third contacts, each of the third contacts having a preferred mating leg configured to interface with one of the mating portions and a sacrificial leg configured to interface with one of the disconnect portions.

In still yet another embodiment, the present invention is a communication connector connectable to at least one of a communication cable and communication equipment, the communication connector capable of transmitting power over Ethernet. The communication connector includes means for interfacing the communication connector with a corresponding connector, means for establishing an electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for establishing the electrical path being located within the communication connector and occurring over a first physical path, and means for breaking the electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for breaking the electrical path being located within the communication connector and occurring over a second physical path.

In still yet another embodiment, the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken while each of the plug contacts maintains contact with one of the PICs.

In still yet another embodiment, the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken at a point other than between each of the plug contacts and respective one of the PICs.

In still yet another embodiment, the present invention is a communication system that includes, a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, each the current path traversing one of the plug contacts and respective one of the PICs. The communication plug is further configured to disconnect from the communication jack such that at least one the current path is broken while respective one of the plug contacts maintains contact with respective one of the PICs.

In still yet another embodiment, the present invention is a communication system including a communication plug and a communication jack. The communication system includes means for connecting the communication plug to a plug-cable having at least one conductor. The communication system also includes means for connecting the communication jack to a jack-cable having at least one conductor. The communication system also includes means for electrically and physically interfacing the communication plug with the communication jack. The communication system also includes means for transmitting a current between the at least one conductor of the plug-cable and the at least one conductor of the jack-cable. The communication system also includes means for breaking the current at a point that does not include the means for electrically and physically interfacing the communication plug with the communication jack.

These and other features, aspects, and advantages of the present invention will become better-understood with reference to the following drawings, description, and any claims that may follow.

DETAILED DESCRIPTION

An exemplary embodiment of the present invention is illustrated inFIG. 1, which shows a communication system110, which includes a patch panel112with RJ45 jacks114and corresponding RJ45 plugs116. Respective cables120are terminated to plugs116, and respective cables118are terminated to jacks114. Once a plug116mates with a jack114data can flow in both directions through these connectors. Although the communication system110is illustrated inFIG. 1as having a patch panel, alternative embodiments can include other active or passive equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, wall jacks, etc. Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and power-over-Ethernet equipment as can be found in data centers and or telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers, and other peripherals as can be found in workstation areas. Communication system110can further include cabinets, racks, cable management and overhead routing systems, and other such equipment.

The sled assembly128is illustrated in greater detail inFIGS. 9-11. As shown therein, it includes a first sled support130, first plug interface contacts (PICs)132, second PICs134, flexible PCB136, second sled support138, first rigid PCB140, springs142, first wiping contacts144, second wiping contacts146, first contact support148, second contact support150, and second rigid PCB152.

Referring to the exploded views of the sled assembly128shown inFIGS. 12-14, during the assembly of sled assembly128, a portion of the flexible PCB136is trapped between first rigid PCB140and first sled support130. Press posts168of first sled support130align with holes170and172of respective flexible PCB136and first rigid PCB140, and flexible PCB136is wrapped around mandrel173of first sled support130. First PICs132and second PICs134are installed into vias174of first rigid PCB140, and comb features176of second sled support138align with both first PICs132and second PICs134. Snaps178of second sled support138align with and join snap pockets180of first sled support130to secure the two pieces together. When second sled support138and first sled support130are secured, flexible PCB136, first PICs132, and second PICs134become trapped and are thereby secured. Front spring posts182of first sled support130and back spring posts184of second contact support150capture springs142during final assembly. First wiping contacts144align with respective contact slots186of first contact support148and have a controlled bend188around mandrel190. Second wiping contacts146align with respective contact slots192of second contact support150and have a controlled bend194around mandrel196. Relief slots198and200on respective first contact support148and second contact support150, provide clearance for IDCs154during final assembly.

After assembly of the sled assembly128, IDCs154are placed in IDC slots216of rear sled156and are then secures to second rigid PCB152making the back end assembly228as shown inFIG. 15. Back end assembly228is then assembled into conductive housing126forming partial jack assembly229show inFIG. 16. Referring again toFIG. 15, rails230of conductive housing126align back end assembly228and match up with the edges of first rigid PCB140. Latch arms232and234of rear sled156align with and secure to latch pockets236and238of conductive housing126. Once partial jack assembly229is assembled, it is joined with the jack shield124as shown inFIGS. 16 and 17. Jack shield124wraps around partial jack assembly229and shield latches240align and join with shield snaps242to partially enclose the assembly. Thereafter, wire cap grounding flanges244of jack shield124are wrapped around grounding flange slots246of rear sled156. When assembled to a cable, wire cap grounding flanges244make contact with conductive rear cap162to provide an appropriate grounding connection. Plug grounding flange slots248,250, and252of conductive housing126align with respective plug grounding flanges254,256, and258of jack shield124.

Referring now toFIGS. 18 and 19, to connect the partially assembled jack to a data cable, cable118is strung through rear conductive cap162and the wire containment cap160with conductor slots210enabling alignment of conductors164during assembly. Wire containment cap160is secured to conductive rear cap162through latches202and204which align with latch pockets206and208, respectively. In their default state, flexible arms212of conductive strain relief clip88engage with teeth214of conductive rear cap162. To disengage, the flexible arms212are compressed inward towards each other. As the wire cap assembly158is assembled, conductors164are positioned in preparation for joining with the partially assembled jack. Thereafter, wire cap assembly158is secured to rear sled156through the engagement of the flexible latch218of rear sled156with a corresponding latching feature220. The mating of the wire cap assembly158and the rear sled156causes the IDCs154to make contact with the conductors164of the cable118and thereby establish a communication link through the jack.

To achieve the improved levels of reliability, jack114utilizes first and second wiping contacts144,146in conjunction with specifically designed contacts on the rigid PCB140.FIG. 20is a first side of first rigid PCB140andFIG. 21is a second side of first rigid PCB140. First rigid PCB140includes first contact pads288and second contact pads290. Each contact pad contains a mating portion and a disconnect portion. The mating portion is the section of the contact pad with which a respective wiping contact is engaged during the mated and over-travel states. The disconnect portion is the section of the contact pad with which a respective wiping contact is engaged between the pre-release and release states. In the currently described embodiment, contact pads288have a mating portion292and a disconnect portion294, and contact pads290have a mating portion296and a disconnect portion298. For each contact pad, the mating portion and the disconnect portion is positioned such that each portion comes into direct contact with an alternate side of a respective wiping contact. This configuration allows for potential arcing or corona damage to occur on one side of the wiping contact, leaving the other side unharmed.

FIGS. 22-30illustrate the interaction between the contact pads and the wiping contacts throughout various stages of the plug/jack mating process. It is worth noting that in the section views ofFIGS. 22, 24, 26, 28, and 30, sled assembly128and plug PCB assembly274are not sectioned to show the plug/jack mating interaction between wire contacts276,278and PICs132,134, and the interaction between the wiping contacts144and contact pads288. In addition, press posts168have been leveled off along the surface of respective first rigid PCB140in all section views for clarity.

FIG. 22is a cross-section view, taken along section line22-22ofFIG. 2, across the mating interface of shielded RJ45 network jack114and shielded RJ45 plug assembly116. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134, and first wiping contacts144are in contact with mating portion292of first contact pads288. Second wiping contacts146are in contact with mating portion296of second contact pads290(not shown). As illustrated in the detailed view of the wiping contacts and contact pads, wiping contacts144interface with the mating portion along the wiping contacts' first side. This is the static state of a mated RJ45 plug116/jack114combination.

FIG. 23is a front isometric view of RJ45 network jack114and RJ45 plug assembly116and respective cables118and120in the over-travel state. The over-travel state allows for insertion of RJ45 plug assembly116into shielded RJ45 network jack114. RJ45 plug assembly116is inserted roughly .032inches further into RJ45 network jack114when compared to the mated static state shown inFIG. 2.FIG. 24is a cross-section view, taken along section line24-24ofFIG. 23across the mating interface of RJ45 network jack114and RJ45 plug assembly116in the over-travel state. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134. First wiping contacts144are in contact with mating portion292of first contact pads288. Second wiping contacts146are in contact with mating portion296of second contact pads290(not shown). Similar to the static state, wiping contacts144interface with the mating portion along the wiping contacts' first side. In between the mated state and the over-travel state there is no mechanical/electrical disconnection between any plug/jack interfaces.

FIG. 25is a front isometric view of RJ45 network jack114and RJ45 plug assembly116and respective cables118and120in the pre-release state. The pre-release state is a period where the wiping contacts are in contact with the disconnect portion of their respective contact pads but prior to the release state in the retraction cycle (this position is equivalent to the position during initial insertion of shielded RJ45 plug assembly116into shielded RJ45 network jack114prior to the over-travel and mated states).FIG. 26is a cross-section view, taken along section line26-26ofFIG. 25across the mating interface of RJ45 network jack114and RJ45 plug assembly116in the pre-release state. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134. First wiping contacts144are in contact with disconnect portion294of first contact pads288. Second wiping contacts146are in contact with disconnect portion298of second contact pads290(not shown). As illustrated in the detailed view of the wiping contacts and contact pads, wiping contacts144interface with the disconnect portion along the wiping contacts' second (alternate) side as compared to the static and over-travel states.

FIG. 27is a front isometric view of RJ45 network jack114and RJ45 plug assembly116and respective cables118and120in the release state. The release state is the moment before wire contacts276and278are no longer in electrical contact with respective first PICs132and second PICs134(this position is equivalent to the position during initial insertion of shielded RJ45 plug assembly116into shielded RJ45 network jack114just after the wire contacts276and278come into electrical contact with respective first PICs132and second PICs134).FIG. 28is a cross-section view, taken along section line28-28ofFIG. 27across the mating interface of RJ45 network jack114and RJ45 plug assembly116in the release state. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134. First wiping contacts144are no longer in contact with disconnect portion294of first contact pads288. Second wiping contacts146are no longer in contact with disconnect portion298of second contact pads290(not shown). In between the pre-release state and the release state respective wiping contacts disconnect from contact pads along the disconnect portion of the contact pad. The electrical discharge that occurs upon disconnection of the wiping contacts and the contact pads occurs on the disconnect portion of the contact pad and corresponding side of the wiping contact. This is opposite of the mating side of the contact and controls where the damage to the contact occurs in the case of PoE damage during use. Contact point300, between wire contacts276and278and respective first PICs132and second PICs134, remains relatively the same between mated, over-travel, pre-release, and release states with a minimal wiping zone as this helps reduce the electrical distance to compensation that may be implemented on the PCB140.

FIG. 29is a front isometric view of RJ45 network jack114and RJ45 plug assembly116and respective cables118and120in the unmated state.FIG. 30is a cross-section view, taken along section line30-30ofFIG. 29across the mating interface of shielded RJ45 network jack114and shielded RJ45 plug assembly116in the unmated state. In this state wire contacts276and278are no longer in electrical contact with respective first PICs132and second PICs134. First wiping contacts144are no longer in contact with first contact pads288. Second wiping contacts146are no longer in contact with second contact pads290(not shown). Sled assembly128is in approximately the same position in the unmated state as in the release state.

In order to ensure contact on a specific side of either first contact pads288or second contact pads290, it is preferred that first contact pads288or second contact pads290be raised with respect to the rest of the PCB in the area of contact. Some non-limiting means of ensuring reliable contact can include increasing the plating thickness on contact pads288and290, or removing/lowering the adjacent solder mask.

An alternative embodiment of the first rigid PCB302is shown inFIGS. 31 and 32withFIG. 31showing a first side of first rigid PCB302andFIG. 32showing a second side of first rigid PCB302. First rigid PCB302includes first contact pads304and second contact pads306. As with first rigid PCB140, each contact pad contains a mating portion and a disconnect portion, except there is no perpendicular section linking the two portions on the contact pads of PCB302. Instead, PCB302uses an angled section. It should be noted that the shape of the contact pads may take any form so long as the mating portion and the disconnect portion are positioned such that the wiping contact maintains a constant electrical bond with the contact pad as it travels between the mating and disconnect portions and such that different sections of the wiping contacts make contact with the mating and disconnect portions.

Yet another alternative embodiment of the first rigid PCB308is shown inFIGS. 33 and 34withFIG. 33showing a first side of first rigid PCB308andFIG. 34showing a second side of first rigid PCB308. First rigid PCB308includes first contact pads310and second contact pads312. Cutouts314and316on first rigid PCB308are a secondary mechanical alternative that is less dependent on minor changes in plating or solder mask to ensure reliable electrical contact on the specific side of wiping contacts and contact pads. The shape of the cut out sections can be any shape so long as the contact pads provide appropriate functionality as described previously.

FIGS. 35-39illustrate an alternative embodiment of a sled assembly318that could be used in jack354(which is similar in construction to jack114). Sled assembly318includes first sled support130, first PICs132, second PICs134, flexible PCB320, second sled support138, first rigid PCB322, springs142, first dual wiping contacts324, second dual wiping contacts326, first dual contact support328, second dual contact support330, and second rigid PCB332. While flexible PCB320and second rigid PCB332may be mechanically the same as respective flexible PCB136and second rigid PCB152, with the added crosstalk the electrical design of these boards may be different.

The primary difference between sled assembly318and the previously described sled assembly128is in the design of the wiping contacts and the design of the contact pads on the first rigid PCB322.

FIG. 40is a trimetric view of second dual contacts326andFIG. 41is a trimetric view of first dual contacts324. Second dual wiping contacts326include two wiping contacts comprised of a preferred mating leg338and a sacrificial leg340. Likewise, first dual wiping contacts324include two wiping contacts comprised of a preferred mating leg334and sacrificial leg336.FIG. 42illustrates a first side of first rigid PCB322andFIG. 43illustrates a second side of first rigid PCB322. It includes first dual contact pads342, which include a mating portion344and sacrificial portion346, and second dual contact pads348, which include a mating portion350and sacrificial portion352.

The interaction of the dual wiping contacts and the dual contact pads is shown inFIGS. 44-48which illustrate cross-section views of jack354and plug116at different mating states. FIG.44shows the jack354and the plug116in a fully mated state. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134. Preferred mating leg334of first dual wiping contacts324is in contact with mating portions344of first dual contact pads342. Sacrificial mating leg336of first dual wiping contacts324is in superfluous contact with sacrificial portion346of first dual contact pads342. Preferred mating leg338of second dual wiping contacts326is in contact with mating portion350of second dual contact pads348(not shown). Sacrificial mating leg340of second dual wiping contacts326is in superfluous contact with sacrificial leg352of second dual contact pads348(not shown).

FIG. 45is a cross-section view of RJ45 network jack354and RJ45 plug assembly116, with respective cables118and120, shown in the over-travel state. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134. Preferred mating legs334of first dual wiping contacts324are in contact with mating portions344of first dual contact pads342. Sacrificial mating legs336of first dual wiping contacts324are in superfluous contact with sacrificial portions346of first dual contact pads342. Preferred mating legs338of second dual wiping contacts326are in contact with mating portions350of second dual contact pads348(not shown). Sacrificial mating legs340of second dual wiping contacts326are in superfluous contact with sacrificial portions352of second dual contact pads348(not shown). In between the mated state and the over-travel state there is no mechanical/electrical disconnection between the plug/jack interfaces.

FIG. 46is a cross-section view of RJ45 network jack354and RJ45 plug assembly116, with respective cables118and120, shown in the pre-release state. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134. Preferred mating legs334of first dual wiping contacts324are no longer in contact with mating portions344of first dual contact pads342. However, sacrificial mating legs336of first dual wiping contacts324are still in contact with sacrificial portions346of first dual contact pads342. Likewise, while preferred mating legs338of second dual wiping contacts326are no longer in contact with mating portions350of second dual contact pads348(not shown), sacrificial mating legs340of second dual wiping contacts326are still in contact with sacrificial portions352of second dual contact pads348. Given that continuity between the dual wiping contacts and the dual contact pads is still maintained at this this stage, the disconnection (or connection in case of plug insertion) of the preferred mating legs from the respective mating portions of the dual contact pads does not result an arcing or corona discharge, preventing potential damage to the respective surfaces.

FIG. 47is a cross-section view of RJ45 network jack354and RJ45 plug assembly116, with respective cables118and120, shown in the release state. In this state wire contacts276and278are in electrical contact with respective first PICs132and second PICs134. Preferred mating legs334of first dual wiping contacts324are no longer in contact with mating portions344of first dual contact pads342. Sacrificial mating legs336of first dual wiping contacts324are no longer in contact with sacrificial portions346of first dual contact pads342. Preferred mating legs338of second dual wiping contacts326are no longer in contact with mating portions350of second dual contact pads348(not shown). Sacrificial mating legs340of second dual wiping contacts326are no longer in contact with sacrificial portions352of second dual contact pads348(not shown). In between the pre-release state and the release state respective sacrificial mating legs disconnect from sacrificial portions of contact pads (during the insertion of the plug into the jack the respective sacrificial mating legs connect to sacrificial portions of contact pads). The electrical discharge upon disconnection/connection of the sacrificial mating legs and the sacrificial portions of the contact pads occurs outside of the preferred mating zone and in the sacrificial areas. This helps maintain the integrity of the preferred mating legs of the dual wiping contacts and the mating portion of the dual contact pads.

FIG. 48is a cross-section view of RJ45 network jack354and RJ45 plug assembly116, with respective cables118and120, shown in the unmated state. In this state wire contacts276and278are no longer in electrical contact with respective first PICs132and second PICs134. Preferred mating legs334of first dual wiping contacts324are no longer in contact with mating portions344of first dual contact pads342. Sacrificial mating legs336of first dual wiping contacts324are no longer in contact with sacrificial portions346of first dual contact pads342. Preferred mating legs338of second dual wiping contacts326are no longer in contact with mating portions350of second dual contact pads348(not shown). Sacrificial mating legs340of second dual wiping contacts326are no longer in contact with sacrificial portions352of second dual contact pads348. Sled assembly318is in approximately the same position in the unmated state and the release state.

First wiping contacts144, second wiping contacts146, first dual wiping contacts324, and second dual wiping contacts326are shown with compliant pins but may be attached to respective second rigid PCBs through any non-limiting means. First PICs132and second PICs134are shown with solder connections but may be attached to respective first rigid PCBs through any non-limiting means. Cable118and120are shown as shielded cable but may be any other non-limiting form of cable including but not limited to F/UTP or UTP cabling.

An exemplary schematic for the plug116/jack114,354combination is shown inFIG. 49.

While the above-described embodiments illustrate examples of jacks with improved robustness for PoE, it is also possible to provide improved designs in the plug.FIG. 50illustrates an isometric view of one such plug116by way of an exemplary embodiment. Plug116includes front housing122, left housing140, right housing142, and bend radius control boot144.FIGS. 51-53provide exploded views of the plug116. As shown therein, plug116also includes a first PCB assembly124with first plug contacts126, second plug contacts128, first rigid PCB130, and springs132, and a second PCB assembly134with wiping contacts136and second rigid PCB138. Back PCB pads146on second rigid PCB138are used to terminate cable120; through other non-limiting means of termination may be used. During mating/un-mating with a corresponding jack, while second rigid PCB138remains stationary relative to the plug's housings, the first rigid PCB assembly124translates between different positions. The first rigid PCB130and second rigid PCB138are electrically linked to each other via wiping contacts136and contact pads148.

FIG. 54illustrates a first side of first rigid PCB130. Each contact pad148contains a mating portion150and a disconnect portion152. The mating portion is the portion of a contact pad that is engaged with a respective wiping contact during the mated and over-travel state (the over-travel state allows for insertion of RJ45 plug assembly116into RJ45 network jack54. The disconnect portion is the portion of a contact pad that is engaged with a respective wiping contact during the pre-release state. As will be made clear during the discussion of the following drawings, that each mating portion and respective disconnect portion are displaced laterally from each other. This allows a single wiping contact that is wide enough to at least partially overlap both of the portions to rely on one side thereof to make contact with the mating portion and to rely on the second side thereof to make contact with the disconnect portion. This allows the second side (i.e., the side that makes contact with the disconnect portion) to sustain most of the damage that may be caused by PoE, leaving the first side (i.e., the side that makes contact with the mating portion) unscathed.

FIG. 55is a cross-section view across the mating interface of shielded RJ45 network jack54and RJ45 plug assembly116(wiping contacts136and first rigid PCB130are not sectioned to show the interface between wiping contacts136and first rigid PCB130). In this state plug contacts126and128are in electrical contact with respective PICs70. Wiping contacts136are in contact with mating portion150of contact pads148. This is the static (mated) state of an RJ45 network plug116mated with an RJ45 network jack54.

FIG. 56is a cross-section view across the mating interface of shielded RJ45 network jack54and RJ45 plug assembly116shown in the pre-release state. In this state plug contacts126and128are in electrical contact with respective PICs70. Wiping contacts136are in contact with disconnect portion152of contact pads148. In the pre-release state there is still an electrical connection throughout the channel, but it is not a static state of installed RJ45 network jack54and RJ45 plug assembly116. This state occurs either during insertion of RJ45 plug assembly116into RJ45 network jack54prior to the mated state, or upon retraction of RJ45 plug assembly116from RJ45 network jack54prior to the release state.

FIG. 57is a cross-section view across the mating interface of shielded RJ45 network jack54and RJ45 plug assembly116in the release state. In this state, while plug contacts126and128are in electrical contact with respective PICs70, wiping contacts136are no longer in contact with contact pads148. In the release state there is no longer an electrical connection throughout the channel. This state occurs either during insertion of RJ45 plug assembly116into RJ45 network jack54prior to the pre-release state or upon retraction of RJ45 plug assembly116from RJ45 network jack54after the pre-release state. In between the pre-release state and the release state, respective wiping contacts136disconnect from contact pads148along the disconnect portions152. The electrical discharge upon disconnection of wiping contacts136and contact pads148occurs on disconnect portion152and corresponding side of wiping contact136. This is opposite of the side of the wiping contact136that contacts the mating portion, controlling where the damage to the contact occurs in the case of PoE. In between the mated state and the release state there is approximately 0.040″ of travel for first rigid PCB assembly. In the mated/over-travel state the plug/jack interface is approximately in the IEC-60603-7:2010 preferred electrical mating point location. In all other states the plug/jack interface is typically not in the IEC-60603-7:2010 preferred electrical mating point location, and the force between PICs70and plug contacts126and128overcomes the force from springs132. After the release state, the unmated state follows in which plug contacts126and128are no longer in electrical contact with respective PICs70.

To ensure contact on a specific side of contact pads148, it is preferred that contact pads148be raised with respect to the rest of the PCB in the area of contact. Some non-limiting means of ensuring reliable contact can include increasing the plating thickness on contact pads148or removing/lowering the adjacent solder mask.

FIG. 58illustrates an exemplary schematic for the plug116/jack54combination.

Note that while this invention has been described in terms of several embodiments, these embodiments are non-limiting (regardless of whether they have been labeled as exemplary or not), and there are alterations, permutations, and equivalents, which fall within the scope of this invention. For example, while references have been made to rigid PCBs, one of ordinary skill in the art would recognize that the use of flexible PCBs or combinations of flex/rigid PCBs would also be within the scope of the disclosure. Additionally, the described embodiments should not be interpreted as mutually exclusive, and should instead be understood as potentially combinable if such combinations are permissive. Furthermore, in some cases same numbers are used to refer to similar elements in different embodiment. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that claims that may follow be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.