A shielded in-line connector includes conductive first and second body portions, each with a securement feature, as well as conductive first and second clips. The first and second body portions are secured to one another to define an unshielded connector-receiving cavity as well as first and second shielded cable openings; each of the first and second shielded cable openings being proximate the respective clip securement feature. Each of the clip securement features includes a channel supportive of a respective shielded cable extending from each of the first and second shielded cable openings; each of the shielded cables having an exposed shield. The first and second clips are adjustably secured to a respective one of the first and second securement features to position the respective clip in direct contact with the exposed shield of the respective shielded cable.

TECHNICAL FIELD

The present disclosure is directed to electrical connectors and, more specifically, to shielded in-line connector.

BACKGROUND

In-line devices for connecting or splicing two cables carrying pairs of twisted wire leads are generally known. In applications wherein electromagnetic interference (EMI), or “noise,” is of little or no concern, unshielded twisted pair (UTP) cables are used. In-line connectors for use with UTP cables are designed without shielding considerations. In applications where noise is of concern, shielded twisted pair (STP) cables are used. Typically, the use of an STP cable would require a new connector design that includes shielding features. However, design of a completely new connector utilizes valuable engineering resources. Ideally, it would be possible to use a previously designed UTP connector in an STP application.

SUMMARY

The present disclosure is directed to a shielded in-line connector that can be used in combination with an unshielded twisted pair (UTP) in-line connector to supply the shielding capabilities absent from the UTP in-line connector. The shielded in-line connector provides the electrical coupling with one or more shielding elements of each of first and second shielded twisted pair (STP) cables whose one or more twisted pairs are electrically coupled by the UTP connector. The shielded in-line connector provides electrical continuity from the first STP cable to the second STP cable with the shield ultimately connected to ground and serving to reduce electromagnetic noise (EMI).

An aspect of the present disclosure is directed to a shielded in-line connector. The shielded in-line connector includes conductive first and second body portions, each with a clip securement feature, as well as conductive first and second clips. The first and second body portions are secured to one another to define an unshielded connector-receiving cavity as well as first and second shielded cable openings; each of the first and second shielded cable openings being proximate the respective clip securement feature.

Each of the clip securement features includes a channel supportive of a respective shielded cable extending from each of the first and second shielded cable openings; each of the shielded cables having an exposed shield. The first and second clips are adjustably secured to a respective one of the first and second securement features to position the respective clip in direct contact with the exposed shield of the respective shielded cable.

Another aspect of the present disclosure is directed to a shielded in-line connector system. The shielded in-line connector system includes the shielded in-line connector described immediately above and an unshielded in-line connector that is enclosed by the shielded connector. The unshielded in-line connector electrically couples the one or more pairs of conductors the first shielded twisted pair cable to the one or more pairs of conductors of the second shielded twist pair cable

Still another aspect of the present disclosure is directed to a method of coupling first and second shielded twisted pair cables. For each of the first and second shielded twisted pair cables the method includes: stripping a portion of a jacket of the respective cable; folding back a shield, of the respective cable, over a remaining portion of the jacket of the cable to reveal one or more twisted pairs of conductors; and connecting the one or more pairs of conductors to contacts within an unshielded in-line connector serving to electrically couple the first and second shielded twist pair cables. The method further includes enclosing the unshielded in-line connector with a shielded in-line connector. The shielded in-line connector includes a conductive housing having first and second cable openings to accommodate the first and second shielded cables extending from the unshielded in-line connector. The shielded in-line connector further includes a first clip securement feature proximate the first cable opening and a second clip securement feature proximate the second cable opening; each of the first and second securement features including a cable-supporting channel that supports the respective first and second shielded twisted pair cable. The method further includes securing a first and second conductive clip to a respective one of the first and second clip securement features to position the respective first and second conductive clips in direct contact with the shields of the respective first and second shielded cables.

DETAILED DESCRIPTION

FIGS.1A and1Billustrate an example of a prior art unshielded in-line connector10suitable for use with an unshielded twist pair (UTP) cable. The in-line connector10is used to connect one or more pairs of wire leads of a first cable to a second cable. The in-line connector10generally comprises a housing structure12that includes a first base20and a second base22, which is identical to the first base20but oppositely oriented; each of the first and second bases20,22include a ratchet strip23having a plurality of teeth25. The in-line connector10additionally includes a first wiring cap24and a second wiring cap26, which is identical to the first wiring cap24but oppositely oriented. Upon assembly, the first wiring cap24engages the first base20and defines a first cable opening28. Further, the second wiring cap26engages the second base22and defines a second cable opening30. The in-line connector10additionally includes one or more pairs of doubled ended insulation displacement contacts32(IDCs). A first end32aof the IDC32is configured to be electrically coupled to a lead of a twisted pair of a first cable and a second end32bof the IDC32is configured to be electrically coupled to a lead of a twisted pair of a second cable.

Further details regarding the unshielded in-line connector10can be found in PCT Publication WO 2018/075769, entitled “In-line Cable Connector Assembly and Methods” and having an international filing date of Oct. 19, 2017. The identified PCT Publication is hereby incorporated by reference in its entirety. It should be noted that the in-line connector ofFIGS.1A and1Bis but one example of many possible unshielded in-line connectors with which the shielded connector of the present disclosure may be used.

FIGS.2and3provide an exploded view and a semi-assembled view, respectively, of the unshielded in-line connector10in position to be enclosed by a shielded in-line connector100of the present disclosure. In certain embodiments, as illustrated, the shielded in-line connector100mimics the shape of the unshielded connector10that it will enclose. In other embodiments, the shielded in-line connector100has a distinctive shape from that of the unshielded in-line connector it will enclose.

The shielded in-line connector100generally comprises a first body portion110and a second body portion112, which is identical but oppositely oriented to the first body portion110. Together the first and second body portions110,112form a housing114(seeFIG.10A) of the shielded in-line connector100. The shielded in-line connector100further includes a first spring clip116and a second spring clip118. In certain embodiments, the first and second body portions110,112are die cast components fabricated with a metal or metal alloy and finished with one or more conductive metals. Other fabrication processes and/or materials (or combination of materials) are also possible. In certain embodiments, the first and second spring clips116,118are die cut from stainless steel and finished with one or more conductive metals; other fabrication processes and/or materials (or combination of materials) are also possible.

Further details of the shielded in-line connector100of the present disclosure can be appreciated with respect toFIGS.4-10C. It should be noted that first and second body portions110,112are identical as are first and second spring clips116,118so that a description of one body portion applies to the other body portion and a description of one spring clip applies to the other spring clip.

Referring toFIGS.4and5A-5B, each of the first and second body portions110,112includes a first side wall120and second side wall122. which are connected by a first end wall124and a second end wall126. The walls120-126define a perimeter of a face128, having an inner surface130and an outer surface132, and further define an opening to an interior cavity of the body portion110,112.

Each of the first and second side walls120,122includes a shoulder projection134establishing a space between the unshielded connector10, which is placed within the body portion110,112(seeFIG.3), and the respective side wall120,122. Each shoulder projection134includes a slot136through which a cable tie can be passed; see cable tie192securing two shielded in-line connectors inFIG.1013.

Each of the first and second end walls124,126includes a recess138. When the first and second body portions110,112are secured to one another, the combined recesses138define an opening to accommodate a diameter of a twisted pair cable. The second end wall126further includes a clip securement feature140. The clip securement feature140defines a channel142to the recess138. The channel142incorporates a cradling profile having inner inward angling side walls143that rise to edges144that define the sides of a recess145. In certain embodiments, the recess145includes a knurled surface147to assist in retaining a cable placed therein.

The clip securement feature140further presents first and second outer side walls146,148to either side of the channel142. Each of the first and second side walls146,148includes first and second tabbed edges150that define a slot152into which the respective spring clip116,118is inserted helping to retain the respective spring clip116,118proximate the respective outer side wall146,148. Each of the first and second outer side walls146,148further includes a ratchet surface154to which the respective spring clip116,118interfaces. The ratchet surface154is an elongate surface presenting a plurality of teeth156enabling the respective spring clip116,118to be secured at a plurality of locations along the surface154. As such, the positioning of the respective spring clip116,118relative to the clip securement feature140can be adjusted to accommodate cables of differing diameters.

The inner surface130of the face128of each of the first and second body portions110,112includes a plurality of alignment posts158that interface with corresponding cavities (not shown) of the unshielded in-line connector10. The alignment posts158assist in centering the unshielded in-line connector10within the first and second body portions110,112of the shielded in-line connector100. The inner surface130of the face128further includes a centrally located ratchet strip160having a plurality of teeth162. In certain embodiments the teeth162of the ratchet strip160interface with the teeth25of the ratchet strip23(seeFIGS.1A-1B) of the shielded in-line connector10to prevent slippage/movement of the shielded in-line connector10within the shielded connector100. The outer surface132of the face128of each of the first and second body portions110,112also includes a ratchet strip164with a plurality of teeth165. The ratchet strip164provides a grippable surface for manual handling of the shielded in-line connector100and further provides a surface for interfacing with ratchet strips of other shielded in-line connectors100to assist in preventing slippage of proximate stacked shielded in-line connectors100.

Referring toFIGS.6A-6B and7A-7B, features for removably securing the first and second body portions110,112can be appreciated. Specifically,FIG.6Aillustrates that each shoulder projection134of each of the first and second body portions110,112includes a press fit rib166that interfaces with a fin-shaped wall167on the opposing body portion110,112to removably secure the first body portion110to the second body portion112and to create an electrical contact between the two shield halves, e.g., the first and second body portions110,112. Notably, each of the spring clips116,118is electrically coupled to only one of the halves of the shield, e.g., only one of the body portions110,112, thus, the interface between the rib166and fin-shaped wall167ensures that all components of the shielded in-line connector100are ultimately electrically connected.

FIG.6Billustrates that each of the first and second body portions110,112includes a plurality of lip edge features169that run about the top of the exterior walls120,122,124,126e.g., at each corner of first and second end walls124,126, as well as along each of the first and second side walls120,122. The lip edge features169provide an overlapping construction of the first and second body portions110,112when coupled to one another. This overlapping construction helps to prevent the escape or infiltration of electromagnetic waves between the inner connector, e.g., non-shielded inline connector10, and the outside environment.

FIGS.7A-7Billustrate that each of the first and second side walls120,122of each of the first and second body portions110,112includes a tab168and tab recess170to receive a respective one of the tabs168providing four interfacing locations between the first and second body portion110,112in addition to the four interfacing locations provided by the press fit ribs166. The interface locations enable one to snap together the first and second body portion110,112by hand to form the housing114of the shielded in-line connector100. Further, each of first and second side walls120,122of each of the first and second body portions110,112include a release slot172enabling insertion of a flathead screwdriver to release the first body portion110from the second body portion112. The ability to release the first body portion110from the second body portion112provides the opportunity to reuse the shielded in-line connector100if needed.

Features of the identical first and second spring clips116,118can be appreciated with respect toFIGS.8and9A-9B. Each of the first and second spring clips116,118is a unitary component defined by an inner surface174and an outer surface176. Each end of the first and second spring clips116,118includes a pair of elongate side walls178with each of the pair including an outward extending tab180and an inward extending tab182. Each of the inward extending tabs182interfaces with a tooth156of the ratchet surface154, seeFIG.9B, of the clip securement feature140enabling the first and second spring clips116,118to be height adjustable. The outward extending tabs180are usable to pull outward and release the respective inward extending tabs182from the respective ratchet surface154. Each of the first and second spring clips116,118includes a transition section184to an inwardly angled section186corresponding to the cradling profile and inward angling side walls143of the clip securement feature140. The inwardly angled sections186then transition to form a single arch188.

The arch188includes a plurality of indents190protruding away from the inner surface174of the first and second spring clips116,118. The indents190assist in fixing the position of a cable passing under the single arch188when the respective spring clip116,118is secured to the clip securement feature140. The outward extending tabs180of each of the spring clips116,118can be pulled outward, away from the clip securement feature140to release the clip116,118. When secured to the clip securement feature140so as to be in contact with an underlying cable, the first and second spring clips establish electrical coupling with a shield of the cable (e.g., foil, drain wire and/or wire mesh) and with the first and second body portions110,112of the connector. The first and second spring clips116,118further function as a strain relief device for the cable helping to prevent mechanical force applied to an exterior of the cable from being transferred to the electrical terminations within the unshielded connector10.

FIGS.10A-10Cillustrate that the shielded in-line connector100can be used in conjunction with the unshielded in-line connector in a single connector application, e.g.FIG.10A, or in a multi-connector application where shielded in-line connectors are positioned side-by-side, e.g.FIG.10B, or stacked, e.g.,FIG.10C. In a multi-connector application cable ties192can be used to secure one shielded in-line connector100to another.

FIGS.11A-11GIllustrate a method for connectorizing first and second shielded twisted pair cables202,204utilizing the unshielded in-line connector10and shielded in-line connector100of the present disclosure.

Referring toFIG.11A, each shielded twisted pair cable202,204has a portion of a jacket210removed revealing underlying shielding foil212. The shielding foil212is folded back and twisted completely about the jacket210to reveal one or more pairs of conductors214. A drain wire216should also be folded back to lie against the shielding foil212.

Referring toFIG.11Bthe one or more pairs of conductors214of each shielded twisted pair cable202,204are then terminated in their respective wiring caps24,26(seeFIG.1A), and the conductors214of one shielded twisted pair cable202are electrically coupled to the second shielded twisted pair cable204with the dual-ended IDCs30(seeFIG.1A).

Referring toFIG.11C, the first and second base20,22are then placed about the coupled wiring caps24,26and secured to one another to complete assembly of the unshielded in-line connector10. The shielding foil212and drain wire216remain accessible outside the unshielded in-line connector10.

Referring toFIG.11D, the unshielded in-line connector10is placed within either of the body portions110,112(in this instance second body portion112) positioning at least a portion of the shielding foil212and the drain wire216within the channel142of the clip securement feature140.

Referring toFIG.11E, the first body portion110is placed atop the second body portion112and manually pressed together resulting in the closed configuration of the housing114of the shielded in-line connector100illustrated inFIG.11F. The housing114is now ready receive the first and second spring clips116,118.

Referring toFIG.11G, each spring clip116,118is received within their respective slot152of the clip securement feature140and pressed in a first direction until the respective spring clip116,118is in tight contact with the shielding foil212and drain wire216, and the respective spring clip116,118is interfaced with the ratchet surface154(seeFIG.4) of the clip securement feature140. The assembly of the shielded in-line connector100is now complete. Any additional shielding foil212and/or drain wire216extending beyond the shielded in-line connector100can be trimmed away.

FIGS.12A-12Cillustrate modifications to the method described inFIGS.11A-11Gwhen a shielded twisted pair cable includes a braided shield alone or in combination with shielding foil.

Referring toFIG.12A, a cable302,304is illustrated having a both a braided shield311and a shielding foil312. The braided shield311is folded back over a jacket310of the cable302,304and the shielding foil312is trimmed away to reveal the underlying one or more twisted pairs of conductors as shown inFIG.11A; the process is the same with a cable having only a braided shield, however, no trimming of a shielding foil is required.

Referring toFIG.12B, the one or more twisted pairs of conductors of each cable302,304are terminated in the wiring caps24,26as illustrated inFIG.11B, and the first and second base20,22are placed about the wiring caps24,26to complete assembly of the unshielded in-line connector10.

Referring toFIG.12C, the braided shield311is twisted and bunched around the first and second cable openings28,30(seeFIGS.1A-1B) of the assembled unshielded in-line connector10. The first and second body portions110,112of the shielded in-line connector100are then placed about the unshielded in-line connector10and pressed together to establish the housing114of the shielded in-line connector. The bunched braided shield311preferably does not extend beyond the confines of the housing but rather lies within the channel142of the clip securement feature140. The spring clips116,118can then be placed in contact with the bunches braided shield311and secured to the housing114, as described with reference toFIG.11G, to complete assembly of the shielded in-line connector.

Referring toFIG.13, the shielded in-line connector100, containing the unshielded in-line connector10, can be utilized in a pigtail configuration400, where a length of shielded twisted pair cable402has a first end404pre-terminated to the connectors10and100and a second end406that is unterminated or pre-terminated with a different type of connector408. In the pigtail configuration400, each of the connectors10and100can be opened, and subsequently re-secured, to accommodate conductor coupling and shield coupling of another shielded twisted pair cable.

It will 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 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.

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.