Add-on electrical assembly with light transmission means

An add-on electrical assembly is provided for association with an electrical connector for receiving a complementary mating plug to a circuit board. The electrical connector may be a standard modular jack including a connector housing having a front face with a receptacle receiving the plug, a top wall, a rear wall and a bottom face adapted for mounting on the circuit board. A plurality of terminals each include one end extending into the receptacle for making electrical contact with a corresponding terminal on the plug and the other end adapted to contact the circuit board. A separate LED assembly is provided with housing for mounting over the top and rear walls of the connector housing. A light emitting device is mounted on the LED housing and is viewable through a front face thereof adjacent the receptacle. Conductors extend from the light emitting device through the LED housing for connection to the circuit board. At least one snap latch is provided between the LED housing and the connector housing.

FIELD OF THE INVENTION
 This invention generally relates to the art of electrical connectors and,
 particularly, to an add-on electrical connector assembly which has light
 transmission means for visual indication of the status of an associated
 electrical connector.
 BACKGROUND OF THE INVENTION
 Electrical connectors having built-in indicator lights have been known for
 some time. In these connectors, the indicator lights typically are located
 at the front of the connector. A typical connector may include an integral
 LED device to emit a light which indicates an operational function such as
 the reception or transmission of data or voice signals, verification of a
 good connection between separate pieces of equipment, indication when
 power is on or off, indication of a defect in a network transmission or
 any other state or condition in the equipment with which the connector is
 operatively associated.
 Visual light indicating connectors are popular in modular jacks or similar
 types of connectors commonly used in telecommunications and data
 networking equipment. These jacks often are mounted on a circuit board to
 which they are to be connected. Problems have been encountered in
 incorporating such light indicating devices, such as LED devices, directly
 onto the connector due to the ever-increasing miniaturization of
 telecommunications and data networking equipment. There may simply not be
 enough space to mount the desired LED devices directly on the connector
 housing. In addition, regardless of the size of the connector or jack,
 connectors which include light transmitting devices are expensive to
 manufacture and assemble for an otherwise relatively inexpensive
 component. For instance, for an integral LED device the connector or jack
 housing must be provided with internal molded passages to accommodate the
 light indicating devices as well as the conductors which lead from the
 devices. Such provisions might not be practical or cost effective.
 The present invention is directed to solving these problems by providing an
 add-on assembly for an electrical connector or modular jack assembly which
 provides light indicating capabilities without making the source of the
 light integral with the connector or modular jack itself.
 SUMMARY OF THE INVENTION
 An object, therefore, of the invention is to provide a new and improved
 add-on electrical connector assembly capable of transmitting and
 indicating light for various visual indication purposes.
 In the exemplary embodiment of the invention, a printed circuit board
 mounted connector assembly is adapted for electrically connecting a
 complementary mating plug to a printed circuit board. The connector
 assembly is disclosed as a modular jack assembly.
 More particularly, the assembly includes a board mounted connector having a
 connector housing mounted on the printed circuit board. The housing
 includes a front face with a cavity therein defining a plug-receiving
 opening or receptacle, a top wall and a rear wall. A plurality of
 terminals are mounted on the housing and each terminal includes one end
 extending into the cavity for making electrical contact with a
 corresponding terminal on the plug and an opposite end adapted to contact
 the printed circuit board.
 An LED module is provided separate from the board mounted connector for
 association with the connector housing. The module includes a separate LED
 housing adapted to be mounted over the top and rear walls of the connector
 housing. A light emitting device is mounted on the LED housing and is
 viewable through a front face thereof adjacent the plug-receiving opening.
 Conductor wires extend from the light emitting device through the interior
 of the LED housing and downward for connection to the printed circuit
 board.
 As disclosed herein, the LED housing is generally L-shaped to include a top
 portion adapted to overlie the top wall of the connector housing and a
 rear portion adapted to overlie the rear wall of the connector housing.
 The terminals of the connector and the distal ends of the LED conductor
 wires include feet for surface mounting on the printed circuit board. The
 feet of the terminals and the conductor wires are generally in a line. In
 the embodiment shown the light emitting device is snap fit into a recess
 formed in the bottom of the LED housing, and the conductor wires are snap
 fit into channels formed in the bottom of the LED housing.
 Another feature of the invention includes complementary interengaging
 retaining means on the LED housing and the connector housing for retaining
 the LED module mounted on the board mounted connector. The retaining means
 may provide a snap type releasable latch system. With the L-shaped module
 housing, the retaining means include a first snap latch near the front of
 the top wall of the connector housing and a second snap latch near the
 bottom of the rear wall of the connector housing.
 Other objects, features and advantages of the invention will be apparent
 from the following detailed description taken in connection with the
 accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
 Referring to the drawings in greater detail, and first to FIGS. 1, 2, and 3
 the invention is embodied in a LED module 10 shown associated with a
 printed circuit board mounted connector assembly, generally designated 12.
 The connector assembly is in the form of a modular jack adapted for
 electrically connecting a complementary mating plug (not shown) to a
 printed circuit board (not shown) as is known in the art.
 According to our aspect of the invention, the LED module 10 is separate
 from the modular jack 12 and, as best seen in FIG. 2, the separate LED
 module generally overlies the top and rear surfaces of the modular jack
 such as a prior art modular jack shown in FIG. 1.
 More particularly, modular jack 12 is of a convention design and includes a
 housing 16 having a front face 18 (FIG. 1 and 3) defining a cavity 20
 which forms a plug-receiving opening or receptacle for the complementary
 mating plug. The housing further includes a top wall 22, a rear wall 24
 and a bottom face 26 adapted for mounting on the circuit board. To that
 end, the housing includes a pair of integral mounting posts 28 depending
 from bottom face 26 for insertion into appropriate mounting holes in the
 circuit board. As best seen in FIG. 1 and 2, a conductive shroud 30 may be
 positioned about the inside of receptacle 20 to define a shield for
 engaging a grounding shield of the mating plug. The shroud or shield 30
 has a pair of legs 32 projecting through slots 34 in the side walls of
 housing 16, with the legs terminating in generally planar feet or "fitting
 nails" 36 for solder connection to appropriate ground pads on the circuit
 board.
 A plurality of terminals 39 are mounted within connector or jack housing 16
 for electrically connecting the complementary mating plug to circuit
 traces on the circuit board. Such terminals are well known in the art and
 include inner ends 37 which extend in a cantilevered fashion into
 receptacle 20 for making electrical contact with corresponding terminals
 on the complementary mating plug. Opposite ends of the terminals project
 from the housing as at 38 in FIG. 2 for solder connection to appropriate
 circuit traces on the circuit board. As shown, ends 38 of the terminals
 are provided as feet for surface mounting to the circuit traces on the
 board. The surface mount feet are generally in a line.
 Referring to FIGS. 4 and 5 in conjunction with FIGS. 2 and 3, the LED
 module 10 includes a dielectric housing, generally designated 40, which is
 generally L-shaped to include a top portion 42 and a rear portion 44. The
 separate LED module then can be associated with, including mounting
 directly thereto, the top of modular jack housing 16 with top portion 42
 over top wall 22 of the jack housing and rear portion 44 over rear wall 24
 of the jack housing, as shown in FIG. 2. LED housing 40 can be unitarily
 molded of dielectric material such as plastic or the like.
 Still referring to FIGS. 4 and 5, LED module 10 includes a pair of light
 emitting devices 46 which are snap-fit into recesses 48 in the bottom of
 LED housing 40 as seen in FIG. 5. The recesses and, therefore, the light
 emitting devices are located at a front face 42a of top portion 42 of the
 LED housing so that the devices are viewable through front face 42a
 adjacent receptacle 20 of modular jack 12, as shown in FIG. 3.
 Generally, a pair of conductors 50 extend from each light emitting device
 46 through the interior of LED housing 40 and downward for connection to
 the printed circuit board. The conductors terminate in feet 52 adapted for
 surface mounting to circuit traces on the printed circuit board. Feet 52
 of conductors 50 can be seen in FIG. 2 to be in line with terminal feet
 38.
 More particularly, referring to FIG. 6 in conjunction with FIG. 5, a pair
 of channels 54 are formed in the bottom of top portion 42 of LED housing
 40, and a pair of channels 56 are formed in rear portion 44 of the LED
 housing to accommodate each pair of conductors 50 leading from each light
 emitting device 46. FIG. 6 shows that detent bosses 58 can be formed to
 project inwardly into channels 54 and 56 to facilitate snapping or press
 fitting the conductors into the channels and retaining the conductors
 therein. Therefore, it can be understood that separate LED module 10 can
 be easily assembled by simply snapping or press-fitting light emitting
 devices 46 into recesses 48 and snapping or press fitting conductors 50
 into channels 54 and 56. The recesses and channels can be very easily
 molded into LED housing 40. The subassembly of LED module 10 then is
 simply positioned onto the top and rear of modular jack 12 as seen in
 FIGS. 2 and 3.
 With the simple and inexpensive connector or jack assembly described above,
 various options are available for retaining the LED module on the
 connector or jack housing 16. For instance, with the jack housing also
 being unitarily molded of dielectric material such as plastic or the like,
 the plastic LED housing simply can be ultrasonically welded to the plastic
 jack housing. Of course, this would provide a permanent retention. On the
 other hand, it may be desirable to releasably mount the LED module onto
 the modular jack with a releasable retention system as shown in FIGS. 7
 and 8.
 More particularly, the embodiment of FIGS. 7 and 8 show that a snap-latch
 clip 60 can be molded integrally with rear portion 44 of LED housing 40.
 The clip defines an inwardly directed hook 60a which can snap beneath a
 bottom edge of rear wall 24 of modular jack housing 16. Top wall 22 of the
 modular jack housing can be provided with an integral, upstanding boss as
 shown in phantom in FIG. 1 for insertion into a hole 62 in the underside
 of top portion 42 of the LED housing, as by a press-fit. With such an
 arrangement the separate LED module 10 can be assembled downwardly onto
 modular jack 12 in the direction of arrow "A" (FIG. 8) whereupon the post
 on the top of the modular jack enters hole 62 of the LED module, and
 retention clip 60 snaps behind a bottom edge of the front wall of the
 modular jack. If it is desired to remove the LED module for inspection,
 repair or other purposes, the lower edge of the rear portion 44 simply is
 pulled outwardly in the direction of arrow "B" (FIG. 8) to clear retention
 clip 60 from the front wall of the modular jack, and LED module 10 simply
 is lifted off of the modular jack opposite the direction of arrow "A".
 Even without retention clip 60, the embodiment of FIGS. 1-5 may include
 hole 62 on the underside of top portion 42 of LED housing 40 as shown in
 phantom in FIGS. 5 and 6, simply to receive a locating post upstanding
 from jack housing 16.
 FIGS. 9-13 show another embodiment of a printed circuit board mounted
 connector assembly in the form of an LED module 10 associated with a
 modular jack 12 adapted for electrically connecting a complementary mating
 plug (not shown) to a printed circuit board (not shown) as is known in the
 art. Like the connector assembly in FIGS. 2 and 3, the connector assembly
 of FIGS. 9-13 includes two major subassemblies, namely a board-mounted
 connector or jack, generally designated 12 and an LED module, generally
 designated 10. Again, the LED module is separate from the modular jack.
 The separate LED module is generally L-shaped and mounted over the top and
 rear of modular jack 12.
 Because of the similarities between the connector in FIGS. 9-13 and the
 connector in FIGS. 2-8, like reference numerals will be applied throughout
 all of FIGS. 9-15 corresponding to like elements described above and
 referenced in FIGS. 2-8. The major differences between the features of the
 connector assembly of FIGS. 9-15 and the connector assembly of FIGS. 2-8
 reside in the arrangement of the retaining means or latches as well as the
 light emitting components, as described hereinafter.
 More particularly, referring to FIG. 11 in conjunction with FIGS. 9 and 10,
 LED module 10 includes a light emitting device (LED) 66 covered by a light
 diffusing block 68. One of the LED's and diffusing block assemblies is
 mounted within each front corner of the LED module. The LED's are
 connected to conductors 50, and portions of the diffusing blocks are
 exposed through openings 70 in front face 42a of the LED housing.
 FIG. 11 shows that LED module 10 has a modified form of retaining means or
 snap latch arrangement. Specifically, like the embodiment of FIGS. 7 and
 8, a snap-latch flange or clip 60 is molded integrally along the bottom
 edge of rear portion 44 of LED housing 40. The latch flange defines an
 inwardly direct hook 60a. A pair of latch holes 72 are formed in top
 portion 42 of the LED housing immediately behind front face 42a thereof. A
 latch rib 74 projects inwardly of each latch hole 72.
 Turning to FIGS. 12 and 13, LED module 10 (FIG. 11) is mounted on modular
 jack 12 in the direction of arrow "A" (FIG. 12). When the housing of the
 LED module is snapped into latching engagement with the housing of the
 modular jack, hook 60a of latch flange 60 snaps behind a bottom edge 76 of
 rear wall 24 of modular jack housing 16. In addition, a pair of latch
 bosses 78 project upwardly from the front top corner of the modular jack
 housing and enter latch holes 72 at the front of the LED housing. A latch
 groove 80 is formed in the front face of each latch boss 78 for receiving
 the latch rib 74 within the respective latch hole 72 of the LED housing.
 The top front corner 78a of each latch boss 78 is chamfered or rounded so
 that latch ribs 74 ride over the latch bosses and snap into latch grooves
 80.
 In an alternative mounting method, the module 10 may be initially tilted a
 slight angle allowing lateral ribs 78 to enter respective grooves 80 and
 then the module may be rotated into latching engagement with the housing
 of the modular jack.
 FIG. 14 shows a modified form of LED module wherein a pair of diffusing
 blocks 68A are provided and are exposed through openings 70A in front face
 42a of the LED housing. Openings 78a are larger than openings 70 in FIG.
 11 to expose greater portions of diffusing blocks 68A. In addition, LED
 module 10 in FIG. 14 has a single latch hole 72A and a corresponding
 single latch rib 74A, versus the two latch holes 72 and corresponding two
 latch ribs 74 of the module embodiment shown in FIG. 11. Of course, the
 modular jack housing would have a single latch boss for projecting into
 the single latch hole 72A.
 Finally, FIG. 15 shows a form of LED module, generally designated 10, which
 includes a pair of elongated light pipes 82 embedded within elongated
 recesses 84 within top portion 42 of the LED housing. LED's 86 are
 disposed within the LED housing near the juncture of the top portion 42
 and rear portion 44 thereof. The LED's are electrically connected to
 conductors 50. Each light pipe 82 has a front face 82a exposed through an
 opening 90 in front face 42a of the LED housing. Light pipes 82, as well
 as diffusing blocks 68 and 68a are homogeneous structures fabricated of
 such materials as a substantially clear polycarbonate material.
 It will be understood that the invention may be embodied in other specific
 forms without departing from the spirit or central characteristics
 thereof. The present examples and embodiments, therefore, are to be
 considered in all respects as illustrative and not restrictive, and the
 invention is not to be limited to the details given herein.