Abstract:
A communication plug is described. The communication plug can have a load bar, housing, and a divider. The load bar has a first half with first conductor receiving apertures and a second half with second conductor receiving apertures with a hinge connecting the first half and the second half. The load bar folds around the divider and then is inserted into the housing.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/864,924, filed Apr. 17, 2013, which claims priority to U.S. Provisional Patent Application No. 61/635,669, filed Apr. 19, 2012 and is incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    With the steady increase of users adopting 10GBASET Ethernet for areas such as high performance computing (HPC), storage area networks (SANs), and cloud computing, there is a need for an even greater increase data rates in the network backbone. The highest established data transmission rate for structured copper cabling is currently 10 Gigabits per second (Gps) running on Category 6A (CAT6A) cabling. Additionally, pointtopoint copper cabling solutions can run through a 40 Gps Quad Small Formfactor Pluggable (QSFP) connector via twinaxial copper cable. Unfortunately the QSFP connectivity comes with multiple drawbacks where one of the deficiencies is the maximum distance of 7 meters while the lengths used for HPC can be up to 50 meters. Other drawbacks of QSFP connectivity are that it is not backwards compatible with RJ45 connectivity, and does not currently support structured cabling. 
         [0003]    Because of the split pair (pair 36 as defined by ANSI/TIA568C.2) in RJ45 connectivity and because of current practical modulation techniques, RJ45 connectivity is not currently capable of reaching higher data rates beyond 10 Gps. One of the problems with RJ45 connectivity is the inability to mitigate nearend crosstalk (NEXT) at frequencies above 500 MHz (for example, 2 GHz) where the current materials and crosstalk compensation techniques are some of the limiting factors. Another issue with RJ45 connectivity is the high level of signal reflection due to the split pair geometry in the RJ45 plug which causes high loss in the data transmitted in the frequencies beyond 500 MHz. Because of the inability for the RJ45 interface to operate effectively at frequencies above 500 MHz, the International Electrotechnical Commission (IEC) developed the IEC 6060377 and 60603771 standard for Category 7 and 7A connectivity. This standard defines a new connector interface, commonly referred to as GG45, where the jack supports a bandwidth greater than 500 MHz (600 MHz for Category 7 and 1000 MHz for Category 7A), while also having backwards compatibility to accept an RJ45 plug. U.S. Provisional Patent Application No. 61/543,866, titled “Backward Compatible Connectivity for High Data Rate Applications”, filed Oct. 6, 2011, which is herein incorporated by reference in its entirety, describes such a jack that is compliant with the IEC 6060377 standard. The plug defined in the IEC 6060377 standard differs from an RJ45 plug in that the four conductor pairs are separated into four quadrants, eliminating the 36 split pair that limits the bandwidth of the RJ45 solution. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is a perspective view of a communication system using a plug according to an embodiment of a present invention. 
           [0005]      FIG. 2  includes top and bottom front isometric views of the plug of  FIG. 1 . 
           [0006]      FIG. 3  is an exploded perspective view of the plug of  FIG. 2 . 
           [0007]      FIG. 4  is a perspective view showing the hinging load bar of the plug of  FIG. 2  in an open position before the conductors of a twisted pair cable are inserted into their respective load bar holes. 
           [0008]      FIG. 5  is a perspective view showing the hinging load bar of  FIG. 4  still in the open position but with the conductors of the cable inserted into their respective load bar holes. 
           [0009]      FIG. 6  is a perspective view of the subassembly of  FIG. 5  collapsing around the metal divider. 
           [0010]      FIG. 7  is a perspective view of the subassembly of  FIG. 6  with the conductors of the cable inserted into their respective holes of the hinging load bar and the hinging load bar collapsed around the metal divider. 
           [0011]      FIG. 8  are perspective views illustrating the subassembly of  FIG. 7  being inserted into the plug housing of  FIG. 2 . 
           [0012]      FIG. 9  is a crosssectional view taken along section line  99  in  FIG. 8 . 
           [0013]      FIG. 10  are perspective views of the back housing of the plug of  FIG. 2  being inserted into the subassembly of  FIG. 8 . 
           [0014]      FIG. 11  is a perspective cutaway view of the GG45 plug of  FIG. 2  showing the shear form barbs and overlapping flanges of the metal divider engaging the braid of the cable. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0015]    In one embodiment, the present invention is a plug compliant with IEC 6060377 (hereby referred to as GG45 plug) and has the ability to operate at frequencies above 500 MHz for use in higher data rates future applications (ex. 40GBASET). 
         [0016]      FIG. 1  illustrates a copper structured cabling communication system  30  which includes a patch panel  32  with GG45 jacks  34  and corresponding GG45 plugs  36 . Respective cables  38  are terminated to GG45 jacks  34 , and respective S/FTP cables  40  are terminated to GG45 plugs  36 . Once a GG45 plug  36  mates with a GG45 jack  34  data can flow in both directions through these connectors. 
         [0017]    Referring now to  FIG. 2 , GG45 plug  36  can include a plug release latch  42  that engages and locks GG45 plug  36  to GG45 jack  34 . Boot  44  can be used to constrain cable  40  so that it does not bend less than a minimum bend radius for S/FTP cable  40  exiting GG45 plug  36 . Front nose element  46  is a feature defined by IEC 6060377 and is used to toggle a switching mechanism inside of GG45 jack  34 . A traditional RJ45 plug does not have a feature like front nose element  46  of GG45 plug  36 . Therefore when an RJ45 plug is inserted into GG45 jack  34 , the switching mechanism is not toggled. When GG45 plug  36  is inserted into GG45 jack  34 , however, front nose element  46  toggles the switching mechanism so that GG45 jack  34  is converted to its alternate mode of operation capable of supporting frequencies above 500 MHz. U.S. Provisional Patent Application No. 61/543,866 contains more detail on an embodiment of a switching mechanism and two modes of operation for GG45 jack  34 . 
         [0018]    GG45 plug  36  contains eight transmission paths  48 . The subscript numerals after  48  in  FIG. 2  indicate the signal pin out as defined by IEC 6060377. Grounding pads  50  are present to bond to unneeded plug interface contacts (PICs) of GG45 jack  34  and bring them to ground. Grounding pad 503456 grounds PICs 3, 4, 5, and 6 of GG45 jack  34  as these PICs are only used during RJ45 mode of operation and are unused at frequencies above 500 MHz. Additionally, grounding pads  500  and  509  are present to ground PICs 0 and 9 of GG45 jacks  34  should they exist. It may be advantageous to include PICs 0 and 9 in GG45 jack  34  in order to achieve as much of a balanced design as possible. For example, transmission paths  48   7  and  48   8  represent a transmission pair. When PIC 6 is grounded by grounding pad  50   3456 , transmission path  487  has a ground running parallel adjacent in the form of PIC 6. If there is no grounded PIC 9 running parallel adjacent to transmission path  48   8 , then the system may become unbalanced. The same holds true for transmission paths  48   1  and  48   2 . Therefore, in one embodiment, GG45 plug  36  can have grounding pads  50   0  and  50   9  as provisions for a highly balanced system that may extend into GG45 jack  34 . GG45 plug  36  can also have dividing wall  52  which reduces crosstalk between signal transmission pair  48   3′  and  48   6′  and signal transmission pair  48   4′  and  48   5′ . 
         [0019]    Signal transmission paths for conductors 1, 2, 7, and 8 are in the same locations for both GG45 plug  36  and a standard RJ45 plug. Numerals with a prime, specifically  3 ′,  4 ′,  5 ′, and  6 ′, are unique to the GG45 interface and are not present in RJ45 plugs and jacks. An exploded view of GG45 plug  36  is shown in  FIG. 3 . GG45 plug  36  may contain plug housing  54  (which may be metal die cast for example), divider  56  (which may be a sheet metal part), eight plug insulation piercing contacts (IPCs)  58 , hinging load bar  60 , and plastic back housing  62 . 
         [0020]    To terminate STIP cable  40  to GG45 plug  36 , S/FTP cable  40  must be prepped as shown in  FIG. 4 . Hinging load bar  60  can be molded in an open orientation. Plug contacts  58  can be stitched into hinging load bar  60  only so deep as to not fall out. Conductors  64  are arranged according to their signal transmission pin out as defined by IEC 6060377 and cut to a prescribed length. Additionally, foil  66  that surrounds each signal transmission pair of conductors  64  must be trimmed as shown in  FIG. 4 . Braid  68  of shielded/foiled twisted pair (S/FTP) cable  40  is rolled back and trimmed to the appropriate length. Hinging load bar  60  can be positioned between the four pairs of conductors. Conical guide element  70  aids in the positioning of hinging load bar  60  relative to S/FTP cable  40 . 
         [0021]    With S/FTP cable  40  prepped and hinging load bar  60  together with its first half  65  and second half  67  in its proper position, each conductor  64  is inserted into its respective hole  72  as shown in  FIG. 5 . An advantage to molding hinging load bar  60  in an open orientation is that holes  72  are much more accessible than if hinging load bar  60  was molded closed. This advantage can result in reduced assembly time and lower standard cost. Divider  56  is then positioned between the top and bottom rows of conductor pairs as shown in  FIG. 6 . Divider  56  is used to provide isolation between the top and bottom signal pairs. It also bonds to braid  68  of S/FTP cable  40  to carry the ground throughout GG45 plug  36 . Divider  56  contains overlapping flanges  74  that reduce long gaps in coverage thereby providing a 360° bond around braid  68 . Shear form barbs  76  are present to bite into the braid and cable jacket of S/FTP cable  40 , providing the necessary strain relief to pass applicable strain relief testing.  FIG. 7  shows hinging load bar  60  with its first half  65  and second half  67  closed about hinges  78 . At this time, contacts  58  are mechanically crimped to a distance that is in accordance with IEC 6060377. The crimping operation can result in contacts  58  penetrating their respective conductor  64  such that contacts  58  make an electrical bond to the copper core of respective conductors  64 . 
         [0022]    Subassembly  80  is inserted into metal plug housing  54  as shown in  FIG. 8 . This insertion electrically bonds divider  56  to plug housing  54 , resulting in a continuation of the ground throughout the assembly. Post  82  of plug housing  54  goes through conical guide element  70  of hinging load bar  60  and touches all four conductor pair foils  66  as indicated in the  FIG. 9  section view. Although foil  66  makes an electrical bond with divider  56 , conductive post  82  of plug housing  54  also makes an electrical bond with foil  66 , creating an additional bonding region and improving the overall robustness of the design. Additionally, post  82  provides mechanical support by pushing conductor pair foils  66  outwardly and reinforcing cable  40  to create rigidity in region  84 . This outward force results in a higher pressure at the interface between cable  40  and shear form barbs  76  of metal divider  56 , resulting in a more effective electrical bond as well as improved mechanical strain relief. 
         [0023]      FIG. 10  shows that plastic back housing  62  then slides forward over cable  40 , completing the assembly of GG45 plug  36 . Four latches  86  from back housing  62  engage four pockets  88  from plug housing  54  to hold the assembly together. Rigid pads  90  from back housing  62  drive load bar  60  to the front of plug housing  54  and prevents load bar  60  from backing out. Dividing wall  52  of plug housing  54  fits within slot  92  of back housing  62 . Dividing wall  52  also constrains release latch  42  and prevents it from buckling or moving out of position. When fully assembled, back housing  62  applies uniform compression to rear region  94  of divider  56  as shown in  FIG. 11 . The inward pressure from back housing  62 , coupled with the outward pressure from post  82  of plug housing  54 , creates a pressured interface between divider  56  and cable  40  resulting in a reliable electrical bond as well as the necessary mechanical strain relief 
         [0024]    Although communication system  30  is illustrated a patch panel in  FIG. 1 , alternatively it can he other active or passive equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punchdown-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 poweroverEthernet 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 system  30  can further include cabinets, racks, cable management and overhead routing systems, and other such equipment. Cables  34  can be used in a variety of structured cabling applications including patch cords, zone cords, backbone cabling, and horizontal cabling, although the present invention is not limited to such applications. In general, the present invention can be used in military, industrial, telecommunications, computer, data communications, marine and other cabling applications. 
         [0025]    While particular embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations may be apparent from the foregoing without departing from the spirit and scope of the invention as described.