Abstract:
An electronic connector plug for high speed transmission provides an electronic connector plug conforming to Category 6 standards. The plug includes an insert element which holds the third twisted pair on a level different from the level of other three twisted pairs in a stagger manner, and allows each twisted pair maintaining twisted state before reaching the contacts of the plug, thereby to achieve more reliable high speed transmission performance.

Description:
FIELD OF THE INVENTION 
     The invention relates to an electronic connector plug and particularly an electronic connector plug that is conformed to Category 6 standard for high speed transmission. 
     BACKGROUND OF THE INVENTION 
     In order to respond the growing applications of high speed networks after the Ethernet networks widely adopted, working groups in Telecommunications Industry Associations (TIA) of U.S.A. has developed and announced an Enhanced Cat. 6 standard based on the wiring system of Category 5 (Cat. 5) 100 MHZ (titled: TSB-67). The Cat. 6 standard expands from 100 MHZ of Cat. 5 to 200 MHZ and increases more than 25% of performance than the Cat. 5 standard. Hence, test frequency for Cat. 6 also has to reach 250 MHZ. The Cat. 6 standard has big advantages over the Cat. 5 standard, especially on the performance improvements in cross talk interference and return loss. On the full duplex high speed network applications in the new generation, improved performance on return loss is very important. Cross talk is a critical factor for implementing wide band applications. Although 100 MHZ is still the mainstream of the present network installations, Cat. 6 standard is a more desirable protocol to meet future requirements. 
     The current Fast Ethernet standard specification of IEEE802.3u utilizes EIA/TIA-568 as the standard of twisted pair. The twist pair, depending on their constructions, can be categorized in Unshielded Twisted Pair (UTP) and Shielded Twisted Pair (STP). The main difference between the two is that STP has one more metal shield and a grounding brass line, and is more expensive and more difficult to install. As a result, UTP is more popular and is the commonly adopted twisted pair standard. 
     Whereas the aforesaid standards are not solely for high speed communication cables. In order to maintain same level of high speed transmission performance in the high speed communication network systems, the peripheral facilities associated with the high speed communication cables, especially connection elements (such as RJ-45 type plugs and jacks) also should have matching designs. The RJ-45 connectors (including plug and jack) used in high speed communication networks generally are 8P8C type. 8P means eight positions, and 8C means eight gold plated contacts. However, in practical applications, only two pairs of lines are used. Another two pairs of lines may be used for other apparatus such as telephones and facsimiles. There are two types of connectors according to EIA/TIA specifications, i.e. EIA/TIA-568A and EIA/TIA-568B. EIA/TIA-568A is rarely used now, while EIA/TIA-568B is continuously being used. Its leg positions 1-8 are arranged sequentially and encased respectively by colored cables of white-orange, orange, white-green, blue, white-blue, green, white-brown, and brown. 
     In the past, most of the designs have been focused on the structure of the jacks and tried to conform to the standards set forth above. For instance, ROC Patent publication No. 224547 discloses “Communication connector terminals for eliminating noise” which makes the metal terminals of the jack overlapping in a non-contact manner, but has little design improvements on the plug. In the conventional jacks, four pairs (eight lines) of cable lines are laid on the same level to connect the contacts. Such a structure has greater cross-talk and return loss, and can hardly meet the Cat. 6 standard. 
     R.O.C. Patent publication No. 424353 discloses “Connector using conduction line for transmitting high frequency data” which proposes a design separating each twisted pair at the end of the cable, and connects each contact through a conduction wire connecting means. The separated lines are located in the plug at a selected sequence, and are connected to an insulation frame in a parallel manner. The frame has two channels separated by a flat plate for a selected distance in an up and down manner. Four pairs of conduction lines are held separately in the two channels at different levels. The ends of the channels have electric contact elements to connect the electric contacts located at the front end of the plug. While the techniques suggested by the public No. 424353 has some improvements over conventional plugs, there are still problems unresolved, notably: 
     1. The original design object of the twisted pair is to reduce the interference of noise and cross-talk. As conduction lines with electric current flowing thereon will generate electromagnetic field and interfere other conduction lines, twisting the positive and negative signal line can cancel out the magnetic fields generated by the two different lines and decrease the interference. But the design suggested by the public No. 424353 has to separate the end portion of the twist pair lines. Such a design contradicts the originally design object of the twist pair cable and will result in higher cross talk and return loss. 
     2. Although separating multiple twist pairs in parallel on different levels offers some improvements, the improved effect is limited. 
     3. The electric contact elements are located at the end of the channel of the frame. 
     The construction is complicated. 
     SUMMARY OF THE INVENTION 
     The primary object of the invention is to provide an improved electronic connector plug that is conformed to the Category 6 standard for high speed transmission. The plug of the invention includes an insert element insertable into the electronic connector plug. The insert element has a plurality of guiding tunnels located on different elevations. Each twisted pair of the high speed communication cable will be channeled through one tunnel and connected to metal contacts located at the front end of the plug. The plug thus constructed can achieve the original object of the twisted pair for reducing noise and cross-talk. Through disposing the multiple pairs of twisted pair located on different levels in a staggered manner, it also can meet the Cat. 6 standard for high speed communication. 
     Another object of the invention is to provide an electronic connector plug that has better assembly quality. 
     In order to attain the foregoing objects, the insert element of the invention is adopted a two-piece design. The insert element has a cradle body and a clamping cap. Before each twisted pair and the insert element being inserted into the casing of the plug, the high speed communication cable may be clamped tightly by the cradle body and clamping cap to prevent the end section of any cable line from withdrawing or skewing during assembly and to achieve accurate connection to the metal contacts. 
     The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded view of the invention. 
     FIG. 2 is a perspective view of the invention, with the cradle body coupled with the clamping cap, and located in the inserting direction before coupling with the plug casing. 
     FIG. 3 is a sectional view of the invention assembled with a high speed communication cable and an insert element. 
     FIG. 4 is a cross section view of the invention taken along line IV—IV in FIG. 3, showing metal contacts connecting the cable lines. 
     FIG. 5 is a cross section view of the invention taken along line V—V in FIG. 2, showing tunnels locations when the clamping cap and cradle body of the insert element are coupled. 
     FIG. 6 is a schematic view for assembling of the invention, showing a method for assembling the high speed communication cable and the insert element. 
     FIG. 7 is a schematic view for assembling the invention, showing the cable lines held in the line roughs after the high speed communication cable and the insert element are assembled. 
     FIG. 8 is a cross section view of the clamping cap, showing the arrangement of tunnels. 
     FIG. 9 is a cross section view of the clamping cap, showing another arrangement of tunnels. 
     FIG. 10 is a cross section view of the invention, showing metal contacts connecting the cable lines on the same plane. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, the electronic connector plug of the invention consists of: 
     a plug casing  10  which has dimensions conforming to the RJ-45 type electronic connector plug specifications. The casing  10  is a hollow element and has an upper wall  11   a , a lower wall  11   b , a left side wall  12   a , a right side wall  12   b , and an elastic tab  13  located beneath the bottom side of the lower wall  11   b  extending rearwards in a slant manner for engaging with an electronic connector jack (not shown in the drawing). The front end of the casing leading to the insertion direction with the jack has a closed front wall  14 . The rear end opposite to the front wall has a port  15  communicating with the exterior. The front end of the casing  10  further has eight metal contacts  21 - 28  which are inserted through apertures  110  formed at the front end of the upper wall  11   a . The metal contacts  21 - 28  have pointed front ends to connect with the cable lines  31 - 38  of the high speed communication cable  30 ; and 
     an insert element which may be inserted into the casing  10  through the port  15  in the direction same as the direction of the casing  10  inserting into the plug. The insert element includes: 
     a cradle body  40  which is a narrow and elongated element with a passage running through the front end and the rear end, and has a bottom section  41 , a left side wall  42   a  and a right side wall  42   b . The front end of the bottom section  41  closest the casing  10  is extended forwards to form a plurality of line troughs  51 - 58  which are located respectively below the metal contacts  21 - 28  for holding cable lines  31 - 38  such that the pointed front ends of the metal contacts  21 - 28  can pierce through the insulation skin of the cable lines  31 - 38  to contact the metal conduction wire. In the middle portion of the bottom section  41 , there is a lower guiding trough  64   a  longitudinally formed along the center axis of the bottom section  41  for channeling the third twisted pair lines  33  &amp;  36  passing through the cradle body  40  on a lower level than the rest twisted pair lines  31  &amp;  32 ,  34  &amp;  35 ,  37  &amp;  38 ; and 
     a clamping cap  60  which is an elongated element and may be wedged in the narrow passage of the cradle body  40  surrounding by the bottom section  41 , left side wall  42   a  and right side wall  42   b  (referring to FIG.  2 ). The clamping cap  60  includes a front section  6 A and a rear section  6 B aligning along the axis direction. The front section  6 A has three tunnels  61 - 63  running therethrough for channeling the twisted pairs  31  &amp;  32 ,  34  &amp;  35 ,  37  &amp;  38  (Pair  1 ,  2 ,  4 ) other than the third twisted pair  33  &amp;  36 . The front section  6 A further has an upper guiding trough  64   b  formed in the middle of the bottom side thereof to couple with the lower guiding trough  64   a  of the cradle body  40  to form a fourth tunnel  64  for channeling the third twisted pair  33  &amp;  36  (shown in FIG.  5 ). The rear section  6 B has a plurality of latch lugs  65  (such as latch hooks) formed on two side walls  42   a  and  42   b  for engaging with matching latch notches  43  (such as hook slots) formed on the left side wall  42   a  and right side wall  42   b  of the cradle body  40 , thereby allow the clamping cap  60  and the cradle body  40  to couple together. The clamping cap  60  further has a plurality of jutting clamping teeth  66  formed on the side facing the cradle body  40 . The bottom section  41  of the cradle body  40  also has a clip plane  44  facing and mating the clamping teeth  66 . Hence when the clamping cap  60  and the cradle body  40  are coupled together, the clamp teeth  66  and the clip plane  44  will clamp the high speed communication cable  30  tightly between the clamping cap  60  and the cradle body  40  (shown in FIG.  3 ). 
     Basically, the four tunnels  61 - 64  are located on different elevations, especially the fourth tunnels  64  is located on the level that different to the three tunnels  61 - 63 . In the first preferred embodiment, the three tunnels  61 - 63  are located on same plane (i.e. same level, shown FIG.  1 ). In the other preferred embodiment, the three tunnels  61 - 63  are located on different plane respectively (shown FIG.  8 - 9 ). 
     According to the present invention, the three tunnels  61 - 63  not limited in the form as a tube (shown FIG.  1 ). In another preferred embodiment, each of the three tunnels  61 - 63  could be formed as a trough (shown FIG.  8 - 9 ). 
     In a preferred embodiment, the line troughs  51 - 58  are located on different elevations, especially the line troughs  53  and  56  for holding the third pair of cable lines (Pair  3 , which contains the third and sixth cable lines) has a lower elevation than the rest of line troughs  51 ,  52 ,  54 ,  55 ,  57 ,  58  (shown FIG.  1 ). In the other preferred embodiment of the invention, the line troughs  51 - 58  are located on same plane (shown FIG.  10 ). 
     Referring to FIG. 6, when connecting the connector plug  10  of the invention with the high speed communication cable  30 , first, peel off the outer shrouding layer of the cable  30  to expose four pairs of twisted pairs (Pair  1 - 4 ) without separating the twisted pair lines of each pair, then channel respectively the twisted pairs  31  &amp;  32 ,  34  &amp;  35 ,  37  &amp;  38  of the Pair  1 ,  2  and  4  through the tunnels  61 - 63  located on the upper level of the insert element, and dispose the twisted pair  33  &amp;  36  of the Pair  3  below the upper guiding trough  64   b , and move the insulation layer of the cable  30  between the clamp teeth  66  of the clamping cap  60  and the clip plane  44  of the cradle body  40 , then couple the clamping cap  60  with the cradle body  40  together with the latch lugs  65  on two sides of the clamping cap  60  engaging with the latch notches  43  of the cradle body  40 , thereby to clamp and hold the cable  30  tightly therebetween. 
     It is to be noted, before the clamping cap  60  and the cradle body  40  are coupled, make sure that the ends of the twisted pairs  31 - 38 , after passing through the tunnels  61 - 64 , will be extended for a sufficient length to lay and expose on the line troughs  51 - 58 . Then the insert element which has the cable  30  encased therein may be inserted into the plug casing  10  through the port  15  (shown in FIG. 7) until a snap latch  67  located on the top surface of the rear section  6 B of the clamping cap  60  engaging with a matching latch aperture  111  formed on the upper wall  11   a  of the plug casing  10 . Finally, insert the metal contacts  21 - 28  through the apertures  110  to make the pointed front ends of the metal contacts  21 - 28  connecting with the twisted pairs  31 - 38  of the cable  30 . 
     In the invention, it is preferable to form the line troughs  51 - 58  of the cradle body  40  with upper openings cross section wise. The openings have a width slightly smaller than the outside diameter of each cable line  31 - 38  so that when the clamping cap  60  and the cradle body  40  coupled, besides channeling the cable lines  31 - 38  through the line troughs  51 - 58  in the axial direction, the cable lines  31 - 38  may also be straightened and depressed downwards through the openings into the line troughs  51 - 58 . 
     To increase the clamping effect for the cable, the clip plane  44  of the cradle  40  may also be designed with the abrasive surface, or formed in an undulated or saw type profile. Such a design, coupling with the clamping teeth  66  of the clamping cap  60 , can clamp the cable  30  tightly and the cable lines  31 - 38  can be held securely without slipping away even subject to force when the insert element is inserted into the plug casing  10 . This also help to connect with the metal contacts  21 - 28  accurately. To further facilitate coupling of the insert element, the clamping cap  60  may have an anchor pin  68  jutting downwards from the bottom side, while the cradle body  40  has a mating cavity  45  to engage with the anchor pin  68  so that the clamping cap  60  may be coupled with the cradle body  40  more precisely and reliably. 
     In summary, through the guiding tunnel structure in the insert element of the invention, the multiple twisted pairs are separated only at locations closer to the metal contacts. Hence the invention can maintain the original design function of twisted pair to reduce noise and cross-talk. The design of deploying the twisted pairs on different levels can better achieve the high speed data transmission standard of Cat. 6. 
     Moreover, the design of two-piece insert element allows tight and secure clamping for the high speed communication cable before each twisted pair and the insert element being inserted into the plug casing, and can prevent the end section of the cable from retreating or skewing during assembly processes and achieve more accurate and reliable connection between the cable and metal contacts. 
     While the preferred embodiment of the invention has been set forth for the purpose of disclosure, modifications of the disclosed embodiment of the invention as well as other embodiment thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention.