Abstract:
A telecommunications connector system for connecting to a mating telecommunications jack includes a housing that is configured to provide a contact chamber, a carrier configured to receive a plurality of insulated conductive lines, and electrically-conductive contacts at least partially disposed in the carrier, each contact including first, second, and third portions, each of the first portions being movably connected to the second portion and configured to move relative to the second portions in response to applied forces and to return to resting positions in response to removal of the applied forces, each of the third portions being movably connected to a corresponding second portion and including a blade configured to pierce an insulator coating of a corresponding insulated conductive line received by the carrier, where the carrier is at least partially disposed inside the housing such that the contacts are at least partially disposed in the contact chamber.

Description:
FIELD OF THE INVENTION 
   The invention relates to telecommunications cable terminations. 
   BACKGROUND OF THE INVENTION 
   The use of telecommunications in today&#39;s society increases at an incredibly rapid pace. As the use of telecommunications increases, so to does the corresponding need for telecommunications infrastructure. Such infrastructure includes cabling, switching systems and connectors for cabling to connect to the switching systems and for connection to telecommunications&#39; devices such as telephones, fax machines, etc. As more telecommunication infrastructure is used in single locations (e.g., to accommodate more and more telecommunications devices at single locations) telecommunications infrastructure becomes more and more complex and crowded. Thus, as with many things in today&#39;s society there is a drive for smaller and more economical devices in telecommunications infrastructure. 
   There are several existing styles of telecommunications cable connectors that exist today. For example, insulation displacement connectors (IDC) exist currently. These connectors are assembled by inserting individual wires into slots in a wire termination area of the connector, and then moving the movable portion of that connector toward another portion of the connector to close the connector and simultaneously force metal contacts through the insulation of the wire and into contact with the conductors of the wires. Other connectors include receptacles where individual wires are assembled by inserting the wires into the receptacles. A pair of blades exposed within the receptacles split the insulation around the wire and make contact with the conductor inside the insulation. 
   SUMMARY OF THE INVENTION 
   In general, in an aspect, the invention provides a telecommunications connector system for connecting to a mating telecommunications jack, the connector system including a housing that is configured to provide a contact chamber, a carrier configured to receive a plurality of insulated conductive lines, and electrically-conductive contacts at least partially disposed in the carrier, each contact including first, second, and third portions, each of the first portions being movably connected to the second portion and configured to move relative to the second portions in response to applied forces and to return to resting positions in response to removal of the applied forces, each of the third portions being movably connected to a corresponding second portion and including a blade configured to pierce an insulator coating of a corresponding insulated conductive line received by the carrier, where the carrier is at least partially disposed inside the housing such that the contacts are at least partially disposed in the contact chamber. 
   Implementations of the invention may include one or more of the following features. The carrier provides grooves corresponding to the contacts such that portions of the contacts can be inserted into the grooves, and walls providing the grooves help to retain the contacts within the carrier and help to electrically isolate the contacts from each other. At least the third portions of the contacts are disposed in the grooves and heights of the walls of the carrier providing the grooves have at least two different heights, the walls being relatively smaller under the first portions of the contacts and being relatively larger where the third portions of the contacts are disposed in the grooves. The grooves under the first portions of the contacts are configured to allow the first portions of the contacts to move in the grooves. The carrier provides holes for receiving the insulated conductive lines, the holes being aligned with a respective one of the grooves. The carrier includes barriers each disposed between a respective one of the grooves and a respective one of the holes. The third portions of the contacts are configured to be disposed around the barriers and to move relative to the second portions such that the blades will pierce the insulated conductive lines if the lines are disposed in the holes adjacent to the barriers. The system further includes the insulated conductive lines, and the blades are wedged into the conductive lines through insulator casings of the insulated conductive lines and held in place by friction. 
   In general, in another aspect, the invention provides a multi-user telecommunications outlet assembly system including a first subsystem cable including a first set of connector cables each including a plurality of insulated conductive lines, and a first set of telecommunications connectors for connecting to mating telecommunications jacks, each connector of the first set of connectors coupled to a corresponding connector cable of the first set and including: a housing that is configured to provide a contact chamber; a carrier configured to receive a corresponding set of the insulated conductive lines, the corresponding set of the insulated conductive lines being partially disposed in the carrier; and electrically-conductive contacts at least partially disposed in the carrier, each contact including first, second, and third portions, each of the first portions being movably connected to the second portion and configured to move relative to the second portions in response to applied forces and to return to resting positions in response to removal of the applied forces, each of the third portions being movably connected to a corresponding second portion and including a blade configured to pierce an insulator coating of a corresponding insulated conductive line received by the carrier, where the carrier is at least partially disposed inside the housing such that the contacts are at least partially disposed in the contact chamber. 
   Implementations of the invention may include one or more of the following features. The system further includes a second subsystem cable similar to the first subsystem cable, a second set of telecommunications connectors similar configured and coupled similarly to the first set of telecommunications connectors, and a rack-mountable faceplate providing openings through which the first and second sets of telecommunications connectors are respectively disposed. 
   In general, in another aspect, the invention provides a telecommunications cable including a housing providing a contact chamber and a connector receptacle, insulated wires, an electrically-insulating contact carrier coupled to the housing and disposed at least partially in the housing and including a set of walls that provide grooves, the grooves having first regions of a first depth and a second region of a second, deeper, depth, the contact carrier providing a plurality of wire holes, each wire hole aligned with a corresponding one of the grooves, each of the wire holes including a trough portion in which the carrier provides less than a full circumference wall, electrically-conductive contacts, each contact being a monolithic conductor, each contact including a base portion, an upper portion, and a blade portion, the base portion being disposed in a corresponding one of the grooves, the upper portion being disposed at least partially in the contact chamber and being configured and arranged to bend relative to the base portion to bias against and make electrical contact with a mating contact of a mating connector inserted into the connector receptacle, at least a portion of the blade portion being disposed in the second region of the corresponding groove, the blade portion including a blade disposed through a portion of an insulating shell of a corresponding one of the insulated wires and making electrical contact with the wire. 
   Implementations of the invention may include one or more of the following features. Each blade of the contacts biases the corresponding one of the insulated wires against a wall of the carrier providing the trough portion of the corresponding wire hole such that the blade is inhibited, by friction between the blade and the insulated wire, from being removed from insulated wire. The system consists essentially of the housing, the wires, the carrier, and the contacts. Each of the blades includes cutting points disposed along a length of the corresponding contact. The carrier includes barriers separating the first portions of the grooves from the trough portions of the wire holes. The contacts are disposed about the barriers, with the blades on first sides of the barriers and the base portions on second, opposite sides of the barriers. 
   In general, in another aspect, the invention provides a telecommunications connector system for connecting to a mating telecommunications jack, the connector system including a housing that is configured to provide a contact chamber, a carrier configured to receive a plurality of insulated conductive lines, and electrically-conductive contacts at least partially disposed in the carrier, each contact including a first portion configured to make electrical contact with a corresponding one of the conductive lines, a second portion connected to the first portion by a first bend in the contact, and a third portion connected to the second portion by a second bend in the contact, the third portion being configured and arranged to make electrical contact with mating contacts of a mating connector received by the telecommunications connector system, where the contacts are each configured to flex at the first bend, such that forces are developed in the first bend, in response to the third portion being pressed upon by one of the mating contacts. 
   Implementations of the invention may include one or more of the following features. The carrier is configured to provide room below each of the second portions of the contacts with the first bends in unflexed states such that the second portions of the contacts can move into the room as the contacts flex at the first bends. The first bend is configured such that the forces developed in the first bend cause reduced amounts of force to be developed in the first portion and the second bend than if the first portion was connected to the second portion without the first bend. 
   Various aspects of the invention may provide one or more of the following capabilities. A telecommunications connector can be provided without using additional intermediate interface connector components to terminate wires. Telecommunications connectors can be provided with electrical contacts that are not soldered to corresponding wires. Termination contacts can be provided in a telecommunication connector that are part of the same component as the jack contacts. Connector contacts can be mass terminated to wires in a single operation to assemble a telecommunications connector. A connector can be provided with or without cable strain relief. A telecommunications connector can be provided with a short body construction of approximately 22 mm in length or less. A telecommunications connector can be provided with positive, dynamic contact position retention during and after termination. A telecommunication connector can occupy less space than previous connectors and/or use fewer components and/or less costly components than previous connectors. A telecommunications connector can be terminated faster and/or with less labor than with previous connectors. Outlet box space can be better utilized. Reduced size MUTOA (multi-user telecommunications outlet assembly) devices can be created using the connector. A telecommunications connector can be provided that is applicable to the 2, 4, 6, 8, 10, or more pin circuits for low and/or high bandwidth applications. Terminated connector can also be introduced into a patch cable type housing and used as a network extension cable, not being incorporated with additional panels, wall plates or housings. 
   These and other capabilities of the invention, along with the invention itself, will be more fully understood after a review of the following figures, detailed description, and claims. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIG. 1  is an exploded perspective view of a telecommunications connector according to the invention. 
       FIG. 2  is a partially exploded perspective view of the connector shown in  FIG. 1 . 
       FIG. 3  is a perspective assembled view of the connector shown in  FIGS. 1 and 2 . 
       FIG. 4  is a perspective view of the connector shown in  FIGS. 1–3  with wire insertion channels at a rear of the connector. 
       FIG. 5  is a partially cut-away view of the connector shown in  FIG. 4 . 
       FIG. 6  is a perspective view of a set of electrical contacts that are part of the connector shown in  FIGS. 1–3 . 
       FIG. 7  is a block flow diagram of a process of assembling the connector shown  FIGS. 1–3 . 
       FIG. 8  is a perspective view of a tool for use in assembling the connector shown in  FIGS. 1–3 . 
       FIG. 9  is a perspective assembled view of an alternative telecommunications connector according to the invention. 
       FIG. 10  is a block flow diagram of a process of assembling the connector shown in  FIG. 9 . 
       FIG. 11  is a perspective view of a portion of a multi-user telecommunication outlet assembly system. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   Embodiments of the invention provide techniques for manufacturing and providing connectors, in particular for telecommunications. The connectors in accordance with embodiments of the invention can have relatively few parts and a relatively compact size with a small foot print. An exemplary embodiment includes a housing that contains a contact carrier, and the contract carrier contains and holds a set of electrical contacts. The contacts are configured to be pre-inserted into the contact carrier, and with wires inserted into the contract carrier, blade portions of the contacts can be moved down into the wires. Contact grooves provide sufficient friction force to maintain contact placement prior to and after termination. This friction fit helps to retain the contacts within the contact carrier when assembled preferably without additional parts or adhesives used to hold the contacts in the contact carrier. The blades are configured to pierce insulation of the wire and to be moved into contact with conductors inside the insulation, making electrical connections with the conductors of the wires. The assembled contact carrier and contact combination, with the contacts connected to the wire conductors, is inserted into the housing for completion of the telecommunications connector. Other embodiments are within the scope and spirit of the invention. 
   Referring to  FIGS. 1–3 , a telecommunications connector  10  includes a housing  12 , a contact carrier  14 , and a set  16  of contacts  18 . The housing  12 , and the contact carrier  14  are preferably made out of an electrically insulating material such as a plastic. When assembled, the connector  10  is preferably configured to provide a standard category 5e, 6 (CAT 5e, Cat6) connection for telecommunications, although other forms of connectors are possible. The contacts  18  are made of an appropriately electrically conductive material such as gold-plated phosphor, bronze, or an appropriate alloy. Preferably, the assembled connector shown in  FIG. 3  has dimensions of about 22 mm or less in length  4 , about 18 mm or less in width  6 , and about 24 mm or less in height  8 . 
   The housing  12  is configured to receive the carrier  14  and the contact set  16 , as assembled, into a mating receptacle  22  that is configured to receive the combination of the contact carrier  14  and the contact set  16 . A front wall  24  of the housing  12  provides an end for the receptacle  22 . The front wall includes an opening  26  configured to receive an appropriate telecommunications mating connector plug for insertion into the housing  12  for connection with the contacts  18 . The opening  26  includes a cut-out  28  sized for receiving a tab on a mating connector inserted into the opening  26 . The mating connector can be inserted through the opening  26  and the tab, that is spring biased, can move upwardly once inserted to help retain the mating connector within the housing  12 . The opening  26 , as shown, has a height of approximately 6.8 mm, a width of approximately 11.9 mm, and a depth of approximately 10.8 mm. 
   The contact casing  14  is configured to receive and hold or retain the set  16  of contacts  18 , and a set of wires. As shown, the casing  14  is preferably substantially L-shaped. 
   As shown in  FIG. 1 , the casing  14  provides a set of lower grooves or slots  30  and a corresponding set of upper grooves or slots  32  that are in alignment with the lower slots  30 . Referring also to  FIG. 4 , the casing  14  provides an equal-in-amount corresponding set  34  of wire holes  36  that are sized for receiving standard 24 or 26 AWG wires with insulation. 
   The quantity of the wire holes  36  is the same as the quantity of the upper slots  32  and the lower slots  30 . As shown in  FIG. 4 , the wire holes  36  provided by the contact casing  14  and are arranged in two off-set rows  40 ,  42  such that the holes  36  in the upper row  40  are horizontally displaced from the holes  36  in the lower row  42  such that holes in the two rows  40 ,  42  are not vertically over-lapping. Thus, the wire holes  36  in the upper row  40  correspond to alternating ones of the upper grooves  32 , and the wire holes  36  in the lower row  42  correspond to other alternating ones of the upper grooves  32 , interlaced with the upper grooves  32  corresponding to the wire holes  36  of the upper row  40 . The wire holes  36  are sized to receive a desired size of wires, but provide little room beyond the diameter of the corresponding desired-size wire. Referring also to  FIG. 5 , barrier tabs  38  are provided by the contact casing  14  to separate the wire holes  36  from the lower grooves or slots  30 . Portions of the wire holes  36  beneath the upper grooves  32  do not have upper containment and thus are wire trough portions  44  of the holes  36 . The holes  36  become the troughs  44  because the upper grooves  32  extend down to the holes  36 , so that a portion of the wall surrounding the hole  36  does not exist in the region beneath the upper grooves  32 . 
   Referring to  FIG. 6 , each of the contacts  18  in the contact set  16  includes an upper portion  46 , a lower portion  48 , an arm  50 , and a blade  52 . The contacts  18  are shown in their resting positions. The contacts  18  are configured to flex about bends  54  such that the upper portions  46  can pivot toward the lower portions  48  about the bends  54 . The contacts  18  are made of a resilient metal such that the contacts maybe repeatedly bent and will return to their resting position as shown in  FIG. 6 . The contact channels  30  provide additional space below the contacts  18  for flexing of the lower portions  48  to help prevent permanent contact distortion at the contact bends  54  that would leave the upper portions  46  in depressed positions. The arms  50  extend upwardly away from the lower portions  48  and then parallel to the lower portions  48  extending away from the upward portion in a direction away from the bends  54 . The blade  52  extends downwardly from upper portions  56  of the arms  50 . The arm  50  and the blade  52  provide a receptacle  58  that is configured to receive the vertical barrier  38  of the contact carrier  14  ( FIGS. 4–5 ). The lower portions  48  of the contacts  18  are configured to fit within the lower grooves  30  of the contact carrier  14 , preferably with a separating but floating fit. 
   The arms  50  are configured as resilient, bendable members that can pivot relative to the lower portions  48  about bends  60  where the arms  50  extend away from the lower portions  48  of the contacts  18 . The arms  50  absorb contact movement to help prevent movement of the upper portions  46  from causing movement of the blades  52 . The blades  52  are shown having two cutting points  62  although other numbers of cutting points  62 , e.g., one, three, etc., are acceptable. The points  62  are displaced from each other along a length of the upper arm portion  56  (i.e., along a length of the contact  18 ). The cutting points  62  are configured to pierce insulation of the wires inserted into the wire holes  36  up to the vertical barrier  38  ( FIG. 4 ). The blades  52 , in particular the cutting points  62 , are configured to make electrical contact with conductors of the wires in the wire holes  36 . The blades  52  are preferably integrally formed as monolithic pieces with the arms  56 . Indeed, preferably, the entire contact  18  is an integrally-formed monolithic piece. The blades  52  are configured as tapered members with narrow points at the cutting tips  62  with larger widths where the blades  52  meet the upper portions  56  of the arms  50 . The blades  52  are configured to be inserted into the wires and to force the wires outwardly to contact walls of the wire troughs  44 . This provides friction between the blades  52  and the wires in excess of the spring bias force of the arm  50  to help retain the blades  52  in electrical contact with the conductors of the wires. 
   Referring again to  FIG. 7 , with further reference to  FIGS. 1–3 , a process  70  for assembling the connector  10  includes the stages shown. The process  70  is exemplary only, and not limiting. The process  70  can be modified, e.g., by adding, removing, and/or rearranging stages. 
   At stage  72 , the connectors  18  are inserted into the grooves  30 – 32  of the contact casing  14 . The lower portions  48  of the contacts  18  are inserted into the lower grooves  30  of the casing  14  while the arm portions, including the arms  50  and the blades  52  of the contacts  18  are inserted into the upper grooves  32 . 
   At stage  74 , the wires are inserted into the wire holes  36  until they butt up against the vertical barriers  38  of the contact carrier  14 . Preferably, the wires are not stripped, thus leaving them with their insulation intact. 
   At stage  76 , the upper portions  56  of the arms  50  are pushed downwardly to cause the blades  52  and in particular the cutting points  62 , to pierce the wires. The points  62  pierce through the insulation of the wires and into the conductors of the wires. The blades  52  push the conductors and the insulation outwardly to contact the walls of the wire troughs  44 . The pressure exerted by the walls on the insulation is transferred through to the conductors and to the blades  52 . Sufficient pressure is exerted on the blades  52  to provide a friction fit for the blades  52  in the wires, thus inhibiting upward movement of the blades  52  and helping to insure continued electrical contact between the blades  52  and the conductors of the wires. Referring also to  FIG. 8 , a special tool  90  can be provided for simultaneously pushing multiple ones of the blades  52  into the corresponding wires. The tool  90  can be configured to push down on any number of the upper contact portions  56 . Preferably, the tool  90  is configured to push down on the upper portions  56  of all of the contacts  18 . The tool  90  is sized such that individual tines  92  can be inserted into the upper grooves  32  and contact the upper portions  56  of the arms  50 . The tool  90  can be configured differently than as shown, e.g., as a ratcheting-pliers type tool. 
   At stage  78 , the assembled combination of the contacts  18  and the contact casing  14  is inserted, as indicated by arrow  82  in  FIG. 2 , into the receptacle  22  of the housing  12 . The contact casing  14  can be sized to provide a ramp/detent friction fit within the receptacle  22  by press fitting into the housing  12  to inhibit removal of the casing  14  from the housing  12 . Alternatively, other techniques for helping to retain the casing  14  within the housing  12  maybe used, e.g., using tabs and slots on the housing  12  and the casing  14 . 
   In use, with the connector  10  assembled as described above, the female connector  10  can receive a male connector for telecommunications. A male connector can be inserted into the receptacle  26  of the housing  12  such that contact of the male connector can touch and make electrical contact with the contact  18  of the connector  10 . Thus, telecommunications can be enabled with electrical signals being communicated across the contacts  18  to and from the male connector. 
   Other embodiments are within the scope and spirit of the invention. For example, used. The contact casing  114  includes a tab  115  that extends downwards to the interior of the casing  114 . The tab  115  is wide enough and extends deep enough into the interior of the casing  114  to pinch a wire bundle outer sheathing/jacket  137  that incorporates the wires for making contact with electrical contacts of the connector  110 . The tab  115  is configured to be biased against the-cable outer sheathing  137  compressing the cable  137  in place within the casing  114 , thus relieving strain on individual wires in the cable  137  and connected to the contact of the connector  110 . Referring also to  FIG. 10 , a process  120  for assembling the connector  110  includes the stages shown. The process  120  is similar to the process  70  shown in  FIG. 7  and described above, but the stage  120  includes a stage  77  for applying strain relief. At stage  77 , the tab  115  is pushed inward to crimp the cable  137  to inhibit the cable  137  from being pulled from the casing  114 , providing strain relief. Strain relief may be provided in conjunction with stage  74  where the wires are inserted into the casing  114 , with the tab already being disposed to clamp onto the cable  137  and automatically providing strain relief when the cable  137  is inserted into the casing  114 . 
   Referring to  FIG. 11 , a MUTOA system  150  includes cables  152 , multiple sets  154  of connectors  156 , and a faceplate  158 . Each cable  152  includes 24 pairs of wires for connection to a corresponding one of the sets  154  of the connectors  156 . The connectors  156  may be the connectors  10  or the connectors  110 , or another embodiment of the connectors according to the invention. Each set  154  includes six of the connectors  156  disposed adjacent to each other, such that each connector  156  is coupled to eight wires from the cable  152 . The faceplate  158  provides mounting holes  160 , with a matching set of mounting holes on the end of the faceplate  152  that is not shown. The faceplate is approximately 19″ long and is configured to be mounted in a standard IT rack for containing IT equipment. The faceplate as shown is a 1U panel is approximately 19″ long and is configured to be mounted in a standard IT rack for containing IT equipment. The faceplate provides 4 openings for holding 4 corresponding sets  154  of the connectors  156  providing a 24-port panel. Thus, although only two cables  152  are shown, the system  150  preferably includes 4 cables  152 , with 4 corresponding sets  154  of the connectors  156 . The faceplate provides approximately 113 mm×19 mm openings for accepting 1×6 MUTOA heads corresponding the sets  154  of the connectors  156 , with the associated cable having approximately a 12.7 mm diameter. ‘Y’ cables incorporating two sets of connector heads in a 2×6 configuration having openings of approximately 113 mm×38 mm may also be used. 
   Still further embodiments are within the scope and spirit of the invention.