Abstract:
A telecommunications connection system including a plug; an outlet; the plug including: a plug body; transmission contacts supported in the plug body, the transmission contacts transmitting signals when the plug is mated with the outlet; a plug contact mounted on the plug body, the plug contact deflecting towards the plug body upon mating the plug with the outlet, the plug contact carrying a connectivity signal for monitoring port-to-port connectivity; a conductor in electrical connection with the plug contact; an outlet contact for making contact with the plug contact for transmission of the connectivity signal; outlet transmission contacts in the outlet making electrical contact with the transmission contacts.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional patent application Ser. No. 60/978,180 filed Oct. 8, 2007, the entire contents of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Patch panels are often used to provide an interconnection between telecommunication outlets and active equipment. One difficulty experienced with patch panels is knowing which port of the patch panel is connected to which port on other patch panels or active equipment. One solution to this problem is disclosed in U.S. Pat. No. 6,574,586, the entire contents of which are incorporated herein by reference. As shown in  FIG. 1 , U.S. Pat. No. 6,574,586 discloses a system in which an adapter jacket  1  having an external plug contact  2  is placed on the plug  3 . The plug contact  2  is biased by a spring  4 . An additional conductor  5 , often referred to in the art as the ninth wire, electrically connects plug contacts on opposite ends of a patch cord. Plug  3  mates with an outlet  6  in a patch panel. Above outlet  6  is an adapter printed circuit board (PCB)  7  having an outlet contact  8 . The outlet contacts  8  are wired to an analyzer that then can determine which outlets are connected by patch cords by applying a connectivity signal to each outlet contact. 
         [0003]    U.S. Pat. No. 7,193,422, the entire contents of which are incorporated herein by reference, describes a patch panel system in which a screen is provided on a plug to make electrical contact with a conductive tab at an outlet. This electrical connection allows port-to-port connectivity to be monitored. Alternate plug contacts for ninth wire systems are shown in pending U.S. patent application publication 20070197094, the entire contents of which are incorporated herein by reference. 
         [0004]    In the system of U.S. Pat. No. 6,574,586, the spring-loaded pin provided on the plug boot has drawbacks. One problem with the spring-loaded pin is that it is difficult to captivate in relation to the RJ45 or fiber connector. Current methods used to captivate the spring-loaded pin include an overmolded boot, a clip on boot or a boot designed specifically to work with the spring-loaded. These methods are more difficult to assemble than standard patch cords. 
         [0005]    Another problem is that the spring-loaded pin  2  is deflected in a direction normal to the patch panel front face. This has several drawbacks. First, if there is a problem with the PCB  7  on which the outlet contact  8  is positioned, it is impossible to replace the PCB  7  without disturbing the data connections established by the plug  3  and outlet  6 . In other words, the plug  3  must be disconnected to service the outlet contact PCB  7 . Second, RJ45 and fiber mated connections have a certain amount of “play” in the connection. The “play” travel is greater in the horizontal direction (i.e., normal to the face of the patch panel) versus the vertical direction. To compensate for the horizontal play a longer contact pin  2  is required on the plug, making the pin  2  more prone to damage during use. Lastly, incidental contact with the pogo pin  2  (during normal use) is usually applied in a vertical direction, or parallel to the face of the patch panel. This can damage the pin  2 , making it unable to perform its normal function. 
       SUMMARY 
       [0006]    Exemplary embodiments include a telecommunications connection system including a plug; an outlet; the plug including: a plug body; transmission contacts supported in the plug body, the transmission contacts transmitting signals when the plug is mated with the outlet; a plug contact mounted on the plug body, the plug contact deflecting towards the plug body upon mating the plug with the outlet, the plug contact carrying a connectivity signal for monitoring port-to-port connectivity; a conductor in electrical connection with the plug contact; an outlet contact for making contact with the plug contact for transmission of the connectivity signal; outlet transmission contacts in the outlet making electrical contact with the transmission contacts. 
         [0007]    Other exemplary embodiments will be or become apparent to one with skill in the art upon review of the following drawings and detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  illustrates a conventional plug with an outlet. 
           [0009]      FIG. 2  illustrates a plug mated with an outlet in an embodiment of the invention. 
           [0010]      FIG. 3  illustrates a printed circuit board carrying outlet contacts in an embodiment of the invention. 
           [0011]      FIG. 4  is a side view of the plug of  FIG. 2 . 
           [0012]      FIG. 5  illustrates the plug contact in an embodiment of the invention. 
           [0013]      FIG. 5A  illustrates the plug in an embodiment of the invention. 
           [0014]      FIG. 6  illustrates a printed circuit board with outlet contacts an alternate embodiment of the invention. 
           [0015]      FIG. 7  illustrates a printed circuit board with outlet contacts an alternate embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]      FIG. 2  illustrates a plug  10  mated with an outlet  40  mounted in a patch panel  60 . Plug  10  includes a plug body  11  that supports certain plug components. Plug  10  includes transmission contacts  12  that mate with outlet transmission contacts  42  for carrying voice and/or data signals as known in the art. Plug  10  also includes a plug contact  14  that mates with an outlet contact  54  formed on a substrate  50  (e.g., a printed circuit board or PCB). PCB  50  is mounted on the outside face of patch panel  60 . The plug contact  14  and the outlet contact  54  provide an electrical connection for transmitting a connectivity signal for monitoring port-to-port connectivity. Cable  80  includes transmission conductors  82  that carry voice and/or data signals along the patch cord. Transmission conductors  82  are electrically connected to plug transmission contacts  12  via a printed circuit board  16 . It is understood that a PCB  16  may be replaced with lead frame elements, or eliminated completely with transmission conductors  82  mating directly with plug transmission contacts  12 . Cable  80  also includes a conductor  84  that carries a signal for connectivity analysis. Conductor  84  is often referred to as the ninth wire in the art. 
         [0017]    When plug  10  is mated with outlet  40 , the plug contact  14  physically contacts outlet contact  54  to establish electrical connection. As described in further detail herein, the plug contact deflects downwards towards the plug body in a direction parallel to the front face of the patch panel  60 . In other words, the plug  10  enters the outlet  40  along a plug-mating axis, X, shown in  FIG. 2 . The plug contact  14  deflects towards the plug body  11 , along a deflection axis Y that is not parallel to the plug-mating axis X. Deflection axis Y may be substantially perpendicular to plug-mating axis X. This is an improvement over prior art systems of  FIG. 1  where the pin deflects in a direction normal to the face of the patch panel  60 . 
         [0018]      FIG. 3  is front view of the patch panel  60  showing the PCB  50  mounted above outlets  40 . As shown in  FIG. 3 , the outlet contacts  54  are formed on a bottom edge of the PCB  50  as a scalloped area. The outlet contacts  54  are formed by providing a conductive plated area on the scalloped portions of the PCB  50 . Plug contact  14  touches the scalloped area to make electrical contact between plug contact  14  and outlet contact  54 . PCB  50  includes traces  56  for transmitting a signal to and from the outlet contacts  54 . This signal may be provided to an analyzer for determining connectivity of patch cords as known in the art. 
         [0019]    The PCB  50  in  FIG. 3  is depicted above the outlets  40 , but other orientations may be used. The PCB  50  may be positioned below outlets  40  with the plug contact  14  positioned to engage the scalloped portions of the PCB. Further, the outlet contacts  54  may be positioned on either side of the outlet on PCB extensions that are positioned on either side of the outlets  40 . In this embodiment, the plug contact  14  would also be positioned on the corresponding side of plug  10 . 
         [0020]      FIG. 4  is a side view of the plug  10  of  FIG. 2 . Plug  10  includes a boot  18 , which covers a majority of the plug contact  14 , leaving a plug contact beam  22  exposed so that the beam  22  can engage outlet contact  54 . A plug contact test pad  24  is also exposed at the rear end of the plug housing  18 . The test pad  24  allows a technician to monitor signals on the plug contact  14  and apply diagnostic signals to the plug contact  14 . Conductor  84  is in electrical connection with plug contact  14  as described in further detail herein. 
         [0021]      FIG. 5  is a perspective view of the plug contact  14 . Plug contact  14  includes a base  26  having a contact point including an insulation displacement contact (IDC)  28  extending there from. The IDC  28  makes electrical connection with conductor  84 . It is understood that other connections may be used such as an insulation piercing contact, crimp style contact or a solder terminal. Arms  30  extend from base  26  and bend downwards to barbed ends  31 . Barbed ends  31  engage openings in the plug body to secure the contact  14  to the plug  10 . Housing  18  is also placed over plug contact  14  to further secure plug contact  14  to the plug body. 
         [0022]    Plug contact beam  22  extends from base  26  and bends downward at a distal end to form a cantilever beam  22 . As described above, the cantilevered beam  22  deflects downwards towards the plug body so that when the plug  10  is mated with outlet  40 , deflection is in a direction parallel to the front face of patch panel  60 . Finger  32  extends upwards from one arm  30  and terminates at test pad  24 . 
         [0023]    When plug  10  is mated with outlet  40 , beam  22  deflects downwards towards the plug body and into an opening in the plug body.  FIG. 5A  is a perspective view of plug  10 . As shown in  FIG. 5A , the plug body includes an opening  23  into which the beam  22  deflects when plug  10  is mated with outlet  40 . This allows the plug  10  to be compatible with existing outlets and meet IEC dimensional requirements for plugs, even with the inclusion of the plug contact  14 . 
         [0024]      FIG. 6  shows a plug  10  mounted in outlet  40  in an alternate embodiment. In this embodiment, a PCB  80  is mounted on the patch panel  60  such that the PCB  80  is in a horizontal configuration, rather than vertical as shown in  FIG. 2 . An outlet contact  84  is formed on the PCB  80  by plating an area of the PCB  80 . Other components are similar to those in  FIG. 2 . 
         [0025]      FIG. 7  illustrates an alternate embodiment of plug  100  in which the plug contact  104  is rigid and the outlet contact  114  deflects when the plug  100  is mated with outlet  40 . Plug contact  114  is a metal contact biased by a resilient member  112  (e.g., spring) contained in a housing  110 . In this embodiment, the deflection of the outlet contact  114  is in a direction parallel to the face of patch panel  60 . Again, this limits damage to the outlet contact as the outlet contact doe not extend away from the patch panel in a direction normal to the face of the patch panel. 
         [0026]    The vertical travel, rather than horizontal travel, of the plug contact  14  allows for removal of PCB  50  or  80 , or another conductive surface that resides on the patch panel without disturbing or removing the voice/data connections established by the plug and outlet. Incidental contact with the plug contact  14  is typically in a vertical direction. Since the plug contact  14  is designed to depress into the plug body when vertical force is applied, it is more robust and less likely to deform during normal use. The outlet contact surface on or in the patch panel mates with the plug contact on the plug in a vertical direction. If the PCB  50  or  80 , or components mounted to the PCB are damaged, the entire PCB could be removed and replaced without disturbing the data connections in the panel. 
         [0027]    Embodiments of the invention provide several benefits. Deflection of plug contact  14  parallel to the face of the patch panel increases reliability of the mated connection and reduces or eliminates damage to the plug contact in patch plugs during normal use. Embodiments also allow for replacement or repair of the PCB assembly on a patch panel without disturbing voice/data connections between the plug and outlet. There is also a reduced cost to manufacture the plug, as the design is simpler than existing pogo pin designs in the prior art as shown in  FIG. 1 . 
         [0028]    Embodiments of the invention have been described with reference to an RJ45 plug and outlet. It is understood that other electrical plug formats may be used and the invention is not limited to RJ45 plugs and outlets. Further, the plug contact  14  and outlet contact  54  may be used in conjunction with other types of connectors such as fiber, coaxial, etc. Thus, the terms plug and outlet and intended to cover a variety of transmission media (copper, fiber, coax) and a variety of connector formats. 
         [0029]    While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt to a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed for carrying out this invention.