Abstract:
An RJ modular connector ( 1 ) includes a housing ( 10 ) defining a terminal insert receiving space ( 12 ). A terminal insert ( 20 ) is received in the terminal insert receiving space ( 12 ) and includes a substrate ( 3 ) having a plurality of conductive traces ( 30   a - 30   d ) and a plurality of terminals ( 21 - 28 ). One trace ( 30   a ) of the plurality of traces is aligned with only a selected terminal ( 21 ) attached on the second face ( 32 ) of the substrate while extends over a parallel terminal ( 22 ) and is electrically connected to another selected terminal ( 23 ) thereby establishing electrical coupling between said two selected terminals by said trace.

Description:
[0001]    This application is a continuation-in-part (C-I-P) application of copending application Ser. No. 09/863,942 filed on May 22, 2001. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to a RJ modular connector, and more particularly to a RJ modular connector having a substrate provided therein to balance electrical couplings between terminals.  
           [0004]    2. Description of Related Art  
           [0005]    RJ modular connector has been widely used in telecommunication system since it was firstly created. A so-called RJ 45  modular connector has been widely used in the network system.  
           [0006]    The RJ45 modular connector includes totally eight terminals. Resulting from miniaturization of the computer, all corresponding components, including connectors, have to be reduced for their dimension and size. One of the negative consequences or problem created from miniaturization is electrical coupling between terminals. When the RJ connector is used in low speed signal transmission, the couplings between adjacent terminals can be ignored in light of its effect. However, when the RJ connector is used for high speed signal transmission, the couplings between adjacent terminals create a great problem. Unless the electrical coupling can be effectively controlled within an accepted level, it is unlikely that the RJ 45 modular connector can be used in the high-speed signal transmission.  
           [0007]    One of the approaches is to select a pair of terminals as a differential pair. In the differential pair, two terminals transmit the same signal but with inverted phase. By this arrangement, the noise introduced thereto can be finally subtracted in a data processing unit.  
           [0008]    As shown in an attached catalog from The Siemon Company, there are at least eight different patterns in selecting terminals as differential pair, i.e. T568A, T568B, USOC 4-pair, USOC 1-, 2- or 3-pair, 10BASE-T (802.3), Token Ring (802.5), 3-pair (MMJ), and TP-PMD (X3T9.5) and ATM. In each implementation, two terminals are selected as a pair in which some are close to each other, while some are apart from each other. Each pattern has its own uniqueness, while each also carries a coupling issue need to be solved.  
           [0009]    Among those patterns, T568A and T568B are widely used and in T568A, terminals 1, 2 configure 3rd pair, terminals 3, 6 configure 2nd pair, terminals 4, 5 configure 1st pair, while terminals 7, 8 configure 4th pair. In T568B, terminals 1, 2 configure 2nd pair, terminals 3, 6 configure 3rd pair, terminals 4, 5 configure 1 st pair, while terminals 7, 8 configure 4th pair.  
           [0010]    Since those eight terminals are equally spaced, electrical couplings between terminals will surely create some problems, i.e. coupling or crosstalk. For example, if we take terminal 3 into consideration, terminal 3 will naturally pick up energy coupled from terminals 2, and 4 which are close to terminal 3. On the other hand, terminal 6, which carries signal having inverted phase of the signal carried by terminal 3, will also pick up energy coupled from terminals 5 and 7. However, energy coupled into terminals 3, 6 from terminals 2 and 7 can not be suitably eliminated because terminals 3, 6 is unlikely to establish couplings between terminals 1 and terminals 8 to balance the couplings between terminals 2, 3 and 6, 7. Accordingly, signals transmitted by terminals 3, 6 carry noises generated by their adjacent terminals 2, 7. In addition, terminals 3 and 6 will also carry noises coupled thereto from terminals 4, 5 and which couplings should be also carefully taken to avoid certain noises  
           [0011]    In order to decrease the effects of electrical coupling between the (3rd, 4th) and (3rd, 2nd) terminals, and (6th, 5th) and (6th, 7th) terminals, many approaches have been provided, such as creating electrical couplings between 3rd and 1st terminals and 3rd and 5th terminals, to balance the electrical coupling between the 3rd and 2nd terminals and 3rd and 4th terminals, and creating electrical coupling between 6th and 8th terminals and 6th and 4th terminals to balance the electrical couplings between the 6th and 7th terminals and 6th and 5th terminals.  
           [0012]    However, as mentioned above, those eight terminals are arranged in a common plane, it is impossible to create those balancing electrical couplings, i.e. (1st, 3rd), (3rd, 5th), and (4th, 6th), (6th, 8th) terminals when all terminals are located in the same level, it is unlikely to create any electrical channels therebetween to create those electrical couplings accordingly.  
           [0013]    The Siemon Company, a US company, discloses a solution posted on the Internet, http://www.siemon.com/white_papers/99-08-30-through-hole.asp. A hard copy thereof is herein attached for reference.  
           [0014]    As clearly shown in FIG. 4 of that reference, 6th and 2nd terminals are arranged in the first layer, while 8th, 5th, 4th, and 1st terminals are arranged in the second layer, and 7th and 3rd terminals are arranged in the third layer.  
           [0015]    The 6th terminal in the first layer has a rectangular loop having its longitudinal sides aligned with terminals 4th and 8th located in the second layer, while terminal 3 in the third layer also has a rectangular loop having its longitudinal sides aligned with terminals 5th and 1st located in the second layer.  
           [0016]    In addition, the right longitudinal loop side of the terminal 6th further includes a square corresponding to a square formed in terminal 4th. The left longitudinal loop side of the terminal 3 includes also a square with respect to the square formed on terminal 5th.  
           [0017]    Arrangements suggested by Siemon are to increase the couplings between (1st, 3rd), (3rd, 5th), and (4th, 6th), (6th, 8th) terminals thereby helping to balance electrical couplings of the terminals.  
           [0018]    However, those eight or four set sets of terminals are arranged in three different layers, and each set of terminals are separately divided by an insulative sheet material. This will no doubt increase the complexity of the connector.  
           [0019]    In addition, there are different shapes and configurations among those eight terminals. Each terminal has its own shape which is different from each other, especially the 3rd and 6th terminals, each including the rectangular loop portion which overlap to corresponding terminals to create wanted electrical couplings. Each loop further forms the square to increase the electrical couplings with corresponding terminals having the square. The electrical couplings created can help to meet higher system requirements. The eight different configurations of the terminals will surely increase the difficulty and complexity in production.  
           [0020]    There are some other approaches that including routing terminal tails of those 3rd, 6th and 4th, 5th terminals to alter their position and affect couplings between 3rd, 2nd and 3rd, 4th; and 6th, 5th, and 6th, 7th terminals. However routing terminal tails will inevitably increase the manufacturing cost.  
           [0021]    U.S. Pat. No. 6,120,329 issued to Steinman on Sep 19, 2000, discloses another approach to solve the above-addressed problem. Again, terminals are configured with different shapes and dimensions making the production complex.  
           [0022]    U.S. Pat. No. 5,069,641 issued to Sakamoto et al. discloses a suggestion of using substrate in the RJ modular housing, however, it is addressed to different issues.  
         SUMMARY OF THE INVENTION  
         [0023]    It is an object of this invention to provide an RJ modular connector, and more particularly to a RJ modular connector having a substrate with conductive traces provided thereon to balance electrical couplings between terminals.  
           [0024]    It is still an object of this invention to provide a RJ modular connector which can be easily manufactured.  
           [0025]    In order to achieve the objective set forth, an RJ modular connector in accordance with the present invention comprises a housing defining a plug receiving section, and a terminal insert receiving section. A terminal insert is received in the terminal insert receiving section and includes a substrate having a plurality of conductive traces and a plurality of terminals. Each trace has a large portion which is aligned with only a selected terminal soldered on the second surface of the substrate and a small portion which is electrically connected to another selected terminal whereby electrical coupling is established between said two selected terminals by said trace.  
           [0026]    Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0027]    [0027]FIG. 1 is a perspective view of a RJ modular connector in accordance with the present invention;  
         [0028]    [0028]FIG. 2 is a front view of the RJ modular connector of FIG. 1;  
         [0029]    [0029]FIG. 3 is another perspective view of the RJ modular connector of FIG. 1;  
         [0030]    [0030]FIG. 4 is exploded view of the modular connector to show a terminal insert and a housing of the modular connector;  
         [0031]    [0031]FIG. 5 is a side view of the terminal insert of the RJ modular connector of the present invention;  
         [0032]    [0032]FIG. 6 is a extend over-sectional view of the terminal insert of FIG. 5 taken along line  6 - 6 ;  
         [0033]    [0033]FIG. 7 is an exploded view of the terminal insert with an upper substrate separating therefrom;  
         [0034]    [0034]FIG. 8 is another exploded view of the terminal insert with the upper substrate separating therefrom;  
         [0035]    [0035]FIG. 9 is a bottom view of the upper substrate of the terminal insert of FIG. 7;  
         [0036]    [0036]FIG. 10 is an enlarge side view of a left part of the upper substrate of the terminal insert of FIG. 7; and  
         [0037]    [0037]FIG. 11 is a top view of the upper substrate of the terminal insert of FIG. 7. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]    For facilitating understanding, like components are designated by like reference numerals throughout the various embodiments of the invention as shown in the various drawing figures.  
         [0039]    Referring to FIGS.  1 - 4 , a RJ modular connector  1  in accordance with the present invention includes an insulative housing  10 , and a modular terminal insert  20 . The housing  10  defines a plug receiving space  11  in a front end for mating with a complement connector (not shown), and a terminal insert receiving space  12  in a rear end of the housing  10  for receiving the modular terminal insert  20 .  
         [0040]    Referring to FIGS.  4 - 11 , the modular terminal insert  20  comprises an upper substrate  3 , a lower substrate  4  and eight signal terminals  21 ,  22 ,  23 ,  24 ,  25 ,  26 ,  27  and  28  and two conductor  29  for being sandwiched between the upper substrate  3  and the lower substrate  4 . The upper substrate  3  has a first surface  31 , a second surface  32  opposite the first surface  31 , a first side  33 , and a second side  34  opposite the first side  33 . Among the signal terminals, signal terminals  21 ,  22  configures a first differential pair, signal terminals  23 ,  26  configures a second differential pair, signal terminals  24 ,  25  configures a third differential pair, while terminals  27 ,  28  configures a fourth differential pair.  
         [0041]    The upper substrate  3  defines four conductive traces  30   a ,  30   b ,  30   c  and  30   d  on the first surface  31  arranged side by side. The first and second traces  30   a  and  30   b  are close to the first side  33  of the substrate  3 . The third and fourth traces  30   c  and  30   d  are close to the second side  34  of the substrate  3 . Each of the four conductive traces  30   a ,  30   b ,  30   c  and  30   d  has a large portion  130   a ,  130   b ,  130   c  and  130   d  and a pair of small portions  230   a ,  230   b ,  230   c  and  230   d  connected to a pair of ends of the large portion  130   a ,  130   b ,  130   c  and  130   d . Each small portion  230   a ,  230   b ,  230   c  and  230   d  has a via  330   a ,  330   b ,  330   c  and  330   d  at a free end thereof extending from the first surface to the second surface  32  of the upper substrate  3 . The first and second small traces  230   a  and  230   b  are extended toward the second side  34  of the upper substrate  3 . The third and fourth small traces  230   c  and  230   d  are extended toward the first side  33  of the upper substrate  3 . The large portion  130   b ,  130   c  all have a first width, and the large portion  130   a ,  130   d  all have a second width. The first width is larger than the second width.  
         [0042]    Referring to FIG. 9, the upper substrate  3  has eight pairs of solder pads  301 ,  30   k ,  30   j ,  30   i ,  30   h ,  30   g ,  30   f ,  30   e  arranged side by side on the second surface  32  thereof. A first connection trace  30   n  is located between the pair of third solder pads  30   j  and is electrically connected therebetween. A second connection trace  30   m  is located between the pair of sixth solder pads  30   g  and is electrically connected therebetween. A third connection trace  30   s  is located between the pair of first solder pads  301  and is electrically connected therebetween. A fourth connection trace  30   t  is located between the pair of eighth solder pads  30   e  and is electrically connected therebetween. Meanwhile, on the second surface, the first and second connection traces  30   n  and  30   m  all have a third width, and the third and fourth connection traces  30   s  and  30   t  all have a fourth width. The third width is wider than the fourth width. A pair of side pads  30   p  is defined on the second surface  32  of the upper substrate  3  separately completely extending along the first side  33  and the second side  34 .  
         [0043]    Referring to FIG. 9, each via  330   a ,  330   b ,  330   c  and  330   d  is electrically connected with corresponding solder pad  30   j ,  30   h ,  30   i  and  30   g  on the second surface  32 .  
         [0044]    Referring to FIGS. 7 and 8, each signal terminal  21 ,  22 ,  23 ,  24 ,  25 ,  26 ,  27  and  28  has a middle portion  210 ,  220 ,  230 ,  240 ,  250 ,  260 ,  270  and  280 , a contact portion  212 ,  222 ,  232 ,  242 ,  252 ,  262 ,  272  and  282  at one end of the middle portion and being bent to an angle and a solder portion  214 ,  224 ,  234 ,  244 ,  254 ,  264 ,  274  and  284  bending downwardly for being soldered to a mother board (not shown). A first distance between one terminal of the first, third, fourth differential pairs signal terminals  21 ,  22 ,  24 ,  25 ,  27  and  28  to one terminal of the second differential pair signal terminals  23  and  26  is larger than a second distance between the two terminals adjacent to each other in one differential pair terminals  21  and  22  or  24  and  25  or  27  and  28 . Each conductor  29  has a side beam  290  and a ground tail  294  bending downwardly for being soldered to the motherboard. The ground tail  294  will bring ground into the modular terminal insert  20  from the motherboard. Each side beam  290  has a plurality of barbs  296  for interfering with the housing  10  and securing the modular terminal insert  20  to the housing  10 .  
         [0045]    The modular terminal insert  20  further comprises a lower substrate  4  which has a plurality of solder pads (not labeled) on an upper surface corresponding to the solder pads  301 ,  30   k ,  30   j ,  30   i ,  30   h ,  30   g ,  30   f ,  30   e  and  30   p  of the upper substrate  3 . A bottom surface of the lower substrate  4  is made of conductive material, which can help to prevent electrical influence to the modular jack connector  1 . The middle portions  210 ,  220 ,  230 ,  240 ,  250 ,  260 ,  270 ,  280  of the signal terminals  21 ,  22 ,  23 ,  24 ,  25 ,  26 ,  27  and  28  are surface mounted on the solder pads of the upper surface of the lower substrate  4 . The side beams  290  of the conductors  29  are surface mounted on the solder pads  30   p  of the upper surface of the lower substrate  4  separately. The signal terminals  21 ,  22 ,  23 ,  24 ,  25 ,  26 ,  27  and  28  and conductors  29  are correspondingly soldered with the solder pads  301 ,  30   k ,  30   j ,  30   i ,  30   h ,  30   g ,  30   f ,  30   e  and  30   p  of the second surface  32  of the upper substrate  3  whereby the first trace  30   a  aligns with the first terminal  21 , the second trace  30   b  aligns with the third terminal  23 , the third trace  30   c  aligns with the sixth terminal  26  and the fourth trace  30   d  aligns with the eighth terminal  28 , the vias  330   a  of the first trace  30   a  electrically connect with the pair of pads  30   j , the vias  330   b  of the second trace  30   b  electrically connect with the pair of pads  30   h , the vias  330   c  of the third trace  30   c  electrically connect with the pair of pads  30   i , and the vias  330   d  of the fourth trace  30   d  electrically connects with the pair of the pads  30   g . The side beams  290  increase the solder area with the upper and the lower substrates  3  and  4  and are securely soldered with the upper and lower substrates  3  and  4  together. The small portions  230   b  of the second trace  30   b  on the first surface  31  of the upper substrate  3  extend over the fourth signal terminal  24  on the second surface  32 , and the small portions  230   c  of the third trace  30   c  on the first surface  31  of the upper substrate  3  extend over the fifth signal terminal  25  on the second surface  32 .  
         [0046]    Referring to FIG. 10, each trace  30   a ,  30   b ,  30   c ,  30   d ,  30   n ,  30   m ,  30   s ,  30   t  has an insulative film  30   v  attached thereon for insulating the trace.  
         [0047]    Because electrical coupling between the first signal terminal  21  and the third signal terminal  23  is established, electrical influence to the third signal terminal  23  created by the second signal terminal  22  can be better balanced to help improve crosstalk performance. Because electrical coupling between the third signal terminal  23  and the fifth signal terminal  25  is established, electrical influence to the third signal terminal  23  created by the fourth signal terminal  24  can be better balanced to help improve crosstalk performance. Because electrical coupling between the fourth signal terminal  24  and the sixth signal terminal  26  is established, electrical influence to the sixth signal terminal  26  created by the fifth signal terminal  25  can be better balanced to help improve crosstalk performance. Because electrical coupling between the sixth signal terminal  26  and the eighth signal terminal  28  is established, electrical influence to the sixth signal terminal  26  created by the seventh signal terminal  27  can be better balanced to help improve crosstalk performance. The conductors  29  are correspondingly soldered on the first and second sides  33 ,  34  of the upper substrate  3  to connect the upper substrate  3  and the lower substrate  4  together.  
         [0048]    The modular terminal insert  20  is correspondingly inserted and secured in the terminal insert receiving space  12  of the housing  10  with the barbs  296  of the conductors  29  interfering with the housing  10 .  
         [0049]    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.