Abstract:
A device and method for repairing a failed modular connector having a broken locking tab by providing an adapter which receives the broken modular connector and includes a mechanism for retaining the broken modular connector, which may include a retaining clip, retaining barbs, or teeth, tight friction, friction bumps, adhesive or other retaining device. The adapter mechanically and electrically connects to the broken connector and provides a straight through wired modular plug with a retaining clip so that the assembly comprising the broken connector and adapter may plug into a jack for the original broken connector and be securely retained.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit under 35 USC 119(e) of U.S. provisional application Ser. No. 61/078,679, titled: “Repair Adapter for Modular Plug,” filed 7 Jul. 2008 by Kelly H. Myers. All of the above listed US Patent Documents and Patent Applications are hereby incorporated herein by reference in their entirety. 
     
    
     BACKGROUND  
       [0002]    1. Field of the Invention 
         [0003]    The present invention pertains generally to the field of interconnection wiring for, inter alia, network communications, more particularly to the repair of modular connectors typically used for, but not limited to network and general telecommunications applications. 
         [0004]    2. Background of the Invention 
         [0005]    Modular connectors, in particular a series of connectors commonly known as RJ-45, RJ-22, RJ-11 and related connectors are commonly used as computer network connectors and telephone connectors. These connectors are frequently connected and disconnected as equipment is moved or reconfigured. Laptops and other portable equipment are particularly subject to frequent plugging and unplugging of connectors. The modular connectors typically include a locking tab to hold the connector into the socket. The locking tab typically makes a familiar click as the connector is pushed into the socket. The locking tab is, however, fragile and easily broken off of the connector, leaving a connector that otherwise works, but is too easily removed from the socket and may fall out with the weight of the cable, leading to unreliable operation. Since modular connectors require special tools for proper installation on the cable, and because some cables require special pinouts, cables are usually not repaired, but rather replaced, which can be expensive. 
         [0006]    Thus, there is a need for a simple way to repair modular connectors having a broken locking tab, potentially saving both time and expense. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0007]    The present invention pertains to a device and method for repairing a failed modular connector having a broken locking tab by providing an adapter which receives the broken modular connector and includes a mechanism for retaining the broken modular connector, which may include a retaining clip, retaining barbs, or teeth, tight friction, friction bumps, adhesive or other retaining device. The adapter mechanically and electrically connects to the broken connector and provides a straight through wired modular plug with a retaining clip so that the assembly comprising the broken connector and adapter may plug into a jack for the original broken connector and be securely retained. 
         [0008]    In one embodiment, the repair adapter comprises a single unitary body forming the modular plug and modified jack. The single unitary body may be formed by a single molding or by assembly of multiple moldings. Alternatively the plug and modified jack may be connected by a short flexible cable. 
         [0009]    In another embodiment the retaining barbs may be inwardly directed to a cavity for receiving the broken plug and the barbs may comprise metal. 
         [0010]    In another embodiment, the retaining clip may be formed as an extension of a side or bottom of the modified modular jack. The arm may terminate in a catch that engages the back side of the broken plug. 
         [0011]    In another embodiment, the broken plug may be retained in conjunction with an adhesive between the inside sides of the jack and the sides of the broken plug. 
         [0012]    In some embodiments of the invention the retention of the broken plug may be permanent, i.e., a subsequent attempted separation of the broken plug and repair adapter will likely result in damage to one or both. In alternative embodiments, the broken plug and repair adapter may be subsequently separated without further damage to either. 
         [0013]    These and further benefits and features of the present invention are herein described in detail with reference to exemplary embodiments in accordance with the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0014]    The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit(s) of a reference number identifies the drawing in which the reference number first appears. 
           [0015]      FIG. 1  illustrates an adapter shown with a broken modular connector in accordance with the present invention. 
           [0016]      FIG. 2  illustrates one embodiment of the adapter using a friction mechanism to hold the broken connector. 
           [0017]      FIG. 3  shows an alternative embodiment using clips to hold the broken connector. 
           [0018]      FIG. 4  shows a cross section view of the clip portion of the embodiment of  FIG. 3 . 
           [0019]      FIG. 5  shows a cross section view of the holding mechanism of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    The present invention relates to a repair connector which may be adapted to one or more connectors of various standards relating to “modular” connectors. These connectors include connectors often referred to as RJ11, RJ45, RJ22, 6P6C, 8P8C, 6P4C, 4P4C, or other connectors of these series. Dimension information may be found in various standards, for example, but not limited to TIA-968-A. Further description may be found in U.S. Pat. No. 3,860,316, issued Jan. 14, 1975 to Hardesty, which is incorporated herein by reference in its entirety. Thus, the term modular connector within this disclosure and associated claims refers to these series of connectors. A modular compatible connector is a connector that is electrically and mechanically usable with a modular connector but may or may not be in strict compliance with a particular industry standard. 
         [0021]      FIG. 1  illustrates an adapter shown with a broken modular connector in accordance with the present invention. Referring to  FIG. 1 , the adapter  102  comprises a plug portion  104  (male connector portion), a jack portion  108  (female connector portion) and a locking clip  106 . Locking clip  106  may alternatively be referred to as a locking tab, latch, or hook. Also shown is a cable end  110  comprising a broken connector  112 , i.e., a connector having a broken and/or separated locking clip  114  and a cable  116 . The broken connector  112  would otherwise work except for the ease with which the cable may be pulled out or fall out of an equipment jack (not shown). The adapter  102  includes an alternate locking mechanism (see  FIG. 2  and  FIG. 3 ) that is not dependent on the locking clip  114  on the broken connector  112 . Thus, the broken connector  112  may be inserted into the adapter  102  and will be held in place securely, even when the locking clip  114  is missing. The adapter  102  includes straight through wiring from the jack portion  108  to the plug portion  104  and may then be plugged into the equipment jack and locked into place using the locking clip  106  on the adapter, thus securing the cable connection. The straight through wiring connects each pin in the jack to the respective, same number, pin in the plug. 
         [0022]      FIG. 2  illustrates one embodiment of the adapter using a friction mechanism to hold the broken connector.  FIG. 2  and  FIG. 3  show a top perspective view showing greater detail of the jack end  108  of the adapter for receiving the broken plug  112  and illustrating further details of the mechanism for securing the broken plug  112  in place. Referring to  FIG. 2 , the inside of the jack portion  108  of the adapter  102  includes friction structures  202  to hold the broken connector  112 .  FIG. 2  shows gripper barbs  202  to increase the friction and hold the broken connector  112  in place. The gripper barbs  202  may be made of plastic, metal, composite (e.g. glass filled plastic), or other suitable material. The gripper barbs  202  may bend as the broken plug is inserted, providing a spring loaded grip to hold the broken plug  112 . The backward orientation of the griper barbs  202  acts to dig into the broken connector and hold tighter as the broken connector  112  is attempted to be pulled out. Alternative friction structures including rough surfaces and/or spring loaded members may be used. 
         [0023]      FIG. 3  shows an alternative embodiment using clips  304  to hold the broken connector. Referring to  FIG. 3 , the adapter  102  includes clips  304  having flexible fingers  308  that wrap around a back corner of the broken plug to hold the broken plug  112  in place. The clips  204  may also have diagonal faces  306  to allow easy insertion of the broken plug  112 . 
         [0024]      FIG. 4  shows a cross section view of the clip portion of the embodiment of  FIG. 3 . Referring to  FIG. 4 , the flexible and resilient arms  308  are shown extending from the walls of the jack portion of the repair adapter and running along the side of the broken connector, then wrapping around the back corner  402  of the broken connector  112  to retain the broken connector  112  in the jack of the repair adapter  108 . Alternatively, the arms run along the side of the body of the broken plug and end in a catch that engages a back side of the broken plug. The ends of the arms have a sloping or beveled face  306  for ease in insertion of the broken connector. Insertion of the broken connector will open the arms  308  and allow further insertion of the broken connector. When completely inserted, the arms  308  will snap into place and hold the broken connector  112 . The resilient arms  308  and catch of the clip  304  form a spring loaded catch  304 . The spring loaded catch  304  of  FIG. 4  shows the arms and catch being of the same molded plastic of the body  108 ; however, the arms and/or catch may comprise metal or other materials as desired for forming the arms and catch. The spring loaded clip  304  is shown on the sides Alternatively the spring loaded clip may be positioned on the bottom (opposite the broken locking tab). 
         [0025]      FIG. 5  shows a cross section view of the holding mechanism of  FIG. 2 . Referring to  FIG. 5 , the wall of the cavity of the repair adapter jack  108  that receives the broken connector may include retaining barbs  202 . The barbs preferably are inwardly directed, i.e., have a slope toward the interior of the cavity to allow insertion of the broken connector. The barbs  202  are dimensioned for interference fit with the broken connector  112  and preferably to slightly dig  502  into the broken connector to hold the connector  112 . The inward slope will further enhance the digging in and holding of the broken connector  112 . As shown at the top of  FIG. 5 , the barb  202  is molded into the wall of the repair adapter  108  and made of substantially the same material. Alternatively, as shown at the bottom of  FIG. 5 , the barbs  504  may be of a different material, for example metal, and may be molded with the wall of the repair adapter  108  or may be attached by techniques known in the art for attaching metal to plastic. 
         [0026]      FIG. 5  also shows a friction bump method of holding the broken connector. The friction bumps  506  may be dimensioned for interference fit with the broken connector  112 . Friction bumps  506  or other friction patterns may be used alone or in conjunction with the barbs  202 ,  504 , or clips  304 . The friction pattern may be used with or without adhesive. 
         [0027]    Other embodiments include adhesive, including pressure sensitive adhesive to hold the broken plug. Adhesive can result in a permanent bond, depending on the adhesive used. The permanent bond can be either an advantage or disadvantage, depending on the application. If the adapter locking clip breaks and the broken connector is not permanently attached, the adapter may be removed and replaced with a new adapter. If the broken connector is permanently attached, another adapter may be connected in series. 
         [0028]    In a further embodiment, the plug and jack of the adapter may be configured at other angles than the in-line configuration shown in the diagrams, e.g., at a right angle, or 45 degree angle, or offset, or with a short length of flexible cable between the plug and jack. The short length is preferably less than 10 centimeters and may be less than 1 Meter. In one alternative embodiment, the jack may be supplied without the plug, but with cable attachment capability to be connected by cable to a standard plug or for use in special situations. 
         [0029]    In a further alternative, the adapter may include a flexible cover or boot over the locking clip  106  to protect the locking clip  106  from damage while allowing operation of the locking clip  106 . The boot may be made of rubber or other flexible material. 
         [0030]    In a further embodiment, the adapter may be included with a cable as a kit. 
         [0031]    While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.