Abstract:
Embodiments of the invention describe an electrical audio connector assembly used in a variety of applications, such as for connecting audio components for transferring audio signals. For example, microphones may be connected to other electrical components by XLR connectors or a phone line. An electrical audio connector assembly includes an XLR connector or three pins and an RJ connector mounted on opposite ends of a body structure. Three metal binding posts project from the body structure, and are conductively coupled to both the XLR connector and the RJ connector.

Description:
TECHNICAL FIELD 
   This invention relates to electrical connection devices, and more particularly to an electrical connector assembly that includes binding posts, an XLR connector and a registered jack (“RJ”) connector to connect to a phone line. 
   BACKGROUND OF THE INVENTION 
   Various types of electrical connectors are used for a wide variety of applications. Particularly common in the professional audio industry is the use of binding posts with XLR plugs for connecting audio components to transfer audio signals. 
   Conventional binding posts generally provide reasonably good surface area contact for reliable conductivity. Binding posts are versatile terminals, and may accept banana plugs, alligator clips, bare wires, spade lugs or other electrical connections. The XLR plug in a conventional binding post assembly is an added feature that enables a number of cables to be coupled together to achieve any desired length. XLR connectors are widely used for audio connections because they provide balanced lines capable of traveling long distances without significant interference. 
   A conventional XLR binding post assembly  100  is shown in  FIG. 1A . The conventional assembly  100  consists of three binding posts  114  corresponding to the three conductive wires found in standard XLR three pin connectors. A male-type XLR plug  130  is found at the base of the assembly  100 . Although not shown, the assembly  100  may instead have a female-type XLR plug. Industry standard XLR binding posts come in either male or female types, to enable the connection of the three conductive wires between one XLR connector to a complementary connector. Each binding post  114  includes an internal metal post  120  capped by a plastic cover. The binding posts  114  are typically color-coded to indicate high, low and ground terminals. The internal metal post  120  includes a through-hole for receiving bare wire connections. Each internal metal post  120  is mounted on a metal platform  122  with a plastic external cover. The metal posts  120  are internally coupled to the corresponding conductive pins of the XLR plug  130  within the body structure. The entire assembly  100  is housed by a protective ABS plastic case. 
   In the professional audio industry, situations arise where it is necessary to access a phone line for various purposes. For example, microphones are commonly connected to other electrical components by either using XLR connectors or phone lines. Professional microphones in particular may need to be connected to various electrical devices and tested over long distances. A user may want the option of connecting the microphone through a phone jack or may need access to a phone in a remote location to communicate to others during testing. Typically, the user must then extend a separate phone line to that location, which is often cumbersome and time consuming. Having access to phones, however, is common practice in the audio industry, and with a phone users are able to conveniently “ring down” to another phone at the remote location. 
   Another drawback to the conventional XLR binding post is when bare wires  132  are received by the assembly  100 , they must be threaded through the through-hole of each metal posts  120 , as demonstrated in  FIG. 1B , and clamped down by tightly twisting down the cap on the binding post  114 . The assembly  100  of  FIG. 1B  is the same as the assembly  100  of  FIG. 1A , and in the interest of brevity it will not be described again. XLR binding posts are typically manufactured with the through-hole centered on the internal metal posts  120 . A common problem with this assembly  100  occurs when the bare wires  132  are guillotined as the binding post  114  caps are tightly screwed down. The through-hole is elevated above the metal platform  122  due its orientation in the metal post  120 , which typically cause the bare wires  132  to stretch and break as the caps on the binding posts  114  are tightened. This is particularly a problem if the threaded wires  132  are phone wires, since phone wires are typically thinner. 
   There is therefore a need for an XLR binding post assembly having a phone jack for connecting to phone lines on a single device. Additionally, the XLR binding post assembly must be able to receive particularly thin wires without inflicting severe damage or causing breakage. 
   SUMMARY OF THE INVENTION 
   The invention is directed to an electrical audio connector assembly having an XLR connector and an RJ connector. In one aspect of the invention, a plastic body of the connector assembly houses two or more metal binding posts. The XLR connector and the RJ connector are both conductively coupled to at least one of the binding posts. The XLR connector is designed to connect to complimentary terminals of another connector for transferring electrical signals between the metal binding posts and any other attached connectors. The XLR connectors may be of the male or female type. The RJ connector is designed to connect to another RJ connector and transfer electrical signals between the metal binding posts and any other connectors. 
   In another aspect of the invention a method of manufacturing an electrical audio connector assembly with an attached XLR connector and RJ connector is disclosed. The method includes forming a plastic body structure around two or more metal binding posts. The method further includes attaching the XLR connector on one end of the plastic body structure and the RJ connector on the other end. The method also includes providing a conductive pathway between the XLR connector and the RJ connector to the metal binding posts. Screw caps are then attached to the metal binding posts. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is a front elevational view of a conventional XLR binding post assembly. 
       FIG. 1B  is an isometric view of a conventional XLR binding post assembly with threaded wires. 
       FIG. 2A  is a side elevational view of a center structure of an XLR binding post assembly according to an embodiment of the invention. 
       FIG. 2B  is a bottom plan view of the center structure of an XLR binding post assembly according to an embodiment of the invention. 
       FIG. 3A  is a side elevational view of an XLR binding post assembly according to an embodiment of the invention. 
       FIG. 3B  is a side elevational view of an XLR binding post assembly according to another embodiment of the invention. 
       FIG. 3C  a side elevational view of an XLR binding post assembly according to another embodiment of the invention. 
       FIG. 4A  is a front elevational view of a male XLR connector according to an embodiment of the invention. 
       FIG. 4B  is a front elevational view of a female XLR connector according to another embodiment of the invention. 
       FIG. 4C  is a rear elevational view of an RJ connector binding post assembly according to an embodiment of the invention. 
       FIG. 5  is a schematic drawing of the binding posts electrically connected to the RJ connector according to an embodiment of the invention. 
       FIG. 6  shows a method for manufacturing an XLR binding post assembly according to an embodiment of the invention. 
       FIG. 7  is an isometric view of an XLR binding post assembly according to another embodiment of the invention. 
   

   DETAILED DESCRIPTION 
   Embodiments of the present invention are directed to an XLR binding post assembly and method for manufacturing the assembly having an RJ connector for connecting to phone lines. Certain details are set forth below to provide a sufficient understanding of the invention. However, it will be clear to one skilled in the art that the invention may be practiced without these particular details. In other instances, well-known circuits, control signals, and timing protocols have not been shown in detail in order to avoid unnecessarily obscuring the invention. 
   The center structure of an XLR binding post assembly  200  according an embodiment of the invention is shown in  FIGS. 2A and 2B . A plastic body  280  houses three metal posts  254   a - 254   c  evenly mounted across the center region. The metal posts  254   a - 254   c  may be any type of metal that provides a the necessary conductivity, and includes nickel, aluminum, gold-plated metals and other metals. The top portion of the metal posts  254   a - 254   c  are threaded to attach plastic terminal screw caps. Each metal post  254   a - 254   c , which includes a through-hole  260 , are fitted through the plastic body  280 . As previously described, the through-hole  260  is designed to receive and hold bare wires. The through-hole  260  is formed to be flush with a metal platform  262  in order to clamp bare wires threaded through the through-hole  260  without shearing them, as will be further described in later sections. The metal posts  254   a - 254   c  are laid through the plastic body  280  to provide a conductive path between external pins and wires to the internal wiring of the assembly  200 . The assembly  200  also includes a plastic casing  270  on one end for an RJ connector, and an insertion point  274  with an O-ring groove  276  on the other end for attaching either a male or female XLR connector. Any internal wiring through the plastic body  280  is confined to the underside of the assembly  200 , and will be described in detail next. A plastic cover  295  is then placed over the internal wiring on the underside of the assembly  200  to provide protection, and also gives the body  280  a cylindrical shape. Although the preferred embodiment of the body  280  is cylindrical, other body shapes and types may be used. 
     FIG. 2B  is a bottom plan view of the same assembly  200  of  FIG. 2A . The underside of the assembly  200  is shown without the plastic cover  295  that fits over the underside region. A metal base  284  corresponding to each of the metal posts  254   a - 254   c  appear along the underside region. Each metal base  284  includes a protruding metal center stud  281  with a rectangular groove formed across its center to easily connect and solder wires to each of the metal posts  254   a - 254   c . The metal bases  284  are encompassed by a plastic wire channel  290  that spans across the horizontal plane of the underside region. The plastic wire channel  290  opens into the RJ connector plastic casing  270 . The plastic wire channel  290  also extends to the XLR insertion point  274  through a small opening, and provides a place for laying internal wires coupled to the metal posts  254   a - 254   c  and to the pins of the XLR connector, or alternatively to the RJ connector. Once the wires are laid, the plastic cover  295  is then placed over the region of the plastic wire channel  290 . 
     FIG. 3A  is a side elevational view of a complete XLR binding post assembly  300  according to an embodiment of the invention. A male XLR connector  311  is attached to one end of the assembly  200 , and an RJ connector  370  is attached to the other end. The internal structure of each connector will be described further later. A protective plastic overcoat covers the entire body structure  384  of the assembly  200 . Binding posts  354   a - 354   c  include a plastic terminal screw cap that screws on each of the metal posts  254   a - 254   c  of  FIGS. 2A and 2B . The tops of the terminal screw caps  354   a - 354   c  are open to expose the hollow centers of the metal posts  254   a - 254   c  so that the binding posts  354   a - 354   c  may receive banana plugs, alligator clips, spade lugs or other electrical connections. The terminal screw caps may be color-coded with different colors to indicate the type of terminal it is, such as high, low or ground. 
   As previously described, wires may be threaded through the through-holes  260  of the binding posts  354   a - 354   c , shown in  FIG. 3B . The terminal screw caps of the binding posts  354   a - 354   c  are unscrewed to expose the through-holes  260 . Once the wires are threaded through, they are held in place by screwing the caps back down. The binding posts  354   a - 354   c  are confined by a slightly elevated platform  313  that rises to the level of the through-holes  260  to provide a leveled planar surface for supporting the threaded wires. Since the through-holes  260  are flush with the platform  313 , the wire may be clamped in place, and not bent or sheared as the screw caps are tightened. 
   A female XLR binding post assembly  301  is shown in  FIG. 3C  having essentially the same configuration as the male XLR assembly  300 . In the interest of brevity, elements that are the same will not be described again. The female XLR assembly  301  further includes a female connector  315  attached to the plastic body structure  384  instead of the male XLR connector  311 . The female connector  315  additionally includes having standard metal clasps  317  for fastening to complimentary male connectors. The male XLR connectors  311  typically includes a gap or hole (not shown) on its external rim, for receiving the metal clasps  317  of the female XLR connector  315 . One of the metal clasps  317  locks complimentary connectors together, while the other releases them. 
     FIGS. 4A ,  4 B and  4 C show the front elevational views of a male XLR connector  311 , female XLR connector  315  and an RJ connector  370 , respectively. The male and female XLR connectors are industry-standard three pin connectors, as previously describe. The male XLR connector of  FIG. 4A  has a first metal pin  427   a , a second metal pin  427   b  and third metal pin  427   c  protruding from the internal plastic body  280  of the assembly  300 . The pins  427   a - 427   c  are shielded by the protective plastic overcoat of the male XLR connector  311  component. The metal pins  427   a - 427   c  are internally wired to respective binding posts  354   a - 354   c , as already described. From this view, the binding post  354   c  and the bind post platform  313  are also seen. The female XLR connector  315  has three pin holes  443   a - 443   c , embedded in the internal plastic body of the female XLR connector  315 , for receiving corresponding pins  427   a - 427   c  of the male XLR connector  311 . From this view, the binding post  354   c  and the connecting clips  317  are also seen. 
   The internal structure of the RJ connector  370  is shown in  FIG. 4C . The RJ connector  370  is housed on the end opposite the XLR connectors  311 ,  315 , and from this view the binding post  354   a  is seen. A standard RJ plug  463  is embedded into the plastic-filled casing of the RJ connector  370 . The RJ connector  370  is also internally wired to the binding post as already described. Two electrical pins  465 ,  467  are wired from two of the binding posts  354   a - 354   c  and installed in the RJ plug  463  for connecting to an external phone line. Although the preferred embodiment uses the standard 6-position RJ plug  463 , other connectors such as the 8-position connectors may also be installed. 
     FIG. 5  is a schematic drawing that may represent the internal electrical connection of the binding posts  254   a - c  to the RJ connector  463  in the plastic casing  270  and the XLR connectors  427 ,  433  in the XLR insertion point  274  of the XLR binding post assembly  200  in  FIG. 2A . As shown in  FIG. 5 , the ends of the binding posts  354   a - 354   c  are connected to respective XLR pins  573 ,  575 ,  577 . For example, the binding post  354   a  is internally coupled to the XLR pin  575 , which connects to pin  2  of an external XLR connector. Each of the binding posts  354   a - 354   c  are internally wired to each of the XLR pins  573 ,  575 ,  577 . Similarly, the RJ plug  563  is also internally wired to the binding posts  573 ,  575 ,  577 . Since RJ plug  563  requires only two pins  563 ,  564 , only two of the binding posts  354   a ,  354   b  are assigned. 
     FIG. 6  shows a method for manufacturing the XLR binding post assembly  300  of  FIGS. 2A-2B  and  3 A- 3 C according to an embodiment of the invention. At step  610 , metal posts  254   a - 254   c  are placed, without the terminal screws, in a predetermined product mold to form the cylindrical plastic body  280 . At step  620 , an ABS plastic is injected into the product mold, which forms the plastic body  280 . ABS plastic is the preferred material for molding the center plastic body  280 , but other industrial plastic compounds or other materials may be used instead. The plastic body  280  is formed to include the O-ring groove  276  for appending an O-ring, at step  630 , prior to attaching the connectors. The O-ring prevents the mold compound from leaking, when the assembly  300  is later placed into an overmold and injected with an outer coating material at step  680 . Step  644  includes the substeps  642  and  644  in no particular order. At substep  642 , a metal piece of the XLR connector  311 ,  315  is press fit on the plastic body  280 , and keyed so that the pins are correctly aligned. At substep  644 , an RJ connector  370  is inserted on the other end of the plastic body  280 . The RJ wires are connected to the XLR connector pins  573 ,  575 ,  577  at step  650 . The wires to the XLR connector pins  573 ,  575 ,  577  are then coupled to the binding posts  354   a - 354   c  at step  660 , and the wires are soldered onto the metal studs  281  at the base of the metal posts  284 . At step  670 , the plastic cover  295  is placed over the wire channel  290  after the wires have been correctly oriented. The entire center assembly  200  is then placed into the overmold at step  680 , and the outer plastic coating is applied. The attached O-ring from step  630  is in place to prevent any of the injected coating material from leaking out. At step  690 , the plastic screws are placed on the binding posts  354   a - 354   c  to fabricate the complete the assembly  300 . 
     FIG. 7  is an isometric view of an XLR binding post assembly  700  according to an alternate embodiment of the invention. The assembly  700  essentially includes parts and elements of the assembly  300  of  FIGS. 3A-3C , and in the interest of brevity, these common parts will not be described again. The assembly  700  in this embodiment includes an RJ connector  770 , positioned orthogonal to the plastic body structure  384 . 
   Although the present invention has been described with reference to the disclosed embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. Such modifications are well within the skill of those ordinarily skilled in the art. Accordingly, the invention is not limited except as by the appended claims.