Abstract:
A plug locking assembly comprises a housing comprising a top surface, a bottom surface and opposing sidewalls defining an open space therebetween, the open space for receiving and carrying a plug comprising a spring member. The plug locking assembly is adapted to prevent unwanted access to modular plugs engaged in associated jacks. In one embodiment, the plug locking assembly comprises a plug protection member comprising a surface spaced apart from the open space and positioned to overlie at least a portion of the spring member with the plug engaged within the housing. The plug locking assembly may further comprise a locking clip releasably securable within the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 12/031,810, filed Feb. 15, 2008, which is a continuation of U.S. application Ser. No. 11/679,610, filed Feb. 27, 2007, now U.S. Pat. No. 7,354,291, which claims the benefit of U.S. Provisional Application Ser. No. 60/777,892, filed Mar. 1, 2006 and U.S. Provisional Application Ser. No. 60/821,017, filed Aug. 1, 2006, the subject matter of which is incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a plug locking assembly and, more particularly, to a plug locking assembly for preventing unwanted access to a plug positioned within an associated jack. 
       BACKGROUND 
       [0003]    Modern telecommunication and data processing equipment often includes modular plugs that engage jacks or receptacles to create electrical connections. Typical modular plugs include an integral resilient spring or latch mechanism for releasably securing the plug within the jack. In most cases, the springs or latches comprise a tab that projects out of the receptacle after insertion. Because these tabs are readily accessible by fingernails and/or small tools, the unauthorized removal of modular plugs from their corresponding jacks is a common problem. 
         [0004]    There is a need, therefore, for a plug locking assembly that protects modular plugs and prevents their unintended disconnection from associated jacks. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention relates to an improved plug locking assembly. 
         [0006]    In one embodiment, the plug locking assembly comprises a housing comprising a top portion, a bottom portion and opposing sidewalls defining an open space therebetween, the open space for receiving and carrying a plug comprising a spring. The open space is dimensioned such that at least a portion of the spring extends beyond the open space with the plug engaged within the housing. The plug locking assembly of this embodiment further comprises a plug protection member connected to the housing. The plug protection member comprises a surface spaced apart from the open space and positioned to overlie at least a portion of the spring with the plug engaged within the housing. 
         [0007]    In another embodiment, the plug locking assembly comprises a housing, a locking clip and an angled surface formed on at least one of the locking clip and the housing. The housing comprises a top portion, a bottom portion and opposing sidewalls defining an open space therebetween. The open space is designed to receive and carry a plug comprising a cantilevered spring with a fixed end and a free end. The locking clip is releasably securable to the housing. The angled surface is positioned to overlie and retain the free end of the cantilevered spring with the plug engaged within the housing. 
         [0008]    In yet another embodiment, the plug locking assembly comprises a housing and a locking clip. The housing comprises a top portion, a bottom portion and opposing sidewalls defining an open space therebetween. The open space receives and carries a plug comprising a cantilevered spring with a free end and a fixed end. An internal surface of the bottom portion comprises a ramp and the housing comprises a stop surface defining a channel therebetween. The locking clip is releasably securable to the housing, and is designed to secure the plug into position within the housing. 
         [0009]    The foregoing embodiments may include various additional features. 
         [0010]    The housing may, for example, include an internal surface comprising a ramp and a stop surface defining a channel therebetween. The internal surface and the stop surface may be positioned in different planes. The housing may also include two or more windows for receiving a plug removal tool and the internal width of at least a portion of the open space within the housing may be tapered. Internal surfaces of housing sidewalls may comprise two or more slots. Additionally or alternatively, these internal surfaces may comprise guide rails extending longitudinally throughout the housing and oriented in a parallel relationship to one another. A spring depression member associated with the housing may be positioned to interact with the spring of the plug. The housing may further comprise a tab extending outwardly therefrom. The tab may comprise a top surface and opposing sidewalls, with the underside of the top surface comprising a downwardly facing hook. An external surface of the bottom portion of the housing may comprise a core out. 
         [0011]    The plug protection member may exhibit various configurations and be formed integrally on the housing or the locking clip. The plug protection member may comprise opposing arms connected to a top planar surface, the arms capable of movement to reposition the top planar surface. 
         [0012]    The locking clip may further comprise a spring retaining member comprising an angled surface positioned to overlie and retain the spring. The locking clip releasably may also include opposing flanges adapted to mate with the two or more slots positioned on the internal surfaces of the housing. Similarly, the locking clip may comprise a T-shaped member adapted to ride over the upper guide rails of the housing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    Certain embodiments of the present invention are illustrated by the accompanying figures. It should be understood that the figures are not necessarily to scale and that details not necessary for an understanding of the invention or that render other details difficult to perceive may be omitted. It should also be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. 
           [0014]      FIG. 1A  is a rear exploded perspective view of a plug and the plug locking assembly of the present invention; 
           [0015]      FIG. 1B  is a rear assembled perspective view of  FIG. 1A ; 
           [0016]      FIG. 2A  is a front exploded perspective view of a plug and the plug locking assembly of the present invention; 
           [0017]      FIG. 2B  is a front assembled perspective view of  FIG. 2A ; 
           [0018]      FIG. 2C  is a bottom perspective view of  FIG. 2B ; 
           [0019]      FIG. 3  is an end elevational view of  FIG. 2C ; 
           [0020]      FIG. 4  is an enlarged view of detail AB of  FIG. 3 ; 
           [0021]      FIG. 5  is a cross-sectional view along line AC-AC of  FIG. 3 ; 
           [0022]      FIG. 6  is an enlarged view of detail AD of  FIG. 5 ; 
           [0023]      FIG. 7  is a cross-sectional view along line AA-AA of  FIG. 3 ; 
           [0024]      FIG. 8  is a top perspective view of the plug locking assembly engaging a plug positioned within a jack; 
           [0025]      FIG. 9  is a side elevational view of  FIG. 8 ; 
           [0026]      FIG. 10  is an end elevational view of  FIG. 8 ; 
           [0027]      FIG. 11A  is a cross-sectional view along line AE-AE of  FIG. 10 ; 
           [0028]      FIG. 11B  is a cross-sectional view along line AF-AF of  FIG. 10 ; 
           [0029]      FIG. 12  is a top perspective view of  FIG. 8 , with a removal tool positioned to engage the housing of the plug locking assembly; 
           [0030]      FIG. 13  is a bottom perspective view of  FIG. 12 , with the removal tool positioned to engage the housing of the plug locking assembly; 
           [0031]      FIG. 14  is a bottom perspective view similar to  FIG. 13 , with the removal tool engaged with the housing of the plug locking assembly; 
           [0032]      FIG. 15  is a bottom perspective view similar to  FIG. 13 , after the removal tool removes the plug and the plug locking assembly from the jack; 
           [0033]      FIG. 16  is an end elevational view of  FIG. 13 ; 
           [0034]      FIG. 17A  is a cross-sectional view along line AG-AG of  FIG. 16 ; 
           [0035]      FIG. 17B  is a cross-sectional view along line AH-AH of  FIG. 16 ; 
           [0036]      FIG. 18  is a rear exploded perspective view of a plug locking assembly according to another embodiment of the present invention; 
           [0037]      FIG. 19  is a front exploded perspective view of the plug locking assembly of  FIG. 18 ; 
           [0038]      FIG. 20A  is a front exploded perspective view of yet another embodiment of the plug locking assembly of the present invention; 
           [0039]      FIG. 20B  is a rear perspective view of  FIG. 20A ; 
           [0040]      FIG. 21  is an end elevational view of  FIGS. 20A and 20B , with the locking clip installed in the housing; 
           [0041]      FIG. 22  is a cross-sectional view along line AA of  FIG. 21 ; 
           [0042]      FIG. 23  is a cross-sectional view along line BB of  FIG. 21 ; 
           [0043]      FIG. 24A  is a front exploded perspective view of the plug locking assembly of  FIG. 20A  and a plug; 
           [0044]      FIG. 24B  is a rear perspective view of  FIG. 24A ; 
           [0045]      FIG. 24C  is a rear perspective view similar to  FIG. 24B , with a plug installed; 
           [0046]      FIG. 24D  is a front perspective view similar to  FIG. 24A  with a plug installed; 
           [0047]      FIG. 25  is an end elevational view of  FIG. 23 , with a plug installed; 
           [0048]      FIG. 26  is a cross-sectional view along line DD of  FIG. 25 ; 
           [0049]      FIG. 27  is a cross-sectional view along line EE of  FIG. 25 ; 
           [0050]      FIG. 28  is a top perspective view of the plug locking assembly of  FIG. 20A , engaging a plug positioned within a jack; 
           [0051]      FIG. 29  is a side elevational view of  FIG. 28 ; 
           [0052]      FIG. 30  is a blown up view of detail H shown in  FIG. 29 ; 
           [0053]      FIG. 31  is a top perspective view of  FIG. 25 , with a removal tool positioned to engage the locking clip of the plug locking assembly; 
           [0054]      FIG. 32  is an end elevational view of  FIG. 31 ; 
           [0055]      FIG. 33  is a cross-sectional view along line FF of  FIG. 32 ; 
           [0056]      FIG. 34  is a cross-sectional view along line GG of  FIG. 32 ; 
           [0057]      FIG. 35  is a top perspective view of the removal tool shown in  FIG. 31 ; and 
           [0058]      FIG. 36  is a cross-sectional view similar to  FIG. 34 . 
       
    
    
     DETAILED DESCRIPTION 
       [0059]    Referring now to  FIGS. 1A-2C , one embodiment of the plug locking assembly  110  of the present invention is shown. Locking assembly  110  comprises housing  114  and pre-assembled locking clip  116 . 
         [0060]    Housing  114  comprises front  118 , rear  120  and sidewalls  122 , defining open space or center  124  therebetween for receiving plug  112 . Front  118  may include two or more access windows  126  which, as shown in  FIGS. 1A and 1B , exhibit a rectangular shape. It is likewise contemplated that windows  126  may be formed from various other shapes. Front  118  may further include tab  128 , integrally formed with housing  114 . Tab  128  comprises top portion  130 , sidewalls  132  and downwardly facing hook  134 , shown in  FIGS. 10 and 11A . Internal portions of sidewalls  122  of housing  114  may comprise longitudinal grooves  136 , as seen in  FIGS. 3 and 4 . Housing  114  is typically dimensioned such that at least a portion of plug  112  extends beyond open center  124 , with plug  112  engaged within housing  114 , as seen in  FIG. 1B . Housing  114  may further comprise core out  137  and shoulder  138 , best seen in  FIGS. 6 and 7 . 
         [0061]    As seen in  FIGS. 1A and 2A , locking clip  116  comprises central body  139 , spring retaining member  140 , plug protection member  142 , opposing flanges  144  and  146  and bosses  148  and  150 . Both spring retaining member  140  and plug protection member  142  may exhibit inverted U-shaped configurations and may directly or indirectly connect to the housing. Although spring retaining member  140  and plug protection member  142  are formed on locking clip  116  they may, in alternate embodiments, be formed integrally with housing  114 . Spring retaining member  140  is adapted to receive and hold a portion of plug  112 , while plug protection member  142  is positioned to overlie at least a portion of plug  112  after installation within housing  114 . 
         [0062]    Plug  112  may comprise housing  152 , latch arm assembly  154  and electrical contacts  155 . Housing  152  receives and retains wire  160 . Latch arm assembly  154  comprises latch  156 , cantilevered spring  158  and nose portion  159 , as seen in  FIGS. 1A and 2A . Spring  158  is constructed of a flexible material and comprises fixed end  162  and free end  164 . Spring  158  may further comprise bent portion  166 . 
         [0063]    In operation, locking assembly  10  is used to secure and lock plug  112  into position within jack  168 . Locking assembly  110  helps prevent tampering with and unintended removal of plug  112  from jack  168  as seen in  FIG. 12 . A user typically secures plug  112  within locking assembly  110 , followed by insertion of plug  112  into jack  168 . 
         [0064]      FIGS. 1B ,  2 B and  2 C show locking assembly  110  and plug  112  in an assembled state. With locking clip  116  positioned within housing  114 , opposing flanges  144  and  146  engage longitudinal grooves  136 , thereby helping secure locking clip  116  into position. This tongue and groove arrangement is shown in  FIGS. 3 and 4 . Additionally, opposing bosses  148  and  150  ride over and engage shoulders  138  positioned within housing  114 , as shown in  FIGS. 5 and 6 . With opposing bosses  148  and  150  engaged with shoulders  138 , locking clip  116  and housing  114  become very difficult to separate without damaging locking assembly  110 . Once locking clip  116  is engaged with housing  114 , plug  112  may be inserted into open center  124 . During insertion, tab  128  or spring retaining member  140  can act as a spring depression member to ride over and depress cantilevered spring  158 , eventually allowing cantilevered spring  158  to spring back into position. Once insertion is complete, a portion of latch arm  154 , as well as plug protection member  142 , extend beyond rear  120  of housing  114 , as shown in  FIGS. 2B ,  2 C and  7 . 
         [0065]    With locking assembly  110  securely in position, plug  112  may be inserted into jack  168 .  FIGS. 8-11B  illustrate insertion of plug  112  into T-shaped opening  170  within jack housing  172 . As is known, a snap-fit engagement secures plug  112  within jack  168  and creates a connection between electrical contacts  155  of plug  112  and electrical contacts  174  of jack  168 . During insertion, latch arm  154  depresses slightly and then snaps back into place, thereby securing latch  156  against top internal surface of jack opening  170 . 
         [0066]    After insertion, a narrow gap  176  between rear  120  of housing  114  and a front surface of jack housing  172  exists, as seen in  FIG. 9 . To prevent unwanted access to latch arm  154  through gap  176 , as seen in  FIG. 2A , top surface  179  of plug protection member  142  is advantageously positioned to shield latch arm assembly  154  by occupying at least a portion of gap  176 —in this case that portion of gap directly above latch arm assembly  154 , as shown in  FIG. 9 . Accordingly, locking assembly  110  helps prevent unwanted removal of plug  112  by a screwdriver or other flat tool. 
         [0067]    To free plug  112  from jack  168 , removal tool  178  may be employed.  FIGS. 12-17B  illustrate use of removal tool  178  with locking assembly  110 . Specifically,  FIGS. 14 and 15  show removal tool  178  removing locking assembly  110  and plug  112  from jack  168 . The features of removal tool are illustrated and described in co-pending, co-owned U.S. patent Ser. No. 11/207,853 filed Aug. 18, 2005, which is hereby incorporated by reference in its entirety. 
         [0068]    Removal of plug  112  from jack  168  can be accomplished by positioning removal tool  178  such that prongs  180  are aligned with opposing access windows  126  of housing  114  and hook  182  is aligned with downwardly facing hook  134  of tab  128 . As prongs  180  are inserted through access windows  126 , distal ends  184  of prongs  180  contact and exert a force on spring retaining member  140  depressing latch arm assembly  154  and freeing latch  156  from jack opening  170 . As a result, latch  156  no longer engages a top internal surface of jack opening  170 . At the same time, hook  182  engages underside of tab  128 . At this point, plug  112  can now be removed from the jack opening  170 , as seen in  FIG. 15 . The use of tool  178  to disconnect plug  112  from jack  168  can be particularly useful in congested areas where it may otherwise be difficult to access plug  112  by hand. 
         [0069]      FIGS. 18 and 19  illustrate another embodiment of plug locking assembly  110 ′. Since locking assembly  110 ′ functions similarly to plug locking assembly  110  the same reference numerals will be used with the addition of the prime (′) notation. Locking clip  116 ′ of this embodiment includes angled plug protection member  142 ′, which may occupy a larger gap than plug protection member  142 . 
         [0070]    Yet another embodiment of the present invention is illustrated by  FIGS. 20A-36 . Referring now to  FIGS. 20A and 20B , plug locking assembly  210  of this embodiment is shown. Locking assembly  210  comprises housing  212  and pre-assembled locking clip  214 . 
         [0071]    Housing  210  comprises front  216 , rear  218 , top  220 , bottom  221  and sidewalls  223 , defining open space or center  224  therebetween for receiving plug  226 . Housing  212  is typically dimensioned such that at least a portion of plug  226  extends beyond open center  224 , with plug  226  engaged within housing  212 . Front  216  may include two or more access windows  228 , as shown in  FIG. 20A . Rear  218  may comprise plug protection member  230 , which may be integrally formed with housing  212  and positioned to overlie at least a portion of plug  226  after installation in housing  212 . Plug protection member  230  may exhibit an inverted U-shaped configuration. As shown in  FIG. 20B , plug protection member  230  comprises opposing arms  231  and top planar surface  233 . Sidewalls  223  of housing  212  comprise internal surfaces  234 . Internal surfaces  234  may comprise opposing slots  238  and guides comprising upper guide rails  237  and lower guide rails  239 , as seen in  FIGS. 20A and 20B . Upper and lower guides rails  237  and  239  may extend longitudinally throughout housing  212  and be oriented in a parallel relationship to one another. Housing  212  may further comprise channel  241 , defined by ramp  243  and front stop surface  245 . An internal surface of bottom  221  and stop surface  245  may be positioned in different planes. 
         [0072]    Locking clip  214  may comprise spring retaining member  244 , flexible opposing arms  246  and  248  leading into opposing flanges  250 , T-shaped member  247  and tab  251 . Spring retaining member  244 , which may exhibit a triangular cross-section, comprises top surface  253  and ramp  254 . As shown in  FIGS. 20A and 20B , opposing flanges  250  may be T-shaped. Tab  251 , integrally formed with locking clip  214 , may comprise top portion  256 , sidewalls  258  and downwardly facing hook  255 , best seen in  FIGS. 26 and 33 . Tab  251  helps prevent unintended access to plug  226  while positioned within locking assembly  210 . 
         [0073]    Referring now to  FIGS. 24A-B  and  26 , plug  226  may comprise housing  262 , boss  263 , latch arm assembly  264  and electrical contacts  266 . Housing  262  receives and retains wire or cable  268 . Latch arm assembly  264  comprises latch arm or cantilevered spring  272  and nose portion  274 . Spring  272  is constructed of a flexible material and comprises fixed end  276  and free end  278 . Spring  272  may further comprise bent portion  280 . 
         [0074]    Locking assembly  210  operates similarly to the previously described embodiments. In operation, locking assembly  210  is used to secure and lock plug  226  into position within jack  282 . Locking assembly  210  helps prevent tampering with and unintended removal of plug  226  from jack  282 , as seen in  FIGS. 28-30 . A user typically secures plug  226  within locking assembly  210 , followed by insertion of plug  226  into jack  282 . 
         [0075]      FIGS. 21-23  show locking assembly  210  in an assembled state. With locking clip  214  positioned within housing  212 , opposing flanges  250  engage slots  238 , thereby helping secure locking clip  214  into position. This arrangement, shown in  FIG. 22 , makes it difficult to separate housing  212  from locking clip  214 , without damaging locking assembly  210 . To accomplish engagement, flexible opposing arms  246  and  248  may be squeezed inwardly before insertion of locking clip  214  into housing  212 , thereby allowing them to spring into slots  238  during the insertion process. Alternatively, the internal width dimension of open space  224  may taper so that opposing flanges  250  of locking clip  214  spring into slots  238  during insertion. Additionally, T-shaped member  247  rides over upper guide rails  237 , providing stability against rocking of locking clip  214  within housing  212 . 
         [0076]    Once locking clip  214  is engaged within housing  212 , plug  226  may be inserted into open center  224 .  FIGS. 25-27  show plug  226  installed within locking assembly  210 . During insertion, tab  251  or spring retaining member  244  can act as a spring depression member to ride over and depress cantilevered spring  272 . Plug  226  is held in place by boss  263 , which rests in channel  241 , between ramp  243  and stop surface  245  of housing  212 . Under these circumstances, it is difficult to remove plug  226  without damaging locking assembly  210 . 
         [0077]    With plug  226  secured within locking assembly  210 , plug  226  may be inserted into jack  282 .  FIGS. 28-30  illustrate insertion of plug  226  into opening  284  within jack housing  286 . As is known, a snap-fit engagement secures plug  226  within jack  282  and creates a connection between electrical contacts  266  of plug  226  and electrical contacts (not shown) of jack  282 . Plug  226  is typically inserted so that top  220  of housing  212  faces down and bottom  221  of housing  212  faces up, though the opposite orientation may be employed depending on jack orientation. During insertion, spring  272  depresses slightly and then snaps back into place, thereby securing spring  272  against a bottom internal surface of jack opening  284 . 
         [0078]    After insertion, gap  288  between rear  218  of housing  212  and a front surface of jack housing  286  exists, as seen in  FIGS. 29 and 30 . To prevent unwanted access to spring  272  through gap  288 , top surface  233  of plug protection member  230  is advantageously positioned to shield spring  272  by occupying at least a portion of gap  288 , as shown in  FIG. 30 . Plug protection member  230  is self-adjusting. That is, depending on the geometry of the plug-jack arrangement, plug protection member  230  may flex forward or backward (between about 0.05 inches to about 0.2 inches and more particularly about 0.1 inches) to automatically fill gap  288 . 
         [0079]    To free plug  212  from jack  282 , the same removal tool used in connection with earlier embodiments may be employed.  FIGS. 31-36  illustrate use of removal tool  290  with the locking assembly  210  of the present invention.  FIG. 34  shows removal tool  290  removing locking assembly  210  and plug  212  from jack  282 . Removal tool  290  is locked to locking assembly  210 . 
         [0080]    Removal of plug  226  from jack  282  can be accomplished by positioning removal tool  290  such that prongs  292  may be inserted through open center  224  of housing  212  under wire or cable  268  into channels  296 , while hook  294  of removal tool  290  is aligned with downwardly facing hook  255  of tab  251 , as shown in  FIG. 33 . Removal tool  290  is oriented with release button  298  facing upward, opposite wire  268 . Upper and lower guide rails  237  and  239  direct prongs  292 . After insertion, prongs  292  are used to contact and exert an inward force on flexible arms  246  and  248 , thereby freeing opposing flanges  250  from slots  238 , as shown in  FIG. 36 . At this point, removal tool  290  may be used to move locking clip  204  slightly forward within housing  212 , as shown in  FIG. 34 . As locking clip  204  moves forward, ramp  254  of spring retaining member  244  depresses spring  272  so that plug  226  can be pulled out of jack opening  284 , as shown in  FIG. 33 . As a result, spring  272  no longer engages an internal surface of jack opening  284  and latch arm assembly  264  is released from jack  282 . Plug  226 , however, remains secured within locking assembly  210 . Use of tool  290  to disconnect plug  226  from jack  282  can be particularly useful in congested areas where it may otherwise be difficult to access plug  226  by hand. Tool  290  is released from locking assembly  210  by depressing release button  298  after plug  226  is removed, as shown in  FIG. 31 . 
         [0081]    Plug locking assembly  110 ,  110 ′ or  210  may be molded as a two-piece component, with housing and locking clip created from separate molds. This type of construction eliminates the need for side actions in the mold tooling, thereby simplifying molding and increasing security by reducing the need for core outs, though core out  137 , as seen in  FIGS. 2C and 7 , is typically formed on a bottom surface of housing. 
         [0082]    While certain embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims.