Abstract:
The present invention generally relates to the field of network communication. In an embodiment, the present invention is a breakaway RJ45 cable assembly that includes a standard RJ45 plug inserted into a modified RJ45 jack that, upon a sufficient amount of tension, releases the installed standard RJ45 plug. To insure that, as tension builds up in the cable assembly, the connection between the modified RJ45 jack and the patch cord to which the standard RJ45 plug is connected to experience tension substantially along the plug and jack body lengths the breakaway cable assembly is installed in the middle of a communication channel.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 62/058,404, filed on Oct. 1, 2014, which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention generally relates to the field of network communication, and more specifically, to jacks and assemblies designed to release an RJ45 plug without substantial damage thereto. 
       BACKGROUND 
       [0003]    RJ45 plugs and jacks are generally designed to prevent unintentional disconnection. This is typically achieved by providing vertical face-to-face interaction between the plug latch tabs and the jack housing, where the interaction is disengaged when a user depresses the plug latch. Such design can be advantageous in settings where unintentional large tensions are not likely to be applied on the mated plug/jack combination. However, in other scenarios such designs may actually contribute to potential equipment damage. 
         [0004]    For instance, a problem can occur where an end user forgets to disconnect an RJ45 patch cord in a mobile application and a relatively large tension is applied along a patch cord which puts expensive equipment at risk of damage. One example of where this situation is a common occurrence is in hospitals where technicians are rapidly changing locations between patients with a mobile cart of equipment and, when leaving quickly in case of an emergency for example, forgets to disconnect network connectivity damaging a network port in the process. Such damage can result in downtime and significant repair costs. 
         [0005]    An additional element of this problem is that the directionality of the pull on the network connectivity is not consistent. In cases where the direction of pull is along that of the plug body length, the plug itself is more likely to fail. However, as the angle increases to be more perpendicular to that of the plug body length the RJ45 plug is more likely to bind to the side of the jack housing causing damage to the equipment. 
         [0006]    As such, there is a need for devices, systems, and methods which provide a secure RJ45 connection under normal conditions, and yet help reduce the withdrawal force of an RJ45 plug when the plug is engaged such that upon a sudden application of tension in the cable the cable is withdrawn in a non-destructive manner. 
       SUMMARY 
       [0007]    Accordingly, at least some embodiments of the present invention are directed towards devices, systems, and methods which provide a secure RJ45 connection under normal conditions, and yet help reduce the withdrawal force of an RJ45 plug when the plug is engaged such that upon a sudden application of tension in the cable the cable is withdrawn in a non-destructive manner. 
         [0008]    In an embodiment, the present invention is a breakaway RJ45 cable assembly that includes a standard RJ45 plug inserted into a modified RJ45 jack that, upon a sufficient amount of tension, releases the installed standard RJ45 plug. To insure that, as tension builds up in the cable assembly, the connection between the modified RJ45 jack and the patch cord to which the standard RJ45 plug is connected to experience tension substantially along the plug and jack body lengths the breakaway cable assembly is installed in the middle of a communication channel. 
         [0009]    In another embodiment, the present invention is an RJ45 communication jack for receiving an RJ45 plug, the RJ45 plug having a plug latch with a stop surface. The jack includes a housing for receiving the RJ45 plug, the housing including a side being positioned adjacent to the RJ45 plug latch when the RJ45 plug is received within the RJ45 communication jack, the side including a flexible member, the flexible member including at least one plug-latch-stop configured to interact with the plug latch when the RJ45 plug is received within the RJ45 communication jack. 
         [0010]    In yet another embodiment, the present invention is an RJ45 communication cord. The cord includes a twisted pair cable and an RJ45 communication jack connected to at least one end of the twisted pair cable, the RJ45 communication jack configured to receive an RJ45 plug having a plug latch with a stop surface, the RJ45 communication jack including a housing for receiving the RJ45 plug, the housing having a side being positioned adjacent to the RJ45 plug latch when the RJ45 plug is received within the RJ45 communication jack, the side including a flexible member, the flexible member including at least one plug-latch-stop configured to interact with the plug latch when the RJ45 plug is received within the RJ45 communication jack. 
         [0011]    In still yet another embodiment, the present invention is an RJ45 communication jack, the jack having an axis of an RJ45 plug insertion, the RJ45 plug having a plug latch. The jack includes a housing with a housing front defining an opening for receiving the RJ45 plug therethrough, and a housing side, the housing side being positioned adjacent to the RJ45 plug latch when the RJ45 plug is received within the RJ45 communication jack, the housing side including a substantially rectangular flexible member having four flexible member sides, the flexible member being secured to the housing side along one of the four flexible member sides. 
         [0012]    These and other features, aspects, and advantages of the present invention will become better-understood with reference to the following drawings, description, and any claims that may follow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  illustrates a communication system according to an embodiment of the present invention. 
           [0014]      FIG. 2  illustrates a communication system according to an embodiment of the present invention. 
           [0015]      FIG. 3  illustrates an embodiment of an assembly according to the present invention. 
           [0016]      FIG. 4  illustrates an exploded view of the assembly of  FIG. 3 . 
           [0017]      FIG. 5  illustrates a front perspective view of a jack housing from the assembly of  FIG. 3 . 
           [0018]      FIG. 6  illustrates a front perspective view of a jack housing from the assembly of  FIG. 3 . 
           [0019]      FIG. 7  illustrates a top view of a jack housing from the assembly of  FIG. 3 . 
           [0020]      FIG. 8  illustrates a rear perspective view of a jack housing from the assembly of  FIG. 3 . 
           [0021]      FIG. 9  illustrates a cross-sectional view of the assembly of  FIG. 3  mated with an RJ45 plug. 
           [0022]      FIG. 10  illustrates an embodiment of an assembly according to the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    Referring to  FIG. 1 , an embodiment of the present invention includes a communication system  20  with patch panel  22  populated with RJ45 jacks  24 , a breakaway RJ45 cable assembly  26 , and an RJ45 patch cord  34 . The breakaway RJ45 cable assembly  26  includes an RJ45 plug  28 , a cable  30  with central axis  36 , and a breakaway RJ45 jack  32 . Plug  28  is installed into jack  24  and RJ45 patch cord  34  is installed into breakaway jack  32  via an RJ45 plug.  FIG. 2  illustrates communication system  20  with the orientation of the installation of cable assembly  26  changed to demonstrate that the direction of the cable  30  and the patch cord  34  remain approximately in line with that of central axis  36  of breakaway RJ45 jack  32 . 
         [0024]    While equipment  22  is illustrated as a patch panel in  FIGS. 1 and 2 , current systems can include passive and/or active equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, faceplates, surface mount box, media distribution unit (MDU), wall jacks, etc. Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and power-over-Ethernet equipment as can be found in data centers/telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers and other peripherals as can be found in workstation areas. Communication system  20  can further include cabinets, racks, cable management and overhead routing systems, and other such equipment; and application specific devices such as, in healthcare applications, biomedical instruments, diagnostic and treatment equipment such as might be found in a hospital or other such environment. 
         [0025]      FIGS. 3 and 4  illustrate the breakaway cable assembly  26  in greater detail. As shown therein, the assembly  26  includes breakaway jack housing  38 , sled assembly and rear jack portion  40 , foil  42 , wire cap  44 , twisted pair cable  30 , and plug assembly  28 . Plug assembly  28  includes plug boot  46 , strain relief collar  48 , divider  50 , load bar  52 , and plug housing assembly  54  with a plug latch  62  and tabs  59 . 
         [0026]    Referring to  FIGS. 5-8 , the jack housing  38  includes a flexible member  58  positioned on the top of the jack housing and adjacent to the plug/jack latching point. In the currently described embodiment, the flexibility of the flexible member  58  is achieved by providing cut-outs  56  positioned along the two parallel sides of the flexible member  58 . The cut-outs  56  partially detach the flexible member  58  from the rest of the jack housing  38 , enabling a predetermined level of flexibility. 
         [0027]    The jack housing  38  further includes modified plug-latch-stops  60  positioned accordingly to interact with tabs  59  of the plug latch  62 . The plug-latch-stops  60  include a vertical surface  61  and an angled surface  63 , both of which are illustrated in the rear view of the jack housing shown in  FIG. 8 . While the angled surface is illustrated as a flat surface, in other embodiments the surface may be evenly or unevenly curved. In addition, there may be one or more flat or curved intermediate sections positioned between the angled surface  63  and a vertical surface  61 . Furthermore, the vertical surfaces  61  may vary in size, or they may be omitted altogether. 
         [0028]    The interaction of the latching mechanism of a standard RJ45 plug and the catching mechanism of the modified RJ45 jack is illustrated in some detail in  FIG. 9  which is a cross-section view of a mated plug/jack combination taken about section line  9 - 9  of  FIG. 1 . When the standard RJ45 plug  68  is fully mated with the modified RJ45 jack  32 , the tabs  59  positioned on the plug latch  62  are constrained by the plug-latch-stops  60  of the jack housing  38 , causing the plug  68  to remain within the jack  32  until sufficient pulling force is applied. In a case where the plug-latch-stops  60  include a vertical surface  61 , the vertical surface  61  and the rear vertical surface  70  of the tabs  59  provide added restraint of the plug since the plane  72  defined by the two interacting surfaces  61 ,  70  is approximately perpendicular to the axis  36  along which the majority of pulling tension would be experienced. 
         [0029]    While the interaction of the latching components detailed in  FIG. 9  provides some restraint of the plug assembly  28  and prevents relatively low tension disconnects, it allows the plug and the jack to non-destructively disconnect upon application of sufficient pulling force substantially along the axis  36 . Due to the interaction between the tabs  59  and the plug-latch-stops  60 , the plug latch  62 , and thereby the plug  68 , are prevented from unrestricted withdrawal. However, in the event of longitudinal tension force F across the plug/jack combination and along the central axis  36 , the plug assembly  28  and the jack  32  begin to separate provided that force F is sufficiently large to overcome the engagement between plug latch  62  and plug-latch-stops  60 . In the detail view of  FIG. 9 , horizontal component force F H  and the vertical component of force F V  are shown at the point of interaction  74 . Horizontal component force F H  is approximately equal to force F along the central axis  36 . Variation between these forces comes from frictional effects and any forces that the jack contacts exert onto plug assembly  28  in the horizontal direction. Vertical component of force F V  is a resultant of the flexibility of plug latch  62  and its angle θ relative to the horizontal direction. Because flexible member  58  is attached to the housing  38  at its rear  76 , (see  FIG. 7 ), the deflection of the flexible member  58  translates into a rotation thereof at or about point  67  due to moment M  69  in the counterclockwise direction relative to the orientation of  FIG. 9 . In the static system (prior to plug assembly  28  releasing from jack housing  38 ) moment M  69  can be calculated as: 
         [0000]        M =( F   H   *δv )+( F   V *δ H )  Eqn. (1)
 
         [0000]    where δ v  is the vertical distance between point of interaction  74  and central flexure axis  65  and δ H  is the horizontal distance between point of interaction  74  and point  67  (reference detail view of  FIG. 9 ). It is worth noting that the above equation represents the static system prior to plug assembly  28  releasing from jack housing  38 . As forces increase, moment M  69  will also increase resulting in additional flexure in member  58  until plug assembly  28  releases from jack housing  38  in a dynamic manner. 
         [0030]    This rotation of flexible member  58  alters the angle α of the plane  72  relative to the angle of the central axis  65  causing a to increasingly deviate from 90° as greater tension is applied. While at relatively low a deviations the friction between the tabs  59  and the plug-latch-stops  60  prevents the latch  62  from being released, at a sufficient angle α this friction is reduced to the point where the tabs  59  slip relative to the plug-latch-stops  60 . The point at which this slippage occurs may be adjusted in any number of ways, including, but not limited to, adjusting the size and/or shape of the plug-latch-stops  60  (including vertical surfaces  61  and/or angled surfaces  63 ), adjusting the materials from which the flexible member  58  is made, and adjusting the size/length/thickness of the flexible member  58 . Since prior to the slippage of the tabs  59  relative to the plug-latch-stops  60  the plug latch  62  also deflects in the direction relatively parallel to that of plane  72 , it is preferable to design the point at which the slippage occurs prior to the plug latch  62  deflecting to the point of plastic deformation. Likewise, it is also preferable to design the point at which the slippage occurs prior to the flexible member  58  deflecting to the point of plastic deformation. In an embodiment, the deflection of the latch  62  and/or the flexible member  58  ranges from greater than 0° to about 15° relative to the central axis  36 . 
         [0031]    Upon slipping, the tabs  59  first clear the vertical surfaces  61  of the plug-latch-stops  60  and thereafter come into contact with the angled surfaces  63 . Because the angles of the angled surfaces  63  relative to the rear vertical surfaces  70  is greater than that of the vertical surfaces  61  relative to the rear vertical surfaces  70 , the tabs continue to slip past the angled surfaces  63 , clearing the plug-latch-stops  60  and allowing the latch  62  and the flexible member  58  to deflect back into their rested/default positions. This releases the plug  68  from the jack  32 . 
         [0032]    Referring back to  FIGS. 5 and 6 , a relief area  64  can be provided above the flexible member  58  to provide room for the flexible member  58  to deflect. This feature may be useful in embodiments where without the relief  64  the installation environment could constrain flexible member  58  and prevent proper deflection. 
         [0033]    In an embodiment, the jack  32  includes the following characteristics: 
         [0000]                                    TABLE 1                       Height   Radius of               Length of flexible   of angled   intermediate   Force (lb.)       Example   member 58   surfaces 63   sections   for release                   1   0.3 in    0.03 in   0.01 in    8-13       2   0.45 in    0.035 in   0.01 in   2-4       3   0.3 in   0.035 in   0.01 in   5-9                    
where the length of the flexible member  58  is measured from the tip thereof near the front of the jack housing  38  to its rear  76 ; the height of angled surfaces  63  is measured vertically relative to the length of the jack  32 ; the radius of intermediate sections is the measure of the radius of a curved intermediate sections positioned between the vertical sections  61  and the angled surfaces  63 , and the force for release is a measure of force needed to release a standard RJ45 plug from the jack with the corresponding characteristics. All measurements in Table 1 can be varied by +/−5%; alternatively, measurements in Table 1 can be varied by +/−10% or +/−20%, for examples.
 
         [0034]    An alternate embodiment of a breakaway RJ45 cable assembly according to the present invention is shown in  FIG. 10  where the assembly  66  includes a jack to jack configuration where both ends utilize breakaway housing  38 . In yet another embodiment, the breakaway housing  38  is used inside a piece of passive and/or active equipment akin to jack  24  shown in  FIGS. 1 and 2 . 
         [0035]    Note that while this invention has been described in terms of several embodiments, these embodiments are non-limiting (regardless of whether they have been labeled as exemplary or not), and there are alterations, permutations, and equivalents, which fall within the scope of this invention. Additionally, the described embodiments should not be interpreted as mutually exclusive, and should instead be understood as potentially combinable if such combinations are permissive. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that claims that may follow be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.