Abstract:
Embodiments of the present invention generally relate to the field of telecommunication, and more specifically to the connectivity components implemented therein. In an embodiment, the present invention is an RJ45-compatible network jack which includes a front sled PCB assembly incorporating short PICs, a compensation printed circuit board, and a spring loaded movement designed to provide a portion of the total displacement necessary to accommodate plug travel of a mated plug. The PICs are capable of displacement which is designed to be adequate to provide reliable contact while mating with a plug.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 62/065,245, filed on Oct. 17, 2014, which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF INVENTION 
       [0002]    Embodiments of the present invention generally relate to the field of telecommunication infrastructure and more specifically to communication connectors such as RJ45 jacks. 
       BACKGROUND 
       [0003]    RJ45 connectors have come to be extensively used within the realm of network communication. RJ45 plugs typically have eight plug contacts arranged in a row and configured to interface eight plug interface contacts (PICs) provided in an RJ45 jack. The closely spaced parallel conductors which allow the jack and the plug to interface to each other produce a known amount of crosstalk (set by an ANSI/TIA (American National Standards Institute/Telecommunications Industry Association) standard) between any two wire-pairs. To maintain the integrity of the signal through the plug/jack connector combination, this offending crosstalk may be canceled or reduced by a compensating signal within the jack. 
         [0004]    The crosstalk compensation can generally be simplified by shortening the distance from the plug/jack contact point on the PICs (approximate location of the source of crosstalk in a mated plug and jack combination) to the crosstalk compensation network employed within the jack. Shortening of this distance simplifies the jack crosstalk compensation by reducing the phase delay between the plug/jack contact point and the crosstalk compensation network. For a fixed physical distance between the plug/jack contact point and the jack crosstalk compensation network phase delay is a function of frequency (increasing with frequency) and an RJ45 jack typically needs to be tuned for a range of frequencies (1 to 500 MHz for CAT6A, for example). Consequently, reduction of the above mentioned phase delay tends to increase the bandwidth of the jack. 
         [0005]    While the theoretical desire to shorten the crosstalk-to-compensation distance is known, real-world implementations of jacks employing such design features are hampered by constraints such as, for example, manufacturing costs and form factor requirements. Furthermore, jacks are required to be compatible with mating plug contacts at the limits of size and position tolerances allowed by governing standard bodies. For instance, to allow for proper plug latching, a jack housing latch stop face is designed to have plug over-travel. However, such design requirements can have an undesired effect on the crosstalk-to-compensation distance. 
         [0006]    Therefore, there continues to be a need for improved communication jack designs which reduce and/or maintain the electrical distance from the crosstalk to the initial stage of compensation. 
       SUMMARY 
       [0007]    Accordingly, at least some embodiments of the present invention are directed towards jack designs which reduce and/or maintain the electrical distance from the crosstalk to the initial stage of compensation. 
         [0008]    In an embodiment, the present invention is an RJ45 network jack which includes a front sled PCB assembly incorporating short PICs, a compensation printed circuit board, and a spring loaded movement designed to provide a portion of the total displacement necessary to accommodate plug travel of a mated plug. The PICs are capable of displacement which is designed to be adequate to provide reliable contact while mating with a plug. The PICs feature individual supports that control the PIC bend radius and limit the PIC displacement. After the PICs bottom out on the supports, added plug travel results in the sled PCB assembly displacement against the spring load which provides added normal force to assure a reliable interface with a mated plug. The spring load further acts to return the sled assembly to its original (resting) position in an unmated state. 
         [0009]    In another embodiment, the present invention is a communication connector for connection with a communication plug. The communication connector includes a housing including a plug receiving aperture, and a sled assembly at least partially received within the plug receiving aperture, the sled assembly including a sled and a crosstalk compensation apparatus connected to the sled, the sled assembly further including a plurality of plug interface contacts connected to the crosstalk compensation apparatus, the sled assembly at least partially movable within the housing when the communication plug is inserted in the housing. Such a communication plug may be a part of a larger communication system which includes communication equipment. 
         [0010]    In yet another embodiment, the present invention is a method of making contact between and a communication plug, having a plurality of plug contacts, and a communication jack, having a plurality of plug interface contacts. The method includes the steps of inserting the communication plug into the communication jack, impinging the plug contacts on respective the plug interface contacts, and moving the plug interface contacts to maintain an approximately predetermined distance between a point of contact of the plug contacts and the plug interface contacts, and a first compensation stage. 
         [0011]    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 DRAWINGS 
         [0012]      FIG. 1  illustrates a perspective view of a communication system according to an embodiment of the present invention. 
           [0013]      FIG. 2  illustrates a plug/jack combination according to an embodiment of the present invention. 
           [0014]      FIG. 3  illustrates an exploded view of a communication jack according to an embodiment of the present invention. 
           [0015]      FIG. 4  illustrates the front sled assembly of the jack of  FIG. 3 . 
           [0016]      FIG. 5  illustrates an exploded view of the front sled assembly of  FIG. 4 . 
           [0017]      FIG. 6  illustrates a rear perspective view of the front housing of the jack of  FIG. 3 . 
           [0018]      FIG. 7  illustrates a front view of the jack of  FIG. 3 . 
           [0019]      FIG. 8  illustrates a cross-sectional view of the jack of  FIG. 3  in an unmated state, taken along section line  8 - 8  in  FIG. 7 . 
           [0020]      FIG. 9  illustrates a fragmentary perspective view of the jack of  FIG. 3  together with a plug in an unmated state. 
           [0021]      FIG. 10A  illustrates a cross-sectional view of the jack of  FIG. 3  together with a plug in a partially mated state. 
           [0022]      FIG. 10B  illustrates a perspective view of the jack of  FIG. 3  together with a plug in a partially mated state. 
           [0023]      FIG. 11A  illustrates a cross-sectional view of the jack of  FIG. 3  together with a plug in a mated state. 
           [0024]      FIG. 11B  illustrates a perspective view of the jack of  FIG. 3  together with a plug in a mated state. 
           [0025]      FIG. 12  illustrates a jack according to an embodiment of the present invention. 
           [0026]      FIGS. 13A and 13B  illustrate a jack according to an embodiment of the present invention. 
           [0027]      FIG. 14  illustrates a jack according to an embodiment of the present invention. 
           [0028]      FIG. 15  illustrates an embodiment of a front sled assembly for use in a jack according to an embodiment of the present invention. 
           [0029]      FIG. 16  is a perspective view of another plug/jack combination according to an embodiment of the present invention. 
           [0030]      FIG. 17  is an exploded perspective view of the jack of  FIG. 16 . 
           [0031]      FIG. 18  is an exploded perspective view of the sled assembly of the jack of  FIG. 16 . 
           [0032]      FIG. 19  is a cross-sectional view of the plug/jack combination of  FIG. 16 , taken along section line  19 - 19  in  FIG. 16 , with a detailed view. 
           [0033]      FIG. 20  is a front view of the jack of  FIG. 16 . 
           [0034]      FIG. 21  is a fragmentary perspective view of the plug/jack combination of  FIG. 16 , partially sectioned about a plane defined by section line  21 - 21  as shown in  FIG. 20 . 
           [0035]      FIG. 22  is an exploded perspective view of another embodiment of a sled assembly according to the present invention with a rigid/flex combined PCB, similar to that used and shown in  FIG. 17 , but with an alternate routing of the flexible PCB around the sled assembly. 
           [0036]      FIG. 23  is an exploded perspective view of another jack according to the present invention. 
           [0037]      FIG. 24  is an exploded perspective view of the sled assembly of the jack of  FIG. 23 . 
           [0038]      FIG. 25  is a cross-sectional view of a plug/jack combination using the jack of  FIG. 23 , with a detailed view. 
           [0039]      FIG. 26  is a perspective view of another embodiment of a sled assembly according to the present invention. 
           [0040]      FIG. 27  is an exploded perspective view of the sled assembly of  FIG. 26 . 
           [0041]      FIG. 28  is a perspective view of another plug/jack combination according to an embodiment of the present invention. 
           [0042]      FIG. 29  is an exploded perspective view of the jack of  FIG. 28 . 
           [0043]      FIG. 30  is an exploded perspective view of the sled assembly of the jack of  FIG. 28 . 
           [0044]      FIG. 31  is a cross-sectional view of the plug/jack combination of  FIG. 28 , taken along section line  31 - 31  in  FIG. 28 . 
           [0045]      FIG. 32  is a front view of the jack of  FIG. 28 . 
           [0046]      FIG. 33  is a fragmentary perspective view of the plug/jack combination of  FIG. 28 , partially sectioned about a plane defined by section line  33 - 33  as shown in  FIG. 32 . 
       
    
    
     DETAILED DESCRIPTION 
       [0047]    An exemplary embodiment of the present invention is illustrated in  FIG. 1 , which shows a communication system  30 , which includes a patch panel  32  with jacks  34  and corresponding RJ45 plugs  36 . Respective cables  38  are terminated to plugs  36 , and respective cables  40  are terminated to jacks  34 . Once a plug  36  mates with a jack  34  data can flow in both directions through these connectors. Although the communication system  30  is illustrated in  FIG. 1  as having a patch panel, alternative embodiments can include other active or passive equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, 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 and or 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  30  can further include cabinets, racks, cable management and overhead routing systems, and other such equipment. 
         [0048]    The jack and plug combination of  FIG. 1  is also shown in  FIG. 2  which illustrates the network jack  34  mated with the RJ45 plug  36 . Note that in this figure, the orientation of the network jack  34  and the RJ45 plug  36  is rotated 180° about the central axis of cable  40  as compared to the orientation of  FIG. 1 . 
         [0049]      FIG. 3  illustrates an exploded view of the network jack  34 , which includes a front housing  42 , a front sled assembly  44 , a vertical printed circuit board (PCB)  46  (which in some embodiments may have crosstalk compensation components thereon), resilient member or springs  48 , insulation displacement contacts (IDCs)  50 , a rear housing  52 , and a wire cap  54 . In some embodiments, the jack  34  can additionally include alien crosstalk-reducing materials such as a foil. Additionally, while the springs  48  are shown as compression helical wound springs, other embodiments of resilient member  48  can be implemented as stamped or spiral springs, or they can be configured to be extension springs, torsion springs, or other resilient members. 
         [0050]      FIGS. 4 and 5  illustrate the front sled assembly  44  with a sled  58 , PICs  56 , intermediate contacts  60 , PCB  62 , and PIC supports  64  in greater detail. The subscript numbers of each PIC  56  and each PIC support  64  correspond to the RJ45 pin positions as defined by ANSI/TIA-568-C.2. 
         [0051]    The sled  58  can be made from any suitable material including plastic. It includes two spring pockets  66  which comprise elongated cavities positioned along the bottom of each side of the sled with openings towards the rear of the jack  34 . The pockets  66  can be of any shape and with the exception of the rear openings may be partially or fully enclosed so long as they can securely house springs  48  such that the springs  48  will not dislodge from their intended position in their default and/or compressed positions. The sled  58  further includes a receiving area for a first PCB  62  which in some embodiments may have crosstalk compensation circuitry and/or other signal conditioning circuitry thereon. 
         [0052]    The PCB  62  includes eight vias for receiving PICs  56   1 - 56   8 , and another eight vias for receiving intermediate contacts  60  which electrically connect the first PCB  62  to the vertical PCB  46 . Compared to conventional PICs, PICs  56  have a relatively short length. In an embodiment, the length of PICs can be between 0.060 inches and 0.125 inches. PICs  56  can have a layered construction, such as, for example, those disclosed in U.S. Patent Publication No. 2014/0148057 to Patel et al., which is incorporated herein by reference in its entirety. 
         [0053]    In an embodiment, the front sled assembly  44  is fabricated by first inserting the PCB  62  into the sled  58 . The PCB  62  and the sled  58  are held together by staking sled&#39;s rectangular post features  68  after fitting them through the PCB holes  70 . Formed PICs  56  and the intermediate contacts  60  can then be assembled to PCB  62  such that the PICs  56   1 - 56   8  are positioned in front of the respective PIC supports  64   1 - 64   8 . Referring to  FIG. 6 , once assembled, the front sled assembly  44  is mounted within the front housing&#39;s guide rails  88 . The guide rails  88  support the assembly  44  and constrain its movement in at least some directions while allowing some degree of forward and backward movement. 
         [0054]    A cross-sectional view of an assembled jack  34  taken along the section line  8 - 8  in  FIG. 7  is visible in  FIG. 8 . This view illustrates the default position of the jack&#39;s internal components when the jack is in an unmated state. In this state, the springs  48  push the front sled assembly  44  into a forward-biased default position closer to the front of the jack&#39;s opening. At this stage, the PICs  56  are also in their default non-deflected position. 
         [0055]      FIGS. 9-11B  illustrate the interaction of the jack  34  with the plug  36  as the connector set goes from an unmated state to a fully latched state. In  FIG. 9 , the plug/jack assembly  90  is shown with plug  36  at the early stage of insertion into jack  34 . At this point, the plug contacts  72  have not yet engaged PICs  56  and the plug latch stop  74  is some distance away from the jack housing&#39;s  42  latch stop  76 . Additionally, at this stage the front sled assembly  44  is pushed fully into its forward position closer to the front of the housing  42  by the springs  48 . As the plug  36  is pushed further into the jack  36 , the plug contacts  72  of the plug  36  begin to come into contact with the PICs  56 . This can be seen in  FIGS. 10A and 10B  where the forward force of the contacts  72  begins to deform and deflect the PICs  56 . To keep the deformation of the PICs  56  within an elastic range and prevent plastic deformation, respective PIC supports  64  are positioned behind each of the PICs  56 . The PIC supports  64  provide bend radius and deformation control as the PICs  56  deform, preventing any one of the PICs  56  from deflecting past a certain point. PICs  56  deformation over PIC support  64  is preferably designed to provide adequate wiping and contact for plug contacts  72  at the limits of position and size tolerance as allowed by the governing standards. In addition to the PIC supports  64 , to maintain the PICs&#39;  56  deformations in an elastic range while having adequate normal force, PICs  56  can have a layered construction as noted previously. After the PICs  56  bottom out against the PIC supports  64 , the forward force of the plug being inserted into the jack transfers to the front sled assembly  44  which in turn starts to compress springs  48  and slide rearward within the jack along the guide rails  88 . This can be seen in the illustration of  FIGS. 11A and 11B . The compression of the springs  48  provides additional normal force at the interface between the PICs  56  and the plug contacts  72 . 
         [0056]    To accommodate the rear movement of the front sled assembly  44  and the static position of the vertical PCB, the intermediate contacts  60  are designed to non-plastically deform/compress as the front sled assembly  44  is pushed back during the plug/jack mating process. In the currently described embodiment, this deformation/compression of contacts  60  is allowed for by the implementation of the “S” curved section which allow the deformation of the contacts  60  to remain in an elastic range. 
         [0057]    An alternate embodiment of the present invention is shown in  FIG. 12 , and includes a jack  92  with a flexible PCB  78 , a sled  80 , and a support  82 . The sled  80  is designed to provide a rigid support for flexible PCB encapsulation to facilitate the mounting of PICs  56 . Plastic support  82  also encapsulates the flexible PCB to provide rigid support for IDCs  50  mounting and support during wire cap  54  termination. In another embodiment, the flexible PCB  78  may replace the intermediate contacts  60  of the previous embodiment, whereby the first PCB  62  and the vertical PCB  46  would still remain. Implementing the flex PCB  78  may allow for a compensation network to be positioned closer to the source of the crosstalk. 
         [0058]    Yet another alternate embodiment of the present invention is shown in  FIGS. 13A and 13B , where intermediate contacts  60  are replaced with intermediate contacts  84 . The intermediate contacts  84  are mounted to the vertical PCB  100  at one end and at another end feature wiping arms  101  which wipe against contact pads positioned on the bottom of the PCB  98 . As the front sled assembly along with the PCB  98  travel into their rearward position upon mating with a corresponding plug, contact pads positioned on the bottom of the PCB  98  slide into position or keep contact with the wiping arms  101 , allowing data to flow between the PICs and the vertical PCB  100 . 
         [0059]    Yet another alternate embodiment of the present invention is shown in  FIG. 14  where the vertical PCB of the embodiment shown in  FIGS. 13A and 13B  is replaced by lead-frame style contacts, whereby the lead-frame style contacts span from the wiping arms  101  to the IDCs. 
         [0060]      FIG. 15  illustrates yet another alternate embodiment according to the present invention where the front sled assembly  103  has shielding partitions  105  to selectively isolate contacts  60 . Shielding partitions  105  can be made of conductive or semi-conductive material and can be floating or grounded. The shielding partitions  105  can also be connected to the PCB or they can be part of jack housing, or otherwise. In addition, the shielding partitions can be formed in any desired shape and/or size to accommodate the front sled assembly  103  and associated jack housing geometries. 
         [0061]    Referring now to  FIGS. 16-21 , in another embodiment according to the present invention, network jack  120  includes front housing  42 , front sled assembly  122 , IDCs  50 , rear housing  52 , and wire cap  54 . IDCs  50 , rear housing  52 , and wire cap  54  of network jack  120  are the same as, or similar to the components of the previous embodiment. Jack  120  can additionally include alien crosstalk reducing foil as described in U.S. Pat. No. 8,167,661, incorporated by reference as if fully set forth herein.  FIG. 18  shows an exploded view of the front sled assembly  122  with PIC  124 , spring  138 , spring connecting bar  130 , springs  48 , combined rigid and flex PCB (RFPCB)  128 , RFPCB pad  136 , sled  126 , PIC support  134 , and spring support  132 . The subscript numbers of each PIC  124 , PIC support  134 , spring  138 , and RFPCB pad  136  represent RJ45 pin positions as defined by ANSI/TIA-568-C.2. Front sled assembly  122  is fabricated by first inserting springs  138  into the sled  126  pockets, then spring support  132 , RFPCB  128 , PICs  124 , and springs  48  are assembled. PICs  124  are assembled to sled by heat staking, sonic welding, mechanical staking, or similar processes. Spring support  132  is attached to sled  126  by staking or other processes. 
         [0062]      FIG. 19  is a cross-sectional view of a mated plug  36  and jack  120  taken about section line “ 19 - 19 ” in  FIG. 16 , and illustrates plug  36  contact  140  and jack  120  PIC  124  in a mated position. RFPCB  128  is pinched between PIC  124  and PIC support  134 . Spring  138  provides added force to maintain RFPCB pad  136  against PIC  124 .  FIG. 21  is a fragmentary isometric view of the mated plug  36  and jack  120  along section line  21 - 21  in  FIG. 20 . 
         [0063]    In an alternate embodiment of the present invention, an alternate sled assembly  240  (shown in  FIG. 22 ) with a rigid flex PCB  142 , routed over PIC support  134  from back to front, can be substituted in place of the sled assembly  122  in jack  120 . 
         [0064]    In another embodiment according to the present invention (shown in  FIGS. 23-25 ) jack  150  includes sled assembly  152  with sled  154 , PICs  156 , first rigid PCB  158 , second rigid PCB  168 , PCB contacts  166 , PIC support contacts  178 , and RFPCB  200 . PICs  156  are mechanically attached to sled  154  by staking, insert molding, or similar processes. PIC supports  178  are conductive and the ends  174  of the PIC supports  178  are assembled to first rigid PCB  158  in holes  162 . PIC support ends  180  are assembled to the second PCB  168  in holes  170 . First PCB  158  is connected to second PCB  168  thru PCB contacts  166  via holes  164  and  172 . RFPCB  200  is connected to first rigid PCB  158  at holes  160  and fingers  202 . PICs  156  are supported by PIC supports  178 . When mated with the plug, PIC  156  deformation follows PIC support  178  radius. In an embodiment, PIC supports  178  are connected to first PCB  158  and second PCB  168  where one end of each PIC support is connected to a signal trace and the other end is connected to a compensation network (not shown). If the signal trace is on the second PCB  168 , a PCB contact  166  can allow it to connect to RFPCB  200  thru first PCB  158 . 
         [0065]      FIG. 25  shows mated plug  36  and jack  150  (with sled assembly  152 ) cross-section view, taken about a plane similar to section line  19 - 19  in  FIG. 16 , and illustrates mated plug contact  140 , PIC  156 , PIC support  178 . PIC support end  174  is connected to first PCB  158  and end  180  connected to second PCB  168 . First PCB  158  is connected to second PCB  168  thru PCB contact  166 . 
         [0066]      FIGS. 26 and 27  illustrate another alternate embodiment with sled assembly  210 , according to the present invention, which can be substituted in place of previously described sled assemblies in respective jacks. In this embodiment, two separate PCBs  158 ,  168  of sled assembly  152  can be combined (or the functionality thereof) into one PCB  220 . PICs  212  and PIC support  214  ends  218  are assembled to PCB  220  via holes  224 . PIC supports&#39; other ends  216  are connected to PCB  220  via holes  222 . PCB  220  is mechanically attached to sled  230  thru PCB holes  228  and sled posts  232 . RFPCB  200  is connected to PCB  220  via holes  226  and RFPCB finger  202   s.  In an embodiment, one end of the PIC supports  214  is connected to compensation circuitry (not shown) and the other end is connected to respective signal traces. 
         [0067]    In another embodiment according to the present invention (shown in  FIGS. 28-33 ) modular jack  260  includes housing  262 , sled assembly  264 , sled holder  268 , and wire cap  266 . Sled assembly  264  includes sled  270 , PICs  282 , PICs  274 , PCB  272 , PIC support contacts  276 , IDC holder  278 , and IDCs  280 . PICs  282  are attached to PCB  272  at holes  284  from bottom of the PCB and are wrapped around sled  270  from front at positions  1 ,  2 ,  7  and  8 . PICs  274  are attached to PCB at holes  284  from top at positions  3 ,  4 ,  5  and  6 . PIC supports  276  are assembled to PCB at holes  286  and support PICs  274 . PIC supports  276  enable a short path to signal and compensation circuitry (not shown) that can be positioned on PCB  272 . IDCs  280  are mechanically attached to IDC support  278  that is made of insulating material. IDC ends  290  are attached to PCB  272  at holes  288 . Springs  48  fit within sled pockets and return sled  270 , PICs  282 , PICs  274 , and PCB  272  assembly to front of the housing  262  in an unmated state. IDC  280  loop features provide added spring force while allowing sled  270  along with PCB  272  to travel with the plug. IDCs  280  are connected to PICs  282  and  274  via traces on PCB  272  (not shown). Longer PICs  282  allow jack  260  to mate with  6  position plugs without sustaining damage at PIC positions  1 ,  2 ,  7 , and  8 . 
         [0068]    Springs  48  and  138  are shown as compression helical wound springs or stamped but they can be any configuration such as stamped, spiral or configured to be an compression, extension springs or torsion springs. 
         [0069]    Other embodiments can have other combinations of previously described elements; for example, IDCs  86  can be combined with sled assembly  152  (minus RFPCB  200 ) where IDCs  86  then have wiping contact with PCB  158 . 
         [0070]    The aforementioned embodiments and their equivalents may help reduce the electrical distance between the source of crosstalk within the plug and at the plug/jack mating point, and any compensation network that may be employed within a communication jack. Furthermore, there may be an additional benefit of maintaining an approximately static crosstalk-to-compensation distance regardless of allowable post-latching plug over-travel. 
         [0071]    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.