Patent Publication Number: US-7905744-B1

Title: Cartridge lock registered jack and method of use thereof

Description:
BACKGROUND OF INVENTION 
     1. Technical Field 
     The present invention relates generally to electrical connectors. In particular the invention relates to a cartridge lock registered jack connector and method of use thereof. 
     2. Related Art 
     Registered jacks are widely used in telecommunication systems for facilitating connection of electrical communication components. Ease of installation and consistent termination of internal insulated wires of a communications cable are two important features of a registered jack. Ordinary jacks are designed to orient untwisted wires of a cable for termination with corresponding wire contact terminals according to common communication standards. Standard jack designs involve termination of the untwisted wires with contacts at a terminal location spaced away from where the wires are still bundled and twisted. Wire termination in ordinary jacks is often tedious because each wire must be individually aligned and positioned for termination. Moreover wire termination in common jacks can be faulty because the wires are not precisely located for termination with the jack during cable installation and because wires are often loosely oriented during installation instead of being firmly positioned into a proper termination location. In addition, movement of a cable, once installed, can cause strain that may dislodge the wires from proper termination with ordinary jack terminal contacts. Some known jacks also require use of special tools in order to consistently terminate the wires during installation of the cable to the jack. Accordingly a need exists for an improved registered jack and related method of use. 
     SUMMARY OF THE INVENTION 
     A first aspect of the present invention provides a cartridge lock registered jack comprising: a housing, having a plug socket opening and a cartridge cavity; at least one conductive terminal, located within the housing, the conductive terminal having a first contact portion and a second contact portion, wherein the second contact portion extends into the socket; and a cartridge member, having two opposing box-wing portions flexibly attached to a gate portion including at least one vertical opening through which the first contact portion is extendable, wherein the cartridge member includes a retaining bar spaced apart from the at least one vertical opening and around which an insulated wire is positionable, wherein the cartridge member moves with respect to the housing between a first unlocked position and a second locked position, wherein when the cartridge member is in the second locked position the retaining bar acts upon an insulated wire positioned partially around the retaining bar and terminates the wire into electrical connection with the first contact portion of a corresponding at least one conductive terminal. 
     A second aspect of the present invention provides a registered jack comprising: a housing portion; a plug socket, extending into the housing portion; a cartridge cavity, extending into the housing portion; a plurality of insulation displacement contacts located within the housing portion; and a cartridge sized for insertion into the cartridge cavity in a direction substantially parallel to the direction of extension of the socket into the housing portion, the cartridge including a plurality of openings corresponding in size to the plurality of insulation displacement contacts, so that the plurality of insulation displacement contacts are each extendable through the plurality of openings when the cartridge resides in a locked position; and wherein the cartridge includes a retaining bar having a plurality of grooves for receiving a plurality of insulated wires wrapped around the retaining bar prior to and during insertion of the cartridge into the cartridge cavity, so that the plurality of insulated wires are electrically contacted by the plurality of insulation displacement contacts extending through the plurality of openings. 
     A third aspect of the present invention provides a method for assembling a cartridge lock registered jack, the method comprising: providing a housing, having a plug socket and a cartridge cavity; providing at least one conductive terminal within the housing, the conductive terminal having a first contact portion and a second contact portion; providing a cartridge member having a retaining bar spaced apart from a gate portion having a plurality of openings, the cartridge member being movable with respect to the housing; feeding at least one insulated wire through the space between the openings of the gate portion and the retaining bar; pulling tight at least one insulated wire and bending it about the retaining bar; and moving the cartridge member into the cartridge cavity until the tightened at least one insulated wire bent around the retaining bar is terminated and held in electrical contact with the first contact portion of a corresponding at least one conductive terminal. 
     A fourth aspect of the present invention provides an cartridge lock registered jack comprising: a housing, having a plug socket; at least one conductive terminal within the housing, the conductive terminal having a first contact portion and a second contact portion; a cavity extending into the housing, the cavity including pockets and guide tracks; and movable means for terminating and securing the received at least one insulated wire in electrical connection with the first contact portion, wherein the means include at least a retaining bar over which the at least one insulated wire may be bent. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows an exploded perspective view of an embodiment of a cartridge lock registered jack connector, in accordance with the present invention; 
         FIG. 2  shows a side perspective view of an embodiment of a cartridge lock registered jack connector with the cartridge in an unlocked position, in accordance with the present invention; 
         FIG. 3  shows side view of an embodiment of a cartridge lock registered jack connector with the cartridge in an unlocked position, in accordance with the present invention; 
         FIG. 4  shows a side view of an embodiment of a cartridge lock registered jack connector with the cartridge in a locked position, in accordance with the present invention; 
         FIG. 5  shows a side view of an embodiment of a cartridge lock registered jack connector with the cartridge in a locked position, with internal components shown in ghosted lines, in accordance with the present invention; 
         FIG. 6  shows a side view of an embodiment of a conductive terminal, in accordance with the present invention; 
         FIG. 7  shows a side view of an embodiment of a cartridge lock registered jack, wherein a cable is initially engaging the cartridge in an unlocked position, in accordance with the present invention; 
         FIG. 8  shows a side perspective view of an embodiment of a cartridge lock registered jack, wherein a cable is initially engaging the cartridge in an unlocked position, in accordance with the present invention; 
         FIG. 9  shows a side view of an embodiment of a cartridge lock registered jack, wherein a cable is fully engaging the cartridge in an unlocked position, in accordance with the present invention; 
         FIG. 10  shows a side view of an embodiment of a cartridge lock registered jack, wherein a cable is fully engaging the cartridge in a locked position, in accordance with the present invention; 
         FIG. 11  shows a perspective view of an embodiment of a cartridge lock registered jack, wherein a cable is fully engaging the cartridge in a locked position, in accordance with the present invention; and 
         FIG. 12  shows a side view of an embodiment of a cartridge lock registered jack, wherein a cable is fully engaging the cartridge in a locked position, and wherein the jack has received a corresponding connector plug, in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Although certain embodiments of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of an embodiment. The features and advantages of the present invention are illustrated in detail in the accompanying drawings, wherein like reference numerals refer to like elements throughout the drawings. 
     As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents, unless the context clearly dictates otherwise. 
     With reference to the drawings,  FIG. 1  depicts an exploded perspective view of an embodiment of a cartridge lock registered jack connector  100 . The cartridge lock registered jack connector  100  is shown, having a housing portion  105 . Housing portion  105  may comprise two separate pieces, for example a first housing portion  125  and a second housing portion  130 , attachably connected to form main body  105 . Embodiments of a cartridge lock registered jack connector  100  may be configured according to typical registered jack communication standards. As such, the first housing portion  125  may include a plug socket  110  sized to accept a standard registered jack plug (shown in  FIG. 12 ). The second housing portion  130  may include a mating element  165 , such as protruding member or other physically engaging feature, in order to aid in the assembly of the overall housing portion  105 . Mating element  165  may be designed to be inserted into a corresponding hollow of the first housing portion  125 . The various component elements of the housing portion  105  may be formed of plastic material, or any other material that would help insulate electrical wiring from the outside environment, such as rubber or any other polymer. Moreover, various features of the overall housing portion  105  may be formed of different materials. For example the first body portion  125  may be formed of a clear plastic material, while the second body portion  130  may be formed of a different translucent plastic material. As further shown in  FIG. 1 , embodiments of a cartridge lock registered jack connector  100  include a cartridge  180 , at least one conductive terminal  170  having an insulation displacement contact (IDC) member  121 , and a conductive terminal housing  170 . 
     Referring still to  FIG. 1  and with additional reference to  FIG. 2 , housing portion  105  may further comprise a resilient latch tab  135 . The resilient latch tab  135  may cooperate with fixed latch member  115  to releasably retain the cartridge lock registered jack connector  100  in assembly with an associated apertured wall plate (not shown). The resilient latch tab  135  and the fixed latch member  115  may be located on opposing faces of the overall housing body portion  105 . It should be understood by one of ordinary skill that latching combination  135 ,  115  is not limited to that as shown in  FIGS. 1-12 , but may also be a fastener, a catch, a clasp, a clench, a grip, a hold, a lock, a press, a snap and a vice, as screw, a bolt, or any other fastening structure, so long as cartridge lock registered jack connector  100  is releasably retained in operable assembly with an associated wall plate or other mounting device. A flange member(s)  195  extending from the housing portion  105  may also serve to assist in operably attaching the cartridge lock registered jack connector  100  to a mounting device. 
     As mentioned, embodiments of a cartridge lock registered jack connector  100  include a plug socket  110  opening up into the housing  105 . The socket  110  may be located on a face of main body  105 , and may be configured to accept a cable plug, including, but not limited to any type of registered jack (RJ) connector. For example, socket  110  may be configured to accept the plug connector of a shielded twisted pair (STP) cable, an unshielded twisted pair (UTP) cable, a screened shielded twisted pair (S/STP) cable, a fully shielded twisted pair (FTP) cable, or any variant thereof. Embodiments of a cartridge lock registered jack connector  100  may therefore be any form of registered jack. 
     Turning further to  FIG. 2 , greater detail is depicted with respect to various connector  100  components including the cartridge  180  member. As shown, the cartridge  180  may be a plug-like body configured to receive and capture a cable  10 , when the cartridge  180  is inserted into a corresponding cartridge cavity  160  of the housing portion  105 . The cartridge cavity extends into the housing  105  opposite the plug socket  110 . The cartridge member may include two opposing box-wing members  182   a  and  182   b , wherein the box-wing members  182   a - b  may be flexibly attached to a gate portion  181 . The gate portion may include a plurality of vertical slits or openings  186 , the number of which may correspond to the number of conductive terminals operably associated with the cartridge lock registered jack connector  100  embodiment. Spaced apart from the gate portion  181  is a retaining bar  188 , wherein the retaining bar  188  spans a distance between the box-wing members  182   a  and  182   b . The retaining bar  188  may included a plurality of grooves  187  or depressions, wherein the grooves may be sized to receive a wire from a twisted wire pair of a communication cable  10  ultimately connected to the cartridge lock registered jack connector  100 . On an inner portion of one or both of the box-wing members  182   a - b  may be at least one gripping rib  183 . The gripping rib(s)  183  may serve to compress against a received cable  10  to help prevent movement of the cable  10  once the cartridge  180  has been inserted to a locked position  118  (see  FIGS. 4-5 ) within the housing portion  105 . When in an unlocked position  108 , the cartridge  180  may be completely structurally free from the housing portion  105 . However, other embodiments may be employed wherein the cartridge  180  remains slightly attached to the body during cable  10  installation. To help guide the cartridge  180  during insertion into the body, guide rails  184   a  and  184   b  may be located on the outer faces of opposing box-wing members  182   a  and  182   b . The guide rails  184   a - b , may correspond in size and shape to guide tracks  194   a  and  194   b  formed on opposing surfaces of the cavity  160 . As such, the guide rails  184   a - b  may be slightly smaller than the guide tracks  194   a - b  of the cavity  160  of the housing portion  105 . Yet it should be appreciated that the tolerance between the parts may facilitate ready insertion, but prevent active wiggling once inserted. The front edges of the guide rails  184   a - b  may be ramped or tapered so as to facilitate ready insertion into the guide tracks  194   a - b  of the cavity  160  of housing portion  105  of an embodiment of a cartridge lock registered jack connector  100 . 
     With further reference to  FIGS. 1-2  and additional reference to  FIGS. 3-4 , the unlocked  108  and locked  118  positions of the cartridge  180  are explained in greater detail. When in an unlocked position  108 , the cartridge  180  may be freely moveable and locatable with respect to the housing portion  105 . However, as described above, an unlocked position  108  may also correspond to a position of the cartridge  180  with the housing portion  105 , such that the cartridge member  180  may be connected to the housing portion  105 , but still be movable with respect to the housing portion  105 . When in a locked position  118 , the cartridge  180  becomes secured to and substantially immovable with respect to the housing portion  105 . The physical securing of the  180  within the housing portion  105  may be facilitated by locking tabs  185   a  and  185   b  that protrude from the guide rails  184   a  and  184   b  near the rear of the box-wing members  182   a  and  182   b . The shape of the protruding tabs  185   a - b  may be ramped or tapered so as to allow the tabs  185   a - b  to click into side pockets  190   a  and  190   b  in the cavity  160 . The side pockets  190   a  and  190   b  may be holes extending through the guide tracks  194   a - b  and out the sides of housing portion  105 . Hence, when the cartridge member  180  is inserted into the cavity, such that the locking tabs  185   a - b  click into the side pockets  190   a - b , then the physical interference fit between the protruding locking tabs  185   a - b  and the pockets  190   a - b  into which the tabs  185   a - b  extended thereby renders the parts substantially immovable with respect to each other. This immovability of the parts correlates with a locked position  118 . If for some reason, it was necessary to remove the cartridge  180  from the locked position  118  within the housing portion  105  then the tabs  185   a - b  may be pushed out of interference with the pockets  190   a - b  by inserting a tool or other implement through the pocket openings on the outside of the housing portion  105  until the tabs are moved out of physical interference, thereby allowing retraction of the cartridge  180  from out of the housing portion  105 . 
     Referring further to the drawings,  FIGS. 5-6  depict a side view of an embodiment of a cartridge lock registered jack connector  100  with the cartridge  180  in a locked position, with internal components shown in ghosted lines, wherein one of those internal components, the conductive terminal  175 , is embodied as depicted in  FIG. 6 . As can be seen in  FIG. 5 , when the cartridge  180  is in a locked position  118 , the insulation displacement contact  121  members of the conductive terminals  175  extend through the vertical openings  186  of the gate portion  181  of the cartridge  180 . In this manner, when the wires from the twisted wire pairs are disposed in the space between the vertical openings  186  and the retainer bar  188 , then the insulation displacement contacts (IDCs)  121  can pierce the wires and make electrical contact therewith. The mating element  165  of the second housing portion  130  can be seen (in ghosted lines) located in a mated position with a corresponding opening of the first housing portion  125 . Moreover, it can also be seen that the second contact portions  150  of the conductive terminals  175  extend a distance into the plug socket opening  110  when the cartridge lock registered jack connector  100  is assembled. 
     As depicted in  FIG. 6 , embodiments of a cartridge lock registered jack connector  100  include at least one conductive terminal  175 . The conductive terminal  175  may be housed within the housing portion  105  of the cartridge lock registered jack connector  100 . A further conductive terminal housing  170  may also be provided to further house, orient, and protect the conductive terminals  175 . A conductive terminal  175  may include a first wire contact portion  120  having one or more wire contact points, such as insulation displacement contacts (IDCs)  121   a - c , and a second wire contact portion  150 . The may have sharpness sufficient to pierce or slice the insulation of the wires  60 - 67 , thereby terminating insulated wires  60 - 67 . There may be a plurality of IDCs  120  each corresponding to at least one insulated wire  60 - 67 . In operation, the first contact portion  120  and the second contact portion  150  may be located within conductive terminal housing  170 . However, the first contact portion  120  and the second contact portion  150  may also be operably located outside of conductive terminal housing  170 . Second contact portion  150  may be a conductive finger, configured to be electrically connected to a modular plug (shown in  FIG. 12 ), whereby the conductive finger  150  may be located within socket  110 , as described above. 
     With continued reference to  FIGS. 1-6  and additional reference to  FIGS. 7-10 , further description is herein provided with respect to the installation of a cable  10  with embodiments of a cartridge lock registered jack connector  100 . The cable  10  typically includes a plurality of twisted wire pairs. For example, the cable  10  may include 8 individual wires, such as wires  60 ,  61 ,  62 ,  63 ,  64 ,  65 ,  66 , and  67  depicted in  FIG. 8 . It is advantageous to terminate the connection and make electrical contact with the wires  60 - 67  as close to the twisted wire pair configuration as possible, because of the extra physical strength and electromagnetic performance associated with the wire pairs. When installing a cable  10 , a user may trim the cable  10  and untwist the wire pairs a distance sufficient to separate the wires  60 - 67 . The untwisted wires  60 - 67  may then be inserted through the space between the gate portion  181  and the retaining bar  188  of the cartridge  180 . The wires  60 - 67  may also be positioned and nestled into corresponding grooves  187  formed on the retaining bar  188  on the side facing the gate portion  181  of the cartridge  180 . When the insulated wires  60 - 67  extend through the opening between the retaining bar  188  and the gate portion  181 , the wires  60 - 67  may be pulled tight until the twisted pairs and the main body of the cable  10  abut the bottom surface of the cartridge  180 . This pulling tight may help ensure that the ultimate termination of the wires occurs at a location close to the wire pair configuration. Excess wire  60 - 67  may be cut if the wires  60 - 67  extend too far. As depicted in  FIGS. 7-8 , the cable  10  is in an initially engaging position  12  with respect to the cartridge  180 . Insulated wires  60 - 67  may be the internal twisted wires of a STP, UTP, S/STP, or FTP cable  10 , as described above. 
     Once the wires  60 - 67  are pulled tight, they can be bent down around the retaining bar  188 , while the remaining body of the cable  10  can be bent up to reside between the box-wing members  182   a - b  of the cartridge  180 . In this manner, the untwisted wires  60 - 67  may remain in a fairly taut and vertically straight alignment about the retaining bar  188 . The box-wing members  182   a - b  may have some flexibility to accommodate the body of the cable within. Once the cable  10  is received, the box-wing members  182   a - b  may be compressed upon the cable  10  body to begin to more fully secure the cable  10  into position with respect to the cartridge  180 . Hence, with the body of the cable  10  properly bent up into position and with the wires  60 - 67  properly bent down and around the retaining bar  188 , the cartridge  180  and cable  10  are in a fully engaging position  14  and are prepared for insertion and securing within the housing portion  105 . Insertion involves the cartridge  180 , with the fully engaged cable  10  being pushed, driven or otherwise located within the cavity  160 , until it is secure. The cartridge  180  is movable between a first unlocked position  108  and a second locked position  118  in a direction substantially parallel to the direction of extension of the socket  110  into the housing  105 . As described above, insertion may involve operable movable interaction between the guide rails  184   a - b  and the guide tracks  194 . Securing the cable  10  in a locked position  118  with respect to the housing portion  105  involves the employment of an interference fit between the locking tabs  185   a - b  of the cartridge  180  and the side pockets  190   a - b  of cavity  160 . While being inserted into the cavity  160 , the cartridge  180  may be compressed together, such that the cable is somewhat crimped by the gripping ribs  183  on the inner portions of the box-wing members  182   a  and  182   b . When compressed within the cartridge  180 , in this manner, the cable  10  is securely fastened to the registered jack connector  100  and has a heightened capacity to resist strain that, with regard to ordinary jack terminal contacts may dislodge the wires from proper termination. Insulated wires  60 - 67  may be held in electrical connection with conductive terminal  175  by the insertion of cartridge  180  into cavity  160 , so that the cartridge  180  is secured into a compressed locked position  118 , wherein the wires  60 - 67  are engaged by the contact points  121  of IDC&#39;s  120 . 
     Once an embodiment of a cartridge lock registered jack  100  has been installed with a cable, wherein the cable  10  is fully engaging the cartridge  180  in a locked position  118 , the jack  100  is in condition for use. For example, as depicted in  FIG. 11 , an embodiment of a cartridge lock registered jack  100  includes a plug socket  110  for connecting the terminals of the plug with the wires, such as wires  60 - 67 , so that electromagnetic communications may extend therethrough. Moreover, as depicted in  FIG. 12 , a registered jack plug  5 , having an installed cable  1 , may be operably connected to the cartridge lock registered jack  100 . Optimally, the jack  100  may help facilitate a signal exchange from cable  1  to cable  10 , wherein there is little to no signal loss through the cartridge lock registered jack  100 . 
     It will be apparent to those skilled in the art that the means for terminating and securing the received insulated wire  60 - 67  in electrical connection with the first contact portion may take various forms. For example, terminating means may include a separable cartridge  180 , operable with a housing body  105  to lock the wires  60 - 67  into electrical connection, as described hereinabove, or alternately, embodiments of the cartridge lock registered jack connector  100  may not include a separable cartridge  180 . Instead, terminating means may comprise the entire housing  105  sliding forward, with respect to an integral cartridge-like component, thereby compressing insulated wire  60 - 67  against insulation displacement contact  120  when the wires have been pulled tight around the retaining bar  188 . 
     Referring to  FIGS. 1-12 , a method for assembling a cartridge lock registered jack connector  100  comprises providing a housing containing a socket which is configured to receive a plug. The housing and socket may be similar to those described hereinabove as housing  105  and socket  110 , as shown in  FIGS. 1-12 . The plug  5  may be any standard plug operable with internal twisted wires of a STP, UTP, S/STP, or FTP cable, such as cable  10 . For instance, the plug may be a typical registered jack plug, such as an RJ-45 plug. Further methodology includes providing at least one conductive terminal within the housing, the conductive terminal having a first and second contact portion, the second contact portion configured for electrical connection to the plug  5 . The conductive terminal and first and second contact portions may be similar to those described hereinabove as conductive terminal  175 , first contact portion  120 , and second contact portion  150 , as shown in  FIGS. 1-12 . Additionally, the cartridge lock registered jack assembly method includes a step of providing a cartridge member  180  having a retaining bar  188  spaced apart from a gate portion  181  having a plurality of openings  186 , the cartridge member  180  being movable with respect to the housing  105 . Moreover the methodology includes feeding at least one insulated wire  60 - 67  through the space between the openings  186  of the gate portion  181  and the retaining bar  188  and also pulling tight at least one insulated wire  60 - 67  and bending it about the retaining bar. Still further the methodology includes moving the cartridge member  180  into the cartridge cavity  160  until the tightened at least one insulated wire  60 - 67  bent around the retaining bar  188  is terminated and held in electrical contact with the first contact portion  120  of a corresponding at least one conductive terminal  175 . 
     In addition to the methodology described above, the cartridge lock registered jack assembly method may further comprise a step of untwisting twisted insulated wires  60 - 67  before feeding the wires into the space of the cartridge member  180  between the gate portion  181 . This step may include orienting the twisted pairs into proper position so that they may be fed into corresponding grooves  187  of the retaining bar  188 . The proper position of the wires may correspond to the type of cartridge lock registered jack connector being assembled. For instance, assembly of a registered jack may include untwisting the wires and positioning them in the conduit for contact with conductive terminals that corresponding to a specific registered jack configuration, such as an RJ-45 configuration. 
     While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims. The claims provide the scope of the coverage of the invention and should not be limited to the specific examples provided herein.