Patent Publication Number: US-2023155316-A1

Title: Electrical connector with removable load bar

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is application is a continuation of U.S. application Ser. No. 17/202,536 filed Mar. 16, 2021, which is fully incorporated herein by reference. 
    
    
     BACKGROUND OF THE PRESENT INVENTION 
     As more and more devices incorporate network connectivity, termination of network connectors takes place outside a closed environment on a more regular basis. Terminating a connector in the field raises many issues including poor connectivity resulting from improper insertion of wires into modular connectors. Improper terminations can lead to degraded device performance or device failure. With a traditional modular plug, wires are hand cut to a length that will allow the wires to engage with the crimping portion of the plug. However, many times the wires are cut inconsistent lengths such that the wire do not fully engage the crimping portion of the plug resulting in a bad connection. 
     A need exists for a plug that will allow for easy insertion an crimping of cables in the field. 
     SUMMARY OF THE PRESENT INVENTION 
     One embodiment of the present disclosure includes a modular plug system including a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end and an opening opposite the front end, and a cavity extending from the front end to the opening in the back end, and a load bar sized to engage the cavity in the modular plug, the load bar including two extensions on an upper surface of the load bar, the extensions sized to engage two openings in the top surface of the plug housing when the load bar is inserted into the cavity. 
     One embodiment of the current disclosure includes a modular plug system including a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end and an opening opposite the front end, and a cavity extending from the front end to the opening in the back end, a load bar sized to engage the cavity in the modular plug, the load bar including two extensions on an upper surface of the load bar, the extensions sized to engage two openings in the top surface of the plug housing when the load bar is inserted into the cavity. 
     Another embodiment includes a front side of each extension portion is sloped towards a front end of the load bar. 
     In another embodiment each extension portion is sized to prevent the load bar from exiting the cavity after the load bar is installed. 
     In another embodiment the load bar includes a plurality of holes sized to each accommodate a wire. 
     In another embodiment each hole in the load bar is sized to concentrically align with one of a plurality of holes in the front end of the modular plug. 
     In another embodiment the extensions push the load bar towards the bottom of the housing. 
     In another embodiment the front end of the housing includes a single row of openings. 
     In another embodiment the front end of the housing includes multiple rows of openings. 
     In another embodiment a wire passed through one opening in the load bar is guided to a corresponding opening in the front of the modular plug. 
     In another embodiment the top of the extension portion is coplaner with the top surface of the plug. 
     Another embodiment includes a modular plug system including a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end and an opening opposite the front end, and a cavity extending from the front end to the opening in the back end, a load bar including a guidance portion connected to a management portion that is sized to engage the cavity in the modular plug, the management portion including two extensions on an upper surface of the management portion, the extensions sized to engage two openings in the top surface of the plug housing when the load bar is inserted into the cavity. 
     In another embodiment a front side of each extension portion is sloped towards a front end of the load bar. 
     In another embodiment each extension portion is sized to prevent the load bar from exiting the cavity after the load bar is installed. 
     In another embodiment the guidance portion includes a plurality of holes sized to each accommodate a wire. 
     In another embodiment each hole in the guidance portion is sized to concentrically align with one of a plurality of holes in the front end of the modular plug. 
     In another embodiment the extensions push the management portion towards the bottom of the housing. 
     In another embodiment the front end of the housing includes a single row of openings. 
     In another embodiment the front end of the housing includes multiple rows of openings. 
     In another embodiment a wire passed through one opening in the guidance portion is guided to a corresponding opening in the front of the modular plug. 
     In another embodiment the top of the extension portion is coplaner with the top surface of the plug. 
    
    
     
       DRAWING SUMMARY 
         FIG.  1    depicts a perspective view of a load bar being inserted into the opening of the modified connector housing. 
         FIG.  2    depicts a rear view of the modular connector housing with the load bar inserted into the opening. 
         FIG.  3    depicts a perspective cut away view of the modular connector housing. 
         FIG.  4    depicts another perspective cut away view of the modular connector housing. 
         FIG.  5    depicts a cut away view of the modular connector housing. 
         FIG.  6    depicts an embodiment of a plug and a load bar. 
         FIG.  7    depicts a cut away view of the plug and load bar. 
         FIG.  8    depicts a cut away view of the load bar being inserted into the plug. 
         FIG.  9    depicts a partial cut away view of the plug and load bar. 
         FIG.  10    depicts a close up view of the locking unit. 
         FIG.  11    depicts a perspective view of a multi row plug. 
         FIG.  12    depicts a cut away view of a multi row plug with a load bar inserted into the plug. 
         FIG.  13    depicts another embodiment of a multi row plug. 
         FIG.  14    shows a breakaway view of the plug and load bar. 
         FIG.  15    depicts a cut away view of the plug with the load bar inserted into the plug. 
         FIG.  16    depicts a side cut away view of the plug showing the front surface of the load bar being co-plainer with the front surface of the plug. 
         FIG.  17    shows the arrangement of wires in the load bar. 
         FIG.  18    shows another embodiment of the plug. 
     
    
    
     DETAILED DESCRIPTION 
       FIG.  1    depicts a perspective view of a load bar  500  being inserted into the opening of the modified connector housing  122 . The modified connector housing  122  includes an opening  402 . The load bar  500  is sized such that the load bar  500  can be inserted into the opening  402 .  FIG.  12    depicts a cut away side view of the modular connector housing  122  with the load bar  500  inserted into the opening  402 . When inserted, a front surface of the load bar  500  is adjacent to a plurality of wiring channels  404 . The load bar  500  is positioned in the opening  402  such that each wire of a plurality of wires inserted into the opening  402  are guided into a respective wire channel  404 . 
       FIG.  2    depicts a rear view of the modular connector housing  122  with the load bar  500  inserted into the opening  402 . The load bar  500  includes four openings  502 ,  504 ,  506  and  508 . In one embodiment, the openings  402  are arranged in a single row and three of the four openings  502 ,  504  and  506  are arranged such that each of the openings  502 ,  504  and  506  align with at least two wiring channels  404 . In another embodiment, the openings  402  are arranged into multiple rows and the openings  502 ,  504 ,  506  and  508  are arranged such that each opening is aligned with at least one opening  402 . 
       FIG.  3    depicts a perspective cut away view of the modular connector housing. The load bar  500  is positioned adjacent to the wiring channels  402  such that wires pass through the openings  502 ,  504 ,  506  and  508  of the load bar  500  to engage the wiring channels  402 .  FIG.  4    depicts another perspective cut away view of the modular connector housing.  FIG.  5    depicts a cut away view of the modular connector housing. The load bar  500  is positioned such that wires passing through the openings  502 ,  504 ,  506  and  508  are positioned in the wiring channels  402  such that the contact blades  36  engage each wire in each wiring channel  402  when the modular connector housing  122  is crimped. 
       FIG.  6    depicts an embodiment of a plug  600  and a load bar  700 . The load bar  700  includes a wire management portion and a load portion  704 . The wire management portion  702  includes a plurality of wiring channels  706  that are sized to each engage a wire extending from the load portion  704 . When positioned in the plug  600 , each wiring channel  706  is aligned with one opening  602  in the plug  600  to allow a wire to extend outward form the opening  602 . The load portion  704  includes flanges  708  and  710  that extend from a central base portion. Each flange  708  and  710  includes a locking unit  712  and  714  with the locking units  712  and  714  being positioned on the top surface of each flange  712  and  714  such that each locking portion  712  and  714  engages an opening  604  and  606  in the top surface of the plug  600 . 
       FIG.  7    depicts a cut away view of the plug  600  and load bar  700 . The load bar  700  is sized to rest in a cavity inside the plug  600 . The wire channels  706  are positioned on the load bar  700  such that each wire channel  706  is aligned with a respective opening  602 . The flanges  708  and  710  are positioned such that the flanges do not interfere with the sides or top of the plug  600  and the locking units  712  and  714  are positioned such that the locking units  712  and  714  engage an opening  604  and  606  on the plug.  FIG.  8    depicts a cut away view of the load bar  700  being inserted into the plug. In one embodiment, the lower inner surface of the plug includes a step down portion  608  to accommodate larger cables. 
       FIG.  9    depicts a partial cut away view of the plug  600  and load bar  700 . When inserted into the plug, the flanges  708  and  710  bend as the locking units  712  and  714  come into contact with the upper inner surface of the plug  600 . The flanges  708  and  710  move upward as the locking units  712  and  714  engage the openings  604  and  606 .  FIG.  10    depicts a close up view of the locking unit  712 . Each locking unit  712  and  714  has a top surface  800  that slopes towards the openings  602  in the plug  600 . The locking units  712  and  714  include a front wall  802  and a back wall (not shown) that extend from the flange  708  or  710 . When the top surface  800  comes into contact with an inner surface of the plug  600 , the sloped surface  800  deflects the flange  708  or  710  down to allow the locking unit  712  and  714  to engage the openings  604  and  606 . 
       FIG.  11    depicts a perspective view of a multi row plug  900 . The plug  900  includes a first row  902  of openings and a second row  904  of openings. In one embodiment, the plug includes more than two rows of openings. The openings may be concentrically aligned or staggered. Each of the openings is configured to align with a channel in the load bar (not shown) such that wires extending through each channel in the load bar (not shown) extend through a respective opening in the first row  902  or second row  904  of openings.  FIG.  12    depicts a cut away view of a multi row plug  1000  with a load bar  1002  inserted into the plug  1000 . The load bar includes a first row of openings  1004  and a second row of openings  1006 . The openings  1004  and  1006  in the load bar  1002  are aligned with openings in a first row  902  and second row of the plug  1000  such that each wire that extends through an opening  1004  and  1006  in the load bar  1002  extends through a respective opening in the plug  1000 . 
       FIG.  13    depicts another embodiment of a multi row plug  1100 . The plug  1100  includes openings  602  and  604  to engage the load bar, a front surface  1102 , and an opening  1104  in the lower portion of the front surface. The opening  1104  is configured to accommodate the front surface of a load bar  1106  inserted into the plug  1100 .  FIG.  14    shows a breakaway view of the plug  1100  and load bar  1108 . The plug  1100  has an opening  1104  in the front surface that extends through the length of the plug  900 . The load bar  1108  includes the front surface  1106 , a wire support structure  1110 , two locking units  712  and  714  on a top surface of the wire support structure  1110 . A plurality of wires  1112  pass through the support structure  1110  with each wire  1112  exiting the support structure and engaging one of a plurality of channels  1114  in the front portion of the load bar  1108 . The wires  1112  are cut to a length such that the front surface of each wire  1112  extends to the back of the front surface  1106  of the load bar  1108 . 
       FIG.  15    depicts a cut away view of the plug  1100  with the load bar  1108  inserted into the plug  1100 . The front surface  1106  of the load bar  1108  is co-planer with the front surface  1102  of the plug  1100  such that the front surface  1106  of the load bar  1108  acts to fill the opening  1104  in the plug  1100 .  FIG.  16    depicts a side cut away view of the plug  1100  showing the front surface  1106  of the load bar  1108  being co-plainer with the front surface  1102  of the plug  1100 .  FIG.  17    shows the arrangement of wires  1112  in the load bar  1108 . The wires  1112  are separated into two levels with two wires  1112  being positioned in different portions of the support structure  1110 . Each wire exiting the load bar enters into a channel  1114  in the load bar  1108 . In one embodiment, the channels  1114  are arranged in a multi row configuration. In another embodiment, the channels  1114  are arranged in a single row. 
       FIG.  18    shows another embodiment of the plug  1100 . The load bar  1108  includes a plurality of openings  1202  through the front surface  1106  that allow the wires  1112  to pass through the openings  1200 . In one embodiment, the load bar  1108  is configured to engage a cutting surface on a tool the cuts the wires such that the ends of the wires are co-planer with the front surface  1106 . In another embodiment, the load bar  1108  is inserted into the plug  1110  such that the wires extend from the front surface  1102  of the plug  1100 . In one embodiment, the modular plug  1100  is configured to engage a tool that cuts the wires such that the front ends of the wires are co-planer with the front surface  1102 . In one embodiment, a plastic cap  1202  us placed in the opening  1104  after the load bar  1108  is inserted into the plug  1100 .