Patent Publication Number: US-6988914-B2

Title: Electrical coupler with splitting receptacle jack interfaces

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/455,025 filed Mar. 14, 2003, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates generally to electrical couplers, and more specifically, to electrical couplers capable of splitting signal inputs to an input receptacle jack to a pair of output receptacle jacks. 
     A rising number of increasingly complicated networked devices in voice and data communication systems presents several challenges to interconnecting the network of devices. In particular, a number of switching devices and switching equipment facilitate operation of the network, and connecting a large number of network devices to the switching devices is problematic. The switch devices and equipment are typically configured for a predetermined number of connections, and the limited capacity of the switching equipment for connections has been met. While higher capacity switching devices may be employed, replacing lower capacity yet functional switching devices with newer switching equipment is an expensive solution, and in light of the number of switching devices that exists in the network, replacing the switching equipment may not be a feasible option. 
     Even for existing equipment, connecting a large number of network devices to the switches can be difficult due to physical space limitations in the area proximate the switching devices and equipment. Also, as the number of connections increases, accommodation of the cables associated with the connections can become unmanageable in the vicinity of the switches. Especially in high-speed data transmission systems, these problems can become acute. 
     In some systems, couplers have been employed to combine two high-speed data applications in a single cable. The couplers include dual receptacle jacks connected to a single edge card connector. The edge card connector plugs into an outlet which is, in turn, coupled to the cable. When connected to the respective receptacle jacks, two networked devices (e.g., laptop PC&#39;s) running high speed data applications may be supported by a single cable, sometimes referred to as a “shared-sheath” application. While shared-sheath applications may be effective in reducing the number of cables in a network, accommodating a large number of connections to known switching devices remains problematic. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In accordance with an exemplary embodiment of the invention, an electrical coupler comprises a first housing comprising at least one receptacle jack. A second housing is coupled to the first housing, and the second housing comprises at least a pair of receptacle jacks corresponding to the at least one receptacle jack. A splitter assembly extends between the first and second housing, and the splitter assembly comprises a plurality of contacts located in each of the receptacle jacks. 
     In an exemplary embodiment, the splitter assembly includes a printed circuit board adapted to split input signals to the at least one receptacle jack to each of the pair of receptacle jacks. The receptacle jacks are each RJ45 jacks for pluggable connection to switching equipment and to networked devices. Two network devices may therefore be connected to switching equipment through the coupler. One of the first and second housings is adapted for mounting the coupler to a panel. A plurality of couplers can be mounted to a panel assembly in use. 
     In accordance with another exemplary embodiment of the invention, an electrical coupler is provided. The coupler comprises a splitter assembly comprising a plurality of contact arrays and a plurality of contacts located on each contact array. The contact arrays include an input contact array and first and second output contact arrays. A portion of the contacts on the input array are coupled to a portion of the contacts on the first output array, and a portion of the contacts on the input array are coupled to a portion of the contacts on the second output array. A first jack interface receives the input contact array, and a second jack interface receives the first and second output contact arrays. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of an electrical coupler according to an embodiment of the present invention. 
         FIG. 2  is a top rear perspective view of the coupler shown in  FIG. 1 . 
         FIG. 3  is a bottom rear perspective view of the coupler shown in  FIG. 1 . 
         FIG. 4  is an exploded bottom rear perspective view of the coupler shown in  FIG. 1 . 
         FIG. 5  is an exploded top front perspective view of the coupler shown in  FIG. 1 . 
         FIG. 6  is a front perspective view of a splitter assembly for the coupler shown in  FIG. 1 . 
         FIG. 7  is an exploded perspective view of a coupler system employing the coupler shown in  FIG. 1 . 
         FIG. 8  is a perspective assembly view of the system shown in  FIG. 7 . 
         FIG. 9  is a top front perspective view of a coupler formed in accordance with another embodiment of the invention. 
         FIG. 10  is a top rear perspective view of the coupler shown in  FIG. 9 . 
         FIG. 11  is an exploded front perspective view of the coupler shown in  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a front perspective view of an electrical coupler  100  formed in accordance with an exemplary embodiment of the present invention. As explained in detail below, coupler  100  provides expanded connection capability with existing switching devices and equipment. While coupler  100  is particularly suited for high-speed data transmission systems, it is recognized that the benefits and advantages of coupler  100  may accrue to other applications as well. The description set forth below is therefore provided for illustrative purposes only, and is not intended to limit the invention to any particular end use application. 
     Coupler  100  includes a front housing  102  and a rear housing  104 . The front housing  102  is fabricated from a known plastic material according to known processes and techniques and is generally rectangular in the illustrated embodiment. Thus, the front housing  102  includes a top wall  106 , a bottom wall  108 , side walls  110 ,  112  extending between the top wall  106  and the bottom wall  108 , and a front wall  114  defining a jack interface  116 . The jack interface  116  includes a pair of receptacle jacks  118 ,  120  horizontally aligned with one another in a side-by-side arrangement. The receptacle jacks  118 ,  120  extend inward from the front wall  114  and are adapted to receive a known mating plug connector (not shown) coupled to a cable (not shown). The receptacle jacks  118 ,  120  each have a channel  122 ,  124  along one side thereof and the channels  118 ,  120  are configured to receive respective flexible prongs extending from the front end of the plug connector. When the plug is inserted into the receptacle, the prong retains the plug within the respective receptacle jack  118 ,  120 . 
     The cable contains several signal wires that may, in different embodiments, be shielded or unshielded and made of fiber optics or copper. The signal wires in the cable are coupled to contacts  126  in the respective receptacle jack  118 ,  120  when the associated plug is connected thereto. In an exemplary embodiment, the cable includes eight signal wires, each of which is coupled to one of the contacts  126 . Additionally, the eight signals wires are arranged in four pairs corresponding to pairs of contacts  126  in the receptacle jacks  118 ,  120 . It is recognized, however, that cables having greater or fewer signal wires and greater or fewer numbers of signal pairs may be employed in alternative embodiments of the invention with appropriate modification to contacts  126  in the receptacle jacks. In one embodiment, the receptacle jacks  118 ,  120  are known RJ45 jacks configured to mate with known connector plugs, although it is appreciated that a variety of known receptacles and plugs may be employed in various embodiments of the invention. 
     The top wall  106  of the front housing  102  includes projecting ridges  128 ,  130  extending generally parallel to one another and defining a slot  132  therebetween. In the illustrated embodiment, the ridges  128 ,  130  are substantially triangular in cross section, although it is appreciated that other shapes and configurations of ridges  128 ,  130  may be employed in alternative embodiments of the invention. The bottom wall  108  of the front housing  102  has a stepped contour and a resilient latch member  134  extending therefrom. The latch member  134  extends beneath the bottom wall  108  and includes a planar body portion  135  extending substantially parallel to the top wall  106 . The body portion  135  of the latch member  135  includes projecting ridges  136 ,  138  extending outwardly and downwardly from the body portion  135 . The ridges  136 ,  138  on the latch member  134  are positioned opposite one another and form a slot  140  extending therebetween. Like the ridges  128 ,  130  in the top wall  106 , the ridges  136 ,  138  in the latch member are substantially triangular in cross section, although it is understood that ridges  136 ,  138  may be differently shaped in alternative embodiments. Additionally, it is contemplated that ridges  128 ,  130 ,  136 ,  138  need not have a similar shape to one another in further and/or alternative embodiments of the invention. 
     The slot  132  in the top wall  106  and the slot  140  in the latch member  134  are substantially aligned with one another so that the front housing  102  may be supported on a panel (not shown in  FIG. 1 ) in use. The stepped contour of the bottom wall  108  provides a clearance for pivotal movement of the latch member  134  about an end  142  of the latch member  134  extending from the bottom wall  108 . Mounting of the coupler  100  to the panel is described further below. 
       FIG. 2  illustrates the rear housing  104  extending from the front housing  102  opposite the jack interface  116 . The rear housing  104  is fabricated from a known plastic material and includes a cap portion  150  and a jack interface  152 . The cap portion  150  encloses a rear end of the front housing  102 , and the jack interface  152  extends outwardly from the cap portion  150 . The jack interface  152  includes a receptacle jack  154  approximately centered in the cap portion  154  and oriented 180° from the jack interface  116  of the front housing  102 . That is, while the front housing  102  includes forward facing receptacle jacks  118 ,  120 , (shown in  FIG. 1 ) the rear housing  104  includes a rearward facing receptacle jack  154 . While the oppositely facing receptacle jacks on the front housing  102  and the rear housing  104  are believed to be advantageous, it is appreciated that the receptacle jacks on the front and rear housing  102 ,  104  may be otherwise oriented relative to one another in alternative embodiments of the invention. 
     The receptacle jack  154  of the rear housing  104  extends inward from the jack interface  152  and is adapted to receive a known mating plug connector (not shown) coupled to a cable (not shown). The receptacle jack  154  has a channel  156  along one side thereof and the channel  156  is configured to receive a respective flexible prong extending from the front end of a plug connector (not shown) inserted into the receptacle to retain the plug connector to the receptacle jack  154 . 
       FIG. 3  illustrates contacts  160  situated within the receptacle jack  154  of the rear housing  104 . The contacts  160  establish electrical connection with signal wires of a cable coupled to a plug connector. In different embodiments, the cable may be shielded or unshielded and made of fiber optics or copper. The signal wires in the cable are coupled to the contacts  160  in the receptacle jack  154  when the plug is connected thereto. In an exemplary embodiment, the cable includes eight signal wires, each of which is coupled to one of the contacts  160 . Additionally, the eight signal wires are arranged in four pairs corresponding to pairs of contacts  160 . It is recognized that cables having greater or fewer signal wires and greater or fewer numbers of pairs may be employed in alternative embodiments of the invention with appropriate modification to contacts  160  in the receptacle jack  154 . In one embodiment, the receptacle jack  154  is a known RJ45 jack configured to mate with a known connector plugs, although it is appreciated that a variety of known receptacles and plugs may be employed in various embodiments of the invention. 
     When a cable is coupled to the receptacle jack  154  in the rear housing  104 , the input signals received by the contacts  160  are split into the receptacle jacks  118 ,  120  (shown in  FIG. 1 ) in the front housing  102 . Thus, when the receptacle jack  154  is coupled to a cable in line with a switching device/equipment (not shown), two network devices may be connected, respectively, to the receptacle jacks  118 ,  120  in the front housing  102 . Thus, with one cable connection to the switching device via receptacle jack  154 , two network devices may be switched via the receptacle jacks  118 ,  120  output from the coupler  100 , thereby expanding the number of potential connections to the switching device/equipment. Additionally, connections to the coupler  100  may be made in a remote location from the switching device or switching equipment, thereby improving accessibility to the cable connector plugs and alleviating crowded connections to the switching device/equipment in a relatively small amount of space. 
     Also, as illustrated in  FIG. 3 , the latch member  134  attached to the bottom wall  108  of the front housing  102  extends substantially the longitudinal length of the front housing  102 . Ridge  138  is substantially solid and extends the length of the latch member  134 , while the ridge  136  includes gaps  162  therein exposing the slot  140  extending between the ridges  136 ,  138 . The gaps  162  facilitate mounting of the coupler  100  to a panel, as further described below. 
       FIGS. 4 and 5  illustrate a splitter assembly  180  extending between the front housing  102  and the rear housing  104 . The splitter assembly  180  includes a printed circuit board  182 , a rear contact array  184  extending from one side of the printed circuit board  182 , and a pair of front contact arrays  186 ,  188  extending from the other side of the printed circuit board  182  opposite the rear contact array  184 . The contact arrays  184 ,  186 ,  188  extend substantially perpendicular to the printed circuit board  182  and hold the respective contacts  160 ,  126  of the front and rear receptacle jacks in the rear housing  104  and the front housing  102 . The contacts  126 ,  160  are coupled to conductive traces on the printed circuit board  182  which splits, for example, a four pair contact signal input to the receptacle jack  154  in the rear housing  104  to a two pair contact output signal in each of the receptacle jacks  118 ,  120  in the rear housing. Additionally, in an exemplary embodiment, the printed circuit board  182  includes known components to process the input signals as desired to boost signal strength, attenuate noise, etc. as those in the art will appreciate. 
     The contact arrays  184 ,  186 ,  188  are fabricated from an insulative material, such as plastic, and are shaped and dimensioned to be received and retained in respective cavities in the front housing  102  and the rear housing  104 . When the coupler  100  is assembled, the contacts  160 ,  126  are located in the respective receptacle jacks in the respective rear and front housings  104 ,  102 . 
       FIG. 6  is a magnified view of the splitter assembly  180  illustrating the contacts  126  situated on the contact arrays  186 ,  188 . The contacts  126  include rounded distal ends situated in slots  200  extending longitudinally in a forward end of the contact arrays  186 ,  188 . Each of the contacts  126  is terminated at an opposite end to the printed circuit board  126  via through-hole terminations to establish electrical connection to circuitry on the printed circuit board  182 . Intermediate the rounded ends and the terminations, selected contact pairs of the contacts  126  cross over one another for enhanced signal transmission and reduced noise. Contacts  160  are arranged similarly on contact array  184  as contacts  126  are arranged on the contact arrays  186 ,  188 . 
     As illustrated in  FIG. 6 , the contacts  126 ,  160  face opposite directions from one another on either side of the printed circuit board  182 . In other words, while the contacts  126  extend on the top surface of the front contact arrays  186 ,  188 , the contacts  160  extend on the bottom surface of the rear contact array  184 . Stated another way, if the contacts  126  are located in the bottom of the receptacle jacks  118 ,  120  on the front housing  102 , the contacts  160  are located in the top of the receptacle jack  154  in the rear housing  104 . As such, the receptacle jacks  118 ,  120  are inverted relative to the receptacle jack  154 . 
       FIG. 7  is an exploded view of a coupler system  220  including a panel assembly  222  and a plurality of couplers  100 . The panel assembly  222  includes a flat front panel  224  having an opening or cutout  226  therethrough, and a frame  228  extends inward from the front panel  224  and surrounds the opening  226 . The frame  228  includes a bottom wall  230 , a top wall  232 , and side walls  234 ,  236  defining a receptacle for receiving the couplers  1100 . A shelf  238  extends across the upper end of the opening  226  in a spaced apart relationship from the top wall  232 . The shelf  238  includes a ridge  240  on one side thereof that engages the slot  132  (shown in  FIG. 1 ) on each of the top walls  106  of the couplers  100 . The bottom wall  230  of the frame  228  includes outwardly projecting fingers  242  extending rearwardly therefrom. The fingers  242  are received in the gaps  162  (shown in  FIG. 3 ) in the ridge  136  (shown in  FIG. 3 ) of the latch members  134  on the bottom wall  108  of the couplers  100 . 
       FIG. 8  illustrates the jack interfaces  116  of the couplers  100  received in the opening  126  in the flat panel. The ridge  240  (shown in  FIG. 7 ) of the shelf  238  is located in the slots  132  (shown in  FIG. 1 ) of the top wall  106  (shown in  FIGS. 1 and 7 ) of each of the couplers  100 . The latch members  134  of each of the couplers  100  are engaged to the fingers  242  of the frame  228 . The fingers  242  deflect the latch member  134  of each coupler  100 , causing the latch members  134  to pivot downward toward the bottom wall  108  of each coupler  100 . Deflection of the latch members  134  provides a biasing force to retain the couplers  100  to the frame  228 . By virtue of the slots  132  in the top wall  106  and the latch member  134  on the bottom wall  108  of each coupler  100 , the couplers  100  are supported on the top and the bottom in the panel assembly  222  to securely mount the couplers  100  for use. 
     The panel assembly  222  may be located in a location remote from the switching device, and the couplers  100  may therefore be mounted in a convenient location for making connections to the switching device. The pluggable connections to the receptacle jacks  118 ,  120  and  154  simplifies installation of the couplers  100 , while the couplers  100  double the number of connections otherwise available from the switching device. 
       FIGS. 9–11  illustrate another embodiment of a coupler  250  including a front housing  252  and a rear housing  254 . The front housing  252  includes a jack interface  256  having a pair of receptacle jacks  258 ,  260  arranged vertically relative to one another in the jack interface  256 . Ridges  262 ,  264  are formed in a top wall  266  of the front housing, and together define a slot  268  for supporting the coupler  250  in a panel assembly, such as panel assembly  222  shown in  FIGS. 7 and 8 . 
     The receptacle jacks  258 ,  260  in the front housing  252  each have a channel  270 ,  272  along one side thereof and the channels  270 ,  272  are configured to receive respective flexible prongs extending from the front end of a plug connector (not shown). When the plug is inserted into the receptacle, the prong retains the plug within the respective receptacle jack  258 ,  260 . Contacts  274  are located in each of the receptacle jacks  258 ,  260 . The receptacle jacks  258 ,  260  are inverted relative to one another so that the contacts  274  face in opposite directions on contact arrays  276 ,  278  ( FIG. 11 ) of a splitter assembly  280 . Contact arrays  276 ,  278  receive the contacts  274  and are fitted into receptacles in the front housing  252  to complete the receptacle jacks  258 ,  260 . 
     The rear housing  254  includes a single receptacle jack  280  formed therein that is oppositely faced from the receptacle jacks  258 ,  260  of the front housing  252 . Thus, while the receptacle jacks  258 ,  260  are forward facing, the receptacle jack  280  is rearward facing and oriented 180° from the receptacle jacks  258 ,  260 . The receptacle jack  280  in the rear housing  254  includes contacts  282  therein and are arranged on a contact array  284  to establish an electrical connection with a plug connector of a cable that is connected to switching equipment. A printed circuit board  282  (shown in  FIG. 11 ) includes circuit traces to connect the contacts  282  to the contacts  274  of the receptacle jacks  258 ,  260  of the front housing  252 . The printed circuit board  282  is adapted to split the signals from the receptacle jack  280  to the receptacle jacks  258 ,  260  and provide any signal compensation desired. 
     A plurality of couplers  250  may be mounted to a panel assembly in substantially the same manner as described above. Coupler  250  provides substantially the same benefits and advantages as coupler  100  described above. 
     In each of the illustrated embodiments, coupler  100  and coupler  250  includes a front jack interface having two receptacle jacks, and a rear jack interface having one receptacle jack. It is understood, however, that in further embodiments more than one receptacle jack could be provided in the rear housing, with each of the receptacle jacks in the rear housing corresponding to a pair of receptacle jacks in the front housing. For example, two receptacle jacks may be provided in the rear housing and four receptacle jacks provided in the front housing (i.e., two receptacle jacks for each of the receptacle jacks in the rear housing). As another example, three receptacle jacks may be provided in the rear housing with six receptacle jacks provided in the front housing. The receptacle jacks may be provided in practically any orientation, and are not limited to an aligned horizontal row or vertical column arrangement of the illustrated embodiments. 
     The versatility of the invention to conveniently accommodate connections of networked devices to existing switching equipment is now believed to be apparent. The relatively low cost coupler of the present invention provides a practical and affordable solution to the network connection issues discussed above. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.