Patent Publication Number: US-11381032-B2

Title: Electrical plug connector

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a Continuation of U.S. patent application Ser. No. 16/564,171, filed on Sep. 9, 2019, now U.S. Pat. No. 10,840,633, which is a Continuation of U.S. patent application Ser. No. 15/751,400, filed on Feb. 8, 2018, now U.S. Pat. No. 10,411,398, which is a U.S. National Stage Application of PCT/US2016/046583, filed on Aug. 11, 2016, which claims the benefit of U.S. Patent Application Ser. No. 62/204,016, filed on Aug. 12, 2015, the disclosures of which are incorporated herein by reference in their entireties. To the extent appropriate, a claim of priority is made to each of the above disclosed applications. 
    
    
     BACKGROUND 
     Telecommunications cable lines are typically connected into port or jack terminals using plug connectors that enable the cables to be easily connected and disconnected. The cable lines are comprised of a number of wire pairs surrounded by a cable jacket. Quick connect cables are often constructed by securing a connector plug to the end of the cable wires and sliding the connector plug into a matching port terminal where it locks into place with a simple lever lock. An RJ45 type connector is one example. 
     Improvements are desired. 
     SUMMARY 
     Some aspects of the disclosure relate to an electrical plug connector configured to terminate an electrical cable. The electrical plug connector includes a base, a plug housing, and a strain-relief boot. The base includes a divider structure that defines a plurality of channels. The divider structure includes separation walls. At least one of the separation walls defines an abutment surface against which a forward end of the electrical cable abuts when terminated by the electrical plug connector. The plug housing defines an interior sized to receive a plurality of electrical contacts and a portion of the base. The plug housing defines slots so that the electrical contacts are accessible. The strain-relief boot defines a passage sized to receive the electrical cable. The strain-relief boot includes grip members configured to axially secure an outer jacket of the electrical cable against rearward movement relative to the strain-relief boot. The at least one separation wall inhibits forward axial movement of the outer jacket of the electrical cable relative to the base. 
     In certain implementations, the strain-relief boot is integrally formed with the base. 
     In certain implementations, the plurality of separation walls includes a first separation wall and a plurality of second separation walls. The second separation walls are orthogonal to the first separation wall. The at least one separation wall that inhibits forward axial movement of the outer jacket of the electrical cable is one of the second separation walls. 
     In certain examples, the first separation wall includes a forwardly extending flange coplanar with the first separation wall. The forwardly extending flange extends farther forwardly than the second separation walls. In an example, the forwardly extending flange extends between two adjacent ones of the second separation walls. 
     In certain implementations, the first separation wall extends between side walls of the base, wherein no other structure extends from the sidewalls to engage the electrical cable. 
     In certain implementations, the grip members define rearwardly facing ramps and forwardly facing shoulders. 
     In certain implementations, the grip members are disposed circumferentially around the passage defined by the strain-relief boot. 
     In certain implementations, the base includes a plurality of tabs having rearward facing shoulders and the plug housing defines openings having forward facing shoulders. The rearward facing shoulders of the tabs engage the forward facing shoulders of the openings to secure the plug housing to the base. 
     In certain implementations, the divider structure defines six channels. 
     In certain examples, the six channels are arranged in a top row of three channels and a bottom row of three channels. The channels in the top row are vertically aligned with the channels of the bottom row. 
     In certain implementations, a load bar configured to carry the plurality of electrical contacts. The load bar is sized to fit within the plug housing. 
     In certain examples, the base includes forward flanges that extend forwardly of the divider structure. The forward flanges being sized and spaced to abut a rearward-facing abutment surface of the load bar so that the forward flanges push the load bar within the plug housing towards slots defined in the plug housing when the base is pushed into the plug housing. 
     In an example, the forward flanges are sufficiently sized to inhibit pinching the conductors between the divider structure and the load bar. In an example, the abutment surface of the load bar is taller than a remainder of the load bar. 
     Other aspects of the disclosure relate to a base of an electrical plug connector including a strain-relief section and a manager section integrally formed with the strain-relief section and extending forwardly from the strain-relief section. The strain-relief section defines a passage sized to receive an electrical cable. The strain-relief boot includes grip members configured to axially secure an outer jacket of the electrical cable against rearward movement relative to the strain-relief boot. The manager section includes a divider structure that includes a first separation wall extending between opposing sidewalls. The divider structure also includes a second separation wall that extends orthogonal to the first separation wall. The second separation wall extends rearwardly of the first separation wall. 
     In certain implementations, flanges extend forwardly of the manager section, the flanges being coplanar with the opposing sidewalls. 
     Other aspects of the disclosure relate to a method of terminating an electrical cable having an outer jacket surrounding a plurality of twisted wire pairs. The method includes inserting an end of the electrical cable through a passage defined in a base until a forward end of the outer jacket abuts part of a divider structure of the base; routing twisted wire pairs through channels defined by the divider structure; inserting ends of the twisted wire pairs into the load bar; inserting electrical contacts into the load bar to make electrical contact with the twisted wire pairs; and pushing the load bar and electrical contacts into a plug housing using the base. 
     In certain implementations, routing the twisted wire pairs through the channels defined by the divider structure comprises routing one of the twisted wire pairs through a corresponding channel defined by the divider structure. In certain examples, the divider structure defines a top row of channels and a bottom row of channels. Routing the twisted wire pairs through the channels includes routing a twisted wire pairs through each channel in the top row and through only a middle channel in the bottom row. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an example electrical plug connector configured in accordance with the present disclosure; 
         FIG. 2  is an exploded view of the electrical plug connector of  FIG. 1 ; 
         FIG. 3  is a perspective view of the wire manager of the electrical plug connector of  FIG. 1 ; 
         FIG. 4  is another perspective view of the wire manager of the electrical plug connector of  FIG. 1 ; 
         FIG. 5  is an end view of the wire manager of the electrical plug connector of  FIG. 1 ; 
         FIG. 6  is a bottom plan view of the electrical plug connector of  FIG. 1  with a plug housing exploded forwardly of a remainder of the electrical plug connector; 
         FIG. 7  is a longitudinal cross-sectional view of the electrical plug connector of  FIG. 6  taken along the 7-7 line; 
         FIG. 8  is a bottom plan view of the electrical plug connector of  FIG. 1 ; 
         FIG. 9  is a longitudinal cross-sectional view of the electrical plug connector of  FIG. 8  taken along the 9-9 line; 
         FIG. 10  is a perspective view of another example wire manager suitable for use in the electrical plug connector of  FIG. 1 ; 
         FIG. 11  is a perspective view of an electrical plug connector with a color-coded clip configured in accordance with the present disclosure; 
         FIG. 12  is a plan view of the electrical plug connector of  FIG. 11 ; 
         FIG. 13  is a perspective view of the electrical plug connector of  FIG. 11  with the clip exploded from a boot of the electrical plug connector; 
         FIG. 14  is a perspective view of the boot of  FIG. 13 ; and 
         FIG. 15  is an end view of the wire manager of the electrical plug connector of  FIG. 1  showing a plurality of wire pairs being routed through the wire manager. 
     
    
    
     DETAILED DESCRIPTION 
     The disclosure is directed to an electrical plug connector configured to terminate twisted pairs of conductors of an electrical cable. In certain implementations, the electrical plug connector includes an integral wire manager and boot. In certain implementations, the electrical plug connector includes a wire manager having dividing walls that inhibit forward axial movement of the electrical cable or jacket thereof. In certain implementations, the electrical plug connector includes a wire manager that includes forward flanges configured to push a load bar into position within a plug housing. 
       FIG. 1  illustrates an example electrical plug connector  100  configured in accordance with the principles of the present disclosure. The electrical plug connector  100  is configured to terminate an electrical cable  105 . In particular, the electrical plug connector  100  is configured to terminate twisted pairs  107  ( FIG. 7 ) of conductors of an electrical cable  105 . The electrical plug connector  100  extends from a first end  101  to a second end  102 . The electrical cable  105  extends into the electrical plug connector  100  at the second end  102 . Twisted pairs  107  of conductors of the electrical cable  105  are routed through the electrical plug connector  100  to electrical contacts  103  towards the first end  101  (see  FIG. 7 ). 
     As shown in  FIG. 2 , the electrical plug connector  100  includes a base  140 , a load boar  120 , multiple electrical contacts  130 , and a plug housing  110 . The load bar  120 , the electrical contacts  130 , and a portion of the base  140  are sized and shaped to fit within an interior of the plug housing  110  when the electrical plug connector  100  is assembled. In certain implementations, the base  140  includes a strain-relief boot  148  to provide strain-relief to the electrical cable  105 . In certain implementations, the base  140  includes grip members  150  that inhibit axial and/or rotational movement the electrical cable  105  relative to the base  140 . 
     To assemble the electrical plug connector  100 , the electrical contacts  130  are positioned in the load bar  120 . The electrical contacts  130  and the load bar  120  are pushed into an open rear of the plug housing  110  using the base  140 . The base  140  is configured to axially secure to the plug housing  110  to hold the load bar  120  and electrical contacts  130  thereat. 
     The plug housing  110  includes a body  111  that extends from a closed forward end  112  to an open rearward end  113 . The body  111  defines a plurality of slots  114  towards the forward end  112 . The body  111  also defines a latching handle  115  having shoulders  116  configured to secure the electrical plug connector  110  at a receptacle (e.g., an electrical jack). The body  111  also defines latching openings  118  as will be described in more detail herein. 
     The load bar  120  includes a body  121  defining slots  122  sized to receive the electrical contacts  130 . The load bar  120  is configured to carry the electrical contacts  130  when the electrical contacts  130  are disposed within the slots  122 . The load bar body  121  is shaped to fit within an interior of the plug housing  110  so that the electrical contacts  130  align with the slots  114  of the plug housing  110 . The load bar  120  also includes a rearward-facing abutment surface  123 . 
     The base  140  includes a manager section  141  that organizes the twisted pairs  107  of conductors of the electrical cable  105 . The manager section  141  includes a divider structure  143  that defines a plurality of channels  144  (see  FIG. 5 ). In the example shown, the divider structure  143  defines six channels  144 . In other examples, however, the divider structure  143  can define a greater or lesser number of channels  144 . In an example, the divider structure  143  can define four channels  144 . In another example, the divider structure  143  can define five channels  144 . In another example, the divider structure  143  can define eight channels  144 . In another example, the divider structure  143  can define four channels  144 . 
     As shown in  FIGS. 3-5 , the divider structure  143  includes a first separation wall  145 . Some of the twisted pairs  107  of conductors are directed to one side of the first separation wall  145  and others of the twisted pairs  107  of conductors are directed to another side of the first separation wall  145  (see  FIG. 7 ). The divider structure  143  also includes one or more second separation walls  146  that extend outwardly from the first separation wall  145 . In the example shown, the second separation walls  146  extend orthogonal to the first separation wall  146 . In certain implementations, side walls  147  are disposed at opposite ends of the first separation wall  145 . In an example, the side walls  147  extend parallel to the second separation walls  145 . The sidewalls  147  and second separation walls  146  cooperate to define the channels  144 . 
     In certain implementations, the second separation walls  146  have rear-facing shoulders  146   a . In certain implementations, the second separation walls  146  extend further rearward than the first separation wall  145  so that the rear-facing shoulders  146   a  are spaced rearward from the first separation wall  145  (see  FIG. 4 ). In certain implementations, a flange  145   a  can extend forward of the first separation wall  145  (see  FIG. 10 ). For example, the flange  145   a  can be planar with the first separation wall  145 . In the example shown in  FIG. 14 , the first separation wall  145  defines a forward recess  145   b  between the second separation walls  146 . 
     In certain implementations, the forwardly extending flange  145   a  facilitates maintaining separation of twisted pairs as the twisted pairs extend through the channels. In some examples, the forwardly extending flange  145   a  extends between two adjacent second separation walls  146  (see  FIG. 10 ). In other examples, the forwardly extending flange  145   a  extends across at least a majority of a width of the first separation wall  145 . In certain implementations, the second separation walls  146  are disposed further rearwardly than the first separation wall so that a section of the first separation wall  145  is disposed forward of the second separation walls  146 . In certain examples, the second separation walls  146  extend further rearward than the flange  145   a  extends forward of the first separation wall  145 . 
     In certain implementations, the base  140  also includes a strain-relief boot section  142  ( FIG. 4 ). The boot section  142  includes a boot body  148  that defines a through-passage  149  sized to enable the electrical cable  105  to extend therethrough. An inner diameter of the through-passage  149  is sized so that an outer jacket  109  of the cable  105  extends fully through the boot body  148  and into the manager section  141  of the base  140  (see  FIG. 7 ). In certain implementations, the outer jacket  109  of the cable  105  extends to the rear-facing shoulders  146   a  of the second separation walls  146  (see  FIG. 7 ). In such implementations, the rear-facing shoulders  146   a  inhibit continued forward axial movement of the outer jacket  109 . 
     In certain implementations, the boot body  148  includes one or more grip members  150  (see  FIGS. 3, 5, and 7 ) disposed within the through-passage  149  to engage the outer jacket of the cable  105 . Each grip member  150  includes a forward shoulder and a rearward ramp that bite into the outer jacket  109  of the cable  105 . In certain examples, the grip members  150  inhibit rotational movement of the cable  105  relative to the base  140 . In certain examples, the grip members  150  inhibit rearward axial movement of the cable  105  relative to the base  140 . In the example shown, the boot body  148  includes four grip members  150  circumferentially spaced along the through-passage  149  (see  FIG. 5 ). In other implementations, the boot body  148  can include a greater or lesser number of grip members  150 . 
     In certain implementations, the base  140  includes forward flanges  152  that extend forwardly of the divider structure  143  (see  FIG. 3 ). The forward flanges  152  are sized and spaced to abut the rearward-facing abutment surface  123  of the load bar  120 . When the base  140  is pushed into the plug housing  110 , the forward flanges  152  push the load bar  120  within the plug housing  110  towards the slots  114 . In certain examples, the forward flanges  152  are sufficiently sized to inhibit pinching the conductors between the divider structure  143  and the load bar  120 . 
     In certain implementations, the base  140  is configured to lock to the plug housing  110  in an axially and rotationally fixed position. In the example shown, the plug housing  110  defines holes  118  that have forward facing edges  119  (see  FIG. 2 ). The base  140  includes tabs  153  that each have a forward ramp  154  and a rearward shoulder  155  (see  FIG. 4 ). When the base  140  is inserted into the plug housing  110 , the tabs  153  enter the holes  118  and the rearward shoulders  155  engage the forward facing edges  119  (see FIGS.  1  an  8 ). In other implementations, the base  140  may define the holes and the plug housing  110  may define the tabs. In still other implementations, the base  140  may otherwise secure to the plug housing  110 . 
     In accordance with some aspects of the disclosure, an electrical cable is terminated by inserting an end of the electrical cable through a passage defined in a base until a forward end of the outer jacket abuts part of a divider structure of the base; and routing twisted wire pairs through channels defined by the divider structure. Ends of the twisted wire pairs are inserted into a load bar. Electrical contacts also are inserted into the load bar to make electrical contact with the twisted wire pairs. The load bar and electrical contacts are pushed into a plug housing using the base, thereby assembling an electrical plug connector. 
     In certain implementations, the twisted wire pairs are routed through the channels defined by the divider structure by routing each of the twisted wire pairs through a corresponding channel defined by the divider structure. 
     In certain implementations, the divider structure  143  defines a top row  172  of channels  144  and a bottom row  174  of channels  144 . In certain examples, the electrical cable includes four twisted wire pairs  170 . In such examples, routing the twisted wire pairs  170  through the channels  144  includes routing a first of the twisted wire pairs  170  through a first channel  144  in the top row  172 , a second of the twisted wire pairs  170  through a second channel  144  in the top row  172 , a third of the twisted wire pairs  170  through a third channel  144  in the top row  172 , and a fourth of the twisted wire pairs  170  through only a middle channel  144  in the bottom row  174  (see  FIG. 15 ). 
     In certain examples, the electrical plug connector is an RJ45 connector. 
     In accordance with certain aspects of the disclosure, one or more color-coded features can be added to the plug or cable to identify one or more traits of the plug or cable. For example, the color-coded feature can identify whether the plug is shielded, the type of cable (e.g., number of jackets, number of twisted pairs, etc.), the diameter of the cable, the subscriber receiving the signals conveyed over the cable, etc. 
       FIGS. 11-14  illustrate an example clip  160  that can be mounted to the plug connector  100 . In some implementations, the clip  160  can be mounted to a boot  140 ′ of the plug connector  100 . In other implementations, the clip  160  can be mounted to a plug housing  110  of the plug connector  100 . In still other implementations, the clip  160  can be mounted to the cable. 
     In certain examples, the clip  160  is flush with the boot  140 ′ on at least one side. In the example shown, the clip  160  is flush with the boot  140 ′ on three sides. In certain examples, the clip  160  is flush with the plug housing  110  of the plug connecter  100 . In the example shown, the clip  160  is flush with the plug housing  110  on three sides. 
     The plug housing  110  has a first side  110   a  and an opposite second side  110   b  that extend between a front and a rear of the plug housing  110 . The plug housing  110  also includes opposite first and second ends that extend between the first and second sides  110   a ,  110   b  and between the front and the rear of the plug housing  110 . The latching handle  115  is disposed at the first end and the slots  114  are accessible at the second end. In certain examples, the clip  160  does not extend beyond the first and second sides  110   a ,  110   b  of the plug housing  110  when mounted at the plug connector  100 . In the example shown in  FIG. 12 , the clip  160  is flush with the first and second sides  110   a ,  110   b  of the plug housing  110  when mounted at the plug connector  100 . 
     In certain implementations, the clip  160  includes a base  161  having two flexible arms  163  extending outwardly therefrom to respective distal ends. Each of the arms  163  includes a latching member  164  at the distal end. In certain examples, the latching members  164  extend parallel with the base  161 . 
     In certain implementations, the clip  160  wraps around and latches to the plug housing  110 , boot  140 , or cable. In certain examples, the base  161  defines a notch  162  to accommodate a latching assist arm L or other feature on the plug connector  100 . 
     In some implementations, the entire clip  160  is uniformly colored. In other implementations, the base  161  of the clip  160  has a different color from the flexible arms  163 . 
     Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto.