Patent Publication Number: US-8979574-B2

Title: Modular plug

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 13/586,408, filed Aug. 15, 2012, and entitled “MODULAR PLUG FOR POWER APPLICATIONS”, the subject matter of which is herein incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to modular plugs. 
     In electrical systems, there is increasing concern for powering electronic devices. Some electrical systems supply power over typical connectors. For example, industry standard type RJ-45 communication connectors provide Power over Ethernet connections by supplying current along the 8 signal circuits. Such connectors have limited current carrying capability. 
     A connector capable of having higher current carrying ability is needed. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, a modular plug includes a plug housing, plug contacts held by the plug housing, and a stuffer cap coupled to the plug housing. The stuffer cap includes a cable channel configured to receive a cable therein. The stuffer cap includes an interior side that defines at least a portion of the cable channel. The modular plug includes a strain relief member held by the plug housing. The strain relief member includes a base and a spring beam extending from the base such that the spring beam is cantilevered from the base. The spring beam is configured to engage the cable and thereby pinch the cable between the interior side of the stuffer cap and the spring beam. 
     In another embodiment, a modular plug includes a plug housing, plug contacts held by the plug housing, and a strain relief member held by the plug housing. The strain relief member includes a base and a spring beam cantilevered from the base. A stuffer cap is pivotally coupled to the plug housing. The stuffer cap includes a cable channel configured to receive a cable therein. The stuffer cap includes an interior side that defines at least a portion of the cable channel. The stuffer cap is configured to press wires of the cable into electrical contact with the plug contacts when the stuffer cap is pivoted to a closed position. The stuffer cap includes a slot that extends through the stuffer cap into the cable channel. The slot is configured to receive the spring beam of the strain relief member therein as the stuffer cap is pivoted to the closed position such that the spring beam pinches the cable between the interior side of the stuffer cap and the spring beam. 
     In another embodiment, a modular plug includes a cable having an insulative cable jacket and an end, a plug housing, and plug contacts held by the plug housing. A stuffer cap is coupled to the plug housing. The stuffer cap includes a cable channel and an interior side that defines at least a portion of the cable channel. The end of the cable is received within the cable channel. A strain relief member is held by the plug housing. The strain relief member includes a base and a spring beam cantilevered from the base. The spring beam is engaged with the insulative jacket of the cable such that the cable is pinched between the interior side of the stuffer cap and the spring beam. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an electrical connector system formed in accordance with an exemplary embodiment. 
         FIG. 2  is an exploded view of a plug for the electrical connector system shown in  FIG. 1  and formed in accordance with an exemplary embodiment. 
         FIG. 3  is a rear perspective view of the plug in a pre-terminated assembled state. 
         FIG. 4  is a cross sectional view of the plug and wire termination. 
         FIG. 5  is a bottom view of the plug. 
         FIG. 6  is a perspective view of a plug formed in accordance with an exemplary embodiment. 
         FIG. 7  is a rear perspective view of the plug in a pre-terminated assembled state. 
         FIG. 8  is a perspective view of a plug formed in accordance with an exemplary embodiment. 
         FIG. 9  is another perspective view of the plug shown in  FIG. 8 . 
         FIG. 10  is a perspective view of a portion of the plug shown in  FIGS. 8 and 9 . 
         FIG. 11  is a cross-sectional view of the portion of the plug shown in  FIG. 10 . 
         FIG. 12  is a perspective view illustrating the plug shown in  FIGS. 8-11  as assembled. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of an electrical connector system  10  formed in accordance with an exemplary embodiment. The electrical connector system  10  includes a modular jack  12  and a modular plug  14  configured to be mated with the jack  12 . The jack  12  and plug  14  may be referred to hereinafter as electrical connector(s). In an exemplary embodiment, the jack  12  is provided on a substrate, such as a printed circuit board  16 . The jack  12  may be mounted vertically on the printed circuit board  16 , horizontally on the printed circuit board  16  or at other configurations. Optionally, the jack may be a right angle jack with the printed circuit board  16  perpendicular to the mating end. The jack  12  may be mounted on a wall or panel, or, alternatively, may be mounted in an electrical device or apparatus. Alternatively, the jack  12  may be wire or cable mounted at an end of a power cable. In an exemplary embodiment, the plug  14  is provided at an end of a power cable  18  that transmits power to/from the electrical connectors. The jack  12  may be configured as an in-line device, where the jack  12  and corresponding plug  14  are utilized to connect two cables. In an exemplary embodiment, the electrical connector system  10  is used as part of a power application for supplying power to and/or from devices connected to the jack  12  and/or plug  14 . 
     The jack  12  and plug  14  will be described in terms of electrical connectors having components meeting certain requirements of industry standard type RJ-45 connectors, however the jack  12  and plug  14  may have some components that are outside of or do not comply with such industry standards. For example, the size, shape, position and configuration of certain components may comply with the standard, however the electrical connectors are used as power connectors rather than data connectors and thus may have different components to achieve power transmission. In an exemplary embodiment, the electrical connectors have eight contacts, however the eight contacts are used for power transmission rather than data transmission as is typical of RJ-45 connectors. 
     The jack  12  includes eight mating contacts  20  that are accessible at a mating end  22  to provide a connection interface for the printed circuit board  16 . A housing  26  of the jack  12  may be mounted to the printed circuit board  16 . In an exemplary embodiment, the eight mating contacts  20  are electrically commoned as part of one or more power circuits. For example, two power circuits may be provided with four mating contacts  20  in each power circuit. The mating contacts  20  are accessed through an opening  28  in the mating end  22  of the housing  26 . A locking mechanism  30  extends into opening  28  that is configured to engage a portion of the plug  14  to retain the plug  14  within the jack  12 . 
     In an exemplary embodiment, a mating interface  32  of the jack  12  defines an RJ-45 modular jack mating interface. The mating interface  32  is defined by features, such as, the size and shape of the opening  28 , the positioning of the mating contacts  20  in the opening  28 , the spacing of the mating contacts  20 , the positioning of the locking mechanism  30 , and the like. 
     The plug  14  has a plug housing  34  having a mating end  36  and a cable end  38 . The plug housing  34 , at the mating end  36 , has a substantially similar cross section as the opening  28  of the jack  12 . The mating end  36  is plugged into the opening  28  during mating of the plug  14  with the jack  12 . 
     The plug housing  34  includes a plurality of contact slots  40  formed therein at the mating end  36 . Plug contacts  42  are located in each of the contact slots  40 . Each plug contact  42  is configured to make electrical contact with one of the mating contacts  20  when the plug  14  is inserted into the jack  12 . In the illustrated embodiment, the plug  14  includes eight plug contacts  42  that are accessible at the mating end  36  to provide a connection interface for corresponding wires  44  (shown in  FIG. 2 ) of the power cable  18 . In an exemplary embodiment, the eight plug contacts  42  are electrically commoned as part of one or more power circuits. For example, two power circuits may be provided with four plug contacts  42  in each power circuit. The plug contacts  42  are accessible along a bottom  46  of the plug housing  34  and/or through a front  48  of the plug housing  34  for mating engagement with corresponding mating contacts  20  of the jack  12 . 
     The plug  14  includes a latch  50  for latching the plug  14  to the jack  12 , utilizing the locking mechanism  30  within the jack  12 . The latch  50  extends from a top  52  of the plug housing  34  proximate to the mating end  36 . 
     In an exemplary embodiment, a mating interface  54  of the plug  14  defines an RJ-45 modular plug mating interface. The mating interface  54  is defined by features, such as, the size and shape of the exterior of the plug housing  34  at the mating end  36 , the positioning of the plug contacts  42  along the plug housing  34 , the spacing of the plug contacts  42 , the positioning of the latch  50 , and the like. 
     It is to be understood that the benefits described herein are also applicable to other types of electrical connectors, having other standardized mating interfaces, which may carry fewer or greater numbers of contacts in alternative embodiments. The following description is therefore provided for illustrative purposes only and is but one potential application of the subject matter described herein. 
       FIG. 2  is an exploded view of the plug  14  formed in accordance with an exemplary embodiment. The plug  14  includes the plug housing  34 , a leadframe assembly  60  configured to be received in the plug housing  34  and a stuffer cap  62  configured to receive the wires  44  of the power cable  18  and configured to be coupled to the plug housing  34 . The stuffer cap  62  is used to electrically connect the wires  44  to the leadframe assembly  60  during assembly. For example, the wires  44  may be pressed into electrical contact with the leadframe assembly  60  when the stuffer cap  62  is coupled to the plug housing  34 . In the illustrated embodiment, the stuffer cap  62  is a separate component from the plug housing  34 . The stuffer cap  62  is configured to be secured to the plug housing  34  to hold the wires  44  and the power cable  18  with respect to the plug housing  34  and the leadframe assembly  60 . In an alternative embodiment, the stuffer cap  62  may be formed integral with the plug housing  34 . 
     The leadframe assembly  60  is configured to be loaded into the plug housing  34 . In an exemplary embodiment, the leadframe assembly  60  includes a first leadframe  64  and a second leadframe  66 . The first and second leadframes  64 ,  66  form first and second power circuits for the plug  14 . The first and second leadframes  64 ,  66  are configured to be connected to different wires  44  of the power cable  18 . 
     In an exemplary embodiment, the first leadframe  64  defines a positive terminal of the plug  14  and the second leadframe  66  defines a negative terminal of the plug  14 . Different groups of the plug contacts  42  are ganged together by the first and second leadframes  64 ,  66 . For example, in an exemplary embodiment, the plug  14  includes 8 plug contacts  42  with four of the plug contacts  42  defining a first group of plug contacts  42  associated with the first leadframe  64  and four of the plug contacts  42  define a second group of plug contacts  42  that are associated with the second leadframe  66 . In an exemplary embodiment, the first leadframe  64  and the second leadframe  66  are vertical stacked with the plug contacts  42  being internested at the mating end  36  of the plug housing  34  when assembled. 
     The first leadframe  64  includes a commoning pad  70 , a plurality of the plug contacts  42  extending forward from the commoning pad  70  and a terminating leg  72  extending rearward from the commoning pad  70 . The commoning pad  70  electrically commons the first group of plug contacts  42  together. In an exemplary embodiment, the plug contacts  42  are formed integral with the commoning pad  70 . For example, the plug contacts  42  and the commoning pad  70  may be stamped from a metal sheet to form the leadframe. 
     The terminating leg  72  is positioned for terminating to the corresponding wire  44  of the power cable  18 . In the illustrated embodiment, the terminating leg  72  includes spikes  74  that are configured to pierce the wire  44 . The wire  44  may be a stranded wire conductor, or alternatively may be a solid conductor. Other types of terminating features may be provided in alternative embodiments for mechanically and electrically connecting the first leadframe  64  to the wire  44 . For example, the terminating leg  72  may include an insulating displacement contact, a crimp barrel, a spring beam, or another type of terminating feature. 
     The second leadframe  66  includes a commoning pad  80 , a plurality of the plug contacts  42  extending forward from the commoning pad  80  and a terminating leg  82  extending rearward from the commoning pad  80 . The commoning pad  80  electrically commons the second group of plug contacts  42  together. In an exemplary embodiment, the plug contacts  42  are formed integral with the commoning pad  80 . For example, the plug contacts  42  and the commoning pad  80  may be stamped from a metal sheet to form the leadframe. 
     The terminating leg  82  is positioned for terminating to the corresponding wire  44  of the power cable  18 . In the illustrated embodiment, the terminating leg  82  includes spikes  84  that are configured to pierce the wire  44 . The wire  44  may be a stranded wire conductor, or alternatively may be a solid conductor. Other types of terminating features may be provided in alternative embodiments for mechanically and electrically connecting the second leadframe  66  to the wire  44 . For example, the terminating leg  82  may include an insulating displacement contact, a crimp barrel, a spring beam, or another type of terminating feature. 
     During assembly, the leadframe assembly  60  is loaded into the plug housing  34 . For example, the leadframe assembly  60  may be loaded into the plug housing  34  through the cable end  38 . Optionally, the first and second leadframes  64 ,  66  may be loaded into the plug hosing  34  together as a unit. Alternatively, the first and second leadframes  64 ,  66  may be separately and individually loaded into the plug housing  34 . When the leadframe assembly  60  is loaded into the plug housing  34 , the plug contacts  42  are arranged at the mating end  36  of the plug housing  34 . The terminating legs  72 ,  82  are positioned proximate to the cable end  38  of the plug housing  34  for terminating to the wires  44 . 
       FIG. 3  is a rear perspective view of the plug  14  in a pre-terminated assembled state. The stuffer cap  62  is aligned with the plug housing  34 . Optionally, the stuffer cap  62  may be pre-staged in an open position with respect to the plug housing  34 . In the pre-staged, open position, the stuffer cap  62  is coupled to the plug housing  34  and is movable with respect to the plug housing  34  in a closing direction such that the stuffer cap  62  may be moved to a closed position with respect to the plug housing  34 . The pre-staged, open position allows the relative position of the stuffer cap  62  to be held with respect to the plug housing  34  wherein relative movement between the stuffer cap  62  and the plug housing  34  is controlled or limited in one or more predetermined direction. For example, from the pre-staged, open position, the stuffer cap  62  may be moved vertical downward after the wires  44  are loaded into the stuffer cap  62  to terminate the wires  44  to the leadframe assemblies  60  (shown in  FIG. 2 ). 
     The stuffer cap  62  includes securing features  90  configured to engage corresponding securing features  92  of the plug housing  34 . In the illustrated embodiment, the securing features  90  constitute clips or tabs extending from the stuffer cap  62 . In the illustrated embodiment, the securing features  92  constitute openings that receive the securing features  90 . The securing features  90 ,  92  are used to secure the stuffer cap  62  to the plug housing  34  in the pre-staged, open position and/or the closed position. 
     The stuffer cap  62  includes wire channels  94  that receive corresponding wires  44 . The wires  44  are loaded into the wire channels  94  in a wire loading direction. Once the wires  44  are fully loaded into the wire channels  94  the stuffer cap  62  may be moved to the closed position. As the stuffer cap  62  is moved to the closed position, the stuffer cap  62  forces the wires  44  into electrical contact with the leadframe assembly  60  by forcing the spikes  74 ,  84  through insulation of the wires  44 . 
     In an exemplary embodiment, the stuffer cap  62  includes a strain relief feature  96  used to provide strain relief for the power cable  18 . In the illustrated embodiment, the strain relief feature  96  includes a lid or cover that may be closed tightly around the power cable  18  to provide strain relief between the power cable  18  and the plug  14 . Other types of strain relief features may be provided in alternative embodiments. 
       FIG. 4  is a cross sectional view of the plug  14  showing the leadframe assembly  60  electrically connected to the power cable  18 . The spikes  84  of the terminating leg  82  are shown in  FIG. 4  piercing the insulation of the wire  44  of the power cable  18 . During assembly, as the stuffer cap  62  is pressed vertically downward toward the plug housing  34 , the wires  44  are pressed into electrical contact with the spikes  84 . The spikes  84  pierce through the insulation of the wire  44  to create an electrical connection with the conductor of the wire  44 . 
       FIG. 5  is a bottom view of the plug  14 . The contact slots  40  and plug contacts  42  are illustrated in  FIG. 5 . In the illustrated embodiment, eight plug contacts  42  and eight contact slots  40  are provided. Separating walls  98  separate the contact slots  40 . In an exemplary embodiment, the eight plug contacts  42  are arranged to define a RJ-45 modular plug connector interface. 
     Any of the plug contacts  42  may be ganged together depending on the particular application. In an exemplary embodiment, the plug contacts  42  at positions 1, 3, 5, 7 are electrically commoned together as part of the first leadframe  64  (shown in  FIG. 2 ) while the plug contacts  42  at positions 2, 4, 6, 8 are electrically commoned together via the second leadframe  66  (shown in  FIG. 2 ). Alternative configurations are possible in alternative embodiments, such as the plug contacts  42  at positions 1, 2, 3, 4, being electrically commoned while the plug contacts  42  at positions 5, 6, 7, 8 are electrically commoned together by a different leadframe. In other alternative embodiments, more than two leadframes and groups of contacts may be electrically commoned together. In other alternative embodiments, unequal numbers of plug contacts  42  may be electrically commoned by a leadframe. Having many plug contacts  42  electrically commoned together allows higher current caring capability for the plug  14 , as compared to electrical connects where only one or two of the plug contacts carry current. 
       FIG. 6  is a perspective view of a modular plug  114  formed in accordance with an exemplary embodiment. The modular plug  114  may be similar to the modular plug  14  (shown in  FIG. 1 ) in some respects and may be mated with the modular jack  12  (shown in  FIG. 1 ). The plug  114  is provided at an end of a power cable  118  that transmit power to/from the electrical connectors. The plug  114  meets certain requirements of industry standard type RJ-45 connectors. For example, the size, shape, position and configuration of certain components may comply with the standard, however the plug  114  is used as power connector rather than a data connector and thus may have different components to achieve power transmission. 
     The plug  114  has a plug housing  134  having a mating end  136  and a cable end  138 . The plug housing  134  includes a plurality of contact slots  140  formed therein at the mating end  136 . Plug contacts  142  are located in each of the contact slots  140 . The plug contacts  142  may be substantially similar to the plug contacts  42  (shown in  FIG. 2 ). The plug contacts  142  may be part of a leadframe assembly in a similar manner as the plug contacts  42 . In an exemplary embodiment, the plug  114  includes the leadframe assembly  60  (shown in  FIG. 2 ). 
     In the illustrated embodiment, the plug  114  includes eight plug contacts  142  that are accessible at the mating end  136  to provide a connection interface for corresponding wires  144  (shown in  FIG. 7 ) of the power cable  118 . In an exemplary embodiment, the eight plug contacts  142  are electrically commoned as part of one or more power circuits. For example, two power circuits may be provided with four plug contacts  142  in each power circuit. The plug contacts  142  are accessible along a bottom  146  of the plug housing  134  and/or through a front  148  of the plug housing  134  for mating engagement with corresponding the mating contacts  20  of the jack  12 . 
     In an exemplary embodiment, a mating interface  154  of the plug  114  defines an RJ-45 modular plug mating interface. The mating interface  154  is defined by features, such as, the size and shape of the exterior of the plug housing  134  at the mating end  136 , the positioning of the plug contacts  142  along the plug housing  134 , the spacing of the plug contacts  142 , the positioning of a latch  150 , and the like. 
     The plug  114  includes a stuffer cap  162  configured to receive the wires  144  of the power cable  118  and configured to be coupled to the plug housing  134 . The stuffer cap  162  is used to electrically connect the wires  144  to the leadframe assembly  60  of the plug  114  during assembly. For example, the wires  144  may be pressed into electrical contact with the leadframe assembly  60  when the stuffer cap  162  is coupled to the plug housing  134 . In the illustrated embodiment, the stuffer cap  162  is pivotably coupled to the plug housing  134 . The stuffer cap  162  may include pins or posts  164  extending into the plug housing  134  that operate as an axle for the stuffer cap  162 . Alternatively, the stuffer cap  162  may be formed integral with the plug housing  134  and is connected thereto at a living hinge. 
       FIG. 7  is a rear perspective view of the plug  114  in a pre-terminated assembled state. The stuffer cap  162  is partially opened to a pre-staged position with respect to the plug housing  134 . The stuffer cap  162  is pivoted in a pivoting closing direction  166  once the wires  144  are loaded therein. 
     Plugs  14 ,  114  are provided that define power connectors having RJ-45 mating interfaces. The plug contacts  42 ,  142  are electrically commoned as part of leadframes that define power terminals of the plugs  14 ,  114 . Having many plug contacts  42 ,  142  electrically commoned together allows higher current caring capability for the plugs  14 ,  114 , as compared to electrical connects where only one or two of the plug contacts carry current. 
       FIGS. 8 and 9  are perspective views of a modular plug  214  formed in accordance with an exemplary embodiment. The modular plug  214  includes an exemplary embodiment of a strain relief member  296  (shown in  FIGS. 10-12 ). The modular plug  214  may be similar to the modular plug  114  (shown in  FIGS. 6 and 7 ) and/or the modular plug  14  (shown in  FIGS. 1-5 ) in some respects and may be mated with the modular jack  12  (shown in  FIG. 1 ) along a connection axis  215  (not shown in  FIG. 9 ). In the illustrated embodiment, the plug  214  is provided at an end  280  of a power cable  218  that transmits power to/from the electrical connectors. The power cable  218  is not shown in  FIG. 9 . 
     The plug  214  has a plug housing  234  having a mating end  236  and a cable end  238 . The plug housing  234  includes a plurality of contact slots  240  formed therein at the mating end  236 . Plug contacts  242  (not visible in  FIG. 9 ) are located in each of the contact slots  240 . The plug contacts  242  may be substantially similar to the plug contacts  42  (shown in  FIGS. 1 ,  2 , and  5 ) and/or the plug contacts  142  (shown in  FIG. 6 ). The plug contacts  242  may be part of a leadframe assembly in a similar manner as the plug contacts  42 . In the illustrated embodiment, the plug  214  includes a leadframe assembly  260  (shown in  FIG. 10 ). 
     In the illustrated embodiment, the plug  214  includes eight plug contacts  242  that are accessible at the mating end  236  to provide a connection interface for corresponding wires  244  (shown in  FIGS. 10-12 ) of the power cable  218 . In an exemplary embodiment, the eight plug contacts  242  are electrically commoned as part of one or more power circuits. For example, two power circuits may be provided with four plug contacts  242  in each power circuit. The plug contacts  242  are accessible along a bottom  246  of the plug housing  234  and/or through a front  248  of the plug housing  234  to define a mating interface  254  of the plug  214  where the plug contacts  242  mate with (i.e., matingly engage) the corresponding mating contacts  20  (shown in  FIG. 1 ) of the jack  12 . 
     The plug  214  may meet certain requirements of industry standard type RJ-45 connectors. For example, the size, shape, position and configuration of certain components may comply with the standard. In an exemplary embodiment, the mating interface  254  of the plug  214  defines an RJ-45 modular plug mating interface. The mating interface  254  is defined by features, such as, the size and shape of the exterior of the plug housing  234  at the mating end  236 , the positioning of the plug contacts  242  along the plug housing  234 , the spacing of the plug contacts  242 , the positioning of a latch  250 , and the like. 
     The plug  214  is not limited to meeting certain requirements of industry standard type RJ-45 connectors. Rather, the plug  214  may be any type of modular plug that meets certain requirements of any industry standard(s). Moreover, the illustrated embodiment of the plug  214  is used as a power connector rather than a data connector and therefore may have different components to achieve power transmission. But, the plug  214  is not limited to being used as a power connector. Rather, the plug  214  may transmit data signals in addition or alternative to transmitting power, no matter which type of modular plug the plug  214  is and which industry standard(s) the plug  214  conforms to. For example, although described as a “power cable”, the cable  218  may additionally or alternatively transmit data signals. In some embodiments, the plug  214  does not transmit power. 
     The plug  214  includes a stuffer cap  262  configured to receive the wires  244  of the power cable  218  and configured to be coupled to the plug housing  234 . The stuffer cap  262  is used to electrically connect the wires  244  to the leadframe assembly  260  of the plug  214  during assembly. For example, the wires  244  may be pressed into electrical contact with the leadframe assembly  260  when the stuffer cap  262  is coupled to the plug housing  234 . In the illustrated embodiment, the stuffer cap  262  is pivotably coupled to the plug housing  234  such that the stuffer cap  262  is pivotable between a pre-staged position and a closed position with respect to the plug housing  234 . The stuffer cap  262  is shown in the closed position in  FIGS. 8 and 12 . The stuffer cap  262  is shown in the pre-staged position in  FIGS. 9-11 . In the pre-staged position, the stuffer cap  262  is positioned for insertion of the power cable  218  into a cable channel  282  (shown in  FIGS. 10-12 ) of the stuffer cap  262  prior to closing the stuffer cap  262  for termination of the power cable  218 . Optionally, the plug  214  may be shipped to a customer in the pre-staged position. 
     One or more pivot pins and/or one or more pivot posts may extend into one or more corresponding openings of the plug housing  234  to operate as an axle for the pivoting action of the stuffer cap  262 . In the illustrated embodiment, the stuffer cap  262  includes opposite pivot posts  264  (only one is visible in  FIGS. 8 and 9 ) that extend into corresponding opposite openings  266  (only one is visible in  FIGS. 8 and 9 ) of the plug housing  234 . The stuffer cap  262  is configured to pivot about the pivot posts  264  to pivot between the pre-staged and closed positions. Of course, the arrangement of one or more of the pivot posts  264  and the corresponding opening  266  could be reversed such that the plug housing  234  includes the pivot post  264  and the stuffer cap  262  includes the corresponding opening  266 . Although shown as extending through an exterior side  268  of the plug housing  234 , each opening  266  may alternatively not extend through the side  268 . In other words, each opening  266  may be a notch that extends into an interior side  270  of a corresponding wall  271  of the plug housing  234  but does not extend completely through the wall  271 . Likewise, any openings  266  that extend into the stuffer cap  262  may not extend completely through the stuffer cap  262  from the side  272  to the side  274 . 
     One example of using one or more pivot pins includes providing a single pivot pin (not shown) that extends through the stuffer cap  262  and has opposite ends that extend into the opposite openings  266  of the plug housing  234 . In addition or alternatively to any pivot posts  264  and/or any pivot pins, the stuffer cap  262  may be formed integral with the plug housing  234  and connected thereto at a living hinge that enables the pivoting action of the stuffer cap  262 . 
     The stuffer cap  262  includes securing features  290  configured to engage corresponding securing features  292  of the plug housing  234  to secure the stuffer cap  262  in the pre-staged position relative to the plug housing  234 . In the illustrated embodiment, the securing features  90  constitute embossments  290   a  (only one is shown herein) that extend outward from opposite sides  272 ,  274  of the stuffer cap  262 . The securing features  292  of the plug housing  234  constitute ledges  292   a  (only one is visible in  FIG. 9 ) of the walls  271 . The embossments  290   a  are configured to be snapped over the corresponding ledges  292   a  to secure the stuffer cap  262  in the pre-staged position. For example, the walls  172  may deflect to enable the embossments  290   a  to clear the ledges  292   a  and thereby snap over the ledges  292   a . Of course, the arrangement of one or more of the embossments  290   a  and the corresponding ledge  292   a  could be reversed such that the plug housing  234  includes the embossment  290   a  and the stuffer cap  262  includes the corresponding ledge  292   a . The stuffer cap  262  may include any number of the securing features  290  and the plug housing  234  may include any number of the securing features  292 . Moreover, in some alternative embodiments, the plug  214  does not include any securing features for securing the stuffer cap  262  in the pre-staged position and a user or a machine holds the stuffer cap in the pre-staged position during insertion of the power cable  218  into the stuffer cap  262 . 
     The plug housing  234  optionally includes one or more openings  273  that receive the embossments  292   a  therein when the stuffer cap  262  is in the closed position, as is shown in  FIG. 8 . The openings  273  enable the walls  271  of the plug housing  234  to be undeflected (i.e., at the natural resting position thereof) when the stuffer cap  262  is in the closed position. Optionally, reception of the embossments  292   a  within the openings  273  may secure the stuffer cap  262  in the closed position, for example in addition or alternatively to the securing features  291 ,  293  (shown in  FIGS. 10-12 ) described below. Although shown as extending through the exterior side  268  of the plug housing  234 , each opening  273  may alternatively not extend through the side  268  (i.e., each opening  273  may be a notch that extends into the interior side  270  of the corresponding wall  271  but does not extend completely through the wall  271 ). 
     Other arrangements may additionally or alternatively be used to secure the stuffer cap  262  in the pre-staged position. For example, the securing features  290 ,  292  are not limited to using the snap-fit connection, but rather may use any other type of connection, such as, but not limited to, using an interference-fit (i.e., press-fit) connection, using stiction between the stuffer cap  262  and the plug housing  234  (e.g., at the pivot axle), using a latch-type connection, using a threaded connection, and the like. Moreover, the securing features  290 ,  292  are not limited to the respective embossments  290   a  and ledges  292   a , but rather may additionally or alternatively include any other type of connection structure, such as, but not limited to, a tab, a notch, a post, an opening, a latch, a clip, a clamp, a threaded fastener, and the like. 
       FIGS. 10 and 11  are perspective and cross-sectional views, respectively, of a portion of the plug  214 . The plug housing  234  has been removed from  FIG. 10  for clarity. The power cable  218  includes the wires  244  and an insulative jacket  278  that holds the wires  244 . The power cable  218  includes an end  280 . In the illustrated embodiment, the power cable  218  includes two of the wires  244 . But, the power cable  218  may include any number of the wires  244 . Each wire  244  of the power cable  218  may be a stranded wire conductor, or alternatively may be a solid conductor. 
     As described above, the plug  214  includes the leadframe assembly  260 . In the illustrated embodiment, the leadframe assembly  260  includes two leadframes, namely a first leadframe  364  and a second leadframe  366 . The first and second leadframes  364 ,  366  form first and second power circuits for the plug  214 . The first and second leadframes  364 ,  366  are configured to be connected to different wires  244  of the power cable  218 . Although two are shown and described herein, the leadframe assembly  260  may include any number of leadframes. 
     In an exemplary embodiment, the first leadframe  364  defines a positive terminal of the plug  214  and the second leadframe  366  defines a negative terminal of the plug  214 . Different groups of the plug contacts  242  (not visible in  FIG. 11 ) are ganged together by the first and second leadframes  364 ,  366 . For example, in an exemplary embodiment, the plug  214  includes 8 plug contacts  242  with four of the plug contacts  242  defining a first group of plug contacts  242  associated with the first leadframe  364  and four of the plug contacts  242  define a second group of plug contacts  242  that are associated with the second leadframe  366 . In an exemplary embodiment, the first leadframe  364  and the second leadframe  366  are vertically stacked with the plug contacts  242  being internested at the mating end  236  (shown in  FIGS. 8 ,  9 , and  11 ) of the plug housing  234  when assembled. 
     The first leadframe  364  includes a commoning pad  370 , a plurality of the plug contacts  242  extending forward from the commoning pad  370  and a terminating leg  372  extending rearward from the commoning pad  370 . The commoning pad  370  electrically commons the first group of plug contacts  242  together. In an exemplary embodiment, the plug contacts  242  are formed integral with the commoning pad  370 . For example, the plug contacts  242  and the commoning pad  370  may be stamped from a metal sheet to form the first leadframe  364 . 
     The terminating leg  372  is positioned for terminating to the corresponding wire  244  of the power cable  218 . In the illustrated embodiment, the terminating leg  372  includes spikes  374  that are configured to pierce the wire  244 . Other types of terminating features may be provided in alternative embodiments for mechanically and electrically connecting the first leadframe  364  to the wire  244 . For example, the terminating leg  372  may include an insulating displacement contact, a crimp barrel, a spring beam, or another type of terminating feature. 
     The second leadframe  366  includes a commoning pad  380 , a plurality of the plug contacts  242  extending forward from the commoning pad  380  and a terminating leg  382  extending rearward from the commoning pad  380 . The commoning pad  380  electrically commons the second group of plug contacts  242  together. In an exemplary embodiment, the plug contacts  242  are formed integral with the commoning pad  380 . For example, the plug contacts  242  and the commoning pad  380  may be stamped from a metal sheet to form the leadframe. 
     The terminating leg  382  is positioned for terminating to the corresponding wire  244  of the power cable  218 . In the illustrated embodiment, the terminating leg  382  includes spikes  384  that are configured to pierce the wire  244 . Other types of terminating features may be provided in alternative embodiments for mechanically and electrically connecting the second leadframe  366  to the wire  244 . For example, the terminating leg  382  may include an insulating displacement contact, a crimp barrel, a spring beam, or another type of terminating feature. 
     Referring now solely to  FIG. 11 , the stuffer cap  262  and plug housing  234  may include the securing features  291 ,  293 , respectively, for securing the stuffer cap  262  in the closed position relative to the plug housing  234 . In the illustrated embodiment, the securing feature  291  of the stuffer cap  262  is a window  291   a  that extends into the stuffer cap  262 . The securing feature  293  of the plug housing  234  constitutes an embossment  293   a  that is configured to be received into the window  291   a  with a snap-fit connection to secure the stuffer cap  262  in the closed position. Of course, the arrangement of the embossment  293   a  and the corresponding window  291   a  could be reversed such that the plug housing  234  includes the embossment  293   a  and the stuffer cap  262  includes the window  291   a . Although shown as extending completely through a wall  295  of the stuffer cap  262 , the window  291   a  may alternatively not extend completely through the wall  295  (i.e., the window  291   a  may be a notch that extends into an interior side  297  of the wall  295  but does not extend completely through the wall  295 ). Likewise, any windows  291   a  that extend into the plug housing  234  may not extend completely through the corresponding wall of the plug housing  234 . The stuffer cap  262  may include any number of the securing features  291  and the plug housing  234  may include any number of the securing features  293 . 
     Other arrangements may additionally or alternatively be used to secure the stuffer cap  262  in the closed position. For example, the securing features  291 ,  293  are not limited to using the snap-fit connection, but rather may use any other type of connection, such as, but not limited to, using an interference-fit (i.e., press-fit) connection, using stiction between the stuffer cap  262  and the plug housing  234  (e.g., at the pivot axle), using a latch-type connection, using a threaded connection, and the like. Moreover, the securing features  291 ,  293  are not limited to the respective window  291   a  and embossment  293   a , but rather may additionally or alternatively include any other type of connection structure, such as, but not limited to, a tab, a notch, a post, a ledge, a latch, a clip, a clamp, a threaded fastener, and the like. 
     Referring again to  FIGS. 10 and 11 , the stuffer cap  262  includes a cable channel  282  that is configured to receive the end  280  of the power cable  218  therein. The cable channel  282  is defined by one or more interior sides  284  of the stuffer cap  262 . In the illustrated embodiment, the cable channel  282  has the general cross-sectional shape of an oval (best seen in  FIG. 12 ) such that the cable channel  282  is defined by four interior sides  282   a ,  282   b ,  282   c ,  282   d  of the stuffer cap  262 . The interior side  282   d  is not shown in  FIG. 11 . Each interior side  282   a - d  defines a portion of the cable channel  282 . In other words, each interior side  282   a - d  defines a segment of the cross-sectional perimeter of the cable channel  282 . The cable channel  282  is not limited to the oval cross-sectional shape shown and described herein. Rather, the cable channel  282  may have any other cross-sectional shape and may be defined by any number of interior sides  282  of the stuffer cap  262 . In some embodiments, the cable channel  282  is defined by a single interior side  282  of the stuffer cap  262  that defines an approximate entirety of the cross-sectional perimeter of the cable channel  282 . Moreover, the cable channel  282  may have any size and shape (e.g., any cross-sectional size and cross-sectional shape) for receiving a cable having any size and shape. In some embodiments, the size and/or shape of the cable channel  282  is configured such that the cable channel  282  is configured to receive a variety of different cable sizes and/or shapes therein. 
     The stuffer cap  262  includes a slot  286  that extends through the stuffer cap  262  into the cable channel  282 . Specifically, the slot  286  extends through a wall  288  of the stuffer cap  262  that includes the interior side  284   c . The slot  286  extends through the interior side  284   c  of the wall  288  such that an end  290  of the slot  286  communicates with the cable channel  282 . The slot  286  extends completely through the wall  288  such that an opposite end  292  of the slot is open. As will be described below, the slot  286  is configured to receive a portion of the strain relief member  296  therein to enable the strain relief member  296  to engage the power cable  218  when the stuffer cap is pivoted to the closed position. Although shown as having the general cross-sectional shape of a rectangle, the slot  286  may have any other shape (and may have any size) that enables the slot  286  to receive the strain relief member  296  such that the strain relief member  296  engages the power cable  218 . 
     As briefly described above, the plug  214  includes the strain relief member  296 . The strain relief member  296  is optionally integrally formed with at least one of the plug contacts  242 . In the illustrated embodiment, the strain relief member  296  is integrally formed with the leadframe  366 . For example, the strain relief member  296 , the second group of plug contacts  242 , and the commoning pad  380  may be stamped from a sheet of material as an integral structure to form the leadframe  366  and strain relief member  296 . In some alternative embodiments, the strain relief member  296  is integrally formed with the leadframe  364 . Moreover, in some other alternative embodiments, the strain relief member  296  is integrally formed with the plug housing  234 . For example, the strain relief member  296  and the plug housing  234  may be fabricated using the same mold. 
     The strain relief member  296  is held by the plug housing  234 . In the illustrated embodiment, the leadframe  366  is held by the plug housing  234  such that the strain relief member  296  is held by the plug housing  234 . In embodiments wherein the strain relief member  296  is formed integrally with the plug housing  234 , the strain relief member  296  is considered to be held by the plug housing  234 . 
     In the illustrated embodiment, the strain relief member  296  extends outward from the commoning pad  380  of the leadframe  366 . Specifically, the strain relief member  296  includes a bridge  294  that extends outward from the commoning pad  380  to a base  298  of the strain relief member  296 . But, the strain relief member  296  may additionally or alternatively extend from any other portion of the leadframe  366 , for example one or more of the plug contacts  242 . 
     The strain relief member  296  includes the base  298 . One or more spring beams  300  are cantilevered from the base  298 . Specifically, each spring beam  300  extends from the base  298  such that the spring beam  300  is cantilevered from the base  298 . In the illustrated embodiment, the strain relief member  296  includes two spring beams  300   a ,  300   b . But, the strain relief member  296  may include any number of the spring beams  300 . As will be described below, the spring beams  300  are configured to engage the power cable  218  and thereby pinch the power cable  218  between the sniffer cap  262  and the spring beams  304 . Each of the spring beams  300   a ,  300   b  may be referred to herein as a “first” and/or a “second” spring beam. 
     The spring beam  300   a  extends from the base  298  to an end  302  of the spring beam  300   a . The spring beam  300   b  extends from the base  298  to an end  304  of the spring beam  300   a . As can be seen in  FIGS. 10 and 11 , the spring beams  300   a ,  300   b  extend from the base  298  such that the ends  302 ,  304  generally oppose (i.e., face) each other. In the illustrated embodiment, the ends  302 ,  304  are free ends. But, alternatively the ends  302 ,  304  may be mechanically connected together (e.g., integrally formed or separately formed and thereafter mechanically connected together). 
     The spring beams  300  are resilient springs that are configured to be deflected as the spring beams  300  are engaged with the power cable  218 . In the illustrated embodiment, the ends  302 ,  304  of the spring beams  300   a ,  300   b  are configured to deflect in the direction of the arrow A, whether or not the ends  302 ,  304  are mechanically connected to each other. As can be seen in  FIG. 11 , the direction A is oriented such that the ends  302 ,  304  of the spring beams  300   a ,  300   b , respectively, are configured to deflect generally toward the base  298  of the strain relief member  296  and generally toward a base  306  of the plug housing  234 . Optionally, the ends  302 ,  304  are configured to deflect a great enough distance such that the ends  302 ,  304  engage in physical contact with the base  298  of the strain relief member  296 . 
     The spring beams  300  are optionally angled relative to the connection axis  215  (not shown in  FIG. 10 ) in a direction generally toward the mating end  236  of the plug housing  234 . For example, as shown in  FIG. 11 , the spring beams  300   a ,  300   b  are angled at an acute angle α relative to the connection axis  215 . The acute angle α may have any value, such as, but not limited to, between approximately 60° and approximately 85°, less than approximately 86°, and the like. In embodiments wherein the spring beams  300  are angled toward the mating end  236  of the plug housing  234 , the spring beams  300  will deflect slightly toward the mating end  236  as the spring beams  300  engage the power cable  218 . The angle α may be small enough such that the spring beams  300  do not engage the base  298  even when the spring beams  300  deflect by a great enough amount in the direction A to engage the base  298  (i.e., the spring beams  300  will overlap the base  298  instead of engaging the base  298 ). 
     Assembly of the plug  214  will now be described. The power cable  218  can be loaded into the cable channel  282  of the stuffer cap  262  when the stuffer cap  262  is in the pre-staged position shown in  FIGS. 10 and 11 . Once the end  280  of the power cable  218  is fully received into the cable channel  282 , the stuffer cap  262  can be pivoted from the pre-staged position to the closed position. As the stuffer cap  262  is moved to the closed position, the stuffer cap  262  forces the wires  244  into electrical contact with the leadframe assembly  60  by forcing the spikes  374 ,  384  through insulation of the wires  244 . 
       FIG. 12  is a perspective view illustrating the plug  214  as assembled. The stuffer cap  262  is shown in phantom lines in  FIG. 12  for clarity. Referring now to  FIGS. 11 and 12 , as the stuffer cap  262  is pivoted from the pre-staged position to the closed position, the spring beams  300  of the strain relief member  296  are received into the slot  286  of the stuffer cap  262 . Specifically, the spring beams  300  extend into the slot  286  and into engagement in physical contact with the insulative jacket  278  of the power cable  218  as the stuffer cap  262  is pivoted to the closed position. Referring now solely to  FIG. 12 , each spring beam  300   a ,  300   b  is shown as engaged with the insulative jacket  278  of the power cable  218 . The engagement of the spring beams  300  with the insulative jacket  278  as the stuffer cap  262  is pivoted to the closed position causes the ends  302 ,  304  of the spring beams  300  to deflect, against the bias thereof, in the direction of the arrow A. The spring beams  300  thus pinch the power cable  218  between the interior side  284   a  of the stuffer cap  262  and the spring beams  300 . The spring beams  300  may also deflect slightly toward the mating end  236  (shown in  FIGS. 8 ,  9 , and  11 ) of the plug housing  234 , which may provide a strain relief force in a direction generally opposite typical cable pull forces. 
     The natural bias of the spring beams  300  against the deflection applies a pinching force to the power cable  218  that pinches the power cable  218  between the spring beams  300  and the interior side  284   a  of the stuffer cap  262 . The pinching force provides the power cable  218  with strain relief. The natural biasing forces of the spring beams  300  that act against deflection of the spring beams  300  may be selected to provide a predetermined pinching force, which may have any value. Optionally, the predetermined pinching force is selected such that the power cable  218  is at least partially compressed between the interior side  284   a  and the spring beams  300 . The power cable  218  may be compressed by any amount. Moreover, the predetermined pinching force may be selected such that the insulative jacket  278  of the power cable  218  is not cut (e.g., penetrated) by the spring beams  300  and/or the interior side  284   a.    
     The deflection of the spring beams  300  may enable the strain relief member  296  to provide strain relief to a variety of different cable sizes and/or shapes. For example, the deflection of the spring beams  300  may enable the same strain relief member  296  to be used with two or more different cables  218  that have different sizes than each other. Moreover, the deflection of the spring beams  300  may enable the strain relief member  296  to provide strain relief to a variety of different cable sizes and/or shapes without cutting the insulative jackets of the cables. Each spring beam  300  may deflect by any amount and may have any natural biasing force that enables the strain relief member  296  to provide strain relief to a cable. 
     Plugs  14 ,  114 ,  214  are provided that define power connectors having RJ-45 mating interfaces. The plug contacts  42 ,  142 ,  242  may be electrically commoned as part of leadframes that define power terminals of the plugs  14 ,  114 ,  214 . Having many plug contacts  42 ,  142 ,  242  electrically commoned together allows higher current caring capability for the plugs  14 ,  114 ,  214  as compared to electrical connects where only one or two of the plug contacts carry current. 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.