Source: https://patents.google.com/patent/US6783402B2/en
Timestamp: 2019-08-24 09:30:29
Document Index: 781362751

Matched Legal Cases: ['art 41', 'art 41', 'art 41', 'arts 43', 'art 41', 'art 41', 'arts 43']

US6783402B2 - Fast electric connector plug satisfying category 6 standard - Google Patents
Fast electric connector plug satisfying category 6 standard Download PDF
US6783402B2
US6783402B2 US10/216,215 US21621502A US6783402B2 US 6783402 B2 US6783402 B2 US 6783402B2 US 21621502 A US21621502 A US 21621502A US 6783402 B2 US6783402 B2 US 6783402B2
US10/216,215
US20040029450A1 (en
2002-08-12 Application filed by Surtec Ind Inc filed Critical Surtec Ind Inc
2002-08-12 Priority to US10/216,215 priority Critical patent/US6783402B2/en
2002-08-12 Assigned to SURTEC INDUSTRIES INC. reassignment SURTEC INDUSTRIES INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHEN, MICHAEL
2004-02-12 Publication of US20040029450A1 publication Critical patent/US20040029450A1/en
2004-08-31 Publication of US6783402B2 publication Critical patent/US6783402B2/en
Please refer to FIG. 1. The disclosed electric connector plug has a plug shell 10 and an insertion element. The plug shell 10 has the size of an RJ-45 electric connector plug. It is a hollow element with a upper wall 11 a, a lower wall 11 b, a left wall 12 a, a right wall 12 b, and an elastic chip 13 located at the bottom of the lower wall 11 b and extending downwards. The elastic chip 13 is used to hold and connect with an electric connector jack (not shown). The front end in the insertion direction toward the electric connectorjack is a closed front wall 14. The other end is an opening 15 to the exterior. The front end of the plug shell 10 has eight metal electrodes 21˜28. The metal electrodes 21˜28 are inserted from the insertion holes 110 at the front end of the upper wall 11 a downward into the plug shell 10. They are connected with the twisted pairs 31˜38 of the fast communication cable 30 through the sharp front ends of the metal electrode 21˜28. The metal electrodes 21˜28 have the same length (see FIG. 4).
The insertion element is inserted into the plug shell 10 through the opening 15 along the same installation direction of the plug shell 10. It has a carrier 40 and a cover 60. The carrier 40 is a narrow and long element. It has a bottom part 41, a left wall 42 a, and a right wall 42 b. Several wire slots 51˜58 at the bottom part 41 near the front end of the plug shell 10 extend forward. These wire slots 51˜58 are underneath eight metal electrodes 21˜28 for supporting different twisted pairs 31˜38. The front end of each metal electrode 21˜28 can prick through the insulating coat of the corresponding twisted pair 31˜38, resulting in electrical communications with the wires.
The cover 60 is also a narrow and long element. It can be installed in the space enclosed by the bottom part 41, the left wall 42 a, and the right wall 42 b of the carrier 40 (see FIG. 2). The cover 60 can be divided into a front section 6A and a rear section 6B along its axial direction. Four guide channels 61˜64 penetrate through the front section 6A for guiding the four twisted pairs 31&32, 33&36, 34&35, 37&38 (Pairs 1˜4) of the fast communication cable 30. The guide channels 61˜64 are long holes (with a rectangular or circular cross section). The four twisted pairs 31&32, 33&36, 34&35, 37&38 (Pairs 1˜4) go through the guide channels 61˜64 in a parallel and non-twisted way. The rear section 6B has several connecting elements 65 (such as hooks) installed on the two walls 42 a, 42 b for connecting with the connecting parts 43 (such as hook holes) formed on the left wall 42 a and the right wall 42 b of the carrier 40, thereby combining the cover 60 and the carrier 40. The cover is further installed with several protruding wire holding saws 66 on the surface facing the carrier 40. A wire holding surface 44 is formed at the corresponding position on the bottom part 41 of the carrier 40. After the cover 60 and the carrier 40 are combined together, the fast communication cable 30 is tightly held between the cover 60 and the carrier 40 (see FIG. 3).
In principle, the guide channels 61˜64 are long holes and have to be formed in four directions around the same central point. As shown in FIG. 5, the guide channels 61, 63 are on the left and right sides, whereas the guide channels 62, 64 are on the upper and lower sides. The four twisted pairs 31˜38 then go through the guide channels 61˜64 in parallel. Since the twisted pairs 31˜38 in this section are parallel with each other and non-twisted, the wire positions after the guide channels 61˜64 can be properly controlled to get compensations for the TT and TR effects. For example, as shown in FIG. 8, if the wire 34 is T (tip) and the wire 35 is R (ring) in the first twisted pair 34, 35 and the wire 31 is T and the wire 32 is R in the second twisted pair 31, 32, then one can make the wire 34 and the wire 32 get closer, producing the TR compensation effect. The first twisted pair 34, 35 is preferably configured above the third twisted pair 33, 36. On the other hand, the guide channels 61˜63 are on the same level, but the guide channel 64 is at a different level (see FIG. 9). The guide channels 61˜64 are still long holes for the twisted pairs 31˜38 to go through in a parallel and non-twisted way. With reference to FIG. 10, the guide channel 64 can be also formed using a lower guide slot in the middle section of the bottom part 41 of the carrier and an upper guide slot 64 b at the center of the bottom surface of the front section 6A of the cover 60.
With further reference to FIG. 6, when the electronic connector plug and the fast communication cable 30 are connected together, the cover layer of the fast communication cable 30 is first peeled. The four twisted pairs 31˜38 (Pairs 1˜4) inside the fast communication cable are taken out and the twisted wires are untangled. Afterwards, the four twisted pairs 31˜38 are inserted in parallel through the guide channels 61˜64 of the insertion element (see FIG. 3). As shown in the drawing, the first and third twisted pairs 33˜36 are in parallel on the same horizontal plane and the second and fourth twisted pairs 31, 32, 37, 38 in parallel on the same vertical plane. The insulating cover layer of the fast communication cable 30 is moved as close as possible between the wire holding saws 66 of the cover 60 and the wire holding surface 44 of the carrier 40. The cover 60 and the carrier 40 are combined in such a way that the connecting elements 65 on both sides of the cover 60 and the connecting parts 43 of the carrier 40 are coupled. At the same time, the fact communication cable is tightly held between the cover 60 and the carrier 40.
It should be emphasized that one has to make sure that the four twisted pairs 31˜38 have to extend out a certain length after penetrating through the four guide channels 61˜64 before the cover 60 and the carrier 40 are combined. The ends of the four twisted pairs 31˜38 extend into the wire slots 51˜58. The insertion element holding the fast communication cable 30 is then inserted into the plug shell 10 from its rear opening 15 (see FIG. 7), until a hook 67 on the top surface of the rear section 6B of the cover 60 catches a hook hole 111 on the top wall 11 a of the plug shell 10. Finally, the metal electrodes 21˜28 are plugged into the insertion holes 110 at the front end of the plug shell 10. In this way, the sharp tips of the metal electrodes 21˜28 can get into electrical contact with the twisted pairs 31˜38 of the fast communication cable 30.
The wire slots 51˜58 on the carrier 40 have a cross section with an upward opening. The width of the opening can be slightly smaller than the outer diameter of a single wire of the twisted pair 3˜38. When the cover 60 and the carrier 40 are combined together, one can directly put the four twisted pairs 31˜38 through along the axial direction of the wire slots 51˜58. Alternatively, one can also straighten these twisted pairs 31˜38 and push them downward through the narrow opening of the wire slots 51˜58.
The wire holding surface 44 on the carrier 40 can be designed to have a wavy, saw-like or rough surface to enhance the holding effect to firmly clinch the fast communication cable. This design can also avoid the problem of incorrect connections between the twisted pairs 31˜38 and the metal electrodes 51˜58 during the process of inserting the insertion element into the plug shell 10. Another preferred design of the insertion element is to have a connecting pin 68 protruding from the bottom of the cover 60 downward. When the cover 60 and the carrier 40 are combined, the connecting pin 68 is plugged into a corresponding hole 45 on the carrier, increasing the reliability in the combination between the cover 60 and the carrier 40.
On the other hand, some fast communication cables have different specifications for the communication connectors on both ends, such as 568A and 568B. On in some special cases, one may need to have jumps. To satisfy such needs and to further enhance the compensation effect, the two guide channels 61˜64 can have at least three position holes. With reference to FIG. 11, the guide channels 61, 63 on the left and right sides have three position holes for the twisted pairs 31˜38 to pass through. As shown in the drawing, three connected circular holes are formed to further limit the wire positions and their relative distances. For example, if one wants that the wire 31 of the second twisted pair is close to the wire 34 of the first twisted pair, but the wire 32 is not close to the wire 33 of the third twisted pair, then the wire 31 of the second twisted pair is put at the top position of the guide channel 61 and the wire 32 in the middle. This can achieve the TT or TR compensation effect. The same configuration also applies to jumps where wires are switched after jumps are made.
This design of at least three positioning holes for the guide channels 61, 63 can also be applied to the other two guide channels 62, 64 (see FIG. 13). The above-mentioned guide channel structure is not limited to circular tubes shown in FIGS. 1, 11, and 13. They can be made to be like a guide groove (see FIGS. 12 and 14), or partly guide grooves and partly circular tubes. After being inserted into the plug shell 10, they are totally covered by the plug shell 10 or the carrier 40, with the same function of guiding the twisted pairs 31˜38.
1. A fast electric connector plug for assembly with a fast communication cable, comprising:
a plug shell, which is a hollow RJ-45 plug and has an opening on at least one end, and eight metal electrodes on its front end, the eight metal electrodes being inserted into the plug shell and in electrical communications with four twisted pairs in the fast communication cable; and an insertion element, which is plugged into the plug shell from the opening thereof, and has a plurality of guide channels for guiding the four twisted pairs in the fast communication cable to connect with the metal electrodes, each guide channel being a long hole for a twisted pair to go through in a parallel and non-twisted way and the guide channels controlling the distances among the wires in the four twisted pairs the guide channels being formed in four directions relative to a central point of the insertion element and one of the guide channels has at least three holes for the wires in the twisted pairs to pass through and the distance between the wires is controlled by their positions in the guide channel with at least three holes.
2. The fast electric connector plug of claim 1, wherein the guide channels which are formed in four directions that are symmetric relative to a central point of the insertion element.
US10/216,215 2002-08-12 2002-08-12 Fast electric connector plug satisfying category 6 standard Expired - Fee Related US6783402B2 (en)
US10/216,215 US6783402B2 (en) 2002-08-12 2002-08-12 Fast electric connector plug satisfying category 6 standard
US20040029450A1 US20040029450A1 (en) 2004-02-12
US6783402B2 true US6783402B2 (en) 2004-08-31
ID=31495019
US10/216,215 Expired - Fee Related US6783402B2 (en) 2002-08-12 2002-08-12 Fast electric connector plug satisfying category 6 standard
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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CHEN, MICHAEL;REEL/FRAME:013185/0238