Patent Document

FIELD OF INVENTION 
       [0001]    The present invention generally relates to the field of telecommunication, and more particularly, to the field of connectors such as plugs and/or jacks used to interconnect electronic equipment. 
       BACKGROUND 
       [0002]    It is common practice to use modular (e.g., RJ45) plugs and jacks in combination with twisted pair cabling to interconnect electronic equipment. While the primary purpose of this type of connectivity is to enable the flow of data, it is also possible to use the same medium to transmit limited amounts of power. This is generally referred to as Power over Ethernet (PoE). 
         [0003]    PoE allows a single cable to provide both electrical power and data connections, which may eliminate the need for additional power cables and devices such as transformers and AC outlets. Some non-limiting examples of PoE devices include Voice over Internet Protocol (VoIP) phones, wireless access points, network routers, switches, industrial devices (controllers, meters, sensors, etc.), nurse call stations, IP security cameras, televisions, LED lighting fixtures, remote point of sale kiosks, and physical security devices. PoE was launched into the market in 2003, standardized under IEEE 802.3af, and allowed for a power draw of 12.95 W and 350 mA per pair (Type 1). POE+ was launched into the market in 2009, standardized under IEEE 802.3at, and allowed for a power draw of 25.5 W and 600 mA per pair (Type 2). As the need for more and more power becomes apparent, non-standard applications, such as Cisco&#39;s Universal Power over Ethernet (UPoE) at 60 W and Power over HDBaseT (100 W), with 1000 mA per pair of current capacity, have arisen. As of 2015 there is a proposal for an IEEE 802.3bt (PoE++) standard with 49 W (Type 3) to 100 W (Type 4) of power draw and 600 mA (Type 3) to 1000 mA (Type 4) per pair of power, and other potential future applications may require a current capacity of 1500 mA per pair or more. 
         [0004]    While the earlier-designed connectors could withstand the rigors of the relatively low power required for earlier PoE applications, these connectors lack the design for durability needed to sustain the ever-increasing power demands. One particular issue is the need to reduce damage that occurs to the plug and/or jack during the mating and disconnection. 
         [0005]    In a PoE application, upon disconnection (and/or insertion) of the plug and jack connector combination there is an electrical discharge that can damage the plug and jack mating interfaces. This electrical discharge can be an electrical arc (spark) or a corona discharge. A spark is a fast single event that is time independent and may cause a large distinct crater on the plug contacts of the plug, the plug interface contacts (PICs) of the jack, or both. A corona discharge is a relatively slower event that is time dependent, has multiple events, and causes many shallow craters or pits that erode the plug contacts, PICs, or both. These effects are worsened after multiple insertions as erosion caused by mechanical abrasion also damages the plug/jack mating interfaces of both the plug contacts and the PICs. IEC 60603-7 requires a minimum of 750 plug insertions into a jack module. Many vendors test to a higher amount of insertion cycles as for some applications 750 plug insertions is relatively low. The effects of this damage can be seen in the form of physical damage, electrical interface degradation, and, over time, corrosion of the contacts. 
         [0006]    Additional constraints on the design are imposed by the need of the connectors to handle a certain amount of bandwidth while at the same time meeting particular parameters such as, for example, near end crosstalk (NEXT), far end crosstalk (FEXT), return loss, and insertion loss requirements. As such, these and other design concerns give rise to the need for robust connectors designed to withstand current and future demands of PoE. 
       SUMMARY 
       [0007]    Accordingly, at least some embodiments of the present invention are directed towards devices, systems, and methods which are related to connectors designed to withstand current and future PoE demands. 
         [0008]    In an embodiment, the present invention is a shielded RJ45 network jack with an inter-jack connection method that has an electrical disengagement point outside of the plug/jack mating point, while still allowing for a relatively short distance to compensation from the plug/jack mating interface. 
         [0009]    In another embodiment, the present invention is an RJ45 plug assembly with an inter-plug connection method that has an electrical disengagement point outside of preferred mating points. 
         [0010]    In yet another embodiment, the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a printed circuit board (PCB), the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion; and a plurality of third contacts, each of the third contacts having a mating section configured to interface with one of the mating portions and a disconnect section configured to interface with one of the disconnect portions. 
         [0011]    In still yet another embodiment, the present invention is a communication connector that includes a connector housing, a plurality of first contacts positioned at least partially within the connector housing, each of the first contacts configured to interface with one of a plurality of interface contacts of a corresponding connector, a PCB, the plurality of first contacts being positioned on the PCB, the PCB further including a plurality of second contacts, each of the second contacts being connected to one of the first contacts and having a mating portion and a disconnect portion, and a plurality of third contacts, each of the third contacts having a preferred mating leg configured to interface with one of the mating portions and a sacrificial leg configured to interface with one of the disconnect portions. 
         [0012]    In still yet another embodiment, the present invention is a communication connector connectable to at least one of a communication cable and communication equipment, the communication connector capable of transmitting power over Ethernet. The communication connector includes means for interfacing the communication connector with a corresponding connector, means for establishing an electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for establishing the electrical path being located within the communication connector and occurring over a first physical path, and means for breaking the electrical path between the corresponding connector and the at least one of the communication cable and the communication equipment, the means for breaking the electrical path being located within the communication connector and occurring over a second physical path. 
         [0013]    In still yet another embodiment, the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken while each of the plug contacts maintains contact with one of the PICs. 
         [0014]    In still yet another embodiment, the present invention is a communication system that includes a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, the communication plug is further configured to disconnect from the communication jack such that each the current path is broken at a point other than between each of the plug contacts and respective one of the PICs. 
         [0015]    In still yet another embodiment, the present invention is a communication system that includes, a communication plug including a plurality of plug contacts and a plurality of plug cable contacts, and a communication jack including a plurality of PICs and a plurality of jack cable contacts. The communication plug is configured to mate with the communication jack such that each of the plug contacts comes into contact with one of the PICs, a current path being established between each of the plug cable contacts and one of the jack cable contacts when the communication plug is mated with the communication jack, each the current path traversing one of the plug contacts and respective one of the PICs. The communication plug is further configured to disconnect from the communication jack such that at least one the current path is broken while respective one of the plug contacts maintains contact with respective one of the PICs. 
         [0016]    In still yet another embodiment, the present invention is a communication system including a communication plug and a communication jack. The communication system includes means for connecting the communication plug to a plug-cable having at least one conductor. The communication system also includes means for connecting the communication jack to a jack-cable having at least one conductor. The communication system also includes means for electrically and physically interfacing the communication plug with the communication jack. The communication system also includes means for transmitting a current between the at least one conductor of the plug-cable and the at least one conductor of the jack-cable. The communication system also includes means for breaking the current at a point that does not include the means for electrically and physically interfacing the communication plug with the communication jack. 
         [0017]    These and other features, aspects, and advantages of the present invention will become better-understood with reference to the following drawings, description, and any claims that may follow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a communication system according an embodiment of the present invention. 
           [0019]      FIG. 2  is an isometric view of an RJ45 network jack mated with an RJ45 network plug according to an embodiment of the present invention. 
           [0020]      FIGS. 3-5  are isometric views of the RJ45 jack and the RJ45 plug of  FIG. 2  in an unmated state. 
           [0021]      FIGS. 6-8  are isometric exploded views of an RJ45 jack according to an embodiment of the present invention. 
           [0022]      FIGS. 9-11  are isometric views of a sled assembly according to an embodiment of the present invention. 
           [0023]      FIGS. 12-14  are isometric exploded views of the sled assembly of  FIGS. 9-11 . 
           [0024]      FIG. 15  is a rear isometric view of the RJ45 jack with back end assembly exploded. 
           [0025]      FIGS. 16 and 17  are isometric views of partial jack assembly and jack shield in the open state. 
           [0026]      FIGS. 18 and 19  are exploded views of a wire cap assembly. 
           [0027]      FIGS. 20 and 21  are views of first and second sides, respectively of a first rigid PCB according to an embodiment of the present invention. 
           [0028]      FIG. 22  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state. 
           [0029]      FIG. 23  is a front isometric view of RJ45 jack and RJ45 plug assembly in an over-travel state. 
           [0030]      FIG. 24  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an over-travel state. 
           [0031]      FIG. 25  is a front isometric view of RJ45 jack and RJ45 plug assembly in a pre-release state. 
           [0032]      FIG. 26  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state. 
           [0033]      FIG. 27  is a front isometric view of RJ45 jack and RJ45 plug assembly in a release state. 
           [0034]      FIG. 28  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state. 
           [0035]      FIG. 29  is a front isometric view of RJ45 jack and RJ45 plug assembly in an unmated state. 
           [0036]      FIG. 30  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an unmated state. 
           [0037]      FIGS. 31 and 32  are views of first and second sides, respectively, of a first rigid PCB according to an embodiment of the present invention. 
           [0038]      FIGS. 33 and 34  are views of first and second sides, respectively, of a first rigid PCB according to an embodiment of the present invention. 
           [0039]      FIGS. 35 and 36  are isometric views of a sled assembly according to an embodiment of the present invention. 
           [0040]      FIGS. 37-39  are isometric exploded views of the sled assembly of  FIGS. 35 and 36 . 
           [0041]      FIGS. 40 and 41  are trimetric views of dual contacts of the sled assembly of  FIGS. 35 and 36 . 
           [0042]      FIGS. 42 and 43  are views of first and second sides, respectively, of a first rigid PCB of the sled assembly of  FIGS. 35 and 36 . 
           [0043]      FIG. 44  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state. 
           [0044]      FIG. 45  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an over-travel state. 
           [0045]      FIG. 46  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state. 
           [0046]      FIG. 47  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state. 
           [0047]      FIG. 48  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in an unmated state. 
           [0048]      FIG. 49  is schematic for the plug/jack combination according to an embodiment of the present invention. 
           [0049]      FIG. 50  is an isometric view of an RJ45 plug according to an embodiment of the present invention. 
           [0050]      FIGS. 51-53  are isometric exploded views of an RJ45 plug according to an embodiment of the present invention 
           [0051]      FIG. 54  is a first side of a first rigid PCB according to an embodiment of the present invention. 
           [0052]      FIG. 55  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a mated state. 
           [0053]      FIG. 56  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a pre-release state. 
           [0054]      FIG. 57  is a cross-section view across the mating interface of RJ45 jack and RJ45 plug assembly in a release state. 
           [0055]      FIG. 58  is schematic for the plug/jack combination according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0056]    An exemplary embodiment of the present invention is illustrated in  FIG. 1 , which shows a communication system  110 , which includes a patch panel  112  with RJ45 jacks  114  and corresponding RJ45 plugs  116 . Respective cables  120  are terminated to plugs  116 , and respective cables  118  are terminated to jacks  114 . Once a plug  116  mates with a jack  114  data can flow in both directions through these connectors. Although the communication system  110  is illustrated in  FIG. 1  as having a patch panel, alternative embodiments can include other active or passive equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, wall jacks, etc. Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and power-over-Ethernet equipment as can be found in data centers and or telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers, and other peripherals as can be found in workstation areas. Communication system  110  can further include cabinets, racks, cable management and overhead routing systems, and other such equipment. 
         [0057]    With the patch panel  112  removed,  FIG. 2  illustrates the RJ45 jack  114  and the RJ45 plug  116  in a mated configuration, and  FIGS. 3-5  illustrate the RJ45 jack  114  and the RJ45 plug  116  in an unmated configuration with  FIG. 4  being rotated 180° about the central axis of cable  118  relative to  FIG. 3 , and  FIG. 5  illustrating a rear isometric view relative to  FIGS. 3 and 4 . 
         [0058]    As shown in  FIGS. 6-8 , the RJ45 jack  114  includes identification icon  122 , jack shield  124 , conductive housing  126 , sled assembly  128 , insulation displacement contacts (IDCs)  154 , rear sled  156 , wire cap assembly  158  (which includes wire containment cap  160 , conductive rear cap  162 , and conductive strain relief clip  88 ). Jack  114  is used to terminate cable  118  which includes conductors  164  and conductive braid  166 . 
         [0059]    The sled assembly  128  is illustrated in greater detail in  FIGS. 9-11 . As shown therein, it includes a first sled support  130 , first plug interface contacts (PICs)  132 , second PICs  134 , flexible PCB  136 , second sled support  138 , first rigid PCB  140 , springs  142 , first wiping contacts  144 , second wiping contacts  146 , first contact support  148 , second contact support  150 , and second rigid PCB  152 . 
         [0060]    Referring to the exploded views of the sled assembly  128  shown in  FIGS. 12-14 , during the assembly of sled assembly  128 , a portion of the flexible PCB  136  is trapped between first rigid PCB  140  and first sled support  130 . Press posts  168  of first sled support  130  align with holes  170  and  172  of respective flexible PCB  136  and first rigid PCB  140 , and flexible PCB  136  is wrapped around mandrel  173  of first sled support  130 . First PICs  132  and second PICs  134  are installed into vias  174  of first rigid PCB  140 , and comb features  176  of second sled support  138  align with both first PICs  132  and second PICs  134 . Snaps  178  of second sled support  138  align with and join snap pockets  180  of first sled support  130  to secure the two pieces together. When second sled support  138  and first sled support  130  are secured, flexible PCB  136 , first PICs  132 , and second PICs  134  become trapped and are thereby secured. Front spring posts  182  of first sled support  130  and back spring posts  184  of second contact support  150  capture springs  142  during final assembly. First wiping contacts  144  align with respective contact slots  186  of first contact support  148  and have a controlled bend  188  around mandrel  190 . Second wiping contacts  146  align with respective contact slots  192  of second contact support  150  and have a controlled bend  194  around mandrel  196 . Relief slots  198  and  200  on respective first contact support  148  and second contact support  150 , provide clearance for IDCs  154  during final assembly. 
         [0061]    After assembly of the sled assembly  128 , IDCs  154  are placed in IDC slots  216  of rear sled  156  and are then secures to second rigid PCB  152  making the back end assembly  228  as shown in  FIG. 15 . Back end assembly  228  is then assembled into conductive housing  126  forming partial jack assembly  229  show in  FIG. 16 . Referring again to  FIG. 15 , rails  230  of conductive housing  126  align back end assembly  228  and match up with the edges of first rigid PCB  140 . Latch arms  232  and  234  of rear sled  156  align with and secure to latch pockets  236  and  238  of conductive housing  126 . Once partial jack assembly  229  is assembled, it is joined with the jack shield  124  as shown in  FIGS. 16 and 17 . Jack shield  124  wraps around partial jack assembly  229  and shield latches  240  align and join with shield snaps  242  to partially enclose the assembly. Thereafter, wire cap grounding flanges  244  of jack shield  124  are wrapped around grounding flange slots  246  of rear sled  156 . When assembled to a cable, wire cap grounding flanges  244  make contact with conductive rear cap  162  to provide an appropriate grounding connection. Plug grounding flange slots  248 ,  250 , and  252  of conductive housing  126  align with respective plug grounding flanges  254 ,  256 , and  258  of jack shield  124 . 
         [0062]    Referring now to  FIGS. 18 and 19 , to connect the partially assembled jack to a data cable, cable  118  is strung through rear conductive cap  162  and the wire containment cap  160  with conductor slots  210  enabling alignment of conductors  164  during assembly. Wire containment cap  160  is secured to conductive rear cap  162  through latches  202  and  204  which align with latch pockets  206  and  208 , respectively. In their default state, flexible arms  212  of conductive strain relief clip  88  engage with teeth  214  of conductive rear cap  162 . To disengage, the flexible arms  212  are compressed inward towards each other. As the wire cap assembly  158  is assembled, conductors  164  are positioned in preparation for joining with the partially assembled jack. Thereafter, wire cap assembly  158  is secured to rear sled  156  through the engagement of the flexible latch  218  of rear sled  156  with a corresponding latching feature  220 . The mating of the wire cap assembly  158  and the rear sled  156  causes the IDCs  154  to make contact with the conductors  164  of the cable  118  and thereby establish a communication link through the jack. 
         [0063]    To achieve the improved levels of reliability, jack  114  utilizes first and second wiping contacts  144 ,  146  in conjunction with specifically designed contacts on the rigid PCB  140 .  FIG. 20  is a first side of first rigid PCB  140  and  FIG. 21  is a second side of first rigid PCB  140 . First rigid PCB  140  includes first contact pads  288  and second contact pads  290 . Each contact pad contains a mating portion and a disconnect portion. The mating portion is the section of the contact pad with which a respective wiping contact is engaged during the mated and over-travel states. The disconnect portion is the section of the contact pad with which a respective wiping contact is engaged between the pre-release and release states. In the currently described embodiment, contact pads  288  have a mating portion  292  and a disconnect portion  294 , and contact pads  290  have a mating portion  296  and a disconnect portion  298 . For each contact pad, the mating portion and the disconnect portion is positioned such that each portion comes into direct contact with an alternate side of a respective wiping contact. This configuration allows for potential arcing or corona damage to occur on one side of the wiping contact, leaving the other side unharmed. 
         [0064]      FIGS. 22-30  illustrate the interaction between the contact pads and the wiping contacts throughout various stages of the plug/jack mating process. It is worth noting that in the section views of  FIGS. 22, 24, 26, 28, and 30 , sled assembly  128  and plug PCB assembly  274  are not sectioned to show the plug/jack mating interaction between wire contacts  276 ,  278  and PICs  132 ,  134 , and the interaction between the wiping contacts  144  and contact pads  288 . In addition, press posts  168  have been leveled off along the surface of respective first rigid PCB  140  in all section views for clarity. 
         [0065]      FIG. 22  is a cross-section view, taken along section line  22 - 22  of  FIG. 2 , across the mating interface of shielded RJ45 network jack  114  and shielded RJ45 plug assembly  116 . In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 , and first wiping contacts  144  are in contact with mating portion  292  of first contact pads  288 . Second wiping contacts  146  are in contact with mating portion  296  of second contact pads  290  (not shown). As illustrated in the detailed view of the wiping contacts and contact pads, wiping contacts  144  interface with the mating portion along the wiping contacts&#39; first side. This is the static state of a mated RJ45 plug  116 /jack  114  combination. 
         [0066]      FIG. 23  is a front isometric view of RJ45 network jack  114  and RJ45 plug assembly  116  and respective cables  118  and  120  in the over-travel state. The over-travel state allows for insertion of RJ45 plug assembly  116  into shielded RJ45 network jack  114 . RJ45 plug assembly  116  is inserted roughly . 032  inches further into RJ45 network jack  114  when compared to the mated static state shown in  FIG. 2 .  FIG. 24  is a cross-section view, taken along section line  24 - 24  of  FIG. 23  across the mating interface of RJ45 network jack  114  and RJ45 plug assembly  116  in the over-travel state. In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 . First wiping contacts  144  are in contact with mating portion  292  of first contact pads  288 . Second wiping contacts  146  are in contact with mating portion  296  of second contact pads  290  (not shown). Similar to the static state, wiping contacts  144  interface with the mating portion along the wiping contacts&#39; first side. In between the mated state and the over-travel state there is no mechanical/electrical disconnection between any plug/jack interfaces. 
         [0067]      FIG. 25  is a front isometric view of RJ45 network jack  114  and RJ45 plug assembly  116  and respective cables  118  and  120  in the pre-release state. The pre-release state is a period where the wiping contacts are in contact with the disconnect portion of their respective contact pads but prior to the release state in the retraction cycle (this position is equivalent to the position during initial insertion of shielded RJ45 plug assembly  116  into shielded RJ45 network jack  114  prior to the over-travel and mated states).  FIG. 26  is a cross-section view, taken along section line  26 - 26  of  FIG. 25  across the mating interface of RJ45 network jack  114  and RJ45 plug assembly  116  in the pre-release state. In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 . First wiping contacts  144  are in contact with disconnect portion  294  of first contact pads  288 . Second wiping contacts  146  are in contact with disconnect portion  298  of second contact pads  290  (not shown). As illustrated in the detailed view of the wiping contacts and contact pads, wiping contacts  144  interface with the disconnect portion along the wiping contacts&#39; second (alternate) side as compared to the static and over-travel states. 
         [0068]      FIG. 27  is a front isometric view of RJ45 network jack  114  and RJ45 plug assembly  116  and respective cables  118  and  120  in the release state. The release state is the moment before wire contacts  276  and  278  are no longer in electrical contact with respective first PICs  132  and second PICs  134  (this position is equivalent to the position during initial insertion of shielded RJ45 plug assembly  116  into shielded RJ45 network jack  114  just after the wire contacts  276  and  278  come into electrical contact with respective first PICs  132  and second PICs  134 ).  FIG. 28  is a cross-section view, taken along section line  28 - 28  of  FIG. 27  across the mating interface of RJ45 network jack  114  and RJ45 plug assembly  116  in the release state. In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 . First wiping contacts  144  are no longer in contact with disconnect portion  294  of first contact pads  288 . Second wiping contacts  146  are no longer in contact with disconnect portion  298  of second contact pads  290  (not shown). In between the pre-release state and the release state respective wiping contacts disconnect from contact pads along the disconnect portion of the contact pad. The electrical discharge that occurs upon disconnection of the wiping contacts and the contact pads occurs on the disconnect portion of the contact pad and corresponding side of the wiping contact. This is opposite of the mating side of the contact and controls where the damage to the contact occurs in the case of PoE damage during use. Contact point  300 , between wire contacts  276  and  278  and respective first PICs  132  and second PICs  134 , remains relatively the same between mated, over-travel, pre-release, and release states with a minimal wiping zone as this helps reduce the electrical distance to compensation that may be implemented on the PCB  140 . 
         [0069]      FIG. 29  is a front isometric view of RJ45 network jack  114  and RJ45 plug assembly  116  and respective cables  118  and  120  in the unmated state.  FIG. 30  is a cross-section view, taken along section line  30 - 30  of  FIG. 29  across the mating interface of shielded RJ45 network jack  114  and shielded RJ45 plug assembly  116  in the unmated state. In this state wire contacts  276  and  278  are no longer in electrical contact with respective first PICs  132  and second PICs  134 . First wiping contacts  144  are no longer in contact with first contact pads  288 . Second wiping contacts  146  are no longer in contact with second contact pads  290  (not shown). Sled assembly  128  is in approximately the same position in the unmated state as in the release state. 
         [0070]    In order to ensure contact on a specific side of either first contact pads  288  or second contact pads  290 , it is preferred that first contact pads  288  or second contact pads  290  be raised with respect to the rest of the PCB in the area of contact. Some non-limiting means of ensuring reliable contact can include increasing the plating thickness on contact pads  288  and  290 , or removing/lowering the adjacent solder mask. 
         [0071]    An alternative embodiment of the first rigid PCB  302  is shown in  FIGS. 31 and 32  with  FIG. 31  showing a first side of first rigid PCB  302  and  FIG. 32  showing a second side of first rigid PCB  302 . First rigid PCB  302  includes first contact pads  304  and second contact pads  306 . As with first rigid PCB  140 , each contact pad contains a mating portion and a disconnect portion, except there is no perpendicular section linking the two portions on the contact pads of PCB  302 . Instead, PCB  302  uses an angled section. It should be noted that the shape of the contact pads may take any form so long as the mating portion and the disconnect portion are positioned such that the wiping contact maintains a constant electrical bond with the contact pad as it travels between the mating and disconnect portions and such that different sections of the wiping contacts make contact with the mating and disconnect portions. 
         [0072]    Yet another alternative embodiment of the first rigid PCB  308  is shown in  FIGS. 33 and 34  with  FIG. 33  showing a first side of first rigid PCB  308  and  FIG. 34  showing a second side of first rigid PCB  308 . First rigid PCB  308  includes first contact pads  310  and second contact pads  312 . Cutouts  314  and  316  on first rigid PCB  308  are a secondary mechanical alternative that is less dependent on minor changes in plating or solder mask to ensure reliable electrical contact on the specific side of wiping contacts and contact pads. The shape of the cut out sections can be any shape so long as the contact pads provide appropriate functionality as described previously. 
         [0073]      FIGS. 35-39  illustrate an alternative embodiment of a sled assembly  318  that could be used in jack  354  (which is similar in construction to jack  114 ). Sled assembly  318  includes first sled support  130 , first PICs  132 , second PICs  134 , flexible PCB  320 , second sled support  138 , first rigid PCB  322 , springs  142 , first dual wiping contacts  324 , second dual wiping contacts  326 , first dual contact support  328 , second dual contact support  330 , and second rigid PCB  332 . While flexible PCB  320  and second rigid PCB  332  may be mechanically the same as respective flexible PCB  136  and second rigid PCB  152 , with the added crosstalk the electrical design of these boards may be different. 
         [0074]    The primary difference between sled assembly  318  and the previously described sled assembly  128  is in the design of the wiping contacts and the design of the contact pads on the first rigid PCB  322 . 
         [0075]      FIG. 40  is a trimetric view of second dual contacts  326  and  FIG. 41  is a trimetric view of first dual contacts  324 . Second dual wiping contacts  326  include two wiping contacts comprised of a preferred mating leg  338  and a sacrificial leg  340 . Likewise, first dual wiping contacts  324  include two wiping contacts comprised of a preferred mating leg  334  and sacrificial leg  336 .  FIG. 42  illustrates a first side of first rigid PCB  322  and  FIG. 43  illustrates a second side of first rigid PCB  322 . It includes first dual contact pads  342 , which include a mating portion  344  and sacrificial portion  346 , and second dual contact pads  348 , which include a mating portion  350  and sacrificial portion  352 . 
         [0076]    The interaction of the dual wiping contacts and the dual contact pads is shown in  FIGS. 44-48  which illustrate cross-section views of jack  354  and plug  116  at different mating states. FIG.  44  shows the jack  354  and the plug  116  in a fully mated state. In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 . Preferred mating leg  334  of first dual wiping contacts  324  is in contact with mating portions  344  of first dual contact pads  342 . Sacrificial mating leg  336  of first dual wiping contacts  324  is in superfluous contact with sacrificial portion  346  of first dual contact pads  342 . Preferred mating leg  338  of second dual wiping contacts  326  is in contact with mating portion  350  of second dual contact pads  348  (not shown). Sacrificial mating leg  340  of second dual wiping contacts  326  is in superfluous contact with sacrificial leg  352  of second dual contact pads  348  (not shown). 
         [0077]      FIG. 45  is a cross-section view of RJ45 network jack  354  and RJ45 plug assembly  116 , with respective cables  118  and  120 , shown in the over-travel state. In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 . Preferred mating legs  334  of first dual wiping contacts  324  are in contact with mating portions  344  of first dual contact pads  342 . Sacrificial mating legs  336  of first dual wiping contacts  324  are in superfluous contact with sacrificial portions  346  of first dual contact pads  342 . Preferred mating legs  338  of second dual wiping contacts  326  are in contact with mating portions  350  of second dual contact pads  348  (not shown). Sacrificial mating legs  340  of second dual wiping contacts  326  are in superfluous contact with sacrificial portions  352  of second dual contact pads  348  (not shown). In between the mated state and the over-travel state there is no mechanical/electrical disconnection between the plug/jack interfaces. 
         [0078]      FIG. 46  is a cross-section view of RJ45 network jack  354  and RJ45 plug assembly  116 , with respective cables  118  and  120 , shown in the pre-release state. In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 . Preferred mating legs  334  of first dual wiping contacts  324  are no longer in contact with mating portions  344  of first dual contact pads  342 . However, sacrificial mating legs  336  of first dual wiping contacts  324  are still in contact with sacrificial portions  346  of first dual contact pads  342 . Likewise, while preferred mating legs  338  of second dual wiping contacts  326  are no longer in contact with mating portions  350  of second dual contact pads  348  (not shown), sacrificial mating legs  340  of second dual wiping contacts  326  are still in contact with sacrificial portions  352  of second dual contact pads  348 . Given that continuity between the dual wiping contacts and the dual contact pads is still maintained at this this stage, the disconnection (or connection in case of plug insertion) of the preferred mating legs from the respective mating portions of the dual contact pads does not result an arcing or corona discharge, preventing potential damage to the respective surfaces. 
         [0079]      FIG. 47  is a cross-section view of RJ45 network jack  354  and RJ45 plug assembly  116 , with respective cables  118  and  120 , shown in the release state. In this state wire contacts  276  and  278  are in electrical contact with respective first PICs  132  and second PICs  134 . Preferred mating legs  334  of first dual wiping contacts  324  are no longer in contact with mating portions  344  of first dual contact pads  342 . Sacrificial mating legs  336  of first dual wiping contacts  324  are no longer in contact with sacrificial portions  346  of first dual contact pads  342 . Preferred mating legs  338  of second dual wiping contacts  326  are no longer in contact with mating portions  350  of second dual contact pads  348  (not shown). Sacrificial mating legs  340  of second dual wiping contacts  326  are no longer in contact with sacrificial portions  352  of second dual contact pads  348  (not shown). In between the pre-release state and the release state respective sacrificial mating legs disconnect from sacrificial portions of contact pads (during the insertion of the plug into the jack the respective sacrificial mating legs connect to sacrificial portions of contact pads). The electrical discharge upon disconnection/connection of the sacrificial mating legs and the sacrificial portions of the contact pads occurs outside of the preferred mating zone and in the sacrificial areas. This helps maintain the integrity of the preferred mating legs of the dual wiping contacts and the mating portion of the dual contact pads. 
         [0080]      FIG. 48  is a cross-section view of RJ45 network jack  354  and RJ45 plug assembly  116 , with respective cables  118  and  120 , shown in the unmated state. In this state wire contacts  276  and  278  are no longer in electrical contact with respective first PICs  132  and second PICs  134 . Preferred mating legs  334  of first dual wiping contacts  324  are no longer in contact with mating portions  344  of first dual contact pads  342 . Sacrificial mating legs  336  of first dual wiping contacts  324  are no longer in contact with sacrificial portions  346  of first dual contact pads  342 . Preferred mating legs  338  of second dual wiping contacts  326  are no longer in contact with mating portions  350  of second dual contact pads  348  (not shown). Sacrificial mating legs  340  of second dual wiping contacts  326  are no longer in contact with sacrificial portions  352  of second dual contact pads  348 . Sled assembly  318  is in approximately the same position in the unmated state and the release state. 
         [0081]    First wiping contacts  144 , second wiping contacts  146 , first dual wiping contacts  324 , and second dual wiping contacts  326  are shown with compliant pins but may be attached to respective second rigid PCBs through any non-limiting means. First PICs  132  and second PICs  134  are shown with solder connections but may be attached to respective first rigid PCBs through any non-limiting means. Cable  118  and  120  are shown as shielded cable but may be any other non-limiting form of cable including but not limited to F/UTP or UTP cabling. 
         [0082]    An exemplary schematic for the plug  116 /jack  114 ,  354  combination is shown in  FIG. 49 . 
         [0083]    While the above-described embodiments illustrate examples of jacks with improved robustness for PoE, it is also possible to provide improved designs in the plug.  FIG. 50  illustrates an isometric view of one such plug  116  by way of an exemplary embodiment. Plug  116  includes front housing  122 , left housing  140 , right housing  142 , and bend radius control boot  144 .  FIGS. 51-53  provide exploded views of the plug  116 . As shown therein, plug  116  also includes a first PCB assembly  124  with first plug contacts  126 , second plug contacts  128 , first rigid PCB  130 , and springs  132 , and a second PCB assembly  134  with wiping contacts  136  and second rigid PCB  138 . Back PCB pads  146  on second rigid PCB  138  are used to terminate cable  120 ; through other non-limiting means of termination may be used. During mating/un-mating with a corresponding jack, while second rigid PCB  138  remains stationary relative to the plug&#39;s housings, the first rigid PCB assembly  124  translates between different positions. The first rigid PCB  130  and second rigid PCB  138  are electrically linked to each other via wiping contacts  136  and contact pads  148 . 
         [0084]      FIG. 54  illustrates a first side of first rigid PCB  130 . Each contact pad  148  contains a mating portion  150  and a disconnect portion  152 . The mating portion is the portion of a contact pad that is engaged with a respective wiping contact during the mated and over-travel state (the over-travel state allows for insertion of RJ45 plug assembly  116  into RJ45 network jack  54 . The disconnect portion is the portion of a contact pad that is engaged with a respective wiping contact during the pre-release state. As will be made clear during the discussion of the following drawings, that each mating portion and respective disconnect portion are displaced laterally from each other. This allows a single wiping contact that is wide enough to at least partially overlap both of the portions to rely on one side thereof to make contact with the mating portion and to rely on the second side thereof to make contact with the disconnect portion. This allows the second side (i.e., the side that makes contact with the disconnect portion) to sustain most of the damage that may be caused by PoE, leaving the first side (i.e., the side that makes contact with the mating portion) unscathed. 
         [0085]      FIG. 55  is a cross-section view across the mating interface of shielded RJ45 network jack  54  and RJ45 plug assembly  116  (wiping contacts  136  and first rigid PCB  130  are not sectioned to show the interface between wiping contacts  136  and first rigid PCB  130 ). In this state plug contacts  126  and  128  are in electrical contact with respective PICs  70 . Wiping contacts  136  are in contact with mating portion  150  of contact pads  148 . This is the static (mated) state of an RJ45 network plug  116  mated with an RJ45 network jack  54 . 
         [0086]      FIG. 56  is a cross-section view across the mating interface of shielded RJ45 network jack  54  and RJ45 plug assembly  116  shown in the pre-release state. In this state plug contacts  126  and  128  are in electrical contact with respective PICs  70 . Wiping contacts  136  are in contact with disconnect portion  152  of contact pads  148 . In the pre-release state there is still an electrical connection throughout the channel, but it is not a static state of installed RJ45 network jack  54  and RJ45 plug assembly  116 . This state occurs either during insertion of RJ45 plug assembly  116  into RJ45 network jack  54  prior to the mated state, or upon retraction of RJ45 plug assembly  116  from RJ45 network jack  54  prior to the release state. 
         [0087]      FIG. 57  is a cross-section view across the mating interface of shielded RJ45 network jack  54  and RJ45 plug assembly  116  in the release state. In this state, while plug contacts  126  and  128  are in electrical contact with respective PICs  70 , wiping contacts  136  are no longer in contact with contact pads  148 . In the release state there is no longer an electrical connection throughout the channel. This state occurs either during insertion of RJ45 plug assembly  116  into RJ45 network jack  54  prior to the pre-release state or upon retraction of RJ45 plug assembly  116  from RJ45 network jack  54  after the pre-release state. In between the pre-release state and the release state, respective wiping contacts  136  disconnect from contact pads  148  along the disconnect portions  152 . The electrical discharge upon disconnection of wiping contacts  136  and contact pads  148  occurs on disconnect portion  152  and corresponding side of wiping contact  136 . This is opposite of the side of the wiping contact  136  that contacts the mating portion, controlling where the damage to the contact occurs in the case of PoE. In between the mated state and the release state there is approximately 0.040″ of travel for first rigid PCB assembly. In the mated/over-travel state the plug/jack interface is approximately in the IEC-60603-7:2010 preferred electrical mating point location. In all other states the plug/jack interface is typically not in the IEC-60603-7:2010 preferred electrical mating point location, and the force between PICs  70  and plug contacts  126  and  128  overcomes the force from springs  132 . After the release state, the unmated state follows in which plug contacts  126  and  128  are no longer in electrical contact with respective PICs  70 . 
         [0088]    To ensure contact on a specific side of contact pads  148 , it is preferred that contact pads  148  be raised with respect to the rest of the PCB in the area of contact. Some non-limiting means of ensuring reliable contact can include increasing the plating thickness on contact pads  148  or removing/lowering the adjacent solder mask. 
         [0089]      FIG. 58  illustrates an exemplary schematic for the plug  116 /jack  54  combination. 
         [0090]    Note that while this invention has been described in terms of several embodiments, these embodiments are non-limiting (regardless of whether they have been labeled as exemplary or not), and there are alterations, permutations, and equivalents, which fall within the scope of this invention. For example, while references have been made to rigid PCBs, one of ordinary skill in the art would recognize that the use of flexible PCBs or combinations of flex/rigid PCBs would also be within the scope of the disclosure. Additionally, the described embodiments should not be interpreted as mutually exclusive, and should instead be understood as potentially combinable if such combinations are permissive. Furthermore, in some cases same numbers are used to refer to similar elements in different embodiment. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that claims that may follow be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.

Technology Category: 5