Patent Document

CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. application Ser. No. 13/347,276, filed Jan. 10, 2012, which is a continuation of U.S. application Ser. No. 12/949,482, filed Nov. 18, 2010, now U.S. Pat. No. 8,113,856, issued on Feb. 14, 2012, which is a continuation of U.S. application Ser. No. 12/749,961, filed Mar. 30, 2010, now U.S. Pat. No. 7,862,365, issued Jan. 4, 2011, which is a continuation of U.S. application Ser. No. 12/331,523, filed Dec. 10, 2008, now U.S. Pat. No. 7,722,378, issued May 25, 2010, which is a continuation of U.S. application Ser. No. 11/207,853, filed Aug. 18, 2005, which claims priority from U.S. Provisional Application Ser. No. 60/603,142, filed Aug. 19, 2004, the entire disclosure of which is hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a cover for a jack module, and more particularly, to a tool for removing the cover from the jack module. 
     BACKGROUND OF THE INVENTION 
     Dust covers, also known as block-out covers, are frequently inserted into jack modules to protect the module and prevent entry of undesirable objects. Some covers include multiple parts or special latch connectors that secure the cover to the modules. Other covers have relatively large open areas designed to receive a flat tool that would enable the end user to release the cover from the module so that it could be removed from the module. The covers with the larger open areas, however, may be accidentally removed from the module. 
     There are also covers that are inserted in the opening of a module and then locked by a rotating key. These covers may only be removed by inserting the key and rotating it to unlock or release the cover from the module. Thus, it is desirable to provide an improved cover and removal tool where the cover would not be accidentally removed from a module but would be easily removed from the module by a simple tool. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a cover for a jack module and a tool for removing the cover from the jack module. The cover has at least one locking arm disposed within the cover for securing the cover to the jack module. The cover also has at least one window designed to receive the removal tool. The tool has a body, a lever secured to the body and prongs extending from the body. The prongs have a cam surface that deflects the cover from locking engagement with the jack module when the tool is inserted in the window in the cover. The lever engages the cover when the tool is inserted into the cover thereby enabling the tool to remove the disengaged cover from the jack module. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a perspective view of a block-out cover installed in a jack module and a block-out removal tool of the present invention; 
         FIG. 2  illustrates a top front perspective view of the block-out cover illustrated in  FIG. 1 ; 
         FIG. 3  illustrates a top rear perspective view of the block-out cover illustrated in  FIG. 1 ; 
         FIG. 4  illustrates a bottom rear perspective view of the block-out cover illustrated in  FIG. 1 ; 
         FIG. 5  illustrates a top perspective view of the removal tool illustrated in  FIG. 1 ; 
         FIG. 6  illustrates a bottom perspective view of the removal tool illustrated in  FIG. 1 ; 
         FIG. 7  illustrates a top plan view of the block-out cover installed in the jack module and the block-out removal tool illustrated in  FIG. 1 ; 
         FIG. 8  illustrates a cross sectional view of the block-out cover and the removal tool taken along line  8 - 8  in  FIG. 7 ; 
         FIG. 9  illustrates a perspective view of the removal tool partially inserted in the block-out cover installed in the jack module illustrated in  FIG. 1 ; 
         FIG. 10  illustrates a cross sectional view of the removal tool partially inserted in the block-out cover installed in the jack module taken along line  10 - 10  in  FIG. 9 ; 
         FIG. 11  illustrates a front cross sectional view of the block-out cover installed in the jack module taken along line  11 - 11  in  FIG. 10 ; 
         FIG. 12  illustrates a perspective view of the removal tool inserted in the block-out cover installed in the jack module illustrated in  FIG. 1 ; 
         FIG. 13  illustrates a cross sectional view of the removal tool inserted in the block-out cover installed in the jack module taken along line  13 - 13  in  FIG. 12 ; 
         FIG. 14  illustrates the removal tool removing the block-out cover from the jack module illustrated in  FIG. 1 ; 
         FIG. 15  illustrates a side view of the removal tool being disengaged from the block-out cover illustrated in  FIG. 1 ; 
         FIG. 16  illustrates a side view of the removal tool disengaged from the block-out cover illustrated in  FIG. 1 ; 
         FIG. 17  illustrates a perspective view of an alternative design of the block-out cover installed in a jack module and a block-out removal tool of the present invention; 
         FIG. 18  illustrates a top front perspective view of the block-out cover illustrated in  FIG. 17 ; 
         FIG. 19  illustrates a top rear perspective view of the block-out cover illustrated in  FIG. 17 ; 
         FIG. 20  illustrates a bottom rear perspective view of the block-out cover illustrated in  FIG. 17 ; 
         FIG. 21  illustrates a rear cross sectional view of the block-out cover taken along line  21 - 21  in  FIG. 20 ; 
         FIG. 22  illustrates a top perspective view of the removal tool illustrated in  FIG. 17 ; 
         FIG. 23  illustrates a bottom perspective view of the removal tool illustrated in  FIG. 17 ; 
         FIG. 24  illustrates a front cross sectional view of the removal tool taken along line  24 - 24  in  FIG. 22 ; 
         FIG. 25  illustrates a top plan view of the removal tool partially inserted in the block-out cover installed in the jack module illustrated in  FIG. 17 ; 
         FIG. 26  illustrates a cross sectional view of the removal tool partially inserted in the block-out cover installed in the jack module taken along line  26 - 26  in  FIG. 25 ; 
         FIG. 27  illustrates a cross sectional view of the removal tool partially inserted in the block-out cover installed in the jack module taken along line  27 - 27  in  FIG. 25 ; 
         FIG. 28  illustrates a cross sectional view of the removal tool fully inserted in the block-out cover installed in the jack module illustrated in  FIG. 26 ; 
         FIG. 29  illustrates a cross sectional view of the removal tool fully inserted in the block-out cover installed in the jack module illustrated in  FIG. 27 ; 
         FIG. 30  illustrates a top front perspective view of the block-out cover of  FIG. 17  with side spring tabs; 
         FIG. 31  illustrates a side view of the block-out cover of  FIG. 30  installed in a jack module; and 
         FIG. 32  illustrates a cross sectional view of the block-out cover installed in a jack module taken along line  32 - 32  in  FIG. 31 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates the removal tool  60  and the block-out cover  30  installed in a jack module  20  of the present invention. As described below, the removal tool is designed to remove the block-out cover from the jack module by simply inserting the tool into the cover until the tool is attached to the cover. Next, the tool and attached cover are simply pulled out of the module. 
     As shown in  FIGS. 2-4 , the block-out cover  30  includes a front  32 , back  34  and sides  36  that define an open center section  38  therebetween. The front  32  of the block-out cover includes two access windows  40 , as shown in  FIG. 2 . The access windows  40  receive the prongs  80  of the removal tool  60 . The access windows  40  have a rectangular shape. However, the access windows may be formed from various shapes as long as the prongs  80  of the removal tool  60  are able to enter and be disposed therein. 
     The front  32  of the block-out cover  30  also includes a connection member  42  that is positioned below the access windows  40  preferably at the center of the cover. The connection member  42  is integrally formed with the cover. The connection member  42  includes a top portion  44  extending from the cover, a downwardly facing hook  46  and sides  48 , as illustrated in  FIG. 8 . The hook  46  extends downward from the top portion  44  and the sides  48  surround the hook  46 . As will be described below, the hook  46  engages a hook  74  extending from the release lever  70  of the removal tool  60  to secure the removal tool  60  to the block-out cover  30 . 
       FIGS. 2-4  also illustrate the block-out cover  30  with locking arms  50  disposed in the open center section  38  of the block-out cover  30 . The arms  50  are integrally formed with the block-out cover  30  such that the arms  50  extend from the back  34  of the cover  30  into the open center section  38 . The arms  50  comprise first portions  51 , second portions or upwardly extending members  52  and third portions or downwardly extending members  54 . As shown in  FIG. 8 , a portion of back  34  and arms  50  may form a generally U-shaped profile. Back  34  may comprise bar member  35  connecting the opposing sides  36  of the cover  30 , with an open space beneath bar member  35  such that back  34  is open ended. Additionally, each downwardly extending member  54  has a flange  56  that extends outwardly towards the sides  36  of the cover  30 . The upwardly extending members  52  enable the cover  30  to be secured inside the jack module  20 , as illustrated in  FIG. 8 . As will be described below, the flanges  56  of the downwardly extending members  54  are deflected to enable the removal tool  60  to disengage the upwardly extending members  52  of the arms  50  from the jack module  20 . 
       FIGS. 5 and 6  illustrate the removal tool  60  of the present invention. The removal tool  60  has a partial oblong shaped body  62  that is easy to handle. The removal tool  60 , however, may be formed from a variety of shapes, as desired. The body  62  of the removal tool  60  includes an opening  64  in the center of the body and a front edge  66 . A release lever  70  is positioned within the opening  64  at the center of the removal tool  60 . The release lever  70  is integrally formed with the removal tool. The release lever  70  includes a raised knob  72  located near the center of the lever and an upwardly facing hook  74  located at the free end of the lever. As will be described with respect to  FIGS. 15 and 16 , when the end user pushes the raised knob  72  downwards the hook  74  at the free end of the lever also moves downwards. 
     The removal tool  60  also includes two prongs  80  that extend from the front edge  66  of the tool  60 . One of the prongs  80  is preferably positioned on either side of the release lever  70 . Each of the prongs  80  includes an inner side  82 , an outer side  84  and a front end  86 . The prongs  80  include a ramp shaped cam  90  located on the inner side  82  of each prong  80 . The ramp shaped cams  90  extend from the front end  86  of each prong  80  downward towards the front edge  66  of the tool  60 . The ramp shaped cams  90  are designed to engage the flanges  56  of the downwardly extending members  54  of the arms  50  when the tool  60  is inserted in the block-out cover  30 . 
     As shown in  FIGS. 7 and 8 , when it is desirable to remove the block-out cover  30  from the jack module  20 , the removal tool  60  is positioned such that the prongs  80  are aligned with the access windows  40  in the front of the block-out cover  30  and the lever  70  of the removal tool  60  is aligned with the connection member  42  extending from the front of the block-out cover  30 . 
       FIGS. 9 and 10  illustrate the removal tool  60  being partially inserted in the block-out cover  30 . As the prongs  80  of the removal tool  60  enter the access windows  40  in the block-out cover  30 , the ramp shaped cams  90  engage the flanges  56  of the downwardly extending members  54  of the arms  50 . As shown in  FIG. 11 , the upwardly extending members  52  of the arms  50  of the block-out cover  30  engage an upper shelf  22  in the jack module  20  to maintain the block-out cover  30  in the jack module  20 . However, as the ramp shaped cams  90  engage the flanges  56  of the downwardly extending members  54 , the upwardly extending members  52  of the arms  50  are deflected away from the upper shelf  22  of the jack module  20 . 
       FIGS. 12 and 13  illustrate the removal tool  60  fully inserted into the block-out cover  30 . As illustrated in  FIG. 13 , the ramp shaped cams  90  have deflected the arms  50  downwardly and back towards the back  34  of the cover  30 . As a result, the upwardly extending members  52  of the arms  50  no longer engage the upper shelf  22  of the jack module  20 . Since the arms  50  have been disengaged from the jack module  20 , the block-out cover  30  may be removed from the jack module  20 . 
       FIGS. 12 and 13  also illustrate that once the tool  60  has been inserted in the cover  30 , the hook  74  at the free end of the lever  70  snaps into engagement with the hook  46  extending from the connection member  42  of the cover  30 . Thus, the removal tool  60  is secured to the block-out cover  30 . As illustrated in  FIG. 14 , after the removal tool  60  has been inserted and secured to the block-out cover  30 , the removal tool  60  and connected block-out cover  30  may be easily removed from the jack module  20 . 
       FIGS. 15 and 16  illustrate the removal tool  60  being removed from the block-out cover  30 . As illustrated in  FIG. 15 , the release knob  72  of the lever  70  is depressed thereby lowering the hook  74  at the end of the lever  70 . As a result, the hook  74  at the end of the lever  70  is no longer engaging the hook  46  extending from the connection member  42  of the cover  30 . As shown in  FIG. 16 , once the hooks have been disengaged, the tool  60  may be pulled away from the block-out cover  30 . As the tool  60  is pulled from the block-out cover  30 , the arms  50  of the block-out cover  30  move forward and upward back to their initial position. 
       FIGS. 17-29  illustrate an alternative design of the block-out cover and removal tool of the present invention. As illustrated in  FIGS. 18-21 , the block-out cover  130  includes a front  132 , a back  134  and sides  136  that define an open section  138  therebetween. The front  132  of the alternative block-out cover  130  is shaped so that the block-out cover fits inside any standard RJ-45 data jack, as illustrated in  FIG. 17 . 
     The front  132  of the block-out cover  130  includes two access windows  140 , as shown in  FIG. 18 . The access windows  140  include a straight top portion  141  and a curved bottom portion  143 . The shape of the access windows  140  restricts the insertion of the removal tool  160  so that the tool  160  may be inserted in the access windows  140  in only one specific orientation, as shown in FIGS.  17  and  25 - 29 . 
     The front  132  of the block-out cover  130  also includes a connection member  142  that is positioned between the access windows  140  in the center of the block-out cover  130 . The connection member  142  is integrally formed with the block-out cover  130 . The connection member  142  includes a top portion  144  extending outwardly from the cover, a downwardly facing hook  146  and sides  148 , as illustrated in  FIG. 26 . The hook  146  engages a hook  174  on the release lever  170  of the removal tool  160  to secure the removal tool  160  to the block-out cover  130 . 
     The block-out cover  130  also includes a single piece locking arm  150  integrally formed with the block-out cover  130 . The arm  150  extends from the back  134  of the cover  130  into the open center section  138  of the cover  130 . The arm  150  includes first portion  151 , second portion or an upwardly extending member  152  and third portion or a downwardly extending member  154 . As shown in  FIG. 26 , a portion of back  134  and arm  150  may form a generally U-shaped profile. Back  134  may comprise bar member  135  connecting the opposing sides  136  of the cover  130 , with an open space beneath bar member such that back  134  is open ended. Additionally, the upwardly extending member  152  of the arm  150  engages an upper shelf  122  in the jack module to secure the cover  130  to the jack module  120  (see  FIGS. 26-27 ). The downwardly extending member  154  includes flanges  156  that extend outwardly from each side of the downwardly extending member  154 . As shown in  FIG. 21 , the flanges  156  extend towards the sides  136  of the cover  130 . As discussed below, the removal tool deflects the flanges  156  extending from the downwardly extending member  154  enabling the upwardly extending member  152  to become disengaged from the upper shelf  122  of the jack module  120 . 
     As illustrated in  FIGS. 22-24 , the removal tool  160  includes a body  162  with an opening  164  in the center of the removal tool  160  and an angled front edge  166 . The removal tool  160  also includes a release lever  170  positioned within the opening  164  and prongs  180  that extend outwardly from the front edge  166  of the removal tool  160 . The release lever  170  has a raised knob  172  located near the center of the lever  170  and an upwardly facing hook  174  located at the free end of the lever  170 . The prongs  180  include an inner side  182 , an outer side  184  and a front end  186 . The inner side  182  of each prong  180  includes a curved cam  190  that extends from the front end  186  of each prong  180  downwards towards the front edge  166  of the tool  160 . The curved cam  190  increases the vertical deflection of the arm  150  when the removal tool  160  is inserted in the block-out cover  130 . 
     As illustrated in  FIGS. 25-29 , the prongs  180  of the removal tool  160  are aligned with the windows  140  in the block-out cover  130 . As the prongs  180  of the removal tool  160  are inserted in the windows  140  of the block-out cover  130 , the curved cam surface  190  of the prongs  180  engages the flanges  156  to deflect the arm  150  downward and back towards the back  134  of the block-out cover  130 . As the prongs  180  deflect the arm  150 , the upwardly extending member  152  of the arm  150  is disengaged from the upper shelf  122  in the jack module  120 . 
     Additionally, as the removal tool  160  is inserted in the block-out cover  130 , the hook  174  of the release lever  170  engages the hook  146  of the connection member  142  to secure the removal tool to the block-out cover. Once the arm  150  has been disengaged, the removal tool and the attached block-out cover  130  may be removed from the jack module  120 . To remove the tool from the block-out cover, the release knob  172  of the lever  170  is depressed to lower the hook  174  at the end of the lever thereby disengaging the hook  146  of the connection member  142 . Once the hooks are disengaged, the removal tool  160  maybe removed from the block-out cover  130 . 
     If desired, the block-out cover may include a spring tab  137  located at each side  136  of the cover (see  FIGS. 30-32 ). The spring tabs  137  fill the gap between the block-out cover  130  and the jack module  120  when the block-out cover  130  is installed in the jack module  120 . Thus, the spring tabs  137  provide a tighter fit between the block-out cover  130  and the jack module  120 . 
     The removal tool and block-out cover of the present invention provide a safe and secure device for blocking jack modules. The block-out cover is designed so that it may only be removed with the two pronged removal tool of the present invention. As a result, the block-out tool would not accidentally or undesirably be removed by a screwdriver or other flat tool. 
     Furthermore, while the particular preferred embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the teaching of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.

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