Modular plug having improved crosstalk characteristics

Information

  • Patent Grant
  • 6227899
  • Patent Number
    6,227,899
  • Date Filed
    Thursday, December 31, 1998
    25 years ago
  • Date Issued
    Tuesday, May 8, 2001
    23 years ago
Abstract
A modular telephone-style plug features a substantially three sided intermediate section which integrally connects the cable receiving end with the contact mating end of the plug. The intermediate section has an opening which spans virtually all of the fourth side of this section. The resultant three sided intermediate section provides for a reduced dielectric constant in the interior space in which the critical conductor transition from jacketed cable to contact termination occurs. This produces lower crosstalk and higher data propagation to allow this modular plug to be capable of a higher frequency for data transmission. The intermediate section features an expanded interior to lower crosstalk between twisted pairs of conductors over a wide range of data transmission rates. The intermediate section's expanded interior space permits greater freedom in the placement and relative positioning of any conductor pair to any other conductor pair. This interior space allows conductor pairs to be located a greater distance apart which reduces crosstalk substantially at higher frequencies. By utilizing the larger interior space, conductor pairs may also be placed angularly to each other so that conductor pairs are not co-planar, which further reduces crosstalk.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




The present invention relates to electrical connectors and, more particularly, is directed toward a telephone-style modular plug that can operate at higher frequencies with lower crosstalk.




2. Description of Related Art




Data communication systems being developed are constantly requiring higher and higher transmission rates. As the rates have increased to the 100 Megahertz (MHz) range, the problem of near end crosstalk (NEXT) has become particularly vexing. Crosstalk refers to the signals induced in an adjacent conductor due to magnetic (inductive) and electric field (capacitive) coupling between the conductors. The crosstalk of interest to this invention occurs in telephone-style modular plugs (near end crosstalk or “NEXT”). The crosstalk in cables and modular jacks are related fields but are not specifically addressed by this invention.




Advances in cable design and improved control of manufacturing processes have improved the electrical performance of network data cables from −32 dB NEXT to better than −42 dB NEXT at a transmission frequency of 100 MHz. This is a dramatic improvement in isolating the coupling of a signal being transmitted through cables, especially those carrying eight conductors twisted together in pairs as used in the telecommunications industry. As a result of these advances in cable electrical performance, the performance of prior art modular plugs has fallen farther behind, so that the amount of crosstalk within a modular plug has become the most significant limiting factor in a system of networking cables, female modular jacks or Alto outlets, and male modular plugs. A large part of the problem arises when the conductors leave the protective confines of the cable jacket, even though crosstalk is minimized by the conductors remaining twisted together in pairs. In order to terminate the conductors in a telephone-style modular plug, however, they must be untwisted and mounted in the plug's dielectric housing in a substantially parallel arrangement, a condition wherein the conductors are most susceptible to NEXT.




NEXT is the electrical field generated by a signal which is transmitted into a first connection, and this electrical field has lines of force which pass around and into a second connection, causing an electrical signal to flow in the second connection. This induced electrical signal flow alters and acts upon any original transmitted signal sent through the second connection, with the outcome that any receiver of the second connection signal sees an altered, distorted signal. This is the source of signals that cannot be correctly understood and therefore requires that the original second transmitted signal be transmitted again, using up valuable data bandwidth and degrading the performance of a connection system. As crosstalk becomes increasingly larger, it can have the same signal strength as the original transmitted signal, rendering the entire connection useless because it is impossible to separate the induced signal (crosstalk) from the original signal. This is commonly referred to as S/N, or signal to noise ratio. If the noise (crosstalk) is as strong as the signal, then it is impossible to separate the original signal from the induced signal (noise). The reduction of crosstalk is extremely important to enable connection systems to transmit signals as error free as possible, and to increase the data frequency that a connection system can deliver with more signal than noise.




A number of years ago, a standards committee comprised of representatives of various companies and organizations in the electronics, computer, and telecommunications industries began the development of a voluntary standard called EIA/TIA 568. The objective of this standard was to provide for interchangeability between various manufacturers' components and to set forth a minimum set of electrical requirements needed to deliver a usable signal at frequencies up to 100 MHz independently of which manufacturer's products might be used in a networking connection system. This standard was completed only in the last few years and sets out mechanical and dimensional requirements for modular female jacks/outlets, and for modular male plugs to assure mating compatibility. This so-called 568 standard also defines a set of minimum electrical requirements for cables, for modular male plugs, and for modular female jacks/outlets at various frequencies from 0.772 MHz to 100 MHz for products classified into categories. For example, the electrical requirements for category 3 components is less stringent than the electrical requirements for category 5 Ad components. This standard also specifies the conductor wiring arrangements within the male plugs, distance limitations for cable and for cable assemblies terminated with modular plugs.




Referring now to the electrical requirements of EIA/TIA 568, it sets out the minimum NEXT for any one conductor pair to any other conductor pair within the cable, as well as within the male plug as terminated onto a section of cable. Inasmuch as modular plugs are relatively small in size, it is inevitable that the close proximity of the contacts and terminated ends of the conductors induce crosstalk between different signal pairs. The most crosstalk allowed for a category 5 modular plug between worst case pairs is −40 dB at 100 MHz. As category 5 cables generally have four conductor pairs, the worst case is those two conductor pairs that have the most crosstalk to each other and more crosstalk than any other two conductor pairs. Because of the wiring arrangement specified by EIA/TIA 568, the worst case pairs are always from pair


1


, corresponding to contact positions in the plug of


4


and


5


, measured to pair


2


, corresponding to contact positions in the plug of


3


and


6


(see the wiring arrangements of FIGS.


1


and


2


). This interleaved wiring arrangement creates a high level of crosstalk within the conductor wiring exposed in the plug.




Various approaches have been used to try and overcome these NEXT deficiencies in the design of the plug. As stated before, NEXT is a function of inductive and capacitive interactions between conductors. The general thrust of the industry is to address only the capacitive problems. Rohrbaugh et al., in U.S. Pat. No. 5,628,647, seek to reduce both the magnetic and capacitive coupling by utilizing the feature of staggering or offsetting conductor receiving channels, but the remainder of the most pertinent related art concentrate solely on the capacitive effects. For example, Kristiansen in his U.S. Pat. No. 5,284,447 forms an elongated aperture in the body of the contact terminals, thus reducing the capacitance between adjacent contact terminals by reducing the amount of their confronting surface areas. U.S. Pat. No. 5,593,314 to Lincoln teaches a structure which staggers the longitudinal location of the confronting bodies of the contact terminals to reduce their capacitance. U.S. Pat. No. 5,727,962, to Caveney et al. teaches the offset terminal end arrangement disclosed in Rohrbaugh et al., supra, and forces the cable into the modular plug as far as possible, so that the length of untwisted conductors will be as short as possible.




All of these prior art patents, specifically incorporated herein by reference, are successful in what they do, but they limit their concerns solely to the electrically conducting components, namely, to the arrangement of the conductors and the structure of the terminal contacts. The instant invention, in contrast, extends this inventive field to include the body of the modular plug.




Undesirable near end crosstalk between conductors is primarily a function of capacitance: the more the capacitance, the more the crosstalk. Thus, in order to reduce the NEXT, the capacitance between the conductors must be reduced. Capacitance is dependent on two factors: (1) it is inversely proportional to the center-to-center distance between the conductors; and (2) it is directly proportional to the dielectric constant of all of the matter surrounding the conductors. Consequently, increasing the distance between the primary conductors lowers the capacitance, and lowering the average dielectric constant in the vicinity of the conductors also lowers the capacitance.




The primary area of interest of the present invention is the reduction of the effective dielectric constant of the material surrounding the conductors, i.e., the average dielectric constant of all of the materials which are present.




While the recent prior art makes some improvement toward addressing the problem of NEXT within the plug as assembled onto the cable, it remains deficient in significantly improving NEXT in the critical transition area of the plug where the conductors leave the controlled structure of the jacketed cable and are exposed to each other in a confined environment prior to their point of termination by the contact blades.




OBJECTS AND SUMMARY OF THE INVENTION




A primary object of the present invention is to provide a modular plug with a reduced dielectric constant in the transition area of the conductors extending from the jacketed cable to the point of termination in the plug to overcome the crosstalk deficiencies of the prior art.




Another object of the present invention is to provide a larger interior volume within the modular plug for the transition of the conductors from the jacketed cable to the point of termination as a means of reducing crosstalk between the conductor pairs.




Yet another object of the present invention is to provide a means for bringing non-planar conductor pairs to their respective conductor channels with a minimum of planar alignment as yet a further means of reducing crosstalk between the conductor pairs.











BRIEF DESCRIPTION OF THE DRAWINGS




The foregoing and other objects, aspects, uses, and advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description of the present invention when viewed in conjunction with the accompanying drawings, in which:





FIG. 1

is a top view which illustrates a telephone-style modular plug in a first preferred embodiment of the present invention;





FIG. 2

is another top view of the modular plug of

FIG. 1

;





FIG. 3

is a side view of the modular plug of

FIG. 1

;





FIG. 4

is a longitudinal sectional view of the modular plug of

FIG. 1

taken along line A—A of

FIG. 5

;





FIG. 5

is a top view of the modular plug of

FIG. 1

;





FIG. 6

is a front view of the modular plug of

FIG. 1

;





FIG. 7

is a cross-sectional view of the modular plug of

FIG. 1

taken along line B—B of

FIG. 3

;





FIG. 8

is a rear view of the modular plug of

FIG. 1

;





FIG. 9

is a cross-sectional view of the modular plug of

FIG. 1

taken along line C—C of

FIG. 5

;





FIG. 10

is a sectional view of the modular plug of

FIG. 1

taken along line D—D of

FIG. 8

;





FIG. 11

is a longitudinal sectional view of a modified embodiment of the modular plug of

FIG. 1

;





FIG. 12

is a longitudinal sectional view which illustrates a second preferred embodiment of a telephone-style modular plug of the present invention; and





FIG. 13

is a longitudinal sectional view which illustrates a third preferred embodiment of a telephone-style modular plug of the present.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




Referring to

FIGS. 1-4

, a telephone-style modular plug


10


comprises a housing


12


having a top


14


, a pair of side walls


16


and


18


, a bottom


20


, a front


22


, and a rear


24


. Housing


12


can be visualized, for descriptive purposes, as being composed of three integral sections, a cable receiving section


26


, an intermediate section


28


, and a contact terminating section


30


.




Cable receiving section


26


includes a cable receiving cavity


32


(

FIG. 4

) which receives the terminal end


34


of a cable


36


.




Cable


36


typically comprises a jacket


38


enclosing, for example, four twisted pairs of insulated conductors


40


(FIGS.


1


-


2


), each conductor comprising either a multiplicity of twisted strands or a solid wire. Cables can also be provided with a different number of conductors; for example, a two line telephone cable contains four conductors terminated in contact positions


3


through


6


of a standard modular plug. A cable housing ten conductors is also available, a construction which may be accommodated by modifications to the preferred embodiments, to be disclosed in greater detail below.




Cable receiving cavity


32


(numbered in FIG.


4


and shown in outline in

FIG. 3

) extends from a cable receiving aperture


42


in rear


24


through cable receiving section


26


and through intermediate section


28


to a pair of opposed, flanking, vertical guide walls


44


which slope inwardly from sidewalls


16


and


18


; see

FIGS. 4

,


5


,


8


, and


10


. Within cable receiving section


26


, the height of cable receiving cavity


32


steps down at shoulders


46


and


48


(

FIG. 4

) from its maximum height at cable receiving aperture


42


to its minimum height throughout intermediate section


28


. The width of cable receiving cavity


32


is essentially the width of housing


12


and is bounded by side walls


16


and


18


(FIG.


10


). A strain relief tab


50


pivots on a living hinge


52


within a transversely elongated aperture


54


in top


14


to pinch cable


36


to provide strain relief therefor, as is conventional in the art; see

FIG. 13

of Caveney et al., supra, for example. Strain relief tab


50


includes a shoulder


56


which latches with corner


58


bordering aperture


54


, when tab


50


is depressed downwardly into operative position. Rounded corners


60


(

FIGS. 4-5

and


10


) facilitate the insertion of cable


36


into cable receiving aperture


42


.




Prior to exiting the terminal end


34


of cable


36


, conductors


40


are protected by jacket


38


from outside electromagnetic influences. Near end crosstalk (NEXT) effects inside cable


36


are minimized by the conductors


40


being twisted together in pairs. But once conductors


40


leave terminal end


34


of cable


36


in intermediate section


28


(e.g., FIGS.


1


-


2


), they must be untwisted to properly enter contact terminating section


30


, as will be described in greater detail hereinafter. Within intermediate section


28


, therefore, conductors


40


are particularly susceptible to NEXT.




The present invention acts to reduce NEXT in intermediate section


28


in various ways, which will now be discussed in turn.




First, and in accordance with the present invention, an opening


62


is formed in top


14


throughout intermediate section


28


. Opening


62


has significant electrical effects on the signals traveling through the conductors


40


in intermediate section


28


, because of its influence on the composite dielectric constant surrounding conductors


40


. Modular plugs are typically made of polycarbonate. Polycarbonate is the preferred material, because of its unique combination of strength, resiliency, chemical inertness, and transparency. Polycarbonate, however, has one serious shortcoming in its properties, that of the dielectric constant. For high speed data transmission, the dielectric constant plays a critical role in the propagation rate of signals. The lower the dielectric constant, the better the electrical properties. Air has a good dielectric constant, while polycarbonate has a relatively poor dielectric constant. Since the present invention provides an opening


62


in intermediate section


28


, the volume of the material of which modular plug


10


is made, namely, polycarbonate, is reduced, thus lowering the dielectric constant in the critical conductor transition area


28


between terminal end


34


of cable


36


and contact terminating section


30


. This is significant because conductors


40


in this transition area are exposed outside of jacket


38


and therefore are more affected by the electrical properties of the material around those conductors. Because of opening


62


, the average dielectric constant of the combination of the surrounding air and polycarbonate is noticeably lower than prior modular plug dielectric constants. Transmission rates are correspondingly improved, therefore.




Second, and in accordance with the present invention, opening


62


expands the volume of cable receiving cavity


32


in intermediate section


28


. As a consequence, individual conductors


40


have more room to separate from each other, and each twisted pair has more room to separate from other twisted pairs. Since capacitance is inversely proportional to separation distance, separating conductors


40


reduces capacitance and thereby reduces NEXT.




Third, and in accordance with the present invention, each pair of conductors is left twisted for as long as possible before entering contact terminating section


30


. Thus, the interactions between conductors is further minimized. See, for example, the conductors in

FIGS. 1 and 2

, to be discussed in greater detail below. In addition, a fourth way to reduce NEXT in intermediate section


28


will be discussed below.




In addition to opening


62


and previously mentioned sloping guide walls


44


, intermediate section


28


also includes other important features. As most clearly seen in

FIGS. 8-9

, but also visible in

FIGS. 1-5

, a pair of opposed longitudinal projections or lips


64


extend horizontally inwardly from the top


66


of sidewalls


16


and


18


. The under-surface


68


of projections


64


is shown as coplanar with the interior ceiling surface


70


, i.e., the interior top surface of the portion of cable receiving cavity


32


in intermediate section


28


(

FIGS. 4

,


8


, and


9


). As a modification to the foregoing, under-surface


68


may protrudes further interiorly of cable receiving cavity


32


. The intersections of under-surfaces


68


with sidewalls


16


and


18


produce interior corners


72


(

FIG. 9

) which can extend a distance less than the length of the intermediate portion, or alternately, may extend a distance equal to the length of the intermediate portion. These interior corners


72


provide a means of limiting any pair of conductors


40


which is routed near a sidewall from lifting above top


14


of modular plug


10


during the assembly process of inserting a cable and conductors into the plug. The lift-limiting corners


72


will help prevent a conductor pair from rising above the exterior of the plug, where it might be subject to damage due to not being protected by the body


12


of plug


10


. Projection


64


may be from one sidewall only, or may consist of multiple projections from the same sidewall (not shown). Projections


64


preferably extend inwardly from both sidewalls


16


and


18


, provided that they do not close opening


62


. Under-surfaces


68


are located substantially away from the conductor pairs and do not serve as guide surfaces or alignment guides for the insertion of the conductors into contact terminating section


30


.




In a second preferred embodiment shown in

FIG. 12

, projections


64


are eliminated (cf. FIGS.


4


and


12


), which expands opening


62


even further compared to the first embodiment of

FIGS. 1-11

. Both embodiments are within the present invention, since each has its own distinct advantages. The projections of the first embodiment protect the conductor pairs, as explained above. The expanded opening


62


of the second embodiment further reduces the composite dielectric constant which concomitantly reduces NEXT. Nonetheless, in either case, the dielectric effect produced by opening


62


contributes to a lower composite dielectric constant than prior art plugs for the intermediate portion


28


of plug


10


, which produces significantly improved signal performance and lower crosstalk in the transition area of the conductors.




Another feature in intermediate section


28


is exterior notches


74


and


76


(

FIGS. 3

,


5


, and


10


) in sidewalls


16


and


18


, respectively, which assist a handler in gripping modular plug


10


.




Contact terminating section


30


is the free end which mates with a female, telephone-style modular jack (not shown). Conductors


40


are therefore arranged such that they will make electrical contact with the spring contacts of a standard modular jack in conformance with the architecture required by FCC regulations. Referring to the cross-sectional view in

FIG. 4

, contact terminating section


30


joins intermediate section


28


at wall


78


. Opening into wall


78


is an elongated, conductor-positioning slot


80


bordered by an upper surface


82


and a lower surface


84


. Upper slot surface


82


includes a horizontal portion


86


and an upwardly angled portion


88


, whereas lower slot surface


84


is strictly horizontal. Also see FIGS.


3


and


7


-


9


.




Angled portion


88


is steeper than corresponding angled surfaces of prior art plugs. The steeper slope of angled portion


88


allows conductors


40


to be untwisted for a shorter distance prior to insertion into slot


80


, so that the twisted arrangement of each conductor pair is preserved for the maximum distance. This preservation of conductors


40


as twisted pairs to within a close proximity of the contact terminating section


30


provides more control of the electrical field surrounding each conductor up to the point of separation from the conductor pair. The benefit of this steeply angled surface is a further reduced crosstalk between the conductor pairs and the conductors belonging thereto.




A plurality of channels


90


are defined within slot


80


by opposed ridges


92


and


94


.

FIG. 4

shows a sectional side view of one of the channels


90


, while

FIGS. 8 and 9

show an end and cross-sectional view of wall


78


and slot


80


as seen through cable receiving cavity


32


from the direction of the rear


24


.

FIG. 10

shows a sectional view taken along lines D—D of

FIG. 8

looking down on lower slot surface


84


. Each channel


90


receives one conductor


40


and constrains it against movement toward or away from the other conductors


40


.




As most clearly seen in

FIGS. 4 and 10

, channels


90


are closed at their front ends


96


. Prior to cable


36


being inserted into modular plug


10


, the terminal end


34


thereof is stripped of jacket


38


to expose the twisted pairs of conductors


40


. Cable


36


is inserted into modular plug


10


, the terminal end of each pair of conductors


40


is untwisted enough to fit within channel


90


with the tip of the conductor abutting end


96


, and the terminal ends of the individual conductors are fully inserted into channels


90


. This position is shown in FIG.


1


. Cable


36


is then forced further into plug


10


to the position shown in FIG.


2


. This last step gently crimps the twisted pairs which are exposed within intermediate section


28


, making them bulge in different directions. The exposed twisted pairs are then non-parallel, i.e., they extend at different angles relative to the other pairs, and they are separated by larger distances than they were prior to their crimping. These conditions reduce NEXT in intermediate section


28


. Being at different angles reduces the magnetic interactions, and being further apart reduces the capacitive effects. Since the bulging is largely uncontrollable, dependent on the relative resistances felt by the conductors, some arrangements of twisted pairs may not be as effective in reducing NEXT as others might be. Opening


62


in intermediate section


28


permits visual inspection of the twisted pairs and manual repositioning of them, if desired. This is the fourth way of reducing NEXT in intermediate section


28


, mentioned initially hereinabove.




Referring now to

FIGS. 6 and 7

, a front view and a cross-sectional front view along the lines B—B of

FIG. 3

are shown. A plurality of parallel, longitudinally extending partitions


98


are uniformly spaced across the width of modular plug


10


. Terminal contact receiving slots


100


are formed between adjacent partitions


98


(only a few partitions and slots are referenced with numerals in the drawings to avoid overcrowding).





FIG. 4

shows a sectional view of a slot


100


taken along line A—A of FIG.


5


. Each slot


100


extends from front


22


of plug


10


to a raised transverse partition


102


(FIGS.


4


-


5


), is open through top


14


, and has a bottom ledge


104


opposite top


14


. Bottom ledge


104


includes a narrow rectangular opening


106


which communicates with both slot


100


and the underlying channel


90


. A terminal contact


108


(

FIGS. 1-2

and


11


-


13


) is forced into each slot


100


until shoulders


110


of contact


100


rest on ledge


104


. Tangs


112


of contact


108


pass through opening


106


into channel


90


, where they pierce the insulation surrounding the conductor


40


residing in channel


90


(not shown). Terminal contact


108


includes a rounded cap


113


designed to make electrical contact with the spring contacts of the mating modular jack, and, as disclosed and claimed by Kristiansen, supra, terminal contact


108


further includes an elongated aperture


114


through contact


108


which reduces the capacitance between adjacent contacts.




Centered on front


22


and protruding therefrom is a conventional guide nose


116


for keying the fit with the mating modular jack. A conventional locking tab


118


is pivotally mounted to bottom


20


at


120


and extends obliquely rearwardly therefrom. Locking tab


118


includes spaced shoulders


122


for locking with complementary latching members (not shown) on the mating modular jack.




Referring now to FIGS.


7


and


11


-


13


, there are times when modular plug


10


is required to carry additional lines of information. In a modification of the first preferred embodiment, plug


10


is adapted to carry ten conductors, be they in the form of a ten conductor cable or the addition of two single conductors. Flanking the eight channels


90


(

FIG. 7

) are two additional slots


124


and


126


which add plug positions


0


and


9


to the regularly provided eight positions


1


-


8


. Slots


124


and


126


communicate via additional rectangular openings


106


(not shown) with two additional conductor holding channels


128


recessed in sidewalls


16


and


18


(only one being shown in FIGS.


11


-


13


). The

FIG. 11

embodiment is identical to the first preferred embodiment shown in

FIGS. 1-10

except for the addition of channels


128


, which expand the utility of modular plug


10


.





FIG. 12

adds to the first preferred embodiment both the additional channels


128


and the elimination of projections


64


, as aforedescribed.





FIG. 13

is also identical to the first preferred embodiment except that to this embodiment has been added a protective grating bar


130


hinged at


132


to top


14


. As few as one grating bar


130


can be employed, or as many as needed, to prevent conductors


40


from extending above top


14


. Plural grating bars


130


can be provided with a common pivot


132


for all grating bars or with each having its own pivoting area such that each grating bar can be pivoted independently of the others. The length of each grating bar


130


is approximately that of the length of opening


62


such that the free end


134


will engage wall


78


after being pivoted to a horizontal orientation from its original vertical orientation. Hinge


132


consists of a thin wall of material such that grating bar


130


may be rotated ninety degrees from its original orientation and hinge


132


will flex and stretch to a new shape without losing strength or fracturing in the pivoting area. Grating bars


130


can include one or more extension tips


136


which are of a size that they will engage corresponding slots


138


in wall


78


.




It can be seen from the above that an invention has been disclosed which fulfills all the objects of the invention. It is to be understood, however, that the disclosure is by way of illustration only and that the scope of the invention is to be limited solely by the following claims.



Claims
  • 1. A modular telephone-style male plug, comprising:a contact mating portion, comprised of a first set of four sides, which includes a plurality of contact slots each for receiving a contact blade; a plurality of contact blades, each said contact blade with an upper mating surface for mateable engagement with a spring contact portion of a modular female jack or outlet, each said contact blade comprising a conductor engaging tip opposite said upper mating surface to electrically terminate and connect to a conductor of a plurality of conductors, each said conductor comprising an electrically conductive wire surrounded by an insulating cover; a plurality of channels, each said channel having a length and a height to receive said conductor such that a portion of each said channel is located adjacent and in alignment with one said contact slot, said length of each said channel being greater than said height of each said channel, whereby each said contact slot aligns each said contact blade to electrically connect to each said conductor; a cable receiving portion comprised of a second set of four sides and including a cable capture mechanism to engage a cable find retain said cable within said cable receiving portion, an opening formed in the interior of said cable receiving portion for receiving said cable, said cable comprising one or more pairs of solid plurality of conductors; an intermediate portion comprising one latch wall having an interior floor and two side walls, said latch wall and said side walls forming an interior space therebetween, said interior space able to contain said one or more pairs of said conductors which traverse said modular plug from said cable receiving portion to said contact mating portion; said intermediate portion further comprising at least one opening, said opening opposite said interior floor of said latch wall, said opening being in direct communication with space surrounding said plug and in direct communication with said interior space of said intermediate portion of said plug; and at least one projecting surface extending from at least one of said side walls such that said projecting surface overhangs a portion of said interior floor, said projecting surface forming an interior corner at the intersection of said projecting surface with said side wall, the outer surface of said projecting surface not extending above the top wall of said plug.
  • 2. A modular plug as set forth in claim 1, in which said opening has the same width as the width between said two side walls.
  • 3. A modular plug as set forth in claim 2, in which the length of said opening is substantially the same as the length of said interior floor of said intermediate portion of said plug.
  • 4. A modular plug as set forth in claim 3, further comprising a slanted surface located at the junction of said intermediate portion and said contact mating portion, said slanted surface being in direct communication with said opening of said plug.
  • 5. A modular plug as set forth in claim 1, in which said projecting surface extends a first distance from said side wall, said first distance being at least as great as the diameter of said conductor.
  • 6. A modular plug as set forth in claim 1, in which said projecting surface extends a second distance from said side wall, said second distance being at least as great as the diameter of said conductor pair.
  • 7. A modular plug as set forth in claim 1, further comprising at least two projecting surfaces extending from a respective one of said side walls, each of said surfaces integrally joined to said side wall and overhanging a portion of said interior floor, respectively.
  • 8. A modular plug as set forth in claim 7, wherein said projecting surfaces are not directly connected to each other.
  • 9. A modular telephone-style male plug, comprising:a contact mating portion, comprised of a first set of four sides, which includes a plurality of contact slots each for receiving a contact blade; a plurality of contact blades, each said contact blade with an upper mating surface for mateable engagement with a spring contact portion of a modular female jack or outlet, each said contact blade comprising a conductor engaging tip opposite said upper mating surface to electrically terminate and connect to a conductor of a plurality of conductors, each said conductor comprising an electrically conductive wire surrounded by an insulating cover; a plurality of channels, each said channel having a length and a height to receive said conductor such that a portion of each said channel is located adjacent and in alignment with one said contact slot, said length of each said channel being greater than said height of each said channel, whereby each said contract slot aligns each said contact blade to electrically collect to each said conductor; a cable receiving portion comprised of a second set of four sides and including a cable capture mechanism to engage a cable and retain said cable within said cable receiving portion, an opening formed in the interior of said cable receiving portion for receiving said cable, said cable comprising one or more pairs of said plurality conductors; an intermediate portion comprising one latch wall having an interior floor having a length and a width and two side walls, said latch wall and said side walls having an interior space therebetween, said interior space able to contain said one or more pairs of said conductors which traverse said modular plug from said cable receiving portion to said contact mating portion; said intermediate portion further comprising at least one opening, said opening opposite said interior floor of said latch wall, said opening being in direct communication with space surrounding said plug and in direct communication with said interior space of said intermediate portion of said plug; and at least one substantially planar surface, said planar surface having one free end and being oriented substantially perpendicularly to said mating wall of said plug, such that said planar surface is integrally connected to said plug at one end by means of a pivotable connection such that said planar surface can be rotated about said pivotable connection from a substantially perpendicular orientation to a substantially parallel orientation to said mating wall of said plug.
  • 10. A modular plug as set forth in claim 9, in which said planar surface has a length substantially equal to said length of said interior floor of said intermediate portion.
  • 11. A modular plug as set forth in claim 10, in which said free end further comprises at least one projection which extends beyond said free end of said planar surface, said projection being of such a size and shape to engage a corresponding slot formed at the junction of said intermediate portion and said contact mating portion.
  • 12. A modular plug as set forth in claim 11 further comprising a slanted surface located at the junction of said intermediate portion and said contact mating portion of said plug, and such that said slanted surface is in direct communication with said opening of said plug.
  • 13. A modular plug as set forth in claim 12, in which said slanted surface has an upper edge with means for engaging said planar surface upon rotation of planar surface from said vertical orientation to said horizontal orientation.
  • 14. A modular plug as set forth in claim 13, in which said upper edge engaging means comprising at least one slot extending from outer surface of upper edge into said upper edge.
  • 15. The combination of a modular plug and a data transmission cable, comprising:a cable comprising a jacket and a plurality of twisted pairs of conductors within said jacket, said twisted pairs of conductors having contact ends, said cable further including a cable terminal end through which said contact ends of said plurality of twisted pairs of conductors are exposed; and a modular plug comprising: a cable receiving section, an intermediate section, and a contact terminating section; said cable receiving section comprising a cavity with said cable received therein; said intermediate section having two side walls closed by a bottom wall with an opening opposed to said bottom wall by a pair of inwardly facing projections, said intermediate section containing said exposed contact ends of said conductors; and said contact terminating section comprising a plurality of conductor receiving channels, each of which receive therein a single one of said conductor contact ends and a contact terminal electrically connected with said single conductor contact end, said contact terminal being arranged to mate with the spring contacts of a female modular jack.
  • 16. The combination of claim 15, wherein said cable receiving section includes a strain relief mechanism for constraining said cable against relative movements.
  • 17. The combination of claim 15, wherein said opening extends from said cable receiving section to said contact terminating section and from one side wall to the other side wall.
  • 18. The combination of claim 17, wherein said side walls and said bottom define an interior space and at least one grating bar extends over said opening to prevent said exposed conductors from protruding outside said interior space.
  • 19. The combination of claim 18, wherein said grating bar is pivotally mounted adjacent said opening.
  • 20. A modular telephone-style male plug, comprising;a contact mating portion, comprised of a first set of four sides, which includes a plurality of contact slots, each for receiving a contact blade; a plurality of contact blades, each said contact blade with an upper mating surface for mateable engagement with a spring contact portion of a modular female jack or outlet, each said contact blade comprising a conductor engaging tip opposite said upper mating surface to electrically terminate and connect to a conductor of a plurality of conductors, each said conductor comprising an electrically conductive wire surrounded by an insulating cover; a plurality of channels, each said channel having a length and a height to receive said conductor such that a portion of each said channel is located adjacent and in alignment with one said contact slot, said length of each said channel being greater than said height of said channel, whereby said contact slot aligns each said contact blade to electrically connect to said plurality of conductors; a cable receiving portion comprised of a second set of four sides and including a cable capture mechanism to engage a cable and retain said cable within said cable receiving portion, an opening formed in the interior of said cable receiving portion for receiving said cable, said cable comprising one or more pairs of said conductors; an intermediate portion comprising one latch wall having an interior floor and two side walls, said latch wall and said side wall latching an interior space therebetween, said interior space able to contain said one or more pairs of said conductors which traverse said modular plug from said cable receiving portion to said contact mating portion; said intermediate portion further comprising at least one opening, said opening opposite said interior floor of said latch wall, said opening being in direct communication with space surrounding said plug and in direct communication with said interior space of said intermediate portion of said plug; and at least two projecting surfaces extending from a respective one of said side walls, each of said surfaces integrally joined to said side wall and overhanging a portion of said interior floor, respectively.
  • 21. A modular plug as set forth in claim 20, wherein said projecting surfaces are not directly connected to each other.
  • 22. The combination of a modular plug and a data transmission cable, comprising:a cable comprising a jacket and a plurality of twisted pairs of conductors within said jacket, said twisted pairs of conductors having contact ends, said cable further including a cable terminal end through which said contact ends of said plurality of twisted pairs of conductors are exposed; and a modular plug comprising: a cable receiving section, an intermediate section, and a contact terminating section; said cable receiving section comprising a cavity with said cable received therein; said intermediate section including two side walls and a bottom wall and an opening opposed to said bottom wall with a grating bar pivotally over said opening, said intermediate section containing said exposed contact ends of said conductors; and said contact terminating section comprising a plurality of conductor receiving channels, each of which receive therein a single one of said conductor contact ends and a contact terminal electrically connected with said single conductor contact end, said contact terminal being arranged to mate with the spring contacts of a female modular jack.
  • 23. The combination of claim 22, wherein said grating bar is pivotally mounted adjacent said opening.
US Referenced Citations (3)
Number Name Date Kind
5727962 Caveney et al. Mar 1998
5984713 Hsien Nov 1999
6007368 Lorenz et al. Dec 1999