Signal conditioned modular jack assembly with improved shielding

Information

  • Patent Grant
  • 6729906
  • Patent Number
    6,729,906
  • Date Filed
    Friday, April 18, 2003
    21 years ago
  • Date Issued
    Tuesday, May 4, 2004
    20 years ago
Abstract
A stack jack modular jack assembly is comprised of a multi-port housing, and a plurality of modular jack subassemblies. The jack subassemblies include upper and lower jack housing sandwiching therebetween, a cross-talk shield. The terminal subassembly is substantially Z-shaped, which allows for increased space there below for signal conditioning components. The terminal module also includes a center shield and a lower shield, and an outer shield, all of which are commoned together and grounded. An outer shield substantially surrounds the entire assembly, and is commoned to the other shield members.
Description




BACKGROUND OF THE INVENTION




The invention relates to a connection assembly providing multiple port connections.




Known connector assemblies exist having multiple receptacle connectors in a common housing, which provide a compact arrangement of such receptacle connectors. Such a connector assembly is useful to provide multiple connection ports. Accordingly, such a connector assembly is referred to as a multiple port connector assembly. In preferred arrays, the housing has jacks one above the other, forming a plurality of arrays in stacked arrangement, so-called “stacked jack” arrangements. The receptacle connectors, that is, modular jacks, each have electrical terminals arranged in a terminal array, and have plug receiving cavities. Specifically, the receptacle connectors are in the form of RJ-45 type modular jacks that establish mating connections with corresponding RJ-45 modular plugs.




For example, as disclosed in U.S. Pat. No. 5,531,612, a connector assembly has two rows of receptacle connectors, that is, modular jacks, arranged side-by-side in an upper row and side-by-side in a lower row in a common housing, which advantageously doubles the number of receptacle connectors without having to increase the length of the housing. The receptacle connectors have plug receiving sections with plug receiving cavities that are profiled to surround modular plugs that are to be inserted in the cavities. The modular plugs have resilient latches, which engage with latching sections on the modular jacks. The latches are capable of being grasped by hand, and being resiliently bent inwardly toward the plugs to release them from engagement with the latching sections on the modular jacks.




One application for such connector assemblies is in the field of telephony, wherein the modular jacks provide ports for connection with a telephone switching network of a telephone service provider, such as a regional telephone company or national telephone company. The corresponding RJ-45 modular plugs terminate opposite ends of telephone cords leading to wall-mounted telephone outlets inside a building. The telephone outlets connect to telephone lines outside of the building, which, in turn, connect to the telephone switching network of the telephone service provider.




Alternatively, such connection systems have found utility in office computer networks, where desktops are interconnected to office servers by way of sophisticated cabling. Such networks have a variety of data transmission mediums including coaxial cable, fiber optic cable and telephone cable. One such network topography is known as the Ethernet network, which is subject to various electrical standards, such as IEEE 802.3 and others. Such networks have the requirement to provide a high number of distributed connections, yet optimally requires little space in which to accommodate the connections.




Furthermore, such networks now operate at speeds of 1 gigabit and higher which requires significant conditioning to the signals. For instance, it is common to require shielding for controlling electromagnetic radiation per FCC standards, while at the same time controlling electromagnetic interference (EMI) within the assembly, between adjacent connections. It is therefore also a requirement to provide such components within the assembly as magnetic coils, inductors, chip capacitors, and the like, to condition the signals. While the technology exists for conditioning the signals, no connection devices exist which are capable of handling such speeds, while at the same time package the signal conditioning components required to maintain these speeds.




Another design is shown in U.S. Pat. No. 6,227,911 to Boutros et al., which discloses a modular jack assembly having multiple ports for connection to multiple modular jacks. While this assembly further discloses having packaged magnetic assemblies, or other components, this design, as in other attempts to signal condition connection devices, simply adds the components to known connection devices. Therefore, the volume within the assembly is inadequate to provide the proper signal conditioning devices for the high speeds now required.




Furthermore, in order to ensure that a proper connection has been made and therefore a link is created between the electrical communication devices, indicators are often incorporated into circuits on the printed circuit board. These indicators are typically light emitting diodes (LEDs) which are turned on when a circuit is completed between the mating connectors and the communication devices. Additionally LEDs can be mounted on the printed circuit board to indicate a number of other conditions including the passage of communication signals between the two communication devices, indication of power, or indication that an error in transmitting the signals has occurred.




In an effort to miniaturize printed circuit boards and save board real estate, LED indicators have been integrated into these connectors. An example of such a connector is disclosed in U.S. Pat. No. 4,978,317 to Pocrass which teaches a connector for receiving a plug having a visual indicator positioned within the front wall of the electrical connector housing. Incorporation of the indicator into the electrical connector eliminates the need for a separate location on the printed circuit board for mounting of such an indicator. The LED indicator is inserted into a recess of the electrical connector such that its electrical leads pass through the recess and connect to the printed circuit board. The indicator is then cemented into the recess or attached using an appropriate adhesive. The LEDs may also be molded into the electrical connector during the molding process of the housing. However, this device of Pocrass is shown for only a single cavity housing, and it is not readily ascertainable how it might be reconfigured for a multi-port or a stacked jack configuration.




The objects of the inventions are therefore to overcome the shortcomings of the prior art.




The objects have been accomplished by providing an electrical connector assembly having a plurality of rows of jacks for mating with a plurality of electrical plugs. The connector assembly comprises plural lead frames, the lead frames including front mating contact sections, and conductor contacting sections. A center shield is positioned between the lead frames, and a transverse shield is positioned transversely to the center shield. A lower shield is positioned below the transverse shield, wherein the center shield, transverse shield and lower shield are commoned together. A first array of passive components are positioned on one side of the transverse shield, between the center shield and the lower shield. A second array of passive components are positioned on the opposite side of the transverse shield as the first array, between the center shield and the lower shield. An insulating module housing at least partially surrounds the pluggable contact module, the center shield, the transverse shield, the lower shield, and the first and second array of passive components, thereby defining a pluggable contact module. An insulating outer housing has a mating face having at least two connector receiving openings for receiving mating connectors therein, and module receiving openings for receipt of the pluggable contact modules.




At least one of the shields comprises a shielding contact extension, and the insulating module housing comprises an opening with the shielding contact extension, extending therethrough. An outer shielding member substantially surrounds the insulating outer housing and the pluggable contact modules. The outer shielding member includes an opening therethrough for receiving the shielding contact extension in an electrically engaging manner. The lead frames include intermediate sections and printed circuit board contact sections, the lead frames being profiled in a substantial Z-shape with the front mating contact sections of the plural lead frames being positioned adjacent to a central plane, with the printed circuit board contact sections from the plural lead frames being positioned proximate each other but remotely from the central plane, thereby defining a volume for the passive devices, the pluggable contact module further comprising at least one printed circuit board carrying passive devices positioned thereon, the printed circuit board being attached to the printed circuit board contact sections, with the passive devices occupying the volume.




The pluggable contact module is comprised of two lead frames. The lead frame intermediate contact sections include forward sections lying in a substantially horizontal plane, with the front mating contact sections being reversely bent from the forward sections. The lead frame intermediate contact sections further comprise perpendicular sections extending from the forward sections. The lead frame intermediate contact sections further comprise rearward sections extending from the perpendicular sections, the rearward sections lying in a substantially horizontal plane.




The intermediate contact sections are at least partially overmolded with insulative material. The lead frames and the intermediate center shield are closely conforming to each other to form a lamination. The rearward sections are each overmolded with an insulative material, to define a side board mounting edge, with the printed circuit contacts extending therefrom. The printed circuit board contacts for each lead frame extend from opposite side edges. Two printed circuit boards are mounted to the side board mounting edges. The lower shield, transverse center shield and the intermediate shield are all electrically commoned together.




An insulative housing shell is positioned around printed circuit board and shields. The insulating housing has a top wall, a bottom wall, an intermediate wall forming an upper and lower row, and a plurality of modular openings formed in the upper and lower row, and the insulative shells are pluggable in the modular openings to form a stacked jack assembly.




In another aspect of the invention, an electrical connector assembly has a plurality of rows of jacks for mating with a plurality of electrical plugs. The connector assembly comprises plural lead frames, the lead frames including front mating contact sections, and conductor contacting sections. A center shield is positioned between the lead frames, and a transverse shield is positioned transversely to said center shield. A first array of passive components are positioned on one side of the transverse shield, between the center shield and the lower shield. A second array of passive components are positioned on the opposite side of the transverse shield as the first array, between the center shield and the lower shield. An insulating module housing at least partially surrounds the pluggable contact module, the center shield, the transverse shield, the lower shield, and the first and second array of passive components, thereby defining a plurality of pluggable contact modules. An insulating outer housing has a mating face having at least two connector receiving openings for receiving mating connectors therein, and module receiving openings for receipt of the pluggable contact modules. An outer shielding member substantially surrounds the insulating outer housing and the pluggable contact modules.




A lower shield is positioned below the transverse shield, wherein the center shield, transverse shield and lower shield are commoned together. At least one of the shields comprises a shielding contact extension, and the insulating module housing comprises an opening with the shielding contact extension, extending therethrough. The outer shielding member includes an opening therethrough for receiving the shielding contact extension in an electrically engaging manner. The lead frames and center shield member are Z-shaped in configuration. The lead frame intermediate contact sections include forward sections lying in a substantially horizontal plane, with the front mating contact sections being reversely bent from the forward sections. The lead frame intermediate contact sections further comprise perpendicular sections extending from the forward sections. The lead frame intermediate contact sections further comprise rearward sections extending from the perpendicular sections, the rearward sections lying in a substantially horizontal plane.




The intermediate contact sections are at least partially overmolded with insulative material. The lead frames and the intermediate center shield are closely conforming to each other to form a lamination. The rearward sections are each overmolded with an insulative material, to define a side board mounting edge, with the printed circuit contacts extending therefrom. The printed circuit board contacts for each lead frame extend from opposite side edges. Two printed circuit boards are mounted to the side board mounting edges. The lower shield is positioned below the printed circuit boards. The lower shield, transverse center shield and the intermediate shield are all electrically commoned together.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view showing the multiple port jack assembly from the front side thereof;





FIG. 2

shows a perspective view of the device of

FIG. 1

from the rear side thereof;





FIG. 3

shows an exploded view of the components of the multiple port assembly of

FIG. 1

, less the outer shielding;





FIGS. 4 and 5

show rear perspective views of the housing of

FIG. 3

;





FIG. 6

shows a front perspective view of the housing of

FIG. 4

or


5


;





FIG. 7

shows an enlarged perspective view of the LED module;





FIG. 8

shows a front perspective view of the double modular jack module;





FIG. 9

shows a rear perspective view of the module of

FIG. 8

;





FIGS. 10 and 11

show exploded views of the module of

FIGS. 8 and 9

;





FIG. 12

shows an enlarged view of the module jack components shown in

FIG. 11

;





FIG. 13

shows a partially assembled perspective view of the module less the magnetic components and outer housing;





FIGS. 14 and 15

show perspective views similar to that of

FIG. 13

, including the side-loaded printed circuit cards having the magnetic components thereon;





FIG. 16

shows a rear perspective view showing the housing loaded with the LED modules, and partially loaded with jack assembly modules;





FIG. 17

shows a lower perspective view of the housing with the lower terminal plate in place; and





FIG. 18

shows an alternate embodiment of the shielding configuration.











DETAILED DESCRIPTION OF THE INVENTION




With respect first to

FIGS. 1 and 2

, a multiple “stacked jack” electrical connector assembly is depicted at


2


. This assembly generally comprises an inner housing at


4


comprised of an insulative material, where the housing


4


is substantially surrounded by a metallic shield at


6


. As shown best in

FIG. 1

, the stacked jack assembly provides a plurality of ports at


8


, which are configured for receiving modular plugs, which are well known in the art.




With respect now to

FIG. 3

, the assembly


2


is shown exploded, less the outer shielded housing


6


. The assembly includes the housing


4


, a plurality of jack modules


10


, a plurality of LEDs


12


, and a plurality of LED modules


14


. Finally, the assembly includes a lower printed circuit board at


16


. With the general componentry of the assembly


2


herein described, the individual components will now be further described in relation to the drawings.




With respect again to

FIGS. 1 and 2

, the outer shield


6


is comprised of an upper wall


20


, side walls


21


and


22


(FIG.


2


), rear wall


23


, and a front face portion


24


. The front face


24


includes a plurality of openings


25


corresponding with the location and number of ports for each of the multiple openings


8


. As is also shown in

FIG. 1

, shield


6


includes commoning springs


26


extending from top wall


20


, commoning springs


27


and


28


(

FIG. 2

) extending from respective side walls


21


and


22


, and commoning springs


29


extending from side edges of openings


25


. As shown best in

FIG. 2

, shield assembly


6


further includes a plurality of grounding tines


30


extending downwardly therefrom, as will be described in greater detail herein. It should also be noted that rear wall


23


includes a plurality of tab slots


32


, which will also be further described herein.




With respect now to

FIGS. 4-6

, the inner housing


4


will be described in greater detail. As shown in

FIG. 4

, housing


4


includes a front face at


34


, rear wall


36


, top wall


38


, and lower wall


40


(FIG.


6


). As shown best in

FIG. 6

, the plurality of ports


8


are partially defined by, and extend through, front face


34


.




With respect now to

FIG. 5

, the rear of housing


4


is shown in greater detail, where a plurality of openings


50


are shown where, for each location of opening


50


, two ports


8


are defined at the front face


34


. As shown in

FIG. 5

, each opening


50


is defined by side walls


52


, where each of the side walls includes a channel


54


, where the channel necks down progressively, as will be described in further detail. At the end of each of the channels


54


, openings


56


are provided, which project through front face


34


, and which are also depicted in FIG.


6


. Two such openings


56


are provided for each of the openings


50


. Openings further include comb-like contact aligning mechanisms


58


, where one comb-like aligning mechanism is provided for each modular jack port


8


, that is, two per opening


50


.




As also shown in

FIG. 5

, housing


4


includes a plurality of wall extensions, such as


60


, extending rearwardly from the rear face


36


, whereby the wall extensions define apertures


62


intermediate the extensions, and for each aperture


62


, an aligning land


64


is provided having an aligning aperture at


66


. The lower side of housing


4


also includes a plurality of lands


68


, each land having an aligning opening at


70


. The lower portion of housing


4


further includes a plurality of centrally located aligning apertures


72


, as will be described further herein.




With respect now to

FIGS. 4 and 6

, housing


4


is also provided with a plurality of LED-receiving channels, as will be described herein. With respect first to

FIG. 4

, top wall


38


of housing


4


is provided with two channels


80


for each top port


8


. For example, as shown in

FIG. 4

, LED channels


80


A and


80


B are provided for a first port


8


, where each of the channels


80


A and


80


B includes an LED-receiving section


82


and lands


84


providing lead-receiving channels at


86


. It should be appreciated that each port


8


would include two such LED-receiving sections and it should also be appreciated that the lead-receiving channels at


86


are generally aligned with the openings


62


defined between top wall extension portions


60


.




With respect now to

FIG. 6

, lower wall


40


also includes LED-receiving channels at


90


, with each LED-receiving channel including lead-receiving channels at


92


. Finally, with respect still to

FIG. 6

, it should be appreciated that each of the ports


8


in the housing are defined by openings


100


through front wall


34


, where each opening


100


is provided with a latching structure, such as T-shaped latching structure


102


for receipt of a modular plug latch as is well known in the art.




With respect now to

FIG. 7

, LED modules


14


will be described in greater detail, where each LED module


14


includes module housing


110


and terminals


112


. LED module housing


110


includes an upper lead receiving section


114


comprised of lead receiving channels at


116


in alignment with each of the terminals


112


. The leading edge


118


of the module housing


110


includes aligning posts


120


, where the linear distance between the posts


120


is chosen to match the linear distance between respective pairs of apertures


66


,


70


(FIG.


5


). Terminals


112


include termination section


122


and lead sections


124


. Termination sections


122


simulate an insulation displacement contact (IDC) portion to receive the LED leads.




With respect now to

FIGS. 8-10

, the jack modules


10


will now be described in greater detail. As shown best in

FIG. 8

, the jack module


10


includes an outer insulative housing shown at


130


holding a jack subassembly


132


. As shown in

FIG. 10

, jack subassembly


132


is generally comprised of an upper jack portion


134


, an intermediate shield at


136


, and a lower jack portion at


138


. As also shown in

FIG. 10

, jack module


10


further includes a lower housing portion


140


, component boards


142


,


144


, and shield members


146


,


148


.




With respect now to

FIG. 12

, the jack subassembly


132


will be described in greater detail. Upper jack portion


134


is comprised of an insulative housing portion


150


and a lead frame


152


. Housing


150


is comprised of a central housing portion


154


, which over-molds a portion of the lead frame


152


, such that free end portions


156


of the lead frame extend from a front end thereof, and are reversely bent to define the modular jack contacts. At the side edges of the central housing portion


154


are alignment ribs


158


having alignment posts


160


extending outwardly therefrom, where one alignment rib


158


includes apertures


162


, and the other alignment rib


158


includes posts


164


(see FIG.


10


).




With respect still to

FIG. 12

, lead frame


152


extends from a rear portion of housing


154


to project upwardly to define terminal sections


165


and are again bent rearwardly to define terminal sections


166


. Terminal sections


166


are over-molded in rear housing portion


168


and exit at a side edge to define printed circuit board tine sections


170


. Rear housing portion


168


further includes a component-receiving channel at


176


, aligning posts


178


and channels


180


, as will be further described herein.




With respect still to

FIG. 12

, center ground plane


136


is substantially Z-shaped and is over-molded to form plastic web portion


190


and upstanding web portion


192


, yet is exposed at rear portion


194


. Portion


194


includes an integrally stamped tab portion


196


, which is stamped from the plane of the material of


194


and then twisted about its side edges to form an upstanding tab as shown.




As shown in

FIG. 12

, the lower jack housing


138


is generally comprised of housing portion


200


and lead frame


202


. Housing portion


200


includes central housing portion


204


, which integrally encapsulates a portion of lead frame


202


therein. Lead frame


202


extends from a front end of housing portion


204


, where they are reversely bent downwardly to define terminals


206


profiled as modular jack contacts. Housing portion


204


further includes two aligning ribs


208


positioned on each side thereof, where each aligning rib


208


includes a post


210


at the front end thereof, and where one rib


208


includes apertures


212


and the opposite rib


208


includes aligning posts


214


.




Lead frame


202


extends from a rear edge of housing portion


204


and is bent vertically so as to define terminal sections


215


and are again bent to a horizontal position to define terminal sections


216


. Lead frame sections


216


are over-molded by housing portion


218


and have sections


220


extending therefrom defining printed circuit board receiving tines.




With respect yet to

FIG. 12

, a grounding clip


230


is shown for interconnection to a passive component


232


, such as a decoupling capacitor. Clip


230


includes a U-shaped member


234


having a grounding tab


236


extending upwardly therefrom, and grounding tines


238


extending from opposite sides thereof.




With respect again to

FIGS. 10 and 11

, component boards


142


and


144


will be described in greater detail. Each of the boards includes a printed circuit board


250


and a plurality of components


252


. In this version of the invention, three magnetic coils are positioned on the board for each terminal. That is, those components labeled with numeral


1


are for terminal


1


, those labeled with numeral


2


are for terminal


2


, etc. Also in this version of the invention, the three coils for each terminal are serially connected and connected to a respective throughhole


254


at one end and to throughhole


256


at the other end.




Also with respect to

FIGS. 10 and 11

, lower housing portion


140


includes a housing portion


260


encapsulating a plurality of contacts


262


and


264


. Contacts


262


include printed circuit board portions


266


extending from a side edge of housing


260


and printed circuit board portions


268


extending downwardly from housing portion


260


. Likewise, terminals


264


include printed circuit board portions


270


extending outwardly from housing portion


260


, and printed circuit board portions


272


extending downwardly from housing portion


260


. Alignment pegs


274


are positioned at front edge of housing portion


260


, as will be described herein.




With respect still to

FIGS. 10 and 11

, shield members


146


and


148


will be described herein. Shield member


146


is L-shaped including a lower plate portion


290


and a transverse section at


292


. Lower section


290


includes grounding tabs


294


extending rearwardly therefrom and through slots at


296


. Lower section


290


further includes an upstanding tab at


293


(

FIG. 11

) having a slot opening at


295


(FIG.


13


). Meanwhile, shield portion


292


includes a through slot at


298


. Shield member


148


includes tabs


300


and


301


extending from a rear edge, tabs


302


extending from a lower edge, and tab


304


extending from a front edge thereof (FIG.


13


).




With respect now to

FIGS. 9 and 10

, insulative housing


130


will be described in greater detail. Housing


130


includes side walls


312


, rear wall


314


and top wall


316


. Top wall


316


is raised relative to a wall portion


318


for clearance purposes, as will be more fully understood herein. Finally, housing


130


includes apertures


320


and


322


through the rear wall


304


for receipt of tabs


294


and


300


.




With the components described as above, the assembly will now be described. With reference first to

FIG. 12

, the upper and lower contact portions


134


and


138


are positioned adjacent to the intermediate cross-talk shield member


136


. It should be appreciated that the corresponding posts and apertures


164


,


212


and


214


,


162


are positioned together, thereby aligning the two housing portions


154


and


204


together, and trapping the shield therebetween. This also aligns corresponding front post members


160


and


210


together, to form one oval post. When in this position, printed circuit board portions


170


extend from one side edge of housing


168


, whereas printed circuit board portions


220


extend from the opposite side of housing portion


218


. The grounding clip


230


is now positioned relative to housing portion


168


, with U-shaped clip section


234


being positioned on the inside of posts


178


, with the printed circuit board portions


238


being positioned in respective channels


180


. This positions tab portions


196


and


236


spanning across the component receiving channel


176


, such that component


232


can be positioned between the two tab portions


196


and


236


. The component is soldered in place to form a permanent electrical connection.




Intermediate shield


148


is now assembled together with shield


146


, such that tab


306


is positioned in slot


299


and tab


304


is positioned in slot


295


, as best shown in FIG.


13


. This also positions tabs


302


through slots


296


, where they can be bent back adjacent to an underside of plate portion


290


, as best shown in FIG.


10


. The assembled terminal subassembly


132


can now be positioned relative to intermediate shield


148


by positioning slot


197


over tab


301


(

FIG. 13

) and by placing alignment ribs


219


over the top edge of shield


148


(FIG.


10


). With the terminal subassembly


132


and shields as assembled in

FIG. 13

, the printed circuit boards


142


and


144


carrying the magnetic components can now be positioned such that the respective apertures


254


,


256


are overlapping their respective contacts


170


,


266


and


220


,


270


(FIGS.


11


and


12


). This positions the assembly into the configuration shown best in

FIGS. 14 and 15

. It should be noted that grounding tines


238


are extending through a respective throughhole


257


, where it is grounded through a trace on the board. Housing


130


can now be slidably received over the entire assembly of the terminal subassembly


132


and shields, such that tabs


300


protrude apertures


320


and tabs


294


protrude apertures


322


, as best shown in FIG.


9


.




With respect now to

FIG. 16

, the LED modules


14


can now be positioned in place within housing


4


. Each LED module


14


(

FIG. 7

) is positioned such that posts


120


are aligned with corresponding apertures


66


and


70


(FIG.


5


), which positions the upper housing portion


114


within apertures


62


, that is, intermediate adjacent housing extensions


60


. It should also be appreciated that a right (


14


A) and left (


14


B) LED module are required for the end of the housing, as these LED modules only carry a singular LED. With the LED modules in place, the individual LEDs


12


can be positioned in their corresponding channels


80


. The LED leads are positioned around posts


84


(

FIG. 4

) and into channels


116


(FIG.


7


), and are electrically interconnected to terminal sections


122


. This electrically interconnects the LED leads with the leads


124


(FIG.


7


), which extend downwardly therefrom. The lower row of LEDs


13


may now be positioned in their respective channels


90


(

FIG. 6

) with the leads extending in their respective channels


92


.




The plurality of modules


10


may now be positioned within the housing member


4


into the position shown in FIG.


16


. It should also be appreciated from viewing

FIG. 16

that the plurality of LED modules


14


,


14


A,


14


B form side wall continuations for the alignment of not only the LEDs, but also the modules


10


. The modules


10


are positioned within the housing as shown in

FIG. 16

, such that the corresponding posts


160


,


210


extend through the corresponding openings


56


(FIG.


17


), whereupon the posts can be heat-staked or otherwise receive a fastener to retain the subassemblies therein. It should also be understood that corresponding ribs


158


,


208


(

FIG. 12

) are received in channels


54


(

FIG. 5

) to align the subassemblies within the openings


50


. This also positions terminal


156


,


206


(

FIG. 12

) with the comb-like alignment members


58


(

FIG. 5

) to hold them in side-by-side non-contacting relation.




When all of the terminal modules


10


are loaded within their respective positions, printed circuit board


16


can be positioned over the plurality of terminals, that is, printed circuit board terminals


268


and


272


(FIGS.


10


and


11


), which are the corresponding printed circuit board terminals for modular jack terminals


156


,


206


and upper LED contacts


340


and lower LED contacts


342


. With the multi-port connector assembled as shown in

FIG. 17

, the outer shield


6


may now be positioned in an overlapping relation to housing


4


, such that tabs


300


(

FIG. 14

) extend through apertures


32


and tabs


294


(

FIG. 14

) extend beneath back wall section


23


, as best shown in FIG.


2


.




An alternate embodiment of the shielding configuration is shown in

FIG. 18

, where an alternate connector


400


is shown having a shield


406


. The connector


400


is identical to that described above, with the exception to the following change. The rear wall


423


includes apertures


434


for receiving tabs


494


therethrough. The tabs are defined so as to contact the shield wall at the location of the slots


434


for grounding purposes. The tabs


300


(

FIG. 2

) are not included, as the two shields are commoned through their connection, as shown in FIG.


13


.




As such, the design disclosed herein provides multiple advantages. Firstly, as the LED modules are positioned intermediate upper and lower rows of cavities for the multi-port or stacked jack connector, the LEDs are easily configurable for both the top and bottom rows of the stacked jack assembly, such that the condition of the connectors can be monitored for multiple levels of ports.




Also, as the terminal subassembly is configured in a laminated configuration with the upper terminal assembly


134


and lower terminal assembly


138


being positioned between the center shield


136


, and with the subassembly being configured in a somewhat Z-shaped configuration, this allows for the area between the lower housing portion


218


and housing portion


140


to be used for signal conditioning. That is, this allows for the area between housing portions


218


and


140


to receive the magnetic components on boards


142


,


144


.




Finally, given the shielding configuration, a center shield


148


can be positioned between signal conditioning components, a lower shield


146


can shield the lower side of the housings and signal conditioning components and a shield portion


194


can be positioned intermediate the two modular jack portions of terminals, all of which are decoupled and commoned to the outer shield member


6


.



Claims
  • 1. An electrical connector assembly having a plurality of rows of jacks for mating with a plurality of electrical plugs, the connector assembly comprising:plural lead frames, said lead frames including front mating contact sections, and conductor contacting sections; a center shield positioned between said lead frames; a transverse shield positioned transversely to said center shield; a lower shield positioned below said transverse shield, wherein said center shield, transverse shield and lower shield are commoned together; a first array of passive components positioned on one side of said transverse shield, between said center shield and said lower shield; a second array of passive components positioned on the opposite side of said transverse shield as said first array, between said center shield and said lower shield; an insulating module housing at least partially surrounding said pluggable contact module, said center shield, said transverse shield, said lower shield, and said first and second array of passive components, thereby defining a pluggable contact module; an insulating outer housing having a mating face having at least two connector receiving openings for receiving mating connectors therein, and module receiving openings for receipt of said pluggable contact modules.
  • 2. The electrical connector assembly of claim 1, wherein at least one of said shields comprises a shielding contact extension, and said insulating module housing comprises an opening with said shielding contact extension, extending therethrough.
  • 3. The electrical connector assembly of claim 2, further comprising an outer shielding member, substantially surrounding said insulating outer housing and said pluggable contact modules.
  • 4. The electrical connector assembly of claim 3, wherein said outer shielding member includes an opening therethrough for receiving said shielding contact extension in an electrically engaging manner.
  • 5. The electrical connector assembly of claim 4, wherein said lead frames include intermediate sections and printed circuit board contact sections, the, lead frames being profiled in a substantial Z-shape with the front mating contact sections of said plural lead frames being positioned adjacent to a central plane, with said printed circuit board contact sections from said plural lead frames being positioned proximate each other but remotely from said central plane, thereby defining a volume for said passive components, the pluggable contact module further comprising at least one printed circuit board carrying said passive components thereon, said printed circuit board being attached to said printed circuit board contact sections, with said passive components occupying said volume.
  • 6. The assembly of claim 5, wherein said pluggable contact module is comprised of two lead frames.
  • 7. The assembly of claim 6, wherein said lead frame intermediate contact sections include forward sections lying in a substantially horizontal plane, with said front mating contact sections being reversely bent from said forward sections.
  • 8. The assembly of claim 7, wherein said lead frame intermediate contact sections further comprise perpendicular sections extending from said forward sections.
  • 9. The assembly of claim 8, wherein said lead frame intermediate contact sections further comprise rearward sections extending from said perpendicular sections, said rearward sections lying in a substantially horizontal plane.
  • 10. The assembly of claim 9, wherein said intermediate contact sections are at least partially overmolded with insulative material.
  • 11. The assembly of claim 10, wherein said lead frames and said intermediate center shield are closely conforming to each other to form a lamination.
  • 12. The assembly of claim 11, wherein said rearward sections are each overmolded with an insulative material, to define a side board mounting edge, with said printed circuit contacts extending therefrom.
  • 13. The assembly of claim 12, wherein the printed circuit board contacts for each lead frame extend from opposite side edges.
  • 14. The assembly of claim 13, further comprising two printed circuit boards mounted to said side board mounting edges.
  • 15. The assembly of claim 14, wherein said lower shield, transverse center shield and said intermediate shield are all electrically commoned together.
  • 16. The assembly of claim 15, further comprising an insulative housing shell positioned around printed circuit board and shields.
  • 17. The assembly of claim 16, wherein said insulating housing has a top wall, a bottom wall, an intermediate wall forming an upper and lower row, and a plurality of modular openings formed in said upper and lower row, and said insulative shells are pluggable in said modular openings to form a stacked jack assembly.
  • 18. An electrical connector assembly having a plurality of rows of jacks for mating with a plurality of electrical plugs, the connector assembly comprising:plural lead frames, the lead frames including front mating contact sections, and conductor contacting sections; a center shield positioned between said lead frames; a transverse shield positioned transversely to said center shield; first and second arrays of passive components positioned on opposite sides of said transverse shield; an insulating module housing at least partially surrounding said pluggable contact module, said center shield, said transverse shield, said lower shield, and said first and second array of passive components, thereby defining a plurality of pluggable contact modules; an insulating outer housing having a mating face having at least two connector receiving openings for receiving mating connectors therein, and module receiving openings for receipt of said pluggable contact modules; and an outer shielding member, substantially surrounding said insulating outer housing and said pluggable contact modules.
  • 19. The electrical connector assembly of claim 18, further comprising a lower shield positioned below said transverse shield, wherein said center shield, transverse shield and lower shield are commoned together.
  • 20. The electrical connector assembly of claim 19, wherein at least one of said shields comprises a shielding contact extension, and said insulating module housing comprises an opening with said shielding contact extension, extending therethrough.
  • 21. The electrical connector assembly of claim 20, wherein said outer shielding member includes an opening therethrough for receiving said shielding contact extension in an electrically engaging manner.
  • 22. The assembly of claim 21, wherein said lead frames and center shield member are Z-shaped in configuration.
  • 23. The assembly of claim 22, wherein said lead frame intermediate contact sections include forward sections lying in a substantially horizontal plane, with said front mating contact sections being reversely bent from said forward sections.
  • 24. The assembly of claim 23, wherein said lead frame intermediate contact sections further comprise perpendicular sections extending from said forward sections.
  • 25. The assembly of claim 24, wherein said lead frame intermediate contact sections further comprise rearward sections extending from said perpendicular sections, said rearward sections lying in a substantially horizontal plane.
  • 26. The assembly of claim 25, wherein said intermediate contact sections are at least partially overmolded with insulative material.
  • 27. The assembly of claim 26, wherein said lead frames and said intermediate center shield are closely conforming to each other to form a lamination.
  • 28. The assembly of claim 27, wherein said rearward sections are each overmolded with an insulative material, to define a side board mounting edge, with said printed circuit contacts extending therefrom.
  • 29. The assembly of claim 28, wherein the printed circuit board contacts for each lead frame extend from opposite side edges.
  • 30. The assembly of claim 29, further comprising two printed circuit boards mounted to said side board mounting edges.
  • 31. The assembly of claim 30, wherein said lower shield, transverse center shield and said intermediate shield are all electrically commoned together.
  • 32. The assembly of claim 31, further comprising an insulative housing shell positioned around printed circuit board and shields.
  • 33. The assembly of claim 32, wherein said insulating housing has a top wall, a bottom wall, an intermediate wall forming an upper and lower row, and a plurality of modular opening formed in said upper and lower row, and said insulative shells are pluggable in said modular openings to form a stacked jack assembly.
Parent Case Info

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/439,755 filed Jan. 13, 2003, the complete disclosure of which is hereby expressly incorporated by reference.

US Referenced Citations (12)
Number Name Date Kind
4978317 Pocrass Dec 1990 A
5531612 Goodall et al. Jul 1996 A
5876240 Derstine et al. Mar 1999 A
5924890 Morin et al. Jul 1999 A
6120318 Reed et al. Sep 2000 A
6162089 Costello et al. Dec 2000 A
6206725 Wu Mar 2001 B1
6227911 Boutros et al. May 2001 B1
6511348 Wojtacki et al. Jan 2003 B1
6572411 Aeschbacher et al. Jun 2003 B1
6586540 De Lange et al. Jul 2003 B1
6655988 Simmons et al. Dec 2003 B1
Provisional Applications (1)
Number Date Country
60/439755 Jan 2003 US