Communication connectors utilizing multiple contact points

• US 10,361,514 B2
• Filed: 02/26/2018
• Issued: 07/23/2019
• Est. Priority Date: 03/02/2017
• Status: Active Grant

• Current Assignee: Panduit Corporation
• Original Assignee: Panduit Corporation
• Inventors: Valenti, Joshua A., Lenz, Sean W., Wachtel, Paul W., Fransen, Robert E., Patel, Satish I.
• Primary Examiner(s): Patel, Tulsidas C
• Assistant Examiner(s): Leigh, Peter G
• Application Number:
  US15/904,620
• Publication Number:
  US 20180254586A1
• Time in Patent Office: 512 Days
• Field of Search: 439676
• CPC Class Codes: H01R 12/585 Terminals having a press fit or a compliant portion and a shank passing through a hole in the printed circuit board
• CPC Class Codes: H01R 13/26 Pin or blade contacts for sliding co-operation on one side only for modular jack type connectors H01R24/62
• CPC Class Codes: H01R 13/6461 Means for preventing cross-talk
• CPC Class Codes: H01R 13/6466 on substrates, e.g. printed circuit boards [PCB]
• CPC Class Codes: H01R 13/6581 Shield structure
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45

Abstract

Disclosed herein are various communications systems allowing for multiple contacts points between plug contacts in a communications plug and plug interface contacts (PICs) in a communications jack. In some disclosed implementations, a communications plug including a first and a second plug contact mated with a communications jack having a first and a second plug PIC may form a plurality of plug/jack interfaces. The plug/jack interfaces may form multiple current paths between the communications plug and the communications jack. When a signal propagates between the communications plug and the communications jack, it may be split in the communications plug between a first current path and a second current path, and recombined in the communications jack after traveling through the plurality of plug/jack interfaces.

Claims

1. A communications plug, comprising:

a conductive shell; and

a printed circuit board (PCB) assembly positioned at least partially in the conductive shell, the PCB assembly comprising;

a PCB orientated parallel relative to a longitudinal direction of the conductive shell; and

a plurality of plug contacts attached to the PCB, the plurality of plug contacts comprising;

a first subset of plug contacts, each of the first subset of plug contacts to mate with two plug interface contacts (PICs) of a mating communications jack; and

second, third, and fourth subsets of plug contacts, each of the second, third, and fourth subsets of plug contacts to mate with at least one PIC of the mating communications jack,

wherein the plurality of plug contacts forms a first plane of mating interfaces and a second plane of mating interfaces, the first plane of mating interfaces being on a different plane than the second plane of mating interfaces, and the first plane of mating interfaces is formed from the first and second subsets of plug contacts.

2. The communications plug of claim 1, wherein each of the first subset of plug contacts is T-shaped.

3. The communications plug of claim 2, wherein each of the second subset of plug contacts is C-shaped.

4. The communications plug of claim 3, wherein each of the third and fourth subsets of plug contacts are upside-down U-shaped.

5. The communications plug of claim 1, wherein the first and second subsets of plug contacts attach to the PCB in a first row of vias in the PCB.

6. The communications plug of claim 5, wherein the third subset of plug contacts attach to the PCB in a second row of vias in the PCB.

7. The communications plug of claim 6, wherein the fourth subset of plug contacts attach to the PCB in a third row of vias in the PCB.

8. The communications plug of claim 1, wherein the second plane of mating interfaces is formed from the first, third, and fourth subsets of plug contacts.

9. A communications jack, comprising:

a jack housing; and

a sled assembly positioned at least partially in the jack housing, the sled assembly comprising;

a printed circuit board (PCB); and

a plurality of plug interface contacts (PICs) secured within a front section of the PCB, the plurality of PICs comprising first, second, third, and fourth different rows of PICs, wherein

a first pair of PICs including a first PIC of the first row of PICs and a first PIC of the third row of PICs, the first pair of PICs to mate with a same first plug contact of a mating communications plug; and

a second pair of PICs including a first PIC of the second row of PICs and a first PIC of the fourth row of PICs, the second pair of PICs to mate with a same second plug contact of the mating communications plug.

10. The communications jack of claim 9, wherein:

a third pair of PICs including a second PIC of the first row of PICs and a second PIC of the third row of PICs, the third pair of PICs to mate with a same third plug contact of the mating communications plug; and

a fourth pair of PICs including a second PIC of the second row of PICs and a second PIC of the fourth row of PICs, the fourth pair of PICs to mate with a same fourth plug contact of the mating communications plug.

11. The communications jack of claim 10, wherein:

a third and a fourth PIC of the first row of PICs, a third and a fourth PIC of the second row of PICs, a third and a fourth PIC of the third row of PICs, and a third and a fourth PIC of the fourth row of PICs all mate with different plug contacts of the mating communications plug.

12. The communications jack of claim 9, wherein:

the PCB is a rigid-flex PCB having a front rigid section, a rear rigid section, and a flexible section connecting the front rigid section to the rear rigid section; and

the plurality of PICs are secured within the front rigid section of the rigid-flex PCB.

13. The communications jack of claim 12, wherein:

the first row of PICs attaches to a first row of vias in the front rigid section;

the second row of PICs attaches to a second row of vias in the front rigid section;

the third row of PICs attaches to a third row of vias the front rigid section; and

the fourth row of PICs attaches to a fourth row of vias in the front rigid section.

14. The communications jack of claim 9, wherein the sled assembly comprises:

a middle sled holder having mandrels to maintain a bend radius of the first and second rows of PICs; and

a back sled holder having mandrels to maintain a bend radius of the third and fourth rows of PICs.

15. A communications system, comprising:

a communications plug, comprising a first and a second plug contact;

a communications jack, comprising a first and a second plug interface contact (PIC);

wherein, when the communications plug and the communications jack are mated;

the first plug contact and the first PIC are in contact at a first plug/jack interface, and the second plug contact and the second PIC are in contact at a second plug/jack interface;

the first plug/jack interface forms a first current path between the communications plug and the communications jack, and the second plug/jack interface forms a second current path between the communications plug and the communications jack; and

a signal propagating between the communications plug and the communications jack is split in the communications plug between the first current path and the second current path, and recombined in the communications jack after the first and the second plug/jack interfaces.