Modular jack contact assembly having controlled capacitive coupling positioned within a jack housing

• US 10,637,196 B2
• Filed: 01/28/2019
• Issued: 04/28/2020
• Est. Priority Date: 11/11/2015
• Status: Active Grant

• Current Assignee: Bel Fuse Limited (Bel Fuse)
• Original Assignee: Bel Fuse Limited (Bel Fuse)
• Inventors: Baum, Andrew David, Belopolsky, Yakov, Gutter, David Henry, Imschwseiler, Derek, Marowsky, Richard D., Ellis, Mark
• Primary Examiner(s): Leigh, Peter G
• Application Number:
  US16/259,455
• Publication Number:
  US 20190157808A1
• Time in Patent Office: 456 Days
• Field of Search: 439 78
• 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 13/6469 on substrates
• CPC Class Codes: H01R 13/6477 by variation of dielectric properties
• CPC Class Codes: H01R 13/6594 the shield being mounted on a PCB and connected to conductive members
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 2201/04 for network, e.g. LAN connectors
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H05K 1/0228 Compensation of cross-talk by a mutually correlated lay-out of printed circuit traces, e.g. for compensation of cross-talk in mounted connectors balanced signal pairs H05K1/0245
• CPC Class Codes: H05K 1/118 specially for flexible printed circuits, e.g. using folded portions
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/10189 Non-printed connector
• CPC Class Codes: H05K 2201/10303 Pin-in-hole mounted pins

Abstract

A modular jack connector compensates for plug characteristics via a controlled primary compensation in the immediate vicinity of the connector interface. A jack contact assembly is positioned within a jack housing and includes first and second sets of elongate contacts each having a plug contact portion and a signal output portion. Each elongate contact is configured such that their respective plug contact portions are coplanar and a signal path is defined between their plug contact portions and their signal output portions. A flexible circuit board is coupled proximate to the plug contact portions, and configured to provide capacitance compensation between respective contacts engaged thereby, wherein the capacitance compensation is offset from a signal path defined between the plug contact portions and the corresponding signal output portions.

Claims

1. A network interface connector, comprising:

a jack housing;

a rigid printed circuit board (PCB);

a jack contact assembly positioned within the jack housing and further comprising a plurality of elongate contacts each having a plug contact engagement portion and a PCB mounting portion,

wherein each of the elongate contacts are configured such that a signal path is defined between their respective plug contact engagement portion and PCB mounting portion, and each of the plug contact engagement portions for the plurality of elongate contacts are substantially coplanar with respect to each other and define substantially equidistant first gaps,

at least a first pair of the plurality of elongate contacts extending towards each other along at least part of their respective lengths wherein at least the respective PCB mounting portions of the at least first pair of elongate contacts define a corresponding second gap smaller than the first gap, wherein the second gap between the at least respective PCB mounting portions of the at least first pair of elongate contacts is less than 0.01 inches; and

a transverse insulator positioned within the second gap between the at least first pair of elongate contacts and having a dielectric strength configured to prevent dielectric voltage breakdown with an application of 1000 volts DC across the at least first pair of elongate contacts.

2. The network interface connector of claim 1, wherein the transverse insulator comprises a liquid crystal polymer material.

3. The network interface connector of claim 1, comprising first and second transverse insulators positioned in respective first and second air gaps between first and second pairs of elongate contacts.

4. The network interface connector of claim 1, wherein the transverse insulator is integrally positioned in respective first and second air gaps between first and second pairs of elongate contacts.

5. The network interface connector of claim 1, wherein an air gap of approximately 0.0005 inches is provided between the transverse insulator and each of the at least first pair of elongate contacts.

6. The network interface connector of claim 1, further comprising a flexible circuit board (FCB) coupled to each of the plurality of elongate contacts via respective FCB mounting portions, wherein the FCB comprises a flexible substrate with at least first and second copper layers on opposing sides thereof and configured to provide a controlled capacitance compensation between respective contacts engaged thereby and offset from the defined signal paths.

7. The network interface connector of claim 6, wherein each of the elongate contacts have first and second opposing ends, the first end corresponding to the PCB mounting portion and the second end corresponding to the FCB mounting portion, wherein the plug contact engagement portion further comprises a portion of the contact between the PCB mounting portion and the FCB mounting portion and proximate to the first end.

8. The network interface connector of claim 6, wherein the FCB comprises a single substrate having a serpentine aperture disposed therein and configured to define air gaps in the substrate between adjacent contacts engaged thereby.

9. The network interface connector of claim 6, wherein each of the elongate contacts have first and second opposing ends corresponding to the plug contact engagement portion and the PCB mounting portion, respectively, and the FCB mounting portion further comprises a middle portion of the contact.

10. The network interface connector of claim 9, wherein the flexible substrate for each FCB is flexed into an arcuate configuration about a central axis coupled to the FCB mounting portion of a respective elongate contact, the flexible substrate further comprising first and second copper layers applied on opposing sides of the central axis.

11. The network interface connector of claim 6, wherein:

a value of the controlled capacitance is based on a controlled dielectric constant and thickness of the flexible substrate further in view of an overlapping area of first and second copper plates respectively associated with the first and second copper layers, and

the controlled capacitance in the one or more FCBs effectively cancels resident capacitance between adjacent plug contacts coupled to the jack contact assembly.

12. The network interface connector of claim 11, wherein the first copper plate is smaller than and enveloped with respect to the second copper plate.

13. The network interface connector of claim 1, further comprising at least one contact alignment member receiving each of the elongate contacts there through.

14. The network interface connector of claim 13, wherein the at least one contact alignment member is molded over the elongate contacts and formed of an insulating material, wherein the transverse insulator is integrally formed with respect to the insulating material.

15. The network interface connector of claim 13, wherein each of the elongate contacts are coupled to the at least one contact alignment member between their respective plug contact and signal output portions.

16. The network interface connector of claim 13, further comprising an electrically isolated compression spring mounted between an internal wall of the jack housing and the at least one contact alignment member, and configured to apply a normal force to the contact assembly.

17. The network interface connector of claim 1, wherein the PCB mounting portions of a first set of elongate contacts are maintained in a first coplanar array, and the PCB mounting portions of a second set of elongate contacts are maintained in a second coplanar array parallel to the first coplanar array.

18. A network interface connector, comprising:

a jack housing;

a plurality of jack contacts disposed within the jack housing for engaging a plurality of plug contacts and providing a like plurality of signal paths from an interface thereto, wherein each of the plurality of jack contacts have a first end and a second end, the first ends for each of the plurality of jack contacts extending in parallel to the interface and defining substantially equal first gaps there between, and the second ends for at least a first pair of the plurality of jack contacts having a second gap smaller than the first gap there between;

primary compensation means for providing a primary controlled capacitance compensation between respective contacts engaged thereby, in immediate proximity with the interface and offset from the defined signal paths;

secondary compensation means for connecting the plurality of signal paths to active equipment or transmission cables and providing a secondary controlled capacitance compensation thereto; and

insulating means for preventing dielectric voltage breakdown with an application of 1000 volts DC across the second gap between the at least first pair of jack contacts.

19. The network interface connector of claim 18, wherein the second gap between the second ends for at least the first pair of the plurality of jack contacts is less than 0.01 inches.

20. A network interface connector, comprising:

a jack housing;

a rigid printed circuit board (PCB);

a jack contact assembly positioned within the jack housing and further comprising a plurality of elongate contacts each having a plug contact engagement portion and a PCB mounting portion;

wherein each of the elongate contacts are configured such that a signal path is defined between their respective plug contact engagement portion and PCB mounting portion, and each of the plug contact engagement portions for the plurality of elongate contacts are substantially coplanar with respect to each other and define substantially equidistant first gaps;

at least a first pair of the plurality of elongate contacts extending towards each other along at least part of their respective lengths wherein at least the respective PCB mounting portions of the at least first pair of elongate contacts define a corresponding second gap smaller than the first gap;

a transverse insulator positioned within the second gap between the at least first pair of elongate contacts and having a dielectric strength configured to prevent dielectric voltage breakdown with an application of 1000 volts DC across the at least first pair of elongate contacts; and

a flexible circuit board (FCB) coupled to each of the plurality of elongate contacts via respective FCB mounting portions, wherein the FCB comprises a flexible substrate with at least first and second copper layers on opposing sides thereof and configured to provide a controlled capacitance compensation between respective contacts engaged thereby and offset from the defined signal paths,

wherein each of the elongate contacts have first and second opposing ends, the first end corresponding to the PCB mounting portion and the second end corresponding to the FCB mounting portion, wherein the plug contact engagement portion further comprises a portion of the contact between the PCB mounting portion and the FCB mounting portion and proximate to the first end.

21. The network interface connector of claim 20, wherein the transverse insulator comprises a liquid crystal polymer material.

22. The network interface connector of claim 21, wherein the transverse insulator is integrally positioned in respective first and second air gaps between first and second pairs of elongate contacts.

23. The network interface connector of claim 21, comprising first and second transverse insulators positioned in respective first and second air gaps between first and second pairs of elongate contacts.

24. The network interface connector of claim 20, wherein an air gap of approximately 0.0005 inches is provided between the transverse insulator and each of the at least first pair of elongate contacts.

25. A network interface connector, comprising:

a jack housing;

a rigid printed circuit board (PCB);

a jack contact assembly positioned within the jack housing and further comprising a plurality of elongate contacts each having a plug contact engagement portion and a PCB mounting portion;

wherein each of the elongate contacts are configured such that a signal path is defined between their respective plug contact engagement portion and PCB mounting portion, and each of the plug contact engagement portions for the plurality of elongate contacts are substantially coplanar with respect to each other and define substantially equidistant first gaps;

at least a first pair of the plurality of elongate contacts extending towards each other along at least part of their respective lengths wherein at least the respective PCB mounting portions of the at least first pair of elongate contacts define a corresponding second gap smaller than the first gap;

a transverse insulator positioned within the second gap between the at least first pair of elongate contacts and having a dielectric strength configured to prevent dielectric voltage breakdown with an application of 1000 volts DC across the at least first pair of elongate contacts; and

a flexible circuit board (FCB) coupled to each of the plurality of elongate contacts via respective FCB mounting portions, wherein the FCB comprises a flexible substrate with at least first and second copper layers on opposing sides thereof and configured to provide a controlled capacitance compensation between respective contacts engaged thereby and offset from the defined signal paths,

wherein a value of the controlled capacitance is based on a controlled dielectric constant and thickness of the flexible substrate further in view of an overlapping area of first and second copper plates respectively associated with the first and second copper layers, and

wherein the controlled capacitance in the one or more FCBs effectively cancels resident capacitance between adjacent plug contacts coupled to the jack contact assembly.

26. The network interface connector of claim 25, wherein the transverse insulator comprises a liquid crystal polymer material.

27. The network interface connector of claim 26, wherein the transverse insulator is integrally positioned in respective first and second air gaps between first and second pairs of elongate contacts.

28. The network interface connector of claim 26, wherein an air gap of approximately 0.0005 inches is provided between the transverse insulator and each of the at least first pair of elongate contacts.

29. The network interface connector of claim 26, comprising first and second transverse insulators positioned in respective first and second air gaps between first and second pairs of elongate contacts.