Metallized sled for communication plug

• US 20050266720A1
• Filed: 05/26/2004
• Published: 12/01/2005
• Est. Priority Date: 05/26/2004
• Status: Active Grant

• Current Assignee: CommScope Inc. (CommScope Holding Company, Inc.)
• Original Assignee: CommScope Inc. (CommScope Holding Company, Inc.)
• Inventors: Lin, Chen-chieh
• Granted Patent: US 7,425,159 B2
• Time in Patent Office: Days
• US Class Current: 439/418
• CPC Class Codes: H01R 13/6461 Means for preventing cross-talk
• CPC Class Codes: H01R 13/6477 by variation of dielectric properties
• CPC Class Codes: H01R 13/6598 Shield material
• CPC Class Codes: H01R 13/6599 Dielectric material made conductive, e.g. plastic material coated with metal
• CPC Class Codes: H01R 24/62 Sliding engagements with one side only, e.g. modular jack coupling devices

Abstract

A connector plug terminates a communication cable having a plurality of conductors therein. The plug includes a conductor organizing sled, which includes a plurality of channels for separating conductive wires. The sled is formed of at least two materials, including a first material being a conductive material and a second material being a dielectric material. The first material may be a metal and the second material may be a plastic. In one embodiment, the first material is impregnated within at least a portion of the second material. In another embodiment, the first material is formed as a layer on an outer surface of at least a portion of the second material.

Claims

1. A connector plug comprising:

a conductor organizing sled;

a plurality of channels formed in said conductor organizing sled, said plurality of channels being capable of separating conductive wires,

wherein said conductor organizing sled is formed of at least two materials, including a first material being a conductive material and a second material being a dielectric material.

2. The connector plug according to claim 1, wherein said first material is a metal and said second material is a plastic.

3. The connector plug according to claim 2, wherein said first material is stainless steel or copper.

4. The connector plug according to claim 1, wherein said first material is impregnated into at least a portion of said second material.

5. The connector plug according to claim 1, wherein said first material is impregnated throughout an entirety of said second material.

6. The connector plug according to claim 4, wherein said first material constitutes approximately 10% of a combined weight of said first material and said second material.

7. The connector plug according to claim 4, wherein said first material constitutes approximately 15% of a combined weight of said first material and said second material.

8. The connector plug according to claim 1, wherein said first material is formed as a layer on an outer surface of said second material.

9. The connector plug according to claim 1, wherein said first material is formed as a layer on an entirety of an outer surface of said second material.

10. The connector plug according to claim 8, wherein said layer of said first material is approximately 5 microns thick.

11. The connector plug according to claim 8, wherein said layer of said first material is applied to said second material by a vacuum metallizing process.

12. The connector plug according to claim 1, wherein said channels are parallel grooves.

13. The connector plug according to claim 12, wherein said parallel grooves are formed on one substantially flat surface of said conductor organizing sled.

14. A connector plug for terminating a communication cable having a plurality of conductors therein, said connector plug comprising:

a housing having a plurality of slots formed therein;

a conductor organizing sled having a cable termination end for receiving conductors of the communication cable and a contact end having a plurality of channels for holding and orienting individual conductors in an array, which array will be aligned with said plurality of slots in said housing when said conductor organizing sled is attached to said housing, wherein said sled is formed of at least two materials, including a first material being a conductive material and a second material being a dielectric material.

15. The connector plug according to claim 14, wherein said housing has a first end with an opening therein for receiving said conductor organizing sled when said conductor organizing sled is attached to said housing, and wherein said plurality of slots are formed in a second end of said housing.

16. The connector plug according to claim 14, further comprising:

a plurality of contact members, each contact member extending through one of said plurality of slots in said housing to make electrical contact with one of said individual conductors in said array.

17. The connector plug according to claim 14, wherein said first material is impregnated into at least a portion of said second material.

18. The connector plug according to claim 14, wherein said first material is formed as a layer on an outer surface of said second material.

19. A method of forming a connector plug comprising the steps of:

providing a conductor organizing sled of a dielectric material; and

applying a layer of conductive material over the dielectric material.

20. The method according to claim 19, further comprising:

placing conductors from an end of a cable within channels of the conductor organizing sled; and

attaching the conductor organizing sled to a housing.

21. The method according to claim 29, wherein said step of applying a conductive material is accomplished by a vacuum metallizing process.

22. A method of forming a connector plug comprising the steps of:

providing a mixture of dielectric material impregnated with conductive material; and

molding a conductor organizing sled using the mixture of dielectric material impregnated with conductive material.

23. The method according to claim 22, further comprising:

placing conductors from an end of a cable within channels of the conductor organizing sled; and

attaching the conductor organizing sled to a housing.