Telecommunication connector

• US 20060035528A1
• Filed: 08/10/2004
• Published: 02/16/2006
• Est. Priority Date: 08/10/2004
• Status: Active Grant

• Current Assignee: Schneider Electric IT Corporation (Schneider Electric SE)
• Original Assignee: American Power Conversion Corporation (Schneider Electric SE)
• Inventors: Bryan, Daniel
• Granted Patent: US 7,097,513 B2
• Time in Patent Office: Days
• US Class Current: 439/676
• CPC Class Codes: H01R 13/502 composed of different pieces H01R13/514 takes precedence
• CPC Class Codes: H01R 13/743 integral with the housing
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H01R 4/2404 the contact members having teeth, prongs, pins or needles penetrating the insulation
• CPC Class Codes: H01R 43/015 Handtools

Abstract

A telecommunications connector system for connecting to a mating telecommunications jack includes a housing that is configured to provide a contact chamber, a carrier configured to receive a plurality of insulated conductive lines, and electrically-conductive contacts at least partially disposed in the carrier, each contact including first, second, and third portions, each of the first portions being movably connected to the second portion and configured to move relative to the second portions in response to applied forces and to return to resting positions in response to removal of the applied forces, each of the third portions being movably connected to a corresponding second portion and including a blade configured to pierce an insulator coating of a corresponding insulated conductive line received by the carrier, where the carrier is at least partially disposed inside the housing such that the contacts are at least partially disposed in the contact chamber.

Claims

1. A telecommunications connector system for connecting to a mating telecommunications jack, the connector system comprising:

a housing that is configured to provide a contact chamber;

a carrier configured to receive a plurality of insulated conductive lines; and

a plurality of electrically-conductive contacts at least partially disposed in the carrier, each contact including first, second, and third portions, each of the first portions being movably connected to the second portion and configured to move relative to the second portions in response to applied forces and to return to resting positions in response to removal of the applied forces, each of the third portions being movably connected to a corresponding second portion and including a blade configured to pierce an insulator coating of a corresponding insulated conductive line received by the carrier;

wherein the carrier is at least partially disposed inside the housing such that the contacts are at least partially disposed in the contact chamber.

2. The system of claim 1 wherein the carrier provides a plurality of grooves corresponding to the plurality of contacts such that portions of the contacts can be inserted into the grooves, and wherein walls providing the grooves help to retain the contacts within the carrier and help to electrically isolate the contacts from each other.

3. The system of claim 2 wherein at least the third portions of the contacts are disposed in the grooves and wherein heights of the walls of the carrier providing the grooves have at least two different heights, the walls being relatively smaller under the first portions of the contacts and being relatively larger where the third portions of the contacts are disposed in the grooves.

4. The system of claim 3 wherein the grooves under the first portions of the contacts are configured to allow the first portions of the contacts to move in the grooves.

5. The system of claim 2 wherein the carrier provides a plurality of holes for receiving the insulated conductive lines, the holes being aligned with a respective one of the grooves.

6. The system of claim 5 wherein the carrier includes a plurality of barriers each disposed between a respective one of the grooves and a respective one of the holes.

7. The system of claim 6 wherein the third portions of the contacts are configured to be disposed around the barriers and to move relative to the second portions such that the blades will pierce the insulated conductive lines if the lines are disposed in the holes adjacent to the barriers.

8. The system of claim 5 further comprising the insulated conductive lines, wherein the blades are wedged into the conductive lines through insulator casings of the insulated conductive lines and held in place by friction.

9. A multi-user telecommunications outlet assembly system comprising:

a first subsystem cable including a first set of connector cables each including a plurality of insulated conductive lines; and

a first set of telecommunications connectors for connecting to mating telecommunications jacks, each connector of the first set of connectors coupled to a corresponding connector cable of the first set and comprising;

a housing that is configured to provide a contact chamber;

a carrier configured to receive a corresponding set of the insulated conductive lines, the corresponding set of the insulated conductive lines being partially disposed in the carrier; and

a plurality of electrically-conductive contacts at least partially disposed in the carrier, each contact including first, second, and third portions, each of the first portions being movably connected to the second portion and configured to move relative to the second portions in response to applied forces and to return to resting positions in response to removal of the applied forces, each of the third portions being movably connected to a corresponding second portion and including a blade configured to pierce an insulator coating of a corresponding insulated conductive line received by the carrier;

wherein the carrier is at least partially disposed inside the housing such that the contacts are at least partially disposed in the contact chamber.

10. The system of claim 9 further comprising:

a second subsystem cable similar to the first subsystem cable;

a second set of telecommunications connectors similar configured and coupled similarly to the first set of telecommunications connectors; and

a rack-mountable faceplate providing a plurality of openings through which the first and second sets of telecommunications connectors are respectively disposed.

11. A telecommunications cable comprising:

a housing providing a contact chamber and a connector receptacle;

a plurality of insulated wires;

an electrically-insulating contact carrier coupled to the housing and disposed at least partially in the housing and including a set of walls that provide a plurality of grooves, the grooves having first regions of a first depth and a second region of a second, deeper, depth, the contact carrier providing a plurality of wire holes, each wire hole aligned with a corresponding one of the grooves, each of the wire holes including a trough portion in which the carrier provides less than a full circumference wall;

a plurality of electrically-conductive contacts, each contact being a monolithic conductor, each contact including a base portion, an upper portion, and a blade portion, the base portion being disposed in a corresponding one of the grooves, the upper portion being disposed at least partially in the contact chamber and being configured and arranged to bend relative to the base portion to bias against and make electrical contact with a mating contact of a mating connector inserted into the connector receptacle, at least a portion of the blade portion being disposed in the second region of the corresponding groove, the blade portion including a blade disposed through a portion of an insulating shell of a corresponding one of the insulated wires and making electrical contact with the wire.

12. The system of claim 11 wherein each blade of the plurality of contacts biases the corresponding one of the insulated wires against a wall of the carrier providing the trough portion of the corresponding wire hole such that the blade is inhibited, by friction between the blade and the insulated wire, from being removed from insulated wire.

13. The system of claim 11 wherein the system consists essentially of the housing, the wires, the carrier, and the contacts.

14. The system of claim 11 wherein each of the blades includes a plurality of cutting points disposed along a length of the corresponding contact.

15. The system of claim 11 wherein the carrier includes a plurality of barriers separating the first portions of the grooves from the trough portions of the wire holes.

16. The system of claim 15 wherein the contacts are disposed about the barriers, with the blades on first sides of the barriers and the base portions on second, opposite sides of the barriers.

17. A telecommunications connector system for connecting to a mating telecommunications jack, the connector system comprising:

a housing that is configured to provide a contact chamber;

a carrier configured to receive a plurality of insulated conductive lines; and

a plurality of electrically-conductive contacts at least partially disposed in the carrier, each contact including a first portion configured to make electrical contact with a corresponding one of the conductive lines, a second portion connected to the first portion by a first bend in the contact, and a third portion connected to the second portion by a second bend in the contact, the third portion being configured and arranged to make electrical contact with mating contacts of a mating connector received by the telecommunications connector system;

wherein the plurality of contacts are each configured to flex at the first bend, such that forces are developed in the first bend, in response to the third portion being pressed upon by one of the mating contacts.

18. The system of claim 17 wherein the carrier is configured to provide room below each of the second portions of the plurality of contacts with the first bends in unflexed states such that the second portions of the plurality of contacts can move into the room as the contacts flex at the first bends.

19. The system of claim 17 wherein the first bend is configured such that the forces developed in the first bend cause reduced amounts of force to be developed in the first portion and the second bend than if the first portion was connected to the second portion without the first bend.