Wiring distribution system and devices for building wiring

• US 5,366,388 A
• Filed: 05/10/1994
• Issued: 11/22/1994
• Est. Priority Date: 06/27/1990
• Status: Expired due to Term

• Current Assignee: Enterasys Networks Incorporated (Extreme Networks, Inc.)
• Original Assignee: Digital Equipment Corporation (HP Inc.)
• Inventors: Freeman, Mike, Morgan, Stuart K., Romm, Mike
• Primary Examiner(s): Paumen, Gary F.
• Application Number:
  US08/240,604
• Time in Patent Office: 196 Days
• Field of Search: 379/332, 379/397, 379/442, 379/443, 439/43, 439/44, 439/47, 439/48, 439/50, 439/52-54, 439/535, 439/49, 439/557, 439/541, 439/544, 439/676, 439/752
• US Class Current: 439/540.1
• CPC Class Codes: H01R 13/447 Shutter or cover plate
• CPC Class Codes: H01R 13/518 for holding or embracing several coupling parts, e.g. frames
• CPC Class Codes: H01R 13/74 Means for mounting coupling parts in openings of a panel
• CPC Class Codes: H01R 13/743 integral with the housing
• CPC Class Codes: H01R 2105/00 Three poles
• CPC Class Codes: H01R 24/52 mounted in or to a panel or structure
• CPC Class Codes: H01R 24/62 Sliding engagements with one side only, e.g. modular jack coupling devices
• CPC Class Codes: H01R 31/06 Intermediate parts for linking two coupling parts, e.g. adapter with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/94
• CPC Class Codes: H01R 4/18 by crimping H01R4/01, H01R4/2495 take precedence; for coaxial cables H01R9/0518
• CPC Class Codes: H02G 3/00 Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles installations of bus-bars H02G5/00; overhead installations H02G7/00; installations in or on the ground H02G9/00
• CPC Class Codes: Y10T 29/49181 by deforming
• CPC Class Codes: Y10T 29/5139 and means to sever work prior to disassembling
• CPC Class Codes: Y10T 29/53261 Means to align and advance work part

Abstract

A wiring distribution system including connectors, tools, and methods is provided for building wiring. The mechanical and electrical interconnection is performed to the individual connector components in a crimping operation to the individual wires after removal of the outer covering. Using panels with apertures for accepting interchangeable connectors reduces the layers of connecting panels used between a wallplate and a computer.

Claims

1. A modular building wiring distribution system for establishing a plurality of building wiring connections between any of a plurality of points of origin through any of a plurality of points of connection to any of a plurality of points of termination, comprising:

(a) a panel having a plurality of aligned receiving apertures, each of said receiving apertures providing one of said plurality of points of connection;

(b) a point-of-origin cable having a first point-of-origin cable end and a second point-of-origin cable end, said point of origin cable having a first plurality of twisted-pair wires and a first covering layer surrounding said first plurality of twisted-pair wires except for a portion of said first point-of-origin end, said point-of origin cable having a first modular connector connected to said first point-of-origin cable end, said first modular connector being either a first modular coupler or a first modular jack, each of said receiving apertures being adapted to receive said first modular connector, both said first modular coupler and said first modular jack being interchangeably positionable within any one of said receiving apertures, said first modular connector being releasably positionable within a first selected one of said receiving apertures corresponding to a first selected point of connection, said second point-of-origin cable end providing an electrical connection with a first selected one of said points of origin, said first modular connector establishing a wiring connection between said first selected point of connection and said first selected point of origin without the use of a hardwire connection, said first modular jack comprising;

(i) an insulative modular housing having a box-like head section and a tail section integrally associated therewith, said head section defined by four sidewalls and a face wall, said face wall having an aperture defining a receiving cavity for receiving a complementary modular plug, said tail section including a passageway for receiving said first plurality of twisted-pair wires, a stop surface, and an inelastically deformable knuckle portion transversely inwardly compressed for retaining said individual ones of said first plurality of twisted-pair wires between said knuckle portion and said stop surface for strain relief engagement of said point-of-origin cable to said housing;

(ii) a plurality of longitudinal slots formed in said head section for receiving said individual ones of said first plurality of twisted-pair wires; and

(iii) a plurality of electrical contacting elements, each of said contacting elements having at least a portion disposed in respective ones of said longitudinal slots and having a crimped knife portion compressed into electrical engagement with one of said first plurality of twisted-pair wires, and a cantilevered leg portion extending from said knife portion into said receiving cavity for forming an electrical interconnection with said complementary modular plug;

(c) a connecting cable having a first connecting cable end and a second connecting cable end, said connecting cable having a second modular connector connected to said first connecting cable end, said second modular connector being either a second modular coupler or a second modular jack, each of said receiving apertures being adapted to receive said second modular connector, both said second modular coupler and said second modular jack being interchangeably positionable within any one of said receiving apertures, said second modular connector being releasably positionable within a second one of said plurality of panel receiving apertures corresponding to a second selected point of connection, said second connecting cable end providing an electrical connection with a second selected one of said points of origin, said second modular connector establishing a wiring connection between said second selected point of connection and said second selected point of origin without the use of a hardwire connection;

(d) a twisted-pair cable having a first twisted-pair cable end and a second twisted-pair cable end, said second twisted-pair cable end providing an electrical connection to a first point of termination, said twisted-pair cable including a second plurality of twisted-pair wires and a second coveting layer surrounding said second plurality of twisted-pair wires except for at least a portion of said first twisted-pair cable end, said first twisted-pair cable end having a first modular plug being adapted to engage said first modular connector to provide an electrical connection from said first point of origin through said first point of connection to said first point of termination;

(e) a point-of-termination cable having a first point-of-termination cable end and a second point-of-termination cable end, said second point-of-termination cable end providing an electrical connection to a second point of termination, said point-of-termination cable including a third plurality of twisted-pair wires and a third coveting layer surrounding said third plurality of twisted-pair wires except for at least a portion of said first point-of-termination cable end, said first point-of-termination cable end having a second modular plug being adapted to engage said second modular connector to provide an electrical connection from said second point of origin through said second point of connection to said second point of termination; and

(f) said first modular connector being alternatively releasably positionable within said first one of said panel receiving apertures for establishing a wiring connection between said first selected point of connection and said second selected point of termination and said second modular connector being alternatively releasably positionable within said second one of said receiving apertures for establishing a wiring connection between said second selected point of connection and said first selected point of termination, said first modular plug and said second modular plug each being alternatively releasably positionable within one of said first modular connector and said second modular connector, but not both at the same time, to alter the order of connection of said points of origin through said points of connection to said points of termination regardless of the type of connector associated with any point of termination or any point of origin.

2. The modular building wiring distribution system of claim 1, wherein said connecting cable comprises a fourth plurality of twisted-pair wires and a fourth covering layer surrounding said fourth plurality of twisted-pair wires except for a portion of said first connecting cable end, said second modular jack comprising:

(a) an insulative modular housing having a box-like head section and a tail section integrally associated therewith, said head section defined by four sidewalls and a face wail, said face wall having an aperture defining a receiving cavity for receiving a complementary modular plug, said tail section including a passageway for receiving said fourth plurality of twisted-pair wires, a stop surface, and an inelastically deformable knuckle portion transversely inwardly compressed for retaining said individual ones of said fourth plurality of twisted-pair wires between said knuckle portion and said stop surface for strain relief engagement of said connecting cable to said housing;

(b) a plurality of longitudinal slots formed in said head section for receiving said individual ones of said twisted-pair wires; and

(c) a plurality of electrical contacting elements, each of said contacting elements having at least a portion disposed in respective ones of said longitudinal slots and having a crimped knife portion compressed into electrical engagement with one of said twisted-pair wires, and a cantilevered leg portion extending from said knife portion into said receiving cavity for forming an electrical interconnection with said complementary modular plug.

3. The modular building wiring distribution system of claim 2, wherein said first modular coupler and said second modular coupler each comprise:

(a) an insulative box-like housing including first and second mating faces along a common axis, said first and second mating faces being diametrically opposed to each other and having first and second plug receiving apertures extending inwardly therefrom to an interior portion of said housing;

(b) a plurality of spaced electrical terminals including intermediate portions disposed in said housing, first leg portions extending from said intermediate portions into said first plug receiving aperture, each of said first leg portions electrically engaging a respective one of said spaced contact elements one of said modular plugs, and second leg portions extending from said intermediate portions into said second plug receiving aperture, each of said second leg portions electrically engaging a respective one of said spaced contact elements another one of said modular plugs.

4. A modular building wiring distribution system for establishing a plurality of building wiring connections between selected points of origin through selected points of connection to selected points of termination, comprising:

(a) a panel having a plurality of aligned receiving apertures, and having mounting means associated therewith;

(b) a first modular connector being either a modular coupler or a modular jack, each of said receiving apertures being adapted to receive said first modular connector, both said first modular coupler and said modular jack being interchangeably positionable within any one of said receiving apertures;

(c) said modular coupler having a first recessed end, a second recessed end and electrical contacting means extending therebetween, each of said first and second recessed ends being adapted to receive a modular plug, said modular coupler having snap detail means for releasably engaging said mounting means associated with a first selected one of said receiving apertures corresponding to a first point of connection;

(d) said modular jack having snap detail means for releasably engaging said mounting means of a selected one of said receiving apertures corresponding to a second point of connection, said modular jack comprising;

(i) an insulative modular housing having a box-like head section and a tail section integrally associated therewith, said head section defined by four sidewalls and a face wall, said face wall having an aperture defining a receiving cavity for receiving a complementary modular plug, said tail section including a passageway for receiving a plurality of twisted-pair wires, a stop surface, and an inelastically deformable knuckle portion transversely inwardly compressed for retaining said individual ones of said twisted-pair wires between said knuckle portion and said stop surface;

(ii) a plurality of longitudinal slots formed in said head section for receiving said individual ones of said twisted-pair wires; and

(iii) a plurality of electrical contacting elements, each of said contacting elements having at least a portion disposed in respective ones of said longitudinal slots and having a crimped knife portion compressed into electrical engagement with one of said twisted-pair wires, and a cantilevered leg portion extending from said knife portion into said receiving cavity for forming an electrical interconnection with said complementary modular plug;

(e) a point-of-origin cable having a first point-of-origin cable end and a second point-of-origin cable end, said first point-of-origin cable end being attached to a first modular plug for connection to one of said recessed ends of said modular coupler to provide an electrical connection between a first selected point of connection and a first point of origin;

(f) a connecting cable having a first connecting cable end and a second connecting cable end, said first connecting cable end being attached to a second modular plug for connection to said modular jack to provide an electrical connection between said second point of connection and a second point of origin; and

(g) a point-of-termination cable having a first point-of-termination cable end and a second point-of-termination cable end, said first point-of-termination cable end being connected to a third modular plug, said second point-of-termination cable end being connected to a selected one of said points of termination, said third modular plug alternatively releasably engaging said modular coupler or said modular jack to connect said selected one of said points of termination to either said first point of origin or said second point of origin.

5. A modular building wiring distribution system for establishing a plurality of building wiring connections between selected points of origin through selected points of connection to selected points of termination, comprising:

(a) a panel having a plurality of aligned receiving apertures, and having mounting means associated therewith;

(b) a first modular connector being either a modular coupler or a modular jack, each of said receiving apertures being adapted to receive said first modular connector, both said first modular coupler and said modular jack being interchangeably positionable within any one of said receiving apertures;

(c) said modular coupler having a first recessed end, a second recessed end and electrical contacting means extending therebetween, each of said first and second recessed ends being adapted to receive a modular plug, said modular coupler having snap detail means for releasably engaging said mounting means associated with a first selected one of said receiving apertures corresponding to a first point of connection, said modular coupler comprising;

(i) an insulative box-like housing including first and second mating faces along a common axis, said first and second mating faces being diametrically opposed to each other and having first and second plug receiving apertures extending inwardly therefrom to an interior portion of said housing; and

(ii) plurality of spaced electrical terminals including intermediate portions disposed in said housing, first leg portions extending from said intermediate portions into said first plug receiving aperture, each of said first leg portions electrically engaging a respective one of said spaced contact elements one of said modular plugs, and second leg portions extending from said intermediate portions into said second plug receiving aperture, each of said second leg portions electrically engaging a respective one of said spaced contact elements another one of said modular plugs;

(d) said modular jack having snap detail means for releasably engaging said mounting means of a selected one of said receiving apertures corresponding to a second point of connection, said modular jack being adapted to receive a modular plug;

(e) a point-of-origin cable having a first point-of-origin cable end and a second point-of-origin cable end, said first point-of-origin cable end being attached to a first modular plug for connection to one of said recessed ends of said modular coupler to provide an electrical connection between a first selected point of connection and a first point of origin;

(f) a connecting cable having a first connecting cable end and a second connecting cable end, said first connecting cable end being attached to a second modular plug for connection to said modular jack to provide an electrical connection between said second point of connection and a second point of origin; and

(g) a point-of-termination cable having a first point-of-termination cable end and a second point-of-termination cable end, said first point-of-termination cable end being connected to a third modular plug, said second point-of-termination cable end being connected to a selected one of said points of termination, said third modular plug alternatively releasably engaging said modular coupler or said modular jack to connect said selected one of said points of termination to either said first point of origin or said second point of origin.