Modular jack assembly

• US 5,704,802 A
• Filed: 06/14/1996
• Issued: 01/06/1998
• Est. Priority Date: 06/14/1996
• Status: Expired due to Fees

• Current Assignee: Maxconn Incorporated
• Original Assignee: Maxconn Incorporated
• Inventors: Loudermilk, Gregory
• Primary Examiner(s): Nguyen, Khiem
• Assistant Examiner(s): Kim, Yong Ki
• Application Number:
  US08/664,144
• Time in Patent Office: 571 Days
• Field of Search: 439/488, 439/489, 439/490, 439/676, 439/717, 439/344
• US Class Current: 439/490
• CPC Class Codes: H01R 12/7023 integral with the coupling device
• CPC Class Codes: H01R 12/716 Coupling device provided on the PCB
• CPC Class Codes: H01R 12/724 containing contact members forming a right angle
• CPC Class Codes: H01R 13/717 with built-in light source
• CPC Class Codes: H01R 13/7172 Conduits for light transmission
• CPC Class Codes: H01R 13/7175 Light emitting diodes (LEDs)
• CPC Class Codes: H01R 24/62 Sliding engagements with one side only, e.g. modular jack coupling devices

Abstract

A modular jack assembly includes a housing having a plug-receiving cavity and an LED assembly attached atop the plug receiving cavity. In a preferred embodiment, the LED assembly is integrally formed with the housing. The LEDs are encased within the LED assembly, being separated from the plug-receiving cavity by a partition. This isolation of the LED helps to minimize the coupling of EMF interference radiated by the leads of the LED while they are operating to the underlying contact pins. Contact pins disposed within the plug-receiving cavity each have a contacting portion which extends along the roof of the cavity. The contacting portions have a varying measure of separation from the roof along their extent. This provides further separation from the LED leads which are disposed above the contact pins in the LED assembly, further lessening the EMF coupling with the LED leads. In an alternate embodiment, the modular jack has a stacked form factor and can be ganged to form a bank of modular jacks.

Claims

1. A modular jack for receiving a plug comprising:

a generally rectangular housing having a face and a cavity, said cavity divided by a partition into a top chamber and a bottom chamber, said bottom chamber shaped to receive said plug, said face having first and second apertures formed therethrough, said first aperture opening into said top chamber, said second aperture opening into said bottom chamber, said housing further including a shell having an interior region, said face of said housing being a front end of said shell, said housing further including a rear insert received at a rear end of said shell, said partition being a cantilevered member formed on said rear insert, whereby said cavity of said housing is formed upon fitting said rear insert into said shell and said cantilevered member divides said cavity into said top and bottom chambers;

a plurality of contact pins disposed within said bottom chamber; and

at least one light emitting diode (LED) element received within said top chamber.

2. The modular jack of claim 1 wherein said at least one LED element includes a bulb portion disposed proximate to said first aperture and further includes LED leads extending from said bulb portion toward said rear end of said shell, said rear insert including a lead frame formed therein, an end of said lead frame protruding beyond a bottom of said rear insert, another end of said lead frame having an internal socket coupled thereto and disposed upon said cantilevered member, whereby said LED lead engages said internal socket when said rear insert is fitted into said rear end of said shell.

3. The modular jack of claim 1 wherein said LED element includes a pair of LED leads enclosed entirely within said top chamber.

4. The modular jack of claim 3 further includes coupling means for connecting to an adjacent modular jack.

5. The modular jack of claim 4 wherein said coupling means is disposed on at least one of left and right exterior sides of said housing, said coupling means being one of a notched region and a raised member.

6. The modular jack of claim 1 wherein each of said contact pins has a contacting portion and a mounting portion, said mounting portion extending downwardly from an upper interior surface of said bottom chamber, proximate a rear wall of said bottom chamber and through a bottom surface of said bottom chamber to the exterior of said housing, said contacting portion having an end proximate said second aperture and extending along said upper interior surface toward said rear wall, the spacing between said contacting portion and said upper interior surface varying along the length of said contacting portion.

7. The modular jack of claim 6 wherein the spacing between said contacting portion and said upper interior surface of said bottom chamber is at a maximum proximate to said second aperture.

8. A modular jack comprising:

a housing member of insulative material having a cavity formed therein, said cavity having a ceiling, a floor and a rear wall, said cavity being shaped for receiving a modular plug, said housing further having an aperture opening into said cavity;

a light emitting diode (LED) assembly disposed atop said cavity and a partition separating said LED assembly from said cavity, said LED assembly having a chamber coextensive with said cavity, said LED assembly further having an LED received in said chamber and a pair of LED leads fully contained within said chamber; and

a plurality of contact pins disposed within said cavity;

each of said contact pins having a first end positioned near to said aperture and disposed proximate to said ceiling;

said contact pins extending rearwardly along said ceiling and having a distance from said ceiling that varies with travel toward said rear wall of said cavity;

said contact pins having a downward turn near said rear wall and a downward extent alongside said rear wall, said contact pins protruding through said floor so that second ends of said contact pins project beyond a bottom exterior surface of said housing.

9. The modular jack of claim 8 wherein said LED assembly is unilaterally formed with said housing member.

10. The modular jack of claim 9 wherein said housing includes a first coupling member formed on an exterior surface thereof, and said LED assembly includes a second coupling member which is complementary to said first coupling member, wherein said LED assembly is attached to said housing by mating said first coupling member to said second coupling member.

11. The modular jack of claim 9 wherein said varying distance of said contact pins from said ceiling has a maximum value substantially at the midpoints of the portions of said contact pins extending along said ceiling.

12. A ganged modular jack assembly comprising:

a left-end member; and

a right-end member;

each member further comprising;

a housing including a body of insulative material and having an interior cavity divided into a light emitting diode (LED) chamber and a plug receiving chamber, said housing further having exterior left, right and bottom surfaces, said LED chamber extending from a front of said housing toward a rear of said housing and being disposed atop said plug receiving chamber;

contact pins disposed within said plug receiving chamber;

at least one LED disposed within said LED chamber, said at least one LED having a pair of LED leads substantially contained within said LED chamber and extending toward said rear of said housing; and

first and second connector leads disposed within said body of insulative material and toward said rear of said housing, an end of each connector lead being electrically coupled to one of said LED leads, another end of each connector lead extending through said exterior bottom surface of said housing;

said left-end member having a coupling member formed on said exterior right surface of said housing;

said right-end member having a coupling member formed on said exterior left surface of said housing.

13. The ganged modular jack assembly of claim 12 further including a middle member having a housing and a coupling member formed on each of exterior left and right surfaces of said housing, whereby a gang of modular jacks is assembled by connecting together one or more of said middle members and connecting said left-side member on the left side thereof and said right-side member on the right side thereof.

14. The ganged modular jack assembly of claim 12 wherein said LED chamber is separated from said plug receiving chamber by a partition, said partition defining a ceiling within said plug receiving chamber, each of said contact pins having an end located proximal to said front of said housing, said contact pins extending from said front toward a rear of said plug receiving chamber alongside said ceiling and with a varying measure of separation from said ceiling.

15. The ganged modular jack assembly of claim 14 wherein portions of said contact pins extending alongside said ceiling have a maximum separation from said ceiling at midpoints of said portions of said contact pins.

16. A stacked modular jack adapted for mounting on a printed circuit board, said stacked modular jack comprising:

a housing member having two vertically-aligned plug-receiving chambers, an upper plug-receiving chamber and a lower plug-receiving chamber, formed therewithin;

a light emitting diode (LED) assembly having two vertically aligned LED-receiving chambers, said LED assembly being disposed atop said housing member;

at least one LED received within each of said LED-receiving chambers, each LED having a pair of LED leads extending toward a rear of said LED-receiving chamber; and

contact pins received within said plug-receiving chambers.

17. The stacked modular jack of claim 16 further including coupling means disposed on right and left exterior sides of said housing member, and wherein said LED assembly is unitarily formed with said housing member.

18. The stacked modular jack of claim 16 wherein said housing member includes a first coupling member formed on an exterior top surface thereof, and said LED assembly includes a second coupling member which is complementary to said first coupling member, whereby said LED assembly is attached to said housing by mating said first coupling member to said second coupling member.

19. The stacked modular jack of claim 16 wherein said contact pins each have a downwardly-extending portion which extends beyond a bottom exterior of said housing member for mounting on said printed circuit board and wherein said LED assembly further includes:

a printed circuit board having at least two conductive vias formed therethrough, each via having a conductive trace which terminates at a contact pad proximate to an edge of said board, said pair of LED leads being connected to said vias;

at least two mounting leads each connected to one of said contact pads and extending in a direction generally parallel to said downwardly-extending portions of said contact pins for mounting on said printed circuit board; and

a lateral support member by which said mounting leads are held in fixed position, thereby preventing lateral displacement of said mounting leads.

20. The stacked modular jack of claim 16 wherein end portions of said contact pins disposed within said upper plug receiving chamber are positioned toward a front of said upper plug receiving chamber, said upper contact pins extending toward a rear of said upper plug-receiving chamber proximate to a ceiling of said upper plug-receiving chamber and with a distance from said ceiling that varies with travel from said front to said rear of said upper plug receiving chamber.

21. The stacked modular jack of claim 20 wherein portions of said contact pins extending proximate to said ceiling each have a maximum distance from said ceiling near a midpoint of said portion.