Low profile modular electrical jack and communication card including the same

• US 6,217,391 B1
• Filed: 03/25/1999
• Issued: 04/17/2001
• Est. Priority Date: 03/26/1998
• Status: Expired due to Fees

• Current Assignee: Bel Fuse Limited (Bel Fuse)
• Original Assignee: Stewart Connector Systems, Inc. (Bel Connector Incorporated)
• Inventors: Colantuono, Robert, Locati, Ronald
• Primary Examiner(s): Abrams, Neil
• Assistant Examiner(s): Zarroli, Michael C.
• Application Number:
  US09/276,209
• Time in Patent Office: 754 Days
• Field of Search: 439/676, 439/131, 439/946, 439/660, 439/626
• US Class Current: 439/676
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45

Abstract

Modular electrical jack including an outer housing part and an inner housing assembly connected to the outer housing part and defining one or more plug-receiving receptacles therewith. The inner housing assembly includes contact/terminal members, at least one of which includes a terminal portion adapted to be connected to a substrate, an arcuate contact portion extending into a respective plug-receiving receptacle and an intermediate bridging portion connecting the terminal portion and the contact portion. The bridging portion is inclined in relation to an inner surface of the outer housing part such that only a very short region of the bridging portion bears against the inner surface of the outer housing part and thus, remaining portions of the bridging portion are spaced from the inner surface. The construction of such contact/terminal members enables the jack to have a height less than that of contact/terminal members in existing jacks of the RJ type while providing the contact/terminal members with sufficient normal contact force to comply with FCC requirements. A communications card such as a PCMCIA card including the jack is also disclosed.

Claims

1. A modular electrical jack, comprising:

an outer housing part, and

an inner housing assembly connected to said outer housing part and defining at least one plug-receiving receptacle with said outer housing part, said receptacle opening at a front of said outer housing part,

said inner housing assembly including contact/terminal members,

at least one of said contact/terminal members including a terminal portion adapted to be connected to a substrate, an arcuate contact portion extending into a respective one of said at least one plug-receiving receptacle and an intermediate bridging portion connecting said terminal portion and said contact portion, said contact portion having a free end facing a rear of said outer housing part, a portion of said bridging portion being inclined in relation to an inner surface of said outer housing part such that only a very short region of said bridging portion bears against an inner surface of said outer housing part, said short region of said bridging portion being closer to said front of said outer housing part than said free end of said contact portion.

2. The jack of claim 1, wherein said inner housing assembly comprises an inner housing part and at least one discrete contact/terminal-retainer assembly, at least one of said contact/terminal members being arranged in each of said at least one contact/terminal-retainer assembly.

3. The jack of claim 2, wherein said at least one contact/terminal-retainer assembly includes a retainer housing, said bridging portion including an elongate section extending obliquely upward and outward from said retainer housing terminating in a curved section, a portion of said curved section bearing against said inner surface of said outer housing part and remaining portions of said bridging portion being spaced from said inner surface.

4. The jack of claim 1, wherein said outer housing part includes a top wall having an inner surface including recessed grooves, said short region of said bridging portion of each of said at least one contact/terminal member being arranged in a respective one of said grooves.

5. The jack of claim 1, wherein said at least one contact/terminal-retainer assembly comprises a plurality of contact/terminal-retainer assemblies and said at least one plug-receiving receptacle comprises a plurality of plug-receiving receptacles.

6. The jack of claim 5, wherein said outer housing part has a height not greater than 10.5 mm and includes an interposed rigid housing portion formed by said inner surfaces between each adjacent pair of said plug-receiving receptacles, each of said interposed portions including a bottom wall, an intermediate wall and a recessed aperture in said intermediate wall.

7. The jack of claim 5, wherein said inner housing part includes a main body portion defining a receiving section for each of said at least one contact/terminal-retainer assembly.

8. The jack of claim 7, wherein said main body portion includes an elongate, planar base and angled support elements for supporting said main body portion over said base.

9. The jack of claim 7, wherein said outer housing part includes an interposed rigid housing portion formed by said inner surfaces between each adjacent pair of said plug-receiving receptacles, each of said interposed portions including a bottom wall, an intermediate wall and a recessed aperture in said intermediate wall.

10. The jack of claim 7, wherein said inner housing part includes guide slots formed in a rear face of said main body portion in alignment with each of said slots, said terminal portion of each of said at least one contact/terminal members being retained in a respective one of said guide slots.

11. The jack of claim 2, wherein said retainer housing of each of said at least one contact/terminal-retainer assembly includes a plurality of transverse channels each retaining one of said at least one contact/terminal member.

12. The jack of claim 2, further comprising cooperating securing means arranged on said inner housing part and said at least one contact/terminal-retainer assembly for securing said retainer housing of each of said at least one contact/terminal-retainer assembly to said inner housing part.

13. The jack of claim 1, wherein said contact portion is concave.

14. The jack of claim 1, wherein said contact portion is convex.

15. A modular electrical jack, comprising:

an outer housing part, and

an inner housing assembly arranged in an interior of said outer housing part and defining at least one plug-receiving receptacle with said outer housing part, said inner housing assembly comprising

an inner housing part, and

at least one contact/terminal-retainer assembly mounted in connection with said inner housing part and in alignment with a respective one of said at least one plug-receiving receptacle,

each of said at least one contact/terminal-retainer assembly including a retainer housing and a plurality of elongate contact/terminal members formed of conductive material,

at least one of said contact/terminal members including a contact portion extending into the respective one of said at least one plug-receiving receptacle, a terminal portion mounted in said inner housing part, and an intermediate bridging portion connecting said terminal portion and said contact portion and arranged at least partially in said retainer housing, said bridging portion being fixedly secured to said retainer housing to prevent movement of said bridging portion relative to said retainer housing.

16. The jack of claim 15, wherein said contact portion is arcuate and a portion of said bridging portion is inclined in relation to an inner surface of said outer housing part such that only a very short region of said inclined bridging portion bears against said inner surface of said outer housing part.

17. The jack of claim 16, wherein said outer housing part includes a top wall having an inner surface including recessed grooves, said short region of said bridging portion of each of said at least one contact/terminal member being arranged in a respective one of said grooves.

18. The jack of claim 16, wherein said contact portion is concave.

19. The jack of claim 16, wherein said contact portion is convex.

20. The jack of claim 15, wherein said contact portion is arcuate and said bridging portion includes an elongate section extending obliquely upward and outward from said retainer housing to a level above an upper wall of said retainer housing and terminates in a curved section, a portion of said curved section bearing against an inner surface of said outer housing part.

21. The jack of claim 15, wherein said at least one contact/terminal-retainer assembly comprises a plurality of contact/terminal-retainer assemblies.

22. The jack of claim 15, wherein said outer housing part has a front wall, a pair of substantially planar side walls, a substantially planar top wall extending beyond said side walls, and inner surfaces contiguous with said front wall, said outer housing part including an interposed rigid housing portion formed by said inner surfaces between each adjacent pair of said plug-receiving receptacles, each of said interposed portions including a bottom wall, an intermediate wall and a recessed aperture in said intermediate wall.

23. The jack of claim 15, wherein said inner housing part includes a main body portion defining a receiving section for each of said at least one contact/terminal-retainer assembly, said main body portion including an elongate, planar base and angled support elements for supporting said main body portion over said base.

24. The jack of claim 15, further comprising cooperating securing means arranged on said inner housing part and said at least one contact/terminal-retainer assembly for securing said retainer housing of each of said at least one contact/terminal-retainer assembly to said inner housing part.

39. The jack of claim 16, wherein said receptacle opens at a front of said outer housing part, said contact portion of at least one of said contact/terminal members having a free end facing a rear of said outer housing part, said short region of said bridging portion being closer to said front of said outer housing part than said free end of said contact portion.

25. A multi-port modular electrical jack, comprising:

an outer housing part, and

an inner housing assembly arranged in an interior of said outer housing part and defining plug-receiving receptacles with said outer housing part,

said inner housing assembly comprising

an inner housing part, and

discrete contact/terminal-retainer assemblies mounted in connection with said inner housing part and in alignment with a respective one of said plug-receiving receptacles, each of said contact/terminal-retainer assemblies including a plurality of elongate contact/terminal members formed of conductive material, each of said contact/terminal members including a contact portion extending through the respective plug-receiving receptacle, a terminal portion mounted in said inner housing part, and an intermediate bridging portion connecting said terminal portion and said contact portion.

26. The jack of claim 25, wherein said contact portion is arcuate and a portion of said bridging portion is inclined in relation to an inner surface of said outer housing part such that only a very short region of said bridging portion bears against said inner surface of said outer housing part.

27. The jack of claim 26, wherein said contact portion is concave.

28. The jack of claim 26, wherein said contact portion is convex.

29. The jack of claim 26, wherein said outer housing part includes a top wall having an inner surface including recessed grooves, said short region of said bridging portion of each of said contact/terminal members being arranged in a respective one of said grooves.

30. The jack of claim 25, wherein each of said contact/terminal-retainer assemblies includes a housing, said contact portion being arcuate and said bridging portion including an elongate section extending obliquely upward and outward from said housing to a level above an upper wall of said housing.

31. The jack of claim 25, wherein said outer housing part has a front wall, a pair of substantially planar side walls, a substantially planar top wall extending beyond said side walls, and inner surfaces contiguous with said front wall, said outer housing part including an interposed rigid housing portion formed by said inner surfaces between each adjacent pair of said plug-receiving receptacles, each of said interposed portions including a bottom wall, an intermediate wall and a recessed aperture in said intermediate wall.

32. The jack of claim 25, further comprising cooperating securing means arranged on said inner housing part and said contact/terminal-retainer assemblies for securing said retainer housing of each of said contact/terminal-retainer assemblies to said inner housing part.

40. The jack of claim 26, wherein said receptacles open at a front of said outer housing part, said contact portion of at least one of said contact/terminal members having a free end facing a rear of said outer housing part, said short region of said bridging portion being closer to said front of said outer housing part than said free end of said contact portion.

33. A communication card for use in a data utilization device, comprising:

a card member having a first and second end,

a printed circuit board having electronic communications components mounted thereon, said components being situated between said printed circuit board and said card member,

an electrical connector arranged at said first end of said card member for enabling electrical connection to the data utilization device,

a jack connected to said second end of said card member and receivable of a mating plug,

said jack comprising

an outer housing part, and

an inner housing assembly connected to said outer housing part and defining at least one plug-receiving receptacle with said outer housing part, said inner housing assembly including contact/terminal members,

each of said contact/terminal members including a terminal portion electrically coupled to said printed circuit board, an arcuate contact portion situated in said plug-receiving receptacle and an intermediate bridging portion connecting said terminal portion to said contact portion, a portion of said bridging portion being inclined in relation to an inner surface of said outer housing part such that only a very short region of said bridging portion bears against an inner surface of said outer housing part.

34. The communication card of claim 33, wherein said outer housing part includes a top wall having an inner surface including recessed grooves, said short region of said bridging portion of each of said contact/terminal members being arranged in a respective one of said grooves.

35. The communication card of claim 33, wherein said contact portion is concave.

36. The communication card of claim 33, wherein said contact portion is convex.

37. The communication card of claim 33, wherein said inner housing assembly comprises an inner housing part and at least one discrete contact/terminal-retainer assembly, said contact/terminal members being arranged in each of said at least one contact/terminal-retainer assembly.

38. The communication card of claim 37, wherein each of said at least one contact/terminal-retainer assembly includes a housing, said bridging portion including an elongate section extending obliquely upward and outward from said housing to a level above an upper wall of said housing.

41. The communication card of claim 33, wherein said receptacle opens at a front of said outer housing part, said contact portion of at least one of said contact/terminal members having a free end facing a rear of said outer housing part, said short region of said bridging portion being closer to said front of said outer housing part than said free end of said contact portion.

42. A modular electrical jack, comprising:

an outer housing part, and

an inner housing assembly connected to said outer housing part and defining at least one plug-receiving receptacle with said outer housing part,

said inner housing assembly comprising contact/terminal members, an inner housing part and at least one discrete contact/terminal-retainer assembly, at least one of said contact/terminal members being arranged in each of said at least one contact/terminal-retainer assembly, said at least one contact/terminal-retainer assembly including a retainer housing,

at least one of said contact/terminal members including a terminal portion adapted to be connected to a substrate, an arcuate contact portion extending into a respective one of said at least one plug-receiving receptacle and an intermediate bridging portion connecting said terminal portion and said contact portion, a portion of said bridging portion being inclined in relation to an inner surface of said outer housing part such that only a very short region of said bridging portion bears against an inner surface of said outer housing part,

said bridging portion including an elongate section extending obliquely upward and outward from said retainer housing terminating in a curved section, a portion of said curved section bearing against an inner surface of said outer housing part and remaining portions of said bridging portion being spaced from said inner surface.

43. A modular electrical jack, comprising:

an outer housing part,

an inner housing assembly connected to said outer housing part and defining at least one plug-receiving receptacle with said outer housing part, said inner housing assembly comprising contact/terminal members, an inner housing part and at least one discrete contact/terminal-retainer assembly, at least one of said contact/terminal members being arranged in each of said at least one contact/terminal-retainer assembly,

cooperating securing means arranged on said inner housing part and said at least one contact/terminal-retainer assembly for securing said retainer housing of each of said at least one contact/terminal-retainer assembly to said inner housing part,

at least one of said contact/terminal members including a terminal portion adapted to be connected to a substrate, an arcuate contact portion extending into a respective one of said at least one plug-receiving receptacle and an intermediate bridging portion connecting said terminal portion and said contact portion, a portion of said bridging portion being inclined in relation to an inner surface of said outer housing part such that only a very short region of said bridging portion bears against an inner surface of said outer housing part.