Board edge termination back-end connection assemblies and communications connectors including such assemblies

• US 7,857,635 B2
• Filed: 02/04/2009
• Issued: 12/28/2010
• Est. Priority Date: 09/12/2007
• Status: Expired due to Fees

• Current Assignee: CommScope Inc. (CommScope Holding Company, Inc.)
• Original Assignee: CommScope Inc. (CommScope Holding Company, Inc.)
• Inventors: Huynh, Nhan, Hashim, Amid I., Goodrich, Robert Ray, Canning, Michael Walter, Larsen, Wayne D.
• Primary Examiner(s): TA, THO DAC
• Application Number:
  US12/365,363
• Publication Number:
  US 20090142968A1
• Time in Patent Office: 692 Days
• Field of Search: 439/76.1, 439/676, 439/344, 439/418, 439/941
• US Class Current: 439/76.1
• CPC Class Codes: H01R 13/33 Contact members made of resilient wire
• CPC Class Codes: H01R 13/501 comprising an integral hinge or a frangible part
• CPC Class Codes: H01R 13/6463 using twisted pairs of wires
• CPC Class Codes: H01R 13/6469 on substrates
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H01R 4/2412 actuated by insulated cams or wedges
• CPC Class Codes: H01R 4/2433 one part of the base being movable to push the cable into the slot
• CPC Class Codes: Y10S 439/941 Crosstalk suppression

Abstract

Communications connectors are provided that include a printed circuit board that has a top side and a bottom side. These connectors each include a housing that receives at least a portion of the printed circuit board. The connectors include first through eighth input contacts that are mounted on the printed circuit board and first through eighth output contacts that are likewise mounted on the printed circuit board. The connectors further include a board edge termination assembly that has an opening that receives an edge of the printed circuit board. The board edge termination assembly has a body that is configured to receive a communications cable having at least eight conductors and to electrically connect the eight conductors to respective ones of the first through eighth output contacts.

Claims

1. A communications plug, comprising:

a printed circuit board having a top side and a bottom side;

a housing that receives at least a portion of the printed circuit board;

first through eighth skeletal plug blades mounted on the printed circuit board;

first through eighth insulation piercing contacts mounted on the printed circuit board; and

a board edge termination assembly that includes an opening that receives an edge of the printed circuit board, the board edge termination assembly comprising a body that is configured to receive at least eight conductors of a communications cable and to electrically connect the eight conductors to respective ones of the first through eighth insulation piercing contacts;

wherein each skeletal plug blade comprises a wire having first and second ends that are each mounted in the printed circuit board.

2. The communications plug of claim 1, wherein four of the first through eighth insulation piercing contacts are mounted on the top side of the printed circuit board and the remaining four of the first through eighth insulation piercing contacts are mounted on the bottom side of the printed circuit board.

3. The communications plug of claim 1, wherein each wire further includes:

a generally vertical segment;

a generally horizontal segment;

a first transition segment;

a generally U-shaped projection segment; and

a second transition segment;

wherein ends of the generally vertical segment are directly connected to the first end of the wire and to the first transition segment, respectively;

wherein ends of the generally horizontal segment are directly connected to the first transition segment and to the generally U-shaped projection segment, respectively; and

wherein ends of the generally U-shaped projection segment are directly connected to the generally horizontal segment and to the second transition segment.

4. The communications plug of claim 1, wherein a length of each respective skeletal plug blade in a longitudinal direction of the plug exceeds a longitudinal distance between a first end and a second end of each respective plug blade.

5. The communications plug of claim 1, wherein the board edge termination assembly includes a first pivotable cap and a second pivotable cap, wherein the first pivotable cap is connected to the body by a first hinge and the second pivotable cap is connected to the body by a second hinge.

6. The communications plug of claim 1, wherein the board edge termination assembly includes a track that is configured to receive two of the eight conductors of the communications cable, wherein the track includes an opening, and at least two of the insulation piercing contact extend through the opening.

7. The communications plug of claim 1, wherein the eight conductors of the communications cable are arranged as four differential pairs of conductors, and wherein the board edge termination assembly includes first through fourth tracks, each of which is configured to receive a respective one of the four differential pairs conductors therein.

8. The communications plug of claim 1, wherein a first side of each skeletal plug blade includes a projection in a direction parallel to the plane defined by the top side of the printed circuit board.

9. The communications plug of claim 8, wherein the projections on adjacent blades extend in parallel but opposite directions.

10. A communications plug, comprising:

a printed circuit board having a top side and a bottom side;

a housing that receives at least a portion of the printed circuit board;

first through eighth skeletal plug blades mounted on the printed circuit board;

first through eighth insulation piercing contacts mounted on the printed circuit board; and

a board edge termination assembly that includes an opening that receives an edge of the printed circuit board, the board edge termination assembly comprising a body that is configured to receive at least eight conductors of a communications cable and to electrically connect the eight conductors to respective ones of the first through eighth insulation piercing contacts;

wherein each skeletal plug blade comprises a wire having first and second ends, and wherein at least one of the first and second ends is positioned to make a wiping contact with a respective conductive element of the printed circuit board.

11. The communications plug of claim 10, wherein the board edge termination assembly further includes a separator that is configured to be inserted into the jacket of the communication cable.

12. The communications plug of claim 10, wherein the board edge termination assembly includes a track for at least one of the eight conductors of the communications cable, wherein the track includes an opening, and wherein at least one insulation piercing contact extends through the opening.

13. The communications plug of claim 10, wherein the body of the board edge termination assembly comprises a non-conductive body that has a top side and a bottom side, and wherein the body includes a horizontal surface on at least one of the top and the bottom sides that is configured to function as an anvil to cut off the ends of at least some of the conductors of the communications cable.

14. A communications plug, comprising:

a printed circuit board having a top side and a bottom side;

a housing that receives at least a portion of the printed circuit board;

first through eighth skeletal plug blades mounted on the printed circuit board;

first through eighth insulation piercing contacts mounted on the printed circuit board; and

a board edge termination assembly that includes an opening that receives an edge of the printed circuit board, the board edge termination assembly comprising a body that is configured to receive at least eight conductors of a communications cable and to electrically connect the eight conductors to respective ones of the first through eighth insulation piercing contacts;

wherein at least one end of each skeletal plug blade contacts the printed circuit board via a compression contact that is not inserted within an aperture in the printed circuit board.

15. A communications plug, comprising:

a printed circuit board having a top side and a bottom side;

a housing that receives at least a portion of the printed circuit board;

first through eighth skeletal plug blades mounted on the printed circuit board;

first through eighth insulation piercing contacts mounted on the printed circuit board; and

a board edge termination assembly that includes an opening that receives an edge of the printed circuit board, the board edge termination assembly comprising a body that is configured to receive at least eight conductors of a communications cable and to electrically connect the eight conductors to respective ones of the first through eighth insulation piercing contacts;

wherein the first through eighth skeletal plug blades comprise first through eighth wires that are bent to form plug blades,

wherein the skeletal plug blades are generally aligned in side-by-side fashion in numerical order,

wherein first ends of each of the first, third, fifth and seventh wires are aligned in a first row,

wherein first ends of each of the second, fourth, sixth and eighth wires are aligned in a second row,

wherein second ends of each of the first, third, fifth and seventh wires are aligned in a third row,

wherein second ends of each of the second, fourth, sixth and eighth wires are aligned in a fourth row, and

wherein the first, second, third and fourth rows are offset from each other.

16. A communications plug, comprising:

a printed circuit board having a top side and a bottom side;

first through eighth elongated skeletal plug blades, wherein each skeletal plug blade comprises a wire having a first end mounted in a respective one of first through eighth openings in the top side of the printed circuit board and a second end; and

first through eighth insulation piercing contacts that are mounted directly into the printed circuit board, wherein four of the first through eighth insulation piercing contacts are mounted to extend above the top side of the printed circuit board and the remaining four of the first through eighth insulation piercing contacts are mounted to extend below the bottom side of the printed circuit board;

wherein the first through eighth insulation piercing contacts include at least one sharpened triangular cutting surface.

17. The communications plug of claim 16, wherein the communications plug further includes a board edge termination assembly that at least partially surrounds the printed circuit board, the board edge termination assembly including first through eighth apertures, wherein each insulation piercing contact extends through a respective one of the first through eighth apertures.

18. The communications connector of claim 16, wherein each wire further includes:

a generally vertical segment;

a generally horizontal segment;

a first transition segment;

a generally U-shaped projection segment; and

a second transition segment;

wherein ends of the generally vertical segment are directly connected to the first end of the wire and to the first transition segment, respectively;

wherein ends of the generally horizontal segment are directly connected to the first transition segment and to the generally U-shaped projection segment, respectively; and

wherein ends of the generally U-shaped projection segment are directly connected to the generally horizontal segment and to the second transition segment.

19. The communications connector of claim 16, wherein a first side of each skeletal plug blade is substantially normal to the printed circuit board and a second side of each skeletal plug blade that is opposite the first side includes a projection in a direction parallel to the plane defined by the top side of the printed circuit board.

20. The communications connector of claim, 19, wherein the projections on adjacent skeletal plug blades extend in parallel but opposite directions.

21. The communications plug of claim 16, wherein the first through eighth skeletal plug blades are mounted in side-by-side fashion in numerical order such that at least a part of each skeletal plug blade is misaligned with respect to an adjacent skeletal plug blade.

22. The communications plug of claim 21, wherein the first, third, fifth and seventh plug blades are aligned in a first row, and the second, fourth, sixth and eighth skeletal plug blades are aligned in a second row that is at least partially offset from the first row.

23. The communications plug of claim 21, wherein each of the first through eighth plug blades have substantially the same shape.

24. A communications plug, comprising;

a printed circuit board having a top side and a bottom side;

first through eighth skeletal plug blades, wherein each skeletal plug blade comprises a wire having a first end mounted in a respective one of first through eighth openings in the top side of the printed circuit board and a second end; and

first through eighth insulation piercing contacts mounted on the printed circuit board, wherein four of the first through eighth insulation piercing contacts are mounted on the top side of the printed circuit board and the remaining four of the first through eighth insulation piercing contacts are mounted on the bottom side of the printed circuit board;

wherein the second end of each wire is mounted in a respective one of ninth through sixteenth openings in the top side of the printed circuit board.

25. A communications plug, comprising:

a printed circuit board;

a skeletal blade comprising a wire having a first end that is received within a first aperture in the printed circuit board and a second end that is received within a second aperture in the printed circuit board; and

an insulation piercing contact that is mounted on the printed circuit board and that is electrically connected to the skeletal plug blade through a conductive path in the printed circuit board;

wherein the skeletal plug blade is configured to mate with a contact of a mating communications jack; and

wherein at least one of the first end and the second end is electrically connected to a conductive element in the printed circuit board.

26. The communications plug of claim 25, wherein the wire is shaped so that the blade includes a projection in a direction parallel to a plane defined by a top side of the printed circuit board.

27. The communications plug of claim 25, wherein the length of the blade in a longitudinal direction of the printed circuit board exceeds the distance between the first end and the second end.

28. A communications plug, comprising:

a printed circuit board;

a skeletal blade comprising a wire having a first end that is received within a first aperture in the printed circuit board and a second end that is received within a second aperture in the printed circuit board

wherein the skeletal plug blade is configured to mate with a contact of a mating communications jack; and

wherein at least one of the first end and the second end is electrically connected to a conductive element in the printed circuit board;

wherein the first end and the second end are configured to be either press fit or soldered into the first and second apertures in the printed circuit board, respectively.

29. A communications plug, comprising;

a printed circuit board; and

a skeletal blade comprising a wire having a first end that is electrically connected to the printed circuit board via a first contact pad and a second end that is electrically connected to the printed circuit board via a second contact pad; and

an insulation piercing contact that is mounted on the printed circuit board and that is electrically connected to the skeletal plug blade through a conductive path in the printed circuit board.