Connector module and patch panel

• US 8,235,731 B1
• Filed: 03/18/2011
• Issued: 08/07/2012
• Est. Priority Date: 03/18/2011
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Poulsen, Jeffrey Alan, Sparrowhawk, Bryan L., Erickson, Jason, Bily, Adam, Taylor, Bret
• Primary Examiner(s): GUSHI, ROSS N
• Application Number:
  US13/051,908
• Time in Patent Office: 508 Days
• Field of Search: 439/76.1, 439/676, 439/941
• US Class Current: 439/76.1
• CPC Class Codes: H01R 13/6464 by adding capacitive elements
• CPC Class Codes: H01R 13/6466 on substrates, e.g. printed circuit boards [PCB]
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: Y10S 439/941 Crosstalk suppression

Abstract

A substrate operable to construct a male-type connector, a female-type connector, and/or a multi-outlet module. The substrate has a plurality of circuits and an edge card male connector including contacts for each circuit. For each circuit, the substrate has a ground plane connected to one or more of the contacts for the circuit. The ground planes may be implemented as localized, electrically floating, isolated ground planes. The substrate may include multiple layers upon which portions of the circuits and ground planes may be disposed. The ground plane corresponding to each of the plurality of circuits may be located in close proximity to conductive elements of the circuit so as to provide a localized common ground to which energy can be conveyed from the conductive elements to thereby limit an amount of energy radiated outwardly from the conductive elements to surrounding conductors.

Claims

1. A substrate comprising:

a plurality of circuits;

a plurality of ground planes comprising a ground plane corresponding to each of the plurality of circuits, each of the plurality of ground planes being spaced apart and disconnected from others of the plurality of ground planes;

an edge card male connector comprising a first and second plurality of contacts;

a first layer comprising a first portion of each of the plurality of circuits, and a first portion of each of the plurality of ground planes, the first plurality of contacts being on the first layer and including contacts corresponding to the first portion of each of the plurality of circuits, for each of the plurality of circuits, the contacts of the first plurality of contacts corresponding to the circuit comprising at least one ground plane contact electrically connected to the first portion of the ground plane corresponding to the circuit and at least one circuit contact electrically connected to the first portion of the circuit;

a second layer comprising a second portion of each of the plurality of circuits, and a second portion of each of the plurality of ground planes, the second plurality of contacts being on the second layer and including contacts corresponding to the second portion of each of the plurality of circuits, for each of the plurality of circuits, the contacts of the second plurality of contacts corresponding to the circuit comprising at least one ground plane contact electrically connected to the second portion of the ground plane corresponding to the circuit and at least one circuit contact electrically connected to the second portion of the circuit;

a first intermediate layer positioned between the first and second layers, the first intermediate layer comprising a third portion of each of the plurality of ground planes; and

a second intermediate layer positioned between the first intermediate layer and the second layer, the second intermediate layer comprising a fourth portion of each of the plurality of ground planes, for each of the plurality of ground planes, the first, second, third and fourth portions of the ground plane being electrically interconnected.

2. The substrate of claim 1, wherein each of the plurality of ground planes is a localized, electrically floating, isolated ground plane.

3. The substrate of claim 1, further comprising:

a first substrate layer having a first surface opposite a second surface;

a second substrate layer having a first surface opposite a second surface; and

an insulating layer disposed between the first and second substrate layers, the second surface of the first substrate layer being adjacent the insulating layer and the first surface of the second substrate layer being adjacent the insulating layer, the first layer being positioned on the first surface of the first substrate layer, the second layer being positioned on the second surface of the second substrate layer, the first intermediate layer being positioned on the second surface of the first substrate layer, and the second intermediate layer being positioned on the first surface of the second substrate layer.

4. The substrate of claim 3, further comprising:

for each of the plurality of ground planes, a plurality of vertical interconnect accesses (“

VIAs”

) interconnecting the first, second, third and fourth portions of the ground plane.

5. The substrate of claim 1, wherein each of the plurality of circuits comprises conductive elements, and the ground plane corresponding to each of the plurality of circuits is a localized, electrically floating, isolated ground plane located in close proximity to the conductive elements of the circuit so as to provide an electrically conductive structure to which energy can be conveyed from the conductive elements of the circuit to thereby limit an amount of electro-magnetic energy radiated outwardly from the conductive elements to at least one of surrounding circuits and conductors.

6. The substrate of claim 1, wherein at least one of the plurality of circuits comprises a pair of conductive elements arranged relative to the ground plane corresponding to the circuit such that the pair of conductive elements have a selected amount of overall common mode impedance to the ground plane, and

the ground plane corresponding to the at least one of the plurality of circuits is a localized, electrically floating, isolated ground plane.

7. The substrate of claim 1, wherein at least one of the plurality of circuits comprises a pair of conductive elements each having a length, the pair of conductive elements being arranged relative to the ground plane corresponding to the circuit and configured such that the pair of conductive elements have a selected amount of common mode impedance to the ground plane at any point along their length, and

the ground plane corresponding to the at least one of the plurality of circuits is a localized, electrically floating, isolated ground plane.

8. The substrate of claim 1, wherein at least one of the plurality of circuits comprises a pair of conductive elements arranged relative to the ground plane corresponding to the circuit such that at least one of the pair of conductive elements has a selected amount of overall impedance to the ground plane, and

the ground plane corresponding to the at least one of the plurality of circuits is a localized, electrically floating, isolated ground plane.

9. The substrate of claim 1, wherein at least one of the plurality of circuits comprises a pair of conductive elements,

a first conductive element of the pair of conductive elements has a length,

the first conductive element is arranged continuously along its length relative to the ground plane corresponding to the circuit such that the first conductive element has a selected amount of common mode impedance to the ground plane at any point along its length, and

the ground plane corresponding to the at least one of the plurality of circuits is a localized, electrically floating, isolated ground plane.

10. The substrate of claim 1, wherein at least one of the plurality of circuits comprises a pair of conductive elements arranged relative to each other and the ground plane corresponding to the circuit such that the pair of conductive elements have a selected amount of overall differential mode impedance to the ground plane, and

the ground plane corresponding to the at least one of the plurality of circuits is a localized, electrically floating, isolated ground plane.

11. The substrate of claim 1, wherein at least one of the plurality of circuits comprises a pair of conductive elements having a length,

the conductive elements of the pair are arranged continuously along their length relative to each other and the ground plane corresponding to the circuit such that the pair of conductive elements have a selected amount of differential mode impedance to the ground plane at any point along their length, and

the ground plane corresponding to the at least one of the plurality of circuits is a localized, electrically floating, isolated ground plane.

12. The substrate of claim 1 for use with a plurality of insulation displacement connectors, the substrate further comprising:

for each of the plurality of circuits, a plurality of VIAs each configured to receive an insulation displacement connector.

13. The substrate of claim 1 for use with a plurality of insulation displacement connectors, the substrate further comprising:

for each of the plurality of circuits, a first plurality of VIAs configured to receive a portion of the plurality of insulation displacement connectors positioned to extend outwardly away from the first layer, the first plurality of VIAs of adjacent ones of the plurality of circuits being offset from one another relative to the edge card male connector; and

for each of the plurality of circuits, a second plurality of VIAs configured to receive a portion of the plurality of insulation displacement connectors positioned to extend outwardly away from the second layer, the second plurality of VIAs of adjacent ones of the plurality of circuits being offset from one another relative to the edge card male connector.

14. The substrate of claim 1, for use with a plurality of cables, one of the plurality of cables corresponding to each of the plurality of circuits, each cable comprising a plurality of wires, wherein the first portion of each of the plurality of circuits comprises an electrical connection between one of the plurality of wires of the cable corresponding to the circuit and one of the contacts of the first plurality of contacts corresponding to the circuit, and

the second portion of each of the plurality of circuits comprises an electrical connection between one of the plurality of wires of the cable corresponding to the circuit and one of the contacts of the second plurality of contacts corresponding to the circuit.

15. The substrate of claim 1, for use with a plurality of cables, one of the plurality of cables corresponding to each of the plurality of circuits, each cable comprising a plurality of wires arranged in twisted pairs, wherein the first portion of each of the plurality of circuits comprises first electrical connections between a first twisted pair of the plurality of wires of the cable corresponding to the circuit and a first pair of the contacts of the first plurality of contacts corresponding to the circuit, and second electrical connections between a second twisted pair of the plurality of wires of the cable corresponding to the circuit and a second pair of the contacts of the first plurality of contacts corresponding to the circuit, a portion of the first portion of the ground plane corresponding to the circuit being positioned between the first and second electrical connections, and

the second portion of each of the plurality of circuits comprises third electrical connections between a third twisted pair of the plurality of wires of the cable corresponding to the circuit and a first pair of the contacts of the second plurality of contacts corresponding to the circuit, and fourth electrical connections between a fourth twisted pair of the plurality of wires of the cable corresponding to the circuit and a second pair of the contacts of the second plurality of contacts corresponding to the circuit, a portion of the second portion of the ground plane corresponding to the circuit being positioned between the third and fourth electrical connections.

16. The substrate of claim 1, for use with a plurality of cables, one of the plurality of cables corresponding to each of the plurality of circuits, each cable comprising a plurality of wires arranged in twisted pairs, wherein the first portion of each of the plurality of circuits comprises first electrical connections between a first twisted pair of the plurality of wires of the cable corresponding to the circuit and a first pair of the contacts of the first plurality of contacts corresponding to the circuit, and second electrical connections between a second twisted pair of the plurality of wires of the cable corresponding to the circuit and a second pair of the contacts of the first plurality of contacts corresponding to the circuit, the at least one ground plane contact connected to the first portion of the ground plane being positioned between the first pair of the first plurality of contacts corresponding to the circuit and the second pair of the first plurality of contacts corresponding to the circuit,

the second portion of each of the plurality of circuits comprises third electrical connections between a third twisted pair of the plurality of wires of the cable corresponding to the circuit and a first pair of the contacts of the second plurality of contacts corresponding to the circuit, and fourth electrical connections between a fourth twisted pair of the plurality of wires of the cable corresponding to the circuit and a second pair of the contacts of the second plurality of contacts corresponding to the circuit, the at least one ground plane contact connected to the second portion of the ground plane being positioned between the first pair of the second plurality of contacts corresponding to the circuit and the second pair of the second plurality of contacts corresponding to the circuit.

17. The substrate of claim 16, wherein the first pair of the first plurality of contacts of each of the plurality of circuits is positioned between ones of the first plurality of contacts corresponding to the circuit connected to the first portion of the ground plane corresponding to the circuit,

the second pair of the first plurality of contacts of each of the plurality of circuits is positioned between ones of the first plurality of contacts corresponding to the circuit connected to the first portion of the ground plane corresponding to the circuit,

the first pair of the second plurality of contacts of each of the plurality of circuits is positioned between ones of the second plurality of contacts corresponding to the circuit connected to the second portion of the ground plane corresponding to the circuit, and

the second pair of the second plurality of contacts of each of the plurality of circuits is positioned between ones of the second plurality of contacts corresponding to the circuit connected to the second portion of the ground plane corresponding to the circuit.

18. The substrate of claim 1, wherein the first portion of each of the plurality of circuits is at least partially surrounded by a portion of the first portion of the ground plane corresponding to the circuit and the second portion of each of the plurality of circuits is at least partially surrounded by a portion of the second portion of the ground plane corresponding to the circuit.

19. A connector for terminating a first plurality of cables, each cable comprising a plurality of wires, the connector comprising a substrate having:

a first surface opposite a second surface;

a circuit corresponding to each of the first plurality of cables, each circuit comprising a first portion disposed on the first surface of the substrate, and a second portion disposed on the second surface of the substrate, a first portion of the plurality of wires of the cable being connected to the first portion of the circuit on the first surface of the substrate, and a second portion of the plurality of wires of the cable being connected to the second portion of the circuit on the second surface of the substrate;

an edge card male connector comprising for each of the first plurality of cables, a first plurality of contacts on the first surface of the substrate and a second plurality of contacts on the second surface of the substrate, ones of the first plurality of contacts being electrically connected to the first portion of the plurality of wires of the cable by the first portion of the circuit corresponding to the cable, and ones of the second plurality of contacts being electrically connected to the second portion of the plurality of wires of the cable by the second portion of the circuit corresponding to the cable; and

a ground plane corresponding to each of the first plurality of cables, the ground plane being electrically connected to ones of the first plurality of contacts corresponding to the cable and ones of the second plurality of contacts corresponding to the cable.

20. The connector of claim 19, wherein for each of the first plurality of cables,

the ones of the first plurality of contacts connected to the ground plane corresponding to the cable are interposed between selected adjacent ones of the first plurality of contacts connected to the first portion of the plurality of wires of the cable, and

the ones of the second plurality of contacts connected to the ground plane corresponding to the cable are interposed between selected adjacent ones of the second plurality of contacts connected to the second portion of the plurality of wires of the cable.

21. The connector of claim 19 for use with a second plurality of cables, wherein the substrate is a first substrate, and the connector further comprises:

a second substrate like the first substrate for use with the second plurality of cables, the first substrate being substantially parallel and aligned with the second substrate.

22. The connector of claim 19, further comprising:

an edge card female connector having (a) an edge card male connector receiving portion and (b) an edge card male connector attachment portion opposite the edge card male connector receiving portion,

the edge card male connector receiving portion being operable to removably receive an edge card male connector other than the edge card male connector of the substrate and form a plurality of electrical connections therewith,

the edge card male connector attachment portion comprising a first plurality of contacts and a second plurality of contacts, the edge card female connector being connectable to the edge card male connector of the substrate to form a first plurality of electrical connections between the first plurality of contacts of the edge card male connector attachment portion of the edge card female connector and the first plurality of contacts of the edge card male connector, and a second plurality of electrical connections between the second plurality of contacts of the edge card male connector attachment portion of the edge card female connector and the second plurality of contacts of the edge card male connector.

23. The connector of claim 19, further comprising:

a cable attachment assembly configured to connect the plurality of cables to the substrate.

24. The connector of claim 23, wherein the cable attachment assembly comprises an annular member positioned circumferentially on each of the first plurality of cables and a transverse channel in which each of the annular members is positioned.

25. The connector of claim 23, wherein the substrate comprises a first through-hole spaced apart from a second through-hole for each of the cables,

the cable attachment assembly comprises a cable tie corresponding to each of the cables, and

for each of the cables, the corresponding cable tie passes through each of the first and second through-holes corresponding to the cable and around a portion of the corresponding cable to secure the cable to the substrate.

26. The connector of claim 25, wherein the cable attachment assembly comprises for each of the cables:

a first cable tie support positioned between the first and second through-holes corresponding to the cable on the first surface of the substrate;

a second cable tie support positioned between the first and second through-holes corresponding to the cable on the second surface of the substrate;

the cable tie corresponding to the cable passing through each of the first and second through-holes corresponding to the cable, and around a portion of the corresponding cable and portions of each of the first and second cable tie supports to secure the cable to the substrate.

27. The connector of claim 26, wherein for each of the cables:

the first portion of the plurality of wires of the cable connected to the first portion of the circuit on the first surface of the substrate extend along the first cable tie support corresponding to the cable; and

the second portion of the plurality of wires of the cable connected to the second portion of the circuit on the second surface of the substrate extend along the second cable tie support corresponding to the cable.

28. The connector of claim 27, wherein for each of the cables:

the cable attachment assembly includes a first divider adjacent the first cable tie support, the first portion of the plurality of wires being separated into two pairs of wires by the first divider; and

the cable attachment assembly includes a second divider adjacent the second cable tie support, the second portion of the plurality of wires being separated into two pairs of wires by the second divider.

29. The connector of claim 19, further comprising:

a frontward facing portion, the edge card male connector being positioned adjacent the frontward facing portion; and

a latch mechanism having a mating portion adjacent the frontward facing portion, the mating portion being configured to engage a mating portion of a different connector.

30. The connector of claim 19, wherein for each circuit:

the first portion of the plurality of wires of the cable corresponding to the circuit are connected to the first portion of the circuit on the first surface of the substrate by insulation displacement connectors, and

the second portion of the plurality of wires of the cable corresponding to the circuit are connected to the second portion of the circuit on the second surface of the substrate by insulation displacement connectors.

31. A multi-outlet module for terminating a first plurality of cables, each cable comprising a plurality of wires, the module comprising:

a housing having a frontward facing opening opposite a rearward facing opening;

a substrate positioned inside the housing; and

an outlet corresponding to each of the first plurality of cables, the outlets being mounted on the substrate and accessible through the frontward facing opening of the housing, the substrate comprising;

a first surface opposite a second surface;

a circuit corresponding to each of the first plurality of cables, each circuit comprising a first portion disposed on the first surface of the substrate, and a second portion disposed on the second surface of the substrate, a first portion of the plurality of wires of the cable being connected to the first portion of the circuit on the first surface of the substrate, and a second portion of the plurality of wires of the cable being connected to the second portion of the circuit on the second surface of the substrate;

an edge card male connector accessible through the rearward facing opening of the housing, the edge card male connector comprising for each of the first plurality of cables, a first plurality of contacts on the first surface of the substrate and a second plurality of contacts on the second surface of the substrate, ones of the first plurality of contacts being electrically connected to the first portion of the plurality of wires of the cable by the first portion of the circuit corresponding to the cable, and ones of the second plurality of contacts being electrically connected to the second portion of the plurality of wires of the cable by the second portion of the circuit corresponding to the cable; and

a ground plane corresponding to each of the first plurality of cables, the ground plane being electrically connected to ones of the first plurality of contacts corresponding to the cable and ones of the second plurality of contacts corresponding to the cable.

32. The module of claim 31, wherein the housing is configured to be mounted within a single rack unit sized patch panel.

33. The module of claim 31, wherein for each of the first plurality of cables,

the ones of the first plurality of contacts connected to the ground plane corresponding to the cable are interposed between selected adjacent ones of the first plurality of contacts connected to the first portion of the plurality of wires of the cable, and

the ones of the second plurality of contacts connected to the ground plane corresponding to the cable are interposed between selected adjacent ones of the second plurality of contacts connected to the second portion of the plurality of wires of the cable.

34. The module of claim 31 for use with a second plurality of cables, wherein the substrate is a first substrate, and the module further comprises:

a second substrate like the first substrate for use with the second plurality of cables, the first substrate being substantially parallel and aligned with the second substrate.

35. A method of reducing crosstalk in a communications connector, the method comprising:

positioning a ground plane on a substrate;

positioning a first conductive element on the substrate, the first conductive element being positioned on the substrate in close proximity to the ground plane, the first conductive element having a first impedance to the ground plane; and

positioning a second conductive element on the substrate, the second conductive element being positioned on the substrate in close proximity to the ground plane, such that a second impedance of the second conductive element to the ground plane is substantially equal to the first impedance, the first and second conductive elements being configured to conduct a differential signal across at least a portion of the substrate.

36. The method of claim 35, wherein the first and second conductive elements are positioned relative to the ground plane such that the first and second conductive elements have a selected amount of overall average common mode impedance to the ground plane.

37. The method of claim 35 for use with a system having a common mode impedance, the communications connector being connectable to the system, wherein the selected amount of overall average common mode impedance to the ground plane is substantially equal to the common mode impedance of the system.

38. The method of claim 35, wherein the first and second conductive elements each have a length,

the first and second conductive elements are arranged relative to the ground plane such that the first and second conductive elements have a selected amount of common mode impedance to the ground plane at any point along their lengths.

39. The method of claim 35, wherein the first conductive element has a length,

the first conductive element is arranged continuously along its length relative to the ground plane such that the first conductive element has a selected amount of common mode impedance to the ground plane at any point along its length.

40. The method of claim 39, wherein the second conductive element has a length,

the second conductive element is arranged continuously along its length relative to the ground plane such that the second conductive element has a selected amount of common mode impedance to the ground plane at any point along its length.

41. The method of claim 35, wherein the first and second conductive elements are arranged relative to each other and the ground plane such that the first and second conductive elements have a selected amount of overall average differential mode impedance to the ground plane.

42. The method of claim 41 for use with a system having a differential mode impedance, the communications connector being connectable to the system, wherein the selected amount of overall average differential mode impedance to the ground plane is substantially equal to the differential mode impedance of the system.

43. The method of claim 35, wherein the first and second conductive elements have a length, and

the first and second conductive elements are arranged continuously along their length relative to each other and the ground plane such that the first and second conductive elements have a selected amount of differential mode impedance to the ground plane at any point along their length.

44. The method of claim 35, wherein the ground plane is a localized, electrically floating, isolated ground plane.

45. A connector for terminating a plurality of cables, the connector comprising a substrate having:

a different circuit corresponding to each of the plurality of cables, each circuit comprising conductive elements having an input portion connected to the cable corresponding to the circuit, and an output portion connectable to an external electrical component; and

a different electrically floating ground plane corresponding to each of the circuits, the ground planes being spaced apart and disconnected from their respective circuits, the ground planes being positioned relative to the conductive elements of their respective circuits to receive electro-magnetic energy radiated outwardly from the conductive elements of their respective circuits and provide a localized common ground for the conductive elements of their respective circuits.