High density high speed data communications connector

• US 9,147,977 B2
• Filed: 06/21/2013
• Issued: 09/29/2015
• Est. Priority Date: 07/05/2012
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Poulsen, Jeffrey Alan, Kim, Frank Chin-Hwan, Bily, Adam, Sparrowhawk, Bryan L.
• Primary Examiner(s): Duverne, Jean F
• Application Number:
  US13/924,405
• Publication Number:
  US 20140154895A1
• Time in Patent Office: 830 Days
• Field of Search: 439/76.1
• US Class Current: 1/1
• CPC Class Codes: H01R 13/518 for holding or embracing several coupling parts, e.g. frames
• CPC Class Codes: H01R 13/6463 using twisted pairs of wires
• CPC Class Codes: H01R 13/658 High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse] coaxial coupling devices specially adapted for high frequency H01R24/40; for flat or ribbon cable connectors H01R12/774; for coaxial cable H01R9/05
• CPC Class Codes: H01R 13/6586 for separating multiple connector modules
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45

Abstract

An outlet that includes first and second substrates, and a plurality of electrical contacts. The first substrate includes an electrical circuit adjacent to and spaced apart from a first ground plane. Each of the electrical contacts is connected to the circuit. The second substrate includes a second ground plane electrically connected to the first ground plane. The circuit is spaced apart from the second ground plane. The electrical contacts are positioned adjacent to the first and second substrates. Together the first and second ground planes may form a localized, electrically floating, isolated ground plane. The outlet may be connected to a cable and/or configured to be mounted to a panel for use with a rack. The outlet may be implemented as a Category 7A and/or Next Generation type outlet having an overall height that allows two rows of twenty-four like outlets to be mounted within one rack unit (“1RU”).

Claims

1. An outlet comprising:

a first substrate comprising a first ground plane and an electrical circuit, the electrical circuit being adjacent to the first ground plane and spaced apart therefrom, wherein the first ground plane comprises a first plurality of layers with a different substantially non-conductive layer being positioned between each adjacent pair of the first plurality of layers, the first plurality of layers being electrically connected to one another;

a second substrate comprising a second ground plane electrically connected to the first ground plane, the electrical circuit being spaced apart from the second ground plane, wherein the second ground plane comprises a second plurality of layers with a different substantially non-conductive layer being positioned between each adjacent pair of the second plurality of layers, the second plurality of layers being electrically connected to one another; and

a plurality of electrical contacts positioned adjacent to the first and second substrates, each of the plurality of electrical contacts being connected to the electrical circuit.

2. The outlet of claim 1, wherein the first substrate is substantially orthogonal to the second substrate such that the first and second substrates define four regions;

and

the plurality of electrical contacts comprises a different pair of electrical contacts corresponding to each of the four regions, each of the different pairs having a portion positioned inside the corresponding region.

3. The outlet of claim 1, wherein the first and second ground planes together form a localized, electrically floating, isolated ground plane.

4. The outlet of claim 1 for use with a plug comprising an electrically conductive plug shield, the first and second ground planes being electrically connected to the plug shield.

5. The outlet of claim 4, further comprising at least one ground contact electrically connecting the first ground plane to the plug shield.

6. The outlet of claim 1 wherein the first substrate comprises a first slot, and the second substrate comprises a second slot configured to mate with the first slot.

7. The outlet of claim 1, wherein the first substrate comprises a first slot having a first conductor disposed therein that electrically connects the first plurality of layers to one another,

the second substrate comprises a second slot having a second conductor disposed therein that electrically connects the second plurality of layers to one another, and

the second slot is configured to mate with the first slot with the second conductor contacting the first conductor to form an electrical connection between the first and second conductors.

8. The outlet of claim 1, further comprising a plurality of electrical connectors, each electrical connector being configured to form an electrical connection with a wire, the electrical circuit comprising a plurality of electrical pathways, each pathway corresponding to a different one of the plurality of electrical connectors and connecting the different one of the plurality of electrical connectors to a different one of the plurality of electrical contacts.

9. The outlet of claim 8, wherein each of the plurality of electrical connectors is mounted on the first substrate.

10. The outlet of claim 9, wherein each of the plurality of electrical connectors is an insulation displacement connector.

11. The outlet of claim 9, wherein the first substrate has a first surface opposite a second surface,

a first portion of the plurality of electrical connectors extends outwardly from the first surface of the first substrate, and

a second portion of the plurality of electrical connectors extends outwardly from the second surface of the first substrate.

12. The outlet of claim 1, wherein the first substrate has a first surface opposite a second surface,

the electrical circuit has a first portion disposed on the first surface of the first substrate,

the electrical circuit has a second portion disposed on the second surface of the first substrate,

a first portion of the plurality of electrical contacts are connected to the first portion of the electrical circuit, and

a different second portion of the plurality of electrical contacts are connected to the second portion of the electrical circuit such that the first portion of the plurality of electrical contacts are physically separated from the second portion of the plurality of electrical contacts by the first substrate.

13. The outlet of claim 12, wherein at least a portion of the second substrate divides a portion of a first side of the first substrate from a portion of a second side of the first substrate,

the first portion of the plurality of electrical contacts comprising a first pair of contacts connected to the electrical circuit on the first side of the first substrate,

the first portion of the plurality of electrical contacts comprising a second pair of contacts connected to the electrical circuit on the second side of the first substrate, the first pair being at least partially separated from the second pair by the second substrate,

the second portion of the plurality of electrical contacts comprising a third pair of contacts connected to the electrical circuit on the first side of the first substrate,

the second portion of the plurality of electrical contacts comprising a fourth pair of contacts connected to the electrical circuit on the second side of the first substrate, the third pair being at least partially separated from the fourth pair by the second substrate.

14. The outlet of claim 1 for use with a plug comprising an electrically conductive plug shield comprising a t-shaped or crucifix-shaped divider portion defining four plug regions,

the first and second ground planes being positioned relative to one another to form a t-shaped or crucifix-shaped assembly defining four outlet regions juxtaposed with the divider portion of the plug shield such that the four plug regions are substantially aligned and continuous with the four outlet regions.

15. The outlet of claim 1 for use with a plug, the outlet further comprising:

a housing in which at least a portion of the first substrate and a portion of the second substrate are housed, the housing comprising a height and an opening configured to receive the plug, the height of the housing being such that two like housings have a combined height of less than 1.75 inches.

16. The outlet of claim 1 for use with a plug and a one rack unit patch panel, the outlet further comprising:

a housing in which at least a portion of the first substrate and a portion of the second substrate are housed, the housing comprising an opening configured to receive the plug, the housing being configured such that 48 like housings are mountable within the one rack unit patch panel.

17. A cable assembly for use with a plug comprising a plurality of pairs of plug contacts, the cable assembly comprising:

a cable having an end and a plurality of pairs of wires, each pair of wires being configured to conduct a differential signal; and

an outlet connected to the end of the cable, the outlet comprising a plurality of pairs of connectors, a plurality of pairs of outlet contacts, and a floating ground plane, each of the pairs of connectors being electrically connected to a different one of the pairs of outlet contacts, a different one of the pairs of connectors being electrically connected to each pair of wires of the cable, the outlet being configured to receive the plug and form an electrical connection between each the pairs of plug contacts and a different one of the pairs of outlet contacts, the floating ground plane having portions positioned at least partially between the pairs of outlet contacts.

18. The cable assembly of claim 17, wherein the floating ground plane is a localized, electrically floating, isolated ground plane.

19. The cable assembly of claim 17, wherein the floating ground plane is shaped to define regions with each of the pairs of outlet contacts being at least partially positioned inside a different one of the regions.

20. The cable assembly of claim 17, wherein the cable comprises at least one of a drain wire and a cable shield, the at least one drain wire and the cable shield being electrically connected to the floating ground plane.

21. The cable assembly of claim 17 for use with the plug comprising a plug shield, wherein the outlet further comprises at least one ground contact configured to electrically connect the floating ground plane to the plug shield.

22. The cable assembly of claim 17, wherein the outlet is configured in accordance with the Registered Jack 45 (“

RJ45”

) standard.

23. The cable assembly of claim 17, wherein the cable is a Class F_A or Type F_A cable.

24. The cable assembly of claim 17, wherein each pair of wires is configured to conduct the differential sign at a transmission frequency of up to 1000 MHz.

25. An outlet comprising:

a first substrate comprising a first ground plane and an electrical circuit, the electrical circuit being adjacent to the first ground plane and spaced apart therefrom;

a second substrate comprising a second ground plane electrically connected to the first ground plane, the electrical circuit being spaced apart from the second ground plane;

a plurality of electrical contacts positioned adjacent to the first and second substrates, each of the plurality of electrical contacts being connected to the electrical circuit; and

a plurality of electrical connectors, each electrical connector being configured to form an electrical connection with a wire, the electrical circuit comprising a plurality of electrical pathways, each pathway corresponding to a different one of the plurality of electrical connectors and connecting the different one of the plurality of electrical connectors to a different one of the plurality of electrical contacts.

26. The outlet of claim 25, wherein the first substrate is substantially orthogonal to the second substrate such that the first and second substrates define four regions;

and

the plurality of electrical contacts comprises a different pair of electrical contacts corresponding to each of the four regions, each of the different pairs having a portion positioned inside the corresponding region.

27. The outlet of claim 25, wherein the first and second ground planes together form a localized, electrically floating, isolated ground plane.

28. The outlet of claim 25 for use with a plug comprising an electrically conductive plug shield, the first and second ground planes being electrically connected to the plug shield.

29. The outlet of claim 28, further comprising at least one ground contact electrically connecting the first ground plane to the plug shield.

30. The outlet of claim 25 wherein the first substrate comprises a first slot, and the second substrate comprises a second slot configured to mate with the first slot.

31. The outlet of claim 25 wherein the first ground plane comprises a first plurality of layers with a different substantially non-conductive layer being positioned between each adjacent pair of the first plurality of layers, the first plurality of layers being electrically connected to one another,

the second ground plane comprises a second plurality of layers with a different substantially non-conductive layer being positioned between each adjacent pair of the second plurality of layers, the second plurality of layers being electrically connected to one another,

the first substrate comprises a first slot having a first conductor disposed therein that electrically connects the first plurality of layers to one another,

the second substrate comprises a second slot having a second conductor disposed therein that electrically connects the second plurality of layers to one another, and

the second slot is configured to mate with the first slot with the second conductor contacting the first conductor to form an electrical connection between the first and second conductors.

32. The outlet of claim 25, wherein each of the plurality of electrical connectors is mounted on the first substrate.

33. The outlet of claim 25, wherein each of the plurality of electrical connectors is an insulation displacement connector.

34. The outlet of claim 25, wherein the first substrate has a first surface opposite a second surface,

a first portion of the plurality of electrical connectors extends outwardly from the first surface of the first substrate, and

a second portion of the plurality of electrical connectors extends outwardly from the second surface of the first substrate.

35. The outlet of claim 25, wherein the first substrate has a first surface opposite a second surface,

the electrical circuit has a first portion disposed on the first surface of the first substrate,

the electrical circuit has a second portion disposed on the second surface of the first substrate,

a first portion of the plurality of electrical contacts are connected to the first portion of the electrical circuit, and

a different second portion of the plurality of electrical contacts are connected to the second portion of the electrical circuit such that the first portion of the plurality of electrical contacts are physically separated from the second portion of the plurality of electrical contacts by the first substrate.

36. The outlet of claim 35, wherein at least a portion of the second substrate divides a portion of a first side of the first substrate from a portion of a second side of the first substrate,

the first portion of the plurality of electrical contacts comprising a first pair of contacts connected to the electrical circuit on the first side of the first substrate,

the first portion of the plurality of electrical contacts comprising a second pair of contacts connected to the electrical circuit on the second side of the first substrate, the first pair being at least partially separated from the second pair by the second substrate,

the second portion of the plurality of electrical contacts comprising a third pair of contacts connected to the electrical circuit on the first side of the first substrate,

the second portion of the plurality of electrical contacts comprising a fourth pair of contacts connected to the electrical circuit on the second side of the first substrate, the third pair being at least partially separated from the fourth pair by the second substrate.

37. The outlet of claim 25 for use with a plug comprising an electrically conductive plug shield comprising a t-shaped or crucifix-shaped divider portion defining four plug regions,

the first and second ground planes being positioned relative to one another to form a t-shaped or crucifix-shaped assembly defining four outlet regions juxtaposed with the divider portion of the plug shield such that the four plug regions are substantially aligned and continuous with the four outlet regions.

38. The outlet of claim 25 for use with a plug, the outlet further comprising:

a housing in which at least a portion of the first substrate and a portion of the second substrate are housed, the housing comprising a height and an opening configured to receive the plug, the height of the housing being such that two like housings have a combined height of less than 1.75 inches.

39. The outlet of claim 25 for use with a plug and a one rack unit patch panel, the outlet further comprising:

a housing in which at least a portion of the first substrate and a portion of the second substrate are housed, the housing comprising an opening configured to receive the plug, the housing being configured such that 48 like housings are mountable within the one rack unit patch panel.

40. An outlet comprising:

a first substrate comprising a first ground plane, an electrical circuit, and a first surface opposite a second surface, the electrical circuit being adjacent to the first ground plane and spaced apart therefrom, the electrical circuit having first and second portions disposed on the first and second surfaces, respectively, of the first substrate,

a second substrate comprising a second ground plane electrically connected to the first ground plane, the electrical circuit being spaced apart from the second ground plane; and

a plurality of electrical contacts positioned adjacent to the first and second substrates, each of the plurality of electrical contacts being connected to the electrical circuit, a first portion of the plurality of electrical contacts being connected to the first portion of the electrical circuit, and a different second portion of the plurality of electrical contacts being connected to the second portion of the electrical circuit such that the first portion of the plurality of electrical contacts are physically separated from the second portion of the plurality of electrical contacts by the first substrate.

41. The outlet of claim 40, wherein at least a portion of the second substrate divides a portion of a first side of the first substrate from a portion of a second side of the first substrate,

the first portion of the plurality of electrical contacts comprising a first pair of contacts connected to the electrical circuit on the first side of the first substrate,

the first portion of the plurality of electrical contacts comprising a second pair of contacts connected to the electrical circuit on the second side of the first substrate, the first pair being at least partially separated from the second pair by the second substrate,

the second portion of the plurality of electrical contacts comprising a third pair of contacts connected to the electrical circuit on the first side of the first substrate,

the second portion of the plurality of electrical contacts comprising a fourth pair of contacts connected to the electrical circuit on the second side of the first substrate, the third pair being at least partially separated from the fourth pair by the second substrate.

42. The outlet of claim 40 wherein the first ground plane comprises a first plurality of layers with a different substantially non-conductive layer being positioned between each adjacent pair of the first plurality of layers, the first plurality of layers being electrically connected to one another,

the second ground plane comprises a second plurality of layers with a different substantially non-conductive layer being positioned between each adjacent pair of the second plurality of layers, the second plurality of layers being electrically connected to one another,

the first substrate comprises a first slot having a first conductor disposed therein that electrically connects the first plurality of layers to one another,

the second substrate comprises a second slot having a second conductor disposed therein that electrically connects the second plurality of layers to one another, and

the second slot is configured to mate with the first slot with the second conductor contacting the first conductor to form an electrical connection between the first and second conductors.

43. The outlet of claim 40, wherein the first substrate is substantially orthogonal to the second substrate such that the first and second substrates define four regions;

and

the plurality of electrical contacts comprises a different pair of electrical contacts corresponding to each of the four regions, each of the different pairs having a portion positioned inside the corresponding region.

44. The outlet of claim 40, wherein the first and second ground planes together form a localized, electrically floating, isolated ground plane.

45. The outlet of claim 40 for use with a plug comprising an electrically conductive plug shield, the first and second ground planes being electrically connected to the plug shield.

46. The outlet of claim 45, further comprising at least one ground contact electrically connecting the first ground plane to the plug shield.

47. The outlet of claim 40 wherein the first substrate comprises a first slot, and the second substrate comprises a second slot configured to mate with the first slot.

48. The outlet of claim 40, further comprising a plurality of electrical connectors each mounted on the first substrate, each electrical connector being configured to form an electrical connection with a wire, the electrical circuit comprising a plurality of electrical pathways, each pathway corresponding to a different one of the plurality of electrical connectors and connecting the different one of the plurality of electrical connectors to a different one of the plurality of electrical contacts.

49. The outlet of claim 48, wherein each of the plurality of electrical connectors is an insulation displacement connector.

50. The outlet of claim 48, wherein the first substrate has a first surface opposite a second surface,

a first portion of the plurality of electrical connectors extends outwardly from the first surface of the first substrate, and

a second portion of the plurality of electrical connectors extends outwardly from the second surface of the first substrate.

51. The outlet of claim 40 for use with a plug comprising an electrically conductive plug shield comprising a t-shaped or crucifix-shaped divider portion defining four plug regions,

the first and second ground planes being positioned relative to one another to form a t-shaped or crucifix-shaped assembly defining four outlet regions juxtaposed with the divider portion of the plug shield such that the four plug regions are substantially aligned and continuous with the four outlet regions.

52. The outlet of claim 40 for use with a plug, the outlet further comprising:

a housing in which at least a portion of the first substrate and a portion of the second substrate are housed, the housing comprising a height and an opening configured to receive the plug, the height of the housing being such that two like housings have a combined height of less than 1.75 inches.

53. The outlet of claim 40 for use with a plug and a one rack unit patch panel, the outlet further comprising:

a housing in which at least a portion of the first substrate and a portion of the second substrate are housed, the housing comprising an opening configured to receive the plug, the housing being configured such that 48 like housings are mountable within the one rack unit patch panel.