Electrical connector with shield cap and shielded terminals

• US 9,847,607 B2
• Filed: 04/23/2015
• Issued: 12/19/2017
• Est. Priority Date: 04/23/2014
• Status: Active Grant

• Current Assignee: CommScope Technologies, LLC (CommScope Holding Company, Inc.)
• Original Assignee: CommScope Technologies, LLC (CommScope Holding Company, Inc.)
• Inventors: Bopp, Steven Richard, Pepe, Paul John
• Primary Examiner(s): Le, Thanh Tam
• Application Number:
  US14/694,393
• Publication Number:
  US 20150311646A1
• Time in Patent Office: 971 Days
• Field of Search: 439395, 439404, 439405, 439417, 43960701, 439676, 439941, 439606, 439736
• CPC Class Codes: H01R 13/42 Securing in a demountable manner
• CPC Class Codes: H01R 13/506 assembled by snap action of the parts
• CPC Class Codes: H01R 13/6461 Means for preventing cross-talk
• CPC Class Codes: H01R 13/6599 Dielectric material made conductive, e.g. plastic material coated with metal
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H01R 4/2429 mounted in an insulating base

Abstract

A shield cap is mounted to an electrical connector for reducing crosstalk between adjoining electrical connectors. The shield cap includes a body portion and opposite shield plates. The body portion is configured to engage the electrical connector and is formed from a non-conductive material. The opposite shield plates are connected to opposite sides of the body portion and configured to at least partially cover one or more insulation displacement contacts exposed from the electrical connector. The electrical connector includes a wire termination conductor configured to be connected to a wire conductor of a cable. The wire termination conductor is at least partially coated with a shielding layer.

Claims

1. An electrical connector comprising:

a connector housing having a front end and a rear end, the connector housing comprising;

a cavity opened at the front end for receiving a plug;

an insulation displacement contact supported by the connector housing and extending from the connector housing at the rear end, and

a shield cap mounted to the connector housing at the rear end, the shield cap comprising;

a molded, electrically non-conductive body portion including one or more unitary latch portions for attaching the shield cap to the connector housing; and

opposite shield plates connected to opposite sides of the body portion and configured to at least partially cover the insulation displacement contact, wherein the opposite shield plates are made from electrically conductive material,

wherein the opposite shield plates are overmolded with the body portion.

2. The electrical connector of claim 1, wherein the opposite shield plates are made from metallic material adapted for reducing crosstalk between adjoining electrical connectors.

3. The electrical connector of claim 1, wherein the body portion is entirely made from homogenous plastic.

4. The electrical connector of claim 1, wherein the shield cap includes a cable sleeve through which a cable is inserted to be connected to the insulation displacement contact.

5. The electrical connector of claim 1, wherein the body portion includes opposite sidewalls configured to engage the shield cap with the connector housing.

6. The electrical connector of claim 5, wherein the opposite sidewalls are configured to at least partially cover the insulation displacement contact.

7. The electrical connector of claim 5, wherein each of the opposite sidewalls includes the latch projection configured to engage the connector housing.

8. The electrical connector of claim 1, wherein the opposite shield plates are connected with a support bar, the support bar arranged to transverse the body portion between the shield cap and the connector housing at the rear end, wherein the support bar is overmolded with the body portion and the opposite shield plates.

9. The electrical connector of claim 1, wherein the opposite shield plates are interconnected with one or more cross members, the one or more cross members configured to be inserted into the body portion during an overmolding process.

10. The electrical connector of claim 1, wherein the insulation displacement contact is at least partially coated with a shielding layer.

11. The electrical connector of claim 1, wherein the shielding layer includes a first layer and a second layer formed above the first layer, the first layer formed with a dielectric material, and the second layer formed with a conductive material.

12. The electrical connector of claim 11, wherein the dielectric material is a polymer.

13. The electrical connector of claim 11, wherein the conductive material is a conductive ink.

14. The electrical connector of claim 13, wherein the conductive ink is a silver ink.

15. A shield cap mounted to an electrical connector, the shield cap comprising:

a molded body portion including one or more unitary latch portions for attaching the shield cap to the electrical connector, wherein the body portion is formed from an electrically non-conductive material; and

opposite shield plates connected to opposite sides of the body portion and configured to at least partially cover one or more insulation displacement contacts exposed from the electrical connector, wherein the opposite shield plates are made from electrically conductive material,

wherein the opposite shield plates are overmolded with the body portion.

16. The shield cap of claim 15, wherein the opposite shield plates are made from conductive material adapted for reducing crosstalk between adjoining electrical connectors.

17. The shield cap of claim 15, wherein the shield cap includes a cable sleeve through which a cable is inserted to be connected to the one or more insulation displacement contacts.

18. The shield cap of claim 15, wherein the opposite shield plates are connected with a support bar, the support bar arranged to transverse the body portion between the shield cap and the connector housing at the rear end, wherein the support bar is overmolded with the body portion and the opposite shield plates.

19. The shield cap of claim 15, wherein the opposite shield plates are interconnected with one or more cross members, the one or more cross members configured to be inserted into the body portion during an overmolding process.

20. A jack assembly for terminating a plurality of line wires of a communications cable, the jack assembly comprising:

a dielectric jack housing having a front end and a rear end, the jack housing comprising;

a cavity opened at the front end for receiving a plug;

a contact subassembly joined to the rear end, the contact subassembly comprising a plurality of arms extending from the contact subassembly against the rear end of the jack housing and spaced part to define a plurality of conductor channels; and

a plurality of insulation displacement contacts, each held within each of the plurality of conductor channels; and

a plurality of electrical contacts configured and positioned in the cavity for engaging corresponding contacts of the plug, and

a shield cap mounted to the jack housing at the rear end to at least partially cover the contact subassembly, the shield cap comprising;

a molded body portion having an inner surface and an outer surface, wherein the body portion is made from a non-conductive material;

a cable sleeve extending outwardly from the outer surface of the body portion and configured to receive a cable having a plurality of conductors, wherein the cable is inserted through the cable sleeve and, wherein each of the plurality of conductors of the cable is connected to each of the plurality of insulation displacement contacts;

opposite sidewalls extending from the inner surface and having one or more latch projections configured to attach the shield cap to the jack housing, wherein the opposite sidewalls including the one or more latch projections are formed to be unitary with the body portion; and

opposite shield plates extending from the inner surface and configured to at least partially cover the contact subassembly, wherein the opposite shield plates are made from an electrically conductive material, and wherein the opposite shield plates and the opposite sidewalls are alternately arranged on a peripheral of the body portion,

wherein the opposite shield plates are overmolded with the body portion.

21. The jack assembly of claim 20, wherein the non-conductive material includes a homogeneous thermoplastic polymer.

22. The jack assembly of claim 20, wherein each of the plurality of insulation displacement contacts includes a slot configured to hold each of the plurality of conducts of the cable.

23. The jack assembly of claim 20, wherein each of the plurality of insulation displacement contacts extends across each of the plurality of conductor channels so that, when each of the plurality of conductors of the cable is inserted into the each of the plurality of insulation displacement contacts, each of the plurality of conductors of the cable rests within each of the plurality of conductor channels.

24. The jack assembly of claim 20, wherein the body portion includes a plurality of cross walls projecting outwardly from the inner surface, each cross wall having first and second wall portions separated by a gap, wherein each cross wall is positioned to be inserted into one of the plurality of conductor channels so that each of the plurality of insulation displacement contacts fits within the gap.

25. The jack assembly of claim 20, wherein the opposite shield plates are connected with a support bar, the support bar arranged to transverse the body portion between the shield cap and the connector housing at the rear end, wherein the support bar is overmolded with the body portion and the opposite shield plates.

26. The jack assembly of claim 20, wherein the opposite shield plates are interconnected with one or more cross members, the one or more cross members configured to be inserted into the body portion during an overmolding process.

27. The jack assembly of claim 20, wherein the plurality of insulation displacement contacts is at least partially coated with a shielding layer.

28. The jack assembly of claim 27, wherein the shielding layer includes a first layer and a second layer formed above the first layer, the first layer formed with a dielectric material, and the second layer formed with a conductive material.

29. The jack assembly of claim 28, wherein the dielectric material is a polymer.

30. The jack assembly of claim 28, wherein the conductive material is a conductive ink.

31. The jack assembly of claim 29, wherein the conductive ink is a silver ink.

32. An electrical connector comprising:

a connector housing having a front end and a rear end, the connector housing comprising;

a cavity opened at the front end for receiving a plug;

an insulation displacement contact supported by the connector housing and extending from the connector housing at the rear end, and

a shield cap mounted to the connector housing at the rear end, the shield cap comprising;

a molded, electrically non-conductive body portion including one or more unitary latch portions for attaching the shield cap to the connector housing; and

opposite shield plates connected to opposite sides of the body portion and configured to at least partially cover the insulation displacement contact, wherein the opposite shield plates are made from electrically conductive material,

wherein the opposite shield plates are connected with a support bar, the support bar arranged to transverse the body portion between the shield cap and the connector housing at the rear end, wherein the support bar is overmolded with the body portion and the opposite shield plates.

33. An electrical connector comprising:

a connector housing having a front end and a rear end, the connector housing comprising;

a cavity opened at the front end for receiving a plug;

an insulation displacement contact supported by the connector housing and extending from the connector housing at the rear end, and

a shield cap mounted to the connector housing at the rear end, the shield cap comprising;

a molded, electrically non-conductive body portion including one or more unitary latch portions for attaching the shield cap to the connector housing; and

opposite shield plates connected to opposite sides of the body portion and configured to at least partially cover the insulation displacement contact, wherein the opposite shield plates are made from electrically conductive material,

wherein the opposite shield plates are interconnected with one or more cross members, the one or more cross members configured to be inserted into the body portion during an overmolding process.

34. A shield cap mounted to an electrical connector, the shield cap comprising:

a molded body portion including one or more unitary latch portions for attaching the shield cap to the electrical connector, wherein the body portion is formed from an electrically non-conductive material; and

opposite shield plates connected to opposite sides of the body portion and configured to at least partially cover one or more insulation displacement contacts exposed from the electrical connector, wherein the opposite shield plates are made from electrically conductive material,

wherein the opposite shield plates are connected with a support bar, the support bar arranged to transverse the body portion between the shield cap and the connector housing at the rear end, wherein the support bar is overmolded with the body portion and the opposite shield plates.

35. A shield cap mounted to an electrical connector, the shield cap comprising:

a molded body portion including one or more unitary latch portions for attaching the shield cap to the electrical connector, wherein the body portion is formed from an electrically non-conductive material; and

opposite shield plates connected to opposite sides of the body portion and configured to at least partially cover one or more insulation displacement contacts exposed from the electrical connector, wherein the opposite shield plates are made from electrically conductive material,

wherein the opposite shield plates are interconnected with one or more cross members, the one or more cross members configured to be inserted into the body portion during an overmolding process.

36. A jack assembly for terminating a plurality of line wires of a communications cable, the jack assembly comprising:

a dielectric jack housing having a front end and a rear end, the jack housing comprising;

a cavity opened at the front end for receiving a plug;

a contact subassembly joined to the rear end, the contact subassembly comprising a plurality of arms extending from the contact subassembly against the rear end of the jack housing and spaced part to define a plurality of conductor channels; and

a plurality of insulation displacement contacts, each held within each of the plurality of conductor channels; and

a plurality of electrical contacts configured and positioned in the cavity for engaging corresponding contacts of the plug, and

a shield cap mounted to the jack housing at the rear end to at least partially cover the contact subassembly, the shield cap comprising;

a molded body portion having an inner surface and an outer surface, wherein the body portion is made from a non-conductive material;

a cable sleeve extending outwardly from the outer surface of the body portion and configured to receive a cable having a plurality of conductors, wherein the cable is inserted through the cable sleeve and, wherein each of the plurality of conductors of the cable is connected to each of the plurality of insulation displacement contacts;

opposite sidewalls extending from the inner surface and having one or more latch projections configured to attach the shield cap to the jack housing, wherein the opposite sidewalls including the one or more latch projections are formed to be unitary with the body portion; and

opposite shield plates extending from the inner surface and configured to at least partially cover the contact subassembly, wherein the opposite shield plates are made from an electrically conductive material, and wherein the opposite shield plates and the opposite sidewalls are alternately arranged on a peripheral of the body portion,

wherein the body portion includes a plurality of cross walls projecting outwardly from the inner surface, each cross wall having first and second wall portions separated by a gap, wherein each cross wall is positioned to be inserted into one of the plurality of conductor channels so that each of the plurality of insulation displacement contacts fits within the gap.

37. A jack assembly for terminating a plurality of line wires of a communications cable, the jack assembly comprising:

a dielectric jack housing having a front end and a rear end, the jack housing comprising;

a cavity opened at the front end for receiving a plug;

a contact subassembly joined to the rear end, the contact subassembly comprising a plurality of arms extending from the contact subassembly against the rear end of the jack housing and spaced part to define a plurality of conductor channels; and

a plurality of insulation displacement contacts, each held within each of the plurality of conductor channels; and

a plurality of electrical contacts configured and positioned in the cavity for engaging corresponding contacts of the plug, and

a shield cap mounted to the jack housing at the rear end to at least partially cover the contact subassembly, the shield cap comprising;

a molded body portion having an inner surface and an outer surface, wherein the body portion is made from a non-conductive material;

a cable sleeve extending outwardly from the outer surface of the body portion and configured to receive a cable having a plurality of conductors, wherein the cable is inserted through the cable sleeve and, wherein each of the plurality of conductors of the cable is connected to each of the plurality of insulation displacement contacts;

opposite sidewalls extending from the inner surface and having one or more latch projections configured to attach the shield cap to the jack housing, wherein the opposite sidewalls including the one or more latch projections are formed to be unitary with the body portion; and

opposite shield plates extending from the inner surface and configured to at least partially cover the contact subassembly, wherein the opposite shield plates are made from an electrically conductive material, and wherein the opposite shield plates and the opposite sidewalls are alternately arranged on a peripheral of the body portion,

wherein the opposite shield plates are connected with a support bar, the support bar arranged to transverse the body portion between the shield cap and the connector housing at the rear end, wherein the support bar is overmolded with the body portion and the opposite shield plates.

38. A jack assembly for terminating a plurality of line wires of a communications cable, the jack assembly comprising:

a dielectric jack housing having a front end and a rear end, the jack housing comprising;

a cavity opened at the front end for receiving a plug;

a contact subassembly joined to the rear end, the contact subassembly comprising a plurality of arms extending from the contact subassembly against the rear end of the jack housing and spaced part to define a plurality of conductor channels; and

a plurality of insulation displacement contacts, each held within each of the plurality of conductor channels; and

a plurality of electrical contacts configured and positioned in the cavity for engaging corresponding contacts of the plug, and

a shield cap mounted to the jack housing at the rear end to at least partially cover the contact subassembly, the shield cap comprising;

a molded body portion having an inner surface and an outer surface, wherein the body portion is made from a non-conductive material;

a cable sleeve extending outwardly from the outer surface of the body portion and configured to receive a cable having a plurality of conductors, wherein the cable is inserted through the cable sleeve and, wherein each of the plurality of conductors of the cable is connected to each of the plurality of insulation displacement contacts;

opposite sidewalls extending from the inner surface and having one or more latch projections configured to attach the shield cap to the jack housing, wherein the opposite sidewalls including the one or more latch projections are formed to be unitary with the body portion; and

opposite shield plates extending from the inner surface and configured to at least partially cover the contact subassembly, wherein the opposite shield plates are made from an electrically conductive material, and wherein the opposite shield plates and the opposite sidewalls are alternately arranged on a peripheral of the body portion,

wherein the opposite shield plates are interconnected with one or more cross members, the one or more cross members configured to be inserted into the body portion during an overmolding process.