Communications Connectors with Jackwire Contacts and Printed Circuit Boards

• US 20070243728A1
• Filed: 04/18/2006
• Published: 10/18/2007
• Est. Priority Date: 04/18/2006
• Status: Active Grant

• Current Assignee: CommScope Inc. (CommScope Holding Company, Inc.)
• Original Assignee: CommScope Inc. (CommScope Holding Company, Inc.)
• Inventors: Ellis, Thomas, Long, Troy, Guelden, Ron, Canning, Michael
• Granted Patent: US 7,591,686 B2
• Time in Patent Office: Days
• US Class Current: 439/76.100
• CPC Class Codes: H01R 13/6467 by cross-over of signal conductors
• 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

Communications connectors having a plurality of signal carrying paths include a printed circuit board and a plurality of contacts. The printed circuit board has a plurality of contact pads, a plurality of output terminals, and a plurality of conductive paths that electrically connect at least some of the plurality of contact pads to respective ones of the plurality of output terminals. The contacts each have a plug contact region. In these connectors, a first of the plurality of signal carrying paths extends from the plug contact region of a first of the plurality of contacts to a first of the plurality of output terminals through a first of the contact pads and a first of the conductive paths.

Claims

1. A communications connector having a plurality of signal carrying paths, the communications connector comprising:

a printed circuit board that includes a plurality of contact pads, a plurality of output terminals, and a plurality of conductive paths that connect at least some of the plurality of contact pads to respective ones of the plurality of output terminals; and

a plurality of contacts, each contact having a plug contact region,

wherein a first of the plurality of signal carrying paths extends from the plug contact region of a first of the plurality of contacts to a first of the plurality of output terminals through a first of the contact pads and a first of the conductive paths.

2. The communications connector of claim 1, wherein each of the plurality of contact pads extends from an edge of the printed circuit board onto a top surface of the printed circuit board.

3. The communications connector of claim 2, wherein at least some of the plurality of contact pads comprise raised contact pads that extend above a top surface of the printed circuit board.

4. The communications connector of claim 1, wherein each of the plurality of contacts includes a contact termination that is mounted in an opening in a first surface of the printed circuit board, and wherein each of the plurality of contacts wraps around the printed circuit board to extend above a second surface of the printed circuit board that is opposite the first surface.

5. The communications connector of claim 4, wherein each of the plurality of contact pads are on at least the top surface of the printed circuit board, and wherein each of the plurality of contacts includes an undulation region that is configured to mate with a respective one of the plurality of contact pads.

6. The communications connector of claim 1, wherein each of the plurality of contacts includes a pad contact region that is arranged to mate with a respective one of the plurality of contact pads, and wherein the pad contact region on each contact is between a mounted end of the contact and the plug contact region.

7. The communications connector of claim 1, wherein each of the plurality of contacts includes a pad contact region that is arranged to mate with a respective one of the plurality of contact pads, and wherein the pad contact region on each contact is between the plug contact region and a free end of each contact.

8. The communications connector of claim 1, wherein each of the plurality of contacts includes a pad contact region that is arranged to mate with a respective one of the plurality of contact pads, wherein the pad contact region is within the plug contact region.

9. The communications connector of claim 3, wherein each of the raised contact pads comprises a nail that is inserted into the printed circuit board.

10. The communications connector of claim 1, wherein the plurality of contacts comprises first, second, third, fourth, fifth, sixth, seventh and eighth contacts, wherein the fourth and fifth contacts comprise a first contact pair for carrying a first balanced signal, the first and second contacts comprise a second contact pair for carrying a second balanced signal, the third and sixth contacts comprise a third contact pair for carrying a third balanced signal, the seventh and eighth contacts comprise a fourth contact pair for carrying a fourth balanced signal, and wherein at least one of first, second third and/or fourth contact pairs includes a crossover.

11. The communications connector of claim 10, wherein the third contact pair includes a crossover.

12. The communications connector of claim 10, wherein the first, second and fourth contact pairs each include a crossover.

13. The communications connector of claim 1, wherein each of the plurality of contacts includes a contact termination that is mounted in respective ones of a plurality of metal-plated holes in the printed circuit board, and wherein the printed circuit board includes a compensation circuit that is electrically connected by respective conductive traces to at least two of the plurality of metal-plated holes.

14. The communications connector of claim 1, the communications connector further comprising a housing, and wherein each of the plurality of contacts includes a mounted end that is fixed in the housing.

15. The communications connector of claim 1, wherein the plurality of conductive paths comprises first, second, third, fourth, fifth, sixth, seventh and eighth conductive paths, wherein the fourth and fifth conductive paths comprise a first pair for carrying a first balanced signal, the first and second conductive paths comprise a second pair for carrying a second balanced signal, the third and sixth conductive paths comprise a third pair for carrying a third balanced signal, the seventh and eighth conductive paths comprise a fourth pair for carrying a fourth balanced signal, and wherein the third and fifth conductive paths at least partially run adjacent each other to form an inductive crosstalk compensation stage.

58. The communications connector of claim 1, wherein each of the plurality of contacts includes an elastically mobile region that extends from a portion of the contact adjacent a bottom part of the forward edge of the printed circuit board through a free end of the contact that is positioned above a top surface of the printed circuit board.

60. The communications connector of claim 4, wherein each of the plurality of contact pads are on at least the top surface of the printed circuit board, and wherein an open area is provided between each contact and the top portion of a forward edge of the printed circuit board that each contact wraps around.

16. A communications connector, comprising:

a printed circuit board that includes a plurality of signal carrying paths that connect a plurality of input terminals of the communications connector to respective of a plurality of output terminals;

a plurality of contacts, each of the plurality of contacts having a mounted end at which the contact is mounted within the communications connector and a plug contact region that comprises one of the plurality of input terminals;

wherein at least some of the mounted ends comprise branches off of the signal carrying paths.

17. The communications connector of claim 16, wherein the mounted end of each contact is mounted in a respective one of a plurality of metal-plated holes in the printed circuit board, and wherein a crosstalk compensation circuit is connected to at least some of the metal-plated holes.

18. The communications connector of claim 16, wherein the printed circuit board further comprises a plurality of contact pads, and wherein each of the plurality of contacts further includes a pad contact region that is configured to mate with a respective one of the contact pads.

19. The communications connector of claim 18, wherein the pad contact region of each contact is between the mounted end of the contact and the plug contact region of the contact.

20. The communications connector of claim 18, wherein each of the plurality of contact pads extends from an edge of the printed circuit board onto a top surface of the printed circuit board.

21. The communications connector of claim 16, wherein each of the plurality of contacts further includes a free end, and wherein the pad contact region is between the plug contact region of the contact and the free end of the contact.

22. The communications connector of claim 16, wherein the mounted end of each contact is mounted on a first surface of the printed circuit board, and wherein each contact wraps around the printed circuit board to extend above a second surface of the printed circuit board that is opposite the first side.

23. The communications connector of claim 18, wherein at least one of the plurality of contact pads comprises a nail that is inserted into the printed circuit board.

24. The communications connector of claim 16, the communications connector further comprising a housing, and wherein the mounted end of each contact is fixed in the housing.

25. The communications connector of claim 16, wherein each of the plurality of contacts are disposed in a parallel side-by-side relationship with respect to the other of the plurality of contacts over at least half of the contacts length.

26. The communications connector of claim 16, wherein each of the plurality of contacts includes a free end, and wherein the free ends of at least two adjacent ones of the plurality of contacts are staggered with respect to each other to increase the distance between the free ends of the at least two adjacent ones of the plurality of contacts.

27. The communications connector of claim 16, wherein each of the plurality of contacts wraps around a forward edge of the printed circuit board and is free-floating adjacent the forward edge of the printed circuit board.

28. A modular jack that is configured to mate with a modular plug, the modular jack comprising:

a printed circuit board;

a plurality of raised contact pads on a first surface of the printed circuit board;

a first plurality of contacts that are aligned with respective ones of the plurality of raised contact pads;

wherein each of the first plurality of contacts is configured to make electrical contact with a respective one of the plurality of raised contact pads at a point above the first surface of the printed circuit board when the modular plug is inserted in the modular jack.

29. The modular jack of claim 28, wherein each raised contact pad comprises a nail mounted in a metal-plated hole on the printed circuit board.

30. The modular jack of claim 28, further comprising a second plurality of contacts that are aligned with respective ones of a second plurality of contact pads.

31. The modular jack of claim 28, wherein each of the first plurality of contacts includes a contact termination that is mounted in an opening in a first surface of the printed circuit board, and wherein each of the first plurality of contacts wraps around the printed circuit board to extend above a second surface of the printed circuit board that is opposite the first surface.

32. The modular jack of claim 31, wherein each of the plurality of raised contact pads are on the second surface of the printed circuit board.

33. The modular jack of claim 28, wherein each of the first plurality of contacts includes a mounted end, a plug contact region and a pad contact region that is arranged to mate with a respective one of the plurality of raised contact pads, and wherein the pad contact region on each of the first plurality of contacts is in between the mounted end and the plug contact region.

34. The modular jack of claim 28, wherein each of the plurality of raised contact pads is part of a respective one of a plurality of signal carrying paths that extend directly from each of the first plurality of contacts to respective ones of a plurality of output terminals of the modular jack.

35. The modular jack of claim 28, wherein each of the first plurality of contacts includes a pad contact region that is arranged to mate with a respective one of the plurality of raised contact pads, and wherein the pad contact region on each of the first plurality of contacts is in between a plug contact region of each contact and a free end of each contact.

36. The modular jack of claim 28, wherein each of the first plurality of contacts includes a contact termination that is mounted in respective ones of a plurality of metal-plated holes in the printed circuit board, and wherein capacitors are connected between at least some of the metal-plated holes.

37. The modular jack of claim 29, wherein an upper surface of each nail is generally dome-shaped.

38. The modular jack of claim 29, wherein a head portion of the raised contact pad is at least three times thicker than the thickness of a plurality a signal carrying traces that are provided on the printed circuit board.

39. The modular jack of claim 29, wherein each nail includes a surface that includes gold that directly mates with a respective one of the first plurality of contacts.

40. The modular jack of claim 28, wherein the modular jack includes a plurality of signal carrying paths that carry a plurality of information signals through respective of the plurality of raised contact pads.

41. The modular jack of claim 28, wherein each of the first plurality of contacts wraps around a forward edge of the printed circuit board and is free-floating adjacent the forward edge of the printed circuit board.

59. The modular jack of claim 28, wherein each raised contact pad comprises a spring contact pad.

42. A communications connector, comprising:

a plurality of contacts, each contact having a contact termination that is mounted in a first substrate; and

a second substrate that is distinct from the first substrate, wherein the second substrate comprises a printed circuit board that includes a plurality of contact pads that mate with respective ones of the plurality of contacts, a plurality of output terminals, and a plurality of conductive paths that electrically connect at least some of the plurality of contact pads to respective ones of the plurality of output terminals.

43. The communications connector of claim 42, wherein each of the plurality of contacts includes a plug contact region, and wherein the portion of each of the plurality of contacts that mates with a respective one of the plurality of contact pads is between the plug contact region of the contact and a free end of the contact.

44. The communications connector of claim 42, wherein each of the plurality of contacts includes a plug contact region, and wherein the portion of each of the plurality of contacts that mates with a respective one of the plurality of contact pads is between the plug contact region of the contact and the termination of the contact.

45. The communications connector of claim 42, wherein the plurality of contacts comprises first, second, third, fourth, fifth, sixth, seventh and eighth contacts, wherein the fourth and fifth contacts comprise a first contact pair for carrying a first balanced signal, the first and second contacts comprise a second contact pair for carrying a second balanced signal, the third and sixth contacts comprise a third contact pair for carrying a third balanced signal, the seventh and eighth contacts comprise a fourth contact pair for carrying a fourth balanced signal, and wherein at least one of first, second third and/or fourth contact pairs includes a crossover.

46. The communications connector of claim 42, wherein the first substrate comprises a dielectric housing of the communications connector.

47. The communications connector of claim 42, wherein the mounting surface comprises a second printed circuit board.

48. The communications connector of claim 42, wherein a first plane defined by the first substrate and a second plane defined by the second substrate are not parallel planes.

49. The communications connector of claim 48, wherein the first plane is substantially normal to the second plane.

50. A modular jack, comprising:

a printed circuit board that includes a plurality of contact pads at or adjacent a forward edge of the printed circuit board, a plurality of output terminals, and a plurality of conductive paths that electrically connect at least some of the plurality of contact pads to respective ones of the plurality of output terminals; and

a plurality of contacts, each contact having a mounted end, a free end and a middle portion extending between the mounted end and the free end;

wherein each of the plurality of contact pads are mounted to make electrical contact with the middle portion of respective ones of the plurality of contacts when a plug is in place in the modular jack.

51. The modular jack of claim 50, wherein the middle portion of each contact includes a plug contact region, and wherein the plurality of contact pads make electrical contact with the respective ones of the plurality of contacts in between the plug contact region of each contact and the mounted end of each contact.

52. The modular jack of claim 50, wherein each of the plurality of contact pads extends from an edge of the printed circuit board onto a top surface of the printed circuit board.

53. The modular jack of claim 50, wherein at least some of the plurality of contact pads comprise raised contact pads that extend above a top surface of the printed circuit board.

54. The modular jack of claim 50, wherein the mounted end of each of the plurality of contacts is mounted in respective ones of a plurality of metal-plated holes in the printed circuit board, and wherein the printed circuit board includes a compensation circuit that is electrically connected by respective conductive traces to at least two of the plurality of metal-plated holes.

55. The modular jack of claim 50, wherein each of the plurality of contacts wraps around a forward edge of the printed circuit board and is free-floating adjacent the forward edge of the printed circuit board.

56. A communications connector having at least first, second, third and fourth signal carrying paths, the communications connector comprising:

a printed circuit board that includes a first contact pad, a second contact pad, a third contact pad and a fourth contact pad, a first output terminal that is electrically connected to the first contact pad via a first interconnection path, a second output terminal that is electrically connected to the second contact pad via a second interconnection path, a third output terminal that is electrically connected to the third contact pad via a third interconnection path, and a fourth output terminal that is electrically connected to the fourth contact pad via a fourth interconnection path;

a first contact, the first contact having a mounted end, a first pad contact region and a first plug contact region, wherein the first signal carrying path extends from the first plug contact region to the first output terminal through the first pad contact region and the first interconnection path;

a second contact, the second contact having a second mounted end, a second pad contact region and a second plug contact region, wherein the second signal carrying path extends from the second plug contact region to the second output terminal through the second pad contact region and the second interconnection path;

a third contact, the third contact having a third mounted end, a third pad contact region and a third plug contact region, wherein the third signal carrying path extends from the third plug contact region to the third output terminal through the third pad contact region and the third interconnection path; and

a fourth contact, the fourth contact having a fourth mounted end, a fourth pad contact region and a fourth plug contact region, wherein the fourth signal carrying path extends from the fourth plug contact region to the fourth output terminal through the fourth pad contact region and the fourth interconnection path;

57. The communications connector of claim 56, wherein the first mounted end region is outside the first signal carrying path but electrically connected to the first signal carrying path, wherein the second mounted end is outside the second signal carrying path but electrically connected to the second signal carrying path, wherein the third mounted end is outside the third signal carrying path but electrically connected to the third signal carrying path, wherein the fourth mounted end is outside the fourth signal carrying path but electrically connected to the fourth signal carrying path.