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EP-3888201-B1 - MODULAR TELECOMMUNICATIONS PLUG AND METHOD

EP3888201B1EP 3888201 B1EP3888201 B1EP 3888201B1EP-3888201-B1

Inventors

  • ANDERSON, TIMOTHY W.
  • OBERSKI, JEFFREY ALLAN
  • FITZPATRICK, BRIAN J.
  • TOBEY, SHAWN PHILLIP

Dates

Publication Date
20260513
Application Date
20191127

Claims (20)

  1. A modular plug (100) for terminating a telecommunications cable (10), the modular plug comprising: a housing (200) defining an internal cavity (216); a wire manager (300) fitted within the internal cavity of the housing and having a plurality of channels (316); a load bar (500) fitted within the internal cavity of the housing, the load bar defining an array of external grooves (512), each external groove being configured to receive a wire from each twisted pair of wires, wherein the load bar includes an internal cavity (504) having a top surface (514) and a bottom surface (516) that converge into the array of external grooves; and a plurality of wire contacts (110) aligned with the array of external grooves; characterized in that each channel has a gate (318) configured to position a twisted pair of wires (710) from the telecommunications cable (10); wherein each gate (318) on the wire manager (300) includes opposing surfaces (330, 332) that diverge in opposite directions, the opposing surfaces being configured to guide a wire from each twisted pair of wires into the internal cavity of the load bar (500).
  2. The modular plug (100) of claim 1, wherein the top surface and the bottom surface of the internal cavity each include a series of internal grooves (508) that funnel into the array of external grooves (512).
  3. The modular plug (100) of any one of the preceding claims, wherein the array of external grooves (512) on the load bar (500) are parallel and are arranged in the same vertical plane.
  4. The modular plug (100) of any one of the preceding claims, wherein the load bar (500) is configured to snap-fit onto a front portion (312) of the wire manager (300).
  5. The modular plug (100) of any one of the preceding claims, wherein the load bar (500) includes notches (506) configured to latch onto corresponding notches (334) on the front portion of the wire manager (300).
  6. The modular plug (100) of any one of the preceding claims, wherein the gates (318) are offset along a longitudinal axis of the wire manager (300).
  7. The modular plug (100) of any one of the preceding claims, wherein the wire manager (300) defines three columns and two rows of channels (316).
  8. The modular plug (100) of any one of the preceding claims, wherein a front portion of the wire manager (300) is tapered and is configured to pinch the twisted pairs of wires.
  9. The modular plug (100) of claim 1, wherein a front portion of the wire manager (300) includes tabs (302) configured to snap-fit into corresponding slots on the housing (200).
  10. The modular plug (100) of any one of the preceding claims, wherein the wire manager (300) includes a rear portion (314) having an aperture (310) configured to receive a terminal end of the telecommunications cable (10), the rear portion having a plurality of ribs (306) that define orthogonal edges (308) on exterior surfaces of the wire manager, and the orthogonal edges being configured to receive an anti-snag protector (400).
  11. The modular plug (100) of claim 10, wherein the aperture (310) on the rear portion (314) of the wire manager (300) includes a form factor (304) configured to fit around the shape of the telecommunications cable (10), the form factor having ribs (320) that define an internal circumference inside the aperture of the wire manager that is configured to grip a jacket of the telecommunications cable.
  12. The modular plug (100) of claim 1, wherein the housing (200) includes a latching handle (206) configured to secure the modular plug to a receptacle.
  13. The modular plug (100) of claim 12, further comprising an anti-snag protector (400) that attaches to the wire manager (300) the anti-snag protector having an arm (404) that extends from a base (402), the arm being configured to prevent the latching handle (206) from being snagged.
  14. The modular plug (100) of claim 13, wherein the base (402) includes a depression (406) configured to receive a form factor (304) of an aperture (310) on a rear portion (314) of the wire manager (300).
  15. The modular plug (100) of claims 13 or 14, wherein the anti-snag protector (400) is configured to snap-fit onto a rear portion (314) of the wire manager (300).
  16. The modular plug (100) of claims 13, 14, or 15, wherein the anti-snag protector (400) includes sides (408) each extending outwardly from the base (402) and each having a latching member (410) at a distal end, the sides being configured to flex around a rear portion (314) of the wire manager (300) and the latching members being configured to engage orthogonal edges on the rear portion of the wire manager.
  17. The modular plug (100) of any one of the preceding claims, wherein the gates (318) have a smallest dimension that is less than twice the diameter of a single wire from each twisted pair of wires (710).
  18. A method of terminating a telecommunications cable (10) with the modular plug (100) of claim 1, the method comprising: attaching a wire manager (300) to a terminal end of the telecommunications cable; using gates (318) on the wire manager to hold twisted pairs of wires (710) from the telecommunications cable; straightening the twisted pairs of wires; sliding a load bar (500) onto the straightened wires; trimming the straightened wires to be flush with a distal end of the load bar; attaching a housing (200) to the wire manager; and crimping wire contacts (110) housed inside the housing to contact the wires.
  19. The method of claim 18, further comprising: trimming the wires to have a predetermined length that extends outside a front portion of the wire manager (300).
  20. The method of claims 18 or 19, further comprising: attaching the load bar (500) to the wire manager (300).

Description

CROSS-REFERENCE TO RELATED APPLICATION This application is being filed on November 27, 2019 as a PCT International Patent Application and claims the benefit of U.S. Patent Application Serial No. 62/773,825, filed on November 30, 2018. BACKGROUND In the field of data communications, communications networks typically utilize telecommunications cable lines designed to maintain the integrity of signals being transmitted via the network. Telecommunications cable lines are typically connected into port or jack terminals using connector plugs that enable the cables to be easily connected and disconnected. The cable lines are typically comprised of twisted pairs of wires surrounded by a cable jacket. Quick connect cables are often constructed by securing a connector plug to the ends of the twisted wire pairs and sliding the connector plug into a matching port terminal where it locks into place with a simple lever lock. An RJ45 type connector is one example. WO2017/027722A1 discloses a modular plug according to the preamble of claim 1. US2002/048990A1 discloses another example of a modular plug. Crosstalk can negatively affect signal integrity in the telecommunications cable lines. Crosstalk is unbalanced noise caused by capacitive and/or inductive coupling between parallel wires. Furthermore, existing connector plug arrangements can be difficult to terminate in the field. For these and other reasons, improvements are desirable. SUMMARY One aspect relates to a modular plug for terminating a telecommunications cable. The modular plug includes a housing defining an internal cavity. A wire manager is fitted within the internal cavity of the housing. The wire manager includes a plurality of channels, each channel having a gate configured to position a twisted pair of wires from the telecommunications cable. A load bar is fitted within the internal cavity of the housing. The load bar defines an array of external grooves, each external groove being configured to receive a wire from each twisted pair of wires. The modular plug further includes a plurality of wire contacts that are aligned with the array of external grooves. The load bar includes an internal cavity having a top surface and a bottom surface that converge into the array of external grooves. The top surface and the bottom surface each may include a series of internal grooves that funnel into the array of external grooves. Each gate on the wire manager includes opposing surfaces that diverge in opposite directions, the opposing surfaces being configured to guide a wire from each twisted pair of wires into the internal cavity of the load bar. The array of external grooves on the load bar are parallel and are arranged in the same vertical plane. In some examples, the load bar is configured to snap-fit onto a front portion of the wire manager. The load bar may include notches configured to latch onto corresponding notches on the front portion of the wire manager. In one example, the gates are offset along a longitudinal axis of the wire manager. In another example, the wire manager defines three columns and two rows of channels. In certain examples, the front portion of the wire manager is tapered and is configured to pinch the twisted pairs of wires. The front portion of the wire manager may include tabs configured to snap-fit into corresponding slots on the housing. In some examples, the wire manager includes a rear portion having an aperture configured to receive a terminal end of the telecommunications cable, the rear portion having a plurality of ribs that define orthogonal edges on exterior surfaces of the wire manager, and the orthogonal edges being configured to receive an anti-snag protector. The aperture on the rear portion of the wire manager may include a form factor configured to fit around the shape of the telecommunications cable, the form factor having ribs that define an internal circumference inside the aperture of the wire manager that is configured to grip a jacket of the telecommunications cable. The housing may include an array of slots along a leading edge of a first end of the housing, each wire contact is received by a slot of the housing and is configured to electrically connect the twisted pairs of wires in the telecommunications cable to the contact springs of a telecommunications jack. The housing may further include a latching handle configured to secure the modular plug to a receptacle. In some examples, the modular plug includes an anti-snag protector configured to attach to the wire manager, the anti-snag protector having an arm that extends from a base, the arm being configured to prevent the latching handle from being snagged. The base may include a depression configured to receive a form factor of the aperture on the rear portion of the wire manager. In some examples, the anti-snag protector is configured to snap-fit onto the rear portion of the wire manager. For example, the anti-snag protector includes sides each extending out