Field-terminateable cable and plug assemblies

Abstract

To provide a strain-relief system that is compact enough to fit into remote devices that a current field terminable plug cannot support because of its size.SOLUTION: A strain-relief system for a cable to be inserted therein has a main housing. The main housing is provided with an opening, and a series of ramp features and a series of serrations on an interior surface. The system also includes a rotating collar with an opening along the opening of the main housing.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 031,868, filed May 29, 2020, and U.S. Provisional Patent Application No. 63 / 066,430, filed August 17, 2020, the entireties of which are incorporated by reference herein. The present invention relates to a field-terminateable cable and plug assembly. [Background technology]

[0002] Field-terminable cable assemblies allow installers to create custom-length cables for their specific installations, eliminating the need for slack management and simplifying the ordering process. With field-terminable connectors, installers can order bulk spools of cable and the appropriate number of connectors without having to determine the part number of the pre-terminated patch cord they need, which can be complicated for both the customer and the distributor. While versatile, current products and their shielded counterparts are larger than standard RJ45 plugs and therefore cannot fit into some applications, such as security cameras and wireless access points. These applications benefit from the ability to field terminate a standard-size copper plug onto bulk cable and mate to the device port.

[0003] Additionally, cable connectors require a method of mechanically securing the cable to the cable entry area of ​​the connector. This is required to prevent the cable from being unplugged from the connector and / or from damaging internal connector components when a removal force is applied to the cable. Securing the cable to the connector is typically achieved with a linear clamping mechanism. While this design is suitable for connectors with a square profile large enough to accommodate such a mechanism, it is not ideal for cylindrical connectors that are too compact to use this cable strain relief method. These prior art systems also typically require the use of special tools to crimp onto the cable jacket. What is needed is an integrated strain relief that fits into compact cylindrical connectors, can accommodate a variety of cable diameters, and can be manually operated without tools. Summary of the Invention [Problem to be solved by the invention]

[0004] There is a need in the market for a product that allows for field termination of copper plugs, which is compact enough to fit into remote devices that cannot support current field-terminateable plugs due to their size. [Means for solving the problem]

[0005] A strain relief system for inserting a cable includes a main housing having an opening and a series of ramp features and a series of serrations on an inner surface thereof. The system also includes a rotatable collar having an opening aligned with the opening of the main housing. The rotatable collar includes a series of follower features configured to be inserted into the opening of the main housing such that, when the rotatable collar rotates relative to the main housing, the follower features engage the ramp features to compress the inserted cable through the strain relief system. The rotatable collar also includes at least one ratchet tab configured to engage the series of serrations on the main housing to provide a ratchet function between the rotatable collar and the outer housing. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is an isometric view of a plug / cable assembly. [Figure 2] FIG. 2 is an exploded isometric view of the plug / cable assembly of FIG. 1. [Figure 3] FIG. 2 is an exploded isometric view of the splice module of FIG. 1. [Figure 4] FIG. 4 is an exploded isometric view of a contact holder assembly of the splice module of FIG. 3. [Figure 5] FIG. 5 is an isometric view of a terminal from the contact holder assembly of FIG. 4. [Figure 6] FIG. 4 is an isometric view of a shield plate from the contact holder assembly of FIG. 3. [Figure 7] 4 is an isometric view of a contact retainer of the contact holder assembly of FIG. 3. [Figure 8] 4 is an isometric view of a contact retainer of the contact holder assembly of FIG. 3. [Figure 9] FIG. 2 is an isometric view of the wire cap assembly of the plug / cable assembly of FIG. 1 without a conductor in the wire cap. [Figure 10]FIG. 2 is an isometric view of a wire cap assembly of the plug / cable assembly of FIG. 1 with conductors within the wire cap. [Figure 11] FIG. 4 is an isometric view of the outer barrel of the splice module of FIG. 3. [Figure 12] FIG. 12 is a cross-sectional view of the outer barrel of FIG. [Figure 13] FIG. 4 is an isometric view of a factory terminated end cap of the splice module of FIG. 3. [Figure 14] FIG. 4 is an isometric view of the user termination end cap of FIG. [Figure 15] 2 illustrates a jack termination tool used to assist in terminating the plug / cable assembly of FIG. 1; [Figure 16] 10 shows an alternative contact holder assembly in which the terminals are staggered in length. [Figure 17] 17 shows the alternative contact holder of FIG. 16 with the conductors terminated to the terminals. [Figure 18] FIG. 4 is an isometric view of a strain relief assembly of the splice module of FIG. 3. [Figure 19] FIG. 19 is an exploded isometric view of the strain relief assembly of FIG. 18. [Figure 20] FIG. 19 is a side view of the strain relief assembly of FIG. 18. [Figure 21] FIG. 19 is a rear view of the stationary main housing of the strain relief assembly of FIG. 18. [Figure 22] FIG. 19 is an isometric view of a rotating collar of the strain relief assembly of FIG. 18. [Figure 23] 19 is a view of the strain relief assembly of FIG. 18 with the rotating collar in a maximum engagement position so that the follower features are fully depressed inward. [Figure 24] FIG. 10 is an isometric view of an alternative method for limiting the amount of travel of a rotating collar. [Figure 25] FIG. 1 is an isometric view of an outdoor shielded plug / cable assembly. [Figure 26] FIG. 26 is an exploded isometric view of the plug / cable assembly of FIG. 25. [Figure 27] FIG. 26 is an exploded isometric view of the splice module of the plug / cable assembly of FIG. 25. [Figure 28] FIG. 28 is an isometric view of an end cap of the splice module of FIG. 27. [Figure 29] FIG. 28 is an isometric view of a wire cap of the splice module of FIG. 27. [Figure 30] FIG. 28 is an isometric view of an insulating barrel of the splice module of FIG. 27. [Figure 31] FIG. 28 is an isometric view of an insulating barrel of the splice module of FIG. 27. [Figure 32] FIG. 26 is a cross-sectional view of the splice module of the plug / cable assembly of FIG. 25. DETAILED DESCRIPTION OF THE INVENTION

[0007] Part of the present invention is a field-terminateable copper plug / cable assembly that includes a standard size RJ45 plug, a short length of cable, and a field-terminateable splice module that allows installation onto bulk copper cable.

[0008] FIG. 1 shows a plug / cable assembly 20 having a standard-sized RJ45 plug 22, a cable portion 24, and a splice module 26. The standard-sized RJ45 plug 22 allows for installation in remote devices where a standard field-terminateable plug cannot mate. The cable portion 24, which carries a standard four-pair Ethernet cable, can be provided in various lengths depending on the application. The splice module 26 allows an installer to splice an existing four-pair Ethernet cable to the plug / cable assembly in the field using only standard TG jack termination tools.

[0009] 2 and 3 show exploded views of plug / cable assembly 20 with splice module 26. Splice module 26 includes outer barrel 28, contact assembly 30, wire cap 32, strain relief collar 33, factory termination end cap 34, and user termination end cap 36. The design intent is for one side of splice module 26 to be sold with cable section 24 already attached to one end. Factory termination end cap 34 features a tamper-evident design to prevent user removal, while the other end features a quick-attach / detach design to allow installers to quickly attach and detach it to an existing horizontal cable.

[0010] 4 shows an exploded view of the contact assembly 30, including the terminals 38, shield plate 40, and contact retainer 42. The terminals 38 are arranged in a cylindrical pattern, with each quadrant containing a pair of terminals. The shield plate 40 is a metallic structure intended to separate the quadrants of terminal pairs and prevent crosstalk between those pairs. The contact retainer 42 positions the terminals 38 and shield plate 40 within the outer barrel 28 of the splice module and also acts as an electrical insulator, preventing performance issues associated with hipots.

[0011] FIG. 5 shows a detailed view of terminal 38 including opposing offset displacement features 44 based on existing TG jack displacement terminal geometry.

[0012] 6 shows a detailed view of shield plate 40. Longitudinal slots 46 allow two shield plates 40 to mate together in a cross-over arrangement. Contact retainer 42 features retain tabs 48, securing the plate within contact assembly 30. Notches 50 provide clearance for cable conductors to cross within the splice module, reducing the risk of inadvertently cutting the conductor insulation.

[0013] 7 shows the interior features of the contact retainer 42. The terminals 38 are placed into the contact pockets 52, with the flats of the offset terminals seating on the ledges of the contact pockets 52 and the insulation displacement features 44 passing through the openings in the contact pockets 52. Notches 54 receive the tabs 48 of the shield plate 40, and cross openings 56 allow the plate to pass through the retainer. Once the terminals and plate are halfway into the retainer, another half of the retainer is placed over the assembly, causing posts 58 to form an interference fit with holes 60 to hold the entire contact assembly together.

[0014] FIG. 8 shows the exterior features of the contact retainer 42. In this view, a portion of the contact pocket 52 is visible, which allows the insulation displacement features 44 to extend through. The intersecting openings 56 include ribs 62 that aid in positioning the shield plate 40. A circumferential notch 64 mates with a rib feature in the outer barrel 28, centering the contact assembly in the barrel. A center button 66 provides structural rigidity to the contact retainer halves and aids in material flow during molding. A cavity feature 68 reduces material shrinkage immediately after the molding process.

[0015] 9 and 10 show detailed views of the wire cap 32, including a front termination area 70 that includes conductor retention features 72. The user inserts the conductors 74 of the user's cable through the center of the wire cap 32, inserting each conductor into the corresponding retention feature 72 and trimming the conductors flush with the outer surface 76. When the wire cap is installed in the splice module, the contact pockets 78 and shield plate pockets 80 allow clearance for the terminals 38 and shield plate 40. The keyed features 82 correspond to features in the outer barrel 28 of the splice module 26, allowing the wire cap to be installed only in a specific orientation to maintain polarity between the factory-installed cable section and the end-user's cable section. The rotating cam strain relief features 84 (described in detail below) help support the end of the cable jacket and also provide a surface for the user-terminated end cap 36 to drive the wire cap into the outer barrel 28.

[0016] Figure 11 shows a detailed view of the outer barrel 28. Pockets 86 engage the latch features on the end caps, locking them in place when they are fully inserted into the end of the barrel. A central notch 88 provides a location for securing the splice module in place using a cable tie. Alignment marks 90 assist in locating the keyed feature 82 on the wire cap 32 prior to insertion into the outer barrel 28.

[0017] 12 shows a cross-sectional view of the outer barrel 28. The keyway 92 aligns with the keyed feature 82 on the wire cap 32 to maintain signal polarity between the cable ends that are connected together within the splice module. The ledge 94 centers the contact assembly 30 within the outer barrel and fits into the circumferential notch 64 in the contact retainer 42. The rib 96 is designed to form an interference fit with the contact assembly 30 to hold it in place before the factory-terminated ends of the splice module are installed.

[0018] 13 shows a detailed view of the factory terminated end cap 34. The factory terminated end cap is intended to be tamper-resistant and is permanently attached at Panduit's manufacturing location during assembly of the cable portion 24 to the plug end of the splice module. The cable portion 24 is inserted through the opening 98. The inner sleeve 100 fits inside the outer barrel 28, and the factory terminated end cap latch 102 engages with the pocket 86 in the outer barrel 28. When the factory terminated end cap 34 is installed on the outer barrel 28, the inner surface 104 presses against the back of the strain relief feature 84 of the wire cap 32, driving the wire cap into the outer barrel 28.

[0019] FIG. 14 shows a detailed view of the user termination end cap 36. Unlike the factory termination end cap 34, the user termination end cap is designed to be installed and removed by the user to allow for pre- and post-termination of existing horizontal Ethernet cables. The user termination end cap latch 106 snaps into the pocket 86 in the outer barrel 28, similar to the factory termination end cap latch 102 of the factory termination end cap 34, but the user termination end cap latch 106 includes a ramp feature 108 that disengages the latch from the pocket 86 in the outer barrel when the end cap is rotated counterclockwise. A grip feature 110 allows the user to rotate the end cap for removal.

[0020] 15 illustrates that a TG jack termination tool can be used to assist in the termination of a customer's horizontal cable 112 onto an indoor field cord assembly 20. The splice module 26 is placed into the TG jack termination tool 114. With the user-terminated end cap 36 driven into the outer barrel 28 as far as can be easily accomplished manually, the TG jack termination tool 114 provides additional leverage to drive the user-terminated end cap 36 fully into the outer barrel 28, and then drives the cable conductors into the insulation displacement terminals to complete the termination.

[0021] The splice module may utilize insulation displacement terminals having staggered lengths to reduce the force required to insert the cable conductors into the terminals. Staggering the terminal lengths reduces the number of cable conductors simultaneously pierced by the terminal for a given distance of wire cap travel.

[0022] 16 shows a side view of a staggered contact assembly 200. A plurality of long terminals 202 and short terminals 204 are disposed within a contact holder 206.

[0023] 17 shows cable conductors 208 positioned within a wire cap (not shown) before being forced into the staggered contact assembly 200. As the conductors are forced into the terminals, the cable conductors 208 are pierced by the long terminals 202 before being pierced by the short terminals 204. This staggered arrangement reduces the force required to pierce the conductor insulation as opposed to piercing all of the cable conductors simultaneously.

[0024] The present invention is a cable strain relief mechanism designed for use with cylindrical connectors. The strain relief is capable of supporting a variety of cable diameters and can be operated without the use of tools.

[0025] 18 shows a strain relief system 20 including a rotating cam cable strain relief 22 and a cable portion 24. The strain relief system 20 can be integral to an internal component such as a cable connector housing or wire cap. The cable portion 24 is inserted through the center of the rotating cam cable strain relief 22 and is secured inside when the rotating cam cable strain relief 22 is actuated.

[0026] 19 shows an exploded view of the rotating cam cable strain relief 22, which includes a stationary main housing 26 and a rotating collar 28. The rotating collar 28 is inserted into the stationary main housing 26 and rotates inside the stationary main housing 26, clamping around the cable to provide strain relief. The mechanism's operating principle is based on a cam system. The stationary main housing 26 includes multiple ramp features 30. Follower features 32 on the rotating collar 28 engage the ramp features 30, forcing the follower features inward toward the central axis of the rotating collar 28, which then grips the cable jacket as the rotating collar 28 rotates clockwise.

[0027] 20 shows that stationary main housing 26 includes a keyway 34 into which a key 36 of rotating collar 28 fits to limit rotation of the collar as it approaches maximum engagement and prevent follower feature 32 from falling out of ramp feature 30. This figure shows a side view of key 36 in a fully rotated position within keyway 34.

[0028] FIG. 21 provides a straight-on view of the rear of the stationary main housing 26. The ramp features 30 are arranged in a circular array around the inner diameter of the housing. A series of serrations 38 are located along the edge of the stationary main housing 26. The serrations 38 engage features on the rotating collar 28 to create a ratchet mechanism that prevents the rotating collar 28 from rotating counterclockwise and loosening around the cable jacket. For re-termination purposes, the rotating collar 28 can be pulled straight back from the stationary main housing 26, releasing the strain relief.

[0029] FIG. 22 shows the features of the rotating collar 28 that interact with the features of the stationary main housing 26, as described in the previous paragraph. The follower features 32 are arranged in a circular pattern similar to the ramp features 30 on the stationary main housing 26, allowing all four followers to simultaneously push inward toward the center of the collar to grip the cable jacket. Rectangular pads 40 located on the inside of the follower features 32 are intended to bite into the cable jacket when the strain relief system is tightened, preventing the cable from sliding and rotating within the rotating collar 28. Ratchet tabs 42 engage with serrations 38 on the stationary main housing 26, allowing the collar to rotate in only one direction.

[0030] 23 shows the strain relief system 20 with the rotating collar 28 in a maximum engagement position, such that the follower features 32 are fully depressed inward. The amount of engagement varies depending on how much the collar is rotated clockwise, allowing the strain relief system to accommodate a variety of cable diameters.

[0031] The strain relief system may use various methods to limit the amount of rotation of the rotating collar within the stationary main housing, including reversing the key to keyway placement so that the key is located on the stationary main housing while the keyway is on the rotating collar. The number of key / keyway features can also be different to facilitate insertion of the rotating collar into the stationary main housing.

[0032] 24 shows the strain relief system 100 with the rotatable collar 102 removed from the stationary main housing 104. The rotatable collar 102 includes a keyway 106 that engages with a key 108 on the stationary main housing 104. Note that the stationary main housing 104 includes two keys 108, resulting in the rotatable collar 102 including two keyways 106. These features function in the same manner as described in FIG. 3 by limiting the maximum rotation of the rotatable collar 102 within the stationary main housing 104. This prevents the collar follower 110 from disengaging from the end of the ramp feature 112 on the stationary main housing 104.

[0033] FIG. 25 shows an outdoor field cord assembly 320 including a standard-size shielded RJ45 plug 322, a cable portion 324, and a splice module 326. The standard-size shielded RJ45 plug 322 allows for installation in remote devices where a standard field term plug cannot mate. The cable portion 324 is a standard four-pair Ethernet cable and can be provided in various lengths depending on the application. The splice module 326 allows the installer to connect an existing four-pair Ethernet cable to the field cord in the field.

[0034] 26 shows the outdoor field cord assembly 320 with the splice module 326 disassembled. The splice module 326 includes a metal outer barrel 328, an O-ring 349, a contact assembly 330, a wire cap 332, a strain relief collar 333, a threaded metal end cap 334, a grounding wave washer 336, a rubber cylindrical seal 335, and an insulating barrel 337. The design intent is for one side of the splice module 326 to be sold with a cable section 324 already attached to one end. This product can also be sold as just the splice module.

[0035] 27 shows threaded feature 38 on metal end cap 334 as well as threaded feature 351 on metal outer barrel 328. An O-ring groove 350, which holds O-ring 349 in place (described below for clarity), can also be seen on metal outer barrel 328. A flat feature 339 on metal end cap 334 is used to seal against O-ring 349, which sits in O-ring groove 350, when the cap is threaded onto metal outer barrel 328.

[0036] 28 provides a view of the inside of the metal end cap 334. Flat features on the end cap 340 are used to help seal the cable by applying force against the rubber cylindrical seal 335.

[0037] Figure 29 shows how strain relief collar 333 is inserted into wire cap 332. For outdoor applications, the strain relief is nickel plated, which also aids in shielding. The camming cutout feature 341 is an indicator of the length the shield cable braid needs to be pulled back. As the part rotates within the wire cap to engage the cable, the camming feature comes into close proximity, causing camming feature face 352 to contact the cable, creating a ground connection from the braid to strain relief collar 333. Tapered feature 342 is used to seal rubber cylindrical seal 335 to the cable.

[0038] 30 and 31 show detailed views of the insulating barrel 337. This barrel is composed of two identical insulating barrels 337 that fit together. They include two circular features 347 to hold the contact assembly 330 in place within the metal outer barrel 328. When the insulating barrels 337 are pressed together inside the metal outer barrel 328, the circular features 347 hold the contact assembly 330 in place so it does not float during termination. To stay in place within the metal outer barrel 328, the insulating barrel 337 includes a ramp feature 343 that snaps into place. The insulating barrel 337 includes three relief cut features 348 that allow the ramp feature 343 to deflect inward during insertion into the metal outer barrel 328. The square feature 344 prevents axial rotation of the contact assembly 330 once it is inserted into place, allowing for termination alignment. Tabs 345 allow insulating barrel 337 to fit together when inserted into notch 346 .

[0039] FIG. 32 provides a cross-sectional view of the assembled splice module. The insulating barrel 337 can be seen fully formed, with snap grooves in the metal barrel 353 to hold the insulating barrel 337 in place via the ramp feature 343. The rubber cylindrical seal 335 can be seen compressed by the strain relief collar 33 due to the tapered feature 42. Compression of the rubber cylindrical seal 335 into the strain relief collar 333 in the wire cap 332 forces the conductor into the IDC in the contact assembly 330 for termination. This compression comes from the metal end cap 334 when it is threaded onto the metal outer barrel 328. Compression of the rubber cylindrical seal 335 onto the back flat 340 of the metal end cap 334 creates an IP67 seal for the internal components of the splice. Compression of the rubber cylindrical seal 335 into the tapered feature 342 creates an IP67 seal for the cable. Overlap is shown in this view to illustrate tapered feature 342. When flat feature 339 of metal end cap 334 is threaded onto O-ring 349, it creates an IP67-rated seal against the threads. The cable has a blade that must also be pulled back over notched cam feature 341 on strain relief collar 333. This blade is grounded when cam feature face 352 engages. Wave washers 336 contact this nickel-plated strain relief collar 333 but not the back flat 340 of metal end cap 334 on both sides of the splice, completing the shielding from one cable to the other. [Explanation of symbols]

[0040] 20 Strain Relief System 24 Cable 32 Wire cap 34 Keyway 36 keys 48 tabs 56 Opening 74 Conductor 326 Splice Module 330 Contact Assembly

Claims

1. a main housing having an opening and including a series of ramp features and a series of serrations on an interior surface thereof; a rotating collar having an opening aligned with the opening in the main housing, the rotatable collar includes a series of follower features configured to be inserted into the opening in the main housing, such that as the rotatable collar rotates relative to the main housing, the follower features engage the ramp features and compress the cable inserted by the strain relief system; the rotating collar further includes at least one ratchet tab configured to engage the set of serrations on the main housing to provide a ratchet function between the rotating collar and the main housing; the follower feature also has a rectangular pad on an innermost portion of an inner surface of the follower feature when the rotating collar is rotated relative to the main housing; The strain relief system, wherein the rectangular pad is configured to bite into the cable when the rotatable collar rotates relative to the main housing.

2. The strain relief system of claim 1 , further comprising a keyway on the main housing and a key on the rotatable collar configured to limit the amount of rotation of the rotatable collar relative to the main housing.

3. The strain relief system of claim 1 , further comprising a keyway on the rotatable collar and a key on the main housing configured to limit the amount of rotation of the rotatable collar relative to the main housing.

4. An outer barrel; a contact assembly including a insulation displacement terminal inserted into the outer barrel; a first wire cap and a second wire cap inserted into the outer barrel on opposite sides thereof and configured to retain a cable and the individual conductors of the cable, the first wire cap and the second wire cap including conductors that engage the insulation displacement terminals of the contact assembly; 1. A splice module comprising: Each wire cap is a main housing having an opening and including a series of ramp features and a series of serrations on an interior surface thereof; a rotatable collar having an opening aligned with the opening in the main housing; Including, the rotatable collar includes a series of follower features configured to be inserted into the opening in the main housing, such that as the rotatable collar rotates relative to the main housing, the follower features engage the ramp features and compress the cable inserted by a strain relief system; the rotating collar further includes at least one ratchet tab configured to engage the set of serrations on the main housing to provide a ratchet function between the rotating collar and the main housing; the follower feature also has a rectangular pad on an innermost portion of an inner surface of the follower feature when the rotating collar is rotated relative to the main housing; The splice module, wherein the rectangular pad is configured to bite into the cable when the rotatable collar is rotated relative to the main housing.

5. The splice module of claim 4 , wherein the outer barrel is constructed from metal, and the splice module includes two metal encapsulations configured to screw onto opposite ends of the outer barrel.

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