(12) United States Patent
`Regnier
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,888,538 B2
`Nov. 18, 2014
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`USOO8888538B2
`
`(54) MODULARJACK WITH ENHANCED
`SHIELDING
`
`(75) Inventor: Kent E. Regnier, Lombard, IL (US)
`(73) Assignee: Molex Incorporated, Lisle, IL (US)
`(*) Notice:
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 204 days.
`
`(21) Appl. No.:
`
`131508,398
`
`(22) PCT Filed:
`(86). PCT No.:
`S371 (c)(1),
`(2), (4) Date:
`
`Nov. 8, 2010
`PCT/US2010/055838
`
`Sep. 28, 2012
`
`(87) PCT Pub. No.: WO2011/057195
`PCT Pub. Date: May 12, 2011
`
`(65)
`
`Prior Publication Data
`US 2013/O 130561 A1
`May 23, 2013
`O
`O
`Related U.S. Application Data
`(60) Provisional application No. 61/258,979, filed on Nov.
`6, 2009.
`(51) Int. Cl.
`HOIR 24/00
`HOIR 3/58
`HOIR 13/6587
`HOIR 2/72
`HOIR 13/6595
`HOIR 24/64
`(52) U.S. Cl
`CPC
`- - - - - - - - H0IR 23/005 (2013.01); HOIR 13/518
`(2013.01); H0IR 13/6587 (2013.01); HOIR
`13/6595 (2013.01): HOIR 24/64 (2013.01);
`H0IR 12/724 (2013.01)
`
`(2011.01)
`(2006.01)
`(2011.01)
`(2011.01)
`(2011.01)
`(2011.01)
`
`
`
`USPC .................... 439/676; 439/540.1; 439/607.23
`(58) Field of Classification Search
`CPC .......................... H01R 23/025; H01R 23/7073
`USPC ......... 439/676,540.1, 541.5, 607.23, 607.24,
`439/607.25, 620.11, 620.17, 620.18, 620.23
`See application file for complete search history.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`6,511,348 B1* 1/2003 Wojtacki et al. ......... 439/620.18
`6,612,871 B1
`9, 2003 Givens
`6,655,988 B1
`12/2003 Simmons et al.
`6,743,047 B2
`6/2004 Korsunsky et al.
`7,153,158 B1* 12/2006 Lee ............................ 439/541.5
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`KR
`
`6, 2003
`2003-0043743 A
`OTHER PUBLICATIONS
`
`International Search Report for PCT/US2010/055838.
`
`Primary Examiner — Hae Moon Hyeon
`(74) Attorney, Agent, or Firm — Stephen L. Sheldon
`
`ABSTRACT
`(57)
`An electrical connector includes a dielectric housing having a
`mating face, a plurality of openings therein configured as
`pairs of aligned openings and a receptacle for receiving a
`plurality of internal modules therein. A plurality of electri
`cally conductive contacts are positioned within the housing
`with a portion of each contact extending into one of the
`openings for engaging contacts of a mateable connector. At
`least one conductive inter-module shield is located within the
`receptacle and extends generally towards the mating face to
`define a plurality of module receiving cavities.
`
`17 Claims, 14 Drawing Sheets
`
`U.D. Electronic Corp., Ex. 1005
`
`

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`US 8,888,538 B2
`Page 2
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`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`T.674,136 B2* 3/2010 Steinke etal
`439/676
`8,393.917 B2 * 3/2013 Regnier ........................ 43948s
`2009/0098766 A1* 4/2009 Steinke et al. ............. 439/541.5
`
`2006, OO30221 A1
`
`2/2006 Hyland et al.
`
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`2009/0149043 A1* 6/2009 Zhang ............................. 439/78
`2009/0253293 A1* 10/2009 Zhang .............
`439/541.5
`2011/0053418 A1* 3/2011 Margulis et al.
`439/620.07
`2012/0280766 A1* 1 1/2012 Regnier ........................ 333,185
`2012/0309233 A1* 12, 2012 O'Malley et al. ............. 439/626
`3:38.2 Å). '33. SSAO 'S',8.
`* cited by examiner
`
`ck
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`1.
`MODULARJACK WITH ENHANCED
`SHIELDING
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This patent application is a national phase of PCT Appli
`cation No. PCT/US2010/055838, filed Nov. 8, 2010, which
`claims the benefit of U.S. Provisional Patent Application No.
`61/258,979, filed Nov. 6, 2009, and which is incorporated
`herein by reference in its entirety.
`
`BACKGROUND
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`The disclosure relates generally to modular telecommuni
`cations jacks and, more particularly, to a high data rate
`capable modular jack.
`Modular jack ('modack') receptacle connectors mounted
`to printed circuit boards (“PCBs) are well known in the
`telecommunications industry. These connectors are often
`used for electrical connection between two electrical commu
`nication devices. With the ever-increasing operating frequen
`cies and data rates of data and communication systems and
`the increased levels of encoding used to transmit information,
`the electrical characteristics of Such connectors are of
`increasing importance. In particular, it is desirable that these
`modijack connectors do not negatively affect the signals trans
`mitted and where possible, noise is removed from the system.
`Based on these requirements and desires, various proposals
`have been made in order to improve modijack connectors used
`with communication or transmission links.
`When used as Ethernet connectors, modijacks generally
`receive an input signal from one electrical device and then
`communicate a corresponding output signal to a second
`device coupled thereto. Magnetic circuitry can be used to
`provide conditioning and isolation of the signals as they pass
`from the first device to the second and typically such circuitry
`uses components such as a transformer and a choke. The
`transformer often is toroidal in shape and includes primary
`and secondary windings coupled together and wrapped
`around a toroid so as to provide magnetic coupling between
`the primary and secondary wire while ensuring electrical
`isolation. Chokes are also commonly used to filter out
`unwanted noise, Such as common-mode noise, and can be
`toroidal ferrite designs used in differential signaling applica
`tions. Modjacks having Such magnetic circuitry are typically
`referred to in the trade as magnetic jacks.
`AS System data rates have increased, improving the isola
`tion between the ports of the magnetic jacks has become
`desirable in order to permit a corresponding increase in the
`data rate of signals that pass through the magnetic jacks
`without being influenced by adjacent magnetic jacks. Cross
`talk and electro-magnetic radiation and interference between
`ports of the magnetic jack can have a significant impact on the
`performance of the magnetic jack and thus the entire system
`as system speeds and data rates increase. Improvements in
`shielding and isolation within the magnetic jack is thus desir
`able.
`
`2
`openings for engaging contacts of a mateable connector. At
`least one conductive inter-module shield is located within the
`receptacle and extends generally towards the mating face to
`define a plurality of module receiving cavities.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Various other objects, features and attendant advantages
`will become more fully appreciated as the same becomes
`better understood when considered in conjunction with the
`accompanying drawings in which like reference characters
`designate the same or similar parts throughout the several
`views, and in which:
`FIG. 1 is a front perspective view of a multiport magnetic
`jack assembly in accordance with a first embodiment;
`FIG. 2 a partially exploded view of the magnetic jack
`assembly of FIG. 1 with the front outer shielding and shield
`interconnection clip removed;
`FIG. 3 is a is a rear perspective view of the magnetic jack
`assembly of FIG. 1;
`FIG. 4 is a partially exploded rear perspective view of the
`magnetic jackassembly of FIG.1 with the internal subassem
`bly modules and inter-module shields in various stages of
`insertion within the housing and with the outer shielding
`removed for clarity:
`FIG. 5 is a rear perspective view similar to FIG. 4 but with
`each of the internal subassembly modules removed and the
`inter-module shields fully inserted;
`FIG. 6 is an enlarged fragmented perspective view of a
`portion of FIG. 5:
`FIG. 7 is a front perspective view of the magnetic jack
`assembly of FIG. 1 with the outer housing removed for clar
`ity;
`FIG. 8 is a fragmented front perspective view of the hous
`ing taken generally along line 8-8 of FIG. 7;
`FIG. 9 is a fragmented front perspective view taken gener
`ally along line 9-9 of FIG. 7 but with the circuit board and
`connector of the internal Subassembly module un-sectioned
`for clarity;
`FIG. 10 is an enlarged fragmented perspective view of a
`portion of FIG.9;
`FIG. 11 is a fragmented front perspective view similar to
`FIG.9 but with an inter-module shield un-sectioned, an addi
`tional internal subassembly module inserted and the shield
`interconnection clip extended for clarity;
`FIG. 12 is a rear perspective view of an internal subassem
`bly module:
`FIG. 13 an exploded perspective view of the internal mod
`ule of FIG. 12 with the windings removed for clarity;
`FIG. 14 is a side elevational view of the twisted wires that
`may be used with the transformer and noise reduction com
`ponents of the disclosed embodiments; and
`FIG. 15 is a side elevational view of a transformer and
`choke subassembly that may be used with the disclosed
`embodiments.
`
`DETAILED DESCRIPTION OF THE
`ILLUSTRATED EMBODIMENTS
`
`SUMMARY
`
`An electrical connector includes a dielectric housing hav
`ing a mating face, a plurality of openings therein configured
`as pairs of aligned openings and a receptacle for receiving a
`plurality of subassembly module therein. A plurality of elec
`trically conductive contacts are positioned within the housing
`with a portion of each contact extending into one of the
`
`60
`
`65
`
`The following description is intended to convey the opera
`tion of exemplary embodiments to those skilled in the art. It
`will be appreciated that this description is intended to aid the
`reader, not to limit the invention. As such, references to a
`feature or aspectare intended to describe a feature or aspect of
`an embodiment, not to imply that every embodiment must
`have the described characteristic. Furthermore, it should be
`noted that the depicted detailed description illustrates a num
`
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`3
`ber of features. While certain features have been combined
`together to illustrate potential system designs, those features
`may also be used in other combinations not expressly dis
`closed. Thus, the depicted combinations are not intended to
`be limiting unless otherwise noted.
`FIG. 1 illustrates the front side of a multiple input, mag
`netic, stacked jack 30 having a housing 32 made of an insu
`lating material such as a synthetic resin (for example, PBT)
`and includes front side openings or ports 33 arranged in
`vertically aligned pairs 33' with each port configured to
`receive an Ethernet or RJ-45 type jack (not shown). The
`magnetic jack 30 is configured to be mounted on circuit board
`100. A metal or other conductive shield assembly 50 sur
`rounds the magnetic jackhousing 32 for radio frequency(RF)
`and electromagnetic interference (EMI) shielding purposes
`as well as for providing a ground reference.
`It should be noted that in this description, representations
`of directions such as up, down, left, right, front, rear, and the
`like, used for explaining the structure and movement of each
`part of the disclosed embodiment are not intended to be
`absolute, but rather are relative. These representations are
`appropriate when each part of the disclosed embodiment is in
`the position shown in the figures. If the position or frame of
`reference of the disclosed embodiment changes, however,
`these representations are to be changed according to the
`change in the position or frame of reference of the disclosed
`embodiment.
`Shield assembly 50 fully encloses housing 32 except for
`openings aligned with ports 33 and the bottom or lower sur
`face of the housing and includes a front shield component 52
`and a rear shield component 53. Additional shielding compo
`nents 54 are positioned adjacent and generally surround ports
`33 to complete shield assembly 50. The joinable front and rear
`shield components are formed with interlocking tabs 55 and
`openings 56 for engaging and securing the components
`together when the shield assembly 50 is placed into position
`around the magnetic jack housing 32. Each of the shield
`components 52.53 includes ground pegs 57,58, respectively,
`that extend into ground through-holes 102 in the circuit board
`100 when mounted thereon.
`As depicted in FIGS. 4-6, the rear portion of the magnetic
`jackhousing 32 includes a large opening or receptacle 34 with
`three evenly spaced metal inter-module shields 60 positioned
`thereinto define four subassembly receiving cavities 35. Each
`cavity 35 is sized and shaped to receive an internal subassem
`bly module 70. While three inter-module shields 60 are
`depicted, a different number of shields may be used to define
`a different number of cavities. More specifically, to provide
`vertical electrical isolation or shielding between each module
`70, one shield fewer in number than the desired number of
`modules is utilized. Shield 60 as depicted is stamped and
`formed of sheet metal material but could be formed of other
`conductive material Such as die cast metal or plated plastic
`material.
`As best seen in FIG. 8, each inter-module shield 60 is a
`generally rectangular, planar member and includes a plurality
`of spaced apart tails 62 for insertion into ground through
`holes 102 in circuitboard 100. The leading or front edge 63 of
`inter-module shield 60 extends the full height of housing 32
`(from the lower surface of the housing to the top wall 42) and
`to a location generally adjacent the front face 36 of housing
`32. In addition, the rear surface of inter-module shield 60
`extends to the rear face 39 of housing 32, the upper surface of
`inter-module shield 60 extends to the top wall 42 of housing
`32 and the lower surface of inter-module shield 60 extends
`downward so as to be generally in line with the lower edges of
`sidewalls 37 of housing 32 and generally adjacent circuit
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`board 100 upon mounting the magnetic jack 30 on circuit
`board 100. Accordingly, inter-module shield 60 extends the
`full depth of magnetic jack 30 in the insertion direction 'A'
`(FIG. 1) of the Ethernet plugs (not shown) that are inserted
`into ports 33 as well as the full height (perpendicular to
`direction 'A') of the magnetic jack. Thus, the shield creates a
`vertical barrier to isolate one pair of vertically aligned ports
`and their internal subassembly module 70 from a pair of
`adjacent aligned ports and the internal Subassembly modules
`associated with Such adjacent ports.
`While shields 60 extend essentially the full depth of ports
`36 (in the insertion direction) in order to create the vertical
`barrier between vertically aligned ports, in some circum
`stances, it may be possible for the shields 60 to extend only
`partway to the front face 36 (e.g., extending only 50% of the
`way between a rear surface of port 33 and front face 36) while
`still providing sufficient shielding. This may be desirable, for
`example, in situations in which it is difficult to mold the
`necessary slots 44 that extend to the front face 36 of housing
`32.
`Each inter-module shield 60 includes two pairs of guide
`projections 64, 65 that extend in opposite directions into
`cavities 35 in order to guide and provide support to subas
`sembly modules 70. More specifically, each inter-module
`shield 60 includes a first pair of guide tabs 64 that are sheared,
`drawn and formed out of the shield and extend in a first
`direction (to the left as seen in FIG. 6) and a second pair of
`guide projections 65 formed in a similar manner and extend
`ing in an opposite direction (to the right as viewed in FIG. 6).
`Together, the guide projections 64, 65 of the pairs of inter
`module shields 60 define guide rails that are dimensioned to
`engage a channel 72 on each side of subassembly module 70.
`Each cavity 35 (defined by a pair of inter-module shields 60)
`includes guide rails defined by projections 64 on one side of
`the cavity and projections 65 across cavity 35 on the other side
`of the cavity. The two outer cavities 35' that are defined by the
`side walls 37 of housing 32 and one of the module shields 60
`have a first guide rail defined by the guide projection of the
`module shield and a second guide rail defined by projection
`38 extending along the inside of side wall 37 of housing 32.
`As a result, the subassembly modules 70 are supported on
`both sides within housing 32 regardless of whether the sides
`of the cavities 35 are defined by a pair of inter-module shields
`60 or a single inter-module shield 60 and a side wall 37 of
`housing 32.
`As depicted, inter-module shields 60 are inserted from the
`rear face or surface 39 of housing 32 and are received in slots
`or channels 41 (FIG. 6) that extend along the inner surface of
`top wall 42 of housing 32 in a direction generally parallel to
`the insertion direction 'A' of the Ethernet or RJ-45 type
`plugs. The front portion 43 of housing 32 at which the ports 33
`are located includes vertical slots 44 (FIGS. 7-9) into which
`the leading edge 63 of inter-module shield 60 is inserted in
`order to permit the leading edge 63 of module shield 60 to
`extend to or almost to the front face 36 of housing 32 in order
`to provide vertical shielding between vertical pairs of ports
`33'. In other words, vertical shielding is provided by inter
`module shields 60 from adjacent the rear face 39 of housing
`32 to adjacent the front face 36 of housing 32.
`Rear tab 66 extends from the rear edge 67 of each inter
`module shield 60 and through slot 69 in rear shield compo
`nent 53 and then is folded over as best seen in FIG.3 in order
`to mechanically and electrically connect inter-module shield
`60 to rear shield component 53. Front tab 68 extends from the
`front edge 63 of each module shield 60 through slot 112 of
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`5
`clip 110 and then is folded over as best seen in FIG.10 in order
`to mechanically and electrically connect inter-module shield
`60 to clip 110.
`Clip 110 is a generally elongated, conductive member that
`extends along the front face 36 of housing 32 between the
`upper and lower ports 33 and is configured to mechanically
`and electrically interconnect various shielding components
`generally adjacent the front portion of jack 30. More specifi
`cally, elongated section 113 of clip 110 includes a plurality of
`slots 112 corresponding in number to the number of inter
`module shields 60 of jack 30 and a plurality of alignment
`holes 114 located between slots 112 and corresponding in
`number to the number of vertically aligned pairs of ports 33.
`Clip 110 is dimensioned to be positioned within a recessed
`area 45 of the housing in the front face 36 of housing 32 with
`alignment projections 46 extending from the recessed area 45
`into alignment holes 114 in order to property position the clip
`110 relative to housing 32.
`A pair of vertically aligned, deflectable contact arms 117
`are located on opposite sides of each slot 112. Each contact
`arm is dimensioned and configured to engage one of the
`conductive ground contact pads 73 located on circuitboard 74
`of internal subassembly module 70. An enlarged shield
`engagement section 115 extends around each side wall 37 of
`housing 32 for engaging front shield 52 once front shield 52
`is mounted on the front portion of housing 32. Raised
`embossments 116 extend outward from engagement sections
`115 to provide areas of increased contact pressure in order to
`create a reliable electrical connection between clip 110 and
`front Shield 52.
`Each inter-module shield 60 is secured within magnetic
`jack 30 on three surfaces. The leading edge 63 is located
`within vertical slot 44 in housing 32 and tab 68 extends
`through slot 112 of shield interconnection clip 110. The upper
`surface of shield 60 is located within channel 41 in upper wall
`42 of housing 32 and the rear edge 67 of shield 60 is secured
`by rear tab 66 that extends through slot 57 in rear shield
`component 51 Each shield 60 is thus electrically and
`mechanically connected to rear shield component 53 and is
`electrically connected to front shield component 52 and each
`circuit board 74 through clip 110.
`Asbest seen in FIG. 8, inter-module shield 60 fully divides
`or splits receptacle 34 and extends from front face 36 of
`housing 32 to the rear edge 39 of housing 32 and from upper
`wall 42 to the lower mounting Surface of housing 32. As a
`result, each module shield 60 provides vertical shielding
`between adjacent pairs 33' of upper and lower ports 33 and
`Ethernet or RJ-45 type plugs (not shown) that are inserted,
`therein as well as the subassembly modules 70 inserted into
`subassembly receiving cavities 35.
`Referring to FIGS. 12-13, internal subassembly module 70
`includes a component housing 75 having transformer cir
`cuitry and filtering components therein. An upper circuit
`board 74 is mounted generally adjacent an upper Surface of
`component housing 75 and includes upper and lower contact
`assemblies 76, 77 mechanically and electrically connected
`thereto. Lower circuit board 78 is mounted generally adjacent
`a lower surface of component housing 75. The upper and
`lower circuit boards 74, 78 include resistors, capacitors and
`other components associated with the transformers and
`chokes located inside the component housing 75.
`Subassembly module 70 includes an upper contact assem
`bly 76 and a lower contact assembly 77 for providing a
`stacked jack, or dual jack, functionality. The upper contact
`assembly 76 is mounted to an upper Surface of upper circuit
`board 74 and provides physical and electrical interfaces,
`including upwardly extending contact terminals 79, for con
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`necting to an Ethernet plug inserted within port 33 in the
`upper row of ports. The lower contact assembly 77 is mounted
`to a lower surface of upper circuit board 74 and includes
`downwardly extending electrically conductive contact termi
`nals 81 for connection to an Ethernet plug inserted within a
`port 33 in the lower row of ports. Upper contact assembly 76
`is electrically connected to the upper circuit board 74 through
`leads, which are soldered, or electrically connected by some
`other means such as welding or conductive adhesive, to a row
`of circuit board pads 82 that are positioned along the top
`surface of upper circuitboard 74 generally adjacent a forward
`edge of component housing 75. Lower contact assembly 77 is
`similarly mounted on a lower Surface of upper circuit board
`74 and is connected to second, similar row of circuit board
`pads (not shown) on a lower surface of upper circuit board 74.
`Referring to FIG. 13, component housing 75 is a two-piece
`assembly having a left housing half75a and right housing half
`75b, one for holding the magnetics 120a of the upper port and
`the other for holding the magnetics 120b of the lower port of
`each pair of Vertically aligned ports. The left and right hous
`ings halves 75a, 75b are formed from a synthetic resin such as
`LCP or another similar material and may be physically iden
`tical for reducing manufacturing costs and simplifying
`assembly. A latch projection 84 extends from the left sidewall
`(as viewed in FIG. 13) of each housing half. A latch recess 85
`is located in the right sidewall of each housing half and
`lockingly receives latch projection 84 therein.
`Each housing half 75a, 75b is formed with a large box-like
`receptacle or opening 86 that receives the filtering magnetics
`120 therein. The receptacles 86 of the two housing halves
`72a, 72b face in opposite directions and have an internal
`elongated shield member 190 positioned between the housing
`halves. The Surface of each housing half facing the elongated
`shield member 190 includes a projection 87 and a receptacle
`88 positioned such that when the two housing halves 72a, 72b
`are assembled together, the projection of each housing half
`will be inserted into the receptacle of the other housing half.
`The elongated shield member 190 includes a pair of holes 192
`aligned with the projections 87 and receptacles 88 such that
`upon assembling the housing halves 72a, 72b and shield
`member 190, each projection 87 will extend through one of
`the 192 holes and into its receptacle 88 in order to secure
`shield member 190 in position relative to the housing halves.
`A first set of electrically conductive pins or tails 91 extend
`out of the lower surface of the housing halves 75a, 75b and are
`inserted through holes 78a in the lower circuit board 78 and
`soldered thereto. Pins 91 are long enough to extend past lower
`circuit board 78 and are configured to be subsequently
`inserted into holes (not shown) in circuit board 100 and sol
`dered thereto. A second, shorter set of pins 92 also extend out
`of the lower surface of the housing halves 75a, 75b. A third set
`of electrically conductive pins 93 extend out of the upper
`surface of housing halves 75a, 75b and are inserted into holes
`74a in upper circuit board 74 and soldered thereto.
`The magnetics 120 provide impedance matching, signal
`shaping and conditioning, high Voltage isolation and com
`mon-mode noise reduction. This is particularly beneficial in
`Ethernet systems that utilize cables having unshielded
`twisted pair (“UTP) transmission lines, as these line are
`more prone to picking up noise than shielded transmission
`lines. The magnetics help to filter out the noise and provide
`good signal integrity and electrical isolation. The magnetics
`include four transformer and choke subassemblies 121 asso
`ciated with each port 33. The choke is configured to present
`high impedance to common-mode noise but low impedance
`for differential-mode signals. A choke is provided for each
`
`

`

`US 8,888,538 B2
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`10
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`15
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`25
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`transmit and receive channel and each choke can be wired
`directly to the RJ-45 connector.
`Referring to FIG. 13, elongated shield member 190 is a
`generally rectangular plate and includes seven downwardly
`depending solder tails 193 configured for insertion and sol
`dering in holes 78a in lower circuit board 78. Tails 193 are
`long enough to extend past lower circuit board 78 and are
`Subsequently inserted into holes (not shown) in circuit board
`100 and soldered thereto. Two upwardly extending solder
`tails 194, 195 extend from a top surface or edge 196 of shield
`member 190 and are configured for insertion and soldering in
`holes 74a in upper circuit board 74. Shield member 190 is
`configured to shield the transformers 130 and chokes 140 as
`well as other circuit components of each housing half from
`those of its adjacent housing half in order to shield the cir
`cuitry of the lower port from that of its vertically aligned
`upper port and to provide a conductive ground or reference
`path between upper circuit board 74 and lower circuit board
`T8.
`As described above, the magnetics 120 associated with
`each port 33 of the connector include four transformer and
`choke subassemblies 121. Referring to FIG. 15, one embodi
`ment of a transformer and choke subassembly 121 can be seen
`to include a magnetic ferrite transformer core 130, a magnetic
`ferrite choke core 140, transformer windings 160 and choke
`windings 170.
`Transformer core 130 is toroidal or donut-shaped and may
`include substantially flat top and bottom surfaces 132,133, a
`central bore or opening 134 that defines a smooth, cylindrical
`inner surface and a smooth, cylindrical outer surface 135. The
`toroid is symmetrical about a central axis through its central
`bore 134. Choke core 140 may be similarly shaped. If desired,
`transformer core 130 and/or choke core 140 may be rectan
`gular, cylindrical, linear, E-shaped or shaped in other man
`ners so long as they operate to efficiently couple the primary
`35
`and secondary windings.
`FIG. 14 illustrates a group of four wires 150 that are ini
`tially twisted together and wrapped around the transformer
`toroid 130. Each of the four wires is covered with a thin,
`color-coded insulator to aid the assembly process. As
`depicted herein, the four wires 150 are twisted together in a
`repeating pattern of a red wire 150r, a natural or copper
`colored wire 150n, a green wire 150g, and a blue wire 150b.
`The number of twists per unit length, the diameter of the
`individual wires, the thickness of the insulation as well as the
`size and magnetic qualities of the toroids 130 and 140, the
`number of times the wires are wrapped around the toroids and
`the dielectric constant of the material Surrounding the mag
`netics are all design factors utilized in order to establish the
`desired electrical performance of the system magnetics.
`As shown in FIG. 15, the four twisted wires 150 are
`inserted into central bore or opening 134 of toroid 130 and are
`wrapped around the outer surface 135 of the toroid. The
`twisted wires 150 are re-threaded through central bore 134
`and this process is repeated until the twisted wire group 150
`has been threaded through the central bore a predetermined
`number of times. The ends of the twisted wires adjacent the
`lower surface 133 of the toroid 130 are bent upward along the
`outer surface 135 of toroid 130 and wrapped around the other
`end of the twisted wires to create a single twist 152 that
`includes all of the wires of the second end wrapped around all
`of the wires of the first end. The individual wires from the first
`and second ends are untwisted immediately beyond (or above
`as viewed in FIG. 15) the single twist 152. One wire from a
`first end of the group of twisted wires is twisted with a wire
`from the other end of the group of wires to create twisted wire
`sections 153. A choke twisted wire section 154 is slid into
`
`55
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`8
`central opening 142 of choke toroid 140 and looped around
`the choke toroid the desired number of times. Four trans
`former and choke assemblies 121 are inserted into each recep
`tacle 86 and the wires are then soldered or otherwise con
`nected to pins 92.93. A shock absorbing foam insert 94 is then
`inserted into each receptacle 86 over the transformer and
`choke assemblies 121 to secure them in place. A cover 95 is
`secured to each housing half 75a, 75b to secure foam insert 94
`within the respective housing half and to provide shielding to
`pins 92,93.
`During assembly, module shields 60 are inserted into hous
`ing 32 and slid forward (opposite the direction of arrow 'A' in
`FIG. 1) so that the shields are received in channels 41 (FIG. 6)
`that extend along the inner surface of top wall 39 of housing
`32 and into vertical slots 44 (FIGS. 7-9) of the front portion 43
`of the housing in order to define a plurality of subassembly
`receiving cavities 35. A subassembly module 70 is then
`inserted into each cavity 35 as depicted in FIG. 4 with the
`channels 72 on the sides of each module engaging the guide
`rails formed either by