Modular jack assembly

Claim 2

A modular jack contact pin assembly comprising: an elongate back plate member having a generally L-shaped cross section; and a plurality of contact pin arrays; each said contact pin array including a unitary insulative member having a plurality of contact pins embedded therein, said unitary member further having an L shape, a portion of the L shape being inserted into said generally L-shaped cross-section of said elongate back plate member, said L-shaped unitary member having first and second legs; each of said contact pins having a first and a second portion protruding from an end of said first leg and an end of said second leg respectively; said elongate back plate member including a first wall having a plurality of holes formed therethrough, said elongate back plate member further including a plurality of grooved attachment sites extending perpendicularly relative to said first wall and aligned with said holes; each said unitary member having grooves formed upon an exterior surface of said first leg thereof to frictionally engage said grooved attachment sites of said elongate back plate member; each said unitary member being attached to said elongate back plate member such that said grooves of said first leg engage one of said grooved attachment sites and said first portions of said contact pins are aligned by said grooved attachment sites so as to extend through said holes of said first wall; wherein said first wall of said elongate back plate member includes additional holes formed through said first wall for receiving ground pin means.

Claim 3

The pin assembly of claim 1 wherein said plurality of contact pin arrays is arranged along two rows and the pin assembly further includes an elongate conductive shield disposed between said two rows.

Claim 4

The pin assembly of claim 2 wherein said elongate conductive shield includes downwardly depending ground pins formed along the length thereof, said ground pins extending through said additional holes.

Claim 5

A modular jack assembly comprising: a housing having a forward face and a rearward bay, said forward face having a plurality of plug receiving apertures opening into a plurality of corresponding plug receiving cavities, said rearward bay having a hole into each said plug receiving cavity; a backplate having a plurality of channeled guides; and a plurality of contact pin arrays, each having a solid non-conductive member within which a plurality of contact pins is formed, each said solid non-conductive member including a plug contacting region exposing first portions of said contact pins; each of said contact pin arrays being coupled to one of said channeled guides, said plug contacting regions of said contact pin arrays extending upwardly from said backplate, whereby the combination of said backplate and said contact pin arrays is a backplate pin sub-assembly; said backplate pin sub-assembly being received within said rearward bay of said housing so that said plug contacting regions of said contact pin arrays extend through said holes of said rearward bay and into said plug receiving cavities, thereby disposing said exposed first portions of said contact pins within said plug receiving cavities; whereby insertion of a modular plug into one of said plug receiving cavities will cause exposed first portions of contact pins disposed within said cavity to electrically contact corresponding pins in said modular plug; wherein said backplate has the shape of an L having a first leg, each said solid non-conductive member further includes a mounting region exposing second portions of said contact pins, said first leg of said backplate has a plurality of holes formed through said first leg, and said second portions of said contact pins extend through said holes.

Claim 6

A modular jack assembly comprising: a housing having a forward face and a rearward bay, said forward face having a plurality of plug receiving apertures opening into a plurality of corresponding plug receiving cavities, said rearward bay having a hole into each said plug receiving cavity; a backplate having a plurality of channeled guides; and a plurality of contact pin arrays, each having a solid non-conductive member within which a plurality of contact pins is formed, each said solid non-conductive member including a plug contacting region exposing first portions of said contact pins; each of said contact pin arrays being coupled to one of said channeled guides, said plug contacting regions of said contact pin arrays extending upwardly from said backplate, whereby the combination of said backplate and said contact pin arrays is a backplate pin sub-assembly; said backplate pin sub-assembly being received within said rearward bay of said housing so that said plug contacting regions of said contact pin arrays extend through said holes of said rearward bay and into said plug receiving cavities, thereby disposing said exposed first portions of said contact pins within said plug receiving cavities; whereby insertion of a modular plug into one of said plug receiving cavities will cause exposed first portions of contact pins disposed within said cavity to electrically contact corresponding pins in said modular plug; wherein said backplate has the shape of an L having a first leg, each said solid non-conductive member further includes a mounting region exposing second portions of said contact pins, said first leg of said backplate has a plurality of holes formed through said first leg, and said second portions of said contact pins extend through said holes.

Claim 7

The modular jack assembly of claim 4 wherein said second portions of said contact pins are aligned to said holes by said channeled guides of said backplate.

Claim 8

The modular jack assembly of claim 4 wherein said plug receiving cavities are arranged along two rows and said channeled guides of said backplate are arranged along two rows.

Claim 9

The modular jack assembly of claim 7 wherein said backplate further includes a second plurality of holes formed through said first leg and said backplate pin sub-assembly further includes a conductive shield being disposed between said two rows of channeled guides and having ground pins extending through said second plurality of holes.

Claim 10

The modular jack assembly of claim 7 wherein, for each of said contact pin arrays, said first portions of said contact pins extend beyond said plug contacting region of said unitary member and are bent back over said plug contacting region.

Claim 11

A modular jack assembly comprising: a housing having an exterior mounting surface and a plurality of plug receiving cavities, each cavity having a forward hole for receiving a modular plug and having a rearward hole; a plurality of contact pin arrays, each including an insulative unitary member formed in the shape of an L and having a plurality of conducting wires spacedly disposed and embedded within said member, said conducting wires extending along a first leg of said L and protruding from the end of said first leg to form spring leads, said conducting wires further extending along a second leg of said L and protruding from the end of said second leg to form mounting leads, said second leg having grooves formed into the exterior surface thereof; and a backplate having a perforated wall, a back wall extending upwardly from said perforated wall and a plurality of mating members for engaging each one of said plurality of contact pin arrays; each one of said mating members having grooves aligned with respective ones of a plurality of holes in said perforated wall of said backplate and matched with said grooves of said second legs of said contact pin arrays, whereby said mounting leads of a contact pin array extend through said holes when said contact pin array is engaged with one of said mating members; said contact pin arrays being engaged with said mating members of said backplate such that said spring leads extend away from said back wall of said backplate, the combination of said backplate and said contact pin arrays being a backplate assembly; said backplate assembly being coupled to said housing so that said spring leads of said contact pin arrays extend through said rearward holes of said housing and into said plug receiving cavities, and so that said mounting leads of said contact pin arrays protrude in a direction perpendicular to said exterior mounting surface of said housing.

Claim 12

A modular jack assembly comprising: a housing having an exterior mounting surface and a plurality of plug receiving cavities, each cavity having a forward hole for receiving a modular plug and having a rearward hole; a plurality of contact pin arrays, each including an insulative unitary member formed in the shape of an L and having a plurality of conducting wires spacedly disposed and embedded within said member, said conducting wires extending along a first leg of said L and protruding from the end of said first leg to form spring leads, said conducting wires further extending along a second leg of said L and protruding from the end of said second leg to form mounting leads, said second leg having grooves formed into the exterior surface thereof; and a backplate having a perforated wall, a back wall extending upwardly from said perforated wall and a plurality of mating members for engaging each one of said plurality of contact pin arrays; each one of said mating members having grooves aligned with respective ones of a plurality of holes in said perforated wall of said backplate and matched with said grooves of said second legs of said contact pin arrays, whereby said mounting leads of a contact pin array extend through said holes when said contact pin array is engaged with one of said mating members; said contact pin arrays being engaged with said mating members of said backplate such that said spring leads extend away from said back wall of said backplate, the combination of said backplate and said contact pin arrays being a backplate assembly; said backplate assembly being coupled to said housing so that said spring leads of said contact pin arrays extend through said rearward holes of said housing and into said plug receiving cavities, and so that said mounting leads of said contact pin arrays protrude in a direction perpendicular to said exterior mounting surface of said housing.

Claim 13

The modular jack assembly of claim 9 wherein said plug receiving cavities of said housing and said mating members of said backplate are arranged along two rows.

Claim 14

The modular jack assembly of claim 10 wherein said perforated wall includes ground pin holes and said backplate assembly further includes a grounding shield disposed between said two rows, said grounding shield having ground pins which extend through said ground pin holes.

Claim 15

The modular jack assembly of claim 11 further including an external ground shield enclosing said housing.

Claim 16

The modular jack assembly of claim 10 wherein for each of said contact pin arrays said spring leads are bent back over said first leg.

Claim 17

The modular jack assembly of claim 13 wherein said spring leads of said contact pin arrays engaged on a first row of mating members are directed away from said spring leads of said contact pin arrays engaged on a second row of mating members.

Claim 18

A stacked modular jack assembly comprising: a housing having a plurality of plug receptacles arranged along at least two horizontal rows, said housing further having a front face, a rearward loading bay and a bottom mounting surface, said front face having a first plurality of openings into said plug receptacles, said rearward loading bay having a second plurality of openings into said plug receptacles; and a backplate assembly including an elongate coupling member, a plurality of pin arrays and a shielding plate, said backplate assembly being fitted to said rearward loading bay; said coupling member having first and second walls arranged in an L shape and further having a plurality of sets of grooves formed on the inside of said L shape of said coupling member and extending in a direction perpendicular to said first wall and arranged along at least two horizontal rows; said first wall of said coupling member having first holes formed therethrough, said first holes being aligned with said sets of grooves; each said pin array including a unitary insulative member having an L shape having a first leg and a second leg, said first leg having grooves formed along the exterior surface thereof, said pin array further including lead wires formed within said insulative member, one end of said lead wires extending along said grooves of said first leg and beyond the end of said first leg to form mounting pins, another end of said lead wires extending beyond the end of said second leg of said L shape of said insulative member and bent back over said second leg to form contact pins; each said pin array being coupled to said coupling member such that said grooves of each said pin array engages one of said sets of grooves of said coupling member and said mounting pins are aligned with and pass through said first holes in said first wall of said coupling member; said first wall further including second holes formed therethrough, said shielding plate and said second holes being disposed between said two rows of said sets of grooves, said shielding having grounding pins which extend through said second holes; whereby said second legs of said pin arrays extend into said plug receiving cavities through said second plurality of openings when said backplate assembly is fitted to said rearward loading bay.

Claim 19

A stacked modular jack assembly comprising: a housing having a plurality of plug receptacles arranged along at least two horizontal rows, said housing further having a front face, a rearward loading bay and a bottom mounting surface, said front face having a first plurality of openings into said plug receptacles, said rearward loading bay having a second plurality of openings into said plug receptacles; and a backplate assembly including an elongate coupling member, a plurality of pin arrays and a shielding plate, said backplate assembly being fitted to said rearward loading bay; said coupling member having first and second walls arranged in an L shape and further having a plurality of sets of grooves formed on the inside of said L shape of said coupling member and extending in a direction perpendicular to said first wall and arranged along at least two horizontal rows; said first wall of said coupling member having first holes formed therethrough, said first holes being aligned with said sets of grooves; each said pin array including a unitary insulative member having an L shape having a first leg and a second leg, said first leg having grooves formed along the exterior surface thereof, said pin array further including lead wires formed within said insulative member, one end of said lead wires extending along said grooves of said first leg and beyond the end of said first leg to form mounting pins, another end of said lead wires extending beyond the end of said second leg of said L shape of said insulative member and bent back over said second leg to form contact pins; each said pin array being coupled to said coupling member such that said grooves of each said pin array engages one of said sets of grooves of said coupling member and said mounting pins are aligned with and pass through said first holes in said first wall of said coupling member; said first wall further including second holes formed therethrough, said shielding plate and said second holes being disposed between said two rows of said sets of grooves, said shielding having grounding pins which extend through said second holes; whereby said second legs of said pin arrays extend into said plug receiving cavities through said second plurality of openings when said backplate assembly is fitted to said rearward loading bay.

Claim 20

The stacked modular jack assembly of claim 15 wherein for each said pin array said first leg is perpendicular to said first wall of said coupling member and said second leg is parallel to said first wall.

Claim 21

The stacked modular jack assembly of claim 15 wherein said contact pins of a first row of pin arrays bend in a direction opposite to that of said contact pins of a second row of pin arrays.

Claim 22

The stacked modular jack assembly of claim 15 further including a ground shield enclosing said housing.