Granted Patent B2

US 7,553,196 · App. 11/981,603 · Granted Jun 30, 2009

Abstract

Claims (23)

1. An insert assembly for a telecommunications jack for use with a plug having plug contacts, the insert comprising:

a) an insulation displacement terminal insert having a main body including a first side positioned opposite from a second side, the insulation displacement terminal insert including:

i) a snap-fit connection structure positioned at the main body for securing the insulation displacement terminal insert to the jack;

ii) an insulation displacement terminal housing positioned at the first side of the main body;

iii) a plurality of insulation displacement terminals housed by the insulation displacement terminal housing, the insulation displacement terminals each including a tip positioned at the second side of the main body;

b) a contact spring insert including a plurality of contact springs held by the contact spring insert, the contact spring insert including a first side positioned opposite from a second side, the contact springs including contact portions positioned at the first side of the contact spring insert for engaging the plug contacts of the plug, the contact springs each including a tip positioned at the second side of the contact spring insert;

c) a circuit board providing electrical connections between the tips of the insulation displacement terminals and the tips of the contact springs, the circuit board being mounted adjacent to the second side of the main body and the second side of the contact spring insert.

2. A method of assembling a telecommunications jack, the method comprising:

providing a jack housing including a front portion positioned opposite from a back portion, the front portion defining a front opening sized for receiving a plug, the back portion defining an open channel, the jack housing further including a base and two opposite facing side walls, the base and the side walls defining at least a portion of the open channel, the jack housing including longitudinal guides extending in a direction from the front portion toward the back portion;

providing a circuit board including electrical tracings thereon;

providing a contact spring insert including contact springs with spring tips,

providing an insulation displacement terminal insert including a main housing with a top side positioned opposite a bottom side, the insulation displacement terminal insert including mating longitudinal guides for slidably mating with the longitudinal guides of the jack housing;

inserting a plurality of insulation displacement terminals with terminal tips into the main housing of the insulation displacement terminal insert from the bottom side of the main housing so that the terminal tips extend from the bottom side of the main housing;

mounting the contact spring insert to the circuit board so that the spring tips project into the circuit board;

mounting the insulation displacement terminal insert to the circuit board so that the terminal tips project into the circuit board and make electrical contact with the spring tips through the electrical tracings on the circuit board;

sliding the circuit board with the insulation displacement terminal insert and the contact spring insert mounted thereon into the open channel of the jack housing by slidably aligning the longitudinal guides of the jack housing with the mating longitudinal guides of the insulation displacement terminal insert.

3. The method of claim 2 , wherein the insulation displacement terminals are press fit into the main housing of the insulation displacement terminal insert.

4. The method of claim 2 , wherein the contact springs are press fit into the contact spring insert.

5. The method of claim 2 , wherein at least a portion of the contact spring insert is positioned between the insulation displacement terminal insert and the circuit board.

6. The method of claim 2 , wherein the main housing of the insulation displacement terminal insert includes a central opening, wherein the contact spring insert is positioned within the central opening.

7. The method of claim 2 , wherein the insulation displacement terminal insert includes a snap-fit connection structure for securing the insulation displacement terminal insert to the jack housing.

8. The method of claim 7 , wherein the snap-fit connection structure includes two flexible lever members each having a locking tab, and the contact spring insert being positioned generally in a region between the flexible lever members.

9. The method of claim 8 , wherein the jack housing includes a hole in each of the side walls for receiving one of the locking tabs.

Assignments (12)