Electrical connector with removable load bar
A modular plug system including a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end having a cavity formed in the front end and an opening opposite the front end, and a cavity extending from the front end to the opening in the back end, and a cap unit that is inserted into the front end such that a surface of the front end is co-planer with the front surface of the cap unit, where the cavity has a back surface that is recessed from the front surface of the plug.
1 . A modular plug system including:
a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end having a cavity formed in the front end and an opening opposite the front end, with the cavity extending from the front end to the opening in the back end;
a cap unit that is inserted into the front end such that a surface of the front end is co-planer with a front surface of the cap unit,
a plurality of separators on a back side of the cap unit, where the separators are sized to accommodate a wire extending through a corresponding channel in the back surface of the cavity;
a plurality of cylinder units each extending from the back side of the cap unit with each cylinder unit being positioned between adjacent separators;
wherein,
the cavity has a back surface that is recessed from the front surface of the plug.
2 . The modular plug system of claim 1 wherein the cap unit is made from a flame resistant material.
3 . The modular plug system of claim 1 wherein the plug is a Power over Ethernet plug.
4 . The modular plug system of claim 1 wherein each cylinder unit has a depth that extends beyond the end of each separator.
5 . The modular plug system of claim 1 wherein the cylinder units are arranged in a single row.
6 . The modular plug system of claim 1 wherein the cylinder units are arranged in more than one row.
7 . The modular plug of claim 1 wherein each cylinder is sized to engage a wire extending from a channel in the back of the cavity wall.
8 . The modular plug of claim 1 wherein each cylinder unit has a depth that is the same depth as each separator.
9 . A method of manufacturing a modular plug system including the steps of:
forming a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end having a cavity formed in the front end and an opening opposite the front end, and
forming a cavity extending from the front end to the opening in the back end;
forming a cap unit that is inserted into the front end such that a surface of the front end is co-planer with a front surface of the cap unit;
forming a plurality of separators on a back side of the cap unit, where the separators are sized to accommodate a wire extending through a corresponding channel in the back surface of the cavity;
forming a plurality of cylinder units each extending from the back side of the cap unit with each cylinder unit being positioned between adjacent separators,
wherein,
the cavity has a back surface that is recessed from the front surface of the plug.
10 . The method of claim 9 wherein the cap unit is made from a flame resistant material.
11 . The method of claim 9 wherein the plug is a Power over Ethernet plug.
12 . The method of claim 9 wherein each cylinder unit has a depth that extends beyond the end of each separator.
13 . The method of claim 9 wherein the cylinder units are arranged in a single row.
14 . The method of claim 9 wherein the cylinder units are arranged in more than one row.
15 . The method of claim 9 wherein each cylinder is sized to engage a wire extending from a channel in the back of the cavity wall.
16 . The modular plug of claim 1 wherein each cylinder unit has a depth that is the same depth as each separator.