RELATED APPLICATIONS

[0001] This application is being filed on 20 March 2013, as a PCT International Patent application and claims priority to U.S. Patent Application Serial No.

61/616,709 filed on 28 March 2012, and U.S. Patent Application Serial No.

13/828,934 filed on 14 March 2013, the disclosure of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure relates to dust caps for protecting an unused telecommunications connector.

BACKGROUND

[0003] Electrical connectors, for example RJ-type connectors, are useful for providing wall sockets where electronic data cables can be terminated and mating electrical plugs can be inserted. A problem with such electrical connectors can occur when dust, dirt or other contaminants come into contact with electrically conductive elements inside the connector. Such contaminants may cause corrosion, unintended conduction or adhesion of components that impedes their movement. Ingress of contaminants into the electrical connector may be particularly likely when the connector is placed in a wall cavity. This may be the case when building works generate abrasions and contaminants, for example.

[0004] Some electrical connectors, such as some RJ-type connectors, are assembled in such a way that an exposed cavity containing one or more conductive elements of the electrical connector is not covered once installed. This exposed cavity may be prone to accumulation of contaminants. It is generally desirable to overcome or ameliorate one or more of the above described difficulties, or at least provide a useful alternative. SUMMARY

[0005] A dust cap for covering a jack recess in a telecommunications jack is disclosed. In one embodiment, the dust cap includes a cover portion attached to a hinge base. The cover portion is rotatable from a closed position, wherein the cover portion covers the jack recess, to an open position, wherein the jack recess is exposed. The cover portion may include a securing feature located on a rear face of the cover portion that is configured to engage with the jack recess to retain the cover portion in the closed position. The cover portion may also include a handle portion located on a front face of the cover portion that is configured to allow a user to move the cover portion between the open and closed positions with a single phalange. The dust cap may also include an adhesive located on a rear face of the hinge base that is configured to engage with a front face of the telecommunications jack to secure the dust cap to the telecommunications jack. DESCRIPTION OF THE DRAWINGS

[0006] Non-limiting and non-exhaustive embodiments are described with reference to the following figures, which are not necessarily drawn to scale, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. [0007] Figure 1 is a front perspective view of a dust cap having features that are examples of aspects in accordance with the principles of the present disclosure.

[0008] Figure l a is a front perspective view of a dust cap of Figure 1 with additional material being provided for a hinge member of the dust cap.

[0009] Figure 2 is a front view of the dust cap shown in Figure 1 . [0010] Figure 3 is a rear view of the dust cap shown in Figure 1 .

[0011] Figure 4 is a side view of the dust cap shown in Figure 1 . [0012] Figure 5 is a front perspective view of a hinge base of the dust cap shown in Figure 1.

[0013] Figure 5a is a front perspective view of a hinge base of the dust cap shown in Figure 1 with relieved surfaces. [0014] Figure 6 is a rear view of a cover portion of the dust cap shown in Figure

[0015] Figure 7 is a front view of the hinge base of the dust cap shown in Figure 1.

[0016] Figure 8 is a cross-sectional view of the hinge base of the dust cap shown in Figure 1 taken along the line 8-8 in Figure 7.

[0017] Figure 9 is a top view of the hinge base of the dust cap shown in Figure

[0018] Figure 10 is a rear perspective view of the dust cap shown in Figure 1.

[0019] Figure 10a is a rear perspective view of the dust cap shown in Figure 1 with a tabbed release liner.

[0020] Figure 1 1 is a front perspective view of the dust cap shown in Figure 1 in addition to a jack receptacle suitable for attachment of the dust cap.

[0021] Figure 12 is a front perspective view of the dust cap shown in Figure 1 attached to the jack receptacle shown in Figure 1 1 with the dust cap in a closed position.

[0022] Figure 13 is a front perspective view of the dust cap shown in Figure 1 attached to the jack receptacle shown in Figure 1 1 with the dust cap in an open position.

[0023] Figure 14 is a side view of the dust cap shown in Figure 1 attached to the jack receptacle shown in Figure 1 1 with a plug inserted into the jack receptacle. [0024] Figure 15 is a side view of an arrangement of a plurality of plugs inserted into jack receptacles, each receptacle having the dust cap shown in Figure 1.

[0025] Figure 16 is a front view of the arrangement shown in Figure 14.

[0026] Figure 17 is a front perspective view of the arrangement shown in Figure 14.

[0027] Figure 18 is a front perspective view of a second embodiment of a dust cap having features that are examples of aspects in accordance with the principles of the present disclosure.

[0028] Figure 19 is a front view of the dust cap shown in Figure 18.

[0029] Figure 20 is a rear view of the dust cap shown in Figure 18.

[0030] Figure 21 is a side view of the dust cap shown in Figure 18.

[0031] Figure 22 is a rear perspective view of the dust cap shown in Figure 18.

[0032] Figure 23 is a side view of the dust cap shown in Figure 18 attached to a jack receptacle, and in a closed position.

[0033] Figure 24 is a side view of the dust cap shown in Figure 18 attached to the jack receptacle shown in Figure 23 in an open position, and with a plug inserted into the receptacle.

[0034] Figure 25 is a front view of the dust cap shown in Figure 18 attached to a jack receptacle.

[0035] Figure 26 is a cross-sectional view of the dust cap and hinge shown in Figure 24 taken along the line 26-26 shown in Figure 25.

[0036] Figure 27 is a cross-sectional side view of a third embodiment of a dust cap having features that are examples of aspects in accordance with the principles of the present disclosure, wherein the dust cap is attached to the jack receptacle shown in Figure 1 1 with the dust cap in a closed position. [0037] Figure 28 is a cross-sectional side view of the dust cap shown in Figure 27 attached to the jack receptacle shown in Figure 1 1 with the dust cap in an open position, and with a plug inserted into the receptacle.

DETAILED DESCRIPTION

[0038] Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.

[0039] Referring now to Figures 1 -4, an example dust cap 100 is shown. Dust cap 100 is for protecting a telecommunications jack 200 of a modular connector from dust and other contaminants when the modular connector is not engaged with a plug 300. One type of modular connector suitable for use with dust cap 100 is an RJ type connector, for example, an RJ45 type connector. Jack 200 includes contact springs 208 on the inside of the jack for contacting a mating plug 300. One skilled in the art will appreciate that dust cap 100 may be used in conjunction with a wide variety of modular type connector jacks, for example fiber optic adapters. In the embodiment shown, dust cap 100 includes a cover portion 1 10 rotatably connected to a hinge base 150.

[0040] As shown, cover portion 1 10 has a front face 1 10a and a rear face 1 10b. When the dust cap 100 is mounted on a jack 200, the cover portion 1 10 is oriented such that the front face 100a is outward facing while the rear face 1 10b faces towards a recess 206 in the main body 202 of the jack 200. An example jack receptacle 200 is shown at Figures 1 1 -13. These figures also show the orientation of the cover portion 1 10 with respect to the jack receptacle 200. Cross-sectional views of a jack receptacle 200 are also provided at Figures 26-28.

[0041] Located on the front face 1 10a is a handle 1 12 configured to allow a user to manipulate the cover portion 1 10 such that the dust cap 100 can be moved from a closed position to an open position. The dust cap 100 is shown as being in the closed position at Figures 12 and 12A, and as being in the open position at Figures 13-17. In the example embodiment shown, the handle 1 12 is configured to allow this action to be initiated by using a single phalange (i.e. a finger and/or a fingernail). [0042] As most easily seen at Figures 3 and 4, a plurality of securing features 1 14, 1 16 are located on the rear face 1 1 Ob of the cover portion 1 10. Securing features 1 14, 1 16 are for retaining the dust cap 100 in the closed position and/or providing an alignment function when mounting dust cap 100 to jack 200. Many configurations and variations of the securing features 1 14, 1 16 are possible.

Additionally, dust cap 100 may be provided with only one of securing features 1 14 and 1 16. In the example embodiment shown, securing features 1 14, 1 16 are configured to frictionally engage the interior sidewalls of the jack recess 206. One skilled in the art will appreciate that other types of engagement connections may be utilized, for example, snap fit connections. Additionally, that more or fewer securing features than what are shown may be utilized.

[0043] As shown, first securing features 1 14 run generally parallel to and engage with side walls 206a and 206b of the jack recess 206 at a location that is below the top wall 206c and above the inset side walls 206d, 206e, as shown in Figure 1 1 . As most easily seen at Figures 3 and 4, each securing feature 1 14 includes a side wall 1 14a having a thickness tl and at least one end wall 1 14b. In the embodiment shown, side wall 1 14a increases from a first height h i in a direction from the hinge base 150 towards the securing feature 1 16 to a second height h2, as can be seen at Figure 4. Each first securing feature 1 14 can also be optionally provided with a chamfered portion 1 14c. The chamfered portion 1 14c and the increasing height of sidewall 1 14a allow for the cover portion 1 10 to register more easily into the jack recess 206 when being moved from the open position into the closed position. One skilled in the art, upon learning of the disclosure, will understand that chamfered portion 1 14c need not be present such that the sidewall 1 14a and end portion 1 14b are generally squared.

[0044] With reference to second securing feature 1 16, a horizontal wall 1 16a is provided and supported by a pair of support features 1 16c. The horizontal wall 1 16a has a width w l and a height h3. Horizontal wall 1 16a also has sides 1 16b. The width wl is such that, when the cover portion 1 10 is moved to the closed position, the sides 1 16b frictionally engage with side walls 206d and 206e of the jack recess 206 that are located just above the plug latch tab connection 206f. Side walls 206d and 206e and latch tab connection 206f are most easily seen at Figures 1 1 and 13.

[0045] Referring back to Figures 1 -4, cover portion 1 10 is shown as additionally including an extension member 1 18. In the embodiment shown, extension member 1 18 is integrally formed onto the front face 1 10a of cover portion 1 10 and functions to connect the cover portion 1 10 with the hinge base 150. As can be seen at Figure 6, extension member 1 18 includes a male hinge member 120 that is received in recesses 154a of corresponding female hinge members 154 in the hinge base 150. This arrangement provides for a snap-fit arrangement in which no tools are required to join or separate the hinge base 150 and the cover portion 1 10. It is noted that hinge member 120 could be alternatively configured as a female hinge member and hinge members 154 could be alternatively configured as male hinge members.

Other types of rotatable connections between cover portion 1 10 and hinge base 150 are possible. Extension portion 1 18 also includes a pair of apertures 122 for allowing the hinge portions 154 to rotate through the cover 1 10 when the dust cap 100 is moved to the open position. With reference to Figure l a, the extension member 1 18 can be formed with additional material at location 1 18a to increase wall thickness to aid in the position of the material feed point.

[0046] Referring to Figures 3-5 and 7-9, the hinge base 150 is shown in greater detail. As shown, the hinge base 1 0 includes a main body 152 having a front face 152a and a rear face 152b. When the hinge base 150 is connected to the cover portion 1 10, the front face 152a faces in the same direction as the front face 1 10a of the cover portion 1 10. The rear face 152b is for securing the dust cap 100 to the front face 204 of the jack 200. In the embodiment shown, the rear face 152b has a surface area that is less than the surface area of the front face 204 of the jack 200. With reference to Figure 5a, the hinge base can be provided with recessed portions 152c that increase clearance between the hinge base 1 0 and the extension member 1 18 of the cover portion 1 10 such that the cover portion can rotate beyond 180 degrees. [0047] In the embodiment shown, the rear face 152b is provided with an adhesive 156 for adhesively attaching the hinge base 150 to the jack front face 204. In the embodiment shown, adhesive 156 covers a majority of the rear surface 150b of the hinge base 150. Many types of adhesives are suitable for this purpose. For example, adhesive 156 may be a double-sided polyurethane foam tape, such as 3M™ MULTIPURPOSE MOUNTING TAPE 4016. In another embodiment, the adhesive 156 is a pressure sensitive double-sided acrylic tape, such as 3M™ VHB™ HEAVY DUTY MOUNTING TAPE 4910. Where using a double-sided tape, one side may be bonded to the rear face 152b of the hinge base 150, and the other side may be bonded to the front face 204 of the jack 200. In other embodiments, a liquid or semi-liquid adhesive may be applied to the rear face 152b rather than a tape. Referring to Figure 10, the adhesive 156 may be additionally provided with a release liner 1 58 for protecting the adhesive 156 prior to application. The release liner 158 may be made from a variety of materials, such as polyethylene or kraft paper, provided they are compatible with the underlying adhesive 156. As shown at Figure 10a, the release liner 158 can be provided with an extension tab 158a that extends beyond the hinge base 150 for easier removal of the release liner 158.

[0048] Referring to Figure 1 1 , the dust cap 100 is shown as being aligned with the front face 204 of a jack 200 prior to attachment of the jack 200. When installing the dust cap 100, a release liner 158 would be removed prior to attachment. Figure 12 shows the dust cap 100 having been attached to the jack 200 wherein the hinge base 150 is adhesively attached to the front face 204 of the jack 200, and with the cover portion 1 10 completely covering the jack recess 206. Not only do securing features 1 14, 1 16 retain the cover portion 1 10 in the closed position, they also serve as alignment guides when initially attaching the dust cap 100 to the jack 200 such that the hinge base 150 is properly oriented on the jack front face 204.

[0049] Referring to Figures 13-17, the dust cap 100 is shown as being in the open position such that the jack recess 206 is exposed, and such that a plug 300 may be inserted into the jack recess 206. Plug 300 terminates a cable to be connected to jack 200. As can be most easily seen at Figure 14, where the dust cap 100 is in the open position and resting on the top of an inserted plug 300, the uppermost part (handle portion 1 12) of the cover portion 1 10, extends a vertical distance h4 above the top of the front face 204 of the jack 200, The small increase in height above the jack front face 204 defined by vertical distance h4 is a result of the dust cap 100 having an adhesively attached, front mounted design and the result of the hinge design principles disclosed herein. [0050] Referring to Figure 1 5, a standard multiple jack arrangement is shown having three rows of jacks 200, each configured to receive a plug 300. As can be seen the total available clearance between the top and bottom of adjacent plugs 300 is a clearance distance h5. Accordingly, the vertical distance h4 is less than the clearance distance h5, thereby allowing for the use of dust cap 100 in a standard multiple jack arrangement. Furthermore, because the dust cap 100 is designed to be attached to the front face 204 of each jack 200, there is no interference provided by the dust cap 100 and an installed wall cover plate 220, as shown in Figures 16- 17. As a result, the disclosed dust cap 100 is especially suitable for retrofit applications.

[0051 ] Referring to Figures 1 8-26, a second embodiment of a dust cap 100' is presented. As many of the concepts and features are similar to the first embodiment shown in Figures 1 - 1 7, the description for the first embodiment is hereby incorporated by reference for the second embodiment, and vice versa. Where like or similar features or elements are shown, the same reference numbers will be used where possible. [0052] As shown, the dust cap 100' has a cover portion 1 10' and a hinge base 150' connected to each other by a living hinge 1 18'. By use of the term "living hinge" it is meant to mean a relatively thin, flexible hinge made from the same material as the cover portion 1 10' and the hinge base 150'. This configuration allows for the dust cap 100' to be produced in a single manufacturing step, as no assembly of the hinge base 150' and the cover portion 1 10' is required.

[0053] In the embodiment shown, the cover portion 1 10' includes a front face 1 10a' and a rear face 1 10b. Located on the front face 1 10a' is a handle portion 1 12' molded into the body of the cover portion 1 10'. Handle portion 1 12' is configured to allow a user to manipulate the cover portion 1 10' such that the dust cap 100' can be moved from a closed position to an open position. The dust cap 100' is shown as being in the closed position at Figures 23 and 25-26, and as being in the open position at Figure 24. In the example embodiment shown, the handle 1 12' is configured to allow this action to be initiated by using a single phalange (i.e. a finger and/or a fingernail).

[0054] Similar to the first embodiment, dust cap 100' also includes a plurality of securing features 1 14', 1 16' located on the rear face 1 10b' of the cover portion 1 10'. Securing features 1 14', 1 16' are for retaining the dust cap 100' in the closed position. Many configurations and variations of the securing features 1 14', 1 16' are possible. In the example embodiment shown, securing features 1 14' are configured to frictionally engage the interior sidewalls 206a, 206b of the jack recess 206.

Additionally, securing feature 1 16' is configured to complete a snap-fit connection with the plug latch tab connection 206f in a manner similar to how the plug 300 latch tab 302 engages with the jack 200. In the exemplary embodiment shown, securing feature 1 16' is formed onto the handle portion 1 12'. The configuration of the securing features 1 14', 1 16' with respect to the jack 200 is most easily seen in the cross-sectional view provided at Figure 26. One skilled in the art will appreciate that other types of engagement connections may be utilized. Additionally, one skilled in the art will appreciate that more or fewer securing features may be utilized.

[0055] Referring to Figures 1 8-22, the hinge base 1 0' is shown in greater detail. As shown, the hinge base 1 50' includes a main body 152' having a front face 152a' and a rear face 152b'. When the hinge base 150' is connected to the cover portion 1 10', the front face 152a' faces in the same direction as the front face 1 10a' of the cover portion 1 10' . The rear face 152b' is for securing the dust cap 100 to the front face 204 of the jack 200. In the embodiment shown, the rear face 152b' has a surface area that is less than the surface area of the front face 204 of the jack 200. [0056] In the embodiment shown, the rear face 152b' is provided with an adhesive 156' for adhesively attaching the hinge base 150' to the jack front face 204. In the embodiment shown, adhesive 156 covers a majority of the rear surface 150b of the hinge base 150. Many types of adhesives are suitable for this purpose. For example, adhesive 156' may be a double-sided polyurethane foam tape, such as 3M™ MULTIPURPOSE MOUNTING TAPE 4016. In another embodiment, the adhesive 156' is a pressure sensitive double-sided acrylic tape, such as 3M™ VHB™ HEAVY DUTY MOUNTING TAPE 4910. Where using a double-sided tape, one side may be bonded to the rear face 152b' of the hinge base 150', and the other side may be bonded to the front face 204 of the jack 200. In other embodiments, a liquid or semi-liquid adhesive may be applied to the rear face 152b' rather than a tape. Referring to Figure 22, the adhesive 156' may be additionally provided with a release liner 158' for protecting the adhesive 156' prior to application. The release liner 158' may be made from a variety of materials, such as polyethylene or kraft paper, provided they are compatible with the underlying adhesive 156'. [0057] Referring to Figure 24, the dust cap 100' is shown as being in the open position such that the jack recess 206 is exposed, and such that a plug 300 may be inserted into the jack recess 206. When the dust cap 100' is in the open position and resting on the top of an inserted plug 300, the uppermost part of the cover portion 1 10', extends a vertical distance h4' above the top of the front face 204 of the jack 200. In one embodiment, distance h4' is less than the clearance distance h5 shown for the first embodiment, thereby allowing for the use of dust cap 100' in a standard multiple jack arrangement. Furthermore, because the dust cap 100' is designed to be attached to the front face 204 of each jack 200, there is no interference provided by the dust cap 100' and a wall cover plate 220 that may be installed in some applications. It is also noted that distance h4' is minimized due to the living hinge 1 18' being located at the bottom of the hinge base 150'. As a result, the disclosed dust cap 100' is especially suitable for retrofit applications.

[0058] Referring to Figures 27-28, a third embodiment of a dust cap 100" is presented. As many of the concepts and features are similar to the first embodiment shown in Figures 1 - 17, the description for the first embodiment is hereby incorporated by reference for the third embodiment, and vice versa. Where like or similar features or elements are shown, the same reference numbers will be used where possible. Due to the similarities between the first and third embodiments, the following description for the third embodiment will be limited primarily to the differences between the first and third embodiments. [0059] As can be seen at Figures 27-28, dust cap 100" has a cover portion 1 10" hingedly attached to a hinge base 150". Similar to the first embodiment, cover portion 1 10" has a handle feature 1 12" and securing features 1 14", 1 16" while hinge base 150" has an adhesive 156" and hinge portions 154". The third embodiment differs from the first embodiment in that the hinge base 150" in two ways. First, the hinge base 150" has a sloped surface 150a" at its upper end. This surface allows for somewhat greater clearance between vertically spaced jacks 200. Second, the third embodiment dust cap 100" has hinge members 154" that are located more towards the middle of the hinge base 150" as compared to the first embodiment. This location accommodates the sloped surface 150a". When the dust cap 100" is in the open position and resting on the top of an inserted plug 300, the uppermost part of the cover portion 1 10", extends a vertical distance h4" above the top of the front face 204 of the jack 200. In one embodiment, distance h4" is less than the clearance distance h5 shown for the first embodiment, thereby allowing for the use of dust cap 100" in a standard multiple jack arrangement.

[0060] In example embodiments, the components of the dust cap 100 may be made of a plastic material, such as injection molded polyethylene and

polypropylene. Other materials can be used.

[0061] The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto.

Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the disclosure.

PARTS LIST

100 first embodiment dust cap

1 10 cover portion

1 10a front face

1 10b rear face

1 12 handle

1 14 first securing feature

1 14a side wall

1 14b side wall

1 14c chamfered portion

h i first height of sidewall

h2 second height of sidewall

tl thickness of sidewall

1 16 second securing feature

1 16a horizontal wall

1 16b horizontal wall sides

1 16c support features

w l width of horizontal wall

1 18 extension portion

1 18 increased material location

120 hinge member

122 apertures

150 hinge base

152 main body

152a front face

152b rear face

152c recessed portions

154 female hinge portions

154a recess

156 adhesive

158 release liner

158a release liner tab

200 jack receptacle

202 main body

204 front face

206 recess

206a wall - main side

206b wall - main side

206c wall - main top

206d wall - inset side at bottom

206e wall - inset side at bottom

206f plug tab latch connector

208 contact springs

220 wall cover plate

300 plug

302 plug latch tab

100' second embodiment dust cap 110' cover portion

110a' front face

110b' rear face

112' handle

114' first securing feature

116' second securing feature

118' living hinge

150' hinge base

152' main body

152a' front face

152b rear face

156' adhesive

158' release liner

100" third embodiment dust cap

110" cover portion

112" handle portion

114" first securing feature

116" second securing feature

150" hinge base

150a" sloped portion

154" hinge portions