Advanced microelectronic connector assembly and method of manufacturing

A multi-port connector assembly comprising:

• a connector housing comprising a plurality of connectors each having:
• a recess adapted to receive at least a portion of a modular plug, said modular plug having a plurality of terminals disposed thereon;
• at least one substrate having at least one electrically conductive pathway associated therewith, said at least one substrate being disposed in substantially orthogonal orientation with respect to a front face of said housing;
• a cavity adapted to receive at least a portion of said at least one substrate;
• a plurality of first conductors disposed at least partly within said recess, said first conductors being configured to form an electrical contact with respective ones of said terminals when said modular plug is received within said recess, and form an electrical pathway between said first conductors and said at least one substrate;
• and
• a plurality of second conductors, at least one of said second conductors being in electrical communication with said at least one electrically conductive pathway of said at least one substrate.

A method of manufacturing a multi-port connector, comprising:

• forming a connector housing having at least one port pair of modular jack recesses, and at least one cavity communicating with said recesses;
• forming at least two primary substrates;
• forming at least two sets of first conductors, said first conductors each having a distal end and a modular plug contacting portion, said act of forming said conductors comprising forming individual ones of said conductors such that the distal ends of said first conductors in each set which mate with the corresponding one of said at least two primary substrates are oriented in an coplanar array which is angled with respect to said modular plug contacting portion;
• mating said distal ends of said conductors of a first of said at least two sets of conductors with a corresponding one of said substrates to form a first insert assembly;
• mating said distal ends of said conductors of a second of said at least two sets of conductors with a corresponding one of said substrates to form a second insert assembly;
• and
• inserting said first and second insert assemblies at least partly into said cavity.

A multi-port connector assembly comprising:

• means for housing comprising a plurality of connectors each having:
• a recess adapted for receiving at least a portion of a modular plug, said modular plug having a plurality of terminals disposed thereon;
• at least one substrate means having at least one electrically conductive pathway associated therewith, said at least one substrate means being disposed in substantially orthogonal orientation with respect to a front face of said means for housing;
• cavity means adapted for receiving at least a portion of said at least one substrate means;
• a plurality of first conductor means disposed at least partly within said recess, said first conductor means being configured to form an electrical contact with respective ones of said terminals when said modular plug is received within said recess, and for forming an electrical pathway between said first conductor means and said at least one substrate means;
• and
• a plurality of second conductor means, at least one of said second conductor means being in electrical communication with said at least one electrically conductive pathway of said at least one substrate means.

A carrier for use within a modular connector assembly having a plurality of means for conducting electrical signals, said carrier comprising:

• a carrier body means;
• means for retaining said means for conducting, said means for conducting being retained in a substantially coplanar configuration within said body means, said means for retaining further being adapted to maintain electrical separation between individual ones of said means for conducting;
• wherein said conductor means are shaped at their distal portions to be substantially curved, each of said substantially curved distal portions of said conductor means having a different effective radius;
• and
• wherein said means for retaining substantially comply with said distal portions of said means for conducting.

A connector assembly comprising:

• a connector housing comprising a connector having:
• a recess adapted to receive at least a portion of a modular plug, said modular plug having a plurality of terminals disposed thereon;
• at least one substrate having at least one electrically conductive pathway associated therewith;
• a cavity adapted to receive at least a portion of said at least one substrate, said at least one substrate being disposed within said cavity such that said at least one substrate is substantially orthogonal to a front face of said connector housing;
• a plurality of first conductors disposed at least partly within said recess, said first conductors being configured to form an electrical contact with respective ones of said terminals when said modular plug is received within said recess, and form an electrical pathway between said first conductors and said at least one substrate;
• and
• a plurality of second conductors, at least one of said second conductors being in electrical communication with said at least one electrically conductive pathway of said at least one substrate.

A method of manufacturing a multi-port connector, comprising the steps of:

• forming a connector housing having at least one port pair of modular jack recesses for receiving corresponding ones of modular jacks therein, and at least one cavity communicating with said recesses for receiving components of said connector;
• forming at least two primary substrates for receiving at least portions of conductors thereon;
• forming at least two sets of first conductors for conducting electrical current, said first conductors each having a distal end and a modular plug contacting portion, said act of forming said conductors comprising forming individual ones of said conductors such that the distal ends of said first conductors in each set which mate with the corresponding one of said at least two primary substrates are oriented in an coplanar array which is angled with respect to said modular plug contacting portion;
• forming at least two sets of second conductors for conducting electrical current, said second conductors each having a distal end and an external device contacting portion;
• mating said distal ends of said conductors of a first of said at least two sets of first conductors with a corresponding first one of said at least two substrates;
• mating said distal ends of said conductors of a first of said at least two sets of second conductors with said first substrate, said acts of mating with said first substrate forming a first insert assembly;
• mating said distal ends of said conductors of a second of said at least two sets of first conductors with a corresponding second one of said at least two substrates;
• mating said distal ends of said conductors of a second of said at least two sets of second conductors with said second substrate, said acts of mating with said second substrate forming a second insert assembly;
• and
• inserting said first and second insert assemblies at least partly into said cavity.