Shielded connector assembly and method of manufacturing

A connector comprising:

• a connector housing comprising a recess adapted to receive at least a portion of a modular plug, said modular plug having a plurality of terminals disposed thereon, said housing further comprising first and second portions;
• at least one substrate having a plurality of electrically conductive pathways associated therewith;
• and
• 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 at least one electrical pathway between said terminals and at least one of said plurality of conductive pathways of said first substrate;
• wherein said first and second housing portions comprise substantially metallic castings.

A connector comprising:

• a connector housing comprising a recess adapted to receive at least a portion of a modular plug, said modular plug having a plurality of terminals disposed thereon, said housing further comprising at least one substantially metallic component adapted for shielding noise in or out of said connector;
• at least one substrate having a plurality of electrically conductive pathways associated therewith;
• a plurality of electronic components electrically disposed within at least some of said conductive pathways;
• and
• 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 at least one electrical pathway between said terminals and at least one of said plurality of conductive pathways of said first substrate.

A method of manufacturing a low-noise connector, comprising;

• forming an insert assembly having at least one substrate, conductors, and electronic components;
• casting a housing adapted to receive said insert assembly, said act of casting comprising casting first and second separable portions from metal;
• disposing said insert assembly within said first portion of said housing;
• and
• mating said second portion of said housing to said first portion;
• wherein said act of mating forms an electronic noise barrier substantially resistant to electronic noise transmission.

A shielded electrical connector, comprising:

• a metallic housing having a front portion and rear portion, said front portion having at least one modular plug port disposed therein;
• a plurality of conductive pathways communicating with said at least one port;
• and
• a plurality of signal conditioning components disposed within said housing and electrically within at least a portion of said conductive pathways;
• wherein said rear portion is adapted to be received substantially within an external structure, said structure being configured to further mitigate noise transmission by said connector.

A connector assembly comprising:

• a substantially metallic connector housing comprising a recess adapted to receive at least a portion of an RJ-45 modular plug, said modular plug having a plurality of terminals disposed thereon, said housing further comprising first and second portions;
• a first substrate having a plurality of electrically conductive pathways associated therewith;
• a second substrate having a plurality of electrically conductive pathways associated therewith;
• 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 at least one electrical pathway between said first conductors and at least one of said plurality of conductive pathways of said first substrate;
• a plurality of second conductors, at least one of said second conductors being in electrical communication with respective ones of at least a portion of said plurality of electrically conductive pathways of said first substrate, and adapted to electrically interface with corresponding electrical pathways of said second substrate;
• a cavity adapted to receive at least a portion of said first and second conductors and said first and second substrates therein;
• an edge-type connector comprised at least in part of a portion of one of said first and second substrates;
• and
• a latch mechanism adapted to allow selective removal of said connector from an external structure;
• wherein said first and second portions of said housing cooperate to form at least a portion of said cavity when said housing portions are assembled.