Modular connector
A modular connector is a type of electrical connector for cords and cables of electronic devices and appliances, such as in computer networking, telecommunication equipment, and audio headsets.
Modular connectors were originally developed for use on specific Bell System telephone sets in the 1960s, and similar types found use for simple interconnection of customer-provided telephone subscriber premises equipment to the telephone network. The Federal Communications Commission mandated in 1976 an interface registration system, in which they became known as registered jacks. The convenience of prior existence for designers and ease of use led to a proliferation of modular connectors for many other applications. Many applications that originally used bulkier, more expensive connectors have converted to modular connectors. Probably the best-known applications of modular connectors are for telephone and Ethernet.
Accordingly, various electronic interface specifications exist for applications using modular connectors, which prescribe physical characteristics and assign electrical signals to their contacts.
Nomenclature
Modular connectors are often referred to as modular phone jack and plug, RJ connector, and Western jack and plug. The term modular connector arose from its original use in modular wiring components of telephone equipment by the Western Electric Company in the 1960s. This includes the 6P2C used for telephone line connections and 4P4C used for handset connectors.Registered jack designations describe the signals and wiring used for voice and data communication at customer-facing interfaces of the public switched telephone network. It is common to use a registered jack number to refer to the physical connector itself; for instance, the regular 8P8C modular connector type is often labeled RJ45 because the registered jack standard of the similar name RJ45S specified a similar, but modified, 8P8C modular connector. Similarly, various six-position modular connectors may be called RJ11. Likewise, the 4P4C connector is sometimes called RJ9 or RJ22 though no such official designations exist.
History
The first types of small modular telephone connectors were created by AT&T in the mid-1960s for the plug-in handset and line cords of the Trimline telephone. Driven by demand for multiple sets in residences with various lengths of cords, the Bell System introduced customer-connectable part kits and telephones, sold through PhoneCenter stores in the early 1970s. For this purpose, Illinois Bell started installing modular telephone sets on a limited scale in June 1972. The patents by Edwin C. Hardesty and coworkers, and , followed by other improvements, were the basis for the modular molded-plastic connectors that became commonplace for telephone cords by the 1980s. In 1976, these connectors were standardized nationally in the United States by the Registration Interface program of the Federal Communications Commission, which designated a series of Registered Jack specifications for interconnection of customer-premises equipment to the PSTN.Gender
Modular connectors have gender: plugs are considered to be male, while jacks or sockets are considered to be female. Plugs are used to terminate cables and cords, while jacks are used for fixed locations on surfaces of walls, panels, and equipment. Other than telephone extension cables, cables with a modular plug on one end and a jack on the other are rare. Instead, cables are usually connected using a female-to-female coupler, having two jacks wired back-to-back.Latching tab and orientation
Most modular connectors are designed with a latching mechanism that secures the physical connection. As a plug is inserted into a jack, a plastic tab on the plug locks against a ridge in the socket so that the plug cannot be removed without disengaging the tab by pressing it against the plug body. The standard orientation for installing a jack in a vertical surface is with the tab down.The modular plug is often installed with a boot, a plastic covering over the tab and body, to prevent the latching tab from hooking into other cords or edges, which may cause excessive bending or breaking of the tab. Such cords are usually constructed by installing the protective boot before the modular plug is crimped.
Size and contacts
Modular connectors are designated using two numbers that represent the maximum number of contact positions and the number of installed contacts, with each number followed by P and C, respectively. For example, 6P2C is a connector having six positions and two installed contacts. Alternate designations omit the letters while separating the position and contact quantities with either an x or a slash.When not installed, contacts are usually omitted from the outer positions inward, such that the number of contacts is almost always even. The connector body positions with omitted or unconnected contacts are unused for the electrical connection but ensure that the plug fits correctly. For instance, inexpensive telephone cords often have connectors with six positions and four contacts, to which are attached just two wires, carrying only line 1 from a one-, two-, or three-line jack.
The contact positions are numbered sequentially, starting from 1. When viewed head-on with the retention mechanism on the bottom, jacks will have contact position number 1 on the left and plugs will have it on the right. Contacts are numbered by the contact position. For example, on a six-position, two-contact plug, where the outermost four positions do not have contacts, the two contacts are numbered 3 and 4.
Modular connectors are manufactured in four sizes, with four, six, eight, and ten positions. The insulating plastic bodies of 4P and 6P connectors have different widths, whereas 8P or 10P connectors share an even larger body width.
Insulation displacement contact types
Internally, the contacts in the plugs have sharp prongs that, when crimped, displace the wire insulation and connect with the conductors inside—a mechanism known as insulation displacement. Cables have either solid or stranded conductors, and a given plug is designed for only one type. The sharp prongs are different in the connectors made for each type of wire, and a mismatch between plug type and wire type results in unreliable connections. A modular plug for solid wire often has three slightly splayed prongs on each contact to securely surround and grip the conductor while scraping along the outside, and a plug for stranded wire has prongs that are designed to pierce the insulation and go straight through to contact multiple wire strands.Interchangeability
Some modular connectors are indexed, meaning their dimensions are intentionally non-standard, preventing connections with connectors of standard dimensions. The means of indexing may be non-standard cross-sectional dimensions or shapes, retention mechanism dimensions or configuration. For example, a Modified Modular Jack using an offset latching tab was developed by Digital Equipment Corporation to prevent accidental interchange of data and telephone cables.| Connector | Length | Width | Height |
| 4P4C | 7.7 | ||
| 6P6C | 13.34 | 9.85 | 6.60 |
| 8P8C | 22.48 | 11.68 | 8.00 |
The dimensions of modular connectors are such that a narrower plug can be inserted into a wider jack that has more positions than the plug, leaving the jack's outermost contacts unconnected. The height of the plug's insertion area is 0.260 inches and the contacts are 0.040 inches apart, so the width is dependent on the number of pin positions. However, not all plugs from all manufacturers have this capability, and some jack manufacturers warn that their jacks are not designed to accept smaller plugs without damage. If an inserted plug lacks slots to accommodate the jack's contacts at the outermost extremes, it may permanently deform the outermost contacts of an incompatible jack. Excessive resistance may be encountered when inserting an incompatible plug, as the outermost contacts in the jack are forcibly deformed.
Special modular plugs have been manufactured which have extra slots beyond their standard contacts, to accommodate the wider jack's outermost contacts without damage. These special plug connectors can be visually identified by carefully looking for the extra slots molded into the plug. The molded plastic bodies of the special plugs may also be colored with a light blueish tinge to aid in quick recognition. The special plugs are preferred for test equipment and adapters, which may be rapidly connected to a large number of corresponding connectors in quick succession for testing purposes. The use of the special plugs avoids inadvertent damage to the equipment under test, even when a narrower plug is inserted into a nominally incompatible wider jack.
Termination
Termination of cables with modular connectors is similar across the various number of positions and contacts in the plug. The crimping tool contains a die that is often exchangeable and is closely matched to the shape and pin count of the modular plug.A crimping die-set looks similar to an 8P8C jack, except for the eight teeth lining the top portion of the die. When the tool is operated, the die compresses around the 8P8C plug. As the die compresses, these teeth force the plug contacts into the conductors of the cable being terminated. The crimper may also permanently deform part of the plastic plug body in such a way that it grips the outer sheath of the cable for secure fastening and strain relief. These actions permanently attach the plug to the cable.