UL STANDARDS call out a polycarbonate material meeting UL FLAME AUTO EXTINGUISH.....94V-0 rated. This material will self extinguish during the prescribed time allowed by UL. Some manufacturers are offering 94V-2 material.....why.....because it is a cheaper compound....problem is.....IT BURNS AND PROMOTES THE SPREAD OF FIRE. That means in a high density application, such as a Data Center with tons of Patch Cables.....you have a really nice FUEL SOURCE!

THE PLUG CONTACT (BLADE) IS NOT MAKING ANY CONTACT WITH THE JACK WIRE (CONTACT) 

This is occurring more and more frequently and is caused by the JACK BEING TOO WIDE (on Ethernet Servers, Switches, Routers, etc. and Wall Outlets) and NOT CONFORMING TO THE DIMENSIONS SPECIFIED BY THE STANDARDS BODIES.

In addition, specifications clearly define critical  RJ45 JACK DIMENSIONS with TOLERANCES and MOLD DRAFT REQUIREMENTS to INSURE PROPER LATCHING, PLUG/JACK TARGETING and GUIDANCE and.....APPROPRIATE SURFACE AREA CONTACT MATING for signal transmission integrity. This is like opening up a can of worms.....and there HAVE BEEN DOCUMENTED AND PROVEN RJ45 FIELD CONNECTIVITY FAILURES. Again, the problems are the result of POOR MOLD DESIGN, WORN OUT TOOLING, POOR QUALITY CONTROL PROCEDURES, SHRINKAGE CHARACTERISTICS, PLASTICS USED, etc.

JACK HOUSING DESIGN
MIN and MAX DIMENSIONS

Here are a few examples taken from the above drawing that may impact CONTACT LIFT OFF.....

PLUG BODY DESIGN
MIN and MAX DIMENSIONS



MINIMUM PLUG SIZE



MAXIMUM PLUG SIZE

Specifications clearly define the MINIMUM and MAXIMUM RJ45 PLUG SIZE DIMENSIONS to insure PROPER TARGETING and GUIDANCE into the RJ45 Jack. We have observed that some suppliers are not in compliance with these dimensions....the end result, POOR MATING CHARACTERISTICS WITH THE RJ45 JACK (WIGGLE, DROOP or RISE) causing INTERMITTENCIES or SIGNAL LOSS. In another case, the PLUG WOULD NOT FIT INTO THE JACK OPENING. The problems are indicative of POOR MOLD DESIGN, WORN OUT TOOLING, POOR QUALITY CONTROL PROCEDURES, SHRINKAGE CHARACTERISTICS, PLASTICS USED, etc.

SELECTION OF CONTACT BASE METAL
PHOSPHOR BRONZE versus BRASS CONTACTS

Selection of the BASIS METAL for the CONTACTS will have a SIGNIFICANT EFFECT ON THE PERFORMANCE CHARACTERISTICS or THE PLUGS and JACKS. This is due to the granular MICROSTRUCTURE of the metal and its impact on STIFFNESS, SPRING QUALITY, CORROSION and WEAR RESISTANCE. Why do some manufacturers use brass instead of phosphor bronze....because it's cheaper....and so is its POROSITY, SOFTNESS and MECHANICAL CHARACTERISTICS.

PLUG CONTACT DESIGN

THE SOLID versus STRANDED CONDUCTOR ISSUE

Some manufacturers promote two (2) different contact designs....one for SOLID CONDUCTOR and the other for STRANDED CONDUCTOR....why not use ONE PLUG THAT ACCOMMODATES BOTH TYPES OF CONDUCTORS.....SENTINEL'S DOES. This contact design is meant to "STRADDLE" the conductor, instead of "PIERCING" the conductor straight down (this could fracture solid conductors). See FLUORESCENT X-RAY below of the contacts straddling the conductors.

CAVEAT EMPTOR.....Let The Buyer Beware

SUB-STANDARD, NON-COMPLIANT and COUNTERFEIT RJ45's coming in from the Far East