Abstract:
A method and apparatus are provided for operatively connecting a controller to an external circuit, by connecting the external circuit to a circuit card mounted for slidable movement into operative engagement with a connection element disposed on a side surface of the controller. The circuit card is slidably supported in a receiver adapted for positioning the controller with respect to the circuit card.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
   This patent application claims the benefit of U.S. Provisional Patent Application No. 60/602,062, filed Aug. 17, 2004, the teachings and disclosure of which are incorporated herein, in their entireties, by reference. 

   FIELD OF THE INVENTION 
   This invention relates to control systems in buildings, and more particularly to connecting a controller to a wiring circuit of a building. 
   BACKGROUND OF THE INVENTION 
   Modern buildings typically include a plurality of controllers, located throughout the building, for providing de-centralized control of building subsystems, such as heating, ventilating and air conditioning (HVAC) systems. Such controllers typically are connected, via an electrical circuit external to the controller, to control panels and/or computers located remotely from the controller which supply electrical power and control signals to the controller, which, in turn, redirects the power and control signals to the equipment connected to the controller. 
   Such controllers typically include active and passive electrical and/or electronic components for performing localized signal conditioning and control functions. 
   Such controllers are susceptible to being damaged during construction of the building, and/or installation of the control system into a building. It is desirable, therefore, to provide an apparatus and method for progressively installing the controller, during initial rough-in of the building and sequential finishing operations, to limit exposure of the controller, and associated interconnection equipment, to potential damage during construction. It is further desirable, that such an improved method and apparatus provide a compact overall package of the controller, and its related interconnecting elements, which is preferably relatively flat and accessible from one side of a wall upon which the controller is mounted, and in a form which minimizes the projection of the controller and its related interconnecting devices away from the wall. 
   Prior apparatuses and methods for mounting controllers in buildings through utilization of traditional methods, such as plugging circuit cards into connectors extending axially from a back plane, are not entirely satisfactory in meeting the desires laid out above. 
   BRIEF SUMMARY OF THE INVENTION 
   The invention provides an improved apparatus and method for operatively connecting a controller to an external circuit, by connecting the external circuit to a circuit board mounted for slideable movement into operative engagement with a connection element disposed on a side surface of the controller. The circuit card may be slideably supported in a receiver adapted for positioning the controller with respect to the circuit card. By making the connections between the controller and the external circuit with a slideably movable circuit card engaging a connection element disposed on a side surface of the controller, rather than making such a connection with a connector on a rear surface of the controller, as was often done in the past, the invention provides an overall package which is relatively flat, and readily attachable to a mounting surface, such as the wall of an electrical enclosure. 
   An apparatus and method, according to the invention, allow for sequentially installing the controller through the steps of: attaching a receiver, according to the invention, to a support structure; slideably attaching the circuit card to the receiver; attaching conductor elements of the external circuit to the circuit card; positioning the controller on the receiver; and sliding the circuit card simultaneously with respect to both the controller and the receiver, to thereby provide operative connection with the connection element on the side of the controller. 
   Through such a sequence, the receiver may be installed very early in the building construction when rough-in operations, such as installation of conduit and pulling wires and/or fiber optic or other power and signal carriers through the conduit, are being accomplished. Once the building has been further completed, to an intermediate state of completion, the circuit card may be attached to the receiver and the wires and/or fiber optic or other power and control carriers connected to the circuit card. When construction of the building has been largely completed, the controller may be installed by positioning it on the receiver, and sliding the circuit card into operative connection with the controller. 
   Engagement of the circuit card with the controller may serve to at least partially retain the controller on the receiver. The receiver may also be configured for holding the controller in position thereon, prior to engagement of the circuit card with the controller. The receiver may engage and hold the controller in position through gravitational force acting on the controller, or alternatively, the receiver and controller may engage one another through a snap-together connection. 
   In the form of the invention, an apparatus for operatively connecting a controller, having a connection element through an external circuit, uses a slideably movable circuit card, defining a card plane and having a mating connection element configured for engagement with the connection element of the controller along a connection axis extending substantially parallel to the card plane. The apparatus may include a receiver for slideably supporting the circuit card, positioning the controller with respect to the card plane, and guiding the circuit card in such a manner that the mating connection element of the circuit card moves substantially along the connection axis between an engaged and a disengaged position of the connection element and mating connection element, as the circuit card is slidingly moved with respect to both the receiver and controller while being supported by the receiver. The apparatus may further include the circuit card and/or the controller. The apparatus may further include a cable support adapted for operative attachment thereto of the receiver. The cable support may take the form of a chassis for enclosing the receiver, controller, and circuit card. 
   In some forms of an apparatus, according to the invention, the controller may also include a second connection element, and the apparatus may further include a second circuit card defining a second card plane and having a second mating connection element configured for engagement with the second connection element of the controller along a second connection axis extending substantially parallel to the second card plane. The receiver may slidingly support the second circuit card, position the controller simultaneously with respect to the first and second card planes, and guide the second circuit card in such a manner that the second mating connection element of the second circuit card moves substantially along the second connection axis between an engaged and a disengaged position of the second connection element and the second mating connection element as the second circuit card is slidingly moved with respect to both the receiver and the controller while being supported by the receiver. The receiver may slidingly support the first and second circuit cards in a common sliding plane, with the first and second circuit cards disposed on opposite sides of the controller, with the first and second connection elements of the controller facing in substantially opposite directions, such that the first and second connections of the controller are engaged by moving the first and second circuit cards toward the controller, and such that the first and second connections of the controller are disengaged by moving the circuit cards away from the controller. 
   A receiver, according to the invention, may further include one or more tracks for receiving and retaining one or more circuit cards therein. An apparatus, according to the invention, may further include one or more retainers for securing the circuit cards in the tracks. 
   The invention may take the form of a method for constructing and/or installing and/or repairing or maintaining an apparatus according to the invention. 
   An apparatus, according to the invention, may also be provided in the form of a kit including one or more of a receiver, circuit card, controller, circuit card retainer, and cable support according to the invention. 
   Other aspects, objects and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings: 
       FIG. 1  is an exploded perspective view of a first exemplary embodiment of a controller connection apparatus, according to the invention; 
       FIG. 2  is a perspective view of the exemplary embodiment of the controller connection apparatus of  FIG. 1 , with various components thereof shown in an assembled position; 
       FIGS. 3 ,  4 ,  6 , and  8  sequentially illustrate the manner in which the first exemplary embodiment of the invention, as shown in  FIGS. 1 and 2 , may be progressively installed and connected into a control circuit in a building, according to a method of the invention. 
       FIG. 5  is an enlarged perspective view of a portion of the first exemplary embodiment of the invention, illustrating the manner in which a circuit card, according to the invention, is connected to a receiver according to the invention. 
       FIG. 7  is an enlarged perspective view of a portion of the first exemplary embodiment of the invention, illustrating the manner in which a controller, of the first exemplary embodiment, is positioned and supported by a receiver of the first exemplary embodiment. 
       FIG. 9  is a perspective illustration of a second exemplary embodiment of a control connection apparatus, according to the invention. 
       FIG. 10  is a schematic cross-sectional illustration of a snap-together connection between a controller and a receiver of the second exemplary embodiment of the invention. 
       FIG. 11  is an enlarged perspective view illustrating handles, according to the invention, for facilitating engagement and disengagement of connection elements, according to the invention. 
       FIG. 12  is a cross-sectional view taken along line  12 - 12  in  FIG. 10 . 
   

   While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims. 
   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  shows a first exemplary embodiment of a controller connection apparatus  100 , according to the invention. The first exemplary embodiment of the controller apparatus  100  includes the controller  102 , a receiver  104 , first and second control cards  106 ,  108 , four circuit card retainers  110 , and a two-part enclosure having a cable-supporting housing  112  and a cover  114 . 
   As shown in  FIGS. 1 ,  2 ,  6  and  8 , the controller  102 , of the exemplary embodiment of the controller connection apparatus  100 , includes first and second connection elements, in the form of multi-pin electrical connector halves  116 ,  118 , extending in opposite directions, from opposite sides of the controller  102 . 
   The first circuit card  106  includes a printed circuit board which defines a card plane  120  of the first circuit card, and includes a mating connection element, in the form of a multi-pin connector half  122 , which is configured for engagement with the first connection element  116  of the controller  102 , along a first connection axis  124  which extends substantially parallel to the first card plane  120 , when the controller  102  and first circuit card  106  are operatively connected to the receiver  104 , in the manner described below in more detail. 
   In similar fashion, the second circuit card  108  includes a printed circuit board defining a second card plane  126 , and also includes a second mating connection element  128 , in the form of a multi-pin electrical connector half configured for engagement with the second connection element  118  of the controller  102  along a second connection axis  130 , which extends substantially parallel to the second card plane  126 , when the second circuit card  108  and controller  102  are operatively installed in the receiver  104 , in the manner described in more detail below. 
   As shown in  FIG. 3 , during rough-in construction of a building, the cable supporting housing  112 , of the enclosure, of the exemplary embodiment, is attached to a substantially vertical wall or support structure of the building. The cable support housing  112  includes a plurality of knock-outs  132  (see  FIG. 2 ), which can be removed to allow attachment of conduit runs  134  to the cable support housing  112 . Power and signal conductors  136 , such as electrical wires and/or fiber optic cables, may then be pulled through the conduit runs  134  into the cable support housing  112 , prior to closing in the walls of the building through which the conduit may need to be run. The receiver  104  may also be installed at the same time as the cable support housing  112 , using a single set of fasteners (not shown) for attaching both the receiver  104  and the cable support housing  112  to the support structure of the building. Alternatively, the receiver  104  may be installed at a later stage of the construction. 
   As shown in  FIG. 4 , after the walls of the building are closed in, or at another appropriate intermediate stage of the construction of the building, the first and second control cards  106 ,  108  may be installed in the receiver  104 , and the power and/or signal conducting elements  136  may be trimmed to length and connected to terminal strips and connectors  138 ,  139  which are part of the first and second control cards  106 ,  108 . 
   As illustrated in  FIGS. 1 and 5 , the receiver  104 , of the first exemplary embodiment of a controller connection apparatus  100 , according to the invention, includes an upper and a lower track rails  140 ,  142  each having respective track portions  144 ,  146  for receiving and retaining within the tracks  144 ,  146  the upper and lower ends respectively of the first and second circuit cards  106 ,  108 . Threaded studs  148  project outward from the track rails  140 ,  142 , through U-shaped slots  150  in the circuit cards  106 ,  108 , adjacent the upper and lower ends thereof, for threaded engagement with the circuit card retainers  110 , which take the form of elongated thumb-screws in the exemplary embodiment. 
   The tracks  144 ,  146  and the upper and lower ends of the circuit cards  106 ,  108  are cooperatively configured in such a manner that, with the circuit card retainers  110  removed, the circuit cards  106 ,  108  can be inserted at an angle into the tracks  144 ,  146  and then moved to a non-angled position with respect to the tracks  144 ,  146 , in which the circuit cards  106 ,  108  are retained within the tracks  144 ,  146 . When the retainers  110  are threaded onto the studs  148 , to a position of close proximity to the first and second circuit cards  106 ,  108 , when the circuit cards  106 ,  108  are positioned within the tracks  144 ,  146 , the retainers  110  prevent the circuit cards  106 ,  108 , from being tilted enough with respect to the tracks  144 ,  146  to allow removal of the circuit cards  106 ,  108 . 
   The tracks  144 ,  146  in the receiver  104  of the first exemplary embodiment of the controller connection apparatus  100 , according to the invention, are configured and oriented to slidingly support the first and second circuit cards  106 ,  108 , and guide the circuit cards  106 ,  108  in such a manner that the second mating connection elements  122 ,  128  move substantially and respectively along the first and second connection axes  124 ,  130  between respective engaged positions, when the circuit cards  106 ,  108  are moved inward toward an innermost extent of their travel within the tracks  144 ,  146 , and respective disengaged positions when the circuit cards  106 ,  108  are moved outward from the controller to an outermost extent of their respective travels within the tracks  144 ,  146 . 
   As shown in  FIG. 1 , a handle  152 , in the form of an L-shaped fin, is attached to each of the first and second mating connection elements  122 ,  128 , to facilitate movement of the circuit cards  106 ,  108  toward and away from the controller  102 , for engagement and disengagement of the first and second mating connection elements  122 ,  128 , with the first and second connection elements  116 ,  118 , respectively, of the controller  102 . 
   As shown in  FIG. 7 , the upper track rail  140  also includes a pair of hooks  154  for engaging corresponding D-shaped openings  156  in the rear surface of the controller  102 , in such a manner that the receiver  104  positions the controller simultaneously with respect to the first and second card planes  120 ,  126  and the first and second connection axes  124 ,  130 . The hooks  154 , of the first exemplary embodiment of the invention, are configured for engaging and holding the controller  102  in position on the receiver  104 , when the connection elements  116 ,  118  and mating connection elements  122 ,  128  are not engaged, through gravitational force acting on the controller  102 . 
   As shown in  FIG. 6 , when construction on the building has progressed to a point where it is desirable and safe to do so, the first and second circuit cards  106 ,  108  are moved outward toward the outermost extent of their travel in the tracks  144 ,  146 , and the controller  102  is placed in position between the circuit cards  106 ,  108  on the receiver  104 . The first and second circuit cards  106 ,  108  are then moved inward, as shown in  FIG. 8 , toward the controller  102 , to thereby engage the first and second mating connector elements  122 ,  128  on the first and second control cards  106 ,  108  with the first and second connection elements  116 ,  118 , respectively, on the controller  102 , to thereby complete installation and connection of the controller  102  into the external circuit of the building. 
     FIGS. 9 and 10  show a second exemplary embodiment of a controller connection apparatus  200 , according to the invention. The second exemplary embodiment of the controller connection apparatus  200  embodies the same aspects and elements of the invention described above with regard to the first exemplary embodiment  100  of the invention, except that the controller  202  and receiver  204  of the second embodiment engage one another through a snap-together connection, as illustrated at  206 , rather than using the hooks  154  and D-shaped openings  156  of the first exemplary embodiment of the controller connection apparatus  100 , described above. The snap-together connection  206  provides an alternate means of securing the controller  202  in position on the receiver  204 , prior to engagement of the controller  202  by circuit boards  208 ,  210 , without reliance upon gravitational force acting on the controller  202 . As a result of this configuration, the second embodiment of the invention  200  may be preferable where the support structure to which the receiver  204  is attached is not substantially vertical. 
   As shown in  FIG. 11 , the circuit cards  208 ,  210  of the second exemplary embodiment of the invention  200  also include handles  212 , in the form of an L-shaped fin, attached to the mating connection elements  214  to facilitate movement of the circuit cards  208 ,  210  toward and away from the controller  202 , for electrically connecting the circuit cards  208 ,  210  with the controller  202 . 
   Although the invention has been described herein with reference to the first and second exemplary embodiments thereof, it will be understood, by those having skill in the art, that the invention may be practiced in many other forms. For example, in some embodiments of the invention, a receiver, one or more circuit cards, and a controller, according to the invention, may be attached directly to a support structure, or installed inside of an electrical cabinet, for example, without utilizing an enclosure  112 ,  114  according to the invention. 
   As illustrated in  FIG. 5 , it is further contemplated, that in practicing the invention, circuit cards, according to the invention, may include electrical and/or electronic circuit components  158 ,  160 , in addition to external circuit connectors, such as the terminal strips  138  and connectors  139  utilized in the exemplary embodiments described herein. For clarity of illustration in the drawings, the electronic and/or electronic circuit components  158 ,  160  are only shown in the enlarged view of  FIG. 5 . It is understood, however, that in many embodiments of the invention, including the two exemplary embodiments  100 ,  200  described herein, the slidable circuit cards  106 ,  108 ,  208 ,  210 , for example, may include electrical and/or electronic circuit components in the manner illustrated in  FIG. 5  specifically with regard to the circuit card  106  of the first exemplary embodiment  100  described herein. 
   The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
   Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.