Abstract:
The present invention provides a support mechanism for holding a component in a component rack, a method of manufacture therefor, and a rack of components. The support mechanism, among other elements, may include a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf. The support mechanism may further included a mounting flange coupleable to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots.

Description:
TECHNICAL FIELD OF THE INVENTION  
       [0001]     The present invention is directed, in general, to a support structure and, more specifically, to a support mechanism for holding a component in a component rack, a method of manufacture therefor, and a rack of components.  
       BACKGROUND OF THE INVENTION  
       [0002]     The myriad of cooperating electrical components available today has created a need for apparatus which can securely and effectively store these components in stacked relationship, not only so that the components can be electrically interconnected with one another, but so that they can be readily accessed and used. This is particularly true in power management situations in which a large number of individual components are typically used together in order to create a desired power management system.  
         [0003]     This need has led manufacturers to standardize the width dimension of rack mounting systems that may house these components. Such systems generally consist of some sort of frame structure to which a pair of rack rails are fixedly mounted at an appropriate distance from one another for accepting shelves supporting the components or the components themselves. Each shelf is then mounted to the rack rails by aligning a pair of apertures or slots on each side of its front face with corresponding apertures in the rack rails and by using bolts or other such fasteners to complete the assembly. These rack mounting systems are extant both in the form of rather large open systems permanently installed in establishments, and in the form of relatively small boxes which fully enclose the shelves of components to protect same from damage due to the surroundings.  
         [0004]     Over the course of many years, as well as many design iterations, the industry has attempted to optimize these rack mounting systems, and particularly the mechanism for fixedly mounting the shelf to the rack rails. Original designs had ears, having apertures or slots therein for fastening the shelf to the rack rails, integrally formed directly into the shelf itself. However, the industry soon realized that any serious malfunction of the ears themselves would require discarding the entire shelf.  
         [0005]     The industry then turned to flanges that could be removable mounted to a sidewall of the shelf itself, wherein the flange then had the ear having apertures or slots therein for fastening the shelf to the rack rails. If the flange itself were to malfunction, it could be removed and a new flange could be installed in its place. Accordingly, the shelves were rarely discarded.  
         [0006]     Turning briefly to prior art  FIG. 1 , illustrated is one mounting system  100  designed such that a flange  110  may be removably mounted to a shelf  120  using a screw  130  and nut  140 . As is shown, the screw  130  extends initially through the flange  110 , then through the shelf  120 , wherein it encounters the nut  140 , thereby rigidly, but removably, mounting the flange  110  to the shelf  120 . Unfortunately, this technique for removably mounting the flange  110  to the shelf  120  has certain design defects. One design defect is the inability to easily fix the threads on the nut  140  if they are damaged. Another design defect is the valuable shelf space that it takes up. For instance, this technique reduces the shelf space by a distance X 1 , wherein the distance X 1  consists of the thickness of the flange  110 , thickness of the shelf  120 , thickness of the nut  140 , at least two safety threads of the screw  130  and any desired clearance. Accordingly, to continue using standardized racks and accommodate this reduction in shelf space X 1 , the components themselves would have to be reduced in size.  
         [0007]     Turning now briefly to prior art  FIG. 2 , illustrated is another mounting system  200  designed such that a flange  210  may be removably mounted to a shelf  220  using a screw  230  and nut  240 . As is shown, this time the screw  130  extends initially through the shelf  220 , then through the flange  210 , wherein it encounters the nut  240 , thereby rigidly, but removably, mounting the flange  210  to the shelf  220 . Unfortunately, this technique for removably mounting the flange  210  to the shelf  220  also has certain design defects. The major design defect is again the valuable shelf space that the mounting system  200  takes up. For instance, the use of this technique reduces the shelf space by a distance X 2 , wherein the distance X 2  consists of the desired clearance, the thickness of the shelf  220 , the thick thickness of the flange  210 , the thickness of the nut  240  and at least two safety threads of the screw  230 . Accordingly, to continue using standardized racks and accommodate this reduction in shelf space X 2 , the components themselves would again have to be reduced in size.  
         [0008]     Accordingly, what is needed in the art is a technique for mounting the flange to the shelf without experiencing the drawbacks discussed above.  
       SUMMARY OF THE INVENTION  
       [0009]     To address the above-discussed deficiencies of the prior art, the present invention provides a support mechanism for holding a component in a component rack, a method of manufacture therefor, and a rack of components. The support mechanism, among other elements, may include a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf. The support mechanism may further included a mounting flange coupleable to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots. Another aspect of the invention is a method for manufacturing the support mechanism.  
         [0010]     In addition to the support mechanism and method of manufacture therefor, the present invention provides the rack of components. The rack of components, without being limited to such, may include 1) a component rack, 2) a plurality of support mechanisms coupled to the component rack at vertically spaced positions, each support mechanism comprising a shelf configured to hold a component, the shelf having a sidewall with at least two slots therein extending from the sidewall and the shelf, and a mounting flange coupled to the shelf, the mounting flange having at least two tabs configured to engage the at least two slots and an ear extending substantially perpendicular to a surface that the at least two tabs are located on, and wherein the ear fastens the flange and shelf to a vertical position along the component rack, and 3) one or more components located in the support mechanisms.  
         [0011]     The foregoing has outlined preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The invention is best understood from the following detailed description when read with the accompanying FIGUREs. It is emphasized that in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:  
         [0013]     Prior Art  FIG. 1  illustrates one mounting system designed such that a flange may be removably mounted to a shelf using a screw and nut;  
         [0014]      FIG. 2  illustrates another mounting system designed such that a flange may be removably mounted to a shelf using a screw and nut;  
         [0015]      FIG. 3  illustrates a plan view of a support mechanism for holding a component in a component rack, manufactured in accordance with the principles of the present invention;  
         [0016]      FIG. 4  illustrates a plan view of the support mechanism illustrated in  FIG. 3  as the mounting flange is coupled to the sidewall of the shelf;  
         [0017]      FIG. 5  illustrates a sectional view of the support mechanism illustrated in  FIG. 4  taken through the line  5 - 5 ; and  
         [0018]      FIG. 6  illustrates a plan view of a rack of components manufactured and assembled in accordance with the principles of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0019]     Referring initially to  FIG. 3 , illustrated is a plan view of a support mechanism  300  for holding a component in a component rack, manufactured in accordance with the principles of the present invention. The support mechanism  300  illustrated in  FIG. 3  includes a shelf  310  configured to hold a component. The shelf  310  may be configured to hold any known or hereafter discovered components, including mechanical, electrical and other types of components. In one particular embodiment of the present invention, however, the shelf  310  is configured to hold rectifiers for use in a power management system. The present invention should, nevertheless, not be limited to such components.  
         [0020]     The shelf  310  illustrated in the embodiment of  FIG. 3  includes a sidewall  320 . While the sidewall  320  is illustrated as projecting upward from a lower surface of the shelf  310 , other embodiments exist wherein the sidewall  320  projects downward from an upper surface of the shelf  310 . Advantageously included within the sidewall  320  are at least two slots  330 . In the illustrative embodiment of  FIG. 3  the at least two slots  330  extend outwardly from the sidewall  320  and the shelf  310 . Another embodiment of the invention, however, exists wherein the at least two slots  330  extend inwardly from the sidewall  320  and the shelf  310 . Outward and inward, as used herein, refer to away from a centerline of the shelf  310  and toward a centerline of the shelf  310 , respectively. Each of the slots  330  in the embodiment of  FIG. 3  may include an opening  335  through a face thereof for accepting a fastener.  
         [0021]     The embodiment illustrated in  FIG. 3  denotes that the shelf  310  may comprise only five slots  330  extending along an entire length of the sidewall  320 . This embodiment should not be used to limit the present invention to an only five-slot design, and further should not be used to limit the present invention to only those designs wherein the slots  330  extend along the entire length of the sidewall  320 . For example, any number of slots  320 , as long as there are at least two, may be located at any position along the sidewall  320 , either horizontal or vertical. One particularly advantageous embodiment, however, has the slots  330  located proximate a front face of the shelf  310 , at a mid point of the shelf  310 , or a combination thereof.  
         [0022]     As further illustrated in  FIG. 3 , the slots  330  may have predetermined and different spacings between themselves. For instance, wherein a spacing Y 1s  between a first slot and a second may be a first value, a spacing Y 2s  between the second slot and a third slot may be a different value (e.g., Y 1s ≠Y 2s ). This configuration, as will be discussed in more detail below, allows for the fast and accurate positioning of the mounting flange  350  with respect to the shelf  310 .  
         [0023]     Those skilled in the art understand the plurality of different processes that could be used to form the slots  330  and the openings  335  in the faces thereof. Nevertheless, one particularly advantageous embodiment has the slots  330  and openings  335  formed by punching the sidewall  320 . Other processes could nevertheless be used.  
         [0024]     As previously mentioned, the support mechanism  300  further includes a mounting flange  350  coupleable to the shelf  310 . The mounting flange  350 , in accordance with the principles of the present invention, has at least two tabs  360  configured to engage the at least two slots  330  in the sidewall  320  of the shelf  310 . In an exemplary embodiment, the at least two tabs  360  are configured to engage the at least two slots  330  and substantially fix all but one axis of movement with respect to eachother. For example, when engaged, the at least two tabs  360  only allow movement in a direction toward or away from the front face of the shelf  310 . This advantageously allows a substantial portion of any forces generated between the shelf  310  and the mounting flange  350  to be focused on the structures themselves rather than any fastener used to couple the shelf  310  and the mounting flange  350  together.  
         [0025]     In one exemplary embodiment of the present invention, each of the at least two tabs  360  contain a threaded opening  365  therein. The threaded openings  365  are configured to correspond with threads of a fastener  380 . Advantageously, the fastener  380  allows the one axis of movement discussed above to be fixed. Accordingly, when the fasteners  380  engage the threaded openings  365  through the openings  335 , the mounting flange  350  is secured to the shelf  310 .  
         [0026]     The embodiment illustrated in  FIG. 3  denotes that the mounting flange  350  may comprise only three tabs  360 . This embodiment should not be used to limit the present invention to an only three tab  360  design. For example, any number of tabs  360 , as long as there are at least two, may be included within the mounting flange  350 . The two most common embodiments, however, include mounting flanges  350  containing two and three tabs  360 .  
         [0027]     As further illustrated in  FIG. 3 , the tabs  360  may have predetermined and different spacings between themselves. For instance, wherein a spacing Y 1f  between a first tab and a second tab may be a first value, a spacing Y 2f  between the second tab and a third tab may be a different value (e.g., Y 1f ≠Y 2f ). In an exemplary embodiment, the predetermined and different spacings between the tabs  360  correspond to the predetermined and different spacings between the associated slots  330 . For example, the distance Y 1s  may equal Y 1f  and the distance Y 2s  may equal Y 2f . Other embodiments also exist wherein all the distances Y 1s , Y 2s , Y 1f  and Y 2f  are the same.  
         [0028]     The mounting flange  350  illustrated in  FIG. 3  further includes an ear  370  extending substantially perpendicular to the surface that the tabs  360  are located on. The ear  370 , as will be shown in later FIGUREs, is configured to fasten the mounting flange  350 , and thus the shelf  310  when the mounting flange  350  is coupled to the shelf  310  using the slots  330  and tabs  360 , to a vertical position along a component rack. The ear  370 , as shown, includes apertures therein for making such a coupling.  
         [0029]     Those skilled in the art understand the number of different processes that could be used to form the tabs  360  in the mounting flange  350 , including conventionally stamping the tabs  360  into the mounting flange  350 . In this embodiment, the tabs  360  would be flush with opposing faces of the mounting flange  350 . Similarly, those skilled in the art understand the processes that may be used to create the threaded openings  365 , including using a conventional tap and die set. While certain examples for forming both the tabs  360  and threaded openings  365  have been given, those skilled in the art appreciate that other processes could nevertheless be used.  
         [0030]     The embodiment illustrated and discussed with respect to  FIG. 3  contains only a single sidewall  320  and a single associated mounting flange  350 . In most embodiments, however, the shelf  310  would contain two sidewalls  320  on opposing sides thereof, and two mounting flanges  360  would be configured to couple to the two sidewalls  320 . Accordingly, the shelf  310  would be supported at two positions to the component rack.  
         [0031]     Turning now to  FIG. 4 , illustrated is a plan view of the support mechanism  300  illustrated in  FIG. 3  as the mounting flange  350  is coupled to the sidewall  320  of the shelf  310 . As is illustrated in this embodiment, the tabs  360  of the mounting flange  350  are engaging the slots  330  in the shelf  310 . As is further illustrated, the fasteners  380  extend through the slots  330  and into the tabs  360  to secure the one free axis of movement.  
         [0032]     In the illustrative embodiment of  FIG. 4 , the mounting flange  350  is mounted substantially flush with a front surface of the shelf  310 . Other embodiments, however, also exist. For instance, another advantageous embodiment exists wherein the mounting flange  350  is mounted at a mid point of the shelf  310 . In this embodiment, the shelf  310  would extend out past a front plane of the component rack when the shelf  310  is mounted therein. This advantageous embodiment allows for easier access to the components held by the shelf  310 .  
         [0033]     Turning now briefly to  FIG. 5 , illustrated is a sectional view of the support mechanism  300  illustrated in FIG.  4  taken through the line  5 - 5 . As illustrated in  FIG. 5 , the unique design of the present invention only reduces a shelf space of the shelf  310  by a distance X, wherein the distance X consists of the thickness of the sidewall  320 , thickness of the mounting flange  350  and distance that the slot  330  extends from the sidewall  320 . Accordingly, the distance X need not account for the thickness of a nut, nor the safety threads, as the prior art structures did. Accordingly, a considerable amount more shelf space is available. Moreover, the unique design of the present invention does not require the difficult task of installing the nuts to the fastener, as required by the prior art.  
         [0034]     Turning finally to  FIG. 6 , illustrated is a plan view of a rack of components  600  manufactured and assembled in accordance with the principles of the present invention. The rack of components  600  initially includes a component rack  610 . The component rack  610  may comprise a number of different component racks while staying within the scope of the present invention. Nevertheless, in the embodiment of  FIG. 6  the component rack  610  comprises a 19″ wide rack capable of containing many support mechanisms  620 .  
         [0035]     As is illustrated, the support mechanisms  620 , each of which may be similar to the support mechanisms  300  illustrated in  FIGS. 3-5 , are coupled to the component rack  610  at vertically spaced positions. Additionally located within the support mechanisms  620  are one or more conventional components  630 . In an exemplary embodiment, the one or more conventional components  630  are chosen from the group consisting of rectifiers, converters, ringers, distributions, controllers, fans, baffles, trays, or combinations thereof. It goes without saying, however, that the present invention should not be limited to any specific component  630 .  
         [0036]     Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form.