Alternately shaped backplane for receiving electrical components

Provided herein are systems and apparatus for reducing vibration interaction between hard drives. In one implementation, an apparatus is provided comprising a backplane that comprises a substrate comprising an at least partially flexible material and a connector island assembly formed in the substrate. The connector island assembly comprises a spring element and a connector island. The spring element extends from a main portion of the substrate, and the connector island extends from the spring element. The connector island assembly is surrounded by the main portion of the substrate and configured to flex independently of the main portion of the substrate.

FIELD OF THE INVENTION

Aspects of the disclosure are related to a backplane for receiving electrical components.

BACKGROUND

As computer systems and networks grow in numbers and capability, there is a need for more and more storage system capacity. Cloud computing and large-scale data processing further increase the need for digital data storage systems that are capable of transferring and holding immense amounts of data.

One approach to providing sufficient data storage is the use of arrays of independent hard disk drives. A number of hard disk drives can be held in a container or enclosure. The hard disk drives are held and operated in close proximity within the container, so that many hard disk drives can be fit into a defined volume. Rackmount enclosures can be used to hold very large amounts of data.

Hard disk drives include spinning disks that are typically rotated at high speeds, such as a speed of 7,200 RPM, for example. A read head is moved inward or outward from the center of the spinning disks in order to read and write data on the disk. These moving components can generate vibrations in the hard disk drive. Hard disk drives include traditional hard disk drives and hybrid drives (combination of traditional rotating storage and solid-state storage).

When a number of hard disk drives are included within a container, the vibrations generated by one hard disk drive can be transferred to other hard disk drives within the container. Additionally, vibrations external to the container may also be transferred to the hard disk drives. The transferred vibrations can interfere with operations of the affected hard disk drive or hard disk drives. The transferred vibrations can cause decreased performance or possible damage to components of the hard disk drive.

Overview

An apparatus comprising a backplane configured to receive electrical components is provided. In one example, an apparatus comprising a backplane configured to receive electrical components, the backplane comprising a substrate comprising an at least partially flexible material and a connector island assembly formed in the substrate. The connector island assembly comprises a spring element having a spring element width and a spring element length orthogonal to and longer than the spring element width and comprises a connector island having a connector island width and a connector island length longer than the connector island width. The spring element extends from a main portion of the substrate at a first end of the spring element along a first direction toward a second end of the spring element, and the first direction is parallel to a spring element central axis extending along the spring element length. The connector island extends from the second end of the spring element at a first end of the connector island along a second direction parallel to the connector island length toward a second end of the connector island, and the second direction is orthogonal to the first direction and parallel to a connector island central axis extending along the connector island length. The connector island assembly is surrounded by the main portion of the substrate and configured to flex independently of the main portion of the substrate.

In another example, a system is included for isolating electrical component vibrations, the system comprising a substrate comprising an at least partially flexible material; a plurality of spring elements formed in the substrate and connected to a main portion of the substrate, wherein the main portion of the substrate extends along a substrate plane; a plurality of connector islands formed in the substrate, wherein each connector island is connected to the main portion of the substrate via a single, respective spring element of the plurality of spring elements; a chassis member positioned adjacently to a first side of the substrate; and a travel limiter assembly comprising a plurality of connector elements extending from a travel limiter frame. Each connector element of the plurality of connector elements is coupled to the chassis member and extends from the chassis member through a respective void in the substrate from the first side of the substrate to the travel limiter frame positioned adjacently to a second side of the substrate. The travel limiter frame is separated from the second side of the substrate by a travel gap. The travel limiter frame is configured to contact a respective connector island of the plurality of connector islands in response to at least a portion of the respective connector island coming into contact with the travel limiter frame due to flexure of the respective spring element connected to the respective connector island.

In another example, a method of manufacturing a backplane assembly is included, the method comprising forming a connector island assembly in a backplane, which comprises: forming a spring element in a substrate of the backplane and forming a connector island in the substrate. The spring element is separated from a main portion of the substrate and comprises: a spring element width; a spring element length orthogonal to and exceeding the spring element width and extending parallel to a spring element central axis; a first end of the spring element connected to the main portion of the substrate; and a second end of the spring element opposite the first end of the spring element along the spring element length. The connector island is separated from the main portion of the substrate and connected to the main portion of the substrate via the spring element. The connector island comprises: a connector island width; a connector island length orthogonal to and exceeding the connector island width and extending parallel to a connector island central axis orthogonal to the spring element central axis; a first end of the connector island connected to the second end of the spring element; and a second end of the connector island opposite the first end of the connector island along the connector island length. The connector island assembly is surrounded by the main portion of the substrate and configured to flex independently of the main portion of the substrate.

DETAILED DESCRIPTION

The following description and associated drawings teach the best mode of the invention. For the purpose of teaching inventive principles, some conventional aspects of the best mode may be simplified or omitted. The following claims specify the scope of the invention. Some aspects of the best mode may not fall within the scope of the invention as specified by the claims. Thus, those skilled in the art will appreciate variations from the best mode that fall within the scope of the invention. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific examples described below, but only by claims and their equivalents.

FIG. 1shows an isometric view of a portion of an exemplary vibration reduction system100.FIG. 2illustrates an exploded view of a portion of the vibration reduction system100. Referring to bothFIGS. 1 and 2, the vibration reduction system100comprises a backplane102for receiving and coupling to a plurality of electrical components, including a plurality of identical electrical components in some examples. The backplane102in some examples is configured to receive multiple rows and columns of electrical components. In one example, the plurality of electrical components comprises a plurality of hard disk drives (HDDs) that couple to an assembled and completed backplane102. However, other or additional electrical components are contemplated and are within the scope of the description and claims.

The backplane102comprises a substrate104. The substrate104is at least partially flexible, wherein the backplane102can be flexed or deformed. The substrate104has a thickness106and can be formed of any suitable material, including plastics, ceramics, or other material wherein the substrate104is at least partially flexible. The substrate104in some examples comprises an electrical insulator or dielectric material. The backplane102in some examples can comprise a single-sided, double-sided, or multi-layer Printed Circuit Board (PCB).

Backplane102includes a plurality of connector island assemblies108formed in the substrate104. Each connector island assembly108includes a connector island110connected to a spring element112. Spring element112is connected to a main portion114of substrate104and to the connector island110, while the connector island110is connected only to the spring element112. The connector island assembly108is formed out of the substrate104and is configured to be at least partially flexible, which allows the connector island110to be displaced up and down or, due to in-plane motion, fore/aft and side-to-side with respect to the substrate104. In one embodiment, the spring element112flexes more than the connector island110when the connector island110is displaced with respect to the substrate104. The spring element112allows a majority of the vibrations originating from either the main portion114or from the connector island110to be dissipated based on movement or motion of the connector island110. Accordingly, the spring element112enables the connector island110to vibrate while reducing the transmission of connector island vibrations to the substrate104. Conversely, the spring element112allows the substrate104to vibrate while reducing the transmission of vibrations from the substrate104to the connector island110. Therefore, the spring element112allows the connector island110to be at least partially vibrationally isolated from the substrate104.

Each connector island110includes a connector116configured to electrically couple with a corresponding mating component. In embodiments of the invention, connector116is a HDD connector configured to electrically couple the backplane102with a HDD600installed thereon (seeFIG. 6). Connector116can be somewhat inflexible. Thus, when installed on a respective connector island110, the connector116can reduce the ability of the connector island110itself to flex. However, there may still be some flexibility of connector island110even with a connector116attached thereto. With the connector116attached, the majority of the displacement of the connector island110is typically provided through flexure of the spring element112.

A plurality of electrical traces118extend across spring element112to electrically couple connector island110with main portion114of substrate104and beyond as necessary. On the connector island110, the plurality of electrical traces118can terminate at a plurality of connector pads120configured to be electrically coupled with corresponding pins or other conductors122of connector116.

Vibration reduction system100includes a chassis member124such as a stiffener attached to a chassis126of a multi-component container. When installed in the multi-component container, backplane102is positioned adjacently to chassis member124. However, backplane102may not be in direct contact with chassis member124. Instead, chassis member124may be separated from one side of the backplane102by an interstitial gap (seeFIG. 4). Within the gap, a connector island vibration isolator128is positioned to limit travel of the connector island assemblies108toward the chassis member124. Connector island vibration isolator128includes a connector island pad130aligned with a respective connector island110and a substrate pad132aligned with a section of the main portion114of the substrate104. The substrate pad132is typically aligned with a main portion section between adjacent connector island assemblies108. In one embodiment, each connector island vibration isolator128is a single piece of material including a connector island pad130for each connector island110in a group of adjacent connector islands110such as the seven neighboring connector islands110shown with connectors116as illustrated inFIG. 1. Connector island vibration isolator128is formed, in one embodiment, of a viscoelastic material with low compressibility and minimizes transference of vibrations from the chassis member124to the respective connector island110. In another embodiment, vibration isolator128may be formed from a transfer adhesive positioned between the connector islands110and the chassis member124. The height of the isolator128may be optimized to allow a large shear stress to be developed in the isolator128to increase modal damping and to limit downward travel of the connector island assemblies108.

Vibration reduction system100includes a travel limiter assembly134to limit upward travel of the connector island assemblies108. Travel limiter assembly134includes a travel limiter frame136from which a plurality of travel limiter connector elements138extend. The travel limiter frame136is positioned adjacently to the other side of the backplane102opposite the chassis member124, and the travel limiter connector element138extend from the travel limiter frame136through voids140in the substrate104to attach to chassis member124. Void140are sufficiently large enough to allow travel limiter connector elements138to pass through without contacting either main portion114of substrate104or any of the connector island assemblies108when they are not flexed. That is, when the connector islands110are not displaced due to flexure of any part of the connector island assemblies108, the travel limiter connector elements138do not contact the connector islands110. In one embodiment, to keep the travel limiter assembly134in place in response to deformation contact by at least one of the connector islands110, multiple travel limiter connector elements138of the travel limiter assembly134contain barbs or hooks142at an end thereof. The hook142counters an upward force exerted on the travel limiter assembly134because of displacement or flexure of the connector island assembly108. In another embodiment, a plurality of standoffs with related fastening hardware may be fastened to and extend from the chassis member124or other fixed body to the travel limiter frame136through voids140to keep the travel limiter assembly134in place.

FIG. 3illustrates a top plan view of the backplane ofFIG. 1according to an implementation. A plurality of connector island assemblies108are shown and discussed in more detail with respect toFIG. 3.

In the implementation shown, twenty-eight connector island assemblies108are shown in groups of seven arranged in two columns and two rows. It is understood that other arrangements of connector island assembly108placements are also contemplated herein such as a different number of columns and/or rows and also in groups of more or less than seven.FIG. 3illustrates four distinct types of connector island assemblies108, referred to hereinbelow as connector island assemblies144-150. Each connector island assembly144-150includes a corresponding connector island110and spring element112connecting the connector island110to main portion114of substrate104. Main portion114is illustrated as a cross-hatch in only two portions of substrate104inFIG. 3to simplify the drawing, but it is understood that main portion114equally applies to similar areas in the remaining portions of substrate104.

Referring to connector island assembly144, spring element112has a spring element width152and a spring element length154. Spring element112extends from main portion114of the substrate104at a first end156of the spring element112along a first direction parallel to a spring element central axis158extending along the spring element length154toward a second end160of the spring element112. Connector island110has a connector island width162and a connector island length164. Connector island110extends from the second end160of the spring element112at a first end166of the connector island110along a second direction parallel to a connector island central axis168extending along the connector island length164toward a second end170of the connector island110. First and second directions are orthogonal in one embodiment. The connector island length164is longer than the spring element length154, and the connector island width162is longer than the spring element width152.

Connector island assembly144is separated from substrate104via one or more cutouts172in the substrate104. In the case of connector island assembly144, a single or continuous cutout in substrate104defines its connector island110and spring element112.

Voids140in the substrate104and connector island110allow the travel limiter connector elements138to pass through from one side of the backplane102to the opposite side. In addition, one or more connector holes174may be formed in connector island110to allow connector116to be coupled thereto. Connector pads120are illustrated between connector holes174for an embodiment of connector116requiring such a configuration. However, other configurations corresponding with the connector layout of the component designed to be coupled with connector island assembly144are also contemplated herein.

As illustrated in the lower illustration of connector island assembly144, electrical traces118are integrally formed in the substrate104and electrically connect the main portion114of the substrate104to the electrical connector pads120along at least a portion of the spring element112and along at least a portion of the connector island110.

Aspects of the connector island assemblies146-150are similar to the description of connector island assembly144above. However, a few distinctions are now described. With respect to connector island assembly146, a difference between that described with respect to connector island assembly144and connector island assembly146includes placement of the voids140, connector holes174, and connector pads120on an opposite side of the connector island110compared with that of the connector island110of connector island assembly144. That is, as illustrated, the voids140, connector holes174, and connector pads120of connector island assembly146are positioned on a side of the connector island110closer to the first end156of the spring element112. Accordingly, the placement position of these elements may be considered to be closer to an “inside” edge176of the connector island110than to an “outside” edge178. In addition, the connector island length164of connector island assembly146is shorter than the connector island length164of connector island assembly144in the embodiment shown, while the connector island length164of connector island assembly146still remains longer than the spring element length154of connector island assembly146as with the connector island assembly144. In another embodiment, the connector island length164of connector island assembly146may be the same as or longer than the connector island length164of connector island assembly144.

With respect to connector island assembly148, connector island assembly148is formed near an edge180of the substrate104, with the edge180forming the outside edge178of connector island assembly148after cutting connector island assembly148out. Furthermore, connector island assembly148is formed outside of a connector island assembly144, requiring the connector island length164of connector island assembly148to be longer than the connector island length164of connector island assembly144in order to align the connector pads120with the other connector pads120in the grid row. Similar to connector island assembly144, placement of the voids140, connector holes174, and connector pads120is on the outside edge178.

With respect to connector island assembly150, connector island assembly150is also formed near an edge182of substrate104. However, unlike connector island assembly148, edge182extends beyond the outside edge178of connector island assembly150in the embodiment shown. Similar to connector island assembly146, placement of the voids140, connector holes174, and connector pads120is on the inside edge176.

While connector island assembly148is shown to form an edge of backplane102and connector island assembly150is shown to be formed away from the edge182of backplane102, embodiments of the invention contemplate edge180of backplane102extending beyond the outside edge178of connector island assembly148while the outside edge178of connector island assembly150may be formed out of the edge182of backplane102.

As illustrated in the left portion ofFIG. 3, main portion114of substrate104completely surrounds connector island assemblies144,146and150. However, since connector island assembly148is formed at an edge of the main portion114of substrate104, main portion114only borders a portion of its connector island110and spring element112. Formation of connector island assemblies144-150as described herein allow each to be flexibly independent of the main portion114of substrate104and of each other.

FIGS. 4 and 5show side plan and isometric views of a portion of the vibration reduction system100ofFIG. 1. As illustrated, travel limiter assembly134is installed with travel limiter connector elements138extending through backplane102to couple with chassis member124. Travel limiter frame136is thus positioned adjacently to one side of the substrate102while the chassis member124is positioned adjacently on the other side. Travel limiter frame136is separated from the side of the substrate104by a travel gap184. In an unflexed and/or an undisplaced state, connector island110is designed to be separated from the travel limiter frame136by the travel gap184. However, as connector island110is displaced or flexed in an upward direction, the gap between at least a portion of the connector island110(e.g., a left-most end of connector island110as illustrated inFIG. 4), and the travel limiter frame136is reduced. The connector island110may be sufficiently displaced or flexed so as to traverse the travel gap184to come into at least partial contact with travel limiter frame136. Travel limiter frame136, however, remains coupled with chassis member124in response to such contact and in response to additional forces that would, without restraint from travel limiter frame136, cause connector island110to deflect farther. Thus, travel limiter frame136limits the upward travel or displacement of connector island110to the distance of travel gap184. Thus, the travel limiter frame136is configured to contact a member of the connector island assembly108only in response to at least a portion of the connector island assembly108coming into contact with the travel limiter frame136due to flexure or displacement of either or both of the spring element112and the connector island110of the connector island assembly108.

An interstitial gap186between chassis member124and backplane102provides a space to position connector island vibration isolator128to limit downward displacement of connector island110as described above. Cutout172separates second end170of connector island110by a cutout gap188sufficient to allow adequate displacement/flexure of connector island110to reduce transmission of vibrations as discussed herein. Voids140allow placement of travel limiter connector element138therethrough sufficient to provide a gap190so that upward displacement/flexure of connector island110does not cause connector island110to contact the travel limiter connector elements138. In addition, gap190may also be of sufficient size to prevent contact between the connector island110and the travel limiter connector elements138due to in-plane motion of the connector island110(i.e., fore/aft or side-to-side motion) and to allow vibration isolator128to dissipate motion of the connector island110via in-plane shear.

FIG. 6illustrates the vibration reduction system100including a HDD600installed thereon. To simplify the figure, only a single HDD600is illustrated. However, it is understood that in a complete system, a respective HDD600would be installed in each position defined by the placement of the connectors116.

FIGS. 7A-7Lillustrate alternative connector island assembly embodiments according to an implementation. Each connector island assembly includes a respective connector island110connected to a spring element112. In some embodiments, the connector islands110are similarly sized; however, the spring elements112of each of the embodiments illustrated inFIGS. 7A-7Lare unique. Embodiments of the backplane102described above may employ one or more of the connector island assemblies in addition to or instead of the connector island assembly108discussed inFIGS. 1-6.