Abstract:
A guide structure and matching printed circuit card carrying cartridge provides hot pluggability functionality even when electronic circuit components need to be disposed in very tight spaces. The guide structure includes front and rear portions linked by slot-defining rungs. Front and rear apertures provide alignment and/or locking functions. The guide structure is easily manufacturable from a single sheet of metal which is stamped and formed to meet all desirable design specifications. A matching self-contained docking cartridge is provided with mating parts for these apertures. EMI shielding and cooling functions are also accommodated.

Description:
BACKGROUND OF THE INVENTION 
     The present invention is generally directed to guides, guide assemblies and/or guide mechanisms for use in conjunction with pluggable cartridges for inserting printed circuit cards into and for removing them from printed circuit boards. More particularly, the present invention is directed to an integral guide structure which provides a guiding, alignment and locking function. Even more particularly the present invention includes a cartridge which mates with the desired guide structure so that cartridges are firmly locked into position to permit a self-contained actuation mechanism within the cartridge to slidably move a printed circuit card within the cartridge so as to forcibly mate a card edge electrical connector to a matching printed circuit board mounted connector. 
     The past twenty-five or so years have seen the development of ever smaller electrical circuit components at the chip level. However, to take fullest advantage of achievements in electrical circuit miniaturization, one must package the resultant printed circuit cards containing these chips in an efficient manner. Clearly, the packaging of printed circuit cards in tight spaces is a direct logical extension of increasing chip level circuit densities. It should also be noted that the tight packaging of integrated circuit chips on printed circuit cards and the correspondingly dense packaging of the printed circuit cards is a design goal that is carried out for more than just the convenience of compactness. Compactness provides shorter distances between circuit components which, in turn, serves the very desirable goal of being able to operate the circuits effectively at higher frequencies, thus increasing the speed of numerous different forms of electrical systems, including but not limited to data processing systems. 
     Moreover, mainly for reasons associated with long-term system operation and reliability, it is likewise very desirable to be able to easily insert and remove these printed circuit cards even when they are disposed in very tight spaces. The insertion and removal operations are also provided as an important part of a “hot-pluggability” function which is very desirable for “on the fly” repairs, replacements, maintenance and upgrades. 
     With increased circuit density there has also been a concomitantly driven increase in the number of power, signal and control lines which require electrical connections to be made between printed circuit cards and printed circuit boards. This means that the electrical connectors that carry these various electrical circuits between the cards and the boards have been required to carry more and more separate individual connections. A significant consequence of the increase in the number of individual electrical connections, all of which require surety of contact, is the corresponding increase in the force needed to insert printed circuit connectors into mating printed circuit board sockets. This aspect provides special design considerations for self-contained cartridges that carry printed circuit cards which are meant to be inserted into printed circuit boards via actuating mechanisms contained within the cartridge itself. 
     The increase in the number of connections also poses other problems in the design of desirably compact packaging systems, particularly those designed for easy cartridge insertion and removal. In particular, the increased number of connections results in the use of connectors with an increased number of pins and socket holes. Since these structures are present in larger and larger numbers, the pin-and-socket connections (or the like) are themselves packed together with smaller and smaller distances between them. This aspect of the packaging problem brings along with it the problem of connecting pin alignment for the purpose of physically connecting oppositely disposed mating pins and socket holes. Alignment failure can severely and permanently damage both the printed circuit card and the printed circuit board into which the card is to be inserted. 
     Also of note is the fact that one of the principle purposes of the present invention is to provide cartridges which are capable of this self-contained insertion actuation function. Even more particularly, the present invention employs cartridges which are designed to have no physical contact with any external structure except the printed circuit board itself. This means that cartridges of the present invention do not require any form of actuation mechanism which relies upon external structures such as an enclosure, cabinet or frame or upon any form of adaptation provided in a surrounding cabinet, frame or enclosure. This also means that there are no frictional elements disposed between the printed circuit board and its surrounding structures. And this is turn implies that the entire printed circuit board may be inserted and removed as an integral, fully populated structure, that is, with a full set of printed circuit cards inserted (within cartridges). However, this desirable feature makes cartridge design more difficult in that there still must be provided some mechanism for resisting insertion forces, however, slight they may sometimes be. 
     Additionally, if the printed circuit board is itself intended to be inserted and removed with its complement of printed circuit cards in place, it should also be substantially rigid particularly in those circumstances in which the horizontal dimensions of the board are large with respect to its vertical height. If the printed circuit board is wide and long but thin, then insertion in particular can result in undesirable bending and flexing of the board which is commonly referred to as “oil canning.” 
     As an additional constraint on packaging design, it should be appreciated that, with increased circuit density, there is also a concomitant increase in power density and heat dissipation. Accordingly, packaging designs should be fully compatible with those aspects of system design associated with cooling functions. Also, to whatever extent possible, packaging designs should be: economical to produce; function smoothly; require little or no maintenance; be producible from inexpensive, readily available materials; and be reliably operable over a large number of insertion and removal operation cycles. 
     Yet one other concern arises in electrical systems as circuit feature size shrinks, operating frequencies increase and packaging densities grow larger, namely, the generation of electromagnetic interference (EMI). Electronic circuit packaging designs should thus also be compatible with structures and configurations that are employed to prevent the leakage of electromagnetic interference. To whatever extent possible, packaging designs should also include structures which actually contribute positively to the containment of electromagnetic interference. 
     Furthermore, it is noted that whatever guide and locking mechanism is employed, it is ultimately placed on the printed circuit board which is intended for printed circuit card insertion (and later removal, as needed or desired). Accordingly, the guide should be compatible with printed circuit board function and, if possible, contribute to its structural rigidity to counteract the above-mentioned oil-canning effect. 
     It is also noted that the present discussion refers to printed circuit boards and printed circuit cards. As contemplated herein, the printed circuit board is the larger component into which at least one printed circuit card is inserted for purposes of electrical connection. The present invention places no specific limits on either the size of a printed circuit board or the size of a printed circuit card. In the most general situation, a circuit board will be populated with a plurality of printed circuit cards. That is, the printed board will have a number of printed circuit cards inserted therein. Accordingly, as used herein, the terms “printed circuit board” and “printed circuit card” are considered to be relative terms. 
     Accordingly, the present inventors are presented with the following sometimes competing packaging problems: connector pin alignment, cartridge alignment, rigid connection to a printed circuit board, circuit board oil canning, dense and close packaging, cooling, electromagnetic interference shielding, hot pluggability, the desire to provide an easy-to-load cartridge for carrying printed circuit cards, mechanisms requiring a mechanical advantage for insertion and removal of printed circuit cards, the removal of fully populated printed circuit boards and the insertion thereof, and means to provide a cooperative EMI shielding arrangement in a system which provides circuit board guide mechanisms which do not require physical contact with a surrounding enclosure or cabinet. 
     SUMMARY OF THE INVENTION 
     In accordance with a preferred embodiment of the present invention, a guide structure which is especially suited for insertion of self-contained pluggable printed circuit board cartridges comprises three major portions: a rear portion, a front portion and slot defining rungs extending between the front and rear portions. The rear portion includes at least one vertical tab with an alignment aperture in the tab. This aperture is meant to receive a corresponding alignment pin on the cartridge to be inserted. The guide structure also includes a forward portion which includes a step. The vertical portion of the step also includes at least one other alignment aperture. One or both of the alignment apertures also provides a locking function. There is also at least one pair of cartridge slot defining rungs extending from the rear portion to the forward portion with the pair of rungs being disposed on opposite sides of a matching pair of the alignment apertures, one of which is disposed in the vertical tab with the other aperture being disposed in the vertical step. 
     In preferred embodiments of the present invention, the guide structure is formed from a single sheet metal stamping. The rear portion preferably includes a channel which act as a stiffening rib both for the guide structure itself and for the printed circuit board on which it is mounted. 
     The present invention also includes a mating printed circuit card carrying pluggable cartridge which is intended for use with the above-described guide structure. A desirable pluggable cartridge intended for such use preferably comprises a rigid frame with a printed circuit card having a pluggable electrical connector being slidably disposed within the frame. A lever mechanism, disposed between the rigid frame and the printed circuit card is provided for slidably moving the printed circuit card relative to the frame. A guide pin is externally affixed to the frame and a locking pin is preferable affixed externally to the frame. Thus, the cartridge is guided into and locked into a mating printed circuit-board-level guide structure so that the lever mechanism may be actuated to cause the pluggable electrical connector on the printed circuit card to mate with a corresponding connector on the printed circuit board. 
     Accordingly, it is an object of the present invention to provide structures and mechanisms for densely package electronic circuit components while at the same time providing easy access and component replacement capabilities, especially for hot pluggability applications. 
     It is a further object of the present to provide a guide for use with cartridges containing pluggable printed circuit cards. 
     It is also an object of the present invention to provide a design for a cartridge guide which is easily and economically fabricatable in the form of a single sheet of stamped metal. 
     It is a still further object of the present invention to provide a board level docking mechanism which provides guide, alignment, locking and holding functions. 
     It is a further object of the present invention to provide a guide mechanism for printed circuit boards which also serves the function of providing an added degree of stiffness to the circuit board on which it is mounted. 
     It is still another object of the present invention to provide a board level cartridge guide mechanism which not only provides a certain level of electromagnetic interference shielding but which also cooperates with the inserted cartridge to meld together card level and board level shielding functions. 
     It is also another object of the present invention to provide a printed circuit card carrying cartridge which not only mates with but which also cooperatively interacts with a desirable board level guide mechanism. 
     It is a further object of the present invention to provide a printed circuit card carrying cartridge which is capable of providing flow through air cooling passages. 
     It is yet another object of the present invention to provide a docking cartridge which is fool proof and which does not require the use of tools. 
     It is a still further object of the present invention to facilitate the packaging of electronic circuit components in tight spaces. 
     It is also another object of the present invention to be able to provide electronic circuit packaging design structures which facilitate easy insertion and removal of printed circuit cards. 
     Lastly, but not limited hereto, it is an object of the present invention to facilitate packaging designs for increasingly dense, fast and powerful electronic systems. 
     The recitation herein of a list of desirable objects which are met by various embodiments of the present invention is not meant to imply or suggest that any or all of these objects are present as essential features, either individually or collectively, in the most general embodiment of the present invention or in any of its more specific embodiments. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which: 
     FIG. 1 is an isometric view illustrating a cartridge of the present invention being inserted into a guide of the present invention which is disposed on a rigid printed circuit board with the guide also operating as a printed circuit board stiffener for increased rigidity; 
     FIG. 2 is an isometric view similar to FIG. 1 but more particularly showing a cartridge in a position in which the cartridge, though not necessarily the printed circuit card, is fully inserted into a mating printed circuit board slot in which it is aligned and locked; 
     FIG. 3 is an isometric view of a guide of the present invention incorporating a plurality of guide slots and, as preferred, from a single sheet of stamped metal; 
     FIG. 4 is a detailed view of a portion of the guide shown in FIG. 3; 
     FIG. 5 is an isometric view showing a detailed view of the portion a FIG. 2 which specifically relates to the function of the guide pin; 
     FIG. 6 is a side elevation view illustrating the locations of the locking and guide pin structures particularly as they relate to their positions relative to the cartridge and the board level guide structure; 
     FIG. 7 is a side elevation view illustrating the interior construction of a cartridge of the present invention so as to particularly show the preferred actuating lever mechanism, the slidable mounting for the printed circuit card and the edge connector; 
     FIG. 8 is an isometric view illustrating the desired shape and arrangement for a snap-in locking pin; 
     FIG. 9A is a top view of an EMI shield spring employable in conjunction with the EMI shield system of the present invention; and 
     FIG. 9B is a side elevation view of the spring shown in FIG.  9 A. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 provides an overall illustration of the various aspects of the present invention. In particular, it is seen that there is provided pluggable cartridge  100  which is shown just prior to its being inserted into guide structure  200 . Cartridge  100  comprises four major components: front wall  103 , back and side walls  101 , bezel  130  and printed circuit card  140  (see FIG.  7 ). Guide structure  200  also serves a dual purpose in that it provides a measure of stiffness to printed circuit board  300 . Printed circuit board  300  also contains connectors  311  which mate with one or more corresponding edge connectors  145  (in FIG. 7) on the printed circuit card contained within cartridge  100 . While FIG. 1 suggests that connectors  311  are female connectors, this aspect is irrelevant to the design and operation of the present invention in its most general form. However, it is the preferred design, since it is relatively easy to fabricate printed circuit cards so as to provide the male connector as part of the card itself. 
     FIG. 2 provides a view of the present invention similar to that shown in FIG. 1 except that cartridge  100  is now shown fully inserted into guide structure  200 . FIG. 2 also shows the inclusion of EMI shield spring  500  which is more thoroughly discussed below in reference to FIGS. 9A and 9B. Although not an essential feature of the present invention, it is completely compatible and cooperative with guide structure  200  and provides for continuous grounding by providing a solid electrical contact between metal front bezel portion  130  of cartridge  100  and guide structure  200 . 
     As shown in FIG. 3, it is seen that overall guide structure  200  possesses a generally ladder-like configuration. Guide structure  200  comprises three main portions: a rear portion, a front portion and rungs  215  extending between the front and rear portion to provide well defined slots for the insertion, the guiding and the locking into place of cartridge  100 . As long as cartridge  100  is configured to have a substantially rectangular cross section, rungs  215  are substantially parallel. This is the preferred structure. However, it is noted that the present inventors appreciate the fact that if the cartridges possessed wedge shaped cross sections, then the present invention would still be applicable, with the only modification being that the rungs were no longer necessarily parallel but rather were conformed to the shape of the cartridge cross section. 
     FIG. 3 also illustrates the fact that preferred embodiments of the guide structure of the present invention include rear portion  212  which is formed as a channel or rib to provide an increased measure of rigidity both to overall guide structure  200 , and also to printed circuit board  300  to which it is affixed so that connectors  311  are disposed between rungs  215 . Guide structure  200  also includes a front portion which includes a step with vertical wall portion  214 . Alignment apertures  220  are disposed within vertical step wall portion  214 . This step also adds to the rigidity of the structure in substantially the same manner as channel  212 . In preferred embodiments of the present invention apertures  220  are provided as square openings to accommodate matching locking pin  120  (see FIG. 6) on cartridge  100 . While the locking function can be provided by either pin  110  (see FIG. 6) or pin  120 , it is preferred that this function be provided at a forward location. The locking function is desirable for alignment purposes between the printed circuit card and board level connectors  311 . Additionally, and more importantly, the locking function assures the user that the cartridge stays fixed as actuating arm  150  is moved so as to force the printed circuit card downward into connector  311 . 
     The rear portion also includes vertical tabs  211  which contain alignment apertures  210  which are shaped to accept matching alignment pin  110  on cartridge  100 . See FIG.  5 . The forward or front portion of guide structure  200  include apertures  220 . In preferred embodiments of the present invention apertures  210  and  220  are disposed along a mid line running between and parallel to rungs  215 . The inclusion of the step in the forward portion also provides rigidity. Additionally, front portion of guide structure  200  also preferably includes two parallel rows of elongate apertures  231  and  232  for receipt of mating portions of shield spring  500  which. as is more particularly described below, includes formed pocket  502  with stamping formed contact prongs  503 . Pocket  502  receives the forward edge of slot  231 . Leading edge  512  of spring shield  500  extends through aperture  232 . 
     FIG. 4 shows essentially the same features as shown in FIG. 3 albeit in an enlarged form. In particular, FIG. 4 provides a more detailed view of the structure of rungs  215 . As cartridge  100  is slid into position between two adjacent rungs  215 , rearward alignment is assured as tapered pin  110  on cartridge  100  enters aperture  210  in tab  211 . Further pressure on bezel  130  urges locking pin (see FIGS. 6 and 8)  120  through aperture  220  to lock cartridge  100  into place. As a last step in insertion, actuating arm  150  on cartridge  100  is urged forward and in doing so the printed circuit card within the cartridge frame is moved downward so that its edge connector is inserted into board connector  311 . This is accomplished without any substantial movement of cartridge  100 . Movement is essentially limited to the actuating mechanism itself and to the printed circuit card. 
     FIG. 5 provides a more detailed view of a docked cartridge with alignment pin  110  extending through aperture  210  in tab  211 . Also particularly visible here are apertures  160  in cartridge  100  which are provided in those circumstances in which cooling is desired, Additionally, air flow cooling apertures  142  are located in the front sides of bezel  130 , which is preferably metal, especially when EMI is a factor (see FIGS. 1,  2  and  5 )Also visible in FIG. 5 is the optional inclusion of base  350  which is provided when even greater levels of stiffening are required over and above that provided by guide structure  200  alone. Base  350  preferably comprises a flat polymeric material which is essentially, and preferably, coextensive with the horizontal dimensions of printed circuit board  300 . 
     In addition to illustrating the presence of apertures  142  for the flow of cooling air, FIG. 6 shows a side view of already inserted cartridge  100 . The side of cartridge bezel  130  which is opposite to the side shown in FIG. 6 also preferably includes an shield spring so that firm electrical contact for EMI shielding purposes is maintained between adjacently inserted cartridges. Additionally of note in FIG. 5 is the presence and location of EMI shield spring  500  which provides firm electrical connection between bezel  130  and guide structure  200 . 
     FIG. 7 illustrate two of the major components of cartridge  100 : printed circuit card  140  (shown in phantom view) and back and side wall portion  101 . FIG. 7 thus also shows the first stage in assembling cartridge  100 . In particular, printed circuit card  140  with edge connector  145  is attached to back and side wall  101  by disposing pin (or pivot point)  153  through a matching aperture in card  140 . This connects card  140  to the actuating mechanism. Printed circuit card  140  is also coupled to cartridge  100  by means of pins, screws or rivets  141   a ,  141   b ,  141   c  and  141   d  which are disposed within corresponding slots  105   a ,  105   b ,  105   c  and  105   d , respectively. These pins and slots provide an interior guide mechanism which helps to assure a more uniform vertical motion for card  140 . Pin or pivot point  153  includes any convenient mechanism for maintaining the pin in place relative to card  140 , such as nuts or friction washers. Assembly of cartridge  100  is completed by adding front wall  103  which is preferably attached via screws through front wall  103  into mating screw holes formed in back and side wall portion  101 . Both front wall  103  and back and side walls  101  preferably comprise an insulative polymeric material. Such wall structures are easily and preferably formed in molding operations. Lastly, bezel  130  is affixed to the front of cartridge  100  also preferably by screws or similar fastening devices. For flexibility, fastening devices employed in conjunction with the cartridge of the present should be removable. 
     FIG. 7 also illustrates a preferred mechanism for imparting vertical motion to printed circuit card  140 . However, any convenient arrangement of pivoted levers may be employed. The only requirement for this mechanism is that it include an externally accessible portion and that it be capable of moving printed circuit card  140  in both downward and upward directions, the latter direction being required for cartridge removal in the event that removal is necessary. If cartridge removal is not a requirement then clearly upward motion is likewise not necessary. As shown, however, the actuation mechanism converts horizontal motion of arm  150  in the directions shown by arrow  170  into vertical motion of printed circuit card  140 , as shown by arrow  180 . 
     Actuating arm  150  includes internal portion  151  which slides within a channel provide for that purpose in plate  157  which is affixed to wall member  101 . Internal arm portion  151  also includes slot  155  which receives fixed pin  158  which is preferably attached to plate  157 . Internal arm portion  151  also includes pivot point  156  which is attached to connecting arm  152  which, for purposes of compactness, is disposed within and moves within recess  102  in back and side wall  101 . The other end of connecting arm  152  is attached to printed circuit card  140  at pivot point  153 , as described above. A preferred return bias mechanism in the form of spring  154  is also provided and is attached to any convenient point on printed circuit card  140  and to any fixed part of cartridge  100  in a manner so as to provide at least some vertical restorative force. Pivot point  153  is a desirably convenient location for this purpose, as is bracket  159  on plate  157 . 
     FIG. 8 provides a more detailed view of a preferred structure for locking pin  120 . In particular, FIG. 8 shows that it preferably comprises two portions,  120   a  and  120   b , which are disposed through aperture  220  in front wall  214  of guide structure  200 . Locking pin  120  is also tapered to permit cartridge removal. Locking pin  120  is preferably formed as part of the molding operation which produces back and side wall  101 . However, any convenient detent providing structure may be employed to effectuate a locking function. Also visible in FIG. 8 are apertures  231  and  232  which are intended to receive EMI shield  500 . 
     FIGS. 9A,  9 B and  3  are also useful for illustrating part of an EMI shielding system employable in conjunction with preferred embodiments of the present invention. In particular, FIGS. 3 and 8 show the inclusion of EMI spring shield mounting apertures  231  and  232  in guide structure  200 . EMI shield spring  500  is shaped to be readily inserted into apertures  231  and  232  in guide  200 . In particular, aperture  231  includes a forward edge which engages a forwardly facing slot or pocket (reference numeral  502  in FIG.  9 B). Accordingly, shield  500  includes an edge which is in firm electrical contact with guide  200 . The other edge of shield  500  includes flexible portion  501  which extends through aperture  232 . The leading edge portion of shield spring  500  includes peak  504  which electrically contacts bezel  130  during cartridge insertion (see FIG.  6 ). 
     FIGS. 9A and 9B provide a detailed description of the structure of EMI shield spring  500 . This spring shield preferably comprises a single sheet of stamped metal which is formed as shown. Preferable materials for this shield spring include beryllium copper (½ hard) with an alternate material being stainless steel (½ hard). FIG. 9A provides a top view of the desired structure, and FIG. 9B provides an end view. There are apertures in spring shield  500  between edges  505  and  507 . Region  509  is a tab region of the structure as is region  501 . Top or peak  504  engages the bottom portion of bezel  130 . Also of note is the presence of pocket or slot  502  which engages an edge of aperture  331  in guide  200 . In particular, it is noted that stamped shield  500  preferably includes prongs  503  which are formed by the stamping operation employed in the manufacture of the shield spring. Prong  503  is also employed to provide improved electrical contact between shield  500  and guide  200 . It is further noted that FIG. 9B is particularly useful in that it identifies a plurality of surfaces or edges that are also visible in FIG.  9 A. Correspondingly numbered parts are shown in these two figures. 
     While the present invention has been presented in terms of the printed circuit card mounted connector being an “edge connector,” there is no essential requirement for this exact placement, although it is certainly to be preferred for reasons of compactness. Likewise, the description above has been described as having a simple slide and pivot arm structure for printed circuit card insertion, with actuation being provided by an exteriorly accessed extension to the slidable arm and a bias spring return mechanism. However, any convenient arrangement of levers and pivot arms may be provided. Moreover, there is no absolute requirement that the connection between the slide actuation mechanism and the printed circuit card be located at or near the top edge of the printed circuit card even though this is the preferred location. Other locations are possible which provide greater mechanical advantage but which would require a greater deal of cooperation with the circuit card designers who are most aware of appropriate non-peripheral card locations for mounting pivoting lever components. In a similar fashion, the present invention has been described as having the locking aperture being disposed in the vertical portion of the guide step and with the guide or alignment pin being shaped to mate with the opening in the vertical tab at the rear of the guide track structure. While this is the preferred arrangement these roles are easily reversed, however, with the alignment pin and the alignment pin aperture being disposed in the forward step portion. Additionally, it is noted that while it is generally preferred that guide structure  200  comprises metal and that it be fabricated by stamping and forming methods, it is also possible to employ molded polymeric materials in the formation of guide structure  200 , especially where electrical conductivity for EMI shielding purposes is not a factor. 
     While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.