Abstract:
A rubber foot assembly and embossed mounting assembly for supporting a structure is provided that comprise: an aperture formed along a lower wall of the structure and a rubber foot engaged in the aperture, wherein the rubber foot has a flexible contoured bottom portion connected to a top portion through a neck portion. The neck region is adapted to freely slide vertically along a wall of the aperture such that a peripheral region of the flexible contoured bottom portion contacts a portion of the embossed mounting assembly, thereby supporting the structure. A plurality of the rubber foot assemblies and embossed mounting assemblies can be incorporated into the structure, which can be a set-top box, to prevent the structure from rocking on uneven surfaces.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit, under 35 U.S.C. §365 of International Application PCT/US2011/039410, filed Jun. 7, 2011, which was published in accordance with PCT Article 21(2) on Dec. 15, 2011 in English and which claims the benefit of U.S. provisional patent application No. 61/397,253, filed Jun. 9, 2010. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a set-top box having an improved foot design. 
     BACKGROUND OF THE INVENTION 
     Set-top boxes continue to be in high demand and an ever increasing need exists to reduce the size and improve aesthetic appeal and stability. 
     In particular, a stability problem that occurs is rocking of set-top boxes or the like when the devices are placed on surfaces that may be warped or not flat. In fact, in many consumer environments, set-top boxes are moved frequently for various reasons which can include general cleaning, rearrangement of entertainment centers, maintenance, etc. Such frequent moves increase the chance of stability variability, because different surfaces and different locations on a surface can have different contours. 
     Even though the sizes of set-top boxes and the like have been decreasing, these devices still require four feet for proper load handling and balancing. This requirement for four feet creates the opportunity for rocking, because the contact points of three feet will define a plane and a fourth foot may have a contact point out of tolerance and/or may have a contact point not in the same plane as the other three. 
     An additional stability problem for a set-top box is damage due to mechanical shocks and vibrations over the device&#39;s lifetime. Because the feet of devices are the principal mechanical contact points with the surrounding environment, the characteristics of the feet are paramount in dictating how shock and vibration are transferred to the set-top box. 
     In light of the above-mentioned stability problems, a need exists for an improved foot design that allows enhanced shock and vibration damping and eliminates the opportunity for device rocking. 
     SUMMARY OF THE INVENTION 
     A rubber foot assembly and embossed mounting assembly for supporting a structure is provided that comprises: an aperture formed along a lower wall of the structure and a rubber foot engaged in the aperture, wherein the rubber foot has a contoured bottom portion connected to a top portion through a neck portion. The top portion can be conically shaped and can have a narrow end directed inward and a wide end having shoulder regions directed outward. The top portion can be inserted in the aperture such that the shoulder regions extend past an interior edge of the aperture, thereby locking the rubber foot into the structure. The contoured bottom portion can have a bottom surface for contacting an external support surface and a top surface directed toward the lower wall and connected to the neck region, wherein the top surface has a central region and a peripheral region in which the peripheral region extends from the central region and curves towards the lower wall such that part of the peripheral region contacts an exterior part of the structure. 
     An electronic device such as a set-top box, computer, server, or the like is also provided that comprises at least one rubber foot and emboss assembly. The device can include a housing having a lower wall; at least one aperture formed along the lower wall; and at least one rubber foot engaged in the at least one aperture, wherein the at least one rubber foot has a contoured bottom portion connected to a top portion through a neck portion and wherein the wide end of the top portion can have a smaller width than a width of the contoured bottom portion. The top portion can be conically shaped and have a narrow end directed inward and a wide end having shoulder regions directed outward. The top portion can be inserted in the aperture such that the shoulder regions extend past an interior edge of the at least one aperture, thereby locking the at least one rubber foot into the housing. The contoured bottom portion, which can be flexible, can further have a bottom surface for contacting an external support surface and a top surface directed toward the lower wall and connected to the neck region, wherein the top surface has a central region and a peripheral region and the peripheral region extends from the central region and curves towards the lower wall such that part of the peripheral region contacts an exterior part of the housing. The at least one rubber foot can have an elongated opening that extends from the neck region and into the top portion, whereby the elongated opening permits the shoulder regions to flex inwardly and pass through the at least one aperture. The contoured bottom portion, the top portion, and the neck portion can each of have a central vertical axis and the central vertical axes that are collinear. The device can further include at least one contoured aperture assembly that extends outwardly from the lower wall to a round peripheral bottom; and a recess within the round peripheral bottom that extends inwardly toward the lower wall to a flat horizontal ledge that surrounds the aperture, wherein the horizontal edge can be lower than the lower wall. The contoured bottom portion can be positioned in the recess such that the peripheral region contacts the horizontal ledge, wherein the horizontal ledge is the above-mentioned exterior part of the housing. In the device, the neck region can be cylindrically shaped and have a vertical height that is greater than a height of a wall that surrounds the aperture, wherein the neck region can be adapted to freely slide vertically along the wall of the aperture while the rubber feet are locked in the lower wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example with reference to the accompanying figures of which: 
         FIG. 1  shows a series of views of the major components of the set-top box according to the invention; 
         FIG. 2  shows two views of an existing rubber foot design; 
         FIG. 3  shows two views of the existing rubber foot design engaged in the set-top box; 
         FIG. 4  shows two views of an enhanced rubber foot design; and 
         FIG. 5  shows two views of the enhanced rubber foot design engaged in the set-top box. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     The set-top box or the like having the novel stabilizing feet according to the invention can include the various components which are shown in  FIG. 1 . These components can be a top broad heat sink  10 , a main printed circuit board  13 , a frame pan  18 , and an outer cover  28 . 
     More particularly,  FIG. 1A  shows a top broad heat sink  10 , which is an internal component. The top broad heat sink  10  can be a generally contoured plate that has a generally planar periphery  12  and a contoured central feature such as a pocket, central depression, notch, recess, multilevel depression, mesa extending from and/or into a plane of the planar periphery. The central feature or central depression  11  can have side walls extending from the planar periphery and form an obtuse angle therewith. The contoured feature can have a flat bottom designed to contact the main integrated circuit and/or other heat generating component  17 . 
       FIG. 1B  shows a main printed circuit board  13  or the like, which can be generally flat. The main printed circuit board  13  can have a main integrated circuit  17  or the like in a central region and holes  16  for mounting and/or securing the main printed circuit board  13  to a frame pan  18 . Other features of the main printed circuit board are shown in the figure which can include jack panel connectors  15  at one edge and a button cluster  14  at another edge, which can be an opposing edge. The main integrated circuit and other heat generating or hot components  17  can contact the flat bottom or other portion of the central depression  11  of the top broad heat sink  10 , which can be in thermal contact with the other heat generating or hot components through a thermal joint which could be a pad. 
       FIG. 1C  shows a frame pan  18  which can have a rectangular shape and four sides and which can house the main printed circuit board (pc board)  13 . The frame pan  18  has a back wall  21  with jack panel apertures  19  to accommodate jack panel connectors  15  or the like and a base wall or base  22  having embosses  20  for the mounting or securing of the pc board  13  through the holes  16  therein. Additionally, the frame pan can have on the back wall  21  at least one opening  25  therethrough which can be through a portion of the back wall that extends beyond the side walls  23  of the frame pan  18 . Additionally, the side walls  23  can have slots therethrough closer to the end of the side walls that are adjacent to the back wall  21 . The slots  23  are used to lock the frame pan  18  in the outer cover  28 . 
       FIGS. 1D and 1E  show a housing or an outer cover  28  of the set-top box in an upright position and a rotated upside down position, respectively. The orifices  29  are shown in the front side  30  which can be decorative. The orifices  29  are designed and aligned to accommodate the button cluster  14 . The outer cover  28  further includes an upper wall  31 , lower wall  32 , two outer sides  34 , and an open back  35 . The exterior side of the lower wall  32  can include rubber feet  110  which can be at least 6 mm in height to ensure adequate air entry under the set-top box for improved thermal management. The assembled internal components of  FIGS. 1A-1C  are inserted into the outer cover  28  via the open back  35 . 
       FIGS. 2A and 2B  show two views an existing rubber foot design which has been considered and to which improvements were believed to be necessary.  FIG. 2A  shows a perspective view of the complete existing rubber foot  90  and  FIG. 2B  shows a perspective view of existing rubber foot  90  cut in half. The existing rubber foot  90  has a bottom portion  91  connected to a top portion  93  through a neck portion  95 . The bottom portion  91  is generally cylindrically shaped disk and has a bottom  92  that contacts a surface to which the set-top box will sit. The top portion  93  is conically shaped and has shoulder regions  94  at the wide end of the top portion. It should be understood that the expression “conically shaped” is intended to include a wedge shape or part of cone or a cone segment. Generally, there can be two shoulder regions  94 . The neck portion  95  is cylindrically shaped and has a smaller diameter than both the wide end of the top portion  93  and the diameter of the bottom portion  91 . The neck portion  95  extends from or is connected to a top surface  96  of the bottom portion  91  and extends to or is connected with the top portion  93  such that the shoulder regions  94  extends away from the neck portion  95 . The bottom portion  91 , top portion  93 , and neck portion  95  each have a central axis  98  that are all aligned with each other. Shown in  FIG. 2B  is an elongated opening  97  in the existing rubber foot  90  in which the elongated opening  97  is vertically oriented and extends from the top surface  96  of the bottom portion  91  through the neck portion  95  and passed the shoulder regions  94  toward the narrow end of the top portion  93 . 
       FIGS. 3A and 3B  show upside down views of the existing rubber foot  90  inserted in the lower wall  32  of the outer cover  28 .  FIG. 3A  shows a cross section view and  FIG. 3B  shows a perspective sectional view. The purpose of the elongated opening  97  is to permit both sides the neck portion  95  and the shoulder regions  94  to flex inward to permit top portion  93  of the existing rubber foot  90  to be squeezed into an aperture  101  in a contoured aperture assembly  100  on lower wall  32  of the outer cover  28 . The contoured aperture assembly  100  can extend out of the lower wall  32  or protrude therefrom and have a round peripheral bottom  102  in which the round peripheral bottom is round from a plan view perspective of the low wall  32 . A recess  103  can be contoured inward from the round peripheral bottom and can have a flat ledge  104  that surrounds the aperture  101  in which the flat edge  104  is parallel to the lower wall  32 . As can be seen in  FIGS. 3A and 3B , the top portion  93  is fully inserted into the aperture  101  such that the shoulder regions  94  snap past interior edges of the aperture  101  and are in contact with the interior edges  105  of the aperture  101  which is parallel with the flat ledge  104 . Concurrently, the top surface  96  of the bottom portion  91  maintains contact with the flat ledge  104 , whereby the existing rubber foot  90  is secured in the set-top box and ready for use. 
       FIGS. 4A and 4B  show two views of an enhanced rubber foot  110  is shown.  FIG. 4A  shows a perspective view of the complete enhanced rubber foot  110  and  FIG. 4B  shows a perspective view of enhanced rubber foot  110  cut in half. The enhanced rubber foot  110  has a contoured bottom portion  111  connected to a top portion  93  through a neck portion  95 . The contoured bottom portion  111  can be flexible, can generally be a concave shaped disk and can have a contoured bottom  112  that contacts a surface to which the set-top box will sit. The top portion  93  is conically shaped and has shoulder regions  94  at the wide end of the top portion. The neck portion  95  is cylindrically shaped and has a smaller diameter than both the wide end of the top portion  93  and the diameter of the contoured bottom portion  111 . The neck portion  95  extends from or is connected to a contoured top surface  116  of the contoured bottom portion  111  and extends to or is connected with the top portion  93  such that the shoulder regions  94  extend away from the neck portion  95 . The concavity of the contoured bottom  112  and the contoured top surface  116  is such that the peripheral regions of the contoured bottom  112  and the contoured top surface  116  curve inwardly toward the top portion  93 . The contoured bottom  112  and contoured top surface  116  can generally be parallel to each other in the sense that they have corresponding surface points that are equidistant to one another in a plan view perspective which can be in a relaxed state. The contoured bottom portion  111 , top portion  93 , and neck portion  95  each have a central axis  98  that are all aligned with each other. Shown in  FIG. 4B  is an elongated opening  97  in the enhanced rubber foot  110  in which the elongated opening  97  is vertically oriented and extends from the contoured top surface  116  of the bottom portion  111  or some position thereabove through the neck portion  95  and past the shoulder regions  94  toward the narrow end of the top portion  93 . 
       FIGS. 5A and 5B  show upside down views of the enhanced rubber foot  110  inserted in the lower wall  32  of the outer cover  28 .  FIG. 5A  shows a cross section view and  FIG. 5B  shows a perspective sectional view. The purpose of the elongated opening  97  is the same as that mentioned above with regards to the existing rubber foot. The elongated opening  97  permits both sides the neck portion  95  and the shoulder regions  94  to flex inward to permit top portion  93  of the enhanced rubber foot  110  to be squeezed into an aperture  101  in a contoured aperture assembly  100  on lower wall  32  of the outer cover  28 . It should be understood that that the elongated opening  97  can go horizontally completely through the rubber foot and the elongated opening  97  can be a U-spaced slot or can be an enclosed hole surrounded by 4 or more sides. The contoured aperture assembly  100  can extend out of the lower wall  32  or protrude therefrom and have a round peripheral bottom  102 . A recess  103  can be contoured inward from the round peripheral bottom and can have a flat ledge  104  that surrounds the aperture  101 . As can be seen in  FIGS. 5A and 5B , the top portion  93  is fully inserted into the aperture  101  such that the shoulder regions  94  snap past interior edges  105  of the aperture  101  and can be in contact with the interior edges of the aperture  101  which is parallel with the flat ledge  104 . Concurrently, the contoured top surface  116  of the contoured bottom portion  111  maintains contact with the flat ledge  104 , whereby the existing rubber foot  90  is secured in the set-top box and ready for use. In this embodiment, the peripheral region  117  of the contoured top surface  116  contacts the flat ledge  104  such that peripheral region  117  of the contoured top surface  116  is applying a inwardly directed force on the flat ledge  104  toward the top portion  93 , thereby causing a central region of the bottom portion  111  to supply an outwardly directed force. In the enhanced rubber foot design the neck region  95  has a vertical height that is substantially greater than a height of the vertical aperture wall  106  that surrounds the aperture  101 , which differs from the existing design in which the neck region  95  has a vertical height that is nearly the same as the height of the vertical aperture wall  106  so the top portion  93  and the bottom portion  91  both contact top and bottom surfaces near the vertical aperture wall  106 . In the enhanced system, the vertical height relationship advantageously permits of the neck region  95  slide along the vertical aperture wall  106  even after the top portion is snapped in place, thereby allowing the contoured bottom portion  111  to flex or move to final and appropriate position. 
     In a preferred embodiment there will be 4 enhanced rubber feet  110  in which the load distribution is such that each enhanced rubber foot  110  automatically compresses to levels that cause the set-top box to be balanced, even when the surface upon which the set-top box is placed is not level. Here, the contoured bottom  112  of the contoured bottom portion  111  can have a flat central portion and a curved peripheral portion in which the curved peripheral portion can fit into the recess  103  of the set-top box and is curved toward the set-top box. The curved peripheral portion contacts the set-top box and flexes outward as downward force is applied from the set-top box toward the bottom portion. In the system where 4 or more of the improved rubber feet are used, each of the respective curved peripheral portions are flexed such that the bottom portions move from their resting state toward the set-top box such that the feet are all stable; as such, the set-top does not rock and is supported evenly by all feet, which assist in damping vibrations. The top portion  94  fits into the set-top box through the aperture  101  in the set-top box and the shoulders regions  94  of the top portion  93  can contact an interior part of the set-top box when no downward force is applied and the feet are in their resting state. In use, depending on the external surface that the set-top box will sit, the enhanced rubber feet  110  may be have contoured bottom portions  111  flexed to different extends in which one or more feet may have shoulder regions  94  contacting the interior edges  105  while other feet have shoulder regions  94  not making contact. 
     It should be understood that although examples of the claimed inventions specifically mention set-top boxes and circuit boards, the invention is not limited to these features. For example, the invention is applicable to computers and other electronic devices having other components.