Abstract:
A modular patch panel module is mountable on an electronics enclosure and includes an angled patch face and mounting structure that enables stacking of modular patch panels without interference of patch panel cords with the top of the enclosure or another patch panel stacked thereon. The patch panel modules may each contain a plurality of RJ-45 ports and punchdown blocks. A cover plate may snap fit to the module to retain the patch panel electrical components therebetween.

Description:
FIELD OF INVENTION 
     The embodiments relate to a modular stackable patch panel mountable to an electronics enclosure or wall and, more particularly, to a patch panel having an angled patch cable mounting plane and mounting structure that enables stacking of the panels without interference with the top of the enclosure or another patch panel stacked thereon. 
     BACKGROUND 
     Buildings, in particular office, condominium or apartment buildings, which use various telecommunications systems, computer networks, or building operations systems, such as fire monitoring or surveillance systems, often rely on intricate patchworks of cables to interconnect the components within these systems and networks. Appropriate interconnection of cables locally within the building, for example an Ethernet, telephone, or building operational system are often centralized at one or more hubs, which allow installation, modification or removal of cable connections within these systems. 
     In many applications, such cabling is mounted on one or more patch panels on a building wall, rack or electrical enclosure, such as a wall mount cabinet, as a multi-dwelling unit/multi-tenant unit (MDU/MTU) solution to route high speed internet and other data voice communications lines to the various units through the hub. Such enclosures have various dimensions, but are often one or more standardized sizes, such as a 14″, 19″, or 23″ wide enclosure of a given depth. Typically, various patch panels are mounted directly or indirectly, such as through a standoff, to a back wall of the enclosure in a single layer. 
     Although connections within such an enclosure are expandable by addition of extra patch panels to the back wall or enclosure, there has been a practical limit for expansion due to the fixed surface area of the back wall. Thus, when the surface area becomes filled, future expansion is not possible without the addition of extra cabinet enclosures. 
     Typical commercial mini patch panels for such applications have taken the form of flat units that mount directly or indirectly to the back wall of the cabinet enclosure. 
     SUMMARY 
     The exemplary embodiments relate generally to an improved patch panel module that allows for additional modular flexibility. More particularly, the patch panel modules may be stackable with other like patch panel modules to improve space efficiency and accommodate additional future growth. Additionally, in exemplary embodiments, the patch panel module has a patch cable mounting plane oriented at an angle relative to a module mounting plane so as to improve clearance for patch panel cabling. By having the cable mounting plane angled, patch panel cabling will not interfere with a stacked module. The angle also helps to satisfy patch cord bend radius requirements to allow sufficient bend radius for the cabling without interference with stacked modules. In one embodiment, the angle of the cable mounting plane is about 35°. 
     To simplify assembly and improve connection quality, vertical compliant pin ports such as RJ-45 ports, may be used, which do not require soldering but instead may be pressed into a printed circuit board for compliant connection. Alternatively, soldered RJ-45 ports may be used. 
     In accordance with additional embodiments, the patch panel module may be a mini patch panel module. 
     In yet further embodiments, the patch panel module may include two opposed C-shaped side walls, each defined by an upstanding wall and two perpendicular mounting walls. Each mounting wall extends along the mounting plane and includes mounting holes for receiving mounting fasteners. 
     In certain embodiments, the patch panel module may have a cover plate that retains electrical components of the patch panel securely fastened. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Certain embodiments of the invention are illustrated by the accompanying figures. It should be understood that the figures are not necessarily to scale and that details that are not necessary for an understanding of the invention or that render other details difficult to perceive may be omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. 
         FIG. 1  is a front perspective view of an exemplary  6  port patch panel module according to an embodiment of the disclosure; 
         FIG. 2  is a perspective view of patch panel electrical components used to form the module; 
         FIG. 3  is an exploded view of the patch panel module of  FIG. 1  showing the base module, electrical components, and patch panel cover; 
         FIG. 4  is a front perspective view of the base module of the patch panel module of  FIG. 1  showing toe and latch features for simple snap action connection of the cover; 
         FIG. 5A  is a top perspective view of the patch panel cover of  FIG. 1 ; 
         FIG. 5B  is a bottom perspective view of the patch panel cover of  FIG. 1 ; 
         FIG. 6  is a rear perspective view of the patch panel module of  FIG. 1 ; 
         FIG. 7  is a front perspective view of two patch panel modules being stackably attached in accordance with an embodiment; 
         FIG. 8  is a front perspective view of the two stacked patch panel modules of  FIG. 7  fitted with a plurality of patch panel cables; and 
         FIG. 9  is an internal side view of the stacked patch panel modules of  FIG. 8  mounted within an electronic telecommunications cabinet enclosure. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     The embodiments relate to a patch panel module particularly suited for use in a wall-mounted telecommunications enclosure, but may be used outside of an enclosure. The patch panel module may be stackable with other like patch panel modules to improve space efficiency and accommodate additional future growth. 
     Referring to  FIGS. 1-6 , a patch panel module  100 , such as the exemplary multiple port patch panel shown, includes a base formed of two C-shaped side walls  110 ,  120  and an angled base support panel  130  provided therebetween. Side wall  110  includes a main upstanding wall  112  and laterally extending mounting walls  114  and  116 , each mounting wall having a series of mounting holes  118  for receiving fasteners  180  to mount the patch panel along a module mounting plane MMP. Similarly, side wall  120  includes a main upstanding wall  122  and laterally extending mounting walls  124  and  126 , each mounting wall having a series of mounting holes  128  for receiving fasteners  180 . The base may be formed from a lightweight plastic material, to reduce weight and cost, but also could be formed of metal. In an exemplary embodiment, side walls  110  and  120  and base support panel  130  are integrally molded as one piece from plastic. While the side walls  110  and  120  are illustrated as C-shaped, other profiles such as I-, L-, or T-shaped side walls may be employed. 
     The base may take various dimensions depending on the application and number of ports required. For example, the base has a length L of about 5″ and a width W of about 2″ as measured from the centerline of fasteners  180  and a height of about 1.375″. 
     The base support panel  130  provides a mounting structure  132  (shown in  FIG. 2 ) that mounts an electrical component assembly (discussed below) to form a cable mounting plane CMP ( FIG. 7 ) oriented at an angle relative to the module mounting plane MMP so as to improve clearance for patch panel cabling. By having the front face angled, patch panel cabling will not interfere with a stacked module. The angle also helps to satisfy patch cord bend radius requirements. In certain embodiments, the angle is in a range between 15° and 60°. In other embodiments, angles outside this range could also be employed. In the embodiment of  FIG. 7 , the angle is about 35°. It is also possible to combine an angled front face with angled connectors to achieve a desired plug insertion angle. For example, the front face could be angled at 15° and a 45° angled jack could be used to give a total plug insertion angle of 60° if desired. 
     As better shown in  FIG. 2 , a patch panel electrical component assembly can include a series of patch panel ports  140  for receiving patch cords that are electrically or optically coupled to a circuit board, such as, for example, a series of RJ-45 ports, and punchdown blocks  150  mounted on printed circuit board  160 . In an embodiment, compliant components, such as press-fit components, may be used on the printed circuit board  160  to avoid the need for a secondary soldering process. As shown, pins  142  of each port  140  may be pressed into corresponding apertures  164  of printed circuit board  160  while pins  152  of each punchdown block  150  may be pressed into corresponding apertures  162  of printed circuit board  160  for compliant connection. Eliminating the soldering process reduces costs and improves quality by eliminating problems that can arise with poorly soldered circuit boards. Suitable ports, such as, for example, RJ-45 ports, are available from Panduit Corporation (P/N: PCM15E1PS-E). Suitable punchdown blocks are also available from Panduit Corporation (P/N: RP110PCB4CR), although the exemplary embodiments are not limited to these. 
     Although the exemplary embodiments are discussed with reference to compliant pins, or press fit pins, any attachment device now known or later developed that avoids the use of a secondary soldering process such as, for example, a vertical latch type pin, is also envisioned in connection with the exemplary embodiments. Embodiments of the present invention may also be used with soldered connectors. 
     As shown in the exploded view of  FIG. 3 , the assembled electrical components  140 ,  150 ,  160  are mounted on an electrical component assembly mounting structure of base support panel  130  and held in place by suitable attachment, such as through a cover  170  fitted through a toe hold and latching system described below. To reduce the weight of the module, base support panel  130  may be formed of gridwork  132  or other support structure serving as the mounting structure. 
     The latching system will be described in more detail with reference to  FIGS. 4 ,  5 A and  5 B. The toe holds and latching system between base  130  and cover  170  may be designed in a manner that obscures the latches from plain sight. In an exemplary embodiment, base  130  has a plurality of spaced apart toes  136  provided along one edge, such as a bottom edge  135  of base  130  as shown, and a plurality of spaced apart cantilever latches  134  provided along an opposite edge, such as a top edge  137  of base  130  as shown. In an embodiment, two snaps  134  and four toes  136  are provided. However, the embodiments are not limited to these and may deviate depending on the size and shape of the patch panel. 
     As shown in  FIGS. 5A and 5B , cover  170  has complementary toe holds  172  and latch ledges  174  on a back side  173  of cover  170  and apertures  176  and  178  on a front side  175  of cover  170 . Toe holds  172  and latch ledges  174  keep the component base  130  and cover  170  firmly held together with the circuit board assembly  140 ,  150 ,  160  in between. Toe holds  172  retain the bottom of the cover on the base support member  130  by mating with toes  136  while latch ledges  174  are mated with cantilever snaps  134  to lock cover  170  to base support member  130 . To assemble the patch panel, printed circuit board  160  with attached ports  140  and punchdown blocks  150  is placed inside the cover  170  so that the ports  140  and punchdown blocks  150  protrude through the corresponding apertures  176  and  178 . Then, cover  170  is placed onto the base support panel  130  so that the toe holds  172  of cover  170  hook under toes  136  of base  130 . Finally, cover  170  is rotated downward until snaps  134  mate with latch ledges  174  to secure the cover to the base. The end result is an assembly shown in  FIGS. 1 and 6  with a clean outer appearance where the latching system is hidden from view. While a latching system is shown and described, other methods of joining the cover and base, such as screws or welds, may be employed in other embodiments. 
     As shown in  FIGS. 7-9 , patch panel modules  100  are able to be stacked on top of each other to accommodate future growth. This is particularly useful when the back wall of the enclosure has become populated and space is very limited. It is also very space efficient. Thus, if more patching ports are needed after an initial installation, another patch panel can be easily mounted atop an existing panel. 
     As discussed earlier, the patch panel module  100  contains electrical components ( 140 - 160 ) oriented to define a cable mounting plane CMP at an angle (α) relative to the module mounting plane MMP, such as between about 15° and 60°, for example, about 35° as illustrated, so that patch cords  200  plugged into a lower module  100  can clear a top module or a front cover of an enclosure without interference (as shown in  FIGS. 8-9 ). That is, rather than having a horizontally arranged cable mounting plane and near-vertical extending patch cords, the angled orientation reduces the necessary height for the assembly and cords, both when used alone and when stacked as a pair or set, and also helps satisfy patch cord bend radius requirements for Cat 5e, Cat 6 or 10 gig cables, for example, even when the modules are stacked. For example, it is often desirable to maintain a cable bend radius of 4× the cable diameter or greater. This is achieved by orienting the cable mounting plane CMP at an angle α, which may be an acute angle, relative to the mounting plane and, when the patch panel modules are stacked, further achieved by an angular relationship and orientation that avoids interference with the stacked module or enclosure wall above the lowermost module. These features will be described in more detail below. 
     As shown in  FIGS. 7-9 , the fasteners can attach the module to a wall, such as the rear wall  300 A of enclosure  300  shown in  FIG. 9 , or to another module  100  as shown in  FIGS. 8 and 9  when the modules are stacked. While a two-layer stack is illustrated, the embodiments are not limited to this. However, when the depth of the enclosure is limited, such as when a front cover wall  300 B is provided as shown, there will be a finite limit to stackability due to space constraints. For example, in the example illustrated in  FIG. 9 , an existing enclosure typically used to house a single row of patch panel modules mounted to the rear wall  300 A has a depth of 3.687″. Conventional modules used in such an enclosure had a patch panel cable mounting plane parallel to the back wall. Because of bend radius requirements, which limit the minimum bend radius that typical telecommunications cabling mounted parallel to this plane could be bent, such enclosures could only accommodate a single row of modules. However, by the inventive patch panel modules&#39; ability to be stacked, and due to the selection of cable mounting plane CMP angle (relative to the module mounting plane) and module height, two modules  100  may be stacked while still meeting necessary bend radius requirements for patch cabling  200  as shown. In this particular embodiment, the patch panel module side walls have a height of about 1.375″ and a front face  102  defining the cable mounting plane CMP for receiving patch panel cabling thereon with an angle (α) of about 35°. Thus, it is possible to maximize the capacity for a given enclosure depth by selection of height and angle that allows stacking, avoids interference, and meets bend radius requirements for the patch panel cabling used. 
     Thus, in exemplary embodiments, the patch panel  100  may be used individually with an angled cable mounting plane to meet bend radius requirements and space constraints of a narrow depth enclosure, or may be stacked two or more layers high. 
     It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. For example, while embodiments have been shown and described above for use with electrical connectors, in other embodiments fiber optic connectors may be employed. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, and are also intended to be encompassed by the following claims.