Abstract:
The present invention is directed to rack-mounted punchdown panels providing enhanced access for establishing connections. The present invention is also directed to punchdown bases providing increased capacity for wire management.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This Application claims priority to Provisional Application Ser. No. 60/565,292, filed on Apr. 26, 2004, the entirety of which is hereby incorporated by reference. 

   FIELD OF INVENTION 
   The present invention is directed to rack-mounted punchdown panels providing enhanced access for establishing connections. The present invention is also directed to punchdown bases providing increased capacity for wire management. 
   DESCRIPTION OF RELATED ART 
   As the use of telecommunications equipment increases in amount and variety of applications, more efficient communications management systems are needed. In many systems, the junction point for voice, data and other communication hardware can become extremely disorganized unless appropriately configured and connected communications racks are employed. In smaller applications, a single, small board or rack may be sufficient, while in larger applications many adjacent or arrayed full-size telecommunication racks may be necessary. 
   Known designs for telecommunications racks include one or more tall, rectangular metal frames in which various devices and connectivity equipment are attached or otherwise mounted. In one common arrangement, a face of the rack is utilized to accommodate input and output lines while the opposite face is used to connect cables so that various inputs and outputs can be interconnected. In a second common arrangement, a rack system includes several racks adjacently situated, with a rack on one end accommodating input and output lines and a rack on another end connecting cables so that various inputs and outputs can be interconnected. Racks within and between the end racks function to appropriately connect the inputs and outputs in a desired configuration and to provide routing to and from intermediate electrical components. 
   While the cable configurations on these known racks can vary from application to application, such racks typically have cabling running vertically near the vertical sides of the frame, occasionally in a channel or a vertical cable manager. Individual cables run across the rack to various devices or connectivity equipment, such as, for example, a patch panel, splice drawer, connector module or fiber optic enclosure. Such racks often also include cable routing structures running horizontally at the top and/or bottom of the rack to organize and direct cables as they enter or exit the rack system as well as to maintain cables in appropriate arrangement within the rack. Additional ducts or cable management structures may also be used to further route and organize cable on the rack to the extent necessary in particular applications. 
   While telecommunications racks present useful solutions to a number of problems relating to organization and storage in a telecommunications system, other problems and/or concerns remain. One common concern is aesthetics. Due to the significant amount of cabling and electronic and connectivity equipment employed in most telecommunications systems, the node where these various elements meet can be extremely unsightly and, if in plain view, can propagate misperceptions regarding the organization and quality of a particular connection configuration or the system itself. 
   Balanced against this concern regarding appearance are concerns regarding function. In some systems, it is necessary, either on occasion or frequently, to add, remove or alter connections and/or equipment. The manner in which connections are made can drastically affect the ease and efficiency with which these operations can be connected. While many of these concerns can be addressed through innovations in the telecommunications rack, great improvement in appearance and function can be achieved by innovations in the design of individual components, and especially connectivity equipment. 
   Punchdown panels are well known connectivity devices. The panels can be attached to a telecommunications rack with other components to provide an interface between incoming or outgoing cable and other devices and applications. Punchdown panels include mounting holes or other mounting features that allow the panels to be mounted to a telecommunications rack. The panels can be mounted in close proximity, one over another, or can be interposed between other equipment on a telecommunications rack. The panels include wire strips, or insulation displacement connectors, that permit a connection to be made between the panel and an insulated wire. The term “punchdown” relates to the process of pressing an insulated wire down into a wire strip or insulation displacement connector to remove or displace the insulation on the wire and make a connection with the panel. Further connectivity to the panel can be achieved using patch cords or other devices. 
   SUMMARY OF THE INVENTION 
   A punchdown panel permits interface with multiple wires in a relatively small area. Because such interface is possible, a punchdown panel includes design elements to accommodate connection with numerous wires while maintaining aesthetics and functionality. For example, known punchdown panels include multiple access openings allowing wire to pass from the back of the panels to the front of the panels for attachment to insulation displacement connectors. Such access openings are generally situated on punchdown panels between or near the insulation displacement connectors to which wires will be connected. The access openings are usually large enough to allow ingress or egress of multiple wires. The difficulty with such access openings, however, is that they are formed in structural elements of the punchdown panels, and thus the size and location of the openings are limited. As a result, multiple wires will pass through a single access opening in a particular location on the punchdown panel in order to contact multiple insulation displacement connectors in multiple locations. This arrangement can make removing, installing or altering a wiring configuration extremely cumbersome because it may be necessary to remove some or all of the wires passing through a single access opening in order to install or remove a single wire through the opening. While it has been suggested that passing wires over the side of a punchdown panel, rather than using access openings, could be one manner of avoiding this difficulty, such an arrangement is wasteful of space and prohibits the possibility of adding additional punchdown panels or other equipment in close proximity to those panels that have already been installed. 
   In addition to providing for wire access, it is necessary that wires connected to a punchdown panel be well organized. Various structural elements are included in punchdown panels to provide for such organization. For example, many punchdown panels include upright members configured in various locations to corral wire that is attached to the insulation displacement connectors. Also, a space or corridor can be provided between rows of insulation displacement connectors to make wires that are connected to the punchdown panel less obtrusive. In many known configurations, these organization solutions are insufficient. For example, corridors provided between the insulation displacement connectors can be too small to accommodate the number of wires that could feasibly be connected to the insulation displacement connectors surrounding the corridor. 
   The present invention provides punchdown panels and punchdown bases that provide solutions to the difficulties identified above. Namely, punchdown panels are provided that are structured to permit wires to be passed from the back of the panel to the front of the panel at any position over a side of the panel, even when multiple panels are installed in close proximity. This function is possible because the punchdown panels according to this invention are varied in width, such that a mounting section of the panel is wider than a punchdown section of the panel. Thus, when the mounting sections of two punchdown panels according to this invention are mounted in close proximity on a telecommunications rack, an access channel remains between the adjacent punchdown sections of the panels. This arrangement simplifies the task of removing, installing or altering a wiring configuration so that a single wire can be installed or removed, without disturbing other wires attached to the panel. Furthermore, side access to the punchdown panel is achieved, without compromising the ability to mount multiple panels in close proximity on a telecommunications rack. 
   Punchdown bases are provided that include an enlarged space between insulation displacement connectors. The enlarged space is made possible by reducing the profile of structural supports that are generally provided between insulation displacement connectors. As a result of this enlarged space, wires that are connected to the punchdown base are less obtrusive, and a greater number of wires can be organized in this less obtrusive manner. 
   In various exemplary embodiments, the punchdown panels according to this invention include a mounting panel and a punchdown base. The punchdown base includes a plurality of insulation displacement connectors, and the mounting panel includes a mounting section and a punchdown section. Preferably, the mounting section includes mounting holes for attaching the punchdown panel to a telecommunications rack, and the punchdown section contacts the punchdown base and includes one or more access openings. The mounting section is greater in width than the punchdown section, such that when the punchdown panel is mounted in close proximity to another device, an access channel is created between the punchdown section and the adjacent device allowing wires to be passed from the back of the panel to the front of the panel at any position on the side of the panel. 
   In various exemplary embodiments, the punchdown bases according to this invention include a wire receptacle base in contact with at least one insulation displacement base and at least one upright member on each of two sides. The punchdown base includes a wire receptacle area having boundaries formed by the wire receptacle base and the at least one insulation displacement base and the at least one upright member at each of the two sides. Preferably, no structural members are situated in the wire receptacle area. 
   For a better understanding of the invention as well as other aspects and further features thereof, reference is made to the following drawings and descriptions. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a partial front view of exemplary punchdown panels according to this invention; 
       FIG. 2(   a ) is a front view of exemplary punchdown panels according to this invention installed in a telecommunications rack; 
       FIG. 2(   b ) is a top view of an exemplary punchdown panel according to this invention installed in a telecommunications rack; 
       FIG. 3  is a front view of an exemplary punchdown panel according to this invention in which the punchdown bases have been removed; 
       FIG. 4  is a partially exploded perspective view of exemplary punchdown panels according to this invention in which some of the punchdown bases have been removed; 
       FIG. 5  is a side view of an exemplary punchdown base according to this invention; 
       FIG. 6  is a side view of a known punchdown base; and 
       FIG. 7  is a cross-section view of an exemplary punchdown base according to this invention holding multiple cables. 
   

   For a better understanding of the invention as well as other aspects and further features thereof, reference is made to the following drawings and descriptions. 
   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIG. 1  is a partial front view of an exemplary embodiment of the punchdown panels  110  according to this invention. In  FIG. 1 , one-half of each of three punchdown panels  110  are shown. The punchdown panels  110  include a mounting panel  120  and a punchdown base  130 . The mounting panel  120  is a generally rectangular support member including various features allowing for mounting the punchdown panel  110  to a telecommunications rack and for ingress and egress of cables. The mounting panel  120  can be formed from any suitable material. For example, the mounting panel  120  can be stamped and formed from metal sheet material. Exemplary features for mounting the punchdown panel  110  to a telecommunications rack include mounting holes  135 . The punchdown panel  110  can be mounted to a telecommunications rack by passing a screw and nut combination or other fastener through the mounting holes  135  and corresponding holes on the telecommunications rack. The mounting panel  120  also includes central access openings  140  and end access openings  150  permitting ingress and egress of cables. The mounting holes  135  and openings  140 ,  150  can be formed in the mounting panel, by any suitable means. 
   Mounted on the punchdown panel  110  is a punchdown base  130 . The punchdown base  130  can be formed of any suitable material. For example, the punchdown base  130  can be formed from a rigid plastic material that exhibits some compliancy and resilience. The punchdown base includes a plurality of insulation displacement connectors  160  situated along the length of the punchdown base  130 . In the embodiment shown in  FIG. 1 , the insulation displacement connectors  160  are arranged end-to-end in two rows on the punchdown base  130 . Other configurations could also be employed. 
   The punchdown panel  110  includes two sections of different widths. The first section is a mounting section  170  and the second section is a punchdown section  175 . The mounting section  170  is wider (top-to-bottom in  FIG. 1 ) than the punchdown section  175 . As a result, when two or more punchdown panels  110  are mounted in close proximity on a telecommunications rack, the wider mounting sections  170  abut, while an access channel  180  remains between the punchdown sections  175 . The access channel  180  allows access to the insulation displacement connectors  160  by wires passed from the back of the punchdown panel  110  at any point along the length of the punchdown base  130 . 
   The mounting sections  170  can differ in width from the punchdown sections  175  by any suitable amount. Ideally, the difference in width will be selected with respect to the diameter of wires that are to be connected to the punchdown panel  110 , so that such wires can be easily passed from the back of the panel  110  to the front of the panel  110  via the access channel  180 . In the embodiment shown in  FIG. 1 , the mounting sections  170  are 0.370 inches wider than the punchdown sections  175 . This difference in width is distributed on both sides of the punchdown panel  110  so that a 0.185 inch distance exists between the outermost edge of the punchdown section  175  and the outermost edge of the mounting section  170 . Accordingly, when two punchdown panels  110  according to the embodiment shown in  FIG. 1  are mounted in proximity, the access channel  180  created between the respective panels  110  will be at least 0.370 inches in width. 
     FIG. 2(   a ) is a front view of exemplary punchdown panels  110  according to this invention installed on a telecommunications rack  210 .  FIG. 1  shows only a partial view of three exemplary punchdown panels  110 .  FIG. 2(   a ) provides a full front view of three punchdown panels  110 , as installed on a telecommunications rack  210 . The telecommunications rack  210  includes a pair of vertical supports to which the punchdown panels  110  or other telecommunications components can be mounted. The rack  210  is situated on the interior surface of a vertical cable manager  220 . The vertical cable manager  220  includes a second pair of vertical supports on which the telecommunications rack  210  can be mounted. The vertical cable manager  220  can be provided with an interior channel and openings, through which cable can be passed. 
     FIG. 2(   b ) is a top view of an exemplary punchdown panel  110  according to this invention installed in a telecommunications rack.  FIG. 2(   b ) is a top view of the vertical cable manager  220 /telecommunications rack  210 /punchdown panel  110  configuration shown in  FIG. 2(   a ), with the additional detail of cables connected to the punchdown panel  110 . A first group of cables  230  and a second group of cables  240  are passed from an unshown origin through the vertical cable manager  220  to the back of the punchdown panel  110 . The first group of cables  230  is passed through the end access openings  150  to the front of the punchdown panel  110  for connection to insulation displacement connectors  160 . The second group of cables  240  is passed through the access channel  180  to the front of the punchdown panel  110  for connection to insulation displacement connectors  160 .  FIG. 2(   b ) also shows patch cords  250  passing from the vertical cable manager  220  to the front of the punchdown panel  110 . 
     FIG. 3  is a front view of an exemplary mounting panel  120  for the punchdown panels  110  according to this invention without the overlying punchdown base  130 . As discussed with respect to  FIG. 1 , the mounting panel  120  includes mounting holes  135 , which permit the punchdown panel  110  to be mounted to a telecommunications rack  210 . The mounting panel  120  also includes a central access opening  140  and end access openings  150 , which permit ingress and egress of cables from the back and front of the punchdown panel  110 . The mounting panel  120  includes two sections of different widths. The mounting section  170  is wider than the punchdown section  175 . When two or more punchdown panels  110  are mounted on a telecommunications rack  210 , the wider mounting sections  170  abut, while the adjacent, but spaced, narrower punchdown sections  175  create an access channel  180  between adjacent punchdown panels  110 . The access channel  180  allows access to the front of the punchdown panel  110  at any point along the length of the punchdown base  130 . 
     FIG. 4  is a partially exploded perspective view of exemplary punchdown panels  110  according to this invention in which some of the punchdown bases  130  have been removed. In this case,  FIG. 4  demonstrates how the central access openings  140 , end access openings  150 , and access channels  180  permit passage of cables  230 ,  240  from the back side of the punchdown panel  110  to the front side, where the insulation displacement connectors  160  are situated. A first group of cables  230  and a second group of cables  240  are passed from the back of the punchdown panel  110  to the front. The first group of cables  230  is passed through the end access openings  150  to the front of the punchdown panel  110  for connection to insulation displacement connectors  160 . The second group of cables  240  is passed through the access channel  180  to the front of the punchdown panel  110  for connection to insulation displacement connectors  160 . As is evident from the positions of the various cables of the second group  240 , the access channel  180  allows access to the insulation displacement connectors  160  from the back of the punchdown panel  110  at numerous locations along the length of the punchdown panel  110 , in contrast with the limited locations for ingress and egress provided by the center access openings  140  and end access openings  150 . 
     FIG. 5  is a side view of an exemplary punchdown base  330  according to this invention. The punchdown base  330  can be used in concert with the punchdown panels  110  discussed with reference to  FIGS. 1-4 , or with other punchdown panels. The punchdown base  330  includes upright members  332 , insulation displacement bases  334  and wire receptacle areas  336  bounded by the upright members  332 , insulation displacement bases  334  and substantially planar wire receptacle bases  338 . 
   The punchdown base  330  according to this invention provides additional space for wires in the wire receptacle area  336 . The origin of this additional space is best observed by comparing the punchdown base  330  according to this invention with a known punchdown base  30 , shown in  FIG. 6 . The known punchdown base  30 , like the punchdown base  330  according to this invention, includes upright members  32 , insulation displacement bases  34  and wire receptacle areas  36  bounded by the upright members  32 , insulation displacement bases  34  and wire receptacle bases  38 . The known punchdown base  30  differs from the punchdown base  330  according to this invention in that the known punchdown base  30  includes ribs  42 , which provide structural support to the punchdown base  30 . The ribs  42  are provided between the upright members  32  and insulation displacement bases  34 , and above the wire receptacle bases  38 . The presence of the ribs  42  introduces three dimensional features to the wire receptacle bases  38 , such that they are not substantially planar. These three dimensional ribs  42  reduce the volume of the wire receptacle areas  36 , thus limiting the number and size of wires that can be stored in the wire receptacle area  36 . In the punchdown base  330  according to this invention, structural support for the punchdown base  330  is provided below, not above, the wire receptacle bases  338  to retain the substantially planar character of the receptacle bases  338 . 
     FIG. 7  is a cross-section view of an exemplary punchdown base  330  according to this invention holding multiple wires.  FIG. 7  includes the additional detail of insulation displacement connectors  344  situated on the insulation displacement bases  334 . As can be seen in  FIG. 7 , the punchdown base  330  is configured such that multiple wires  346  can be stored in the wire receptacle areas  336  bounded by the upright members  332 , the insulation displacement bases  334  and wire receptacle bases  338 . As discussed above, this additional space is made possible by avoiding the use of structural supports on or above the wire receptacle bases  338  in the wire receptacle areas  336 . 
   While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Therefore, the claims as filed and as they may be amended are intended to embrace all known or later developed alternatives, modifications, variations, improvements and/or substantial equivalents.