Abstract:
A racking device for arranging various electronic components is described. The rack has a frame for receiving one or more modules that can be positioned in the rack. The modules have a rear wall and a pair of side panels and a top and bottom panel extending from the rear wall. One or more of the modules may have a face plate.

Description:
This appln. claims the benefit of 60/270,315 filed on Feb. 21, 2001. 

   FIELD OF THE INVENTION 
   The present invention relates to improvements in devices for arranging and racking various electrical components that are used for a variety of applications. The present invention has particular applicability in racking fiber optic components. 
   BACKGROUND OF THE INVENTION 
   Card cage racks or chassis are well known in industry for supporting a variety of electrical components. For example, many commercial buildings today have very complex communications and other electrical needs. In order to provide these commercial establishments with telephone and other communications service that is necessary today, many buildings have dedicated areas or closets for storing this type of equipment. These storage areas are rapidly becoming filled with a variety of electrical components. As a result, there is a need for a device for accommodating this equipment in an orderly, safe and accessible manner. Traditionally, the industry has used a variety of card cage racks to accommodate various modules that are used. 
   Modern electronic systems often employ a number of electronic circuit modules, typically printed wiring boards (PWBs) or printed circuit (PC) cards populated with electronic components and connectors, mounted in an electronic housing or rack. Typical racks often include a plurality of card slots for receiving circuit modules, with card edge guides to hold the cards in alignment, insertion/removal elements, a card connector, and a backplane for providing circuit interconnections. Circuit backplanes are often multilayer printed wiring boards designed for high speed interconnection of signals between different circuit components mounted on physically separated circuit modules in different slots. In most configurations, the circuit modules include electrical connectors affixed to the rear of the circuit module that are plug-action coupled to mating connectors on the backplane. 
   In some rack configurations, for example those employed in the cable television (CATV) and other telecommunications equipment industries, the circuit modules include discrete drop side signal connectors (electrical and/or optical) affixed to the circuit modules that couple to cables that carry signals to and from the equipment rack. In some of these configurations, the discrete signal connectors are mounted to the rear edge of the circuit modules and extend through openings in and the backplane and the housing rack so as to allow connection of the drop side signal cables. In other configurations, connectors are provided on the front edge of a circuit module to allow for signal insertion and extraction. 
   These card cage racks are typically in the form of a box like container having a base member and a top member that are provided with a plurality of rails for retaining cards or modules that are to be held by the rack. The base member and the top member are joined by a pair of opposing side walls and a rear wall. Positioned within the card cage structure are card rails or guides that extend generally between the front and rear cross members. These card guides have grooves that are opposing between the lower and upper card guide rails, for receiving the edges of the circuit boards. The card guides are also laterally spaced from each other, to provide space between the electrical and electronic components secured to the circuit boards. At the end of the known circuit boards, there is an electrical connection that interconnects with an electrical connection on the rear panel, known as the back plane electrical connector. The front wall area is typically left open to install the cards. Once the cards are installed there may be a front cover that is placed over any remaining empty slots in the rack to protect them. The cover is usually connected to flanges that extend from the side walls of the rack to hold the cover. 
   One of the problems with racks of the prior art is their lack of interchangeability and the absence of modularity. Prior art racks come in different sizes and configurations and as a result, the customer or the supplier was required to keep on hand a number of different sizes and configurations. This requires a significant investment. In addition, the prior art racks because of their complexity were relatively expensive. 
   OBJECTS OF THE INVENTION 
   It is an object of the present invention to provide an improved module for carrying electrical and/or optical components. 
   It is also an object of the invention to provide an improved card rack for electrical components including fiber optic components. 
   It is an object of the present invention to provide a system whereby the expensive prior art racks are eliminated. 
   It is also an object of the present invention to provide a modular approach to arranging electrical components. 
   It is further object of the present invention to provide a module that may be attached to a ceiling, wall or other surface while the same module may be connected to a face plate. 
   It is another object of the invention to provide a rack that can be used in a variety of applications. 
   It is an object of the present invention to provide an enclosed case that may contain a metal that provides electro magnetic shielding. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a unique racking system. The racking system of the present invention eliminates the need for the traditional rack. The rack of the present invention has applicability in a number of applications and in particular in fiber optic applications, to be mounted to consoles, power utility control rooms, in customized installations, in television and radio studios, etc. According to the present invention there is provided one or more and more preferably three or more modules. The modules typically have a rear wall that has a pair of side panels and a top and bottom panel extending from the rear wall to form a module with an open end. There may also be a front panel in some applications generally enclosing the module. One or more modules of the present invention may be joined to a faceplate. Alternatively, the individual modules may be directly secured to a wall, ceiling or other surface as desired The individual modules may be secured to a wall, ceiling or other surface by one or more ears extending from one or more of the front or rear panels, or the top or bottom walls or the side walls. The ears may be integral with the walls or panels or may be a separate member removably connected thereto. 
   In a preferred embodiment, one side panel has a base section and a pair of sidewalls that extend upwardly from the edges of the base section. Each sidewall has a first edge that is connected to an edge of the base section and a second edge that is connected to a first flange. Each of the first flanges is generally parallel to the base section and generally perpendicular to the sidewalls. The first pair of flanges extends outwardly from the sidewall on the side of the sidewall opposite the base plate. One purpose of the first pair of flanges is to permit the module to be attached to a wall, a ceiling or other surface if desired. Also extending from one side edge of each of the sidewalls is a second flange. The second flange on each sidewall extends perpendicularly from a side edge of the sidewall. The second flange on each sidewall is also generally perpendicular to the first flange and the base section. As with the first flange the second flange extends outwardly from the sidewall on the side of the sidewall opposite the base plate. The modules are adapted to be connected to a faceplate by the second set of flanges extending from the sidewalls. 
   There is also a top plate that is adapted to be attached to the front wall and the rear wall to form an enclosed module. In an alternative embodiment, either the front plate or the rear plate or both may be removed from the module as the component contained therein have features gauges or indicator lights that must be accessible to the users or their staff. The faceplate may receive a plurality of modules in a side-to-side or other relationship as desired. 
   On of the advantages of the present invention is that the expensive box like prior art rack is no longer needed. In addition, the modularity of the present invention permits interchangeability of the parts thus reducing the cost of manufacture and the need to stock multiple sizes of the product. Furthermore, traditional racks were limited in their versatility and were not able to be adapted to a variety of applications as is the modules of the present invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a module of the present invention. 
       FIG. 1   a  shows a representative connecting means for forming the members of the module of the present invention  FIG. 2  is an end view of the module of  FIG. 1 . 
       FIG. 3  is a side view of the module of  FIG. 1 . 
       FIG. 4  is a perspective view of an alternative embodiment of a module of the present invention. 
       FIG. 5  is a side view of an alternative arrangement of the module of the present invention. 
       FIG. 6  is a side view of an alternative arrangement of the module of the present invention. 
       FIG. 7  is a side view of an alternative arrangement of the module of the present invention. 
       FIG. 8  is a side view of an alternative arrangement of the module of the present invention. 
       FIG. 9  is an exploded view of a preferred embodiment of the module of the present invention. 
       FIG. 10  is an example of a three U faceplate for use in the present invention. 
       FIG. 11  is a example of a one U face plate for use in the present invention. 
       FIG. 12  is a example of a two U face plate for use in the present invention. 
       FIG. 13  is an example of a preferred fastening means of the present invention that may be used with the modules of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention is directed to a module  100  for holding an electrical component. The module typically has a top member  101  and a base member  102  joined by a pair of side members  103  and  104 . The top member  101  may have top edge  110 , bottom edge  111 , and side edge  112  and  113 . The base member  102  similarly has a corresponding top edge, bottom edge, and side edges. The side members  103  and  104  are similarly arranged with edges  114 ,  115 ,  116  and  117 . 
   The top, base and side members preferably form a generally rectangular configuration. The top base and side members may be a single combined unit or they may be made up of individual top base and side members that have been connected by a suitable means. In another embodiment, the members may be in the form of units of two or more preformed members that are adapted to receive the remaining member(s) to form the module. For example, a top member and a side member may be a single member that forms a generally “L” shaped member. This combined member could be combined with two separate members, a bottom member and another side member or another “L” shaped module. Similarly, there can be a single generally “U” shaped member that may combined in a single unit a top member, a bottom member and a side member joining the top and bottom member. Alternatively, there can be two side members joined by either a top or bottom member. Preferably, all of the members are at generally right angles to each other. 
   One suitable means of connecting the walls is by welding another means is by providing each member  119  with a recessed portion  118  that mates with the respective edge of the adjacent member  120 . The connection may be a friction fit or there may be an adhesive present securing the members of the module together. Those skilled in the art will recognize that there are other means of connecting the members to form the module of the present invention. On one open end  105  of the module there may be a front plate (not shown) and on the other open end  106  of the module there is a rear plate (not shown). One or more of the plates may be opened or have one or more openings to permit electrical connections with the interior of the module. The front plate or the rear plate or both, may be connected to a faceplate. Alternatively, the front or rear plate or both may be removed and the open end may be connected to a face plate by any suitable means. It will be appreciated by those skilled in the art that the front plate and the rear plate may be connected to the remainder of the module by any suitable means. 
   In one embodiment of the present invention, either the top member or the bottom member may have a pair of flanges  130  and  131  that extend outwardly from the side edges  112  and  113  of the top or bottom member. These flanges provide a means for mounting the module on a wall, ceiling or elsewhere as a stand alone unit or in combinations of modules. As seen in  FIG. 4  the flanges  130  and  131  may also extend from the top edge  110  and the bottom edge  111  of the top member or the base member.  FIG. 5  shows another embodiment where the flanges  130  and  131  extend from a side member.  FIG. 6  shows another arrangement of the flanges  130  and  131 .  FIGS. 7 and 8  show an arrangement of flanges that are particularly useful where the module will be in a corner where two walls meet, where the ceiling and a wall meet or where the floor and a wall meet. It will be appreciated by those skilled in the art that the flanges  130  and  131  can be arranged in any number of ways on the modue to fit the needs of the equipment and the location. The flanges may also be provided with one or more orifices  132  to aid in mounting the module to a surface. Although the flanges are shown extending from one end of the module to the other, it will be appreciated by those skilled in the art that the flanges can be one or more tabs that have orifices therein instead. 
   A preferred embodiment of the present invention shown in  FIG. 9 . There is a module  10  having a first or base member  11 , which constitutes one of the sidewalls of the module. The first or base member has a base  12  which may be flat and has a top surface  13  and a bottom surface  14  as well as a pair of side edges  15  and  16 . There is also a front edge  17  and a rear edge  18  that extend from the side edges  15  and  16 . Extending upwardly from side edge  15  is the top member  19  of the module  10 . Extending upwardly from the side edge  16  is the bottom member  20 . The top member  19  and bottom member  20  are preferably generally perpendicular to the base  12  and generally parallel to each other. It will be appreciated by those skilled in the art the other configurations are also possible for the relationship between the top member and bottom member. The top member  19  has a top surface  21  and a bottom surface  22  as well as a first side edge  23  and a second side edge  24 . First side edge  23  is adjacent to side edge  15  of the base  12 . The top member also has a front edge  25  and a rear edge  26 . 
   The bottom member  20  has a top surface  27  and a bottom surface  28  as well as a first side edge  29  and a second side edge  30 . First side edge  29  is adjacent to side edge  16  of the base  12 . The bottom member also has a front edge  31  and a rear edge  32 . Flange  33  extends outwardly from the top surface  21  of the top member and is preferably generally perpendicular to the top surface of the top member and generally parallel to the flat base  12 . Flange  34  extends outwardly from the bottom surface  28  of the bottom member and is similarly is preferably generally perpendicular to the bottom surface of the bottom member and generally parallel to the flat base  12 . Flanges  33  and  34  are usually provided with one or more orifices  33 A and B and  34 A and B for fastening the flanges of the module to a wall or other surface by any suitable means known to those skilled in the art. These means may include nailing, screws, adhesives etc. 
   The module  10 , in addition to the first or base member  11  has a front plate  35  and a rear plate  36 . Front plate  35  has a front surface  37  and a rear surface  38  as well as side edges  39  and  40 . Extending rearwardly from the rear surface  38  of the front plate  35  is a pair of flanges  41  and  42 . Flange  41  extends from side edge  39  while flange  42  extends from side edge  40 . The flanges are preferable generally parallel to each other and generally perpendicular to the rear surface  38  of the front plate  35 . The front plate  35  may be provided with one or more cut out portions to provide access to the component contained within the module. The front plate  35  is joined to the first member by a suitable fastening means that extends through the first member  11  and the flange  41  of the front plate  35 . Although the face plate is shown with the flanges extending from side edge  39  and side edge  40 , it will be appreciated by those skilled in the art that the flanges can alternatively extend from side edges  39 A and  40 A of the front plate if desired and if corresponding modifications are made to the first or base member as well. 
   Rear plate  36  has a front surface  43  and a rear surface  44  as well as side edges  45  and  46 . Extending frontwardly from the rear surface  44  of the plate  36  are a pair of flanges  47  and  48 . Flange  47  extends from side edge  45  while flange  48  extends from side edge  46 . The flanges are generally parallel to each other and generally perpendicular to the rear surface  44  of the rear plate  36 . The rear plate  36  may be provided with one or more cut out portions to provide access to the component contained within the module. The rear plate  36  is joined to the first member by a suitable fastening means that extends through the first member  11  and the flange  47  of the rear plate  36 . Although the face plate is shown with the flanges extending from side edge  45  and side edge  46 , it will be appreciated by those skilled in the art that the flanges can alternatively extend from side edges  45 A and  46 A of the front plate if desired and if corresponding modifications are made to the first or base member as well. 
   Attached to flange  42  in the front plate  35  and flange  48  in the rear plate is a second side member  49 . Second side member  49  is generally a flat plate having top and bottom edges  50  and  51  as well as front and rear edges  52  and  53 . Second side member  49  may be attached to the flanges  42  and  48  by any suitable means such as by a screw or other suitable fastener. The second side member may be provided with supports  54  and  55  that provide additional rigidity to the side member. Support  54  is adjacent to top surface  27  of bottom member  20 . Support  55  is adjacent to bottom surface  22  of top member  19 . The edges  26  and  32  are provided with a pair of attachment members  56  and  57 . The attachment members are each preferably provided with an orifice of other means for fastening a faceplate to the module. The attachment members are generally perpendicular to the base  12  and the bottom and top members  19  and  20 . The attachment members  56  and  57  are also generally parallel to front plate  35  if a front plate is present. 
   The module may be any width desired for the application. Similarly, the depth of the module may also vary as desired. One of the advantages of the module of the present invention is the modularity of the components. For example, where the width of the module must be increased to accommodate a larger component, the first member need not be replaced to in view of the increase in width. Similarly, the size of the second side member need not change in a dimension. Only the front and rear plate dimensions are required to change. As result, fewer types of component pieces are necessary to have in inventory to accommodate changes in the widths of the components. Another significant advantage over the prior art cage is that the electrical components contained within the module of the present invention are protected mechanically, electrically and/or magnetically in a superior fashion compared to the components contained in the traditional rack system. 
   Where there are a plurality of modules in the system, they can be linked or joined together by means of face plate  60 . Face plate  60  is typically adapted to receive a number of modules together. The face plate  60  shown in  FIG. 10  is a three U face plate. The three U face plate  60  of  FIG. 10  may have room for any number of modules in a side to side relation. The face plate of  FIG. 10  will accept up to 14 modules.  FIG. 11  is an example of a one U face plate for use in the present invention. This face plate will accept up to three modules.  FIG. 12  is an example of a two U face plate for use in the present invention. This face plate will accept up to six modules. It will be appreciated that the face plates may be of virtually any size as desired. 
   The face plate  60  is generally rectangular in shape with a top edge  61  a bottom edge  62  and side edges  63  and  64 . The face plate  60  is provided with a plurality of openings  65  to accommodate the openings in the modules for the components. The openings are preferably rectangular in shape, having two long sides  66  and  67  and two short sides  68  and  69 . Above and below the short sides are orifices  70  and  71  for receiving a connecting means for connecting the module to the face plate. 
   The connecting means may be any suitable article. For example, the connecting means may be a screw, or other fastener. A preferred fastening means is shown in  FIG. 13 . The fastener  80  of  FIG. 5  has two members. A pin  81  having a head  84  passes through a ring  85 . The ring  85  has two or more wings  82  and  83  extending from the underside of the ring. When the fastening means is being used to secure two members the head is in a raised position so that the pin and the wings may pass through the orifices of the members to be joined. Once through the orifices, the downward motion of the head causes the wing to expand thus causing the two members to be secured together. If the two members need to be separated raising the pin will cause the wings to retract thus permitting removal to the fastening means.