Patent Publication Number: US-2023164367-A1

Title: Node housing with lid-based mounting of node components for use in a broadband distribution network

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to broadband distribution networks, and more particularly, to a node housing that maintains a target operational temperature within the same based on a lid-mounted arrangement of node components, and preferably, node components such as a radio frequency (RF) amplifier. 
     BACKGROUND INFORMATION 
     Existing broadband distribution networks, such as cable television (CATV) networks, utilize a head/hub that communicates signals to subscribers via one or more feed lines. Each feeder line is associated with one or more service groups that can provide signals, such as CATV signals, to associated subscribers. Generally, subscribers are associated with a particular service group based on their home or business&#39;s geographic location. 
     In the context of a CATV network, each feeder line generally includes a plurality of components/nodes such as splitters, taps, and amplifier nodes that collectively enabled downstream CATV signals to reach subscribers as well as for upstream signals to be sent from subscribers to target destinations, e.g., an Internet endpoint. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features and advantages will be better understood by reading the following detailed description, taken together with the drawings wherein: 
         FIG.  1 A  shows an example existing amplifier node for use in a broadband distribution network. 
         FIG.  1 B  shows an exploded view of the amplifier node of  FIG.  1 A . 
         FIG.  2    shows a perspective view of an example node for use within a broadband distribution network consistent with aspects of the present disclosure. 
         FIG.  3    shows another perspective view of the node of  FIG.  2   , in accordance with aspects of the present disclosure. 
         FIG.  4    shows another perspective view of the node of  FIG.  2   , in accordance with aspects of the present disclosure. 
         FIG.  5    shows another perspective view of the node of  FIG.  2   , in accordance with aspects of the present disclosure. 
         FIG.  6    shows a partially exploded view of the node of  FIG.  2   , in accordance with aspects of the present disclosure. 
         FIG.  7    shows another perspective view of the node of  FIG.  2   , in accordance with aspects of the present disclosure. 
         FIG.  8    shows a cross-sectional view of the node of  FIG.  2    taken along line  8 - 8  of  FIG.  4   , in accordance with aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Nodes such as amplifier nodes are often implemented via a clamshell housing with a base and rotatably coupled cover. The base includes amplifier circuitry and receptacles for coupling with, for instance, coaxial cable(s) and power interconnects for coupling to power lines such as AC mains. Power distribution via a node is generally in series whereby each node along a feed line provides power to the following node in a pass-through manner. 
     Present approaches to such node housing includes coupling the amplifier circuitry as close as possible, i.e., within the base, to the coaxial cable receptacles to avoid signal loss and introduction of noise. This results in power supply circuitry being disposed in the cover portion and electrical coupling with the power interconnect in the base being via a channel/riser. Removal of the amplifier circuitry for maintenance or upgrades, for instance, unfortunately disconnects power to down-stream nodes on a feed line as the amplifier circuitry is a single unit that not only includes the amplifier-specific circuitry but the power interconnect to allow a power signal to be passed through the base to supply power to down-stream nodes. 
     For example,  FIGS.  1 A and  1 B  show one such example node  100  of a CATV network implemented as an amplifier node. The node  100  includes a housing shown collectively at  102  and individually as a first housing portion  102 - 1  and a second housing portion  102 - 2 . The first housing portion  102 - 1  and the second housing portion  102 - 2  can couple together via a hinge  103  and define a cavity therebetween, which may also be referred to as a component cavity. 
     The first housing portion  102 - 1  of the node  100  includes RF connector ports  110  for coupling to a coaxial cable of a feed line as well as power interconnects/receptacles to provide power to loads within the node  100 . The first housing portion  102 - 1  further preferably includes an amplifier  104  disposed therein, which may also be referred to as an RF amplifier. The first housing portion  102 - 1  further provides a recess  111  for receiving a portion  113  of the amplifier  104 . This configuration allows for the portion  113  of the amplifier to be disposed between the sections of the first housing portion  102 - 1  that provides the assemblies to support coaxial pin seizure and power interconnections shown generally at  118 - 1  and  118 - 2 . 
     The portion  113  can provide additional space/footprint within the amplifier  104  to house circuitry for amplification of an RF signal and/or for power pass-through. The first housing portion  102 - 1  can include mounts (not shown) to couple to a building or other suitable structure. The first housing portion  102 - 1  may also be referred to herein as a base. 
     The second housing portion  102 - 2  includes a power supply  106  disposed therein for receiving power, e.g., AC main, and providing power to loads such as the amplifier  104  via a riser  108 . The second housing portion  102 - 2  may also be referred to herein as a cover. Covers tend to have a greater internal volume than the internal volume of an associated base. 
     In operation, power flows through the node  100  via power interconnections shown generally at  118 - 1  and  118 - 2 , with the amplifier  104  providing power passthrough circuitry to supply power to downstream nodes, and to loads within the node  100 . Removal of the amplifier  104  then electrically decouples the power interconnect circuitry, and thus by extension, disrupts/disconnects power distribution to downstream nodes. This can ultimately result in loss of service for one or more service groups serviced by the impacted downstream nodes until the amplifier  104  (or a replacement) is electrically coupled into the node  100 . 
     An aspect of the present disclosure includes a node housing for use in a broadband distribution network that includes coupling/mounting the amplifier to a lid portion (also referred to herein as a cover portion) and providing an interface plate in the base portion that allows for RF and power signals to be provided to the RF amplifier within the lid portion. The base portion preferably includes receptacles, such as the RF connector ports  110 , to couple to a feedline, and preferably a coaxial cable of a feedline to send/receive RF signals (e.g., CATV signals). Preferably, the base portion includes a recess such as the amplifier recess discussed above with regard to  FIGS.  1 A and  1 B . However, the base preferably includes a power supply disposed in the recess defined by the base. The power supply further preferably electrically couples to external power, e.g., AC mains, via an electrical interconnect disposed in the base portion. The interface plate disposed within the base portion further preferably provides power pass-through to downstream nodes that remains electrically connected when the amplifier is decoupled from the lid portion, or the lid portion is decoupled from the base portion. 
     Accordingly, an amplifier node consistent with the present disclosure allows for an amplifier to be decoupled from a node, e.g., for maintenance or upgrade, without disrupting down-stream power distribution. In addition, a node consistent with the present disclosure can achieve increased heat dissipation for circuitry such as the amplifier by disposing the same in the lid rather than the base. The lid can feature a relatively larger overall internal volume that increases thermal isolation between the amplifier and adjacent circuitry such as the power supply. In addition, the lid can feature relatively larger heat sink structures such as fins to further increase thermal communication of heat from the amplifier to the surrounding environment for example. Aspects of the present disclosure has identified that this arrangement allows or increased power consumption by node components such as the amplifier, e.g., up to and beyond 80 watts, while maintaining an internal temperature of the node at or below 85 degrees Celsius through passive cooling (e.g., natural convection), which is to say without the necessity of active cooling. Thus, aspects of the present disclosure enable increased power consumption within a node to achieve production bandwidths of 1.8 Ghz and greater. 
     The term “coupled” as used herein refers to any connection, coupling, link or the like between elements. Such “coupled” elements are not necessarily directly connected to one another and may be separated by intermediate components. 
     A base or base portion means a housing portion that includes at least one RF connector port for coupling to a feedline in a broadband network. On the other hand, a lid or lid portion means a housing portion that does not have RF connector ports. Further, a base consistent with the present disclosure preferably has a first overall internal volume, V 1 , that is less than a second overall internal volume, V 2 , of an associated cover. 
     The term substantially, as generally referred to herein, refers to a degree of precision within acceptable tolerance that accounts for and reflects minor real-world variation due to material composition, material defects, and/or limitations/peculiarities in manufacturing processes. Such variation may therefore be said to achieve largely, but not necessarily wholly, the stated/target characteristic. To provide one non-limiting numerical example to quantify “substantially,” such a modifier is intended to include minor variation that can cause a deviation of up to and including ±5% from a particular target quality/characteristic unless otherwise provided by the present disclosure. 
     Referring to  FIGS.  2 - 8   , an example node  200  is shown consistent with aspects of the present disclosure. The node  100  is preferably implemented as an amplifier node for use broadband distribution network, such as a CATV network that comports with a DOCSIS 3.1 standard or beyond. 
     As shown, the node  200  preferably includes a housing shown collectively at  202  and individually as a first housing portion  202 - 1  and a second housing portion  202 - 2 . The housing  202  is preferably formed from a material such as aluminum. The housing  202  preferably has an ingress protection (IP) rating of at least IP68. 
     The first housing portion  202 - 1  and the second housing portion  202 - 2  are preferably configured to be rotatably coupled together. More preferably, the first housing portion  202 - 1  and the second housing portion  202 - 2  are rotatably coupled by a hinge  203 . The hinge  203  is preferably configured to allow the first housing portion  202 - 1  to rotate relative to the second housing portion  202 - 2  about a rotational axis  209  (See  FIG.  4   ). The first housing portion  202 - 1  and the second housing portion  202 - 2  are preferably configured to couple together and form a node cavity therebetween. The node cavity is preferably configured to have at least one node component therein. The node cavity is preferably collectively defined by a first cavity  205 - 1  provided by the first housing portion  202 - 1  and a second cavity  205 - 2  provided by the second housing portion  202 - 2 , which are discussed in further detail below. 
     The first housing portion  202 - 1  is further preferably configured to be removably coupled to the second housing portion  202 - 2 . More preferably, the first housing portion  202 - 1  is removably coupled to the second housing portion  202 - 2  by way of the hinge  203 . For example, the hinge  203  can be configured to allow for separation of the first housing portion  202 - 1  from the second housing portion  202 - 2 . This advantageously allows for a technician to separate/decouple the first housing portion  202 - 1  and the second housing portion  202 - 2  from each other for purposes of maintenance and upgrades, for example. Moreover, this allows for the technician to decouple the housing portions without disrupting/interrupting power to downstream nodes based on the first housing portion  202 - 1  having an interruptible configuration as disclosed herein. 
     The first housing portion  202 - 1  may also be referred to as a base portion or simply a base. The first housing portion  202 - 1  is preferably defined by a plurality of sidewalls that define the first cavity  205 - 1 . 
     The first housing portion  202 - 1  can include a plurality of mounts (not shown) for fixedly mounting to a wall or other suitable structure. The first housing portion  202 - 1  further preferably includes a planar surface  220  that can be used to, for example, mount the first housing portion  202 - 1  a location such as a vertical wall. The planar surface  220  can be defined at least in part by sidewalls of the first housing portion  202 - 1  that define a recess within the same, further description of which is provided below. The recess is preferably formed with the first housing portion  202 - 1  as a single, monolithic structure. This recess may also be referred to herein as a node component compartment or simply a component compartment. The component compartment is preferably disposed at a midpoint of the first housing portion  202 - 1 . One such example component compartment  224  is shown more clearly in  FIG.  4   . The component compartment  224  is preferably configured to include at least one node component disposed therein, such as a power supply. 
     The first housing portion  202 - 1  further preferably includes at least one RF connector port, and more preferably, a plurality of RF connector ports  210 . The plurality of RF connector ports  210  are preferably configured to couple to a coaxial cable that provides a feedline within a broadband distribution network. Each of the plurality of RF connector ports  210  can be implemented as G-type RF connectors, for example. Each of the plurality of RF connector ports  210  are preferably disposed at distal ends of the first housing portion  202 - 1 . 
     The first housing portion  202 - 1  further preferably includes a first heatsink structure  222 - 1  and a second heatsink structure  222 - 2 . The first heatsink structure  222 - 1  and the second heatsink structure  222 - 2  are preferably implemented as a plurality of fins. The fins of the first heatsink structure  222 - 1  and the second heatsink structure  222 - 2  preferably extend transverse relative to a longitudinal axis  250 - 1  of the first housing portion  202 - 1  (See  FIG.  3   ). 
     The first heatsink structure  222 - 1  and the second heatsink structure  222 - 2  are further preferably formed with the first housing portion  202 - 1  as single, monolithic piece of material. The planar surface  220  of the component compartment  224  is preferably disposed between the first heatsink structure  222 - 1  and the second heatsink structure  222 - 2 . In the example of  FIG.  3   , this results in the first heatsink structure  222 - 1 , the planar surface  220 , and the second heatsink structure  222 - 2  being disposed along the longitudinal axis  250 - 1  of the first housing portion  202 - 1 . 
     The first housing portion  202 - 1  preferably defines a first cavity  205 - 1  having an overall volume V 1 . The overall volume V 1  of the first cavity  205 - 1  can be in a range of 60 to 80 cubic inches. The first cavity  205 - 1  further preferably includes an upper cavity, and a lower cavity that defines the component compartment  224 . 
     The upper cavity has an overall height H 1  preferably measuring 0.81±0.5 inches, an overall length L 1  preferably measuring 14.4±1.0 inches, and an overall width W 1  preferably measuring 5.2±1.0 inches (see  FIG.  6   ). 
     The lower cavity defining the component compartment  224  includes an overall height H 2  preferably measuring 1.7±1.0 inches, an overall length L 2  preferably measuring 5.1±1.0 inches, and an overall width W 2  preferably measuring 5.2±1.0 inches. 
     Preferably, an interface plate  280  is disposed in the upper cavity defined by the first cavity  205 - 1 . The interface plate  280  is preferably formed from a material such as aluminum, although other materials are within the scope of this disclosure such as copper. The interface plate  280  is preferably securely/fixedly coupled to the first housing portion  202 - 1 . 
     The interface plate  280  preferably includes an overall length and width that is equal to or less than the overall length L 1  and overall width W 1  of the upper cavity. The interface plate  280  further preferably includes a height/thickness T 1  measuring 0.25±0.10 inches. 
     The interface plate  280  further preferably defines an opening  282  with a length L 3  and a width W 3 . The opening  282  is preferably in communication with the component compartment  224  when the interface plate  280  is disposed in the first housing portion  102 - 1  to allow for insertion of a node component. The length L 3  of the opening  282  can be greater than, equal to, or less than the overall length L 2  of the lower cavity. Preferably the length L 3  of the opening  282  is equal to the overall length L 2 . The width W 3  of the opening  282  can be greater than, equal to, or less than the overall width W 2  of the lower cavity. Preferably, the width W 3  of the opening  282  is equal to the overall width W 2  of the lower cavity. More preferably, the width W 3  and the length L 3  of the opening  282  is equal to the overall width W 2  and the overall length L 2  of the lower cavity, respectively. 
     The interface plate  280  further preferably defines a plurality of apertures  284 . Each aperture of the plurality of apertures  284  is preferably aligned with an electrical interconnect/electrical post provided by the RF connector assemblies disposed within the first cavity  205 - 1 , such as electrical interconnect  285 . Each of the electrical interconnects of the RF connector assemblies is preferably configured to extend through corresponding apertures of the plurality of apertures  284 , such as shown by electrical interconnect  285  in the example of  FIG.  4   . The electrical interconnects are preferably electrically coupled to the amplifier  204  for sending/receiving RF by way of a riser  299  (See  FIG.  7   ). 
     Optional circuitry/components such as a first component  281 - 1  and/or a second component  281 - 2  can be mounted to the interface plate  280 . The optional circuitry can include, for example, power circuitry for providing an uninterruptable power supply to downstream nodes or other components/circuitry such as amplifiers, line extenders, and taps. In one example, the first component  281 - 1  can be an RF preamp and/or a RF reverse amp, and the second component  281 - 2  can be power circuitry to provide pass-through power to downstream nodes. This configuration may also be referred to herein as an electrical passthrough arrangement, which is preferably configured to maintain power output to downstream nodes when the amplifier  204  is electrically decoupled from the power supply  206 . 
     Preferably, a power supply  206  is disposed within the component compartment  224  (See  FIG.  7   ). Preferably, the power supply  206  can be decoupled/removed from the component compartment  224  via the opening  282  of the interface plate  280 . Accordingly, the power supply  206  can be preferably removed from the opening  282  without the necessity of decoupling/removing the interface plate  280  from the first housing portion  202 - 1 . As shown in  FIG.  7   , the power supply  206  can electrically couple to external power, such as AC mains, via a power receptacle  211  defined by the second housing portion  202 - 2  and riser  299 , for example. Further, the power supply  206  preferably electrically couples to the amplifier  204 , e.g., via riser  299 . Preferably, electrical decoupling of the amplifier  204  from the power supply  206  does not interrupt power to downstream nodes. 
     The interface plate  280  can be configured to thermally isolate components within the first housing portion  202 - 1  from components within the second housing portion  202 - 2 . Alternatively, or in addition to the thermal shielding provided by the interface plate  280 , the interface plate  280  can also provide RF shielding between components of the first housing portion  202 - 1  and the second housing portion  202 - 2 . 
     The second housing portion  202 - 2  may also be referred to as a cover portion or simply a cover. The second housing portion  202 - 2  is preferably defined by a plurality of sidewalls that define the second cavity  205 - 2 , as discussed further below. 
     The second housing portion  202 - 2  can also include a plurality of mounts (not shown) for fixedly mounting to a wall or other suitable structure. The second housing portion  202 - 2  further preferably includes a power receptacle  211 . The power receptacle  211  can be configured to couple to power, e.g., AC mains. 
     The second housing portion  202 - 2  further preferably includes a third heatsink structure  222 - 3  (See  FIG.  2   ). The third heatsink structure  222 - 3  is further preferably configured to extend along a longitudinal axis  250 - 2 , and more preferably from end-to-end of the second housing portion  202 - 2  along the longitudinal axis  250 - 2  (See  FIG.  3   ). The third heatsink structure  222 - 3  is preferably implemented as a plurality of fins. Each of the fins of the third heatsink structure  222 - 3  preferably extend transverse relative to the longitudinal axis  250 - 2  of the second housing portion  202 - 2 . The third heatsink structure  222 - 3  is further preferably formed with the second housing portion  202 - 2  as single, monolithic piece of material. 
     The second housing portion  202 - 2  preferably defines the second cavity  205 - 2 . The second cavity  205 - 2  includes an overall volume V 2 . The overall volume V 2  of the second cavity  205 - 2  is preferably at least 280 cubic inches. The overall volume V 2  of the second cavity  205 - 2  is preferably greater than the overall volume V 1  of the first cavity  205 - 1 . Preferably, the ratio of the overall volume V 2  of the second cavity  205 - 2  relative to the overall volume V 1  of the first cavity  205 - 1  is 2:1.0, 2.5:1.0 or at least 1.5:1.0. 
     The second cavity  205 - 2  has an overall height H 3  (see  FIG.  6   ) that preferably measures 3.2±1.0 inches, an overall length L 4  that preferably measures 14.4±1.0 inches, and an overall width W 4  that preferably measures 5.2±1.0 inches (see  FIG.  6   ). 
     An amplifier  204  is preferably disposed in the second cavity  205 - 2  of the second housing portion  102 - 2 . More preferably, the amplifier  204  is mounted to a bottom surface  261  (see  FIG.  8   ) that defines the second cavity  205 - 2  such that a first gap (e.g., an air gap) is provided between the amplifier  204  and a mating surface  289  (or upper edge) of the second housing portion  102 - 2  that forms an interface between the first housing portion  102 - 1  and the second housing portion  102 - 2  when coupled together. 
     The amplifier  204  is preferably implemented by a printed circuit board (PCB)  259 , such as shown in  FIGS.  6  and  8   . More preferably, the amplifier  204  is implemented via a single circuit board, although this disclosure is not limited in this regard. The PCB  259  is preferably mounted (directly) to the bottom surface  261  of the second cavity  205 - 2 , or alternatively via a mounting structure such as rubber feet. 
     The first gap preferably provides an overall offset distance OD 1  between the PCB  259  and the mating surface  289 , which is to say between the amplifier  204  and the interface between the first housing portion  102 - 1  and the second housing portion  102 - 2 . The overall offset distance OD 1  preferably measures at least 3 inches. 
     The PCB  259  is preferably disposed at an overall offset distance OD 2  from the bottom surface  261 . The overall offset distance OD 2  preferably measures 0.25±0.1 inches. Preferably, the offset distance OD 2  between the PCB  259  and the bottom surface  261  is uniform along an entire length of the PCB  259 . Preferably, the offset distance OD 2  provides a second gap (e.g., an air gap). 
     As shown in the examples of  FIGS.  6  and  8   , the PCB  259  preferably does not include an associated housing/enclosure/chassis, such as the chassis shown above with regard to the amplifier  104  of  FIG.  1 B . This advantageously reduces the overall footprint of the amplifier  204 , and can provide at least one thermal communication path, e.g., thermal communication paths  255  and  257 , for communication of heat from the amplifier  204  to, for instance, the third heatsink structure  222 - 3  for heat dissipation purposes. The at least one thermal communication path is preferably a direct thermal communication path. A direct thermal communication path refers to a path between a first component, e.g., PCB  259 , and a second component, e.g., the bottom surface  261  of the second housing portion  102 - 2 , that does not include an intermediate medium/structure other than air. Preferably, the thermal communication paths  255 ,  257  extend through the third heatsink structure  222 - 3 . Preferably, the thermal communication paths  255 ,  257  extend in a direction that is away from the first housing portion  102 - 1 . 
     More preferably, this configuration provides a plurality of such direct thermal communication paths along an entire length of the PCB  259  to increase thermal communication with the third heatsink structure  222 - 3  by way of bottom surface  261 . For example, the thermal communication paths  255 ,  257  preferably extend in parallel and represent a plurality of such direct thermal communication paths along the entire length of the PCB  259 . 
     In accordance with an aspect of the present disclosure a node for use in a broadband distribution network is disclosed. The node comprising a first housing portion that defines a first cavity, the first housing portion having at least one radio frequency (RF) connector port for coupling to a feedline of a broadband distribution network, a second housing portion that defines a second cavity, an amplifier disposed in the second cavity of the second housing portion, wherein the first housing portion and the second housing portion are configured to couple together and collectively provide a component cavity therebetween based on the first cavity and the second cavity, and wherein an overall volume V 1  of the first cavity of the first housing portion is less than an overall volume V 2  of the second cavity of the second housing portion. 
     While the principles of the disclosure have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the disclosure. Other embodiments are contemplated within the scope of the present disclosure in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present disclosure, which is not to be limited except by the following claims.