Patent Publication Number: US-7220145-B2

Title: Patch panel system

Description:
BACKGROUND OF THE INVENTION 
   The present invention generally relates to a patch panel system for interconnecting electronics or fiber optic cables and more specifically to a patch panel system having a space efficient geometry. 
   Numerous patch panel systems exist today and are used in various electronics equipment applications, such as telecommunications, data transmission, networking, video and the like. Typically, to install a patch panel system, a rack frame is securely mounted to the floor within the room in which the system is to be maintained. Multiple patch panels or boxes are then secured to the frame in a stacked arrangement. Each patch panel includes multiple connector ports (e.g. RJ45 connector ports) along the front face thereof. Each connector port is adapted to receive a plug on a mating cable that conveys a single data stream, such as for an individual user and the like. 
   Conventional patch panels are generally constructed with a rectangular or square horizontal cross sectional geometry or footprint. Each patch panel includes a planar front face. When the patch panels are mounted within the frame, the front faces align with one another in a vertical plane. The patch panels have a height in the vertical direction and a width in the lateral direction. The number of patch panels that are vertically stacked upon one another and the width of the individual patch panels determine the outer dimensions of a connectivity interface within which individual connector ports are retained and arranged in a desired pattern. 
   As information technology evolves and advances, the need increases for each patch panel system to support more and more individual users. As the number of users increases so does the need for more connector ports and cables which increases the overall physical size. To add capacity at the connectivity interface, the front face is expanded vertically by stacking additional patch panels upon one another. Alternatively or in addition, the connectivity interface is expanded laterally by increasing the width of each patch panel. 
   However, patch panel systems are reaching the size limits afforded by certain standards and/or by physical constraints of rooms and environments in which the patch panel systems are mounted. 
   A need remains for an improved patch panel system having a more space efficient geometry along the front face of the patch panels. 
   BRIEF DESCRIPTION OF THE INVENTION 
   A patch panel system is provided that comprises a frame, a patch panel and connector ports. The patch panel is attached to the frame and has first and second connectivity interfaces. The first connectivity interface has multiple sections joined to form an N-sided portion of a polygon where N is greater than 2. The connector ports are provided at the first connectivity interface. 
   The multiple sections of the first connectivity interface may have individual planar front surfaces and may be formed integrally with one another along a substantially arcuate path. At least one of the multiple sections includes a plurality of the connector ports which may be arranged in a matrix or array. The connector ports may be configured to convey multiple data streams or individual data streams associated with multiple or single information sources/destinations, respectively. Optionally, the first connectivity interface may be comprised of connector ports configured to convey single data streams, while the second connectivity interface includes multiport connectors which are configured to convey multiple data streams through each connector port. 
   Each patch panel may include one or more circuit boards containing individual communications paths (e.g. traces or lead frames) that individually join to corresponding connector ports and convey data streams between the first and second connectivity interfaces. 
   In accordance with an alternative embodiment, a patch panel is provided having a body with first and second connectivity interfaces provided on the body. The first connectivity interface has multiple sections joined to form an N-sided polygon where N is greater than 2. Connector ports are provided on the first connectivity interface. The body may include a base and front, back and side walls having a wedge shape. The front and back walls define the first and second connectivity interfaces respectively. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates an isometric view of a cable management system formed in accordance with an embodiment of the present invention. 
       FIG. 2  illustrates an isometric view of the cable management system of  FIG. 1  with several patch panels and wire managers removed. 
       FIG. 3  illustrates an isometric view of a wire manager formed in accordance with an embodiment of the present invention. 
       FIG. 4  illustrates a reversed isometric view of the wire manager of  FIG. 3  formed in accordance with an embodiment of the present invention. 
       FIG. 5  illustrates a front isometric view of a patch panel formed in accordance with an embodiment of the present invention. 
       FIG. 6  illustrates a rear isometric view of the patch panel of  FIG. 5 . 
       FIG. 7  illustrates an exploded isometric view of the intersection between a patch panel and wire manager. 
       FIG. 8  illustrates a top view of the cable management system of  FIG. 1 . 
       FIG. 9  illustrates a cable management system formed in accordance with an alternative embodiment. 
       FIG. 10  illustrates a patch panel having connector modules that directly connect to cables in accordance with an alternative embodiment. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  illustrates a cable management system  10  formed in accordance with an embodiment of the present invention. The cable management system  10  includes a frame  12  that is configured to be mounted to the floor and/or ceiling of an applications room. A plurality of patch panels  14  are arranged in a manner stacked upon one another forming a distribution assembly  15 . The patch panels  14  are securely attached to the frame  12 . A plurality of wire managers  16  are also stacked upon one another and arranged in first and second groups on opposite sides of the patch panels  14  forming wire manager modules  18  and  20 . The frame  12  extends upward through each of the wire managers  16  and is securely attached to each wire manager  16  and to each patch panel  14  in a manner explained below in more detail. The frame  12  includes a base plate  24  having an upper flange  26  that is joined to support brackets  28  and  30 . 
   An equipment system  22  (such as a switching network) is also shown in  FIG. 1 , although the system  22  may be entirely removed or may be located in a different location. The system  22  is not considered part of the cable management system  10 . 
   The patch panels  14  and wire managers  16  are arranged in a non-orthogonal relationship to one another. The term “non-orthogonal”, as used throughout, shall include any non-parallel or non-perpendicular angle or geometry. 
     FIG. 2  illustrates the cable management system  10  with a majority of the patch panels  14  and wire managers  16  removed. Each wire manager  16  includes an opening  32  there through which permits the wire managers  16  to be loaded onto corresponding support brackets  28  or  30 . Once each wire manager  16  is loaded onto the corresponding support bracket  28  or  30 , the wire manager  16  is secured to the corresponding support bracket  28  or  30  through any of several conventional fastening means, such as bolts, screws, welding, adhesive, hooks and the like. In the exemplary embodiment of  FIG. 2 , a series of holes  34  are provided though each wire manager  16  which align with holes  36  in the corresponding support bracket  28  or  30 . Pins or bolts are inserted through the holes  34  and  36  to achieve a secure connection. 
     FIG. 3  illustrates an individual wire manager  16  in more detail. The wire manager  16  includes a body  38  that is constructed with a generally curved geometry or contour. More specifically, the body  38  includes a front wall  40 , a back wall  42  and side walls  44  and  46 . The front, back and side walls  40 ,  42 ,  44  and  46  surround a cavity  48  having a curved interior contour. The cavities  48  of a wire management module  18  or  20  define a vertical wire guide. The curved interior of the cavity  48  may take many shapes other than the shape illustrated in  FIG. 3 . In  FIG. 3 , the cavity  48  is shown with a semi-circular geometry, however it is understood that the interior contour is not limited to semi-circular. Instead, the geometry of the interior contour may resemble a circle, an oval, a triangle, an S-shape, a wave shape, a polygon (other than a square or rectangle, such as a pentagon, an octagon and the like) or any other non-square or non-rectangular shape. Optionally, the front walls  40  of the wire managers  16  may be shaped as N-sided polygons where N is two or greater. As N approaches a large number, the surface described resembles a cylindrical or ellipsoidal section. 
   In the example of  FIG. 3 , the back wall  42  is convex bowing into the cavity  48 , while the front, back and side walls  40 ,  42 ,  44  and  46  are formed integral with one another. Optionally, the wire manager  16  may be formed from multiple separate discrete pieces that are joined with one another in a variety of manners, such as screws, hooks, soldering, welding, mortise and tenon and the like. Optionally, the wire manager  16  may be constructed in two or more separate components that are not fully joined with one another, but instead are separately mounted to the frame  12 . The front wall  40  includes an opening  32 , through which cables are inserted. Optionally, the opening  32  may be closable with a closure member, such as a hinged door which a latch that shuts to enclose fully cavity  48 . 
   In the example of  FIG. 3 , the front wall  40  is divided at opening  32  into first and second segments  50  and  52  that are formed integrally with the corresponding side walls  44  and  46  via bracket segments  54  and  56 , respectively. Optionally, the wire manager  16  may be configured to permit segments  50  and  52  to close opening  32  and secure to one another. The bracket segments  54  and  56  include inner surfaces  58  and  60  configured to flushly abut against the front surface  62  ( FIG. 2 ) of a corresponding support bracket  28  or  30 . The holes  34  in the bracket segments  54  and  56  are shown in more detail in  FIG. 3 . The side walls  44  and  46  of the wire manager  16  flare outward from one another as the side walls  44  and  46  extend from the back wall  42  towards the front wall  40 . 
   The wire manager  16  also includes manager interconnects  64  which are formed at the intersections of the back wall  42  and side walls  44  and  46 . The manager interconnects  64  include mounting posts  66  that project in a direction (generally denoted by arrow A) outward transversely from the plane generally containing the body  38  of the wire manager  16 . The manager interconnects  64  also include post receptacles  68  aligned transversely to the plane of the body  38 , but opening in a direction opposite to that of the mounting post  66 . The post receptacles  68  are configured to mate with adjoining mounting posts  66  when wire managers  16  are stacked upon one another (as shown in  FIGS. 1 and 2 ). Optionally, the manager interconnects  64  may be entirely removed or provided at different positions along the body  38 . Further, only a single or more than two manager interconnects  64  may be used. As a further alternative, the manager interconnects  64  may be alternated, such that the mounting posts  66  upon a pair of manager interconnects  64  on a single wire manager  16  face in opposite directions, as well as the corresponding post receptacles  68 . 
   The side walls  44  and  46  include outer surfaces  70  having rails  72  formed thereon and extending outward therefrom. Each rail extends along the length of the corresponding side wall  44  or  46  and is configured to be received in a corresponding slot in a patch panel  14  ( FIG. 1 ) when joined. Optionally, the rails  72  may be of different dimensions to provide a keying feature, such as a dovetail, to ensure proper orientation and alignment of corresponding patch panel  14 . 
     FIG. 4  illustrates the wire manager  16  turned in the opposite direction to better illustrate the mounting posts  66  and the contour of the front wall  40 . More specifically, the front wall  40  includes a notched-out section  74  formed in the edge  75  of segment  50 . The outer end of the notched-out section  74  includes a ridge  76 . The notched-out section  74  permits a desired subset of cables to enter/exit the wire manager  16  at a desired vertical position along the height of the wire manager module  18  or  20  ( FIG. 1 ). The ridge  76  prevents the cables from moving into the opening  32 . 
     FIG. 5  illustrates a more detailed view of a patch panel  14 . The patch panel  14  includes a body  80  comprised of a base  82 , side walls  84  and  86  and a front face  88 . The patch panel  14  generally includes front and rear connectivity interfaces  90  and  92 , respectively. The front connectivity interface  90  includes multiple connector modules  94 , each of which includes an array or matrix of openings that hold receptacle jacks or ports  96 . In the example of  FIG. 5 , each connector module  94  contains twelve receptacle jacks  96  arranged in a 2×6 matrix. 
   Optionally, the number of receptacle jacks  96  may be varied as may the dimensions of the matrix. For instance, each connector module  94  may hold a single row of discrete or grouped receptacle jacks  96  or may hold receptacle jacks  96  arranged in 2×2, 3×2, 3×3, 4×3 matrices and the like. As a further option, the jack configuration of different connector modules  94  in the front connectivity interface  90  may be varied. For example, the receptacle jacks  96  may constitute RJ45 connectors, optical connectors, power connectors and the like. However, many other types of connectors may be substituted and utilized. In the example of  FIG. 5 , each receptacle jack  96  receives a connector plug and cable that conveys a single stream of information, such as associated with a single source or destination. As an example, a single stream of information may be from one user station. At this point, power distribution, optical signal combining, distribution, or amplification, signal indication (such as with LEDs) and optical or electrical signal conditioning may be added. 
   The patch panel  14  includes one or more circuit boards  83  mounted on the base  82 . The circuit board  83  is generally semi-circular in shape to follow the curvature of the base  82 . The circuit board  83  includes conductive signal paths provided thereon, such as traces or in a lead frame. The traces interconnect individual contacts within each connector module  94  with a corresponding multiport connector  98  which is mounted on the circuit board  83 . The patch panel  14  includes multiple multiport connectors  98  mounted on the circuit board  83 . The multiport connectors  98  each include a receptacle  100  ( FIG. 6 ) which is configured to receive a multiport plug and cable that convey multiple independent data streams. In the exemplary embodiment, the receptacle jacks  96  on the front connectivity interface  90  are each associated with a single or sub-set of data streams and/or power feeds, a group of which are collected within an associated multiport connector  98 . Optionally, the power feed may be maintain as a separate path independently of the multiport connector  98 . The individual data streams from the receptacle jacks  96  are not merged with one another, but instead are grouped at receptacle  100  for a single plug and cable configured to convey multiple independent data streams. Examples of the receptacle  100  are RJ-21, D-Subminiature, MPO, SCSI connectors and the like. The multiport connectors  98  define the rear connectivity interface  92 . 
   Alternately, a wire or optical fiber may be directly terminated to the rear face of the receptacle jacks  96  through means of crimping, soldering, adhesives, insulation displacement termination, splicing, connectorization and the like 
   The body  80  of the patch panel  14  further includes retention tabs  102  formed proximate both side walls  84  and  86 . The retention tabs  102  include holes  104  and extend laterally outward at an obtuse angle from the side walls  84  and  86 . The retention tabs  102  are configured to fit against the outer surface  59  of a related bracket segment  54  on a corresponding wire manager  16 . 
     FIG. 6  illustrates a rear view of the patch panel  14  to better illustrate the multiport connectors  98  and the side walls  84 . Each side wall  84  includes a slot  106  having an open back end which is configured to fit over corresponding rails  72  ( FIG. 3 ) when the patch panels  14  are loaded onto the cable management system  10 . The rear end  108  of the base  82  includes notches  110 , within which the cables may rest or be secured once plugged into the receptacles  100  in the multiport connectors  98 . As illustrated in  FIG. 6 , the base  82  formed in a semi-circular arc. Optionally, the circuit board  83  may be rectangular or divided into rectangular or wedge shaped separate boards and may contain fiber optic components. For example, a multiplexed fiber optic signal may be distributed from a single connector, actively, passively, with fibers or electronically. 
   Returning to  FIG. 5 , the front face  88  is formed with multiple sections  112  that have planar front surfaces  114 . Each section  112  includes an opening  116  that receives a corresponding connector or connector module  94 . The sections  112  are formed integrally with one another at bends  113  in the example of  FIG. 5 , but may be formed discrete from one another. The front sections  112  intersect at bends  113  at obtuse angles with respect to one another to define collectively an N-sided portion of a polygon. In the example of  FIG. 5 , four sections  112  are illustrated, however the number of sections  112  may be varied. For example, three sections or more than four sections  112  may be utilized. The sections  112  join along a substantially arcuate path. A comparison of  FIGS. 5 and 6  illustrates that the front and rear connectivity interfaces  90  and  92  are arranged along concentric arcuate paths (generally denoted by arrows B and C in  FIG. 6 ). The retention  102  or bracket segment  54  may be hinged for ease of assembly and access. 
     FIG. 7  illustrates an enlarged view of the interface between a patch panel  14  and a corresponding wire manager  16 . As shown in  FIG. 7 , the wire manager  16  is secured at bracket segment  54  to the frame  12  (not shown in  FIG. 7 ) by a screw  118 . Once the wire manager  16  is attached to the frame  12 , the patch panel  14  is added such that the retention tab  102  fits over the bracket segment  54 . An enlarged hole  120  aligns with a screw  118 , while screws  122  secure the patch panel  14  to the frame  12 . Optionally, retention tab  102  and/or segment  54  may be hinged. 
     FIG. 8  illustrates a top view of the cable management system  10 . The switch system  22  is mounted within the frame  12  above the base plate  24 . A pair of wire manager modules  18  and  20  are mounted on opposite sides of patch panel  14  to form a C-shaped geometry. Optionally, the frame  12  may be entirely removed and the patch panel  14  and wire manager modules  18  and  20  joined as shown to be free standing independent of and without any need for the frame  12 . The C-shaped geometry formed by the wire manager modules  18  and  20  and patch panel  14  affords a very stable footprint that may not necessarily need any additional supporting structure. The patch panel  14  and wire manager modules  18  and  20  extend along common interior and exterior circular arcs as denoted by arrows D and E, respectively. As better shown in  FIG. 8 , the back walls  42  of the wire managers  16  are bowed convexly along an arc equaling the arc of the rear edge  108  of the base  82  of the patch panel  14 . 
   The patch panel  14  join with each of the wire manager modules  18  and  20  at respective abutting side walls  44  and  46 , on the wire managers  16 , and  84  and  86  on the patch panel  14 . The side walls  44  and  46  of the wire managers  16  and the side walls  84  and  86  of the patch panel  14  are oriented to abut against one another along radial axes generally denoted by arrows F and G which extend outward from a center  124  of the cable management system  10 . 
   Optionally, the patch panel  14  and wire managers  16  may be constructed in other non-orthogonal geometries other than a C-shape. For example, the non-orthogonal geometry may resemble other cylindrical shapes, such as a complete circle, a complete or partial oval, a complete or partial polygon, and the like. 
     FIG. 9  illustrates an alternative embodiment for a cable management system  200  that includes a frame  212 , patch panel  214  and wire managers  216 . In the alternative embodiment of  FIG. 9 , the patch panel  214  have been divided into two separate groups  215  and  217  arranged at the front and back of the cable management system  200 . Each of the patch panel  214  in group  215  and in group  217  may be constructed similarly and if so would be interchangeable. By adding the group  217 , the overall interconnectivity of the cable management system  200  is doubled. Optionally, individual or small groups of patch panels  214  and/or wire managers  216  may be replaced by spaces to facilitate access to the inner cavity or rear of the patch panels  214 . 
   While the overall geometry of the cable management system  200  resembles a complete cylinder, alternative non-orthogonal geometry&#39;s may be utilized. For example, the size and curvature of the patch panel  214  may be increased to form a more oval shape with longer arcuate connectivity interfaces on the exterior of the patch panel  214  in each of groups  215  and  217 . 
     FIG. 10  illustrates a patch panel  414  formed in accordance with an alternative embodiment. The patch panel  414  includes a front connectivity interface  490  comprised of multiple sections  412 . Each section  412  includes a connector module  494  comprised of an array of receptacle jacks  496 . The rear face  495  of the connector module  494  is configured to be directly terminated to cables  497 , thereby avoiding the use of a multiport connector as explained above. The cables  497  may be electrical, fiber optic and the like. The cables  497  may be terminated at individual contacts  499  within each receptacle jack  496  through a variety of means, such as crimping, insulation displacement, soldering, and the like. 
   The foregoing cable management systems may also be retrofit into existing switching networks. To retrofit such structures, the existing rectangular wire managers and planar patch panels may be removed wholly or partially and replaced with patch panels and wire managers having the above described various structures and geometries. 
   While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.