Patent Publication Number: US-2009239413-A1

Title: Reinforced patch panel frame with rear mounted modules

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. provisional application Ser. No. 61/038,238, filed on Mar. 20, 2008, which is incorporated herein in its entirety by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a reinforced patch panel frame with rear mounted modules. 
     BACKGROUND OF THE INVENTION 
     Although keystone style modular jacks are well known in the art, patch panel frames typically fail to accommodate keystone style modular jacks made in accordance with industry standards, especially at the rear of the patch panel frame due to the width of the modular jack. To overcome these difficulties, prior art assemblies use patch panels, typically one-piece mould die cast, that have a thickness equal to the width of the modular jack in order to accommodate the latter, thus resulting in thick and bulky designs. Other mounting assemblies use modular multi-port modules tailored to a specific performance. Alternatively, the keystone style modular jacks are accommodated on faceplates or mounting brackets attached to the patch panel frame. Still, a major drawback of these assemblies is the complex and expensive nature of the design and construction. Other prior art patch panel assemblies accommodate the keystone style modular jacks on a single frame in order to maximize patch panel density, thus saving money and rack space. Although this results in patch panels of simple construction, in high density applications these structures suffer from a low strength and structural rigidity, as the frame is not reinforced and is thus susceptible to damage due to bending forces or the like. 
     What is therefore needed, and an object of the present invention, is a simplified patch panel assembly that can accommodate a standard keystone modular jack at the rear side of the patch panel while providing structural strength and eliminating costly tooling for plastic or die casting mould. 
     SUMMARY OF THE INVENTION 
     More specifically, in accordance with the present invention, there is provided a patch panel for mounting thereto a plurality of keystone style modular jacks each comprising a forward portion having a plug receiving opening moulded therein. The patch panel comprises a flat frame comprising a first plurality of like rectangular openings, each one of the first plurality of openings adapted to receive one of the plurality of jacks; and a flat panel arranged behind the frame substantially co-planar therewith and comprising a second plurality of like rectangular openings, each one of the second plurality of openings aligned with and of dimensions greater than a respective one of the first plurality of openings. The panel is spaced from the frame by a distance for accommodating the forward portion of the plurality of jacks when the plurality of jacks are received in aligned pairs of the first and the second plurality of openings. Also, when one of the plurality of jacks is positioned within one of the second plurality of openings, the plug receiving opening is accessible via one of the first plurality of openings. 
     Still in accordance with the present invention, there is further provided a patch panel for mounting thereto a plurality of keystone style modular jacks each comprising a forward portion having a plug receiving opening moulded therein. The patch panel comprises a flat frame comprising a first plurality of like rectangular openings, each one of the first plurality of openings adapted to receive one of the plurality of jacks; and a flat panel arranged in front of the frame substantially co-planar therewith and comprising a second plurality of like rectangular openings, each one of the second plurality of openings aligned with and of dimensions smaller than one of the first plurality of openings. The panel is spaced from the frame by a distance for accommodating the forward portion of the plurality of jacks when the plurality of jacks is received in aligned pairs of the first and the second plurality of openings. Also, when one of the plurality of jacks is positioned within one of the first plurality of openings, the plug receiving opening is accessible via one of the second plurality of openings. 
     Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a rear perspective view of a keystone patch panel in accordance with an illustrative embodiment of the present invention; 
         FIG. 2  is a detailed rear perspective view of a frame and a back panel of a keystone patch panel in accordance with an illustrative embodiment of the present invention; 
         FIG. 3A  is a perspective view of a keystone modular jack in accordance with an illustrative embodiment of the present invention; 
         FIG. 3B  is a side view of a keystone modular jack in accordance with an illustrative embodiment of the present invention; 
         FIG. 4  is a detailed rear perspective view of a keystone modular jack mounted in a keystone patch panel in accordance with an illustrative embodiment of the present invention; 
         FIG. 5  is a front perspective view of a keystone patch panel in accordance with an alternative illustrative embodiment of the present invention; 
         FIG. 6  is a detailed front perspective view of a frame and a front panel of a keystone patch panel in accordance with an alternative illustrative embodiment of the present invention; and 
         FIG. 7  is a detailed front perspective view of a keystone modular jack mounted in a keystone patch panel in accordance with an alternative illustrative embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS 
     Referring now to  FIG. 1 , and in accordance with an illustrative embodiment of the present invention, a patch panel assembly, generally referred to using the reference numeral  10 , will now be described. The patch panel assembly  10  comprises at least one keystone patch panel  12  mounted to a standard network rack  14  (e.g. EIA/TIA 19-inch rack) comprising two spaced vertical side rails  16  and  18 . Mounting plates as in  20  are formed integrally with the keystone patch panel  12  at each extremity thereof and comprise mounting apertures as in  22 , which allow the keystone patch panel  12  to be mounted to the rails  16  and  18  using fasteners such as nuts, bolts, and the like (not shown). 
     Referring now to  FIG. 2 , the patch panel  12  illustratively comprises a planar frame  24  and a flat panel  26  fixedly attached substantially co-planar to a rear face of the frame  24  for providing reinforcement to the patch panel  12 . For this purpose, a top strip  28  and a bottom strip  30  respectively project rearwardly from an upper edge and a bottom edge (both not shown) of the frame  24  at a substantially right angle. The panel  26  is illustratively attached to the rear of the frame  24  by respectively securing (using a suitable attachment method, such as welding or the like) an upper edge and a lower edge (both not shown) of the panel  26  to the top strip  28  and to the bottom strip  30 . 
     Referring now to  FIG. 3A ,  FIG. 3B , and  FIG. 4  in addition to  FIG. 2 , the frame  24  and the panel  26  respectively comprise a plurality of aligned openings as in  32  and  34 , which are each sized and shaped to receive therein modular jacks as in  36 . The modular jacks as in  36  are illustratively keystone modular jacks but it will be apparent to a person skilled in the art that other types of latching mechanisms, such as the AMP Netconnect™ style jacks or the like, could be used without departing from the scope of the present invention. As will also be apparent to a person skilled in the art, the modular jack  36  is inserted from the rear of the patch panel  12  substantially straight into a pair of aligned openings as in  32  and  34 . As such, the distance between two vertically stacked modular jacks as in  36  is minimized. 
     Still referring to  FIG. 3A ,  FIG. 3B , and  FIG. 4  in addition to  FIG. 2 , a keystone modular jack as in  36  typically comprises a forward portion  38  having moulded therein a plug receiving opening  40  adapted to receive a mating plug (not shown), for example an RJ-45 style plug, and a rearward portion  42  having a plurality of terminals  44  for terminating individual conductors of a cable (not shown). Illustratively, the forward portion  38  is separated from the rearward portion  42  by a retaining ridge  46  extending along the contour of the rearward portion  42 , such a contour being typically slightly larger than that of the forward portion  38 . Thus, it is desirable for the openings as in  32  of the frame  24 , which receive the forward portion  38  of the keystone modular jacks as in  36 , to be substantially smaller than the openings as in  34 , which receive the rearward portion  42 . In this manner, the patch panel  12  properly accommodates the size and shape of the keystone modular jacks as in  36 , which are secured within the openings as in  32  and  34  by the retaining ridge  46  bearing against the rear surface (not shown) of the panel  26 . Still, as mentioned herein above, the combination of the frame  24  with the panel  26  is provided to improve the structural rigidity of the patch panel  12 . Additionally, the front face of the frame  24  is provided for aesthetic purposes. Thus, the openings as in  32  could be larger than the openings as in  34 , as desired, while still providing the requisite reinforcement. Alternatively, a single opening  32  could encompass a plurality (e.g. two (2)) of openings as in  34 , thus allowing a plurality of plug receiving openings as in  40  to be accessible from the front of the patch panel  12  via a single opening  32 . 
     Still referring to  FIG. 3A ,  FIG. 3B , and  FIG. 4 , it is further desirable to provide sufficient spacing to accommodate the width W of the forward portion  38  when the keystone modular jack  36  is mounted to the rear of the patch panel  12 . For this purpose, the strips  28  and  30  each extend away from the frame  24  by a distance substantially equal to W, such that, when the panel  26  is attached to the frame  24 , a spacing W is provided between the panel  26  and the frame  24  to accommodate the keystone modular jack  36  inserted into the openings  34  and  32 . In this manner, when the keystone modular jack  36  is mounted to the patch panel  12 , the front of the keystone modular jack  36  will be flush with the front surface of the frame  24 , with the plug receiving opening  40  being accessible via the opening  32 . Alternatively, the width W may be selected so that the keystone modular jack  36  is slightly recessed into or protrudes from the frame  24 . 
     Still referring to  FIG. 3A ,  FIG. 3B , and  FIG. 4 , the keystone modular jack  36  further comprises on an upper surface thereof a forwardly extending cantilevered latch arm  48  (having at a distal end thereof a stop surface  50 ) and on a lower surface thereof a raised angled rib  52  (having a stop surface  54 ) for securing the keystone modular jack  36  to the patch panel  12 . In order to accommodate the latch  48  and the rib  52 , the top strip  28  and the bottom strip  30  of the frame  24  each comprise a plurality of recesses as in  56 . As will now be apparent to a person skilled in the art, when the keystone modular jack  36  is mounted to the patch panel  12 , the latch  48  and the rib  52  each engage their respective recesses as in  56  with the stop surfaces  50  and  54  respectively engaging a rearward edge of the respective recesses  56 , thus further securing the keystone modular jack  36  to the patch panel  12 . 
     Referring now to  FIG. 5 ,  FIG. 6  and  FIG. 7 , and according to an alternative illustrative embodiment of the present invention, a patch panel  12 ′ may be provided with a flat panel  26 ′ mounted co-planar to a front face of a planar frame  24 ′. Similarly to the previous embodiment, the frame  24 ′ and the panel  26 ′ are respectively provided with aligned openings as in  32 ′ and  34 ′ sized and shaped to receive therein the keystone modular jack  36 . As the panel  26 ′ is mounted in front of the frame  24 ′, the openings as in  34 ′ illustratively receive therein the forward portion (reference  38  in  FIG. 3A ) of the keystone modular jack  36  while the openings as in  32 ′ illustratively receive therein the rearward portion (reference  42  in  FIG. 3A ) and, as such, the openings as in  34 ′ are substantially smaller than the openings as in  32 ′. Again, as mentioned previously herein above, due to the partially aesthetic nature of the front face of the panel  26 ′, the openings as in  34 ′ could each be larger than the openings as in  32 ′ or alternatively a single opening  34 ′ could encompass a plurality (e.g. two (2)) of openings as in  32 ′, as desired. 
     Still referring to  FIG. 6  and  FIG. 7 , the panel  26 ′ comprises a top strip  28 ′ and a bottom strip  30 ′, which, similarly to strips  28  and  30  described herein above, enable the panel  26 ′ to be fixedly attached to the front of the frame  24 ′ using a suitable method (e.g. welding). The strips  28 ′ and 30′ also extend at a substantially right angle rearwardly from the panel  26 ′ by a distance W substantially equal to the width W of the forward portion (reference  38  in  FIG. 3A ) of the keystone modular jack  36 . The top strip  28 ′ and the bottom strip  30 ′ of the panel  26 ′ further comprise a plurality of recesses as in  56 ′, which enable the latch  48  and rib (reference  52  in  FIG. 3A ) of the keystone modular jack  36  to be engaged therein (similarly to the previous embodiment) when the keystone modular jack  36  is inserted into the openings  32 ′ and  34 ′ of the patch panel  12 ′. 
     Referring back to  FIG. 1  and  FIG. 5 , the present invention advantageously provides a patch panel assembly  10  that accommodates standard keystone modular jacks as in  36  at the rear of the patch panel  12  using a simple design and construction, in which the thickness of the patch panel  12  is of no significance, thus proving less expensive than keystone patch panels currently known in the art. Also, providing a frame (reference  24  in  FIG. 2 ) having a panel (reference  26  in  FIG. 2 ) attached thereto significantly improves the structural strength and rigidity of the patch panel assembly  12 , which can thus advantageously sustain strong bending forces or the like without damage thereto. 
     Although the present invention has been described hereinabove by way of specific embodiments thereof, it can be modified, without departing from the spirit and nature of the subject invention as defined in the appended claims.