Patent ID: 12238881

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and or utilized.

It is to be appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Stated otherwise, although the invention is described below in terms of various exemplary embodiments and implementations, it should be understood that the various features and aspects described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the invention.

One or more embodiments of the present invention define a card cage as a chassis for electrical and or electronic equipment. A chassis is defined in accordance to its ordinary meaning, which is a structural framework (in the present instance) of electrical and or electronic equipment. The term chassis and the phrase “card cage” are deemed equivalent by the present invention and may be used interchangeably.

One or more embodiments of the present invention define a plug-in unit as an element (such as Printed Circuit Board(s)—PCB) that mounts within a card cage that may have a plug-in unit panel.

One or more embodiments of the present invention define a plug-in unit panel as an actual cover that may have securing fasteners and may further include a handle. The plug-in unit handle may comprise a static handle, one or more injector/ejector handles, or both.

One or more embodiments of the present invention defines a filler panel as a cover that fills an opening at a position that would normally be occupied by a plug-in unit. In other words, filler panels may, for example, be comprised of a simple panel with securing fasteners.

In general, there are two types of plug-in units—board (or card) and box. A board (or card) plug-in unit may be comprised of a PCB that may contain one or more connectors intended to connect to a backplane or midplane (defined below), or other devices such as other plug-in units.

A box plug-in unit may be comprised of a “box” that contains any number of electronic or electro-mechanical components such as PC boards, power supplies, disk or solid-state drives, fans, keypads displays, etc. combined into a “box” plug-in unit.

Both box and board plug-in units include one or more connectors intended to connect to the backplane, midplane, or other devices, and have a plug-in unit panel with a plug-in unit handle (e.g., static handle, injector/ejector handle, or both), including securing fasteners.

One or more embodiments of the present invention define backplane or mid-plane as a power-data transmission panel that is comprised of a Printed Circuit Board (PCB), integrated circuitry or bus architecture and connectors for transmission of communication, power, and or data signals between plug-in units.

As is well known, a backplane is a power-data transmission back-panel or PCB that is positioned at or near the back of a card cage and has plug-in unit connectors on only one side thereof, whereas a midplane is a power-data transmission mid-panel or PCB generally positioned at a general middle portion of the card cage and has plug-in unit connectors on both sides thereof. It should be noted that throughout the disclosure, any references to a back-plane are generally equally applicable to mid-planes and vice versa.

As is well known, the phrase “mid-plane” or “middle-plane” does not necessarily mean that the mid-plane is located in a position within card cage that is exactly at the middle of the chassis. For example, a mid-plane may be positioned much closer to one end of the chassis, typically making that end the “rear” of the card cage with shorter plug-in unit depth that is much smaller in volume than the front section. Accordingly, a mid-plane may be positioned anywhere between front and rear of a card cage and still be referred to as “mid-plane” so long as it may receive plug-in units from both sides thereof.

Throughout the disclosure, a guide panel is provided that intentionally includes a large number of added options and complex features for discussion purposes to clearly demonstrate to those skilled in the art the versatility of a guide panel and its manufacturing process in accordance with one or more embodiments of the present invention.

One or more embodiments of the present invention provide a guide panel and manufacturing process thereof that is comprised of a single, unitized piece, which, reduces overall accumulated error tolerances and reduces labor in terms of the assembly of a card cage.

Further, one or more embodiments of the present invention provide a guide panel and manufacturing, process that self-aligns with other components that constitute the overall card cage and in particular, with a power-data transmission panel without the use of plug-in units for alignment.

Additionally, one or more embodiments of the present invention provide a guide panel and manufacturing process that is fully compatible with industry standards requirements and needs to ensure conformity, without loss in functionality.

FIGS.1A to1Eare a non-limiting, exemplary illustration of the various views of a partially assembled card cage with guide panels in accordance with one or more embodiments of the present invention.FIG.1Ais a non-limiting, exemplary illustration of the partially assembled card cage122showing one of the side panels120and a filler panel118, whereas the rest of the figures show the same (from different views) but without any side panel120or filler panels118for clarity and discussion purposes. It should be noted that a fully assembled card cage (with its well known, standardized components) is not illustrated for the sake of clarity.

FIGS.1A to1Eillustrate lower and upper guide panels100and240in accordance with one or more embodiments of the present invention that are associated with a well-known backplane (i.e., power-data transmission panel)102in accordance with one or more embodiments of the present invention.

As detailed below, the only difference between the illustrated lower and upper guide panels100and240in this non-limiting, exemplary embodiment is that lower guide panel100includes, alignment projections126and242(detailed below) whereas the upper guide panel240does not. In other embodiments alignment projections may be on upper guide panel or both upper and lower guide panels. (FIG.3B-2is a rear top view of a flipped upper guide panel240, the rest are various views, of guide panel100). Accordingly, the description details lower guide panel100only as all other aspects of both guide panels100and240are identical, including all assembled parts such as ESD components, fastener nut bars218, etc.

Further illustrated inFIGS.1A to1Eis a well-known single plug-in unit104(details of which is also illustrated inFIGS.6G to6I) associated, with lower and upper guide panels100and240and connected to power-data transmission panel102in accordance with one or more embodiments of the present invention. In this non-limiting, exemplary instance, plug-in unit104is associated with a lower guide panel100by a handle (injector-ejector)194(detailed below) and a fastener-guide set520with upper guide panel240.

FIG.1Aalso illustrates a well-known filler panel118connected to lower and upper guide panels100and240by simple fastener sets522, associated with upper and lower fastener nut bars218in a well-known manner.FIG.1Afurther illustrates lower and upper guide panels100and240connected to a side-panel120(only one side panel is shown for clarity), forming the chassis. Filler panel118and side panels120are not shown in the rest of the figures for simplicity and clarity.

In general, guide panels100may be designed based on the largest size plug-in unit104(FIG.1C) in terms of their height and depth (further defined below), and divided or sub-divided for accommodating smaller sized plug-in units104. Guide panels100may accommodate a wide variety of different sized plug-in units (other plug-in units are not shown). For example, board plug-in units104may be sized 4 HP wide112by 6 U in height114, while an adjacent board plug-in unit (not shown for simplicity) may be comprised of a 6 HP with 6 U height.

As is well known, “HP” stands for Horizontal Pitch. In general, most (but not all) conventional card cages set 1 HP as a fixed horizontal distance112of 0.200 inches. This very limiting conventional set value of 0.200 inch of spacing for base HP (1 HP) is set because of the methods conventional extrusions are produced along with the manner in which the conventional injection molded plastic card guides are designed.

The present invention does not use conventional extrusion methodology along with the conventional injection molded plastic card guides to produce guide panels100. Instead, as detailed below, the present invention utilizes machinery (e.g., Computer Numerical Control—CNC machines, or stamping presses) that enable the use of other HP units without restrictions. For example, instead of setting 1 HP to equal to 0.200 inches, 1 HP may be set to 0.131 inch or other selected values based on the required engineering parameters.

As indicated above, HP units of measurements may be used to manufacture a card cage, including producing different width and depth sized plug-in units, different spacings between guidance slots106and depth of a guide panel100, etc. To ensure minimal confusion the card cage height and depth must be matched to the plug-in unit, height and depth. The width is the variable within a single card cage.

For example, the width distance of a plug-in unit, panel110is measured in terms of HP, which must also account for a small clearance gap or space on either side to ensure unobstructed insertion removal of each plug-in unit panel. Accordingly, a plug-in unit panel width may simply be defined as xHP, where x is multiple of the base unit z. For example, base unit may be selected to equal z=0.112 inches. In the case of base unit z=0.112 inch, systems may include various sized board or box plug-in units, or filler panels (detailed below) such as 4 HP (=0.448 inch), 5 HP (=0.560 inch), 6 HP (=0.672), 8 HP (=8.96 inch), 12 HP (=1.344 inch), or xHP=z*x.

As another example, HP units of measurements are also used for guide panel100and in particular, guidance slot distances108of guide panels100. In other words, the xHP for a guidance slot106separation distance108(from one guidance slot106mto the next, adjacent slot106n) must be commensurate with xHP measurement of a corresponding plug-in unit panel110that will be inserted into the given guidance slot106. As illustrated inFIG.1B. HP may be different from one plug-in unit panel110to next and also, correspondingly, from one guidance slot106to next guidance slot on a single guide panel100.

As is also well known, the measurements of 3 U, 6 U, 9 U, and 12 U refer to the height114of a PCB116of a plug-in unit104that will fit in between lower and upper guide panels100. The 3 U, 6 U, 9 U, and 12 U units of measurements may be used to produce different height sized plug-in units104(box or board) or filler panels118commensurate with distances between lower and upper guide panels100and240.

As is further well known, filler panel118may also be used in, any corresponding location along guide panels100where a plug-in unit panel110may be secured. For example, the illustrated plug-in unit104may be replaced by a simple, well known and conventional filler panel118and instead, the illustrated plug-in unit104may be mounted onto an adjacent position and connected to power-data transmission panel102. As another example, depending on the use of the card cage, the rest of the spaces illustrated inFIGS.1A to1Emay all be covered by filler panels118. In that case, the final card cage would have the illustrated single plug-in unit104. One function of filler panel118is to facilitate and maintain proper airflow within the finalized card cage, otherwise air would escape from the opening not covered by filler panel118which may result in an overheating condition of adjacent plug-in units104. Filler panels118may also be used to facilitate in maintaining faraday cage continuity (well-known).

FIGS.2A to2Dare non-limiting exemplary exploded view illustrations of the various components of only a single guide panel100and power-data transmission panel102combination illustrated inFIGS.1A to1Ein accordance with one or more embodiments of the present invention. The exploded views shown inFIGS.2A to2Dillustrate disassembled, separated components that show the cooperative working relationship, orientation, positioning, and exemplary manner of assembly of the various components of guide panel100and power-data transmission panel102in accordance with one or more embodiments of the present invention, with each component detailed below.

As illustrated and further detailed below, guide panel100may comprise of structures such as various openings to enable mounting of different components such as different types of Electrostatic Discharge components128and270, an angled nut-bar218, indexing elements132, in addition to various openings to interface with a plug-in unit panel110or a filler panel118. Further included are alignment and securing structures (detailed below) that enable proper engagement and securing of guide panel100with power-data transmission panel102.

FIGS.3A to3Nare non-limiting, exemplary illustrations of a guide panel in accordance with one or more embodiments of the present invention.

As indicated above, only guide panel100is discussed in detail. The only difference between the illustrated lower and upper guide panels100and240is that lower guide panel100includes alignment projections126and242(detailed below) whereas the upper guide panel240does not. Accordingly, the below description details lower guide panel100only as all other aspects of both guide panels100and240are identical. As detailed below, number, position, size, and orientation of alignment structures in general and alignment projections126and242and openings184and342(FIG.1D) in particular, may vary depending on the requirements of plug-in unit104.

Guide panel100shown is comprised of unitized (single piece) construction that includes guidance slots106for insertion and securing of plug-in units104. In this non-limiting, exemplary instance, the illustrated guide panel100is comprised of a single, integral, continuous unitized metal panel with airflow openings146in between guidance slots106. Guide panel100may be dimensioned by depth148and longitudinal axis150.

Guide panel100is further comprised of an engagement structure124that interface with plug-in unit panels104or filler panels118. Additionally, guide panel100may include power-data transmission alignment projections126and242, if guide panel100is to be mechanically and physically aligned with a power-data transmission panel (mid- or backplane)102. Optionally, power-data transmission alignment projections126and242may be omitted.

In this non-limiting, exemplary instance, guide panel100optionally accommodates Electrostatic Discharge (ESD) components128and270that are securely mounted on guide panel100via ESD openings130(FIG.3E). Further, in this non-limiting, exemplary instance, guide panel100optionally accommodates well-known, conventional indexing elements132that are securely mounted on guide panel100via index element openings134.

As further illustrated, guide panel100further includes two lateral optionally downward oriented connecting flanges136with securing openings138that connect guide panel100to side panels120. Further included is a rear, downward oriented connecting flange140with plurality of openings for standoffs (female threaded fasteners such as nuts)144for connection to power-data transmission panel102using male fasteners244(detailed below).

In this non-limiting, exemplary instance guide panel100includes multiple slots106aand106b(FIG.3A) that are aligned inline to define depth148that may accommodate a plug-in unit104with PCB116with a depth152(FIG.1C). That is, there are two rows of aligned and inline slots106aand106bfor each plug-in unit104along longitudinal axis150of guide panel100.

For a longer span plug-in units104with greater depth152more guidance slots106may be aligned for each plug-in unit104. For example, three or more aligned, inline guidance slots106a,106b, and106y(not shown) for each plug-in unit104may be provided instead of the illustrated paired slots106aand106b.

Further, for plug-in units104with plug-in unit depth152that is shallower, depth148of guide panel100may be cut shorter so that only single guidance slots106c(FIG.3A) are provided for each plug-in unit104with shallower depth152. Accordingly, guide panels100may include single guidance slot106cor multiple aligned inline guidance slots, depending on the physical dimensions of plug-in units104to be accommodated by guide panel100.

Further, in, this non-limiting, exemplary instance longitudinal axis150of guide panel100is illustrated to accommodate a total of six pairs of guidance slots106as shown. Of course, the number of slots106shown may be varied depending on many factors including the HP of each plug-in unit104. The actual longitudinal axis150of guide panel100may also be varied to accommodate greater number of plug-in units104with even larger or smaller HP values.

As best illustrated inFIG.3G, each slot106is defined by lateral walls158and a slot surface160, providing an ingress end154through which plug-in unit104is inserted into slot106, and an egress end156. Bottom facing side374(FIG.1C) of plug-in unit104rests on slot surface160.

As further illustrated inFIGS.3G and3H, lateral walls158at ingress end154and egress end156have divergent structures164to form chamfered ends for easy insertion and removal of plug-in units104. As illustrated inFIG.311, slot surface160is the same exact identical surface as top surface166of guide panel100.

As indicated above and further detailed below, guide panel100further includes alignment projections126and242, withFIG.311illustrating in detail alignment projections126only. Upper guide panel240does not have these alignment structures.

Upper guide panel240(FIG.3B-2) merely has the same rear, but upward oriented connecting flange140with fastener nuts144, but no alignment projections126and242. In other words, rear downward oriented connecting flange140has no tabs, pins, etc. for alignment with power-data transmission panel102.

In the non-limiting, exemplary instance shown inFIG.3H, alignment projections126are comprised of extended tabs cut out from rear downward oriented connecting flange140of guide panel100. Top side170of projections126is coplanar with top surface166of guide panel100. Openings168are a result of alignment projections126cut out from rear connecting flange140of guide panel100.

Guide panel100is cut and formed such that multiple alignment projections126remain coplanar with both top surface166of guide panel100and slot surface160of slot106on which plug-in unit104rests. Alignment projections126top and bottom surfaces170and172are unaffected by tolerances associated with the forming operation of flange140.

Alignment projections126include a tab top surface170(FIG.3H) and a tab bottom surface172(FIG.3F), where the top surface170is the same exact identical surface as top surface166of guide panel100. Accordingly, slot surface160and top tab surface170define the same exact continuous top surface166of guide panel100.

Alignment projections126are further defined by a length174, a width176, and thickness178(which is obviously identical to the thickness of guide panel100). As further illustrated, alignment projections126may further include radius or chamfered corners180, at cantilevered ends182for easy insertion of alignment projections126into alignment openings184(FIG.1D) of power-data-transmission panel102(detailed below). Alignment projections126further include lateral sides420and422with sufficient span (same as length174) to enable engagement of alignment projection126with alignment openings184. The various reliefs186shown are simply to facilitate the radius or chamfered corners180and projections126to the extended positions as shown and allow bending to occur on either side.

Referring toFIG.3I, guide panel100includes engagement (or stepped interface) structure124that enables mounting of various components, including engagement of plug-in units104or filler panels118. As illustrated, engagement structure124is configured as steps having horizontal and vertical surfaces.

A first horizontal surface188is comprised of a latch-opening190that receives a well-known latch (injector-ejector prongs)192(FIG.3J) of the latch mechanism of well-known an ejector-injector handle194of plug-in unit panel104. The operation of ejector-injector handle194of plug-in unit104is well known and conventional.

Further illustrated, inFIG.3Iis a first vertical surface196of engagement structure124, parts of which will be described in conjunction withFIGS.3J to3N.FIGS.3J to3Nprogressively illustrated the engagement of a plug-in unit panel110of plug-in unit104with engagement structure124of guide panel100.

In the non-limiting, exemplary instance illustrated inFIGS.1A to3N, first vertical surface196is illustrated to include an opening198, an elongated portion of which defines a fastener-opening portion200for receiving a securing fastener204(FIG.3J) of plug-in unit panel110or filler panel118. A non-elongated, but rounded (or circular) portion of opening198defines a guide opening portion206for receiving a first guide-pin208(FIG.3J) of plug-in unit panel110. It should be noted that instead of having a single, continuous opening198, two separate rounded openings may be formed, one as fastener-opening200and the other as guide-opening206.

First vertical surface196also functions to set an insertion depth of plug-in unit104. That is, once fully engaged, contacting surface210of plug-in unit panel110contacts and presses against first vertical surface196and hence, cannot be pushed in any further.

As further illustrated inFIGS.3I to3N, engagement structure124further includes a second horizontal surface212that has securing openings216for securing a fastening bar in a form of an angled nut-bar218using fasteners222. Second horizontal surface212has sufficient width or depth214to provide clearance for indexing elements132(FIG.3J), and a second guide pin220of plug-in unit104.

Engagement structure124further includes a second vertical surface224comprised of indexing openings134for receiving indexing elements (or keys)132, and a second guide opening226for receiving a second guide pin220of plug-in unit104.

Guide panel100provides multiple indexing or key openings134per slot106for insertion and securing of multiple keys132that when properly oriented within selected key opening134in relation to selected orientations of multiple keys132mounted on selected key openings230of plug-in unit104, will enable the correct plug-in unit104to be inserted within the correct slot106on guide panel100.

As illustrated, each slot106of guide panel100may have three key openings134, commensurate with the number of key openings230on handle194of plug-in units104. Each key132has an offset rectangular shape that may be oriented in four different orientations when mounted within any key opening134of guide panel100and key openings230on plug-in unit104.

Accordingly, arrangement of keys132, i.e., selection of the proper key openings134and230on respective guide panel100and plug-in unit104, and insertion of key132at a desire orientation within the selected key openings134and230provides an indexing feature that will allow the correct plug-in unit104to be inserted, within the correct slot. It should be noted that keying and uses thereof is well known, the point of the detailed illustration is that guide panel100and method of making thereof in accordance with one or more embodiments of the present invention is one with substantially reduced parts but without loss in functionality that fully complies with requiring standards.

As further illustrated inFIGS.3I to3N, engagement structure124further includes a third horizontal surface, which is the top surface166of guide panel100. Top surface166at engagement structure124includes electrostatic discharge openings228and268for securing electrostatic discharge components128and270(detailed below).

FIGS.4A to4Care non-limiting, exemplary illustrations of a fastener bar and its connection with a guide panel in accordance with one or more embodiments of the present invention. As illustrated, fastening bar (or angled nut-bar)218includes an angled bar234with mounted threaded elements (or stand-off nuts)232having an opening236aligned with a fastener-opening200of first vertical surface196.

As indicated above, second horizontal surface212may include two or more openings216for securing an angled nut-bar218using fasteners222, with stand-off nuts232having opening236facing fastener-opening200of first vertical surface196for receiving the fastener212of a plug-in unit104.

Angled nut-bar218includes a single piece metal sheet punched and bent, having a plurality of mounted (flare, swage, clinching, screwed fitting, etc.) standoff fasteners232of angled bar234.

A non-limiting, exemplary method of manufacturing angled nut-bar is to use metal (e.g., sheet metal) and cut out all shapes (e.g., by stamping presses, punching, laser cutting or use of CNC machines, etc.), thereafter adding bends and standoffs, resulting in an angle nut strip. This bending action avoids using the extrusion method of manufacturing process additionally requiring threaded strips, spacers, insulators and fasteners, this makes the manufacturing process lower cost, more flexible and more efficient.

FIGS.5A to5Mare non-limiting, exemplary illustrations of various views of electrostatic discharge components in accordance with one or more embodiments of the present invention.

As is well known, optionally, a plug-in unit104may include exposed conductive traces248(e.g., a copper traces shown inFIG.3N) on either or both sides of PCB116of plug-in unit104, both on top end or edge of the PCB116and at its bottom end or edge. Conductive traces248may be used for discharge of any static potential.

Guide panel100of the present invention may optionally include Electrostatic Discharge (ESD) components128and270with resilient extensions that flex258that when contacting conductive traces248(FIGS.1A to1C, and3K to3N) may discharge electrostatic potential on PCB116via guide panel100. It should be noted that since guide panel100is constructed of unitized metal structure, it will discharge any potential electrostatic charge from PCB116and hence, the reasons for the ESD components being optional.

As best shown inFIGS.5B to5G, ESD components128may comprise of injection molded conductive plastics with a resilient single right-side extension250(FIGS.5B and5E), a resilient single left-side extension252(FIGS.5D and5G), or resilient double extensions254and256(FIGS.5C and5F).

The resilient extensions (or elongated flexors) enable ESD components128and270to frictionally contact conductive traces248. Accordingly, a gap260(FIG.5A) between adjacent resilient extensions of adjacent slots106is less than the thickness of PCB116for a firm contact of external surface262of resilient extension with conductive traces248.

As best illustrated inFIGS.5E to5G, ESD components128may be further comprised of non-limiting securing mechanisms264and266to allow ESD components128to be securely mounted within respective ESD securing openings228and268on guide panel100.

First securing mechanism264enables ESD components128to be securely mounted onto guide panel100while second securing mechanism266provides an anti-rotation feature that prevents potential rotation of ESD components128as plug-in unit104is inserted through slots106.

FIGS.5H to5Mare another set of non-limiting, exemplary illustrations of details of optional ESD components in accordance with one or more embodiments of the invention. ESD components270illustrated in FIGS. SIT to5M include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as ESD components128that are shown inFIGS.5A to5G, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIGS.5H to5Mwill not, repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to ESD components128that is shown inFIGS.5A to5Gbut instead, are incorporated by reference herein.

In the instance illustrated inFIGS.5H to5M. ESD components270are made from metal sheet stock and by their very nature provide a conductive path from ground strip248of plug-in unit104to guide panel100.

Further, in this non-limiting, exemplary embodiment ESD components270include a fastener opening272through which a fastener (e.g., a rivet, screw, etc.)274shown inFIG.5Amay be inserted to secure ESD component270onto guide panel100.

As further best illustrated inFIGS.5H to5M, ESD components270further include an anti-rotational feature in a form of a non-limiting, exemplary extended flange (or tab)276that abuts against edge278(FIGS.3B-1,3D, and5A) of guide panel100. As indicated above, anti-rotation feature276prevents potential rotation of ESD components270as plug-in unit104is inserted through slots106.

FIGS.6A to6Iare non-limiting, exemplary illustrations of various detailed views of alignment projections and alignment openings of the guide panel and the power-data transmission panel ofFIGS.1A to5Min accordance with one or more embodiments of the present invention.

As indicated above, in this non-limiting, exemplary instance, it is only guide panel100that includes alignment projections126and242and not upper guide panel240. An alignment projection and an alignment opening may be collectively referred to as an alignment structure.

As further detailed below, number, position, size, and orientation of alignment structures in general, and alignment projections126and242and openings184and342in particular, may vary, depending on the requirements of plug-in unit104and power-data transmission panel102.

As will be apparent from the details below, when a guide panel and a power-data transmission panel are sufficiently sized to achieve proper alignment, then all that is required is for one guide panel to have alignment projections, requiring one set of corresponding alignment openings on the power-data transmission panel. In the exemplary instance illustrated inFIGS.1A to6I, due to the sufficient length span286of both guide panel100and power-data transmission panel102, only a single set of alignment projections126and242and alignment openings184and342is needed.

As will be further apparent from details below, use of minimal number of alignment projections126and242and their corresponding alignment openings184and342is beneficial in that it limits any potential conflict that may arise with third-party manufacturing and engineering limitations of typical power-data transmission panel102.

All alignment openings184and342on power-data transmission panel102must be positioned and located away from trace or bus routings of power-data transmission panel102. Any alignment opening184and342that is too close to the trace or bus routings of power-data transmission panel102would have a negative impact (e.g., may cause signal interference) on transmission timing and signal integrity of power-data transmission panel102.

Referring toFIG.6A, alignment projections126and242of guide panel100are comprised of projections extending from guide panel100that engage alignment openings184and342on power-data transmission panel102to thereby align guidance slots106of guide panel100with connectors246of power-data transmission panel102.

As detailed below, alignment projections126(individually referenced as334,336,338, and340inFIGS.6B to6F) and242and alignment openings184(individually referenced as288,290,294,296, and342inFIGS.6B to6F) facilitate with precision and accuracy an engagement of plug-in units104with power-data transmission panel102. As shown inFIG.6C, combined, they may be referred to as alignment structures398,400,402,404, and406.

Alignment projections126and242further facilitate the prevention of power-data transmission panel102associated with guide panel100from an in-plane rotation movement280(FIG.6B), a lateral movement282, and a vertical movement284. Alignment projections126and242provide precision and accuracy in the engagement by isolating any one of in-plane rotation movement280, lateral movement282, and vertical movement284from any one of the pair of in-plane rotation movement280, lateral movement282, and vertical movement284.

FIGS.6C to6Fexemplary illustrate in detail the cooperative operational relationship between alignment projections334,336,338,340, and242and alignment openings288,290,294,296, and342. As illustrated, in this non-limiting, exemplary instance, guide panel100includes four “tab” alignment projections334,336,338,340and a single “pin” alignment projection242.

The four “tab” alignment projections334,336,338,340engage with the four parallel alignment openings288,290,294,296, and the single “pin” alignment projection242engages the single non-parallel alignment opening342. As illustrated, all alignment facilitators (both structure and opening) are spread across longitudinal axis150(FIG.1C) of guide panel100and longitudinal axis286(FIG.2B) power-data transmission panel102.

As further illustrated, in this non-limiting, exemplary instance, power-data transmission panel102includes four axially parallel alignment openings288,290,294, and296and a single non-parallel (preferably generally perpendicular) alignment opening342.

The four axially parallel alignment openings288,290,294, and296have a longitudinal axis298(FIG.6C) that is parallel to longitudinal axis286of power-data transmission panel102. The four axially parallel alignment openings288,290,294, and296have a transverse axis300(FIG.3D) that is parallel to a transvers axis302(FIG.3C) of power-data transmission panel102.

In this non-limiting, exemplary instance, all four axially parallel alignment openings288,290,294, and296are equally sized. Further, longitudinal axis298(FIG.6D) of all four axially parallel alignment openings288,290,294, and296has a longer length span than width176(and hence free cantilever end182) of alignment projections334,336,338, and340. Accordingly, all four axially parallel alignment openings288,290,294, and296provide lateral spacings328between lateral sides330and332(FIG.6D) of alignment openings288,290,294, and296and their respective alignment projections334,336,338, and340. Accordingly, in this non-limiting, exemplary instance, lateral sides420and422of any of alignment projections334,336,338, and340do not contact any edge of alignment openings288,290,294, and296.

In this non-limiting, exemplary instance, all four axially parallel alignment openings288,290,294, and296have transverse axis300that, has a greater width span than thickness178of alignment projections334,336,338, and340. Accordingly, all four axially parallel alignment openings288,290,294, and296provide spacings358between one edge of alignment openings288,290,294, and296and their respective alignment projections334,336,338, and340.

The single non-parallel alignment opening342has a longitudinal axis304(FIG.6F) that is parallel to transverse axis302(FIG.6C) of power-data transmission panel102. The single non-parallel alignment opening342has a transverse axis306that is parallel to a longitudinal axis286(FIG.6B) of power-data transmission panel102, and receives alignment projection pin242.

Referring toFIG.6D, which is an enlarged illustration of a portion ofFIG.6Cportioned off by dashed lines, as illustrated, the first adjacent pair of parallel alignment openings288and290are axially parallel, but they are not axially inline or aligned. For example, first center longitudinal axis360of first alignment opening288is positioned below second center longitudinal axis362second alignment opening290by a distance292.

Referring toFIG.6E, which is an enlarged illustrated of another portion ofFIG.6Cportioned off by dashed lines, as illustrated, the second adjacent pair of parallel alignment openings294and296are also axially parallel, but they are not axially inline or aligned. For example, third center longitudinal axis364of third alignment opening294is positioned above fourth center longitudinal axis366fourth alignment opening296by the same distance292.

Referring to bothFIGS.6D and6E, first alignment opening288is axially parallel and axially inline and aligned with fourth alignment opening296. Further, second alignment opening290is axially parallel and axially inline and aligned with third alignment opening294.

An upper edge308of first alignment opening288is below an upper edge310of second alignment opening290by a distance292. Upper edge310of second alignment opening290is inline with upper edge314of third alignment opening294.

A lower edge316of first alignment opening288is below a lower edge320of second alignment opening290by a distance292. Lower edge316of first alignment opening288is inline with lower edge322of forth alignment opening296.

An upper edge314of third alignment opening294is above an upper edge324of fourth alignment opening296by distance292. Lower edge322of fourth alignment opening296is below lower edge326of third alignment opening294by the same distance292.

As further illustrated inFIG.6D, a top side surface170(highlighted by a thicker line) of first alignment projection334contacts upper edge308of first alignment opening288. Bottom side surface172of first alignment projection334is a distance292away from lower edge316of first alignment opening288and hence, does not contact with lower edge316.

A bottom side surface172(highlighted by a thicker black line) of second alignment projection336contacts lower edge320of second alignment opening290. Top side surface170of second alignment projection336is a distance292away from top edge310of second alignment opening288and hence, does not contact with top edge310.

As best shown inFIG.6E, a bottom side surface172(highlighted by a thicker black line) of third alignment projection338contacts lower edge326of third alignment opening294. Top side surface170of third alignment projection338is a distance292away from top edge314of third alignment opening294and hence, does not contact with top edge314.

As further illustrated inFIG.6E, a top side surface170(highlighted by a thicker black line) of fourth alignment projection340contacts upper edge324of fourth alignment opening296. Bottom side surface172of fourth alignment projection340is a distance292away from lower edge322of fourth alignment opening296and hence, does not contact with lower edge322. It should be noted that in this non-limiting, exemplary instance, alignment structures398and406are aligned in relation to one another and alignment structures400and404are aligned in relation to one another. However, other combinations and permutations in the arrangements of the alignment structures are also possible so long as vertical and in-plane rotational movements284and280are prevented. As a non-limiting example of alternative permutation and combination, alignment structures404may be aligned with alignment structure398and alignment structure406aligned with alignment structure400. It should further be noted that non-contacting upper or lower edges of an alignment opening (not contacting an alignment projection) need not be aligned as described. Additionally, straight portions of the upper and lower edges of the alignment openings must have a longer span than width176of alignment projection126. All non-contacting edges (upper, lower, lateral, etc.) are to enable easy insertion of alignment projections and hence, must be away from the alignment projections. Further, the non-contacting edges and distances allow for manufacturing tolerances of different process and parts (such as guide panel100and power-data transmission panel102) without an adverse effect on card cage assembly accuracy.

As best shown inFIG.6F, lateral sides of pin alignment projection242contact lateral sides344and346alignment opening342. Pin alignment projection242has a very high side-to-side (or lateral) position accuracy as a result of stamping presses or CNC cutting process.

As best illustrated inFIG.6B, the combination of top surfaces170of alignment projections334and340in contact with upper edges308and324of alignment openings288and294with bottom surfaces172of alignment projections336and338in contact lower edges320and326of alignment openings290and294prevent vertical movement284as well as in-plane rotation movement280of power-data transmission panel102.

Additionally, lateral sides of pin alignment projection242in contact with lateral sides344and346alignment opening342prevent lateral movement282of power-data transmission panel102.

In this non-limiting exemplary embodiment, prevention of vertical and in-plane rotational movements284and280are achieved by, one set of alignment structures, isolated from lateral movement282, which is achieved by other alignment structures. Power-data transmission securing screws244may be added and tightened to further secure it to guide panel100as shown throughout the figures.

In addition to preventing unwanted movements, alignment structures are also used for accurate and precise alignment of power-data transmission panel102in relation to guide panel100.

Alignment structures are used to align guidance slots106of guide panel100with connector246of power-data transmission panel102. That way, when plug-in unit104is inserted into a guidance slot106, its connectors348(FIGS.1A and1B) would be aligned in relation to connectors246of power-data transmission panel102. In other words, well known connector348of plug-in unit104are fully aligned with their respective connectors246of power-data transmission panel102and hence, connector348would not be damaged during insertion of plug-in units104.

As detailed below, there is specific physical relationship between the number, position, size, and orientation of each alignment opening on power-data transmission, panel102in relation to number, position, size, and orientation of each alignment projection on guide panel100to provide an accurate and precise alignment between both.

There are a number of factors that determine the number, position, size, and orientation of alignment projections-openings combinations, in particular, the size of power-transmission panel102. For example, the length and the thickness sizes of power-data transmission panel102and the manufacturing process used in creating openings184will determine if power-data transmission panel102would require more than two alignment openings. The larger and thicker sized power-data transmission panel102may require more alignment openings to achieve maximum alignment opening size accuracy, dictated by the manufacturing processes.

It should be noted that the actual shape and number of the alignment openings and alignment projections may be varied, so long as alignment between guide panel100and power-data transmission panel102is achieved for easy and accurate insertion of plug-in units104.

The actual shape and number of the alignment openings and alignment projections may also be varied so long as vertical movement, in-plane rotational movement, and lateral movement of power-data transmission panel102is prevented.

The specific physical relationship between the number, position, size, and orientation of each alignment opening on power-data transmission panel102in relation to number, position, size, and orientation of each alignment projection on guide panel100is achieved by aligning upper edges308and324of respective alignment openings288and294with top surface170of alignment projections334and340of guide panel100. In other words, upper edges308and324of respective alignment openings288and294are coplanar in relation to top surface166of guide panel100.

The specific physical relationship further requires that lower edges320and326of respective alignment openings290and292are coplanar with bottom surface172of structures334and340of guide panel100, which is the same as the bottom surface of guide panel100.

The above scheme provides for precise and accurate alignment and further, significantly reduces manufacturing and assembly tolerances. Given the above parameters and the fact that slot surface160of guidance slots106is coplanar with top surfaces166and170, when plug-in unit104is inserted onto guidance slots106it is positioned in the same plane as top surface170of an alignment projection, substantially reducing any potential errors (lowering tolerances) in manufacturing and assembly.

As best illustrated inFIGS.6G to6I, one or more embodiments of the present invention use the following methodology for establishing the various interfaces of power-data transmission panel102and guide panel100based on given parameters of a plug-in unit104. The finally resulting interfaces of power-data transmission panel102and guide panel100enable full alignment of connectors of plug-in unit104in relation to connectors of power-data transmission panel102and further, eliminate vertical, lateral, and in-plane rotational movements of power-data transmission panel102in relation to guide panel100.

As further detailed below in relation toFIG.6G, some of the parameters from a manufacturer specification or datasheet of a physical structure of plug-in unit104are used as the controlling factors to construct the physical structure of power-data transmission panel102in terms of the number, position, size, and orientation of alignment openings184(FIG.6A), connectors246, and other physical features such as openings368for securing power-data transmission panel102with guide panel100via fasteners244.

In addition, the parameters from the manufacturer specification or datasheet of the physical structure of plug-in unit104are also used as the controlling factors to construct the physical structure of guide panel100, the number, position, size, and orientation of guidance slots106, alignment projections126and242, and other physical features such as securing fastener openings144for securing power-data transmission panel102with guide panel100via fasteners244.

As detailed below, the methodology in constructing interfaces for power-data transmission panel102and guide panel100to accomplish alignment and prevent movements includes first determining coordinates of one or more connectors of a plug-in unit104.

The methodology further requires mapping those coordinates of the one or more connectors of the plug-in unit104onto power-data transmission panel102, and positioning a corresponding connector of the power-data transmission panel from the mapping. Further, constructing a guidance slot size, position, and orientation of guide panel from the coordinates of the one, or more connectors of the plug-in unit104.

The methodology in accordance with one or more embodiments further requires establishing a slot surface of guidance slot, mapping those coordinates onto power-data transmission panel, and constructing alignment openings of the power-data transmission panel from the mapping.

The method of making guide panel100in accordance with one or more embodiments of the present invention requires using a given thickness370of PCB116of plug-in unit104from the specification or datasheet and determining a PCB116center plane372(or first datum plane372) as shown inFIGS.6G to6I.

PCB116center plane372may be determined by merely dividing the overall given thickness372of PCB116in two. PCB116center (or first datum) plane372may be used as the ordinate (or Y-axis) of the system of coordinates as shown inFIGS.6G to6I, a non-limiting, example of such coordinate system may be a Cartesian coordinate system.

As further illustrated inFIGS.6G to6I, bottom facing side374(which, rests directly on surface slot160of guidance slot106) may be used to represent a base-plane376(a second datum plane), which may be used as the abscissa (or X-axis) of the system of coordinates as shown inFIGS.6H and6I.

Since bottom facing side374(or base-plane376) rests on slot surface160, bottom facing side374is coplanar with top surface160of guide panel100and top surface170of alignment projection126. Accordingly, bottom facing side374, the slot surface160, top surface170, and the overall top surface166of guide panel100are all coplanar, defining the base (or second datum) plane376, which is mapped as the X-axis of the system of coordinates.

As best shown inFIGS.6G to6I, bottom side edge374of plug-in unit104(where first and second datum planes372and376cross) resting on central longitudinal axis380(FIG.3E) of slot surface160of guide panel100is mapped to a (0, 0) value of the illustrated Cartesian coordinate system, which is directly mapped as a corresponding (0, 0) value on power-data transmission panel102. As detailed below, this provides a very precise and accurate starting point for mapping the rest of the interfaces of guide panel100and power-data transmission panel102.

Since it is center plane372that rests within guidance slots106, center plane372may be used to construct the position, size, and orientation of each guidance slot106. In fact, the overall width378(FIG.3G) and in particular, slot central longitudinal axis380(FIG.3E) of each guidance slot106is determined based on center plane372.

Guidance slot106position, size, and orientation and in particular, slot central longitudinal axis380is constructed with the view to enable center plane372of PCB116of plug-unit104to precisely and accurately rest directly on slot central longitudinal axis380of guidance slot106. Use of center plane372eliminates the need for concern regarding any potential variances in the overall thickness370of the PCB116as only an average center plane372value is used as a parameter to construct guidance slots106.

Of course, one of the lateral sides382or384(FIG.6G) of PCB116may also be used instead of center plane372, but to do so would require a shifting of the position of central longitudinal axis380of guidance slot106to align or coincide with center plane372, which is half the thickness370of PCB116.

PCB116center plane372may also be used to determine the “X” coordinate positional value (X, 0) of contacts392(FIGS.6H and6I) of plug-in unit104(as shown inFIGS.6H and6I). In other words, PCB center plane372is one of the aspects that contributes to precise and accurate alignment of X-coordinate positions (X, 0) of contacts392of plug-in units104and connectors246of power-data transmission panel102.

Referring toFIGS.6H and6I, the “Y” coordinates positional value (0, Y) is determined by a given contact-distance identifier388from the manufacturer specification or datasheet. In other words, contact-distance identifier388may be used to determine the “Y” coordinate positional value (0, Y) of the corresponding contact394(FIG.6B) of power-data transmission panel (as shown inFIGS.6H and6I).

Contact-distance identifier388is a given distance that spans from base plane376(or bottom facing edge374) of PCB116of plug-in unit to a center of any one of the first row390of contacts392of plug-in unit104.

Contact-distance identifier388is one of the aspects that contributes to precise and accurate alignment of Y-coordinate positions (0, Y) of contacts392of plug-in units104and contacts394of power-data transmission panel102.

The combination of both X and Y coordinates (X, 0) and (0, Y) as detailed above, point to a center point position (X, Y)PUof a contact392of plug-in unit104, which is mapped onto power-data transmission panel102and constructed as a corresponding position (X, Y)TPof contact394(FIG.6B) of power-data transmission panel102. This process is simply repeated for the rest of connectors348of plug-in unit104to map out and construct the rest of connectors246of power data transmission panel102. Openings396(FIG.6B) are not part of connectors246, but are indexing openings for proper orientation of plug-in unit104for connection with power-data transmission panel102.

As to the alignment openings, as best illustrated inFIG.6B, upper edges308and324of alignment openings288and296on power-data transmission panel102are set to be coplanar with second datum plane376, which is top surface166of guide panel100(which is coplanar with top side170of alignment projections334and340). Further, lower edges320and326of alignment openings290and294on power-data transmission panel102are set to be coplanar with bottom or underside surface172of alignment projections336and338. All alignment openings are well below first row390of connectors246thus preventing any potential issues with trace or bus interferences.

FIGS.7A and7Bare non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIGS.7A and7Binclude similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to6I, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIGS.7A and7Bwill not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to6Ibut instead, are incorporated by reference herein.

As illustrated inFIGS.7A and7B, in this non-limiting, exemplary instance based on parameters of a plug-in unit104requirements, power-data transmission panel102has a shorter longitudinal axis286, but a longer transverse axis302. Accordingly, for this embodiment, both lower and upper guide panels100and240have alignment projections126and242that are inserted into corresponding alignment openings184and342of power-data transmission panel102. As indicated above, number, position, size, and orientation of alignment structures in general, and alignment projections126and242and openings184and342in particular, may vary depending on the requirements of the plug-in unit104.

In this non-limiting, exemplary instance, first alignment structure408is associated with upper guide panel242and upper section of power-data transmission panel102. A second alignment structure410is associated with lower guide panel100and lower section of power-data transmission panel102. In this embodiment, both, the first and the second alignment structures408and410prevent lateral282as well as in-plane rotational280movements of power-data transmission panel102. In this non-limiting, exemplary instance, third and fourth alignment structures412and414are associated with lower guide panel100and lower section of power-data transmission panel102. Both third and fourth alignment structures412and414prevent vertical movement284of power-data transmission panel102.

FIG.8is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.8include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to7B, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIG.8will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to7Bbut instead, are incorporated by reference herein.

As illustrated inFIG.8, in this non-limiting, exemplary instance, alignment structure416prevents lateral movement282of power-data transmission panel102. Alignment structure416includes alignment projection126extending from lower guide panel100and inserted into alignment opening418. In this embodiment, lateral sides420and422of alignment projection126contact straight lateral sides424and426of alignment opening418. Straight lateral sides424and426of alignment opening418must be of sufficient span so that the curved corners of alignment opening418do not interfere with lateral sides420and422of alignment projection126. Accordingly, there is spacing between top and bottom sides170and172of alignment projection126and upper and lower edges428and430of alignment opening418. Additionally, straight portions of the lateral edges of the alignment openings must have a longer span than thickness178of alignment projection126. All non-contacting edges (upper, lower, lateral, etc.) are to enable easy insertion of alignment projections and hence, must be away from the alignment projections. Further, the non-contacting edges and distances allow for manufacturing tolerances of different process and parts (such as guide panel100and power-data transmission panel102) without an adverse effect on card cage assembly accuracy.

FIG.9is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.9include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to8, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIG.9will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to8but instead, are incorporated by reference herein.

As illustrated inFIG.9, in this non-limiting, exemplary instance, alignment structure434and436prevent in-plane rotation, movement280and vertical movement284while alignment structure402prevents lateral movement282of power-data transmission panel102.

Alignment structures432and436include alignment projections126extending from lower guide panel100and inserted into respective alignment opening438and440.

In this embodiment, top and bottom sides170and172of alignment projections126contact respective upper and lower edges442and444of alignment openings438and440. Further, there is spacing328between lateral sides420and422of alignment projections126and alignment openings438and440. Additionally, straight portions of the upper and lower edges442and444of the alignment openings438and440must have a longer span than width176of alignment projection. Further, the non-contacting edges and distances allow for manufacturing tolerances of different process and parts (such as guide panel100and power-data transmission panel102) without an adverse effect on card cage assembly accuracy.

FIG.10is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.10include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to9, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIG.10will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to9but instead, are incorporated by reference herein.

In this non-limiting, exemplary instance, a combination of alignment structures432,416, and436described above are used together.

FIG.11is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel, in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.11include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to10, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIG.11will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to11but instead, are incorporated by reference herein.

In this non-limiting, exemplary instance, alignment structures408and410shown inFIGS.7A and7Bare replaced with alignment structures446and448. Alignment structures446and448are identical to alignment structure418. As with the embodiment illustrated inFIGS.7A and7B, alignment structures prevent lateral and in-plane rotational movements282and280of power-data transmission panel102. Alignment structures412and414prevent vertical movement284of the power-data transmission, panel102.

FIG.12is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission, panel, in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.12include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to11, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIG.12will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described, above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to11but instead, are incorporated by reference herein.

In this non-limiting, exemplary instance, alignment structures structure450(identical to alignment structures432and436) prevent vertical movement of the power-data transmission panel102.

FIG.13is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.13include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to12, and described above. Therefore, for the sake of brevity, clarity, convenience, and to, avoid duplication, the general description ofFIG.13will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to12but instead, are incorporated by reference herein.

In this non-limiting, exemplary instance, alignment structures452and454(identical to alignment structure416) prevent both lateral and as well as in-plane rotation movements282and280of power-data transmission panel102.

FIG.14is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.14include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to13, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIG.14will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to13but instead, are incorporated by reference herein.

In this non-limiting, exemplary instance, alignment structures456is comprised of an alignment opening458and alignment projection126. Both top and bottom surfaces170and172of alignment projection126fully contact respective upper straight section edge460and lower straight section edge462of alignment opening458.

As further illustrated, both lateral sides420and422of alignment projection126also fully contact respective first and second straight section sides464and466. The rounded lateral openings468and470facilitate in constructing alignment opening458.

In this non-limiting, exemplary instance, alignment structure456prevents in-plane rotational movement280, lateral movement282, and vertical movement284because alignment projection126contacts all four edges460,462,464, and466of alignment opening458. Further, alignment structure452in combination with alignment structure456further prevent both lateral and in-plane rotational movements282and280.

FIG.15is non-limiting, exemplary illustrations of an alignment structure for guide panel and power-data transmission panel in accordance with another embodiment of the present invention. Guide panel and power-data transmission panel illustrated inFIG.15include similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as guide panel and power-data transmission panel that are shown inFIGS.1A to14, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIG.15will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to guide panel and power-data transmission panel that are shown inFIGS.1A to14but instead, are incorporated by reference herein.

In this non-limiting, exemplary instance, alignment structures472is comprised of an alignment opening474and alignment projection126. Both top and bottom surfaces170and172of alignment projection126fully contact respective upper straight section edge476and lower straight section edge478of alignment opening474.

As, further illustrated, both lateral sides420and422of, alignment projection126do not contact respective first and second straight section sides480and482. Accordingly, there is a spacing328between lateral sides420and422of alignment projection126and respective sides480and482of alignment opening474. The rounded lateral openings468and470facilitate in constructing alignment opening474.

In this non-limiting, exemplary instance, alignment structure456prevents in-plane rotational movement280, lateral movement282, and vertical movement284of power-data transmission panel102. Further, alignment structure472in combination with alignment structure456further prevent vertical as well as in-plane rotational movements284and280of power-data transmission panel102.

It should be noted that for all, of the embodiments disclosed the precision and accuracy is substantially below +/−0.15 mm (0.005 in) with respect to alignment and lateral, vertical, and in-plane rotational movements of power-data transmission panel102in relation to guide panel100. The best precision and accuracy achieved by well-known conventional systems at best is above +/−0.46 mm (0.018 in), which is substantially less precise and less accurate (about 300% less precise and less accurate) and without preventing lateral, vertical, and in-plane rotational movements.

FIGS.16A to16Iare non-limiting, exemplary illustrations of, a card cage (in particular, guide panel) that includes accommodations for a box type plug-in unit in accordance with another embodiment of the present invention. The guide panel illustrated inFIGS.16A to16Iinclude similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as the guide panels that are shown inFIGS.1A to15, and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description ofFIGS.16A to16Iwill not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to the guide panel that are shown inFIGS.1A to15but instead, are incorporated by reference herein.

FIGS.16A to16Iare non-limiting, exemplary illustrations related to a guide panel assembly of a card cage that is capable of accommodating box type plug-in units in accordance with one or more embodiments of the present invention. As illustrated, in this non-limiting, exemplary instance, lower and upper guide panel assemblies484and524each include a guide panel486, a box guide panel488, a box guide slot490, and angled fastener bar218.FIG.16Afurther illustrates a conventional box plug-in unit526mounted between upper and lower guide panel assemblies484and524and connected to power-data transmission panel102.

As with, lower and upper guide panels100and240, lower and upper guide panel assembly484and524are also identical with the exception of their respective interfaces with power-data transmission panel102. Accordingly, from this point forward, only lower guide panel assembly484is discussed in detail for simplicity and clarity.

Guide panel486has the same identical engagement structure124as described above for accommodating card plug-in units104for the four illustrated guidance slots106. In this non-limiting, exemplary instance, the well-known, conventional box plug-in units526may not require or need second vertical surface224of guide panel484(which includes the key or index openings134, second guide openings226, etc.

As detailed below, one or more embodiments of the present invention are optionally designed to accommodate one or more box plug-in units526, which require a box guide panel488for support. Accordingly, one or more embodiments of the present invention provide a box guide panel488associated with guide panel486, with box guide panel488supporting one or more box plug-in units (not shown, but well known). This embodiment merely illustrates the flexibility of the innovative design of a guide panel of the present invention with reduced parts, while meeting various standards without loss in functionality.

Referring toFIG.16E, guide panel486has identical features compared to any one of the guide panels discussed above with the exception that it has a box guide opening492between its slots106to receive a box guide panel488. Further included on guide panel486are lateral fastener openings494for securing box-guide panel488to guide panel486.

Box guide opening492may be varied in terms of size, position, and number. For example, a box guide opening492may be positioned at a distal lateral end of guide panel486. As another example, two box guide openings492of larger size may be positioned at both distal lateral ends of guide panel486for supporting two box plug-in units.

As illustrated, box guide opening492of guide panel486may be formed by removing some infrastructure from guide panel486, providing openings492for attachment of box guide panel488within opening492. Any type of well-known fastener mechanism may be used to securely attach a box guide panel488to guide panel486, including using the illustrated fasteners496.

As further illustrated (for example, inFIG.16D), top surface498of box guide panel488is at a lower elevation by a distance500from top surface166of guide panel486. Lower elevation distance500of top surface498of box guide panel488provides sufficient spacing (between top and bottom box guide panels—only one box guide panel is shown) to enable box plug-in unit (which has increased, height size than a plug-in unit) to fit in between top and bottom box guide panels.

As illustrated, optimally, box guide panel488also includes ventilation openings146, including openings504for securing box guide slots490for mounting and aligning of box plug-in units. It should be noted that in this non-limiting, exemplary instance, one box-guide slot490is illustrated. However, instead, more box guide slots490may also be optionally used for a single box plug-in unit instead of the one per box plug-in unit.

As illustrated inFIGS.16G to16I, box guide slots490are associated with, box guide panel488to accommodate and support box plug-in units in accordance with one or more, embodiments of the present invention. In this non-limiting, exemplary instance, box guide slots490are not part of box guide panel488but are securely mounted onto box guide panel488.

Each box guide slot490supports a single box plug-in unit on box guide panel488. Box guide slot490may be comprised of the same material as the ESD components128for ESD protection.

Box guide slot490may comprise of chamfered edges506for easy insertion (or sliding) of a box plug-in unit. Box guide slot490may further include resilient extensions508that firmly mechanically contact (“interference fit”) box plug-in units for ESD protection as indicated inFIG.16I.

Resilient extensions508are equivalent to resilient extensions of ESD components128. The opposite side of box guide slot490(FIG.16H) may include interlocking extensions510that snap into respective openings504of box guide panel488.

Referring back toFIGS.16A to16F, box guide panel488has top and bottom box guide panel surfaces498and512, and includes lateral mounting flanges514that include openings502for mounting and securing box guide panel488to underside of lateral sides516of openings494on guide panel486.

Further included are front and rear facing flanges516and518that are bent to enable top surface498of box guide panel488to remain flat and coplanar with second horizontal surface212of engagement structure124of guide panel486. This structural arrangement enables easy insertion and removal of box type plug-in unit enclosures on coplanar surfaces498and212. Surface498may be at a lower elevation than that of surface212. Front and rear flanges516and518may be optional for short box guide panels (as shown) and may function as stiffeners.

Although the invention has been described in considerable detail in language specific to structural features and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Further, the specification is not confined to the disclosed embodiments. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur, to those skilled in the art. For example, the location of alignment projections and alignment openings may be reversed. For example, power-data transmission panels102may comprise the alignment projections and guide panel may comprise the alignment openings. As another example, any number of combinations and permutations of the alignment structures shown throughout the figures may be used for, any card cage or power-data transmission panel. A non-limiting, exemplary method of manufacturing guide panel is to use sheet metal and cut out all shapes (e.g., by punching/laser cut/use of CNC machines, stamping press etc.), bend to selected configurations, and add standoffs at the rear flange and bend desired sections. It should be noted that the slot106infrastructure is, formed during the automated cut-out operations or stamping operations. In other words, slot106opening edges are formed during the same cutting process. Accordingly, the engagement structures124are for example, punched and formed when either CNC or stamping processes are used. During actual final step of assembly of the card cage, all that would be required is the use of fasteners such as rivets or threaded fasteners to connect all manufactured parts. The present application does not preclude the joining of parts through welding, brazing, soldering, etc. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention.

It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, inside, outside, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, lateral, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction, orientation, or position. Instead, they are used to reflect relative locations/positions and/or directions/orientations between various portions of an object.

In addition, reference to “first,” “second,” “third.” and etc. members throughout the disclosure (and in particular, claims) is not used to show a serial or numerical limitation but instead is used to distinguish or identify the various members of the group.

Further the terms “a” and “an” throughout the disclosure (and in particular, claims) do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

In addition, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of,” “act of,” “operation of” or “operational act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.