Electronic device support and method

[0002] This application is a Continuation-in-part application of U.S. application Ser. No. 09/408,148 filed Sep. 29, 1999, now U.S. Pat. No. 6,452,805, the specification of which is herein incorporated by reference.

[0003] This invention relates to hardware for electronic devices, and in particular to a support for supporting electronic devices.

[0004] Commercial use electronic systems typically include electronic devices resting on a special sub-floor allowing for cable routing and grounding beneath the floor surface. In some cases, electronic devices are supported in commercial structures or racks.

[0005] Installation, service and upgrade of a commercial computer system can be a protracted and cumbersome process. Installation may require time consuming placement of supports within the standard racks.

[0006] Service and upgrade of commercial systems also typically requires removal of an electronic device from the rack. The difficulty of removing a module from the rack can be compounded by the increased weight of the element. Service and upgrade also may require disassembly of the computer module housing to access, repair or replace components internal to the module before the module is replaced within a rack.

[0007] When an electronic system is scaled or reconfigured and an electronic device is instead exchanged for another device of a different size, the supports within the rack have to be removed and reinstalled to accommodate the new device in the system. Supports are typically attached to the rack using a multi-piece fastener such as a nut and screw that must be assembled through a standard industry size aperture.

[0008] Electronic systems formed from these discrete units must be assembled together to make a larger system. Modules are typically difficult to align and install into the rack. The position of the module must typically be adjusted into the proper position and must be adjusted in order to be secured within the rack. Accessing portions of the electronic system typically requires accessing a number of discrete modules. Modules will typically be positioned within racks providing poor access to the module. This can slow the installation, service, and upgrade processes making larger systems from these components less desirable. This is also one cause of poor field serviceability. Proper positioning and servicing of modules is often either not done, poorly done, or is improperly done.

[0009] A need exists for improved electronic devices and for an improved means for supporting the electronic devices and for improving the ease with which commercial systems are installed, serviced, upgraded and scaled.

[0010] According to one aspect of the invention, the support bracket includes a front surface and a rear surface each including a portion having at least one threaded hole and a support portion between the front surface and rear surface for supporting an electronic device.

[0011] According to one aspect of the invention, the improved support bracket includes a side portion having a mechanism for coupling the side portion to a structure, a guide portion and a support portion for supporting an electronic device.

[0012] The resulting support bracket improves the ease with which the support bracket is installed, repositioned or removed from a structure and improves placement, installation, service and upgrade of electronic devices.

[0013] FIG. 1 is a view of one embodiment of a support bracket;

[0014] FIG. 2 is a view of one embodiment of a support bracket;

[0015] FIG. 3 is a front view of one embodiment of a rail;

[0016] FIG. 4 is a side view of one embodiment of a rail;

[0017] FIG. 5 is an isometric view of one embodiment of a rail;

[0018] FIG. 6 is a view of a structure having a support bracket;

[0019] FIG. 7 is a view of a structure having a support bracket;

[0020] FIG. 8 is a view of an electronic device;

[0021] FIG. 9 is a view of an electronic device; and

[0022] FIG. 10 is a view of an electronic device.

[0023] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.

[0024] FIG. 1 illustrates an improved support bracket 2100 for use in mounting electronic devices in a structure. The improved support bracket 2100 provides improved adjustability in that the support bracket 2100 can be vertically adjusted along the length of the structure with greater ease than conventional supports. In one embodiment, the support bracket 2100 includes a front mounting portion 2110 and rear mounting portion 2120 including a series of holes 2140 and a support portion 2130 being coupled between the front 2110 and rear 2120 mounting portion. The support can be used to mount an electronic device in a structure 1000 such as that described in U.S. application Ser. No. 09/408148 Computer Module Mounting System and Method.

[0025] In one embodiment, the series of holes 2140 on the front and rear mounting portion 2110, 2120 include threaded holes 2150 for aligning with a first series of apertures 2020 on a structure 1000 or on vertical rail 2000 coupled to a structure 1000.

[0026] FIGS. 3, 4 and 5 illustrate embodiments of a vertical rail 2000 for coupling to a structure 1000. FIGS. 6 and 7 illustrate an embodiment of a plurality of support brackets 2100 coupled to vertical rails 2000 which are coupled to a structure 1000. A threaded fastener inserted through an unthreaded aperture 2020 on the rail 2000 can then engage a threaded hole 2150 on the front 2110 and rear 2120 mounting portion of the support bracket 2100 to secure the support bracket 2100. Where the apertures 2025 on the rail 2000 are of a standard industry size that is relatively small, this may dictate use of relatively small fasteners which can be awkward to handle because of their size. In one embodiment, the threaded hole 2150 aligns with a first series of apertures 2020 on the vertical rail 2000 of a standard industry size 2025. The support bracket improves the ease with which the bracket is installed, repositioned, or removed as the support bracket 2100 eliminates the need for a two piece fastener that must be handled on both sides of the aperture 2025 on the vertical rail 2000 and allows use of a one piece fastener from the outer face 2015 of the rail 2000 instead. In another embodiment, the front and rear mounting portion 2110, 2120 of the support bracket 2100 include threaded holes 2150. In another embodiment, the front and rear mounting portion 2110, 2120 include threaded holes 2150 having an increased number of threads extending from the surface of the front and rear mounting portions 2110, 2120 so that the threaded portion is actually wider than the thickness of the mounting portion 2110. This increases the thread engagement providing for improved fastener retention. In one embodiment, the threaded hole is extended when forming the threads.

[0027] In another embodiment, the mounting portion 2110, 2120 of the support includes at least one unthreaded hole 2145. In one embodiment, the mounting portion 2110, 2120 include at least one threaded 2150 and at least one unthreaded hole 2145. This provides increased flexibility with regard to the type of fastener used to secure the support to the structure 1000. In one embodiment, an internal support mounting system includes a hole 2145 that is precisely machined and located to tight tolerances for aligning with precisely machined and located rail 2000 apertures such as apertures 2020 and 2025. The result is highly consistent placement of electronic devices such within the structure 1000 system. In one embodiment, this helps to improve alignment required by additional features such as an insertion/extraction mechanism for inserting and extracting a portion of an electronic device such as described in U.S. application Ser. No. 09/408,969 Printed Circuit Board Carrier Insertion/Extraction Assembly. In one embodiment, this enables precise and repeatable alignment with other features of the structure such as an external platform as described in U.S. application Ser. No. 09/408148 Computer Module Mounting System and Method for all adjustable positions of the electronic device within the structure and for all adjustable positions of the platform.

[0028] In another embodiment, the support bracket 2100 further includes a side portion 2160 coupled between the front mounting portion 2110 and rear mounting portion 2120 and coupled to the support portion 2130. In one embodiment, the side portion 2160 includes a guide portion 2165 extending from the side portion 2160 for positioning the computer component. The guide portion 2165 helps to guide the position of the electronic device during installation into the structure 1000 and helps to maintain its horizontal placement within the structure 1000. This helps to improve alignment required by additional features such as an insertion/extraction mechanism for inserting and extracting a portion of an electronic device such as described in U.S. application Ser. No. 09/408,969 Printed Circuit Board Carrier Insertion/Extraction embodiment, this enables precise and repeatable alignment with other features of the structure such as an external platform as described in U.S. application Ser. No. 09/408148 Computer Module Mounting System and Method for all adjustable positions of the electronic device within the structure and for all adjustable positions of the platform.

[0029] FIGS. 8, 9 and 10 illustrate embodiments in which the front portion of the electronic device or module 4000 includes flanges 7000 extending out each side. Each flange 7000 includes a pin 7010 portion for inserting into an aperture 2020, 2025 in the rail 2000. In one embodiment, the pin 7010 and aperture 2020, 2025 are precisely machined and located to strict tolerances so that placement of the pin 7010 into the aperture helps to control placement of the module 4000 in the structure. In one embodiment, the pin 7010 is precisely machined, apertures 2020, 2025 are precisely machined and at least one hole 2145 within the series of holes 2140 is precisely machined so that the pin 7010 is received in aperture 2020, 2025 and hole 2145. This helps to improve alignment required by additional features such as an insertion/extraction mechanism for inserting and extracting a portion of a module 4000 such as described in U.S. application Ser. No. 09/408,969 Printed Circuit Board Carrier Insertion/Extraction Assembly. In one embodiment, this enables precise and repeatable alignment with other features of the structure such as an external platform as described in U.S. application Ser. No. 09/408148 Computer Module Mounting System and Method for all adjustable positions of the electronic device within the structure and for all adjustable positions of the platform.

[0030] In one embodiment, the support bracket is formed from one piece of material. In another embodiment, the interface between the side portion 2160 and the support portion 2130 includes embossments 2170 for strengthening the carrying capacity of the internal support 2000. This allows the internal support 2000 to be formed from a thinner material or a lower strength material than could be used otherwise.

[0031] In another embodiment, the internal support 2000 includes side mounting features 3000 that can be used in conjunction with the features 2140 on the front 2110 and rear mounting 2120 portions or can be used independently. In one embodiment, the side mounting features 3000 include tabs 3010, 3020 for engaging slotted apertures 2042 within the series of side apertures 2040 in a custom rail 2000. The side mounting features 3000 include a first set of mounting tabs 3010 extending from the top edge 2180 of the support bracket 2100 and a second set of mounting tabs 3020 extending outward from the support portion 2130. In one embodiment, the custom rail 2000 includes a series of side apertures 2040 which when installed on a structure, run the length of the structure 1000. In one embodiment, the custom rail 2000 includes both a first rail portion 2010 having a first series of apertures 2020 as those described above, and a side rail portion 2050 including the series of side apertures 2040. The series of side apertures 2040 are oriented such that when the mounting tabs 3010, 3020 engage the side apertures 2040 anywhere along the length of the structure 1000, the support bracket 2100 is positioned so that the holes 2150, 2145 on the front mounting portion 2110 and rear mounting portion 2120 align with the first series of apertures 2020 on the structure 1000 or on the rail 2000 installed on the structure 1000. This also improves the ease of fastening the front mounting portion 2110 and rear mounting portion 2120 to the rail 2000.

[0032] In another embodiment, the support includes airflow perforations 2190.

[0033] In another embodiment, the series of side apertures 2040 are oriented such that when the mounting tabs 3010, 3020 engage the slotted apertures 2042 within the series of side apertures 2040 anywhere along the length of the structure 1000, the support bracket 2100 is positioned so that the side holes 2191 on the side portion 2160 align with a side hole 2044 in the series of side apertures 2040 on the structure 1000 or on the rail 2000. The side holes 2191 are for use in securing the position of the support bracket 2100. In one embodiment, a pushpin is inserted through the side hole 2191 on the support bracket 2100 and through the side hole 2044 within the series of side apertures 2040 within the series of side apertures 2040 in the structure 1000 or rail 2000.

[0034] Precise placement of a electronic devices, such as modules 4000, within the structure 1000 with the precision methods described allows for optimization of module 4000 dimensions. Modules 4000 can be designed to have maximum height, width, and depth in order to satisfy industry standards while providing the maximum amount of space internally to the module 4000 and also maximizing module 4000 content within structures 1000. Features providing for automatic alignment and placement of components improves installation, serviceability, upgrade and scalability in an environment traditionally unfavorable to these needs. This provides for improved ability to provide larger computer systems and allows computer systems using these modules 4000 to be scaled, installed, serviced and upgraded at greatly improved levels of performance.

[0035] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.