Patent Grant
7137850
The present invention relates to circuit link connectors. Certain embodiments provide power distribution apparatus utilizing such circuit link connectors.
Electronic equipment racks commonly consist of rectangular or box-shaped housings or rack structures. Electronic equipment is commonly mountable in such racks so that the various electronic components are aligned vertically one on top of the other in the rack. Often, multiple racks are oriented side-by-side, with each rack containing numerous electronic components and having substantial quantities of associated component wiring located both within and outside of the area occupied by the racks.
Power distribution units have long been utilized to supply power to the equipment in such racks. Power distribution units have also been designed to allow a user to remotely monitor and control the power distribution unit or devices attached to the power distribution unit. Examples of such power distribution units can be found in U.S. Pat. Nos. 5,506,573, 5,949,947, and 6,711,613.
One particularly common such power distribution unit consists of an elongated box housing that has one or more power inputs penetrating the housing and a number of power outputs extending along the longitudinal face of the unit. This power distribution unit is designed to mount vertically adjacent or secured to the external rear side of a rack. In this fashion, the power supplied to the unit is then distributed through horizontally extending power outputs to the, typically, horizontally co-aligned electronic components mounted in the rack. An example of such a prior power distribution unit is sold under the trademark POWER TOWER by Server Technology, Inc., of Reno, Nev.
As previously stated, each power distribution unit typically contains a number of power outputs and at least one power input. The power distribution units may also contain other electronic components, such as fuses and monitoring devices. Typically, all of these electronic components must be wired together, which can create numerous problems and inefficiencies.
One such problem is that the size of the electronic components and the associated wiring may limit the dimensions and shape of the housing. A housing having a certain minimum size usually is required merely to hold the electronic components and wiring of the power distribution unit. The size of the housing can limit the locations in which the power distribution unit can be mounted. For example, the power distribution unit may be too large for certain spaces. The size of the components and wiring may limit how many and what kind of components can be included in a power distribution unit. The housing typically must be sized such that the various electronic components do not make undesired contact with each other.
Another problem with such prior art power distribution units is that they often require substantial time and effort to assemble because each electronic component is typically individually mounted in the housing. Furthermore, each electronic component is typically individually wired with line, neutral, and ground connections. The cost to build such power distribution units may be influenced by material costs that are partially determined by factors such as the size of the housing, the amount of wiring in each power distribution unit, and the amount of other materials, such as solder, needed to assemble each power distribution unit. In addition to possibly requiring greater assembly time, the numerous parts and connections in typical prior art power distribution units may result in a greater number of errors during the manufacturing process or a greater chance of equipment failure once the power distribution units are in use.
Another problem with some prior art power distribution units stems from the fuses or other devices that are typically used to protect the power distribution unit and attached electronic devices against current fluctuations. Often, the fuses may only be checked and replaced by removing the power distribution unit from a rack and opening the power distribution unit. In addition to possibly being time consuming and labor intensive, opening up the unit may violate a warranty on the unit.
Many standards setting organizations, certifying bodies, and codes are requiring branched circuit protection. That is, power outlets may be arranged in groups or “branches,” each of which must be separately fused. Branched circuit protection may result in an increased number of fuses in each power distribution unit, thus potentially increasing the size of, and the amount of wiring in, the power distribution unit.
The present disclosure related to a circuit link interconnection board. Certain embodiments provide a power distribution unit constructed using at least one circuit link interconnection board.
In a first embodiment, the circuit link interconnection board includes at least one circuit link. A plurality of contacts are located on the circuit link interconnection board. A first portion of the plurality of contacts may place the circuit link interconnection board in communication with at least a first electrical component.
In a second embodiment, a second portion of the plurality of contacts may place the circuit link interconnection board in communication with at least a second electronic component. In the case of an electrical abnormality, such as a current spike, the circuit link interconnection board will open a circuit, interrupting communication with the first or second electronic components.
In a third embodiment, the circuit link interconnection board is connected to a power source. Power from the power source, such as AC line power, may be transmitted to the first or second electrical components through the circuit link interconnection board. In additional embodiments, the circuit link interconnection board may carry electrical signals which may represent data.
In a fourth embodiment, the first electronic component is a ganged power outlet. In a fifth embodiment, the first and second electronic components are ganged power outlets. Ganged power outlets are single electronic components that contain a plurality of individual power outlets. The outlet gang includes at least one power rail coupled to the individual power outlets. The power rail may be connected to each individual power outlet in the outlet gang in order to deliver power, such as AC line power, to each individual power outlet. The power rail may have a connector at least at one end. In certain embodiments, the power rail has connectors at two ends.
Certain embodiments of the present invention may provide power distribution units having reduced amounts of wiring. Wiring reduction can occur in a number of ways. First, in certain embodiments, electronic components are connected to power supplies or circuit links (such as fuses or circuit breakers) through the circuit link interconnection board. The use of the circuit link interconnection board can obviate the need for discreetly wiring each electronic component.
Similarly, in further embodiments, the electronic components are directly connected to the interconnection board. Direct connection of the electronic components to the interconnection board may eliminate the need to use discrete wires to connect the electronic components to the circuit link interconnection board.
Power distribution units having reduced wiring may provide a number of advantages. For example, the size of a power distribution unit may be reduced because each outlet no longer need necessarily be connected by standard wires. Because of the reduced number of parts, these embodiments may provide other benefits, such as faster assembly, fewer assembly errors, enhanced reliability, and easier repair and service.
In addition, the potential compactness of certain embodiments may allow additional electronic components to be added to the power distribution unit without significantly increasing the size of the housing. Also, the modular nature of circuit link interconnection boards and outlet gangs may allow easier repair or replacement of components of the power distribution unit.
In a sixth embodiment, the circuit link interconnection board comprises a fuse holder. In a seventh embodiment, the circuit link interconnection board includes a plurality of fuse holders. A fuse may be coupled to the fuse holders of the sixth and seventh embodiments.
In an eighth embodiment, the circuit link interconnection board includes a plurality of circuit links and is in power supply communication with a plurality of electrical devices. The electrical devices are connected to the interconnection board in a plurality of branches, each of the branches being protected by at least one circuit link.
In a ninth embodiment, an indicator is provided to display the status of a circuit link. In at least one embodiment, the indicator is coupled to the circuit link interconnection board. For example, an LED may be connected a particular circuit protected by a circuit link and normally lit when the circuit is closed. If the circuit link is tripped, such as when a fuse is blown, the LED will be turned off, indicating that the circuit is open.
In a tenth embodiment, the circuit link interconnection board is a printed circuit board having a plurality of layers. One or more layers of the printed circuit board may transmit a particular electrical component. For example, in AC line power transmission, one layer may correspond to an AC line connection and another layer may correspond to an AC neutral connection. Other layers could be used for a ground connection or to transmit other electrical signals, including communication signals.
Using an entire layer of a circuit board to transmit an electrical component may allow a larger amount of the electrical component, such as a component of AC line power, to be transmitted using the circuit board. The relatively large transmission capacity of the layers of the circuit board may allow the circuit board to function as an assembly of wires.
In an eleventh embodiment, the circuit link interconnection board is similar to the circuit link interconnection board of the tenth embodiment but includes at least one layer formed in a plurality of sublayers. An insulating barrier may separate each sublayer. Accordingly, each sublayer may be used to transmit a different electrical component, such as a component of AC line power or data. The use of a power connection board having a layer formed in a plurality of sublayers may allow the power connection board to have fewer layers, to transmit more electrical components, and/or be attached to a greater number of electrical parts. The size of the sublayer is preferably sufficiently large to allow effective transmission of the particular electric component.
In a twelfth embodiment, the interconnection board may allow connections to electronic components to be made in varying configurations. For example, certain embodiments of the invention may provide two electrical parts in a back to back configuration, with the interconnection board intermediate the electrical parts. If standard wires were used, the wires would need to cross in order to properly connect the electrical parts. The crossed wires may make the assembly of the power distribution unit more complex and may require more space in the housing. Using the interconnection board, this configuration (the crossing of the connection) can be made internal, requiring no modification of the housing or in how the power distribution units are assembled.
In a thirteenth embodiment, the circuit link interconnection board is disposed in a power distribution unit having circuit link access openings. The circuit link access openings may allow access to, or visual inspection of, circuit links of the circuit link interconnection board. In certain embodiments, an operator may reset the circuit link, such as by replacing a fuse or resetting a circuit breaker, without having to remove or disassemble the power distribution unit. The access openings may be covered, including by transparent windows or by protective coverings such as metal or plastic plates.
In a fourteenth embodiment, the circuit link interconnection board includes a ground connection for a circuit of the circuit link interconnection board. A fastener opening may be formed in the circuit link interconnection board and in communication with the circuit. A fastener may be inserted through the fastener opening and coupled to a ground, such as the housing of a power distribution unit. The use of the fastener as a ground connection may reduce the wiring requirements of power distribution units according to this embodiment because this embodiment may obviate wiring a separate ground connection.
It is to be understood that this Summary of the Invention lists various aspects of various embodiments of the present invention. Additional aspects of the present invention will become apparent as this specification proceeds.
It is also to be understood that all features noted above need not be included in a given embodiment and that not all deficiencies noted in the prior art need be overcome by a given embodiment in order for it to fall within the scope of the present invention.
The preferred embodiments are shown in the accompanying drawings in which:
A power distribution apparatus (PDA) 100 according to an embodiment of the present invention is shown in
The housing 104 is made of a substantially rigid and durable material, such as metals or plastics, including polycarbonate resins. In at least one embodiment, the housing 104 is made of sheet metal.
Two power inputs 116 are coupled to the housing 104. Although two power inputs 116 are shown, more or less power inputs 116 could be used. In the illustrated embodiment, the power inputs 116 are connected through the front face 106 of the housing 104, proximate the first end 112 of the housing 104. The power inputs 116 may be connected to a power supply (not shown), such as an AC line power supply, to provide a desired level of power to one or more electrical appliances (not shown). The power inputs 116 may be adapted to employ single phase power or polyphase power, such as double or triple-phase power. In embodiments employing multiphase power, multiphase power may be provided to attached electrical devices. In other embodiments, the phases are resolved and a single phase is delivered to attached electrical devices.
The housing 104 may have one or more outlet apertures 124 (
In certain embodiments, including the embodiment of
The ganged outlets 130 are shown as generally linear arrangements of outlets 128, which may be arranged in columns or rows. Each branch 132 may include one or more ganged outlets 130 and/or outlets 128. As shown, two ganged outlets 130 are placed side-by-side, providing two columns of outlets 128 longitudinally extending down the front face 106 of the PDA 100.
The ganged outlets 130 may be configured to deliver the same or different amounts and types of power to their corresponding power outlets 128 and their associated electronic components. For example, one ganged outlet 130 may provide 120V, 20 A power while another ganged outlet 130 may provide 240V, 50 A power. Other ganged outlets 130 may operate at 208V. In addition, the ganged outlets 130 may have varying numbers of power outlets 128. The ganged outlets 130 may be used exclusively in the PDA 100 or in conjunction with individual outlets 128 (which may be configured to operate at any suitable voltage/current).
With continued reference to
The displays 136 provide users with information on the status of the PDA 100. Such information may include the total current drawn by one or more of the outlet gangs 130, the outlets 128, branches 132, or combinations thereof. In the embodiment of
The PDA 100 is provided with communication connections 138. The communication connections 138 are used to send information from, or provide information to, the PDA 100. For example, the communication connections 138 may be used to provide information over a network, such as the Internet, regarding the PDA 100 to a remote user. In other embodiments, the communication connection 138 may be used by service technicians to troubleshoot, program, or obtain data from the PDA 100. In additional embodiments, sensors, such as temperature and/or humidity sensors, may be attached to the communication connections 138. The communication connections 138 may be configured to accept any desired type of communication means, such as USB connections, Ethernet connections, parallel port connections, serial connections, RS232 connections, etc.
A plurality of access openings 140 are formed in the front face 106 of the housing 104. The rectangular access openings 140 are shown longitudinally disposed at regular intervals on the front face 106 of the housing 104. The access openings 140 allow convenient access to certain components of the PDA 100.
For example, a fuse assembly 144 is accessible through each access opening 140. A fuse 146 may be removed from, or installed into, the fuse assembly 144. Each fuse assembly 144 includes two pairs of clamp arms 148, each pair of clamp arms 148 securing the removable fuse 146 and placing the fuse 146 in electrical communication with a circuit of the PDA 100. Other interrupting devices (circuit links), such as circuit breakers, for example, may be utilized rather than the fuses 146.
The access openings 140 are covered by removable protective coverings, such as plastic or glass windows 150 which are secured to the housing 104 by fasteners 152. In at least one embodiment, the windows 150 are made from Lucite. The fasteners 152 are shown as screws, but other fasteners may be used, including bolts and pins. The fuses 146 may thereby be observed and replaced as desired without removing the PDA 100 from the rack and without significantly disassembling the PDA 100.
A fuse state indicator 154 is provided to indicate the status of a fuse 146. The fuse state indicator 154 may be part of the fuse 146 or separate. For example, a fuse 146 may be provided that changes appearance when it has blown. In other embodiments, such as that illustrated in
With reference now to
Each fuse assembly 144 is mounted to the housing 104 by a fastener (not shown), such as a screw, a nail, a bolt, or a pin, which extends into a standoff mount 322 coupled to a cylindrical protrusion 318 on the housing 104 (also see
As shown in
Alternatively, the housing 104 may be provided with mounting brackets (not shown) at the first 112 and/or second 114 ends of the PDA 100. The mounting brackets may allow the PDA 100 to be mounted in a larger number of configurations. For example, racks are made by a variety of manufacturers and may differ in size and construction. The mounting adapters may allow the PDA 100 to be used with a variety of rack types. For example, racks made by American Power Conversion, Inc., of West Kingston, R.I., may be configured with mounting apertures that receive mounting pegs located on a device. Accordingly, in certain embodiments, the PDA 100 may be provided with mounting pegs (not shown), which may be received by mounting apertures (not shown) in a rack, to help secure the PDA 100 to the rack. Additional mounting adapters, which may be located at the top 114 and/or bottom 112 ends of the PDA 100, may further secure the PDA 100 to the rack.
Turning now to
The lower U-shaped portion 208 and the upper U-shaped portion 206 may be coupled by any suitable means. In the embodiment of
An access opening 140 is disposed between each pair of outlet apertures 124. A window 150 is secured to each access opening 140 by fasteners 152 (
With reference now to
An insulating barrier (not shown), which may be a protrusion, such as a flange or ridge extending from the back of an outlet gang 130, may be used to prevent electrical contact between adjacent power rails 238. In certain embodiments, the power rails 238 may be located internally within the outlet gang 130. Locating the power rails 238 within the outlet gangs 130 may reduce the chance for accidental contact between a power rail 238 and other components of the PDA 100 (including adjacent power rails 238), as well as reducing the possibility of damage to the power rails 238 or other components.
Each power rail 238 has a protrusion (not shown) that extends into a particular receptacle (not shown) of each power outlet 128 in an outlet gang 130. Each receptacle may receive a prong (not shown) from a power plug (not shown) of an electronic device (not shown). The power rails 238 therefore serve to electrically couple each power outlet 128 in an outlet gang 130. Each power rail 238 corresponds to a particular electrical component, such as a line, neutral, or ground connection of AC line power. The power rails 238 are preferably made from a conducting material, such as a conductive metal.
The use of the power rails 238 obviates individually wiring together multiple individual power outlets 128. Although the power rails 238 are shown as parallel, linear rails, other configurations could be used. For example, the power rails 238 could be curved in order to accommodate an arcuate pattern of power outlets 128.
Each power rail 238 has a connecting prong 244. Although the power rails 238 are shown as only having connecting prongs 244 at one end of each power rail 238, in at least certain embodiments, the connecting prongs 244 are located at both longitudinal ends of each power rail 238.
Each connecting prong 244 is used to place a power rail 238, and therefore a corresponding outlet gang 130, in electrical communication with other electrical components. The connecting prong 244 may be coupled to other electrical components by any suitable connecting means. In some embodiments, wires may be used as the connecting means. Of course, the present invention is not limited to power rails 238 having connecting prongs 244. Any suitable means may be used for placing the power rails 238 in electrical communication with other electrical components.
With reference now to
The nonconductive material 252 can be used to prevent unintended electrical communication between adjacent electrical components, such as between the outlet gangs 130 and the fuse assemblies 144 (
In a further embodiment, the PDA 100 includes a circuit link interconnection board 264 that is connected to at least one electrical component. As shown in
The circuit link connector 264 may have a number of holes (or pads) 268 extending therethrough. The holes 268 may be lined with a conducting material, such as a conductive metal. In at least one embodiment, a connecting prong 244 of a power rail 238 associated with an outlet gang 130 engages a hole 268. If desired, the connecting prong 244 may be further secured to the circuit link interconnection board 264, such as by soldering. Nonconductive material 252 may be placed between the connecting prongs 244 and the circuit link interconnection board 264. The connecting prongs 244 may extend through openings 256 in the nonconductive material 252.
The circuit link interconnection board 264 is coupled to the upper U-shaped portion 206 of the housing 104. In one embodiment, the circuit link interconnection board 264 is provided with a fastener hole 270. A fastener 272, such as a screw, is inserted through the fastener hole 270 and securely received by a mount 322 (
The fuse clamp arms 148 (
The circuit link interconnection board 264 may be used to transmit electrical signals to, or electrically couple, electrical parts attached to the circuit link interconnection board 264. In at least one embodiment, the circuit link interconnection board 264 is used to transmit components of AC line power to electrical parts attached to opposite ends of the circuit link interconnection board 264. In the case of outlet gangs 130 having connecting prongs 244 at only one end, similar connections between outlet gangs 130 and the circuit link interconnection board 264 may occur at opposite sides of opposite ends of the circuit link interconnection board 264, such as between position 286 and position 288. However, if the outlet gangs 130 are provided with connectors 244 at each end, similar connections between the outlet gangs 130 and the circuit link interconnection board 264 may occur at the same side at each opposite end of the circuit link interconnection board 264, such as between position 286 and position 290. The fastener 272 may serve as a ground connection for the circuit link interconnection board 264 and electrical components attached thereto, thus eliminating the need to provide a separate ground connection.
As shown in
In embodiments where the circuit link interconnection board 264 is a printed circuit board having multiple layers, each layer may correspond to a single electrical component. For example, when the circuit link interconnection board 264 is used for power transmission, such as AC line power transmission, one layer may correspond to a line, or “hot”, electrical connection, one layer may correspond to a neutral connection, and one layer may be connected to a ground. The use of an entire layer of the circuit link interconnection board 264 for each connection may allow for larger amounts of electricity to flow through the printed circuit board 264.
Layer 412 may be a signal layer having a connection 416 between a first connection point 418 and a second connection point 420. The layer 412 may also have a connection 422 between a third connection point 424 and a fourth connection point 426. Connections 416 and 422 serve to transmit electrical signals to, or electrically couple, devices or components attached to connection points 418, 420 and 424, 426, respectively. Additional connection points, such as connection point 430 may also be provided. Although
Layer 440 is shown as a split plane. The layer 440 may be substantially a solid plane of conducting material, such as copper. However, the layer 440 has an insulating barrier 442 which divides the layer 440 into a first side 444 and a second side 446. The insulating barrier 442 may be an area of the layer 440 where the conducting material has been removed, an insulating material or coating placed on or in the layer 440, or any other suitable insulating means. The layer 440 also has connection points 450, 452 and 454, 456 which may be in communication with connection points 418, 420 and 424, 426, respectively.
Each side 444, 446 of the circuit board 400 may carry an electronic component, such as a component of AC line power, which may be the same or different. In at least one embodiment, the first side 444 carries a line component of AC line power and the second side 446 carries a neutral component of AC line power. In this way, power can be conducted through the layer 440 to devices attached to the connection points 418–426. A connector 458 is shown having at least a portion of its conducting material removed, or otherwise being insulated from the connection point 430.
As shown in
The use of split plane layers may allow for a greater variety of electrical signals and power components to be distributed across the circuit board 400, while allowing circuit boards having a relatively small number of layers to be used. In addition, circuit boards having split plane layers may allow a greater number of connections to be made, a greater variety of connections to be made, and/or a greater number of devices to be connected by, or to, a circuit board 400.
Embodiments of the circuit board 400 are not limited to the circuit board 400 shown in
It can thus be seen that certain embodiments of the present invention provide a PDU having substantially reduced wiring requirements, which may result in faster assembly, more economical construction, smaller size, greater reliability, and easier, safer maintenance or repair of the PDU. Further embodiments provide a PDU having fuses (or other circuit links) which are accessible from the exterior of the PDU without disassembling the PDU or removing the PDU from a rack. Yet further embodiments provide a circuit link interconnection board configured to deliver power to at least one electrical component and to place the at least one electrical component in communication with a circuit link, such as a fuse.
Certain embodiments provide a visual cue on a device containing one or more circuit link that one or more the device's circuit links needs to be reset or replaced. These embodiments may allow an operator to more easily locate such circuit links, among other circuit links on the device and other nearby circuit link containing devices, which may reduce equipment downtime and/or service costs.
At least certain embodiments provide for devices with branched circuit protection, where one or more outlets are protected by a circuit link, and each device typically has a plurality of branches. Reducing the number of outlets protected by each circuit link may limit the scope of any disruption caused by a failed circuit link.
Although generally described as including multiple outlets, a branch may contain a single outlet. The number of outlets protected by a circuit link can be varied as desired, including based on the operating conditions and/or the space available in devices that will contain the circuit links.
It is to be understood that the above discussion provides a detailed description of preferred embodiments. The embodiments are illustrative and not intended to limit the scope of the present invention. The above descriptions of the preferred embodiments will enable those skilled in the art to make many departures from the particular examples described above to provide apparatus constructed in accordance with the present invention. The scope of the present invention is rather to be determined by the scope of the claims as issued.
The present application claims the benefit of, and hereby expressly incorporates by reference in its entirety, U.S. Provisional Patent Application No. 60/624,286, filed Nov. 1, 2004, and entitled “POWER DISTRIBUTION APPARATUS,” by Ewing et al.
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