Equipment cabinet

Abstract

An equipment cabinet having a corrugation in the side panels is disclosed. The panels are affixed to a base by bolting or welding so as to be disposed opposite each other. Holes are provided in opposing surfaces the so that cross members may be secured in a position between the opposing side panels of the cabinet to form a support structure for equipment, such as batteries. Equipment may also be attached using mounting brackets. An equipment retaining bracket includes a retaining cross member, an L-shaped bracket and a bolt to joint the retaining cross member and the L-shaped bracket so as to secure the battery in two dimensions. Retaining brackets may be provided at the front and the rear surfaces of the equipment and, in cooperation with the cross members, retain the equipment in the cabinet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the equipment cabinet;

FIG. 2 is a perspective front view of an example of the equipment cabinet with the top, front and rear closures removed;

FIG. 3 is a perspective rear view of the equipment cabinet with the top, front and rear closures removed;

FIG. 4 is a detailed perspective view of the equipment cabinet shown in FIG. 2;

FIG. 5 is a detailed perspective view of the equipment cabinet shown in FIG. 3, with one of the side panels and some of the batteries removed;

FIG. 6 is a detail perspective view of the retaining bracket assembly shown in FIG. 4;

FIG. 7 is a perspective view of an equipment shelf for use with the equipment cabinet of FIG. 1; and

FIG. 8 is an exploded perspective view of a portion of another example of the equipment cabinet.

DETAILED DESCRIPTION

Exemplary embodiments may be better understood with reference to the drawings, but these examples are not intended to be of a limiting nature. Like numbered elements in the same or different drawings perform equivalent functions. When a specific feature, structure, or characteristic is described in connection with an example, it will be understood that one skilled in the art may effect such feature, structure, or characteristic in connection with other examples, whether or not explicitly stated herein.

In an example, an exterior perspective view of a cabinet 1 is shown in FIG. 1, including a front door 5, top structure 10, and base structure 15. The rear panel or door is not visible in this view. The side panels 20 are shaped into a beam-like structure by a series of corrugations, or U-channels 22 formed into the surface thereof. Four such vertical U-channels 22 are shown; however, the number of U-channels 22 may be selected based on the use of the cabinet and structural requirements. The corrugated panel 20 may be formed from a metal such as steel by manufacturing processes such as cold rolling or a press brake, as is known in the art.

In an aspect, the corrugations may be formed by attaching a U-shaped channel having an everted lip to the panel surface. The everted lip may be in contact with the panel surface and attached by bolting, screwing or welding.

The side panels 20 may attach to vertical rails (not shown) at each corner of the cabinet 1. Alternatively, the panels 20 may act as the corner rails by being formed to have a stiffened end portion. The side panels 20 may be attached to a base structure 15, and a top structure 10 by bolting, screwing, welding or similar fastening technique so as to form a shell-like structure. In this manner, the overall cabinet envelope may be considered to be a hollow beam; sides of the beam that are side panels of the cabinet having U-channels contribute to increased structural stiffness in bending transverse to the surface of the panel, and may have increased buckling strength when compared with conventional flat side panels. Such an increase in bending strength may be attributed, in part, to an increase in the moment of inertia of the side panel structure. Other corrugated structural forms may also be used, such as a hat-stiffened panel.

When the cabinet 1 has a rear panel or door (not shown) in place, and a front panel or door, the overall structure may be considered a closed shell having increased structural rigidity.

FIG. 2 is a front perspective view of the cabinet I with the top, front and rear structures removed. The cabinet 1 is shown in a configuration suitable for accommodating storage batteries 60, and five rows of six batteries 60 are shown. FIG. 3 shows the cabinet from a rear perspective view. In this example, the batteries are shown in ranks of 6 batteries disposed across the width of the cabinet. The battery ranks are disposed such that a lower rank is positioned further towards the front of the cabinet than a higher rank. This arrangement may have serviceability advantages and is described in U.S. Patent application Ser. No. 11/346,042, filed on Feb. 2, 2006, entitled “Tiered Battery Cabinet” which is commonly assigned, and which is incorporated herein by reference. Other battery and equipment mounting arrangements are possible, and the stepped arrangement shown in the present example is not intended to be a limitation. The cabinet is equally suited to receive equipment stacked at a constant distance from the front of the cabinet, or a combination of mounting arrangements.

FIG. 4 is a detailed perspective view of a portion of the front of the cabinet 1. A series of holes 24 is formed in the U-channel surfaces 26. The surfaces 26 are disposed substantially perpendicular to the front-to-rear-direction of the side panel 20. The spacing of the holes 24 may depend on the specific application; however, in many applications this spacing will correspond to an industry standard such as that established by the EIA for electronic equipment. Often, the standard spacing for hole patterns in electronic equipment has a pair of holes for each attachment, and the spacing between the holes in the pair is different than the spacing between pairs of holes. In the EI specification, specifications of 0.625 inch and 0.5 inch are used. However, the holes 24 may be equally spaced, and one or more of the holes 24 may be used to secure equipment or other structures to the side panel 20. Where a U-channel 22 is used only for structural purposes, holes 24 may not be formed therein.

In an example, cross members or cross rails 30 are fitted to one or more of the vertical U-channels 22 so as to form a skeletal shelf to support the batteries 60. Each of the cross rails 30 may be a U channel, an L-channel or similar cross section, and is fitted between opposing vertical U-channels 22 in the side panels 20a, b. Each end of the cross-rails 30 may have a pair of ears 32 extending in the length direction of the cross rail 30 and may have a spacing therebetween which is greater that the longitudinal distance between opposing sides 26 of the vertical U-channel 22. The holes 34 are provided in the ears or tabs 32 of the cross rails 30, sized and dimensioned so as to create an aperture through the ears 32 and to align with the holes 24 in the vertical U-channel 22 when the ears are positioned in a height direction, the alignment being suitable for the insertion of a rod, bolt or sleeve (not shown). The rod or bolt may pass through each of the facing holes 24, 34 in the ears 32 and the U-channel 22 and secure the cross rails 30 in place. For, example, the bolt may be fitted with a nut and, the tabs 32 compressed against the opposing sides 26 of the U-channel 22. The details of the rod, bolt, sleeve, or the like, may depend on the specific use, and on strength and assembly considerations.

When a plurality of cross-rails 30 are connected between opposing side panels 20a, b at the same height above the base 15, a shelf may be formed to support the weight of the batteries 60, or other equipment, in each rank. In the example, the batteries 60 are shown in an arrangement where the front of each rank of batteries is further from the front of the cabinet as the rank of the batteries 60 increases from the base. Depending on the rank of the battery tier, all of the vertical U-channels 22 may not be fitted with cross-rails 30 at each rank level, as the battery 60 may not extend longitudinally to a position where such cross-rails would be needed to provide support when the battery 60 is in an inserted position.

In another aspect, the U-channels 22 may protrude from the side of the panel 20 to protrude outward from the cabinet 1, and the tabs 32 in the cross rails 30 may be sized and dimensioned so that the distance between opposing tabs 32 in a cross rail 30 is less than the distance between opposing interior faces 26 of the U-channel 22 in the side vertical panel 20. In this arrangement, the tabs 32 in the cross rail 30 may be inserted into the space formed between the opposing sides 26 of the U-channel 22, and the holes 34 in the tabs 32 aligned with the holes 24 in the U-channel 22 when the cross rail 30 is in a horizontal position. The cross rail 30 may be secured to the side panel 20 using fasteners inserted into the aligned holes 24, 34, as previously described.

In yet another aspect, the distance between opposing sides of a U-shaped cross rail 30 may be less than the distance between opposing sides of the U-channel 22, and the tabs 32 may be formed by a continuation of the sides of the cross rail 30. In this circumstance, the top of the cross rail 30 may connect the two tabs 32 so that the cross rail 30 is a continuous structure between the opposing ends. This may increase the bearing strength of the section of cross rail 30 in which holes 34 are formed for the purposes of connecting the cross rail 30 to the side panel 20. Other cross sectional shapes for the cross rails 30 are also possible, such as an L-shape, or a box beam.

FIG. 4 also shows a portion of a battery retainer bracket assembly 2. As shown, the battery retainer bracket assembly 2 includes a cross-rail or cross member 70 similar to that used to support the batteries, and positioned near a rear portion of the battery rank. A retaining bracket 71 has a generally L-shaped configuration so that one side may be disposed to oppose a rear surface of the battery, and another side of the L-shaped configuration may be disposed to oppose a top surface of the battery. In this example, the side opposing the top surface of the battery is formed into a series of flat blades which are insertable into slots 74 in the U-shaped retainer cross rail 70. It is equally possible for the top surface of the retaining bracket to be formed without individual blades, and for the battery retainer cross-rail 70 to have another shape, limited only by being adapted to interface with the vertical U-channels 22 in the side panel 20.

FIG. 5 is a further perspective view of the cabinet 1, where the side 20a, retaining bracket assembly 2, and the batteries 60 of rank four have been removed to better show the details of the cross rails 30. The left-hand ends of the cross rails 30 are shown connected to the U-channels 22 of side panel 20 of the cross-rails by aligning the holes 34 in the ears 32 with the holes 24 in the U-channel 22. The batteries 60 of the first battery rank may be retained by a removable bracket 78, attached with metal screws or bolts to the base 15. Similar brackets (not shown) may be attached to the cross rails 30 of higher ranks, or webbing straps used to retain the batteries in the cabinet during shipping, and for seismic events.

FIG. 6 is a detailed perspective view of the retainer bracket assembly 2, including a retainer cross rail 70 and a retaining bracket 71. The retaining bracket 71 is fitted with one or more tabs 76 extending in a vertical direction and having a hole 80 therein. A bolt 82 is insertable in the hole 80 so that the bolt 82 also passes through a hole 84 in the retainer cross-rail 70. The retainer cross-rail 70 may have holes 84 in opposing surfaces of the U-channel, however only one of the pair of holes 84 may be used, depending on the position of the retainer cross-rail 70 with respect to a rear surface 62 of the battery 60 and the length of the bolt 82. The bolt 82 may be turned to draw the side of the retaining bracket 71 against the rear surface 62 of the battery 60 when the battery 60 is in the desired position. Another surface of the retaining bracket 71 opposes a top surface 66 of the battery 60.

In an aspect, the holes in the retainer cross rail 70 may be fitted with press-fit nuts 84 so that the bolt 82 may be inserted into the hole in the retainer cross-rail 70 and tightened after batteries 60 are installed in the cabinet or rack so as to adapt to the battery position. This may permit removal and replacement of individual batteries from the rear direction as well as the front direction when servicing the equipment.

A similar retaining bracket assembly 2 (not shown) may be positioned at the front of the battery 60 to retain the battery in a frontal direction. In such a configuration, the retainer cross rail 70 is disposed below the battery 60 to be retained, and the retaining bracket 71 oriented such that the flat surfaces thereof oppose a front surface 64 and an under surface of the battery 60. The combination of front and rear retaining bracket assemblies 2, cooperating with cross rails 30, may serve to retain the battery 60 securely within the cabinet, and may serve to meet structural requirements for earthquake zones.

Alternatively, a webbing or strap may be used to secure the batteries or other equipment.

FIG. 7 shows an example of a shelf or tray structure 90 which may be suitable for use with the cabinet 1. A tray bottom surface supports the batteries 66, and a front and rear lip, or a retaining plate 92 may be provided to retain the batteries 66. Each side of the tray 90 is provided with a side surface 97, perpendicular, and fastened to the bottom surface. The side surface 97 may be provided with a plurality of mounting holes so that an attachment bracket 95 may be fastened to the side surface 97. Groups of the plurality of holes for attaching the attachment bracket 95 to the side surface 97 may be spaced at a distance corresponding to the distance increment by which successive tiers may be set back by a horizontal distance from each other. The bracket 95 may have holes 34 disposed and spaced so that they may be aligned with holes 24 in the side panels 20.

In another aspect, the bracket 95 may be affixed directly to a chassis or case of any device that may be mounted in the cabinet. The bracket 95 is sized and dimensioned such that a pair of brackets 95, disposed on opposing sides of a device may be spaced such as to align the holes 34 with the holes 24. A nut and bolt or a screw may be used to affix the bracket 95 to the side panels 20.

In still another aspect, a wiring harness may be provided in the cabinet so that batteries positioned on the shelves may be connected in series, parallel or series-parallel to result in a product that has a voltage output and a current output and capacity meeting a specified requirement. The requirement may be expressed by a product specification or by a customer need. The connection of batteries in series results in a voltage that is the sum of the voltages of the batteries in the series string, and the connection of strings of batteries increases the current output to the sum of the currents of a battery in each of the strings. The batteries may be installed in the cabinet during the manufacture of the battery system, or be installed at the location where the cabinet is installed.

In yet another aspect, the equipment to be mounted in the cabinet 1 may be sized and dimensioned so that holes 34 in an extension of a panel of the equipment are disposed so as to be positionable with respect to holes 24 in the side panels 20, so as to permit the equipment to be directly mounted to the side panels 20 using the holes 24.

Another example of the equipment cabinet is shown in a partial exploded view in FIG. 8. Here the second vertical panel, the top the rear closure, and the front closure are not shown so the remainder of the details may be seen with clarity. This example is similar to the first example, and thus only the salient features will be described; the remainder will be apparent to a person of skill in the art.

The side vertical panel 20 is formed so as to have a single broad U shaped channel having side walls 26 and a bottom wall 22, and disposed within the vertical side panel 20. A cut out 120 is provided in the top of the panel 20 so that when a plurality of equipment cabinets I are positioned close together in a row, the cut out 120 may be used to facilitate routing of cables between the equipment cabinets.

A plurality of apertures 24 may be formed in the central wall 22 of the U-channel and where the horizontal spacing pattern of the apertures 26 is repeated in a vertical direction. The spacing between pairs of apertures 26 in the vertical and the horizontal directions may be the same distance, or a different distance. The apertures 24 may have a circular or square cross section. A square cross section may be suitable for accepting a carriage or stove bolt (not shown).

An equipment support member, which may be a shelf or tray 90, may be disposed between the vertical panels 20 and fastened thereto, so as to provide a support for equipment such as a storage battery 60. A plurality of apertures 36 may be formed in a side member of the tray 90. The apertures 36 may be spaced so that pairs of the apertures 36 may be aligned with pairs of the apertures 24. The apertures 36 may have a round or square cross section. The apertures 36 are spaced so that the tray may be disposed at a different distance with respect to the front of the equipment cabinet 1, so as to result in a staggered positioning of the trays. Alternatively, the trays may be disposed directly above one another. The tray 90 may be secured to the vertical panels 20 using bolts passed through the apertures 24 and 36 and secured by a nut. When apertures 24 and 36 have a square cross section, a carriage or stove bolt may be used. The carriage bolt has a square cross section portion adjoining the head, and this portion may engage the side panel 20 and all of, or a portion of, a thickness of the side member 36.

The tray 90 may be provided with a front and rear retaining pieces 92, where the retaining piece 92 is affixed to the horizontal portion 96 of the tray 90. The retaining piece 92 may be made of metal, or of a plastic material such as polycarbonate resin thermoplastic, which may be known, for example, by the trade name LEXAN. The front retaining piece 92 may be formed so as to have two vertical surfaces, and the vertical surfaces may be displaced horizontally from each other. When the front retaining piece 92 is mounted to the tray 90, and batteries 60 are present, a gap may be formed between the inner-facing surface of the upper vertical portion of the front retaining piece 92, and a front surface of the battery 60. Cables may be laid in this gap.

The batteries 60 may be restrained in a vertical direction by a cross piece 38, which may be a U-channel, an L-channel, or the like, and which is attachable to the side panels by a fastener. The cross piece 28 may be fitted with a resilient member on the underside thereof. A similar cross piece may be formed on the underside of each of the trays 90, or the cross piece 38 used at other levels of the equipment cabinet 1.

A fairing panel 18 may be provided, being formed so as to cover the region of the vertical panels 20 having the apertures 24. The fairing panel 18 may be attached to the vertical panel 20 by bolts, tabs or the like. Typically, this may be provided at the vertical panel 20 situated at the end of a row of cabinets.

A method of manufacturing a battery cabinet is described, the method including: providing a base and attaching a pair of vertical panels to the base. The vertical panels are provided with a corrugation portion that has apertures spaced along a length thereof. A pair of cross members or an equipment tray is attached to the vertical panels at a same distance above the base so as to form a shelf dimensioned to support a battery. A wiring harness suitable for connecting a plurality of batteries is installed in the cabinet. A plurality of batteries may be placed on the shelf and connected to the wiring harness.

The batteries may be retained in the cabinet by the combination of the cross members, and one or more retaining brackets or straps, so that the cabinet may be shipped with the batteries installed. Alternatively, a battery shelf may be provided, and the battery shelf may have brackets or straps suitable for retaining the batteries in shipment or in use.

It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.

Claims

1. An equipment cabinet, comprising: a base; anda pair of opposing vertical panels having a corrugation adapted to be connectable to a cross member, one end of each panel fastened to the base.

2. The cabinet of claim. 1, wherein the corrugation is a U-shaped channel formed in a surface of the vertical panel and oriented with a length in a vertical direction.

3. The cabinet of claim 1, wherein the corrugation is formed by a U-channel having an everted lip fastened to the vertical panel.

4. The cabinet of claim 3, where the U-channel is fastened by welding, screwing or bolting.

5. The cabinet of claim 1, wherein apertures having a regular spacing in the vertical direction are provided in a surface of the vertical panel.

6. The cabinet of claim 5, wherein at least one of the apertures is threaded so as to accommodate a bolt or screw.

7. The cabinet of claim 5, wherein the apertures in the vertical panel have a square cross section.

8. The cabinet of claim 1, wherein pairs of apertures are provided in opposing surfaces of the U-shaped channels.

9. The cabinet of claim 1, further comprising a first pair of apertures and a second pair of apertures, spaced vertically on a surface of the pair of vertical panels, a first aperture of the first pair of apertures separated from a second aperture of the first of the pair of apertures by a first distance, and the second aperture of the first of the pair of apertures separated from a first aperture of the second of the pair of apertures by a second distance.

10. The cabinet of claim 9, wherein the first distance is 0.625 inches and the second distance is 0.5 inches.

11. The cabinet of claim 1, further comprising a cross member, the cross member horizontally disposed between the pair of vertical panels and connectable to the corrugation.

12. The cabinet of claim 11, wherein a cross member has a U-channel shape, an L shape, or a hollow beam shape, and is sized and dimensioned so that an aperture therein is alignable with an aperture in the corrugation.

13. The cabinet of claim 11, wherein two cross members are disposed at a same height above the base.

14. The cabinet of claim 11, wherein the cross member is an equipment support tray.

15. The cabinet of claim 14, wherein the equipment support tray is sized an dimensioned to support a storage battery.

16. The cabinet of claim 1, further comprising at least one of a top, a front closure, or a rear closure.

17. The cabinet of claim 1, further comprising a support shelf, the support shelf comprising: a horizontal plate;a pair of side plates disposed orthogonal to opposing edges of the horizontal plate and fastened thereto; andwherein the support shelf is sized and dimensioned so that the shelf is connectable to an aperture pattern in the corrugation by bolting or screwing.

18. The cabinet of claim 17, wherein the horizontal plate has a continuous surface.

19. The cabinet of claim 17, further comprising a bracket fastened to each of the pair of side plates and having an ear extending orthogonal to the surface of the side plate, the ear having a first aperture pattern.

20. The cabinet of claim 19, wherein a plurality of apertures is provided in the side plate, having a pattern compatible with a second pattern of apertures in the bracket, and the bracket is fastened to the side plate using bolting or screwing.

21. The cabinet of claim 19, wherein the aperture pattern in the side plate is a repetitive sequence of the second pattern, disposed so that the bracket attaches to the side plate at one of a plurality of locations along the side plate.

22. The cabinet of claim 17, wherein a first plurality of apertures is provided in the side plate of the support shelf, having a horizontal pattern compatible with a second pattern of apertures in the vertical panel, and the side plate is fastened to the vertical panel using bolting or screwing.

23. The cabinet of claim 17, wherein a retaining bracket is fastened to the horizontal plate and disposed on a surface thereof opposite to a surface adapted for supporting a battery, and dimensioned to restrain the vertical motion of a battery mounted in another support shelf disposed beneath the support shelf.

24. The cabinet of claim 23, wherein a retaining bracket is fastened to the opposing vertical panels and disposable so as to restrain the vertical motion of a battery mounted in the uppermost of a plurality of support shelfs.

25. The cabinet of claim 23, wherein a first and a second restraining lip is fastened to the support shelf and disposed along another pair of opposing edges of the horizontal plate.

26. The cabinet of claim 25, wherein the restraining lip is fabricated from a plastic material.

27. The cabinet of claim 26, wherein the plastic material is a polycarbonate resin thermoplastic.

28. The cabinet of claim 25, wherein the first restraining lip is formed to have two vertical surfaces displaced horizontally from each other, and dimensioned so that a space is formed between the upper of the two vertical surfaces and the area to be filled by a battery.

29. The cabinet of claim 22, wherein the apertures in the support shelf have a square cross section.

30. The cabinet of claim 29, wherein the support shelf is fastened to the vertical panels using a carriage bolt.

31. A retaining bracket assembly, comprising: a cross member, sized and dimensioned so that a slots or holes therein are alignable with apertures in a pair of opposing vertical panels;a bracket having a substantially L shaped form; anda bolt;wherein the bracket has a tab orthogonal to a surface thereof and having a hole therein, and the cross member has a aperture such that the bolt may be inserted.

32. The retaining bracket assembly of claim 31, further comprising a threaded nut, the threaded nut being press-fit to the aperture in the cross member.

33. The retaining bracket assembly of claim 31, wherein the aperture has a screw thread adapted to retain the bolt.

34. An equipment cabinet, comprising: a base; anda pair of opposing vertical panels having corrugations, one end of each panel fastened to the base,wherein the opposing vertical panels are adapted to support a removable cross member.

35. The equipment cabinet of claim 34, further comprising: a pair of removable cross members connectable to the vertical panels; anda wiring harness.

36. The equipment cabinet of claim 34;, further comprising a battery connected to the wiring harness.

37. The equipment cabinet of claim 34, further comprising a support shelf connectable to the vertical panels.

38. A method of manufacturing a battery cabinet, the method comprising: providing a base;attaching a pair of vertical panels to the base, the vertical panels having a corrugation portion with apertures spaced along a length thereof; anddisposing a cross member between the vertical panels and attaching the cross member to the vertical panels by aligning apertures in the cross member with the apertures in the vertical panel.

39. The method of claim 38, further comprising the step of installing a wiring harness.

40. The method of claim 38, further comprising the step of placing a battery on the cross member and connecting the battery to the wiring harness.

41. The method of claim 38, wherein the act of attaching includes at least one of welding, bolting or screwing.

42. The method of claim 38, further comprising the step of shipping the battery cabinet to a customer.