Rack system with minimum dead space

Abstract

A rack system for minimizing dead space includes a frame having a top, a device to be housed, and at least two ears adapted to horizontally secure the device from the top. The ears may be fastened directly to the top of the frame or fastened to two parallel horizontal rails which are braced to the top of the frame. The device is attached to each ear such that the device is parallel to the horizontal rails. The device's position relative to the top of the frame may be adjusted due to vertical slots in a side flange of each of the ears. An alternative embodiment includes a rack system having a frame with a top, a device to be housed, and a tray upon which the device may horizontally sit. The tray is fastened directly to the top of the frame or fastened to two parallel horizontal rails which are braced to the top of the frame. An additional clamp may be provided to secure the device between the tray and the clamp. Methods and kits for minimizing dead space in rack systems are also provided.

Description

FIELD OF THE INVENTION

[0001] The present invention generally relates to rack systems and in particular, to a rack system that horizontally secures a device in an upper portion of the rack system such that dead space is minimized.

BACKGROUND OF THE INVENTION

[0002] Racks provide space for housing various equipment including computer servers, audio, telecommunication, security and other types of equipment. Desirably, racks house as much equipment as possible. If more equipment is housed in a rack, less building space (i.e., square footage) is needed to house the equipment. Consequently, maximizing useable space (or minimizing dead space) lowers building rent payments. Rack space may also be used as an income source where customers pay rent by the rack space (e.g., co-located servers in a data center).

[0003] Space, however, is limited for a number of reasons. Physical constraints on rack fabrication, for example, limit the size of racks. The machines and tools that are used to fabricate racks have physical limits which make it impracticable to build larger racks. Additionally, building ceiling heights, doorway heights and restrictions set by controlling governmental authorities prevent building larger racks.

[0004] Space is also limited by industry standards. The industry's “rack space,” for example, is 1.75 inches in height along two vertical rails that are braced 19 inches apart. Equipment that is intended to be rack mounted must thus fit within these specifications and is typically manufactured in height increments of 1.75 inches.

[0005] Various conventional rack mounting techniques fail to utilize all space available in the racks. The shortcomings of the conventional mounting techniques arise from the conventional rack structure, as described below.

[0006] As shown in FIG. 1, conventional rack frames typically include parallel vertical rails or rackrails 10 and are fabricated from steel or aluminum. The rails 10 are positioned along the sides of the racks at the front and rear. Conventional racks are typically braced such that the rack top 15 includes unused space (dead space) 18. The dead space may be about 3 to 4 inches in height and approximately 19 inches in width. Clearly, the dead space is large enough to house various useful equipment.

[0007] The problem, however, is that conventional rack techniques fail to provide a convenient method to mount equipment in the dead space. Conventional mounting techniques simply fasten equipment to the front of the vertical rack rails which are typically threaded for screws or punched for clip nuts. Devices are thus fastened to the front of the rack frame and are generally perpendicular to the vertical rackrails.

[0008] Front-mounting has been generally preferred over other types of mounting because the front rails are most convenient for human interface. An example of front-mounting is shown in FIGS. 1 and 2. In FIGS. 1 and 2, Device B is shown front-mounted to vertical rails 10. Notably, the conventional bracket is mounted on the face of the vertical rails 10 as shown in FIGS. 1 and 2 such that Device B is perpendicular to the vertical rackrails 10. An enlarged view of a convention bracket or ear 20 is shown in FIG. 3. As shown in FIG. 3, ear 20 includes opening 30 to receive a fastener such as a screw. This conventional technique thus does not provide or suggest a way to utilize the dead space in the upper portion of a rack system.

[0009] Other conventional rack systems likewise fail to minimize the dead space. U.S. Pat. Nos. 5,460,441 and 5,571,256, for example, disclose a slideout outer drawer in a vertically elongated cabinet structure and a server unit drawer structure in a server cabinet respectively. U.S. Pat. No. 6,142,590 to Harvell discloses a shelf having adjustable mounting rails and a drawer in a cabinet of a server system rack. Each of the above referenced patents are hereby incorporated by reference in their entirety. Still, none of these references disclose a rack system having minimum dead space as disclosed herein.

[0010] Even in racks where equipment is installed near the top of the rack, the equipment is front-mounted such that the equipment is perpendicular to the vertical rackrails and the type of equipment is limited. What is needed is a rack system that utilizes the dead space and allows a variety of equipment to be mounted therein.

[0011] It is therefore desirable to provide a rack system with the features of the present invention as disclosed herein.

SUMMARY OF THE INVENTION

[0012] The present invention is useful for mounting equipment in racks and in particular, for mounting a device to a top of a rack frame such that the device is horizontally secured in an upper portion of the rack frame.

[0013] In one variation of the present invention, a rack system comprises a frame having a top and a front; a device; and at least two ears for mounting the device to the frame. The device being mounted to the top of the frame via the at least two ears wherein each of the at least two ears comprises a side flange which is coupled to a side of the device and a top flange which is coupled to the top of the frame such that the device is horizontally secured in an upper portion of the frame.

[0014] In another variation of the present invention, a rack system comprises a frame having a top and a front; a device; and at least two ears for mounting the device to the frame. The frame further comprises at least two horizontal rails at the top of the frame. The horizontal rails being parallel and a sufficient distance apart such that the device may be positioned therebetween. The device being mounted to the horizontal rails via the at least two ears wherein each of the at least two ears comprises a side flange which is coupled to a side of the device and a top flange which is coupled to one of the at least two horizontal rails such that the device is secured in an upper portion of the frame and such that the device is parallel to the horizontal rails.

[0015] In another variation of the present invention, each side flange of the ears includes slotted openings such that the device may be positioned an adjustable distance from the top of the frame.

[0016] Another variation of the present invention includes any of the rack systems defined above further comprising a plurality of devices horizontally secured to the top of the frame via a plurality of ears.

[0017] In another variation of the present invention, a rack system comprises a frame having a top and a front; a device; and a tray for the device to sit. The frame further comprises at least two horizontal rails at the top of the frame. The horizontal rails being a sufficient distance apart such that the device may be positioned therebetween. The tray comprising at least two top flanges for mounting the tray to the at least two horizontal rails and a base region large enough to provide a surface upon which the device may sit such that the device sits in an upper portion of the frame.

[0018] Another variation of the present invention includes the rack system defined above wherein the frame further comprises a pair of vertical rack rails at the front of the frame and wherein the rack system further comprises a second device front-mounted to the vertical rack rails.

[0019] In another variation of the present invention, a rack system comprises a frame having a top and a front; a device; a tray for the device to horizontally sit; and at least one clamp to secure the device between the tray and the clamp. The frame further comprises at least two horizontal rails at the top of the frame. The horizontal rails being a sufficient distance apart such that the device may be positioned therebetween. The tray comprising at least two top flanges for mounting the tray to the at least two horizontal rails and a base region large enough to provide a surface upon which the device may sit. The rack system further comprising at least one clamp adapted to secure the device against the tray. The at least one clamp comprising a body and at least one side region which is adjustably fastened to a side flange of an ear. The ear comprising a top flange which is fastened to one of the horizontal rails. The side flange of the ear also comprising a slotted opening such that the clamp may be urged upwards or downwards to secure the device between the tray and the clamp.

[0020] Another variation of the present invention is a method for securing a device in an upper portion of a rack system. The method comprises the steps of attaching at least two ears to the top of the rack system and fastening a device to the two ears such that the device horizontally hangs in an upper portion of the rack system and wherein each of the at least two ears comprises a side flange which is coupled to a side of the device and a top flange which is coupled to the top of the rack system. The method may further include bracing at least two horizontal rails to the top of the rack system wherein the horizontal rails are a sufficient distance apart such that the device may be positioned therebetween and wherein the device is mounted to the horizontal rails via the at least two ears wherein each top flange is coupled to each horizontal rail such that the device is horizontally secured in an upper portion of the frame. The method may additional comprise the step of bracing a second device on top of the first device in the upper portion of the rack system using a clamp.

[0021] Another variation of the present invention is a method for horizontally securing a device in an upper portion of a rack system. The method comprises the steps of attaching a tray to the top of the rack system and sitting a device on a base region of the tray such that the device hangs in an upper portion of the rack system. The method may further include the step of clamping the device to the tray using a clamp which is adjustable in position.

[0022] Another variation of the present invention comprises modifying or retrofitting an existing rack system by horizontally securing at least one device to the top of the rack system via at least one ear.

[0023] Another variation of the present invention is a kit comprising a plurality of ears as described above. The present invention may also feature a kit which comprises clamps. The kit may additionally include trays.

[0024] Another variation of the present invention includes providing instructions on minimizing dead space in a rack system.

[0025] The present invention also includes racks without devices. That is, the present invention can include a rack and mounting hardware to install a device to a top of a frame or to a pair of horizontal rackrails at the top of a frame such that the device is positioned parallel to the top of the frame or parallel to the horizontal rackrails.

[0026] The present invention also includes any of the above rack systems wherein the rack system houses at least one computer server.

[0027] Yet another variation of the present invention comprises a rack system wherein the frame is a cabinet-shaped structure. Still another variation of the present invention comprises a frame wherein the frame is an elongated rectangular-shaped structure comprising a plurality of vertical spaces. Yet another variation of the present invention includes a rack system having a frame comprising at least one cover.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 is a partial front view of a conventional rack system showing a cabinet frame structure having vertical rackrails, a front-mounted device, and dead space in the upper portion of the fame.

[0029] FIG. 2 is a partial side view of a conventional rack system showing a device front-mounted to vertical rackrails.

[0030] FIG. 3 is a picture of a conventional bracket used to front-mount devices.

[0031] FIG. 4A is a partial front view of a rack system in accordance with the present invention.

[0032] FIG. 4B is a right side view of the rack system shown in FIG. 4A.

[0033] FIG. 4C is a top view of the rack system shown in FIG. 4A.

[0034] FIG. 5 is a partial illustration of an ear joined to a chassis of a device in accordance with the present invention.

[0035] FIG. 6A is a perspective view of an ear in accordance with the present invention.

[0036] FIG. 6B is a front view of the ear shown in FIG. 6A.

[0037] FIG. 6C is a side view of the ear shown in FIG. 6A.

[0038] FIG. 6D is a top view of the ear shown in FIG. 6A.

[0039] FIGS. 7A-7B are pictures showing partial views of a rack system in accordance with the present invention.

[0040] FIG. 8 is a front view of a variation of the present invention including a device tray.

[0041] FIGS. 9A and 9B are front and top views respectively of another variation of the present invention including clamps.

[0042] FIG. 10A is a front view of a clamp in accordance with the present invention.

[0043] FIG. 10B is a side view of the clamp shown in FIG. 10A.

[0044] FIG. 10C is a bottom view of the clamp shown in FIG. 10A.

[0045] FIG. 11 is a picture of a rack system partially assembled in accordance with the present invention.

[0046] FIG. 12 is an illustration of a kit including ears and fasteners in accordance with the present invention.

[0047] FIG. 13 is an illustration of another kit in accordance with the present invention including clamps, ears, and fasteners.

DETAILED DESCRIPTION OF THE INVENTION

[0048] The present invention is a rack system that minimizes dead space typically found in conventional rack systems. The present invention provides a mounting method and hardware that allows equipment and devices to be installed in space which is normally unused (herein referred to as “dead space”). Unlike conventional rack systems, the present invention installs a device on rackrails such that the rackrails and the device are parallel. Further, a variation of the present invention provides for installing non-mountable devices in the dead space of typical rack systems. Other variations will become apparent upon reading the following disclosure in conjunction with the attached drawings.

[0049] A first embodiment of the present invention is shown in FIGS. 4A-4C. Referring to FIG. 4A, a rack system 100 is shown. Rack system 100 includes a cabinet structure or frame made up of, amongst other components, vertical rack rails 110 and horizontal rack rails 120. The horizontal rack rails 120 are attached at the top of the rack system.

[0050] FIG. 4A further shows Device A hung in upper space 125 which is normally mere dead space. Device A is hung in this embodiment using novel ears 130. Ears 130 are fastened to both the horizontal rails 120 and to a chassis of Device A using, for example, screws 140. FIG. 5 depicts an ear attached to a chassis of a device using a screw. However, other fasteners may be used and other fastening techniques may be employed such as adhesives, spot welds, rivets, etc.

[0051] The invention is not limited to particular types of devices or equipment. Device A may be any piece of equipment which fits within the upper space and can be joined to ears 130. Suitable devices to be positioned in the upper space 125 include but are not limited to routers, Ethernet patch bays, keyboard video mount (KVM) expansion units, and any other device which is not required to be mounted along the vertical rackrails. By securing such devices in the upper space of a rack system in accordance with the present invention, valuable space is made available for additional useful devices that must be mounted to the vertical rackrails.

[0052] The present invention is also not limited to a rack system comprising horizontal rails at the top of the rack. Alternatively, ears 130 may be mounted directly to the cover (or top) of the rack. If holes are not present in the cover, holes can be drilled so that ears may be attached thereto.

[0053] Ears 130 are configured to connect Device A to horizontal rails 120. Suitable materials for the ears include steel and aluminum. However, other materials may be used.

[0054] FIGS. 6A-6D show an ear 150 in accordance with present invention. Referring to FIG. 6A, an ear 150 is shown with a top flange or extension 160 extending from a side flange or body 170. Preferably, top flange 160 is perpendicular to side flange 170 as shown in FIG. 6C and is adapted to be fastened to the horizontal rails of the rack frame. Side flange 170 preferably has a height H in the range of about 2.5 to 4 inches and a width W in the range of about 1.5 to 2.5 inches and more preferably a width of about 1.75 inches. While dimensions have been provided in this disclosure, it is to be understood that the dimensions may be different depending on, for example, the dimensions of the devices and rack frames. For example, in a rack system having increased dead space, it may be desirable to increase the height of the ears beyond 4 inches enabling larger devices to be secured therein. Further, it may be desirable to increase the width of the side flange up to the depth of the rack frame. It may also be desirable to horizontally secure multiple devices within the upper (or dead) space of a rack system using the present invention.

[0055] Referring to FIG. 6B, side flange 170 includes two openings or slots 180 which allow for convenient fastening between the device and the ear. The slots 180 also provide a mechanism for adjusting the device's position from the top of the rack system.

[0056] Referring to FIG. 6D, top flange 160 also features openings 190. The openings 190 in the top flange are configured to match with the holes along the horizontal rails such that a fastener, such as a screw, may be inserted through the opening 190 and received by the hole in the horizontal rail. Accordingly, a device may be conveniently hung in the upper space (normally dead space) of a rack system (see, for example, FIGS. 7A and 7B). Unlike some conventional mounts where the device protrudes beyond the plane of the rackrails, the present invention provides for mounting a device horizontally below the rails and within the rack frame such that the device is entirely contained and protected therein. There is thus no need for additional security or other types of covers.

[0057] A variation of the present invention is shown in FIG. 8. FIG. 8 illustrates a rack system 200 with a tray 210. Tray 210 is connected to horizontal rails via a top flange 220. Top flange 220 may be configured similar to top flange 160 of the variation described above. Tray 210 further comprises a side flange 230 which provides a suitable depth for a particular device. Larger devices, for example, will require side flanges 230 with a larger depth D. Notably, tray 210 provides a platform for non-rack mountable devices to sit. In other words, equipment may simply be placed on the tray without requiring an additional fastening step. This variation thus provides another convenient system to utilize the upper space (typically mere dead space) in rack systems.

[0058] Another variation of the present invention features a clamp used in combination with the tray described above. This embodiment is shown in FIGS. 9A and 9B.

[0059] Referring to FIG. 9A, a front view of a rack system is shown having a Device A secured between clamp 310 and a tray 320. FIG. 9B is a top view of the rack system and shows the clamps 310 spanning across the top of Device A and attached to ears 330. Ears 330 are attached to horizontal rails 335. The location and the number of the clamps may be adjusted depending on the application and the device to be secured.

[0060] As shown in FIG. 9A, Device A is urged against tray 320 by clamp 310. The clamping force F results from a combination of factors including but not limited to the resilience of feet 340 which contact the top of Device A; the depth D of tray 310; and, of course, the vertical positioning of the clamps relative to the tray.

[0061] Referring to FIGS. 10A-10C, clamp 310 includes a body 345 and side regions 350. Side regions 350 define aperture 360 which is adapted to receive a fastener. Thus, a fastener may be used to join clamp 310 to an ear 330. The ears 330 are attached to horizontal rails such that the clamp is secured.

[0062] Notably, the vertical position of the clamps relative to the tray is adjustable. The vertical position of the clamps is adjusted by manipulating upwards or downwards the clamp relative to ears 330 before tightening or fastening the clamp thereto. Vertical movement is possible because, as described above, the ears 330 preferably include a vertical slot. Details of the ears 330 are described above in connection with the other embodiments.

[0063] Another variation of the present invention includes use of clamps without a tray. For example, a device may be mounted in the upper space of a rack system and a second device may be placed thereon. The second device can be secured using a clamp such that the second device is properly compressed between the clamp and the first device. The first device, of course, is held in place using the ears, as described above. A partial illustration of this embodiment is shown in FIG. 11 wherein a clamp 375 is attached to only one ear and the ear is shown unattached to horizontal rails. FIG. 11 does not show a second device between the clamp and the first device, however, it is to be understood that a second device may be positioned therebetween.

[0064] The present invention also includes kits for minimizing dead space in racks. A kit in accordance with the present invention is shown, for example, in FIG. 12 and includes a plurality of rack ears 400. Fasteners 410 may also be provided for convenient mounting. The ears 400 are similar to the ears described above in the previous variations of the present invention.

[0065] Another kit is shown in FIG. 13 wherein clamps 450 are additionally provided. The clamps 450 are configured and used as described above with respect to the previous variations of the present invention.

[0066] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed, in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A rack system comprising:

a frame having a top and a front; and

at least two ears for mounting a device to the frame, said device being mountable to the top of the frame via the at least two ears wherein each of the at least two ears comprises a side flange which is adapted to be coupled to a side of the device and a top flange which is adapted to be coupled to the top of the frame such that the device may be horizontally secured in an upper portion of the frame.

2. The rack system of claim 1 wherein each side flange of the ears includes slotted openings such that the device may be positioned an adjustable distance from the top of the frame.

3. The rack system of claim 1 comprising said device.

4. The rack system of claim 1 wherein said frame further comprises a pair of vertical rack rails at the front of the frame and wherein the rack system comprises a second device front-mounted to the vertical rack rails.

5. A rack system comprising:

a frame having a top and a front; and

at least two ears for mounting a device to the frame, said frame further comprising at least two horizontal rails at the top of the frame and said horizontal rails being parallel and a sufficient distance apart such that the device may be positioned therebetween, said device being adapted to be mounted to the horizontal rails via the at least two ears wherein each of the at least two ears comprises a side flange which is adapted to be coupled to a side of the device and a top flange which is coupled to one of the at least two horizontal rails such that the device may be secured in an upper portion of the frame and such that the device may be parallel to the horizontal rails.

6. The rack system of claim 5 comprising said device.

7. The rack system of claim 5 wherein each side flange of the ears includes slotted openings such that the device may be positioned an adjustable distance from the top of the frame.

8. The rack system of claim 5 further comprising a plurality of devices horizontally secured to the top of the frame via a plurality of ears.

9. The rack system of claim 5 wherein said frame further comprises a pair of vertical rack rails at the front of the frame and wherein the rack system further comprises a second device front-mounted to the vertical rack rails.

10. A rack system comprising:

a frame having a top and a front; and

a tray for a device to sit, said frame further comprising at least two horizontal rails at the top of the frame and said horizontal rails being a sufficient distance apart such that the device may be positioned therebetween, said tray comprising at least two top flanges for mounting the tray to the at least two horizontal rails and a base region large enough to provide a surface upon which the device may sit such that the device may sit in an upper portion of the frame.

11. The rack system of claim 10 comprising said device.

12. The rack system of claim 11 wherein said frame further comprises a pair of vertical rack rails at the front of the frame and wherein the rack system further comprises a second device front-mounted to the vertical rack rails.

13. A rack system comprising:

a frame having a top and a front;

a device;

a tray for the device to horizontally sit; and

at least one clamp to secure the device between the tray and the clamp, said frame further comprising at least two horizontal rails at the top of the frame, said horizontal rails being a sufficient distance apart such that the device may be positioned therebetween and said tray comprising at least two top flanges for mounting the tray to the at least two horizontal rails and a base region large enough to provide a surface upon which the device may sit, said rack system further comprising at least one clamp adapted to secure the device against the tray wherein said at least one clamp comprising a body and at least one side region which is adjustably fastened to a side flange of an ear, said ear comprising a top flange which is fastened to one of the horizontal rails and said side flange of the ear also comprising a slotted opening such that the clamp may be urged upwards or downwards to secure the device between the tray and the clamp.

14. A method for securing a device in an upper portion of a rack system comprising:

attaching at least two ears to the top of the rack system and

fastening a device to the two ears such that the device horizontally hangs in an upper portion of the rack system and wherein each of the at least two ears comprises a side flange which is coupled to a side of the device and a top flange which is coupled to the top of the rack system.

15. The method of claim 14 further comprising bracing at least two horizontal rails to the top of the rack system wherein the horizontal rails are a sufficient distance apart such that the device may be positioned therebetween and wherein the device is mounted to the horizontal rails via the at least two ears wherein each top flange is coupled to each horizontal rail such that the device is horizontally secured in an upper portion of the frame

16. The method of claim 15 further comprising bracing a second device on top of the first device in the upper portion of the rack system using a clamp.

17. A method for horizontally securing a device in an upper portion of a rack system comprising:

attaching a tray to the top of the rack system; and

sitting a device on a base region of the tray such that the device hangs in an upper portion of the rack system.

18. The method of claim 17 further comprising clamping the device to the tray using a clamp which is adjustable in position.

19. A method for increasing storage in a rack by at least one of modifying and retrofitting an existing rack system comprising:

horizontally securing at least one device to the top of the rack system via at least one ear.

20. A kit comprising:

a plurality of ears, each of said ears comprises a side flange which is adapted to be coupled to a side of a device and a top flange which is adapted to be coupled to the top of a rack frame such that the device may be horizontally secured in an upper portion of the frame.

21. The kit of claim 20 further comprising at least one of tray and a clamp.

22. The kit of claim 20 further comprising a set of written instructions on minimizing dead space in a rack system.

23. The rack system of claim 1 wherein the rack system houses at least one least one computer server.

24. The rack system of claim 1 wherein the frame is a cabinet-shaped structure.

25. The rack system of claim 1 wherein the frame is an elongated rectangular-shaped structure comprising a plurality of vertical spaces.

26. The rack system of claim 1 wherein the frame comprises at least one cover.

27. The rack system of claim 5 wherein the rack system houses at least one least one computer server.

28. The rack system of claim 5 wherein the frame is a cabinet-shaped structure.

29. The rack system of claim 5 wherein the frame is an elongated rectangular-shaped structure comprising a plurality of vertical spaces.

30. The rack system of claim 5 wherein the frame comprises at least one cover.

31. The rack system of claim 10 wherein the rack system houses at least one least one computer server.

32. The rack system of claim 10 wherein the frame is a cabinet-shaped structure.

33. The rack system of claim 10 wherein the frame is an elongated rectangular-shaped structure comprising a plurality of vertical spaces.

34. The rack system of claim 10 wherein the frame comprises at least one cover.