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`US 6,934,148 B2
`(16) Patent N0.:
`(12) United States Patent
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`Gorenz, Jr. et al. Aug. 23, 2005 (45) Date of Patent:
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`US006934148B2
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`(54) ELECTRONIC CHASSIS AND HOUSING
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`HAVING AN INTEGRATED FORCED AIR
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`COOLING SYSTEM
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`(75)
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`Inventors HEW?” J' Gorenz’ Jr" L516? IL (US)’
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`Wllllam R. Groves, Naperv1lle, IL
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`(US), ROger W- Ady> Chlcag°> IL (Us)
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`(73) Ass1gnee: General Instrument Corporatlon,
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`Horsham, PA (US)
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`Suthetct to artly (11153121161125, thte Eermgf 0:1;
`pa en is ex en e
`or a JUS e un er
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`U.S.C. 154(b) by 0 days.
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`*
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`(
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`) Notice.
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`1/1994 Stone
`5,282,114 A
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`2/1994 Hileman et a1.
`5287244 A
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`4/1996 Kammersqard et 211.
`5,505,533 A
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`9/1997 Stalley ....................... 361/695
`5,663,868 A *
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`1/2000 Wrycraft
`6,011,689 A
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`6,144,549 A * 11/2000 Moss et a1.
`................. 361/681
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`6 315 655 B1
`11
`/2001 McEwan et al.
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`................ 710/300
`6,389,499 B1 *
`5/2002 Frank et a1.
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`6,525,935 B2 *
`2/2003 Casebolt ..................... 361/687
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`OTHER PUBLICATIONS
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`Faneuf et al. (US 2003/0002254 A1), “High Capacity Air—
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`Cooling Systemfor Electronic Apparatus And Associated
`Method”, Jan. 2’ 2003*
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`* cited by examiner
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`Primary Examiner—Yean-Hsi Chang
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`(74) Attorney, Agent, or Firm—Lawrence T. Cullen
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`ABSTRACT
`(57)
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`The invention provides a chassis for housing printed circuit
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`boards comprising: a housing having a top, bottom, front,
`back, left and fight side walls, and having a helght, measured
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`from the bottom wall to the top wall, that is equal to a 1
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`rack-unit. The front wall includes an inlet vent, a display
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`module, and a jack and the back side wall includes an
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`exhaust vent. A front wall face plate overlies the inlet vent,
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`display module and jack, with the inlet vent arranged in
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`parallel, overlapping but offset planes. A centrifugal blower
`is prov1ded 1ns1de the chass1s housmg.
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`18 Claims, 4 Drawing Sheets
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`(21) APPL N05 10/414,346
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`(22)
`Filed:
`Apr. 15, 2003
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`(65)
`Prior Publication Data
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`US 2004/0207981 A1 Oct. 21, 2004
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`7
`(51)
`.................................................. G06F 1/16
`Int. Cl.
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`....................... 361/681; 361/688; 165/80.2
`(52) US. Cl.
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`(58) Field of Search ................................. 361/688—692;
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`165/80.2—80.3, 168—170
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`(56)
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`References Cited
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`U.S. PATENT DOCUMENTS
`1/1988 Hornak
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`6/1993 Basara et a1.
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`4,717,216 A
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`5,216,579 A
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`SONY - Ex.-1001
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`1
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`Sony Corporation - Petitioner
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`Y Ex 1001
`Sony Corporation - Petitioner
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`1
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`SONY - Ex.-1001
`Sony Corporation - Petitioner
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`US. Patent
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`Aug. 23, 2005
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`Sheet 1 0f 4
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`US 6,934,148 B2
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`US. Patent
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`Aug. 23, 2005
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`Sheet 2 0f 4
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`US 6,934,148 B2
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`3
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`US. Patent
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`Aug. 23, 2005
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`Sheet 3 0f 4
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`US 6,934,148 B2
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`US. Patent
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`Aug. 23, 2005
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`Sheet 4 0f 4
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`US 6,934,148 B2
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`5
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`US 6,934,148 B2
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`1
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`ELECTRONIC CHASSIS AND HOUSING
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`HAVING AN INTEGRATED FORCED AIR
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`COOLING SYSTEM
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`BACKGROUND OF THE INVENTION
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`The present invention relates generally to rack-mounted
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`electronics chassis systems and, more particularly,
`to a
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`chassis and housing having an integrated forced air cooling
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`system that preserves the front panel and display appearance
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`generally associated with a rack-mounted electronics chassis
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`system.
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`There exists a trend toward a more compact chassis for a
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`cable modem termination system (CMTS). The reduction in
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`the overall size of the chassis causes two distinct problems.
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`One, a reduction in the size of the chassis requires a
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`corresponding reduction in the size of the front panel and
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`display module. Most chassis manufacturers use variations
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`of material finish (i.e. paint), printed logos, labels, etc. on the
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`front panel to differentiate their products. In addition to
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`reducing the front panel billboard space,
`the reduction
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`reduced the available space for logos, labels, I/O connectors,
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`user displays, user controls, and cooling vents. Accordingly,
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`there exists a need for a reduced size front panel that is
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`equally function and display oriented. Two, the reduced size
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`is an obstacle to maintaining the internal circuitry at a
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`suitable operating temperature. The internal circuitry is
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`electrically driven and generates substantial amounts of heat
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`energy. Larger chassis systems are able to maintain the
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`desired operating temperature by having more space for fans
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`and vents located on the exterior walls. However, a reduc-
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`tion in the size creates an associated reduction in room for
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`such airflow features.
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`Chassis cooling systems in the prior art that provide for
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`front-to-back cooling typically feature 40 mm axial fans that
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`do not have the strength or capacity to pull and/or push air
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`through the high static pressure for a 1 rack-unit (herein after
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`“1U”) chassis. Existing chassis designs have placed the axial
`fans adjacent to the front or rear panels which is not feasible
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`for a 1U chassis that requires substantial area for I/O
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`connectors, user interface, and various other components.
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`The prior art also discloses cooling systems for
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`conventionally-sized chassis (e.g. 2U or larger) with cen-
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`trally located blowers designed to create a low pressure on
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`one side of an internal wall, and high pressure on the other
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`side to achieve front-to-back cooling. However, the prior art
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`centrally located blowers do not direct the path of air intake
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`or divide the airflow exiting the blower.
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`BRIEF DESCRIPTION OF THE DRAWING(S)
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`The present invention will hereinafter be described in
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`conjunction with the appended drawing figures wherein like
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`numerals denote like elements.
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`FIG. 1 is a front perspective view of the chassis of the
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`present invention with the front panel and display module in
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`place.
`FIG. 2 is a perspective view of the front panel and display
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`module portions detached from the chassis and each other.
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`FIG. 3 is a partial top view of the front portion of the
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`chassis with the front panel and display module attached and
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`the top panel removed, showing the internal circuitry and the
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`air intake slot.
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`FIG. 4 is a front perspective view of the chassis with the
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`front panel partially installed.
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`FIG. 5 is a top perspective view of the chassis without the
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`front and top panels, but with the display module, showing
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`the internal components and centrifugal blower.
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`FIG. 6 is a top plain view of the chassis illustrating the
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`internal air flow through the chassis.
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`FIG. 7 is a rear perspective view of the chassis illustrating
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`the exhaust ports and vents.
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`SUMMARY OF THE INVENTION
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`The invention provides a chassis for housing printed
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`circuit boards comprising: a housing having a top, bottom,
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`front, back, left and right side walls, and having a height,
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`measured from the bottom wall to the top wall, that is equal
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`to a 1 rack-unit. The front wall includes an inlet vent, a
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`display module, and a jack and the back side wall includes
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`an exhaust vent. A centrifugal blower is provided inside the
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`chassis housing to establish the air flow pattern. A front wall
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`face plate overlies the inlet vent, display module and jack,
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`respectively so the inlet vent are arranged in parallel, over-
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`lapping but offset planes.
`DETAILED DESCRIPTION OF THE
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`PREFERRED EMBODIMENT(S)
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`The ensuing detailed description provides preferred
`exemplary embodiments only, and is not intended to limit
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`the scope, applicability, or configuration of this invention.
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`Rather,
`the ensuing detailed description of the preferred
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`exemplary embodiments will provide those skilled in the art
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`with an enabling description for implementing the invention.
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`It being understood that various changes may be made in the
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`function and arrangement of elements without departing
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`from the spirit and scope of the invention as set forth in the
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`appended claims.
`FIGS. 1 and 3 through 5 show a chassis 10 for a single
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`“rack-unit” which is commonly referred to as a 1RU cable
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`modem termination system (CMTS). Under current industry
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`standard a “rack-unit” equals approximately 1.75 inches,
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`2RU equals approximately 3.5 inches and etcetera. As seen
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`best in FIGS. 1 and 4, the chassis 10 includes a base 12
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`having a rear 14, left 16 and right 18 side walls, a front panel
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`20, and a top 22, combined to form the base enclosure or
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`housing 24. As shown in FIG. 2, the front panel 20 includes
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`a display module slot 26, an air inlet vent 30 and jack slots
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`32, 33. In this embodiment, the front panel 20 includes left
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`and right handles, 36 and 37 respectively, to aid the user with
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`inserting and removing the chassis 10 from an industry
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`standard communications infrastructure equipment rack (not
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`shown). A display module 28 is detachably secured to the
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`front panel 20 to house a module such as an LCD, and
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`functional switches 27, such scroll, enter select, abort and
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`mode selection, and displays 29, such as LEDs for indicating
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`status or warning signals (thermal conditions or power) for
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`various modules and functions within the chassis.
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`As shown in FIG. 4, the preferred face bar 38 is detach-
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`able from the front panel 20 to ease access for service and
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`cleaning. The face bar 38 may display a logo on the billboard
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`surface 40. The face bar 38 includes a slot 39 for the display
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`module 28 and cut out 41 around jack slots 32 and 33. The
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`face bar 38 also serves to cover and conceal the air inlet vent
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`30. In this embodiment, the face bar 38 is removably secured
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`to the front panel 20 by outwardly biased exterior tabs, 44
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`and 45, which engage behind a respective handle 36 or 37.
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`The face bar 38 is additionally secured by mounting clips, 48
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`and 49 which mate to the display module with a respective
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`tab, 50 or 51. As best shown in FIGS. 1 and 3, an air intake
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`slot 52 is formed by spacing the face bar 38 when it is
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`secured to the front panel 20. The air intake slot 52 permits
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`air from above and below the face bar 38 ingress into the air
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`inlet vent 30 (see FIG. 4). The design of the face bar 38
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`6
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`US 6,934,148 B2
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`3
`accommodates the preferred functional requirements for the
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`front of the chassis 10 while maintaining an attractive
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`appearance.
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`FIGS. 5 through 7 show an internal view of the chassis 10
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`with the face bar 38 and top plate 22 removed. As best
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`shown in FIG. 6, the chassis 10 is preferably divided into
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`three (3) internal chambers, 58, 60, and 62, by an intake
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`dividing wall 54 and a central dividing wall 56. In this
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`embodiment, the chambers include a power supply circuitry
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`chamber 58, a digital printed wiring assembly (PWA) cham-
`ber 60, and a radio frequency (“RF”) PWA chamber 62. The
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`RF PWA chamber 62 may be further divided by an exhaust
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`dividing wall 64 into a receiving PWA chamber 66 and a
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`transmitting PWA chamber 68. The RF PWA chamber 62
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`may be divided into additional chambers by the use of
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`exhaust dividing walls.
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`As best shown in FIG. 6, the intake air flowing into the air
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`inlet vent 30 initially enters the power supply circuitry
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`chamber 58 and the digital PWA chamber 60. One or more
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`axial fans 70, 71 secured to the base plate 12 and located
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`within the power supply circuitry chamber 58, sweep air
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`from the front of the chamber 58 to the rear of the chamber
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`58 to cool the internal circuitry of the chamber 58, including
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`power supply circuitry 72. One example of an axial fan is the
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`Panasonic model 4Bko4f.
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`As shown in FIG. 6, the path of air entering the digital
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`PWA chamber 60 is influenced by the centrifugal blower 74.
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`The centrifugal blower 74 is centrally located within the
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`digital PWA chamber 60 with its blower facing up. One
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`acceptable blower is available from Comair Rotron as model
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`BD12B7, also known as Biscuit (r) DC. This unit occupies
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`a footprint of no more than 4.75 inches squared and has a
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`height or thickness of 1.25 inches. A digital PWA 76 (see
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`FIG. 5) is located within the digital PWA chamber 60. The
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`digital PWA 76 is the most temperature sensitive component
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`within the chassis 10, and accordingly requires a suflicient
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`flow of air to maintain its operating temperature. One or
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`more baflIes 78, 79, may be secured to the top plate 22 to
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`direct air flowing through the digital PWA chamber 60 over
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`as much of the circuitry as possible. In this embodiment, the
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`baffles are made of foam and are carried by the top plate 22.
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`By placing the baffles 78, 79 in an L-shape, the centrifugal
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`blower 74 pulls the intake air in a non-linear path through
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`the circuitry within the digital PWA chamber 60. Of course,
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`the baflIes 78, 79 may be placed in the required configura-
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`tion for the desired airflow to cool each particular circuit
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`design.
`The centrifugal blower 74 pulls the intake air into its
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`intake port 80. The blower intake port 80 faces upward to
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`move the hotter air outwardly through the blower exhaust
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`ports 82, 83 and into the RF PWA chamber 62 (see FIG. 7).
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`Air exiting the centrifugal blower 74 is forced into the RF
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`PWA chamber 62 at a high velocity to cool receiving PWA
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`84 and transmitting PWA 86 (see FIG. 5). Air exiting the
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`centrifugal blower 74 may be separately directed by wall 64
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`into the receiving PWA chamber 66 and transmitting PWA
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`chamber 68 (see FIG. 7). The exhaust dividing wall 64 may
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`also be located to direct a higher volume of air to either the
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`receiving PWA chamber 66 or transmitting PWA chamber
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`68. The final air egress from the RF PWA chamber 62 is
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`through one or more exhaust vents 88, 89 located on the rear
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`wall 14 (see FIG. 7). The use of a dividing wall 64 and
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`multiple ports on the exhaust side of the blower 74 allows
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`the cooling system of the present invention to effectively
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`cool many different components of the internal circuitry.
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`While principles of the invention have been described
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`above in connection with the specific apparatus, it is to be
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`10
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`25
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`35
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`45
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`55
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`60
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`4
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`clearly understood that this description is made only by way
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`of example and not as a limitation on the scope of the
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`invention.
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`What we claim is:
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`1. An electronic chassis and housing having an integrated
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`force air cooling system, comprising:
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`a) a housing having a top, a base and front, back, left and
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`right side walls which define an interior space having a
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`predetermined height, as measured between the top and
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`the base, and an inlet vent in at least one side wall and
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`an exhaust vent in an opposed side wall;
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`b) a centrifugal blower assembly having defined top and
`bottom planes and perimeter walls; a second predeter-
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`mined height measured between the top and bottom
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`planes that is less than the predetermined height of the
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`interior space; and inlet and outlet ports; the blower
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`assembly is mounted within the interior space such that
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`its inlet port is in fluid communication with the inlet
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`vent and its exhaust port is in fluid communication with
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`the exhaust vent; and,
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`c) a baflIe, positioned within the interior space so that it
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`directs the flow of air from the inlet vent through a
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`horizontally non-linear path to the blower inlet port,
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`wherein the baffle is comprised of at least one blower
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`assembly side wall that extends upwardly beyond the
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`top plane and contacts the top of the housing.
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`2. The invention of claim 1, wherein the baflIe is posi-
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`tioned between the housing inlet vent and said blower inlet
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`port.
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`3. The invention of claim 1, wherein the baffle is com-
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`prised of foam gasket material.
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`4. The invention of claim 1, wherein the blower is
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`centrally located within the interior space and includes a fan
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`having a diameter greater than the predetermined height.
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`5. The invention of claim 4, wherein the inlet vent is
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`located in one side wall of the housing, the blower inlet port
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`is directed toward another side wall of the housing and the
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`baflIe directs air past the blower assembly before it enters the
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`blower inlet port.
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`6. The invention of claim 1 further comprising:
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`d) at least one interior wall dividing the interior space into
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`first and second chambers with the centrifugal blower
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`being in one chamber and both chambers being in fluid
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`communication with the inlet and exhaust vents.
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`7. The invention of claim 6 further comprising:
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`e) an axial fan located in other chamber with an inlet port
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`in fluid communication with the inlet vent and an outlet
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`port in fluid communication with the outlet vent.
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`8. A chassis for housing printed circuit boards comprising:
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`a) a housing having a top, bottom, front, back, left and
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`right side walls, and a height, measured from the
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`bottom wall
`to the top wall,
`that
`is equal
`to a 1
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`rack-unit, said front wall including an inlet vent, a
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`display module, and a jack; and,
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`b) a face plate including a bill board surface, display
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`module slot, and a jack slot, arranged to overlay said
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`inlet vent, display module and jack, respectively,
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`wherein said bill board portion and said vent define
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`parallel, spaced apart planes so that said vent is con-
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`cealed from view, but in fluid communication with the
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`exterior ambient atmosphere.
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`9. The chassis recited in claim 8, wherein said front wall
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`includes a plurality of jack, and a pair of installation handles.
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`10. The chassis recited in claim 8, wherein said bill board
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`surface includes identifying indicia thereon.
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`11. A face plate for a printed circuit board chassis having
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`a top, bottom, front, back, left and right side walls, a height,
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`7
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`

`

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`US 6,934,148 B2
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`5
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`measured from the bottom wall to the top wall, which is
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`equal to a 1 rack-unit, said front wall including an inlet vent,
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`a display module, and a jack, said face plate comprising:
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`a) a planar logo surface portion arranged to overlay the
`inlet vent in a parallel, overlapping but offset plane so
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`that said vent is concealed from view from, but is in
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`fluid communication with,
`the front exterior of said
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`chassis;
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`b) a display module slot arranged to overlay the display
`module; and,
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`c) a jack slot arranged to overlay the jack.
`12. A chassis for housing printed circuit boards compris-
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`ing:
`a) a housing having a top, bottom, front, back, left and
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`right side walls, and having a height, measured from
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`the bottom wall to the top wall, that is equal to a 1
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`rack-unit, said front wall including an inlet vent, a
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`display module, and a jack;
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`b) an exhaust vent in said back side wall;
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`c) a centrifugal blower inside said chassis housing, said
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`blower having a housing with top, bottom, and side
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`walls, an inlet port in fluid communication with said
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`inlet vent, and an exhaust port in fluid communication
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`with said exhaust vent, said blower housing having a
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`height, measured from the bottom wall to the top wall,
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`that is less than the height of said chassis housing;
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`d) a partition intermediate said housing inlet vent and said
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`blower inlet port, said partition diverting the flow of air
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`along an indirect path within the housing from said
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`inlet vent to said blower inlet port;
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`e) a front wall face plate including a planar logo surface
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`portion, display module slot, and a jack slot, arranged
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`to overlay said inlet vent, display module and jack,
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`respectively;
`wherein said logo surface portion and said inlet vent are
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`arranged in parallel, overlapping but offset planes so
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`that said vent is concealed from view, but is in fluid
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`communication with, the front exterior of said chassis.
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`13. The chassis recited in claim 12 including:
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`f) a chassis housing interior wall dividing the interior into
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`a first chamber in which the centrifugal blower is
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`located and second chamber, both chambers being in
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`fluid communication with said inlet vent and said
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`exhaust vent; and,
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`5
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`10
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`15
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`20
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`25
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`35
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`40
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`45
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`6
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`g) an axial fan located in said second chamber, said axial
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`fan having an inlet port in fluid communication with
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`said inlet vent and an outlet port in fluid communica-
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`tion with said outlet vent.
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`14. The chassis recited in claim 12, wherein said front
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`wall includes a plurality of jacks, and a pair of installation
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`handles.
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`15. The chassis recited in claim 12, wherein said logo
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`surface includes identifying indicia printed or embossed
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`thereon.
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`16. A printed circuit board chassis for insertion in a
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`standard communications infrastructure equipment rack, the
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`chassis comprising:
`a) a housing having a top, bottom, front, back, left and
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`right side walls, and having a height, measured from
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`the bottom wall to the top wall, that is equal to a 1
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`rack-unit of approximately 1.75 inches, said front wall
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`including an inlet vent, a display module, and a jack;
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`b) an exhaust vent in said back side wall;
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`c) a centrifugal blower inside said chassis housing, said
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`blower having a housing with top, bottom, and side
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`walls, an inlet port in fluid communication with said
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`inlet vent, and an exhaust port in fluid communication
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`with said exhaust vent, said blower housing having a
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`height, measured from the bottom wall to the top wall,
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`that is less than 1.75 inches;
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`d) a partition intermediate said housing inlet vent and said
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`blower inlet port, said partition diverting the flow of air
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`along an indirect path within the housing from said
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`inlet vent to said blower inlet port; and
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`e) a front wall face plate including a planar logo surface
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`portion, display module slot, and a jack slot, arranged
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`to overlay said inlet vent, display module and jack,
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`respectively.
`17. The chassis of claim 16 wherein said logo surface
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`portion and said inlet vent are arranged in parallel, overlap-
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`ping but offset planes so that said vent is concealed from
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`view, but is in fluid communication with, the front exterior
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`of said chassis.
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`18. The chassis of claim 16 wherein said front wall
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`includes a pair of installation handles.
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`8
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`