GB2524231A

GB2524231A - Depth reducing faceplate

Info

Publication number: GB2524231A
Application number: GB1402931.8A
Authority: GB
Inventors: Alex Cooper
Original assignee: XTA ELECTRONICS Ltd
Current assignee: XTA ELECTRONICS Ltd
Priority date: 2014-02-19
Filing date: 2014-02-19
Publication date: 2015-09-23
Anticipated expiration: 2034-02-19
Also published as: GB201402931D0; GB2524231B

Abstract

A faceplate for rack-mountable electronics comprising first 10 and second 20 portions defining a plane. Each portion has a handle 13, 23 extending in said plane. A third portion 30 is positioned between the first and second portions and recessed from said plane by a series of vertical bends or folds or edges 11, 21 in the faceplate, the faceplate also has a plurality of attachment means for attaching the faceplate to a chassis, the handles comprise at least one cut-out 14 and the first and second portions have an aperture 15, 25 for mounting an air filter, the third portion comprises at least one aperture or frangible portion or window 31.The faceplate may comprise a single piece of metal. There may be a cavity between the faceplate and the chassis. Electronic components may be present on the chassis and may extend through an aperture in the faceplate.

Description

Depth Reducing Faceplate Professional audio equipment of the like used by live music venues, theatres, exhibitions etc. is commonly designed so as to fit easily within widely available standardised rack-mount systems, the most common widths being 19-inches and 23-inches.

Rack-mount systems comprise a standard frame onto which further supports may be affixed in order to provide a fully customisable system. The frames are provided with a series of regularly spaced holes, typically 0.625 inches apart, through which the supports and the equipment itself can be mounted by bolts, screws, clips and the like.

The frame is thus divided into rack units (RU), typically of 1.25" or 44.45mm. A full rack is typically 42RU, although half-racks (18-22RU) and other sizes are common.

Racking systems are important for both permanent and semi-permanent installations of audio equipment and for transportable systems, where such rack mount fixings may be provided in transit cases. Pre-installing equipment into transit cases speeds up set-up and take-down times while simultaneously protecting the equipment from damage, although it increases the total volume to be transported.

Due to the prevalence of rack-mounting systems, professional audio equipment is produced in a variety of pre-determined sized modules in order to fit within a rack.

Modules must therefore fit within the constraints of height, width and depth set by the system. Multiple pieces of equipment can be mounted onto a single frame with minimal dead space, thereby saving space and ultimately cost when being transported between venues.

Modular audio equipment which is designed to be rack-mounted typically comprises a solid box-shaped (for example cuboidal) chassis into which the electronic components are mounted. Controls are usually provided on the front of the module for ease of access, and the rear face is often reserved for ports and cabling for connecting with other components of an audio installation. The chassis may be connected directly to the frame of the rack, for example by bolts, screws or clips directly in or on to the chassis. Alternatively, the chassis may be held in position by the use of shelves, sliding runners, arms and other suitable forms of fixing.

A common solution to fixing the chassis to the rack is by use of a face plate. Face plates as known in the art are affixed to the front face of the chassis and extend over the width of the frame. The plates are usually formed from metal in order to provide sufficient strength, and through holes are generally provided at each side of the plate, in a region that extends beyond the chassis. Bolts or screws may then be passed through the faceplate and the frame in order to hold the module in place. Further fixings may or may not be required, depending on the particular module, but often additional support is needed for the rear of the module.

Size and available space is a common problem for equipment manufacturers and customers alike. Smaller units are more desirable since they occupy less space, allowing more units to be attached to a single frame and are thus easier and cheaper to transport. Since the width is limited by the width of the frame, and the height of the unit limited to multiples of 1RU, the only variable dimension available to manufacturers may be the depth of the module. When designing audio equipment, manufacturers must therefore juggle the competing motivations of reducing the size of the unit to reduce costs and increase desirability, while ensuring sufficient room is provided for all of the necessary components and allowing access to both controls on the front face of the chassis and the connections on the rear face.

To simplify the mounting and removal of audio equipment from racking systems, it is also desirable to include a handle or handles on the front face of the module. This allows for the units to be carried easily. Most importantly, it is difficult for a user to gain a firm purchase on a unit without handles, since access to the sides and/or the top and bottom is often restricted. When removing the module, for example, a user cannot grasp the unit to be able to slide it forwards and remove it from the rack. However, since the handles extend forwards from the faceplate or face of the chassis to allow them to be grasped, it is necessary to mount the entire module deeper into the racking system to accommodate the increased depth of the module caused by the protruding handles. The addition of the handles therefore impinges on the available space at the front of the unit, and/or prevents the manufacturer from being able to extend forward into any dead space in the front of a cabinet, case or rack.

It is an aim of the present invention to provide a faceplate for professional audio equipment, which mitigates the above issues. More specifically, it is an aim of the present invention to provide a faceplate for rack mountable professional audio equipment that saves space and provides for improved portability.

According to a first aspect of the invention there is provided a faceplate for rack-mountable electronics comprising: a first and second portion defining a plane, each portion comprising a handle extending in said plane, a third portion positioned between the first and second portions and recessed from said plane by a series of vertical bends or folds or edges in the faceplate, and a plurality of attachment means for attaching the faceplate to a chassis in use, wherein the handles comprise at least one cut-out, and the first and second portions comprise at least one aperture for mounting an air filter therethrough, and the third portion comprises at least one aperture or frangible portion or window.

The handles may extend laterally of the faceplate. For example, they may be co-planar with the faceplate, and/or they may extend outwardly from the faceplate e.g. horizontally. The handles may be angled relative to the plane of the faceplate, for example they may be angled backwards from the faceplate, in the same direction as the recess. Alternatively, they may be angled forwards from the plane of the faceplate, for example, to improve access behind the handles. The handles may each comprise more than one portion, wherein one of the portions extends in a different plane or angle to the plane of the faceplate.

The upper edge and/or a lower edge of the handles may be parallel to an upper edge and/or a lower edge of the first or second portion. Alternatively, the upper edge and/or a lower edge of the handles may be substantially parallel to an upper edge and/or a lower edge of the first or second portion. Additionally or alternatively, the upper edge and/or lower edge may be parallel or substantially parallel in part, for example a portion of the handles may be parallel or substantially parallel.

The handles may be rectangular. Alternatively, the handles may be square, trapezoid, triangular, semi-circular, or any other suitable shape. The two handles may be identical or they may be different. One or more of the edges or corners of the handles may be rounded. For example, the edges of the handles may be rounded to improve comfort when in use. Additionally or alternatively, the handles may comprise a lip and/or bend and/or thickened region suitable for improving comfort in use.

The faceplate may comprise a single piece of metal. Alternatively, the faceplate may comprise one or more parts. The one or more parts may be subsequently joined, e.g. to form a single component, or they may be un-joined, e.g. by attaching to a chassis independently. For example, the faceplate may comprise a left-hand part and a right-hand part, or they may comprise an upper and lower part, or each portion may comprise a separate pad or pads, or any other suitable combination thereof The at least one aperture or frangible portion or window may comprise any suitably shaped and sized apertures or frangible portions or windows and/or any combination thereof.

The at least one aperture or frangible portion or window may comprise a plastic window, for example a transparent or translucent plastic window e.g. a transparent Perspex window. Alternatively, the window may comprise a transparent glass window.

The window may be formed by affixing a window portion to the faceplate, for example by inserting a window portion into an aperture, e.g. an aperture in the third portion of the faceplate. The window portion may by attached or affixed by any suitable means, for example adhesives, mechanical fasteners, clips, interference or friction fits, or any combination thereof.

The faceplate may be attached, for example to the chassis, by any suitable attachment means or combination of attachment means. The attachment means may comprise any attachment means or combination thereof, selected from the following group: bolt or screw holes, flanges, projections, teeth, clips.

According to a second aspect of the invention, there is provided a rack mountable unit comprising a faceplate as described above, affixed to a chassis for housing electronic components. The faceplate may be attached to any suitable part of the chassis, for example, to a front face.

The chassis may comprise a front and rear face defining a depth, an upper and lower face defining a height, two side faces defining a width, and mounting means which project laterally from each side face, wherein the faceplate is affixed to or adjacent the front face of the chassis.

The first and second portions may each define a cavity between the faceplate and the chassis. The cavity may be used for housing further components, for example electrical or electronic components.

Additionally or alternatively, an air filter may be mounted in each said cavity. The air filters may comprise a foam air filter. The air filters may alternatively comprise any other suitable air filter, e.g. a permeable or porous sheet or panel such as a fabric or paper or composite panel.

The air filter may be mounted by a press fit, interference fit or friction fit. For example, the air filter may comprise a compressible material that is compressed and inserted into the cavity. Alternatively, the filter may be mounted by any suitable conventional means, for example, screws, bolts, clips etc. The air filter may be mounted through the aperture in the first and/or second portion.

The handles of the faceplate may extend beyond the width of the chassis to a position in front of the mounting means of the chassis. For example, the handles may be set forward from the mounting means by a separating distance. The handles may be separated from the mounting means by a distance equal to or greater than the depth of the recess. The separation between handles and mounting means may be constant across the area of the handle, or it may vary, e.g. by the handles or mounting means being angled with respect to the other.

The cut-outs in the handles may provide access to the mounting means of the chassis.

For example, the handles may partially cover the mounting means and/or have one or more cut outs or gaps for allowing access to the mounting means. The cut outs or gaps may comprise rectangular portions in the top and/or bottom of the handle. Additionally or alternatively, the handles may have a height less than the height of the first and/or second portions.

The rack mountable unit may further comprise electronic components mounted to the chassis, wherein the controls for the electronic components extend from the front face of the chassis through an aperture in the faceplate. The controls may extend through an aperture in the third portion.

The recess depth may be greater than or equal to the height of the controls. For example, the depth of the recess may be sufficiently deep that the controls are undamaged if the unit is rested on the faceplate.

According to a third aspect of the invention, a method for manufacturing the faceplate may comprise stamping the faceplate from a metal sheet or plate or strip. Additionally or alternatively, the method may comprise stamping parts or portions or segments to construct the faceplate from a metal sheet or plate or strip. The parts or portions or segments may be assembled prior to being attached to the chassis, or they may be assembled in situ.

The invention will now be described by reference to the following drawings, wherein: Figure 1 is a 3D perspective drawing of the faceplate attached to a chassis; Figure 2 is a plan (top) view of the faceplate attached to a chassis; and Figure 3 is a drawing of the faceplate unattached to a chassis.

Figure 1 shows an embodiment of the invention, wherein the faceplate 1 is attached to a chassis 50.

The chassis 50 is a typical chassis for housing audio equipment, such as a metal box.

The chassis 50 is cuboidal, with a front face 2 and a rear face 3 defining the depth, two side faces 4, 5 defining the width, and an upper and lower face 6, 7 defining the height.

The pairs of faces all lie perpendicular to one another in order to maximise space within the chassis, and minimise space wastage when multiple units are mounted within a rack. The chassis houses electrical and electronic components, for example audio components such as are in an amplifier. The controls are typically provided on the front face 2 of the chassis 50, and connections for cables and the like on the rear face 3, although it is common to have additional connectors on the front 2 and some controls on the rear face 3.

The chassis is constructed from thin metal sheet or plate in order to provide strength and durability but without occupying a large volume. In an alternative embodiment (not shown), the metal sheet may have holes or vents in one or more of the faces of the chassis, or meshed sheet may be used. The lower face 7, the two side faces 4, 5 and the rear face 3 are formed from a single piece of metal bent to produce right angled edges. The upper face 6 of the chassis is formed from a separate sheet of metal in a similar manner to that described above, wherein the sheet is bent to form additional side faces which can overlap/sit internally of the side faces 4, 5 and fixed to the rest of the chassis by screws at its periphery, which pass through holes in the upper face and interact with threaded holes provided in the other faces adjacent to the edges to form a single box. Producing the chassis in this manner helps prevent electromagnetic interference although in other embodiments the sections are individually produced and subsequently joined, for example by welding, bolts, screws, rivets or other suitable connections. The front face 2 is produced from a separate sheet of metal that is then joined to the chassis in the manner previously described. This provides for access to the front and rear of the unit where the controls and connections are housed. The upper face is removable so that the internal electronics may be accessed when the face is removed, for example during manufacture or maintenance of the unit.

Additionally the front face is removable so that the internal components may be accessed, for example, when full access to the interior is not necessary.

The sides 4, 5 of the chassis 50 are provided with mounting means 51 for mounting the chassis into a rack-mount frame. The mounting means 51 comprise L-shaped metal tabs 52 with mounting holes 53 through which bolts or screws (not shown) can be threaded substantially in the direction of the depth of the chassis in order to secure the chassis to the rack frame. The tabs are formed integrally to the sides 4, 5 of the chassis by bending the edge perpendicular to the side. In an alternative embodiment (not shown) the mounting means comprise arms, ears, flanges or any other suitable projection from the sides of the chassis. For example, the mounting means may not be a single projection, but produced by two projections per side, each of which may comprise a mounting hole through which a fastener may be fixed. In a further alternative embodiment (not shown) the mounting means are separate components affixed to the sides 4, 5 of the chassis by any conventional means, for example, bolts, screws, rivets, welding, adhesives etc. The mounting means 51 extend from the chassis in a direction parallel to the front face of the chassis. The projection from the sides allows, in use, the mounting means 51 to overlap the rack frame and thus provides a more secure mount. In some embodiments, further mounting means 51 may be provided on the chassis 5, for example near the rear face 3 to support the back of the chassis 5.

The faceplate comprises first and second portions 10, 20 on either side of a third portion 30. The faceplate further comprises two pairs of vertical bends 11, 21 so that the third portion 30 is recessed relative to first and second portions 10, 20. The recessed third portion is recessed substantially in the direction of the depth of the chassis. The first pair of vertical bends 11 defines an angled segment 12 therebetween and the second pair of vertical bends defines a further angled segment 22 therebetween. The size and angle of the segments 12, 22 can be selected by the manufacturer to increase or decrease the depth of the recess of third portion 30. The faceplate can be produced simply by stamping the relevant shape from a sheet of metal. This process can simultaneously cut the faceplate to the relevant size while forming the bends in the plate by way of a mould or former. The manufacture is therefore quicker and more efficient than products that require die casting for example.

First portion 10 is attached at a first edge to third portion 30 by the bends 11 and angled segment 12. The opposite edge of the first portion 10 is provided with a handle 13. The handle is square in shape, with rounded corners and edges to provide a more comfortable hand-hold for a user. The handle 13 further comprises a pair of cut-outs 14 in the top and bottom edges to allow a user access to the mounting means 51 behind it. The cut-outs 14 are also broadly square so that the upper edge and lower edge run parallel to each other and to the upper and lower edges of the faceplate 1. The cut-outs 14 provide access to the mounting means 51 which is positioned on the side 4 of the chassis 50 directly behind the handle 13. A user is thus able to fix bolts or screws through the mounting holes 53 of the mounting means 51 without being hindered by the presence of the handle 13. The square shape of the handles 13 provides the greatest area without blocking access to the mounting means, thereby spreading the weight of the unit over the greatest area and thus being more comfortable.

Second portion 20 has the same arrangement as first portion 10, but in reverse.

Second portion 20 is attached at a first edge to the third portion 30 by the bends and angled segment 21, 22. The opposite edge of the second portion is provided with a handle 23 identical to the handle 13. When a user wishes to remove the unit from the racking, they must first remove any attachments (such as bolts etc.) from the mounting means 51. Then the user is able to pull the unit forward by the two handles 13, 23 provided on either side of the faceplate 1.

The handles are separated from the mounting means behind by a distance 56, which is equal to the depth of the recess 57, although the two distances may vary. For example, where the unit is to be mounted in a rack-mount case or cabinet where additional room is provided at the front of the case or cabinet, the mounting means can be positioned further back (i.e. further towards the rear face) on the sides, thus increasing the distance 56. In practice this allows the unit to be mounted to optimally use the available space. By utilising handles projecting sideways, the unit is easy to transport by hand and slide in and out of a rack-mount, without compromising the internal space in the chassis. The invention therefore provides comfortable and usable handles without increasing the front-to-back depth of the completed unit.

The third portion 30 is recessed relative to the first and second portions 10, 20 in a direction toward the rear face 3, and directly abuts the front face 2 of the chassis 50.

The third portion 30 is provided with a window 31, which is a broadly rectangular portion produced from transparent Perspex® panel affixed in an aperture in the third portion 30. The window 31 comprises an aperture 33. The controls 32 of the internal electronic components thus extend through the aperture 33 and therefore the faceplate 1. Since the window 31 is transparent, any meters, dials or indicators etc. positioned behind are protected from casual damage, but still visible to the user. In an alternative embodiment e.g. as shown in Figure 3, multiple apertures are provided for individual controls or clusters of controls. It is envisaged that any combination of apertures and transparent panels may be used within the scope of the invention.

The faceplate is attached to the chassis by a series of screws 16. The faceplate is provided with a series of attachment means which comprise holes through the faceplate configured to correspond with a series of screw-threaded pillars on the front face of the chassis 50. The faceplate can thus be simply installed and removed by screwing or unscrewing the plate from the chassis, for example to improve access to the interior. In an alternative embodiment (not shown) the faceplate may be attached to the chassis by bolts or rivets extending through the holes in the faceplate to correspond with similar holes provided on the front face 2 of the chassis. In a further embodiment, the attachment means comprise projections that extend from the faceplate 1 toward the rear face of the chassis. In one embodiment the projections are flanges that further comprise holes for affixing as above, but at an alternative angle e.g. from above or side. In another embodiment the projections may be teeth that cooperate with a shaped clip or recess in the chassis, for example by press-fit. In another embodiment the projections are rotatable and have a T-shaped cross-section e.g. by providing two arms that extend perpendicularly from one end. The T-piece is then inserted through a slot provided in the chassis and rotated (for example by 90 degrees) so that the arms of the T piece interact with the sides of the slot to prevent being removed.

Referring now to Figure 2, it is more clearly shown that the third portion 30 abuts the front face of the chassis 50, roughly parallel with the mounting means 51. By recessing the third portion 30, the first and second portions 10, 20 extend forward from the front face 2 of the chassis 50. The recess thus protects the controls from accidental damage or adjustment, as well as ensuring that no damage occurs should the unit be turned onto its face. Furthermore, portions 10, 20 define cavities 54, 55 between the faceplate 1 and the front face 2 of the chassis 50.

Figure 3 shows the faceplate 1 of the present invention unattached to the chassis 50.

The third portion 30 has a window 31 produced from a transparent Perspex® panel.

The window 31 has a series of apertures 33 through which controls may project or otherwise be accessed.

In addition, the first and second portions 10, 20 are also provided with apertures 19, 29 respectively. Apertures 19, 29 are approximately square shaped, and allow access to the cavities 54, 55 behind them that are formed when the faceplate 1 is attached to a chassis 50. The apertures shown have corner portions 18, 28 projecting into the apertures 19 and 29 respectively. The corner portions 18, 28 provide more space for additional apertures or buttons or connectors to be positioned on the front face.

Referring back to Figure 1, the cavities 54, 55 are used to house air filters 15,25 which would conventionally be housed within the chassis 50 directly. The air filters 15, 25 are produced from a flexible material, and can be squeezed or compressed in order for them to be inserted into or through the apertures 19, 29 and held by an interference fit in their respective apertures 19, 29 and cavities 54, 55. Moving the air filters out of the chassis thus increases the available room inside the chassis for housing the electronic components. Alternatively, moving the filters out of the chassis may allow a smaller chassis to be used for the same internal components, thus reducing the size of the completed unit. The completed unit can thus be mounted into smaller racks, thereby reducing overall size and cost of transportation.

Claims

CLAIMS: 1. A faceplate for rack-mountable electronics comprising: a first and second portion defining a plane, each portion comprising a handle extending in said plane, a third portion positioned between the first and second portions and recessed from said plane by a series of vertical bends or folds or edges in the faceplate, and a plurality of attachment means for attaching the faceplate to a chassis in use, wherein the handles comprise at least one cut-out, and the first and second portions comprise at least one aperture for mounting an air filter therethrough, and the third portion comprises at least one aperture or frangible portion or window.
2. A faceplate according to claim 1, wherein the handles extend laterally of the faceplate.
3. A faceplate according to claim 1 or 2, wherein an upper edge and/or a lower edge of the handles is parallel to an upper edge and/or a lower edge of the first or second portion.
4. A faceplate according to any one of the preceding claims, wherein the handles are rectangular.
5. A faceplate according to any one of the preceding claims, wherein one or more of the edges or corners of the handles are rounded.
6. A faceplate according to any one of the preceding claims, wherein the faceplate comprises a single piece of metal.
7. A faceplate according to any one of the preceding claims, wherein the attachment means comprise any attachment means or combination thereof, selected from the following group: bolt or screw holes, flanges, projections, teeth, clips.
8. A rack mountable unit comprising a faceplate according to any one of the preceding claims affixed to a chassis for housing electronic components.
9. A rack mountable unit according to claim 8, wherein the chassis comprises a front and rear face defining a depth, an upper and lower face defining a height, two side faces defining a width, and mounting means which project laterally from each side face, wherein the faceplate is affixed to or adjacent the front face of the chassis.
10. A rack mountable unit according to claim 8 or 9, wherein the first and second portions each define a cavity between the faceplate and the chassis.
11. A rack mountable unit according to claim 10, wherein an air filter is mounted in each said cavity.
12. A rack mountable unit according to claim 11, wherein the air filters comprise a foam air filter.
13. A rack mountable unit according to claim 11 or claim 12, wherein the air filter is mounted by a press fit, interference fit or friction fit.
14. A rack mountable unit according to any one of claims 11 to 13, wherein the air filter is mounted through the aperture in the first and/or second portion.
15. A rack mountable unit according to any one of claims 9 to 14, wherein the handles of the faceplate extend beyond the width of the chassis to a position in front of the mounting means of the chassis.
16. A rack mountable unit according to claim 15, wherein the handles are separated from the mounting means by a distance equal or greater to the depth of the recess.
17. A rack mountable unit according to claim 15 or 16, wherein the cut-outs in the handles provide access to the mounting means of the chassis.
18. A rack mountable unit according to any one of claims 8 to 17, further comprising electronic components mounted to the chassis, wherein the controls for the electronic components extend from the front face of the chassis through an aperture in the faceplate.
19. A rack mountable unit according to claim 18, wherein the recess depth is greater than or equal to the height of the controls.
20. A method of manufacturing a faceplate according to any one of the preceding claims, comprising stamping the faceplate from a metal sheet or plate or strip.
21. A faceplate, substantially as described herein and with reference to any of the accompanying figures.
22. A faceplate as depicted in Figure 3.