Field of the disclosure

The disclosure relates to the field of electrical connectors. The cradle for a power cord of this disclosure may have particular applications in allowing an AC power connector to become a blind mate power connector for a rack mounted device.

Background

Many rack mounted devices slide onto a rail kit that is affixed into a rack. The rack mounted device may be powered using a power cord having a connector that plugs into a connector port on the back of the rack mounted device. The connector and connector port may be electrically insulating. Within the connector port there may be a plurality of electrically conducting connection pins. Within the connector there may be a corresponding plurality of connection sockets, wherein each connection socket includes a conducting portion configured to make contact with the corresponding connection pin. Such an arrangement is well known in the art.

There are two main types of connector arrangement used in this situation. In a first type, a conventional power cord (often referred to as a kettle lead, shown in Figure 1) is connected manually after a device has been inserted into a rack. This must be done each time the power is connected and/or disconnected. Connecting the connector may be complex because it is likely to be difficult to see and/or access the connector at the rear of the device once the device is in the rack, especially if there are other devices immediately above and below the device in question.

In a second type, a rail kit is provided with electrical connection points that include a socket for a generic power cord at the exterior of the rail kit, on a rear side of the rack, and a separate blind connector plug on the interior of the rail kit, on the rear side of the rack. The blind connector plug is configured to facilitate a blind mate connection with a socket of a rack mounted device, when installed. In this way, components of the rail kit itself provide electrical connection functionality. The blind connector plug may be a floating connection so as to provide adjustability. This second type of prior art power connection requires a complex assembly process and must be wired correctly for earthing continuity. This adds time and cost.

There is thus a need for a simple connector arrangement that provides an easy connection, eliminating the problems of lack of view and access, as well as avoiding complex components.

Summary of the disclosure

Against this background, in a first aspect of the disclosure there is provided a cradle for a power cord of a kind comprising a flexible cable that terminates with a rigid connector, the cradle comprising: a front face having an aperture dimensioned (a) to accommodate a front portion of the rigid connector such that the front portion of the rigid connector protrudes through the aperture so as to be receivable in a socket of an apparatus and (b) to abut an abutment of the rigid connector to prevent movement of the abutment in a forward direction through the aperture; a rear retainer adjustable relative to the front face so as to accommodate the rigid connector whilst restricting movement of the rigid connector backwards away from the aperture of the front face; and a lateral flange configured to be adjustably attached to a rail kit so as to accommodate movement in a plane orthogonal to the forward direction.

Accordingly, a floating blind mate connection is provided where the only electrical components are a standard kettle lead and corresponding socket.

The cradle therefore addresses problems associated with in accessibility at the rear of a rack whilst minimising part count and installation cost.

Furthermore, once the cradle is appropriately adjusted for a particular rack mounted device, the rack mounted device can be removed and then reinserted without the need for readjustment on the second insertion. In other words, the process of adjusting the cradle in the rail kit needs to be performed only once for a particular rack mounted device. This may save considerable time and effort on reinsertion in the event that the rack mounted device is temporarily removed from the rack for e.g. maintenance or upgrade.

In a second aspect of the disclosure there is provided a method for connecting a power cord of a kind comprising a flexible cable that terminates with a rigid connector to a rack so as to facilitate a floating blind mate connection using the cradle of any of claims 1 to 16, the method comprising: inserting the front portion of the rigid connector through the aperture in the front face of the cradle; adjusting the rear retainer relative to the front face so as to accommodate the rigid connector whilst restricting movement of the rigid connector backwards away from the aperture of the front face; positioning the cradle through an opening in a rail kit; attaching the cradle to the rail kit.

The method provides an easy connection of a power cord to a rack mounted device. It eliminates the problem of lack of view when connecting a rack mounted device to the power cord. Furthermore, it eliminates the problem of lack of access. It also avoids the need for non-standard electrical components.

Brief description of the drawings

Figure 1 shows a power cord in accordance with the prior art;

Figure 2 shows a power connector in accordance with a first type of prior art;

Figure 3 shows an exploded view of a cradle in accordance with the present disclosure together with a power connector in accordance with the prior art;

Figure 4 shows a rail kit;

Figure 5 shows a cradle in accordance with the present disclosure containing a power cord, the cradle shown in situ in a rail kit in accordance with the present disclosure; Figure 6 shows the cradle of Figure 5 from a different perspective;

Figure 7 shows an exploded view of the cradle in accordance with the present disclosure;

Figure 8 shows a front view of a rack including a rack mounted device;

Figure 9 shows a rear view of a rack including a rack mounted device and with a cradle in accordance with the present disclosure;

Figure 10 shows the same features as Figure 5 plus a rack mounted device approaching a position in which the power connection will be made between the power cord and the corresponding socket in the rack mounted device;

Figure 11 shows the same features as Figure 10 where the power cord is engaged with the socket in the rack mounted device;

Figure 12 shows a cross sectional view of the arrangement of Figure 11 ;

Figure 13 shows the cradle in accordance with the present disclosure together with a power cord having a different geometry from that of the one shown in Figure 5;

Figure 14 shows that it is possible to fasten the front section 7 of the cradle 2 in the rack kit 3 before placing the rigid connector 90 of the cable 1 and then placing the rear section 8 of the cradle 2.

Detailed description

Figure 1 shows a generic power cord 1 often used to connect a rack mounted device 5 (not shown in Figure 1) to a power supply, in accordance with the prior art. The power cord 1 comprises a rigid connector 90, having a front portion 91 , a central portion 93 and a rear portion 94 having a rear face 95. The power cord 1 further comprises a flexible cable 9 connected at one end to the rear portion 94, the other end being connectable to a power source. A front portion 91 of the rigid connector 90 is configured to plug into a socket on a device, such as a rear socket on a rack mounted device 5. The central portion 93 of the rigid connector 90 has a dimension (which, in the illustrated embodiment, is a width) that is larger than the corresponding dimension of the front portion 91 . An interface between the central portion 93 and the front portion 91 provides an abutment 92.

In Figure 2, in accordance with the prior art, the rigid connector 90 of the power cord 1 is inserted directly into a socket at the back of the rack mounted device 5 through an opening in the rail kit 3, after the rack mounted device 5 has been inserted into a rack 4 (shown in Figures 8 and 9). This can be difficult to achieve since access to the rear of the rack 4 may be awkward or not possible.

Figure 3 shows an exploded view of a cradle 2 in accordance with a first embodiment of the disclosure adjacent to a power cord 1 . The cradle 2 comprises a front section 7 and a rear section 8 that together provide an internal cradle volume that may accommodate a rigid connector 90 of a power cord 1 of the type shown in Figure 1 . The cradle 2 also comprises a lateral flange 20 by which the cradle 2 may be fastened to a rail kit 4 of a rack via the lateral flange 20.

In the specific embodiment of Figure 3, the front section 7 of the cradle 2 comprises a front face 71 , a pair of front lateral flanges 74 either side of the front face 71 , and a pair of front intermediate elements 73, each of which extends between one side of the front face 71 and its adjacent front lateral flange 74. The pair of front lateral flanges 74 sit in a first plane and the front face 71 sits in a second plane substantially parallel to the first plane. The first and second planes are offset by the intermediate elements 73. The intermediate elements 73 may be substantially perpendicular to the first and second planes.

In the specific embodiment of Figure 3, the rear section 8 comprises a rear retainer 81 , a pair of rear lateral flanges 84 either side of the rear retainer 81 , and a pair of rear intermediate elements 83, each of which extends between one side of the rear retainer 81 and its adjacent rear lateral flange 84. The pair of rear lateral flanges 84 sit in a third plane and the rear retainer 81 sits in a fourth plane substantially parallel to the third plane. The third and fourth planes are offset by the intermediate elements 83. The intermediate elements 83 may be substantially perpendicular to the third and fourth planes. The internal cradle volume may be bounded, at least in part, by: the front face 71 ; the pair of front intermediate parts 73; the rear retainer 81 ; and the pair of rear intermediate parts 83.

The lateral flange 20 of the cradle 2 comprises the pair of front lateral flanges 74 and the pair of rear lateral flanges 84. In this way the lateral flange 20 extends laterally of the cradle 2.

The front face 71 further comprises an aperture 72 dimensioned to accommodate the front portion of the rigid connector 90. The rear section 8 may further comprise a clamp 82 configured to accommodate the flexible cable 9 of the power cord 1 . The clamp 82 may preferably be U shaped. The clamp 82 may be formed of a soft and/or non-abrasive material to reduce risk of damage to the flexible cable 9. The rear retainer 81 may be planar, as shown in Figure 3, or curved.

The front lateral flanges 74 of the front section 7 comprise a first pair of fixing apertures 75 and a second pair of fixing apertures 76. The rear lateral flanges 84 of the rear section 8 comprise a third pair of fixing apertures 85. Provision of a first pair of coupling members, such as first a pair of bolts 11 , through both the first pair of fixing apertures 75 and the third pair of fixing apertures 85 enables the front section 7 and the rear section 8 to be fastened together. Provision of a second pair of coupling members, such as a second pair of bolts 23, through the second pair of fixing apertures 76 and then through a corresponding pair of apertures 32 on a rail kit 3 enables the cradle 2 to be fastened to the rail kit 3, as explained further below. The coupling elements, such as bolts 11 , 23, may be used in conjunction with nuts and/or in conjunction with a thread, corresponding to that of the coupling element, in one or more of the apertures.

The front section 7 and the rear section 8 may each be formed of a strip of metal bent to the desired shape.

Rail kit

Figure 4 shows a rail kit 3 compatible with the cradle 2 of the disclosure. The rail kit 3 comprises an opening 31 , dimensioned so as to accommodate the front section of cradle 2. The rail kit 3 further comprises a pair of rail kit apertures 32, one on each side of the opening 31 . The rail kit apertures 32 are spaced to correspond with the second pair of fixing apertures 76 of the cradle 2. The shape and/or the dimension of the opening 31 in the rail kit 3 may facilitate modest positional adjustment of the cradle 2 within the opening 31 as explained further below.

Positioning the power cord in the cradle

Referring to Figure 3, in use, the front portion 91 of the rigid connector 90 is placed through the aperture 72 in the front face 71 of the front section 7 of the cradle 2. The flexible cable 9 is placed on the clamp 82 of the rear retainer 81 .

Then, with the front portion 91 of the power cord through the aperture 72 such that the abutment 92 is flush with an inner surface of the front face 71 , the rear section 8 of the cradle 2 is moved towards the front section 7 until an inner surface of the rear retainer 81 meets the rear face 95 of the rigid connector 90. The front and rear sections 7, 8 are then fastened together using coupling members 11 through both the third pair of fixing apertures 85 and the first pair of fixing apertures 75. In this way, the rigid connector 90 is fixed relative to the cradle 2.

A variety of lengths of rigid connector 90 may be accommodated by adding spacing members between the front lateral flanges 74 and the rear lateral flanges 84. This facilitates the ability to accommodate power cords having different dimensions between the abutment 92 and the rear face 95 of the rigid connector 90 (such as shown in Figure 13) whilst also preventing the movement of the rigid connector 90 backwards, i.e. away from the aperture 72 the front face 71 . Restricting the movement of the rigid connector 90 backwards facilitates connecting the rigid connector 90 to the rack mounted device 5 as it is inserted into the rack 4.

Installing the cradle in the rail kit

Figures 5 and 6 show the cradle 2 in use positioned in the rail kit 3, with the power cord 1 in position.

Once the power cord 1 is in position in the cradle 2, the cradle 2 is positioned in the rail kit 3. To position the cradle 2 in the rail kit 3, the front section 7 of the cradle 2 is inserted through the opening 31 in the rail kit 3, such that the lateral flanges 20 on each side of the cradle 2 overlap with the rail kit either side of the opening 31 and such that the front lateral flanges 74 are substantially parallel to the rail kit 3. In this way the front portion 91 of the rigid connector 90 protrudes through the aperture 72.

Then the cradle 2 is fastened to the rail kit 3 using the second pair of coupling members, such as a second pair of bolts 23, through the second pair of fixing apertures 76 and then through the pair of rail kit apertures 32.

In this way, the rigid connector 90 of the cable 1 is fixed to the cradle 2 and the cradle 2 is fixed to the rail kit 3 such that relative movement therebetween is prevented. Therefore, the rigid connector 90 remains stationary as a rack mounted device 5 is moved backwards in the rack 4 until the rigid connector 90 is received within a socket on the rear of the rack mounted device 5.

Figure 8 shows a front view of the rack 4 with the rack mounted device 5 (such as a server) in position. Figure 9 shows a rear view of the rack 4 with the rack mounted device 5 connected to the power cord 1 using a first embodiment of the cradle 2 of the present disclosure.

In order to accommodate modest variation in relative positions of the rack mounted device 5 and the power cable 1 , adjustment functionality for the cradle 2 is provided. This accommodates movement of the cradle 2 in a plane orthogonal to the forward direction. The movement in a plane orthogonal to the forward direction may be said to provide radial float. Radial float allows for small misalignment in the front and rear sections (7, 8) of cradle 2. It also allows for small misalignment of the cradle 2 with respect to the opening 31 in the rail kit 3.

Adjustment functionality

In the illustrated embodiment, adjustment functionality is provided by the rail kit apertures 32 being of a larger diameter than the diameter of the coupling member 23. Washers, each having an aperture only fractionally larger diameter than the diameter of the coupling member 23, are also provided. In this way, an axis of the coupling member 23 is adjustable within the larger diameter rail kit apertures. This enables the position of the cradle 2 to be modestly adjusted up, down, left and right. This in turn enables modest adjustment of the power cord 1 so as to align with the corresponding socket on the rear of a rack mounted device 5.

Equivalent functionality is contemplated in which one or more of the first, second and third pairs of fixing apertures has a diameter larger than that of the coupling member. In the event of more than one set of fixing apertures having a larger diameter than that of the coupling member, further adjustments can be facilitated.

In a first configuration the diameter of the coupling member 23 may be smaller than the diameter of the rail kit aperture 32. This allows the lateral flange 20 to be moved in the plane orthogonal to the forward direction by movement of the coupling member 23 laterally within the rail kit aperture 32. A coupling assembly may comprise the coupling member plus a nut 24 and at least one washer 25. The external diameter of the washer 25 may be larger than the diameter of the rail kit aperture 32. This allows the cradle 2 to move radially around the inside of the rail kit aperture 32 without passing through the rail kit aperture 32.

In a second configuration the diameter of the coupling member 23 may be smaller than the diameter of the second pair of fixing apertures 76. This allows the lateral flange 20 to be moved in the plane orthogonal to the forward direction by movement of each coupling member 23 laterally within its respective one of the second pair of fixing apertures 76. A coupling assembly may comprise the coupling member plus a nut 24 and at least one washer 25. The external diameter of each washer 27 is larger than the diameter of the second pair of fixing apertures 76. This allows the cradle 2 to move radially around the inside of the rail kit aperture 32 without passing through the rail kit aperture 32.

As an alternative to bolts or screws, the connecting element 78 may comprise a sprung screw, as illustrated in Figure 14. A sprung screw allows the front and back sections 7, 8 of the cradle 2 to automatically clamp around the rigid connector 90 when released so that the screws can be tightened without having to hold everything in place.

Application

The cradle 2 of the present disclosure keeps the rigid connector 90 and the flexible cable 9 of the power cord 1 steady and aligned. Consequently the rigid connector 90 is ready to engage, without manual positioning, when the rack mounted device 5 is inserted into the rack 4. The cradle 2 is adjustable so that it can accept a range of power cords 1 having different dimensions and geometries of rigid connector 90. A cradle 2 with an alternative power cord is shown in Figure 13. Figure 13 shows the cradle 2 accommodating a differently shaped rigid connector 90 to that shown in Figure 5. As the skilled person would readily understand, different shapes and sizes of aperture 72 may facilitate accommodation of different styles of power cord. The skilled person would also understand that the length of the cradle 2 is adjusted via the adjustment assembly to fit the length of the rigid connector 90.