Knock-Down Rack

Abstract

Field-adjustable rack systems for mounting communications equipment are disclosed, including an adjustable communications equipment rack where the rack is adjustable from a floor mounted configuration to a wall mounted configuration, and the overall width of the rack may be varied by adjusting the base and the top in a plurality of different configurations. Also, height adjustment to the communications equipment rack is disclosed where the height of the rack may be adjusted without removal of the existing mounted equipment from the rack. Height adjustments are made by coupling a plurality of extensions to the vertical side rails of the rack, to arrive at the rack height desired. Methods are described for field adjusting communications equipment racks into various configurations, including floor mounted configurations and wall mounted configurations in a plurality of widths and heights.

1 . A rack for mounting communications equipment, the rack comprising:
 a base having a plurality of formed members, the base supporting the rack in an upright position;   first and second vertical side rails of formed construction to attach equipment, the side rails coupled to the base, and extending substantially vertically; and   a top having a plurality of formed members, the top being coupled at each end to upper ends of the first side rail and second side rail, respectively,   wherein the base is configured to be coupled to the rack in at least two different mounting positions, including a first mounting position at the bottom of the rack, to allow the rack system to be floor mounted, and a second mounting position at an intermediate point along the extent of the rack, to allow the rack system to be wall mounted.   
   
   
       2 . The rack of  claim 1 , wherein the base further comprises:
 first and second base plates;   first and second substantially planar base side gusset brackets coupled to the first and second substantially planar base plates respectively, so that the first and second substantially planar base side gusset brackets extend substantially perpendicular to the first and second substantially planar base plates respectively; and   first and second substantially planar base adjustment plates, wherein the first and second substantially planar base adjustment plates couple the first and second substantially planar base plates.   
   
   
       3 . The rack of  claim 2 , wherein the first and second substantially planar base plates and the first and second substantially planar base adjustment plates include a plurality of mounting features to adjust the base in one of a plurality of configurations, thereby determining the overall width of the base. 
   
   
       4 . The rack of  claim 1 , wherein the top further comprises first and second top channels, and a top adjustment channel, wherein the top adjustment channel couples the first and second top channels. 
   
   
       5 . The rack of  claim 4 , wherein the first and second top channels and the top adjustment channel include a plurality of mounting features to adjust the top in one of a plurality of configurations, thereby determining the overall width of the top. 
   
   
       6 . The rack of  claim 1 , wherein the base and the top are adjustable between a range of about 19 inches (0.48 meters) to about 26 inches (0.66 meters) in width. 
   
   
       7 . The rack of  claim 1 , wherein the rack is adjustable between a first configuration in which the width is about 19 inches (0.48 meters), and a second configuration in which the width is about 23 inches (0.58 meters). 
   
   
       8 . The rack of  claim 7 , wherein the rack consists of the same components in the first configuration as in the second configuration, and where the footprint area of the rack decreases with a decrease in the width of the rack, and the footprint area of the rack increases with an increase in the width of the rack. 
   
   
       9 . The rack of  claim 1 , wherein each component of the rack is substantially symmetrical about at least one axis, to allow each component to be installed in more than one possible orientation. 
   
   
       10 . The rack of  claim 1 , wherein the vertical side rails have a substantially “C” shaped cross-section. 
   
   
       11 . The rack of  claim 1 , wherein the vertical side rails comprise a lower side rail and at least one vertical extension side rail. 
   
   
       12 . The rack of  claim 1 , wherein a bottom 4 inches (0.10 meters) of the side rails is usable for mounting communications equipment. 
   
   
       13 . The rack of  claim 12 , wherein a 48 inch (1.22 meter) rack includes at least 25 Rack Units of space usable for mounting communications equipment. 
   
   
       14 . The rack of  claim 1 , wherein the rack weighs at most 36 pounds (16.3 kg). 
   
   
       15 . A communications equipment rack system comprising:
 a support structure for mounting communications equipment, wherein the support structure is adjustable in width between a first configuration in which the width is about 19 inches (0.48 meters), and a second configuration in which the width is about 23 inches (0.58 meters),   wherein the support structure consists of the same components in the first configuration as in the second configuration, and where the footprint area of the support structure decreases with a decrease in the width of the support structure, and the footprint area of the support structure increases with an increase in the width of the support structure,   wherein the support structure is adjustable between a first position in which the support structure is to be floor mounted, and a second position in which the support structure is to be wall mounted.   
   
   
       16 . The communications equipment rack system of  claim 15 , wherein the support structure is configured for vertical adjustment in the field while retaining previously mounted equipment to the support structure. 
   
   
       17 . The communications equipment rack system of  claim 15 , wherein the full height of the support structure is usable for mounting communications equipment, including the lowest 4 inches (0.10 meters) of the height of the support structure. 
   
   
       18 . A method of field adjusting a configuration of a communications equipment rack from a first configuration to a second configuration, the method comprising:
 decoupling first and second base side gusset brackets from first and second vertical side rails, respectively;   decoupling first and second base plates from the first and second vertical side rails, respectively;   removing a base from the bottom of the rack;   reattaching the base to an intermediate point along the extent of the rack,   wherein the rack is configured for wall mounting; and   coupling the first and second base side gusset brackets to the first and second vertical side rails, respectively,   wherein the base comprises the first and second base side gusset brackets and the first and second base plates.   
   
   
       19 . The method of  claim 18 , the method further comprising:
 removing first and second base adjustment plates from first and second base plates respectively;   removing a top adjustment channel from first and second top channels;   changing spacing between the first and second base plates and changing spacing between the first and second top channels, thereby determining an overall width of the base and the top respectively;   reattaching the first and second base adjustment plates to the first and second base plates; and   reattaching the top adjustment channel to the first and second top channels.   
   
   
       20 . The method of  claim 19 , the method further comprising:
 rotating each of the first and second base adjustment plates approximately 180 degrees about an axis central to and normal to the top-facing surface of the first and second base adjustment plates prior to reattachment.   
   
   
       21 . The method of  claim 19 , wherein:
 adjusting the configuration of the communications equipment rack from a first configuration to a second configuration is accomplished using the same components in the first configuration as in the second configuration, and   wherein adjusting the configuration of the communications equipment rack from a first configuration to a second configuration decreases the footprint area of the rack with a decrease in the width of the rack, and increases the footprint area of the rack with an increase in the width of the rack.   
   
   
       22 . The method of  claim 18 , the method further comprising:
 removing a top from the ends of a first vertical side rail and a second vertical side rail respectively;   coupling first and second extension side rails to the first and second vertical side rails respectively; and   attaching the top to the ends of the first and second extension side rails respectively.   
   
   
       23 . The method of  claim 22 , wherein:
 coupling first and second extension side rails to the first and second vertical side rails respectively comprises coupling with first and second side rail interior adjustment channels.