Power distribution unit and methods of making and use including modular construction and assemblies

Abstract

Described herein are various embodiments of a power distribution unit having modular components. For example, according to one embodiment, a power distribution unit can include a component portion that comprises at least two modules including outlet modules, circuit protection modules, power input modules, communications I/O modules, and display modules. Each of the at least two modules of the component portion can comprise at least one connection element and can be removably secured to one or more other of the at least two modules via the connection elements. The power distribution unit can also include a housing that defines an interior cavity. The component portion can be removably secured to the housing at least partially within the interior cavity.

We claim: 
     
         1 . A power distribution unit mountable in an electronic equipment rack and configured to distribute power to equipment in the rack, comprising:
 a housing having a pair of opposing sidewalls, a rear wall, and at least one front panel, that define an interior cavity of the housing; the at least one front panel having at least one module aperture that penetrates the front panel and is in open communication with the interior cavity;   at least one module having a pair of opposing side portions, a rear portion, and a front portion;   wiring disposed within the interior cavity of the housing and having at least one terminal end portion that is configured to be electrically connected with the at least one module;   the at least one module aperture being shaped to approximate a peripheral shape of the rear portion of the at least one module such that a substantial portion of the at least one module may be passed through the module aperture, into the interior cavity of the housing;   the wiring having a length that permits the terminal end portion of the wiring to pass through the module aperture, from within the interior cavity, such that an electrical connection or disconnection between the at least one module and the terminal end portion of the wiring may be made exterior to the housing.   
     
     
         2 . A power distribution unit according to  claim 1  wherein the at least one module is at least one of: an outlet module; a circuit protection module; a power input module; a display module; or a communications I/O module. 
     
     
         3 . A power distribution unit according to  claim 1  wherein the at least one module includes at least one of: opposing module side walls; a module rear wall; and a module front panel. 
     
     
         4 . A power distribution unit according to  claim 1  wherein at least one mechanical fastener is passed through the front portion of the at least one module and the at least one front panel of the housing. 
     
     
         5 . A power distribution unit according to  claim 1  wherein at least one mechanical fastener is passed through at least one of the side portions of the at least one module and a side wall of the housing. 
     
     
         6 . A power distribution unit according to  claim 1  wherein:
 the front panel has a plurality of module apertures that penetrate the at least one front panel and are in open communication with the interior cavity; and 
 a plurality of modules are each electrically coupled with the wiring and secured with the housing such that each module is positioned within a module aperture and substantially disposed within the interior cavity of the housing. 
 
     
     
         7 . A power distribution unit according to  claim 6  wherein the plurality of modules include at least two of: an outlet module; a circuit protection module; a power input module; a display module; or a communications I/O module. 
     
     
         8 . A power distribution unit according to  claim 7  wherein at least two of the plurality of modules are configured to be interchangeable with one another. 
     
     
         9 . A power distribution unit according to  claim 8  wherein the at least two of the plurality of modules are outlet modules having dissimilar outlet types. 
     
     
         10 . A method of assembling a power distribution unit, the method comprising:
 positioning a terminal end portion of wiring through a module aperture in a front panel of a housing, wherein a substantial portion of the wiring is disposed within an interior cavity of the housing;   electrically coupling a module with the terminal end portion of the wiring;   disposing at least a substantial portion of the module into the interior cavity of the housing, through the module aperture;   securing the module with the housing such that a front portion of the module is positioned parallel with or coplanar to a front panel of the housing.   
     
     
         11 . A method of assembling a power distribution unit according to  claim 10  further comprising:
 presenting a selection of module types to an end user; the selection of module types including one or more of: an outlet module; a circuit protection module; a power input module; a display module; or a communications I/O module. 
 
     
     
         12 . A method of assembling a power distribution unit according to  claim 11  further comprising:
 electrically coupling one or more selected modules with the wiring; and 
 securing the one or more selected modules with the housing. 
 
     
     
         13 . A method of assembling a power distribution unit according to  claim 10  further comprising:
 removably securing the at least one module with the housing using one or more mechanical fasteners that engage the front portion of the at least one module and the front panel of the housing. 
 
     
     
         14 . A method of assembling a power distribution unit according to  claim 10  further comprising:
 removably securing the at least one module with the housing using one or more mechanical fasteners that engage at least one side portion of the at least one module and a side wall of the housing. 
 
     
     
         15 . A method of assembling a power distribution unit according to  claim 10  further comprising:
 positioning a plurality of terminal end portions of the wiring through a plurality of module apertures in the front panel of the housing; 
 the plurality of modules are electrically coupled with the plurality of terminal end portions of the wiring; and 
 each of the plurality of modules are at least a substantially disposed into the interior cavity of the housing, through one of the module apertures. 
 
     
     
         16 . A method of assembling a power distribution unit according to  claim 10  further comprising:
 electrically coupling a plurality of modules, selected by an end user, with the wiring; and 
 securing the plurality of modules with the housing. 
 
     
     
         17 . A method of assembling a power distribution unit according to  claim 10  wherein, after assembly of the power distribution unit:
 removing the at least one module from within the housing, through the module aperture; 
 disconnecting the electrical connection between the module and the wiring; 
 electrically coupling a second module with the wiring; 
 passing the second module through the module aperture into the interior cavity; and 
 securing the second module with the housing. 
 
     
     
         18 . A method of assembling a power distribution unit according to  claim 17  wherein:
 the at least one module is an outlet module with a first type of outlets and the second module is an outlet module with a second type of outlets; the first type of outlets and second type of outlets being dissimilar from one another. 
 
     
     
         19 . A method of assembling a power distribution unit, the method comprising:
 providing an end user with a selection of power outlet modules and types of outlets associated with the power outlet modules;   positioning a plurality of terminal end portions, associated with a wire harness, through a plurality of module apertures that penetrate a front panel of a housing;   electrically coupling a plurality of power outlet modules selected by the end user with the plurality of terminal end portions of the wire harness;   disposing each of the plurality of power outlet modules at least substantially into the interior cavity of the housing, through one of the module apertures; and   securing the plurality of power outlet modules with the housing such that front portions of the plurality of power outlet modules are positioned parallel with or coplanar to a front panel of the housing.   
     
     
         20 . A method of assembling a power distribution unit according to  claim 19 , further comprising:
 presenting a group of I/O controllers to an end user for selection of a desired I/O controller;   electrically coupling the selected I/O controller with the wire harness; and   securing the I/O controller with the housing.   
     
     
         21 . A method of assembling a power distribution unit according to  claim 19 , further comprising:
 presenting a group of PDU input voltage and current options to an end user for selection of one or more desired power input modules; and   electrically coupling the one or more selected power input modules with the wire harness; and   securing the one or more selected power input modules with the housing.   
     
     
         22 . A method of assembling a power distribution unit according to  claim 19 , further comprising:
 presenting a group of current protection modules to an end user for selection of a desired current protection module; and   electrically coupling the selected current protection module with the wire harness.   
     
     
         23 . A method of assembling a power distribution unit according to  claim 19  wherein, after assembly of the power distribution unit:
 removing at least one of the plurality of power outlet modules from within the housing, through at least one of module apertures; 
 disconnecting the electrical connection between the at least one module and the wire harness; and 
 electrically coupling at least one second power outlet module with the wire harness; 
 passing the at least one second module through at least one of the module apertures into the interior cavity; and 
 securing the at least one second module with the housing. 
 
     
     
         24 . A method of assembling a power distribution unit according to  claim 23  wherein:
 the at least one module is a power outlet module with a first type of outlets and at least one second power outlet module is a power outlet module with a second type of outlets; the first type of outlets and second type of outlets being dissimilar from one another. 
 
     
     
         25 . A method of reconfiguring a power distribution unit, having a housing, at least one module, and wiring that is electrically coupled with the at least one module, while the power distribution unit is coupled with an electronic equipment rack, the method comprising:
 removing a module from within the housing, through a module aperture;   disconnecting the electrical coupling between the module and the wiring;   electrically coupling a second module with the wiring;   passing the second module through the module aperture into the housing; and   securing the second module with the housing.