Modular Server Chassis Anti-Sag Tray Design
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Solution Overview
Problem
Conventional rack-mounted chassis are prone to sagging due to combined weight payloads of components, which can hinder the sliding of adjacent chassis and lead to design limitations, as the small clearance between vertically stacked chassis can cause overload issues.
Innovation Solution
A modular assembly comprising a chassis base with an opening and a reinforcing tray featuring an embossed portion that fits into the chassis base, distributing load onto strengthened areas, thereby preventing sagging and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If desirable component combinations are installed in a chassis to maximize functionality, then the component payload is improved, but the chassis weight increases causing sagging and interfering with adjacent chassis sliding
Solution Approach 1:
The chassis is divided into multiple load-bearing trays (first tray, second tray, third tray) that are vertically distributed throughout the chassis structure. Each tray independently supports specific components, segmenting the weight distribution across multiple attachment points on the rack rather than concentrating all weight at a single location. This allows heavy component combinations to be installed while preventing sagging by distributing the load along the vertical axis of the rack.
Solution Approach 2:
The solution transitions from a single-plane weight support approach to a three-dimensional load distribution system. Load bearing trays are positioned at different vertical heights (first, second, and third trays at progressively lower positions) and extend across different horizontal dimensions. This spatial distribution of support structures transforms the weight management from a one-dimensional problem to a multi-dimensional solution, allowing heavy components to be supported without interfering with adjacent chassis.
2Area of stationary object
If minimal clearance is used between vertically adjacent chassis to maximize space usage, then space efficiency is improved, but the risk of sagging increases due to overload from component weight
Solution Approach 1:
Load bearing trays are pre-installed within the chassis structure before the chassis is mounted in the rack. These trays are permanently attached to the chassis and provide predetermined load distribution paths. By preparing the load-bearing structure in advance, the chassis can immediately support heavy component combinations without risk of sagging, even when minimal clearance is used between vertically adjacent chassis units.
Solution Approach 2:
Different regions of the chassis are assigned different structural qualities through the strategic placement of load bearing trays. Areas with heavy components (such as GPU servers or storage arrays) receive enhanced local support from specifically positioned trays, while lighter areas use standard chassis structure. This localized reinforcement allows minimal clearance between chassis while maintaining reliability in critical load-bearing zones.
Data Source
AI summary
A computing equipment box assembly can include a chassis base and a tray. The chassis base can include a bottom panel, an opening through the bottom panel, and a rim defined around the opening. The tray can include a body configured for supporting computing components, a frame section of the body sized to be supported atop the rim of the chassis base; and a downwardly embossed portion of the body extending downwardly from the rim and sized to fit within the opening of the chassis base when the frame section is supported atop the rim of the chassis base.