WO2009057124A2 - A set-top-box cabinet for natural cooling of internal electronics - Google Patents

A set-top-box cabinet for natural cooling of internal electronics Download PDF

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Publication number
WO2009057124A2
WO2009057124A2 PCT/IN2007/000578 IN2007000578W WO2009057124A2 WO 2009057124 A2 WO2009057124 A2 WO 2009057124A2 IN 2007000578 W IN2007000578 W IN 2007000578W WO 2009057124 A2 WO2009057124 A2 WO 2009057124A2
Authority
WO
WIPO (PCT)
Prior art keywords
box
perforated
panel
bottom panel
storage disk
Prior art date
Application number
PCT/IN2007/000578
Other languages
French (fr)
Other versions
WO2009057124A3 (en
Inventor
Mohan Tambe
Original Assignee
Innomedia Technologies Pvt. Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Innomedia Technologies Pvt. Ltd. filed Critical Innomedia Technologies Pvt. Ltd.
Publication of WO2009057124A2 publication Critical patent/WO2009057124A2/en
Publication of WO2009057124A3 publication Critical patent/WO2009057124A3/en

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Classifications

    • HELECTRICITY
    • H04ELECTRIC COMMUNICATION TECHNIQUE
    • H04NPICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N5/00Details of television systems
    • H04N5/64Constructional details of receivers, e.g. cabinets or dust covers
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00Constructional details common to different types of electric apparatus
    • H05K7/20Modifications to facilitate cooling, ventilating, or heating
    • H05K7/20009Modifications to facilitate cooling, ventilating, or heating using a gaseous coolant in electronic enclosures
    • H05K7/20127Natural convection

Definitions

  • the present invention relates to set-top-boxes, more particularly to the cooling arrangement of the set-top-boxes.
  • Set-top boxes are presently available in the market.
  • Fully integrated set-top boxes have good processors, memory and optional large hard drives. They're . . often used with highspeed connections.
  • Features could include high-speed Internet access, iTV, digital video recording & gaming.
  • Set-top-boxes are generally used in conjunction with a TV and needs to be kept in its proximity, with the remotes usable in TV pointing direction. With the rapid changing technology and shape in TVs, the best position of keeping the set-top- box is no longer on top of the same. Adequate space on the top of the TV has become impossible in the current generation of thin Plasma or LCD TVs.
  • One such available set-top box 8 is shown in figure 1 , wherein the set-top box comprises of an enclosure made from 6 panels having perforations therein.
  • Various electronic components like hard disk 16, PCB, power board 12, connectors 14, storage disks 16 etc.
  • Heat dissipation systems such as fan systems, are being deployed within set-top boxes in order to maintain electrical boards, and the components thereon, below a critical temperature.
  • the electrical components within these systems can generate a large amount of heat, which needs to be dissipated away from these components in order for them to remain below the critical temperature in which these components function properly.
  • the component density and size of electrical systems, and large amount of heat generated by components within these systems has and continues to affect the cooling systems used to dissipate this heat.
  • certain complex electrical systems may present problems for cooling systems because of the board shape on which the system is located or the component locations on the board.
  • a set-top-box 10 cabinet for natural cooling of internal electronics comprises of, an assembly of a first perforated sidewall and positively fixed along edges of a top panel, a front panel, a back panel and a perforated bottom panel.
  • the perforated bottom panel having sufficient clearance from the underlying surface on which the set-top-box is supported to permit entry of fresh air therein.
  • a second perforated sidewall is detachably fixed to the assembly in such a way that the second sidewall is attached oppositely to the first perforated sidewall.
  • the perforated bottom panel in conjunction with the perforated sidewalls that by tapering towards the top panel provide natural cooling to the heat dissipation therein in the set-top-box. Due to the tapering structure of the first perforated sidewall and the second perforated sidewall towards the top panel, the heat dissipated by the power supply board, the storage disk, the electronics board and other user-upgradeable items effectively escape out from the sidewalls and simultaneously fresh air may enter through the perforations provided at the bottom panel.
  • a storage disk and an electronics board are vertically placed in a manner that only their edges are adjacent to each other and operatively connected to each other. The top and the bottom panel support the storage disk and the electronics board with insulation ensuring that the set-top-box itself does not get heated.
  • digi-attachments are placed on either side of the first perforated sidewall and the second perforated sidewall. Further, digi-attachments are coupled to the set-top-box via cable and placed in a manner to have some space available for the heat dissipation.
  • the set-top-box has a pair of wings extending outwardly from the bottom panel for supporting the pair of digi-attachments. This enables the digi- attachments to be firmly fixed on the wings even when the set-top-box is in different orientations.
  • USB devices that are placed in a manner to be comfortably housed and yet dissipate heat effectively.
  • the USB devices are preferably provided on the power supply board and received vertically in the USB ports.
  • an IR transmission/receiving device is placed in a detachable IR dome that can be oriented in four different directions to ensure that the IR dome always faces the user irrespective of orientation of the set-top-box.
  • Fig 1 illustrates the available set-top-box and labeled as prior-art.
  • Fig 2 illustrates the set-top box with perforated side panels according to an embodiment of the present invention.
  • Fig 3a illustrates the placement of internal electronic components in the set-top- box of Fig 2.
  • Fig 3b illustrates the heat dissipation convection process associated with the set- top-box of Fig 2.
  • Fig 4 shows the metal sheet stamped to form various panels and slots therein according to an embodiment of the present invention.
  • Fig 5 shows the linear arrangement of the electronics board and storage device of the set-too-box of fig 3a.
  • Fig 6 shows the digiattachments in connected with the set-top-box according to an embodiment of the present invention.
  • Fig 7a, 7b, 7c and 7d shows the four orientations of the IR dome according to an embodiment of the present invention.
  • Fig 8a and 8b shows the set-top-box of fig 2.
  • a set-top-box 10 cabinet for natural cooling of internal electronics therein comprises of, an assembly of a first perforated sidewall 22 extending longitudinally and positively fixed along edges of a top panel 16, a front panel 18, a back panel 20 and a perforated bottom panel.
  • a second perforated sidewall 14 extends longitudinally and is detachable to the assembly, the second sidewall being fixed oppositely to the first perforated sidewall 22.
  • On the inner side of the set-top-box 10 a storage disk 36 and an electronics board 34 is operatively connected to each other and vertically placed in a manner that only their edges are adjacent to each other.
  • the storage disk 36 and the electronics board 34 are supported by the top and the bottom panel, and a Power supply board 30 placed horizontally on the bottom panel to receive power and distribute the same to the storage disk 36 and the electronics board 34.
  • FIG 4 shows an assembly of a first perforated sidewall 12 that extends longitudinally and positively fixed to one of the edges of the top panel 16, the bottom panel 22, the front panel 18 and the back panel 20.
  • the assembly is constructed from a single panel of metallic sheet that has extensions for respectively forming the top panel 16, the bottom panel 22, the front panel 18 and the back panel 20. Through stampings on the metallic sheet, various slots are provided on the respective panels to house several plug-ins for providing permanent connection to fixed devices such as Ethernet, Phones, HDMI cable, Audio/video cables, smart card, rubber grommets 38 etc.
  • the front panel 18 is also stamped to form various slots that may house a smart card and some connectors for some user pluggable items as described above.
  • the top panel 16 is stamped to accommodate some connectors for some user pluggable items such as head phone, MICS, line-in, Smart card, USB devices (118) and even an external storages device such as SATA drive. Due to absence of perforation in the top panel 16, the entry and settling of dust is prevented, and therefore periodical cleaning and maintaining of the set-top-box 10 is drastically reduced.
  • the back panel 20 of the set-top-box 10 is meant for more permanent connection to fixed devices such as Ethernet, Phones, HDMI cable, Audio/video cables, RS- 232 cables and Power adaptors.
  • the split-rubber grommets 38 allow, as referred in figure 3a, a cable to be simply slid in, via the split thereby fixing it tightly to the rubber grommet. Furthermore, the cable can be snaked through three rubber grommets 38, ensuring that it doesn't slide out even when pulled.
  • the bottom panel 22 forming the set-top-box 10 provides enough clearance from the surface on which the set-top-box 10 is placed (for example table top or wall).
  • the bottom panel 22 also has two sockets 44 provided on the outer surface of the bottom panel 22, which go into the hooks 46 of a wall bracket 48, for a slip-on attachment thereby ensuring tight alignment of the set- top-box 10 with the wall bracket 48.
  • the set-top-box 10 may be opened just by the application of little force and even no screw driver is needed thereby making the set-top-box 10 extremely user-friendly for maintenance point of view.
  • This permits the set-top-box 10 to be used as a portable media player, with a user replaceable storage device.
  • both the first perforated sidewall 22 and the second perforated sidewall 14 tapers towards the top panel 16 to have an "A-shape". This allows free flow of the hot/ warm air via heat dissipation to go outside and the fresh or cold air to come inside to facilitate heat dissipation through convection.
  • the set-top-box 10 may be constructed, for example "A-shape" with flat top, "inverted U-shape” or the like or variety of “A” shape may be possible like the top may be meeting at a point, or have a flat edge, or may be rounded, or may have the perforated sidewalls at different angles.
  • the bottom line that is to be noted herein is that the base of the set-top-box 10 should be broader than the top, and the bottom thereof should be a bit lifted up analogous to the horizontal bar of the letter "A”. Due to the virtue of the "A-shape” design the set-top-box 10 becomes sleek, thereby ensuring easy mixing of internal and external air.
  • the sleek A- shape can be a low profile to ensure that it is hand graspable. This aids in easy portability, without requiring any special handles. Further, the user may easily take it from one place to another place for viewing the contents of the storage disk 36 inside the set-top-box 10.
  • the set-top box may be placed on any horizontal surface, such as that of table or shelf or even the top of a modern new TV, for normal usage. Depth of the conventional CRT TVs is sufficient for allowing the set-top-box 10 to be kept on top or side of the TV, with just the front panel 18 of the set-top-box 10 exposed. The set-top-box 10 thus aesthetically blends along the TVs and the matching cabinets around them. In this way, the connection to the back panel 20 of the TV get made through the back panel 20 of the set-top-box 10 in the most convenient way. Along with Flat TVs, there is not much depth available on the top of the TV or on a shelf adjacent to it.
  • the set-top-box 10 should be mountable on the side of a flat TV, or above or below it.
  • the rubber feet 26 attached to the bottom of the set-top-box 10 keep the set-top-box 10 slightly elevated from the underlying surface, enabling fresh inflow of air.
  • Reference herein is given to the figure 3a that explains the inside constructional parts of the set-top-box 10.
  • the inside of the set-top-box 10 may be categorically divided into two sections, firstly, user-upgradeable parts and secondly not-user- serviceable parts.
  • the not-user-serviceable parts such as the electronics board 34, faces the perforated sidewall of the set-top-box 10 and is placed such that the side with not-user-serviceable components faces the first perforated sidewall 22, thereby ensuring access of only user-upgradeable parts through the detachable second perforated sidewall 14. This makes it extremely difficult for the user to even touch or play with not-user-serviceable components when the set-top-box 10 is opened via detachable second perforated sidewall 14.
  • the user-upgradeable parts of the set-top-box 10 comprise of smart card connector, batteries, USB ports 32, storage disk 36, phone board, etc.
  • the power-supply board for receiving and distributing the power from an external source
  • the power- supply board in the form of strip having the circuitry laid therein may be on the bottom panel 22.
  • the user may easily reach the user-upgradeable parts of the set-top-box 10 via the detachable panel which can be easily detached from the assembly, even without a screwdriver. This makes it easy for any user to service the internal parts of the set-top-box 10 without even without requiring any help of a technician.
  • the storage disk 36 and the electronics board 34 are vertically placed and more towards the first perforated sidewall 22 in manner such that the edges of both the storage disk 36 and the electronics board 34 are placed adjacently and face oppositely each other (as shown in fig 3a).
  • the power-supply board is insulated at the bottom panel 22, whereas the storage disk 36 and the electronics board 34 are attached with insulation to the top and bottom panel 22 in order to prevent the heating of the set-top-box 10.
  • the storage disk 36 is sandwiched between the rubber strips provided on the top and the bottom panel 22 to provide friction mounting and also for shock absorption. This allows the user to have access to and change the storage disk 36 even without requiring help of a screwdriver.
  • the electronics board 34 and the peripherals inside the set- top-box 10 are attached to the bottom panel 22, and the top panel 16, with possible support from the top and the bottom panel 22. It may be noted that the electronics board 34 and the peripherals are not attached to either of the side panels.
  • height of the storage disk 36 that is preferably used thereof is 3.5", while the length is more. Also in order to meet the low profile requirement, it is preferable to place the storage vertically so that the set-top-box 10 has a height slightly more than 3.5" of the storage disk 36. Similarly, height of the electronics board 34 is also adjusted as 3.5" that of the storage disk 36. The resulting height of the overall set-top-box 10 is therefore maintained so that it is easily graspable in a hand.
  • a 2.5" storage disk 36 may also be mounted with additional rubber padding in the space available for 3.5" storage disk 36. This would allow operations in a vibration environment such as a vehicle.
  • an "A- shaped" profile for the set-top-box 10 is possible with a 2.5" storage disk 36.
  • the storage disk 36 entirely with Flash memory, in which case the "A-shaped" profile cabinet may have less depth.
  • some of the user upgradeable parts are provided through USB devices (118) that are placed in a manner to be comfortably housed and yet dissipate heat effectively.
  • the USB devices are preferably provided on the Power supply board 30 and received vertically in the USB ports 32.
  • the power board provides few USB ports 32, for allow vertical plug-in of USB devices 118.
  • the heat from the USB devices 118 can go out through the detachable side panel.
  • a digi-attachment is placed on either side of the first perforated sidewall 22 and the second perforated sidewall 14 respectively.
  • digi-attachments 40 are coupled to the set-top-box 10 via cable and placed in a manner to have some space available for the heat dissipation.
  • the set-top-box 10 has a pair of wings 42 extending outwardly from the bottom panel 22 for supporting the pair of digi-attachments 40.
  • the wings 42 allow two attachments 40 to be placed on either side of the set-top-box 10.
  • the digi-attachments 40 can be connected to the set-top-box 10 through flat cables. This enables the digi-attachments 40 to be firmly fixed on the wings 42 even when the set-top-box 10 is in different orientations.
  • the set-top-box 10 as shown in figure 7 may be oriented into four different orientations depending upon the need of the user and to cater all possible requirements of optimal placement of the set-top-box 10 adjacent to a TV in a tabletop or wall mount application.
  • the digi-attachments 40 can be adapted to the "A-shape", thereby ensuring sufficient availability of the space between the digi-attachment and set- top-box 10.
  • the pair of wings 42 provides rigidity to the pair of digi-attachments 40 as the same is firmly fixed to the bottom panel 22.
  • the wing and the clipping mechanism are strong enough to ensure rigid position of the digi-attachments 40, in all the positions in which the set-top- box 10 can be placed.
  • the clipping position of the wings 42 is such that a minimum distance is maintained between the set-top-box 10 and the attachment to facilitate air flow. Even when the set-top-box 10 is wall mounted, the digi-attachments 40 don't have to be separately wall mounted, they would remain in a rigid position next to the Set-top-box 10.
  • the digi-attachment is used for converting analog/RF video signals into digital streaming signals for various audio/video applications. They thus allow expansion of the features of the set-top-box 10. These features are mostly related to digital video inputs.
  • Each digi-attachment has a back panel 20 whose connectors align with the back-panel of the set-top-box 10.
  • an IR transmission/receiving device is placed in a detachable IR dome 24 that can be oriented in four different directions to ensure the IR dome 24 (shown in fig 2) always faces the user irrespective of the orientation of the set-top-box 10 (as shown in fig 7).
  • the detachable IR dome 24 is attached to the front panel 18 of the set-top-box 10.
  • the IR dome 24 can be easily detached by a user (without any screwdriver) and placed back in a new position.
  • the IR dome 24 can be fixed in four different positions, namely Front position for normal usage, when the set-t ⁇ p-box 10 is kept on the side of a TV, Top Position for allowing the usage of the set-top-box 10 when it is mounted on the wall, Two Side Positions, on the Left panel and the Right Panel, when the set-top-box 10 is kept sideways, adjacent to the TV.
  • the cooling aspect should not get affected. It should be possible to attach the set-top-box 10 on the wall bracket 48, through the hook- sockets 44 provided beneath the set-top-box 10. No screwdriver should be needed. It should be possible to easily detach the set-top-box 10 by just sliding it out. This permits it to be used as a portable media player, with a built-in hard drive.

Abstract

A set-top-box (10) cabinet for natural cooling of internal electronics, comprises of an assembly of a first perforated sidewall (22) extending longitudinally and positively fixed along edges of a top panel (16), a front panel (18), a back panel (20) and a perforated bottom panel (22) having sufficient clearance from the underlying surface to permit entry of fresh air. A second perforated sidewall (14) extending longitudinally and detachable to the assembly and being fixed oppositely to the first perforated sidewall (22). A storage disk (36) and an electronics board (34) that are operatively connected to each other and vertically placed in a manner that only their edges are adjacent to each other. The storage disk (36) and the electronics board (34) is supported by the top and the bottom panel (22) and a Power supply board 30 placed horizontally on the bottom panel (22) to receive power and distribute the same to the storage disk (36) and the electronics board (34). The perforated bottom panel (22) in conjunction with the perforated sidewalls that tapers towards the top panel (16) to provide natural cooling for the heat dissipation therein in the set-top-box (10). The first and the second sidewalls herein taper towards the top panel (16) in such a way to have an 'A-shape' or the like similar shapes.

Description

A SET-TOP-BOX CABINET FOR NATURAL COOLING OF INTERNAL ELECTRONICS. FIELD OF THE INVENTION
The present invention relates to set-top-boxes, more particularly to the cooling arrangement of the set-top-boxes. BACKGROUND OF THE INVENTION
The worldwide phenomenon of rapidly growing digital TV market and the move towards analog broadcast switch-off is offering great opportunity to Set-Top-Box manufacturers across the globe. However, the global market is segmented with different standards being adopted in different regions of the world. Along with the opportunity these markets are throwing many challenges to manufacturers because of highly competitive markets with very tight time to market requirements for feature rich products providing high quality consumer experience.
Responding to the above mentioned challenges many such Set-top boxes are presently available in the market. Fully integrated set-top boxes have good processors, memory and optional large hard drives. They're.. often used with highspeed connections. Features could include high-speed Internet access, iTV, digital video recording & gaming.
Set-top-boxes are generally used in conjunction with a TV and needs to be kept in its proximity, with the remotes usable in TV pointing direction. With the rapid changing technology and shape in TVs, the best position of keeping the set-top- box is no longer on top of the same. Adequate space on the top of the TV has become impossible in the current generation of thin Plasma or LCD TVs. One such available set-top box 8 is shown in figure 1 , wherein the set-top box comprises of an enclosure made from 6 panels having perforations therein. Various electronic components like hard disk 16, PCB, power board 12, connectors 14, storage disks 16 etc.
Heat dissipation systems, such as fan systems, are being deployed within set-top boxes in order to maintain electrical boards, and the components thereon, below a critical temperature.
The electrical components within these systems can generate a large amount of heat, which needs to be dissipated away from these components in order for them to remain below the critical temperature in which these components function properly. The component density and size of electrical systems, and large amount of heat generated by components within these systems, has and continues to affect the cooling systems used to dissipate this heat. For example, certain complex electrical systems may present problems for cooling systems because of the board shape on which the system is located or the component locations on the board.
This heat may damage the processor, as well as components around the processor, and result in instability or failure of the system in which the processor is located. It is therefore very important that the cooling system effectively dissipate this heat away from heat-generating components. In order to dissipate heat effectively, a single fan or multiple fans are already being employed with the set-top boxes. Such set-top boxes effectively dissipate heat through the perforations provided on the panels for initial some time when the set-top box is quite new. The problem occurs when these set-top boxes have operated for quite sometime. Among various problems, one major problem is the orientation in which the set- top box 8 is laid (as shown in figurei). Due to this orientation the dissipation of heat from the bottom panel does not take place due to the hindrance offered by the lying surface on which the set-top box is placed. This prevents effective dissipation of heat thereof and may likely to damage the nearby electronic components such as storage disk 16, connectors 14, power supply 12 etc. Further the fan 10 employed with the set-top box sucks in a lot of dust while in operation from the outside ambience. In long course of time this may lead to creation of lot of noise and maintenance problems. This may hamper the working of the electronic components therein. Moreover, such set-top boxes may not be able to sustain for a longer period of time in dusty and rugged condition. Another problem with these set-top-boxes 8 is that due to the constructional design features they may not be easily transportable from one place to another. Hence the aforementioned conditions are really objectionable and accordingly demand an improvement. SUMMARY
Accordingly it is an object of the present invention to provide an arrangement to a set-top-box enabling the electronic components therein to be naturally cooled. According to an embodiment of the present invention a set-top-box 10 cabinet for natural cooling of internal electronics comprises of, an assembly of a first perforated sidewall and positively fixed along edges of a top panel, a front panel, a back panel and a perforated bottom panel. The perforated bottom panel having sufficient clearance from the underlying surface on which the set-top-box is supported to permit entry of fresh air therein. A second perforated sidewall is detachably fixed to the assembly in such a way that the second sidewall is attached oppositely to the first perforated sidewall. The perforated bottom panel in conjunction with the perforated sidewalls that by tapering towards the top panel provide natural cooling to the heat dissipation therein in the set-top-box. Due to the tapering structure of the first perforated sidewall and the second perforated sidewall towards the top panel, the heat dissipated by the power supply board, the storage disk, the electronics board and other user-upgradeable items effectively escape out from the sidewalls and simultaneously fresh air may enter through the perforations provided at the bottom panel. A storage disk and an electronics board are vertically placed in a manner that only their edges are adjacent to each other and operatively connected to each other. The top and the bottom panel support the storage disk and the electronics board with insulation ensuring that the set-top-box itself does not get heated. A power supply board placed horizontally on the bottom panel to receive power and distribute the same to the storage disk and the electronics board. According to another embodiment of the present invention digi-attachments are placed on either side of the first perforated sidewall and the second perforated sidewall. Further, digi-attachments are coupled to the set-top-box via cable and placed in a manner to have some space available for the heat dissipation. Preferably, the set-top-box has a pair of wings extending outwardly from the bottom panel for supporting the pair of digi-attachments. This enables the digi- attachments to be firmly fixed on the wings even when the set-top-box is in different orientations.
According to another embodiment of the present invention, some of the user upgradeable parts are provided through USB devices that are placed in a manner to be comfortably housed and yet dissipate heat effectively. The USB devices are preferably provided on the power supply board and received vertically in the USB ports. According to another embodiment of the present invention, an IR transmission/receiving device is placed in a detachable IR dome that can be oriented in four different directions to ensure that the IR dome always faces the user irrespective of orientation of the set-top-box. A BRIEF DESCRIPTION OF THE DRAWINGS Fig 1 illustrates the available set-top-box and labeled as prior-art. Fig 2 illustrates the set-top box with perforated side panels according to an embodiment of the present invention.
Fig 3a illustrates the placement of internal electronic components in the set-top- box of Fig 2.
Fig 3b illustrates the heat dissipation convection process associated with the set- top-box of Fig 2.
Fig 4 shows the metal sheet stamped to form various panels and slots therein according to an embodiment of the present invention.
Fig 5 shows the linear arrangement of the electronics board and storage device of the set-too-box of fig 3a.
Fig 6 shows the digiattachments in connected with the set-top-box according to an embodiment of the present invention.
Fig 7a, 7b, 7c and 7d shows the four orientations of the IR dome according to an embodiment of the present invention. Fig 8a and 8b shows the set-top-box of fig 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Now referring to figure 3a, which describes an embodiment of the present invention, a set-top-box 10 cabinet for natural cooling of internal electronics therein comprises of, an assembly of a first perforated sidewall 22 extending longitudinally and positively fixed along edges of a top panel 16, a front panel 18, a back panel 20 and a perforated bottom panel. A second perforated sidewall 14 extends longitudinally and is detachable to the assembly, the second sidewall being fixed oppositely to the first perforated sidewall 22. On the inner side of the set-top-box 10 a storage disk 36 and an electronics board 34 is operatively connected to each other and vertically placed in a manner that only their edges are adjacent to each other. The storage disk 36 and the electronics board 34 are supported by the top and the bottom panel, and a Power supply board 30 placed horizontally on the bottom panel to receive power and distribute the same to the storage disk 36 and the electronics board 34.
The perforated bottom panel in conjunction with the perforated sidewalls, by tapering towards the top panel 16, provides natural cooling in the set-top-box 10. Reference herein is made to figure 4, which shows an assembly of a first perforated sidewall 12 that extends longitudinally and positively fixed to one of the edges of the top panel 16, the bottom panel 22, the front panel 18 and the back panel 20. In the instance shown in the figure 4, the assembly is constructed from a single panel of metallic sheet that has extensions for respectively forming the top panel 16, the bottom panel 22, the front panel 18 and the back panel 20. Through stampings on the metallic sheet, various slots are provided on the respective panels to house several plug-ins for providing permanent connection to fixed devices such as Ethernet, Phones, HDMI cable, Audio/video cables, smart card, rubber grommets 38 etc.
The front panel 18 is also stamped to form various slots that may house a smart card and some connectors for some user pluggable items as described above. Similarly, the top panel 16 is stamped to accommodate some connectors for some user pluggable items such as head phone, MICS, line-in, Smart card, USB devices (118) and even an external storages device such as SATA drive. Due to absence of perforation in the top panel 16, the entry and settling of dust is prevented, and therefore periodical cleaning and maintaining of the set-top-box 10 is drastically reduced.
The back panel 20 of the set-top-box 10 is meant for more permanent connection to fixed devices such as Ethernet, Phones, HDMI cable, Audio/video cables, RS- 232 cables and Power adaptors. The split-rubber grommets 38 allow, as referred in figure 3a, a cable to be simply slid in, via the split thereby fixing it tightly to the rubber grommet. Furthermore, the cable can be snaked through three rubber grommets 38, ensuring that it doesn't slide out even when pulled. The bottom panel 22 forming the set-top-box 10 provides enough clearance from the surface on which the set-top-box 10 is placed (for example table top or wall). This is achieved by attaching pieces of rubber 'feet' 26 to the bottom panel 22 (as shown in fig 2 and 3b). The bottom panel 22 has got enough serrations for air to be drawn in when heat dissipation takes place through the perforated first and second sidewalls. During the operation it may be observed that the perforations provided on the first and second sidewalls and the serrations provided on the bottom panel 22 facilitates natural cooling via convection to the set-top-box 10 having electronics items therein (as shown in Fig 3b). The bottom panel 22 of the set-top-box 10 provides enough clearance from the tabletop or the wall (if mounted), through four rubber 'feet' 26.
As shown in figure 8, the bottom panel 22 also has two sockets 44 provided on the outer surface of the bottom panel 22, which go into the hooks 46 of a wall bracket 48, for a slip-on attachment thereby ensuring tight alignment of the set- top-box 10 with the wall bracket 48.
By virtue of the design of the perforated first panel and the second perforated panel, the set-top-box 10 may be opened just by the application of little force and even no screw driver is needed thereby making the set-top-box 10 extremely user-friendly for maintenance point of view. This permits the set-top-box 10 to be used as a portable media player, with a user replaceable storage device. Now reference herein is being made to the figures 2 and 3b, in which it is illustrated that both the first perforated sidewall 22 and the second perforated sidewall 14 tapers towards the top panel 16 to have an "A-shape". This allows free flow of the hot/ warm air via heat dissipation to go outside and the fresh or cold air to come inside to facilitate heat dissipation through convection. It may be noted that there may similar kind of shapes into which the set-top-box 10 may be constructed, for example "A-shape" with flat top, "inverted U-shape" or the like or variety of "A" shape may be possible like the top may be meeting at a point, or have a flat edge, or may be rounded, or may have the perforated sidewalls at different angles. The bottom line that is to be noted herein is that the base of the set-top-box 10 should be broader than the top, and the bottom thereof should be a bit lifted up analogous to the horizontal bar of the letter "A". Due to the virtue of the "A-shape" design the set-top-box 10 becomes sleek, thereby ensuring easy mixing of internal and external air. Further, the sleek A- shape can be a low profile to ensure that it is hand graspable. This aids in easy portability, without requiring any special handles. Further, the user may easily take it from one place to another place for viewing the contents of the storage disk 36 inside the set-top-box 10.
The set-top box may be placed on any horizontal surface, such as that of table or shelf or even the top of a modern new TV, for normal usage. Depth of the conventional CRT TVs is sufficient for allowing the set-top-box 10 to be kept on top or side of the TV, with just the front panel 18 of the set-top-box 10 exposed. The set-top-box 10 thus aesthetically blends along the TVs and the matching cabinets around them. In this way, the connection to the back panel 20 of the TV get made through the back panel 20 of the set-top-box 10 in the most convenient way. Along with Flat TVs, there is not much depth available on the top of the TV or on a shelf adjacent to it. In this case it should be possible for the set-top-box 10 to be kept sideways, and still allow easy interaction with the user. The set-top- box 10 should be mountable on the side of a flat TV, or above or below it. The rubber feet 26 attached to the bottom of the set-top-box 10 keep the set-top-box 10 slightly elevated from the underlying surface, enabling fresh inflow of air. Reference herein is given to the figure 3a that explains the inside constructional parts of the set-top-box 10. The inside of the set-top-box 10 may be categorically divided into two sections, firstly, user-upgradeable parts and secondly not-user- serviceable parts. The not-user-serviceable parts such as the electronics board 34, faces the perforated sidewall of the set-top-box 10 and is placed such that the side with not-user-serviceable components faces the first perforated sidewall 22, thereby ensuring access of only user-upgradeable parts through the detachable second perforated sidewall 14. This makes it extremely difficult for the user to even touch or play with not-user-serviceable components when the set-top-box 10 is opened via detachable second perforated sidewall 14. The user-upgradeable parts of the set-top-box 10 comprise of smart card connector, batteries, USB ports 32, storage disk 36, phone board, etc. It would be quite apparent to the person skilled in the art to understand the inclusion and functionality of the power-supply board (for receiving and distributing the power from an external source) in the set-top-box 10. The power- supply board in the form of strip having the circuitry laid therein may be on the bottom panel 22. The user may easily reach the user-upgradeable parts of the set-top-box 10 via the detachable panel which can be easily detached from the assembly, even without a screwdriver. This makes it easy for any user to service the internal parts of the set-top-box 10 without even without requiring any help of a technician.
The storage disk 36 and the electronics board 34 are vertically placed and more towards the first perforated sidewall 22 in manner such that the edges of both the storage disk 36 and the electronics board 34 are placed adjacently and face oppositely each other (as shown in fig 3a).
Reference herein is being given to fig 5 wherein the power-supply board is insulated at the bottom panel 22, whereas the storage disk 36 and the electronics board 34 are attached with insulation to the top and bottom panel 22 in order to prevent the heating of the set-top-box 10. The storage disk 36 is sandwiched between the rubber strips provided on the top and the bottom panel 22 to provide friction mounting and also for shock absorption. This allows the user to have access to and change the storage disk 36 even without requiring help of a screwdriver. Further, the electronics board 34 and the peripherals inside the set- top-box 10, are attached to the bottom panel 22, and the top panel 16, with possible support from the top and the bottom panel 22. It may be noted that the electronics board 34 and the peripherals are not attached to either of the side panels.
With reference to figure 2 and 3b, since the combination of storage disk 36 and electronics board 34 are placed more towards the first perforated sidewall 22 and the Power supply board 30 are place more towards the second perforated sidewall 14, during operation a non-interfering heat dissipation takes place. The power-supply board is sufficiently apart from the main board as clearly indicated in figure 3b. Due to this arrangement maximization of the space availability for the power-supply board, storage disk 36 and user upgradeable parts is achieved. So during normal course of operation, fresh air is sufficiently circulated by entering from the serrations provided in the bottom panel 22 towards each of the first and the second perforated sidewall 14 thereby enabling the heat dissipated therein by the electronics to be efficiently removed.
As discussed earlier, due to the portability being an advantageous feature of the set-top-box 10, height of the storage disk 36 that is preferably used thereof is 3.5", while the length is more. Also in order to meet the low profile requirement, it is preferable to place the storage vertically so that the set-top-box 10 has a height slightly more than 3.5" of the storage disk 36. Similarly, height of the electronics board 34 is also adjusted as 3.5" that of the storage disk 36. The resulting height of the overall set-top-box 10 is therefore maintained so that it is easily graspable in a hand.
Alternatively, a 2.5" storage disk 36 may also be mounted with additional rubber padding in the space available for 3.5" storage disk 36. This would allow operations in a vibration environment such as a vehicle. Hence, an "A- shaped" profile for the set-top-box 10 is possible with a 2.5" storage disk 36. Further, it may also be possible to have the storage disk 36 entirely with Flash memory, in which case the "A-shaped" profile cabinet may have less depth. According to another embodiment of the present invention and as illustrated in fig 3a and 3b, some of the user upgradeable parts are provided through USB devices (118) that are placed in a manner to be comfortably housed and yet dissipate heat effectively. The USB devices are preferably provided on the Power supply board 30 and received vertically in the USB ports 32. The power board provides few USB ports 32, for allow vertical plug-in of USB devices 118. The heat from the USB devices 118 can go out through the detachable side panel. According to another embodiment of the present invention and as shown in figure 6, a digi-attachment is placed on either side of the first perforated sidewall 22 and the second perforated sidewall 14 respectively. Further, digi-attachments 40 are coupled to the set-top-box 10 via cable and placed in a manner to have some space available for the heat dissipation. Preferably, the set-top-box 10 has a pair of wings 42 extending outwardly from the bottom panel 22 for supporting the pair of digi-attachments 40. The wings 42 allow two attachments 40 to be placed on either side of the set-top-box 10. The digi-attachments 40 can be connected to the set-top-box 10 through flat cables. This enables the digi-attachments 40 to be firmly fixed on the wings 42 even when the set-top-box 10 is in different orientations.
The set-top-box 10 as shown in figure 7 may be oriented into four different orientations depending upon the need of the user and to cater all possible requirements of optimal placement of the set-top-box 10 adjacent to a TV in a tabletop or wall mount application.
According to an embodiment of the present invention, if the digi-attachments 40 needs to dissipate much heat they can be adapted to the "A-shape", thereby ensuring sufficient availability of the space between the digi-attachment and set- top-box 10. It is to be noted that in every orientation the pair of wings 42 provides rigidity to the pair of digi-attachments 40 as the same is firmly fixed to the bottom panel 22. The wing and the clipping mechanism are strong enough to ensure rigid position of the digi-attachments 40, in all the positions in which the set-top- box 10 can be placed. The clipping position of the wings 42 is such that a minimum distance is maintained between the set-top-box 10 and the attachment to facilitate air flow. Even when the set-top-box 10 is wall mounted, the digi-attachments 40 don't have to be separately wall mounted, they would remain in a rigid position next to the Set-top-box 10.
The digi-attachment is used for converting analog/RF video signals into digital streaming signals for various audio/video applications. They thus allow expansion of the features of the set-top-box 10. These features are mostly related to digital video inputs. Example: Digital Tuner, DTH Tuner and PVR Attachment. Each digi-attachment has a back panel 20 whose connectors align with the back-panel of the set-top-box 10.
According to another embodiment of the present invention, an IR transmission/receiving device is placed in a detachable IR dome 24 that can be oriented in four different directions to ensure the IR dome 24 (shown in fig 2) always faces the user irrespective of the orientation of the set-top-box 10 (as shown in fig 7). Preferably, the detachable IR dome 24 is attached to the front panel 18 of the set-top-box 10.
In all the orientations of the set-top-box 10 it should be possible for the user to interact in the normal way, with his remote pointing towards the TV. This is achieved by having a detachable IR dome 24, which houses the Infra-red electronics. The IR dome 24, can be easily detached by a user (without any screwdriver) and placed back in a new position. As illustrated in figure 6, the IR dome 24 can be fixed in four different positions, namely Front position for normal usage, when the set-tόp-box 10 is kept on the side of a TV, Top Position for allowing the usage of the set-top-box 10 when it is mounted on the wall, Two Side Positions, on the Left panel and the Right Panel, when the set-top-box 10 is kept sideways, adjacent to the TV. Further, in all the position the cooling aspect should not get affected. It should be possible to attach the set-top-box 10 on the wall bracket 48, through the hook- sockets 44 provided beneath the set-top-box 10. No screwdriver should be needed. It should be possible to easily detach the set-top-box 10 by just sliding it out. This permits it to be used as a portable media player, with a built-in hard drive.
While the present invention has been described with reference to certain exemplary embodiments, those skilled in the art will recognize that various modifications may be provided. Accordingly, the scope of the invention is to be limited only by the following claims.
INDEX TO REFERENCE NNUMERALS
10 - Set-top-box
12 - First perforated sidewall
14 - Second perforated sidewall
16 - Top panel
18 - Front panel
20 - Back Panel
22 - Bottom panel
24 - IR dome 6 - Rubber feet 8 - USB device 0 - Power board 2 - USB port 4 - Electronics board 6 - Storage disk 8 - Rubber grommets 0 - Digi-attachments - Wings - Socket - Hooks - Wall bracket

Claims

1. A Set-top-box 10 cabinet for natural cooling of internal electronics, comprising: an assembly of a first perforated sidewall 22 extending longitudinally and positively fixed along edges of a top panel 16, a front panel 18, a back panel 20 and a perforated bottom panel 22 having sufficient clearance from the underlying surface to permit entry of fresh air; a second perforated sidewall 14 extending longitudinally and detachable to the assembly, the second sidewall being fixed oppositely to the first perforated sidewall 22; a storage disk 36 and an electronics board 34 operatively connected to each other and vertically placed in a manner that only their edges are adjacent to each other, the storage disk 36 and the electronics board 34 supported by the top 16 and the bottom panel 22; and a power supply board 30 placed horizontally on the bottom panel 22 to receive power and distribute the same to the storage disk 36 and the electronics board
34, wherein the perforated bottom panel 22 in conjunction with the perforated sidewalls which taper towards the top panel 16, provide natural cooling to the heat dissipation therein in the set-top-box 10.
2. The set-top-box according to claim 1 , wherein the power supply tøoard and the combination of storage disk and electronics board are sufficiently apart from each other for allowing non-interfering heat dissipation.
3. The set-top-box according to claim 1 including user upgradeable components and user-not serviceable components.
4. The set-top-box according to claim 1 and 3, wherein the user-not- serviceable components includes the electronics board, the side of the user-not- serviceable components faces the first perforated sidewall, thereby ensuring access of only user-upgradeable parts through the detachable second perforated sidewall.
5. The set-top-box according to claim 1 and 3, wherein the electronics board is mounted in close proximity to the first perforated sidewall in order to maximize the space available for the power-supply board and storage disk and user upgradeable parts.
6. The set-top-box as claimed in claim 3, wherein some of the user upgradeable parts in the form of USB devices are placed in a manner to be comfortably housed and yet dissipate heat effectively.
7. The set-top-box as claimed in claim 6, wherein the USB devices are received vertically in the USB ports placed on the power supply board.
8. The set-top-box according to claim 1 , wherein digi-attachments are placed side of the first perforated sidewall and the second perforated sidewall, the digi- attachments are coupled to the set-top-box via cable and placed in a manner to ensure space availability for heat dissipation.
9. The set-top-box according to claim 7, wherein the set-top-box has a pair of wings extending outwardly from the bottom panel for supporting the pair of digi- attachments and ensuring sufficient clearance from the sidewalls.
10. The set-top-box according to claim 1 , wherein the set-top-box is oriented in four different directions to cater to all possible requirements of optimal placement adjacent to a TV in a table-top or wall mount application.
11. The set-top-box according to claim 1, wherein an IR transmission/receiving device is placed in a detachable IR dome that can be oriented in four different directions to ensure that the IR dome always faces the user irrespective of the orientation of the set-top-box.
12. The set-top-box according to claim 1 , wherein the storage disk is sandwiched between rubber strips to provide friction mounting and shock- absorption.
13. The set-top-box according to claim 1, wherein the storage disk, the electronics board and the power supply board are attached with insulation to the top panel and/ or the bottom panel in order to prevent the heating of the set-top- box itself.
14. The set-top-box according to claim 1 , wherein the assembly of the set-top- box is made from a single blank of metal sheet which is punched and bent to form the first perforated sidewall, the perforated bottom panel, the front, the back and the top panels.
PCT/IN2007/000578 2007-11-01 2007-12-10 A set-top-box cabinet for natural cooling of internal electronics WO2009057124A2 (en)

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IN1941MU2007 2007-11-01

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US8902588B2 (en) 2009-12-09 2014-12-02 Thomson Licensing Set-top box having microperforations
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CN104581258A (en) * 2014-12-23 2015-04-29 贵州省广播电视信息网络股份有限公司 Wall-hung type tri-network integration-oriented full-service intelligent terminal
CN104581305A (en) * 2014-12-25 2015-04-29 贵州省广播电视信息网络股份有限公司 Wall-hung type triple-network-convergence-oriented full-service intelligent terminal capable of realizing *-shaped heat dissipation
CN105141991A (en) * 2015-09-30 2015-12-09 深圳市九洲电器有限公司 Housing of set-top box and set-top box
CN114268819A (en) * 2021-12-09 2022-04-01 郭雨 Digital television set-top box

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