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Re: Patch-panel fabrication

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On 5/5/2017 12:45 AM, whit3rd wrote:
> On Friday, May 5, 2017 at 12:18:48 AM UTC-7, Don Y wrote:
>
>> But, within that "half 4U panel" space, I am free to arrange connectors
>> however I wish.  *If* I can come up with a way to mechanically support
>> them that is also cosmetically appealing.
>
>> I need a way to make a functionally equivalent plate that has the
>> same mechanical characteristics to support that number of connectors.
>> The easiest approach, IMO, is to laser cut something.
>
> That's what I don't get.   What kind of connector will attach
> to a laser cut panel?   Will it include insulation displacement termination
> of the wires from the depths of the wall?

The connector doesn't attach to the panel.

(Currently) connector mounts on a circuit board along with the
punchdown block (foil traces on the PCB connect the punchdown
block to the connector pins).  Circuit board is fastened to
the front panel with threaded standoffs (screw heads are visible
countersunk in the outside surface of the panel).

(Again, currently) a custom printed (legended) mylar sheet
has holes cut in it for the rows of connectors to peek
through.

(Currently) panel supports 72 (36+36) connectors in rows
of 12 connectors that abut side-to-side.

New panel needs to support 96 (48+48) connectors.  The
easy (? straight-forward?) way to do so is to cannabilize
the "connector-punchdown PCB assemblies" from the old
panel (or, any number of similar panels that I've got
squirreled away).  Mount these to a new plate, laser cut
from acrylic, hardwood, etc.

But, acrylic/hardwood aren't stiff enough, by themselves,
to support someone pushing on such a panel to mate/demate
patch cords.  The plate ends up with so much material
removed to make space for the connector bodies that it
becomes flexible.  So, how to stiffen -- without moving to
something that makes it look like a typical patch panel
(e.g., black painted metal).

One solution is to just increase the thickness of the panel.
But, doing so for the *whole* panel (including the "mounting
ears") makes the panel protrude from the wall surface -- onto
which it fastens.  I.e., imagine a panel made out of "metal"
that was 1/2" thick!

[The connector bodies have a lot of depth, front to rear, so
the PCB sits well behind the panel, supported by standoffs.
This space can be filled with "thicker panel" and still keep
the front of the connector body flush with the outer surface
of the panel without the PCB touching the back side of the
panel!]

So, cut the "reinforcing panel" narrower & shorter so the front
panel piece overhangs it.  The smaller reinforced piece then
can fit *into* the hole in the wall while the actual front
panel sits ON the wall surface.  Standoffs that hold the PCBs
to the panel can be anchored into the panel *or* the
reinforcement behind it (which would keep the mounting screws
blind).  Front panel and reinforcement panel become one piece
(glue/screw/etc)

If the reinforcement layer was metal, it could provide the
stiffness of the current metal panel, with the wood/acrylic
laser cut panel acting like a veneer -- in much the same way
that the mylar legend sheet acts, currently.

But, its much easier to just laser cut another sheet of acrylic
(or wood) to serve this reinforcement role -- just run another
sheet through the laser cutter after changing the outer
dimensions a bit!  E.g., use a piece of hickory (for the outer
layer) and it will "match" the rest of the woodwork.  Or, a
piece of white acrylic and it will match the wall plates for
the electric outlets nearby.

There may be value in depopulating those PCB's (rather than trying
to find a source of soldertail punchdown blocks, etc.) and moving
those "components" to new PCBs laid out to better suit my needs.
E.g., I'd like to associate an indicator with each connector to
provide a convenient way of illustrating the performance/function
of each "port" (the switch isn't immediately visible and its
stock indicators don't indicate the same sorts of things that I'd
want to convey!)

But, silly to go too far down that road until I know how much flexibility
I have in configuring the panel, mechanically.

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Thread

Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-03 12:54 -0700
  Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-03 13:23 -0700
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 00:10 -0700
      Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-04 11:27 -0700
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:43 -0700
        Re: Patch-panel fabrication Clifford Heath <no.spam@please.net> - 2017-05-05 08:57 +1000
          Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-06 05:47 -0700
        Re: Patch-panel fabrication krw@notreal.com - 2017-05-04 19:37 -0400
      Re: Patch-panel fabrication Neon John <no@never.com> - 2017-05-04 17:56 -0400
        Re: Patch-panel fabrication Lasse Langwadt Christensen <langwadt@fonz.dk> - 2017-05-06 05:46 -0700
      Re: Patch-panel fabrication Jasen Betts <jasen@xnet.co.nz> - 2017-05-11 05:57 +0000
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-11 10:37 -0700
  Re: Patch-panel fabrication Martin Riddle <martin_ridd@verizon.net> - 2017-05-03 20:32 -0400
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-03 23:59 -0700
  Re: Patch-panel fabrication Jasen Betts <jasen@xnet.co.nz> - 2017-05-04 06:34 +0000
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 01:45 -0700
  Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-04 01:52 -0700
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:42 -0700
      Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-04 21:22 -0700
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 23:04 -0700
          Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-04 23:24 -0700
            Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-05 00:19 -0700
              Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-05 00:45 -0700
                Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-05 02:17 -0700
  Re: Patch-panel fabrication jrwalliker@gmail.com - 2017-05-04 08:40 -0700
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 10:12 -0700
      Re: Patch-panel fabrication jrwalliker@gmail.com - 2017-05-04 10:27 -0700
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:01 -0700
          Re: Patch-panel fabrication makolber@yahoo.com - 2017-05-04 11:18 -0700
            Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-04 11:27 -0700
      Re: Patch-panel fabrication Don Kuenz <g@crcomp.net> - 2017-05-06 05:33 +0000
        Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-06 15:40 -0700
          Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-06 20:15 -0700
            Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-06 23:47 -0700
              Re: Patch-panel fabrication whit3rd <whit3rd@gmail.com> - 2017-05-07 03:51 -0700
                Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-07 05:20 -0700
          Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 17:30 +0000
            Re: Patch-panel fabrication (POE) Don Y <blockedofcourse@foo.invalid> - 2017-05-07 11:49 -0700
              Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 18:58 +0000
                Re: Patch-panel fabrication (POE) Don Y <blockedofcourse@foo.invalid> - 2017-05-07 12:24 -0700
                Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 19:48 +0000
                Re: Patch-panel fabrication (POE) Don Y <blockedofcourse@foo.invalid> - 2017-05-07 13:29 -0700
                Re: Patch-panel fabrication (POE) Jan Panteltje <pNaOnStPeAlMtje@yahoo.com> - 2017-05-07 20:54 +0000
  Re: Patch-panel fabrication Allan Herriman <allanherriman@hotmail.com> - 2017-05-07 10:35 +0000
    Re: Patch-panel fabrication Don Y <blockedofcourse@foo.invalid> - 2017-05-07 05:26 -0700

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