Abstract:
A control system ( 10 ) is built with functional modules expandable system, usually containing electronic circuit boards ( 24 ). The packaging of the modules allow a variable number of modules to be vertically stacked together to form a variably sized control system. There is a module having a housing which engages the housing of an abutting module in a physically locked relationship, based upon four locking elements. There are modular units ( 16, 18, 20 ) which can be joined vertically by having two interlocking control units in the front of each module and two interlocking control units in the back of each module. Placed above the uppermost intermediate module is a top module ( 12 ) for the control unit. Placed below the lowermost intermediate module is a bottom module ( 14 ) for the control unit.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to control systems; and more particularly the invention relates to a control system built with functional modules which can be vertically stacked together to form an expandable system, usually containing electronic circuit boards. 
     The present invention is directed to a modular control system and particularly to the packaging of the modules which allows a variable number of modules to be vertically stacked together and form a variably sized electronic control system. 
     2. The Prior Art 
     Modular network apparatus is known from the following patents: 
     
       
         
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 U.S. Pat. No. 
                 Patentee 
                 Issue Date 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Des. 318,874 
                 Pushelberg et al 
                 Aug. 6, 
                 1991 
               
               
                   
                 Des. 320,979 
                 Vice et al 
                 Oct. 22, 
                 1991 
               
               
                   
                 Des. 338,874 
                 Renard 
                 Aug. 31, 
                 1993 
               
               
                   
                 Des. 353,143 
                 Namba 
                 Dec. 6, 
                 1994 
               
               
                   
                 Des. 355,419 
                 Namba 
                 Feb. 14, 
                 1995 
               
               
                   
                 Des. 381,337 
                 Fechner et al 
                 Jul. 22, 
                 1997 
               
               
                   
                 Des. 393,251 
                 Kurokawa 
                 Apr. 7, 
                 1998 
               
               
                   
                 5,602,721 
                 Slade et al 
                 Feb. 11, 
                 1997 
               
               
                   
                 5,838,548 
                 Matz et al 
                 Nov. 17, 
                 1998 
               
               
                   
                 6,038,126 
                 Weng 
                 Mar. 14, 
                 2000 
               
               
                   
                   
               
             
          
         
       
     
     The disclosure of each of the above patents is herewith incorporated by reference. 
     The Slade U.S. Pat. No. 5,602,721 discloses that modular units can be joined as follows. There is a rail  36  which slidably engages a recess in the bottom surface of an abutting module. 
     The rail comprises two generally raised triangular portions and with the long sides of the two triangular portions slidably engaging each other to form a generally rectangular rail. A screw  52  extends through the portion  50  and threadably engages the second triangular portion  51  whereby rotation of screw slides triangular portion  51  relative to triangular portion  50  to change the width of the generally rectangular rail for locking and unlocking in a mating recess on the bottom side of an abutting module. 
     The bottom side of the module  28  shows the fans in the front surface  30 . The bottom side has a complimentary configuration relation to the top side for stacking of the modules. A first surface  54  of the bottom side includes a dovetailed recess  56  which mates with the rail  36  shown on the top side. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a modular controller system which is readily vertically expandable. A feature of the invention is a module having a housing which engages the housing of an abutting module in a physically locked relationship, based upon four locking elements. 
     It is a further object of the present invention to provide modular units which can be joined vertically by having two interlocking connector units in the front of each module and two interlocking connector units in the back of each module. 
     The present invention is directed to a vertically stacked control unit which includes an expandable plurality of functional modules. These modules are vertically stacked one above the other. Placed above the uppermost intermediate module is a top module for the control unit. Placed below the lowermost intermediate module is a bottom module for the control unit. 
     More particularly, the present invention relates to a vertically stacked control unit comprising 
     an expandable plurality of functional modules, such as intermediate modules, with each module having a front side, a back side, a top side, a bottom side, a right side, and a left side; 
     said top side of said module having a first skirt receptacle on the right side and having a second skirt receptacle on the left side; 
     said bottom side of said module having a first skirt on the right side and having a second skirt on the left side; 
     said front side of each module having a top edge and a bottom edge; said back side of each module having a top edge and a bottom edge; said front side top edge having a first U-shaped receiver on the right side and having a second U-shaped receiver on the left side; said front side bottom edge having a first pin on the right side and having a second pin on the left side; 
     said back side top edge having a first groove on the right side and having a second groove on the left side; 
     said back side bottom edge having a first tongue on the right side and having a second tongue on the left side; and 
     whereby a plurality of functional modules can be vertically stacked together with a first skirt and a second skirt of an upper module engaging a first and a second skirt receptacle respectively of a vertically adjoining lower module; with said first tongue and said second tongue of said upper module engaging said first groove and said second groove respectively of said vertically adjoining lower module; and with said first pin and said second pin on said upper module fitted respectively within said first U-shaped receiver and said second U-shaped receiver of said vertically adjoining lower module. This technique for interconnecting modules is applicable for connecting together intermediate modules; or for connecting together a top module to an intermediate module; or for connecting together a bottom module to an intermediate module. 
     The first U-shaped receiver on the right side is adjacent to the first skirt receptacle on the right side. The second U-shaped receiver on the left side is adjacent to the second skirt receptacle on the left side. 
     The first pin on the right side is attached to the first skirt on the right side. The second pin on the left side is attached to the second skirt on the left side. The first pin on the right side can also be attached to an extension of the first skirt on the right side. The second pin on the left side can also be attached to an extension of the second skirt on the left side. 
     The back side top edge first groove on the right side is adjacent to the first skirt receptacle on the right side. The back side top edge second groove on the left side is adjacent to the second skirt receptacle on the left side. 
     A first inwardly directed shoulder on the right side connects said first groove on the right side to said first skirt receptacle on the right side. A second inwardly directed shoulder on the left side connects said second groove on the left side to said second skirt receptacle on the left side. 
     The back side bottom edge first tongue on the tight side is adjacent to the first skirt on the right side. The back side bottom edge second tongue on the left side is adjacent to the second skirt on the left side. 
     The bottom module is shaped preferably like a hollow cube or a hollow parallelepiped. The bottom module has five walls, namely a front side wall, a back side wall, a right side wall, a left side wall, all joined to a bottom wall. There is no top wall and the interior is hollow. Electronic components may be placed within this hollow interior. 
     The bottom module of the control unit only has on the front side a top edge, and not a bottom edge on the front side. The front side top edge has a first U-shaped receiver on the right side and has a second U-shaped receiver on the left side. 
     The bottom module of the control unit only has on the back side a top edge, and not a bottom edge on the back side. The back side top edge has a first groove on the right side and has a second groove on the left side. 
     The top module is preferably shaped as a solid flat self-supporting metal sheet having a front side, a back side, a right side, and a left side, all joined to a top side. 
     The top module of the control unit only has on the front side a bottom edge, and not a top edge on the front side. The front side bottom edge has a first pin on the right side and has a second pin on the left side. 
     The top module of the control unit only has on the back side a bottom edge, and not a top edge on the back side. The back side bottom edge has a first tongue on the right side and has a second tongue on the left side. 
     Also, the present invention is directed to a vertically stacked control unit comprising 
     a top module of the control unit only having on a front side a bottom edge, and not a top edge on the front side; said front side bottom edge having a first pin on a right side and having a second pin on a left side; 
     said top module of the control unit only having on the back side a bottom edge, and not a top edge on the back side; said back side bottom edge having a first tongue on a right side and having a second tongue on a left side; said first tongue adjacent to a first skirt-on the right side; and said second tongue adjacent to a second skirt on the left side; 
     a bottom module of the control unit only having on a front side a top edge, and not a bottom edge on the front side; said front side top edge having a first U-shaped receiver on a right side and having a second U-shaped receiver on a left side; 
     said bottom module of the control unit only having on a back side a top edge, and not a bottom edge on the back side; said back side top edge having a first groove on a right side and having a second groove on a left side; and 
     said bottom module having a first skirt receptacle on the right side and having a second skirt receptacle on the left side; and 
     whereby the top and bottom functional modules can be vertically stacked together with a first skirt and a second skirt of the top engaging a first and a second skirt receptacle respectively of a vertically adjoining bottom module; with said first tongue and said second tongue of said top module engaging said first groove and said second groove respectively of said vertically adjoining bottom module; and with said first pin and said second pin on said top module fitted respectively within said first U-shaped receiver and said second U-shaped receiver of said vertically adjoining bottom module. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings which disclose several embodiments of the present invention. It should be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the invention. 
     In the drawings, wherein similar reference characters denote similar elements throughout the figures: 
     FIG. 1 shows a perspective view of the fully assembled vertically stacked control unit of the invention; 
     FIG. 2 show a top perspective front view of an intermediate module of the invention. 
     FIG. 3 shows a bottom perspective front view of the intermediate module of FIG. 2; 
     FIG. 4 shows a front view of the intermediate module of FIG. 2; 
     FIG. 5 shows a rear view of the intermediate module of FIG. 2; 
     FIG. 6 shows a section view of the intermediate module along line  6 — 6  of FIG. 2; 
     FIG. 7 shows a bottom perspective view of the top module of the invention; 
     FIG. 8 shows a section view of the top module along line  8 — 8  of FIG. 7; 
     FIG. 9 shows a front view of the top module of FIG. 7; 
     FIG. 10 shows a rear view of the top module of FIG. 7; and 
     FIG. 11 shows atop front perspective view of the bottom module of the invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Turning now in detail to the drawings FIG. 1 shows a front perspective view of the fully assembled vertically stacked controller unit  10  of the invention. Control unit  10  is made of a top module  12 , and a bottom module  14 , with several intermediate modules  16 ,  18  and  20  position vertically arranged between the top module  12  and the bottom module  14 . 
     The various electrical connector plugs on the front of the control unit as shown as plug  22  are illustrative of connectors which attach to internal circuit boards. These plugs are not a part of the invention. The control unit  10  and all of the modules are preferably made of metal such as stainless steel, aluminum, brass, bronze, or copper and do not rust. Also, they can be made of plastic or ceramic material. 
     FIG. 2 shows a top perspective front view of an intermediate module, such as  16 ,  18  or  20  of the invention. Placed within the module  18  is a circuit board  24  for which the electronic circuit elements are not shown, because these circuit elements are not a part of the present invention. However, auxiliary male connectors  26  and  28  are attached to the plastic circuit board. Auxiliary connectors  26  and  28  are preferably made of metal such as copper, aluminum, or magnesium and will not rust. Connectors  26  and  28  can be made also of plastic or ceramic material. FIG. 3 shows auxiliary female connector  27  and  29  which are attached to the circuit board  24 . Connectors  27  and  29  are made of the same material as are connectors  26  and  28 . 
     Connectors  26  and  27  are matingly engageable, while connectors  28  and  29  are matingly engageable. Connector  26  fits within connector  27 , while connector  28  fits within connector  29 . 
     As shown in FIGS. 2,  3 ,  4 ,  5  and  6 , within the vertically stacked control unit  10  is an expandable plurality of intermediate functional modules, such as module  18 . Module  18  has a front side  30 , a back side  32 , a top side  34 , a bottom side  36 , a right side  38 , and a left side  40 . For the sake of brevity, only module  18  is described, because module  18  is representative of all of the intermediate modules, such as  16 ,  18 , or  20 . 
     The top side  34  of the module has a first skirt receptacle  42  on the right side  38  and has a second skirt receptacle  44  on the left side  40 . 
     As shown in FIGS. 2 and 3, the intermediate module  18  is made by interconnecting four walls  30 ,  32 ,  38  and  40  so as to form a continuous rectangular perimeter which is open at the top and open at the bottom. Circuit board  24  may be placed within the open space of the perimeter and attached to the intermediate module  18 . 
     The bottom side  36  of the module has a first skirt  46  on the right side  3 . 8  and has a second skirt  48  on the left side  40 . 
     The front side  30  of each module has a top edge  50  and a bottom edge  52 . 
     As show in FIG. 5, the back side  32  of each module has a top edge  54  and a bottom edge  56 . As shown in FIG. 4, the front side top edge  50  has a first U-shaped receiver  58  on the right side  38  and has a second U-shaped receiver  60  on the left side  40 . The front side bottom edge  52  has a first pin  62  on the right side  38  and has a second pin  64  on the left side  40 . For simplicity sake, the connector plugs  22  are not shown in FIG.  4 . 
     The back side top edge  54  as shown in FIG. 2 has a first groove  66  on the right side  38  and has a second groove  68  on the left side  40 . As shown in FIG. 3, the back side bottom edge  56  has a first tongue  70  on the right side  38  and has a second tongue  72  on the left side  40 . 
     Therefore a plurality of functional modules such as  12 ,  14 ,  16 ,  18  and  20  can be vertically stacked together and interconnected with a skirt  46  or  48  of an upper module  18  engaging a skirt receptacle  42  or  44  respectively of a vertically adjoining lower module  20 . Also a first tongue  70  and the second tongue  72  of the upper module  18  will engage the first groove  66  and the second groove  68  respectively of said vertically adjoining lower module  20 . Then the first pin  62  and the second pin  64  on the upper module  18  are fitted respectively within the first U-shaped receiver  58  and the second U-shaped receiver  60  of the vertically adjoining lower module  20 . 
     The first U-shaped receiver  58  on the right side  38  is adjacent to the first skirt receptacle  42  on the right side  38 . The second U-shaped receiver  60  on the left side  40  is adjacent to the second skirt receptacle  44  on the left side  40 . 
     The first pin  62  on the right side  38  is attached to the first skirt  46  on the right side  38 . The second pin  64  on the left side  40  is attached to the second skirt  48  on the left side  40 . 
     The first pin  62  on the right side is preferably attached to an extension  46   a  of the first skirt  46  on the right side  38 . The second pin  64  on the left side  40  is preferably attached to an extension  46   a  of the second skirt  48  on the left side  40 . Extension  46   a  and Extension  48   a  extend inwardly toward the center line CL. 
     The back side top edge first groove  66  on the right side  38  is adjacent to the first skirt receptacle  42  on the right side  38 . The back side top edge second groove  68  on the left side  40  is adjacent to the second skirt receptacle  44  on the left side  40 . 
     As shown in FIG. 2, a first inwardly directed shoulder  74  on the right side  38  connects the first groove  66  on the right side  38  to the first skirt receptacle  42  on the right side  38 . A second inwardly directed shoulder  76  on the left side  40  connects the second groove  68  on the left side  40  to the second skirt receptacle  44  on the left side  40 . Shoulders  74  and  76  are inwardly directed toward center line CL. 
     The back side bottom edge first tongue  70  on the right side  38  is adjacent to the first skirt  46  on the right side  38 . The back side bottom edge second tongue  72  on the left side  40  is adjacent to the second skirt  48  on the left side  40 . 
     FIGS. 7,  8 ,  9  and  10  show the top module  12  which closes and seals the upper portion of controller unit  10 . The top module  12  only has on the front side  30  a bottom edge  52 , and not a top edge on the front side. The front side bottom edge  52  has a first pin  62  on the right side  38  attached to skirt  46  and has a second pin  64  on the left side  40  attached to skirt  48 . 
     The top module  12  only has on the back side  32  a bottom edge  56 , and not a top edge on the back side. The back side bottom edge  56  has a first tongue  70  on the right side  38  and has a second tongue  72  on the left side  40 . The top module has a first tongue  70  on the right side  38  adjacent to the first skirt  46  on the right side  38 . The top module has a second tongue  72  on the left side  40  adjacent to the second skirt  48  on the left side  40 . 
     FIG. 11 show the bottom module  14  of the controller unit. The bottom module of the control unit only has on the front side  30  a top edge  50 , and not a bottom edge on the front side  30 . The front side top edge  50  has a first U-shaped receiver  58  on the right side  38  and has a second U-shaped receiver  60  on the left side  40 . The bottom module has a first skirt receptacle  42  on the right side  38 , and has a second skirt receptacle  44  on the left side  40 . 
     The bottom module of the control unit only has on the back side  32 , a top edge  54 , and not a bottom edge on the back side  32 . The back side top edge  54  has a first groove  66  on the right side  38  and has a second groove  68  on the left side  40 . The pins  62  and  64  can be movable nails which are removably placed into position. It is also possible for pins  62  and  64  to be adjustable screw threaded fasteners which can be made to advance outwardly away from front side  30  or can be made to retreat inwardly into the front side  30  of each module  12 ,  16 ,  18 ,  20 , or  14 . This movement of the pins  62  and  64  can occur after the controller unit has been assembled so that the pins are within the U-shaped receiver  58  or  60  in order to seal the controller. When the pins  62  and  64  are tightened within the receivers  58  or  60 , the controller unit is sealed, and the modules are immovable within the stack. When the pins  62  and  64  are sufficiently outwardly, the modules can be removed or rearranged in position or new modules vertically added. 
     The two grooves  66  and  68  on the back side of each module can be C-shaped or can be a modified C-shape, namely &lt;-shaped. Interconnecting with each of the two grooves  66  and  68  are the two tongues  70  and  72 . As shown in FIG. 6, each tongue is seen to be shaped as the lower part of the shape of a reverse C, namely ]-shaped, which is bracket shaped. 
     Because of the universal connectability of the various modules, whether top module  12 , or bottom module  14 , or intermediate modules  16 ,  18  and  20 , these modules may be connected together in various orders. For example, the top module  12  may be connected directly to the bottom module  14 . In another embodiment the top module  12  may be connected to a first intermediate module  16 , and/or to a second intermediate module  18 , and/or to a third intermediate module  20 . Then either the first intermediate module  16  is connected to the bottom module  14 , or the second intermediate module  18  is connected to the bottom module  14 , or the third intermediate module  20  is connected to the bottom module  14 . Thus, the top module may be connected to a first intermediate module which is then connected to the bottom module. In another embodiment, the top module may be connected to a first intermediate module which is then connected to one or several other intermediate modules, the bottom of which is connected to the bottom module. 
     For example, the top and bottom functional modules can be vertically stacked together with a first skirt and a second skirt of the top engaging a first and a second skirt receptacle respectively of a vertically adjoining bottom module; with said first tongue and said second tongue of said top module engaging said first groove and said second groove respectively of said vertically adjoining bottom module; and with said first pin and said second pin on said top module fitted respectively within said first U-shaped receiver and said second U-shaped receiver of said vertically adjoining bottom module. 
     In addition the top and an intermediate functional modules can be vertically stacked together with a first skirt and a second skirt of the top engaging a first and a second skirt receptacle respectively of a vertically adjoining lower intermediate module; with said first tongue and said second tongue of said top module engaging said first groove and said second groove respectively of said vertically adjoining lower intermediate module; and with said first pin and said second pin on said top module fitted respectively within said first U-shaped receiver and said second U-shaped receiver of said vertically adjoining lower intermediate module. 
     Moreover an intermediate and bottom functional modules can be vertically stacked together with a first skirt and a second skirt of the upper intermediate engaging a first and a second skirt receptacle respectively of a vertically adjoining bottom module; with said first tongue and said second tongue of said upper intermediate module engaging said first groove and said ,second groove respectively of said vertically adjoining bottom module; and with said first pin and said second pin on said upper intermediate module fitted respectively within said first U-shaped receiver and said second U-shaped receiver of said vertically adjoining bottom module. 
     The top, intermediate, and bottom module, if made of metal, can each be manufactured by any of the following known metal processing techniques such as casting, stamping, welding, and/or machining. 
     The vertically stacked control unit  10  can be used to control an automated device, apparatus or instrument such as that described in a U.S. Patent Application for the invention titled an Automated Slide Loader Cassette for Microscope, having Ser. No. 10/002,545 filed on Oct. 26, 2001. 
     Accordingly, while a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without described from the spirit and scope of the invention as defined in the appended claims.