Abstract:
Disclosed is a modular barrier system to protect a machine user from injury, the barrier structure having a plurality of modular units that can be manipulated individually to provide variable configurations of the barrier structure, that can be used with different pieces of machinery or for different applications, without removal or changing of the barrier structure in its entirety. The modular units comprise a slide unit and a latch mechanism to lock each individual modular unit in place, by way of ratcheting teeth. The barrier system may be positioned on a rail system that provides for lateral movement of the modular units while maintaining its attachment to the rail by a rail lock mechanism on the modular unit.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/828,856, filed 30 May 2013, and titled “Modular Barrier System.” 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to a safety barrier system that is positioned between the operative parts of a machine and a machine operator or bystanders in the working area. The present invention relates more particularly to a barrier system having a plurality of modular units that can each be individually and selectively positioned at various levels as necessitated by the machine being used and the operations thereof. 
     Industrial machinery may utilize several moving parts that have the potential to cause injury to an operator, or other persons nearby, should they get caught in or struck by any of the moving parts. As such, regulations have been instituted that require barriers and protection to minimize access to the areas of moving parts and therefore lessen the chances of injury. There are several types of barrier structures that are known and used in the industry for this purpose. Some of these structures, however, may be difficult and very time-consuming to manipulate in order to gain access to a machine area for servicing or changing the machine, or for use on different machinery or for different functions. As such, there remains a need for a barrier structure that can be easily modified for these purposes, in particular, without removing or changing the entire barrier structure. 
     SUMMARY OF THE INVENTION 
     The present invention satisfies this need by providing a modular barrier system having a plurality of barrier units that are individually movable to various levels and positions, and are slidable along a rail system to add or remove modular units without removing and/or replacing an entire structure, in order to accommodate use for different machines and for different functions. 
     On aspect of the invention provides a modular barrier system for attachment to a rail structure, with the modular barrier system having at least one adjustable barrier unit having at least two slide units with a first main slide with teeth along a first side of the first main slide slidably received between a first pair of slide guide panels, a second main slide with teeth along a first side of the second main slide slidably received between a second pair of slide guide panels, a latch mechanism having a first a latch mechanism aperture and a second latch mechanism aperture to receive the first and second pair of slide guide panels, respectively, and pivotably affixed to the first and second pairs of slide guide panels, whereby the teeth of the first and second main slides interface with the first and second latch mechanism apertures, and wherein the first and second pairs of slide guide panels are removably received attached to the rail structure. 
     The first main slide may be inter-connected to the second main slide by a slide spacer. 
     At least two adjustable barrier units may be inter-connected by at least one of an upper spacer or a lower spacer. 
     A latch mechanism lock may be connected to at least one of the first and second pairs of slide guide panels and removably engagable with the latch mechanism. 
     A rail lock may be connected to at least one of the first and second pairs of slide guide panels and removably engageable with the rail structure. 
     A static barrier having a solid member and a pair of receiving guides each with a length and a receiving guide aperture extending substantially the length of the receiving guide, wherein the solid member is received within the receiving guide apertures, and whereby the receiving guides are removably attachable to the rail structure may also be provided in the modular barrier system. 
     The static barrier unit may further have a pair of containment members extending alongside the receiving guides, whereby the pair of receiving guides and the solid member are positioned between the pair of containment members, and whereby the pair of containment members are removably attachable to the rail structure. 
     The pair of receiving guides and the pair of containment members may be inter-connected by at least one of an upper containment member or a lower connecting member. 
     The solid member may be comprised of a substantially transparent material. 
     Another aspect of the invention provides a modular barrier system having at least one adjustable barrier unit with at least two slide units, each slide unit having a plurality of slide guide panels each with a guide panel top end portion, a guide panel bottom end portion opposite the guide panel top end portion, a guide panel first surface extending between the guide panel top end portion and the guide panel bottom end portion, and a guide panel rear surface opposite the guide panel first surface, a latch hook located on the guide panel rear surface, a notch extending inwards from the guide panel rear surface at or near the guide panel top end portion, and a flange protruding outward from the guide panel top end portion; a plurality of main slides each having a slide top end portion, a slide bottom end portion, and a slide front edge, wherein each main slide has a vertical slide aperture extending from substantially the slide top end portion to the slide bottom end portion and slide teeth along the slide front edge; a substantially U-shaped latch mechanism having a first latch mechanism aperture within one stem of the “U” of the U-shaped latch mechanism and a second latch mechanism aperture within the other stem; whereby a first main slide is positioned between a first pair of slide guide panels to form a first slide unit; whereby a second main slide is positioned between a second pair of slide guide panels to form a first slide unit; whereby the first slide unit is positioned through the first latch mechanism aperture, with one end of the first latch mechanism aperture received within the first slide unit latch hook and the other end of the first latch mechanism aperture selectively engageable with the first slide unit slide teeth, and the second slide unit positioned through the second latch mechanism aperture, with one end of the second latch mechanism aperture received within the second slide unit latch hook and the other end of the second latch mechanism aperture selectively engageable with the second slide unit slide teeth; and a rail structure comprising an open channel having a substantially flattened U-shaped cross-section wherein the exposed edges along the channel are hooked inward forming an upper form and a lower form; and wherein the at least one barrier unit is removably engageable with the rail structure, whereby the lower form of the rail is received within the notches of the slide guide panels and the flanges of the slide guide panels engage the upper form of the rail. 
     The first main slide may be joined to the second main slide by a slide spacer. 
     At least two adjustable barrier units may be joined together by at least one of an upper spacer or a lower spacer. 
     A latch mechanism lock may be connected to at least one of the first and second pairs of slide guide panels and removably engagable with the latch mechanism. 
     A rail lock may be connected to at least one of the first and second pairs of slide guide panels and removably engageable with the rail structure. 
     A static barrier unit comprising a solid member and a pair of receiving guides each with a length and a receiving guide aperture extending substantially the length of the receiving guide, wherein the solid member is received within the receiving guide apertures, and whereby the receiving guides are removably attachable to the rail structure may also be provided in the modular barrier system. 
     The static barrier unit may also have a pair of containment members extending alongside the receiving guides, whereby the pair of receiving guides and the solid member are positioned between the pair of containment members, and whereby the pair of containment members are removably attachable to the rail structure. 
     The pair of receiving guides and the pair of containment members may be inter-connected by at least one of an upper containment member or a lower connecting member. 
     The solid member may be comprised of a substantially transparent material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment of a modular barrier system according to the present invention. 
         FIG. 2  is a side view of the embodiment of a modular barrier system shown in  FIG. 1 . 
         FIG. 3  is a front view of the embodiment of a modular barrier system shown in  FIG. 1 . 
         FIG. 4A  is an exploded view of the embodiment of a modular barrier system shown in  FIG. 1 . 
         FIG. 4B  is an exploded view of a slide unit according to the present invention. 
         FIG. 5  is a front view of the embodiment of a modular barrier system shown in  FIG. 1  and a rail system. 
         FIG. 6A  is a side view of the rail system connection apparatus of the modular barrier system shown in  FIG. 1 . 
         FIG. 6B  is a detailed view of the rail system connection apparatus shown in  FIG. 6A , shown in an unlocked position. 
         FIG. 6C  is a detailed view of the rail system connection apparatus shown in  FIG. 6A , shown in a locked position. 
         FIG. 7  is an exploded view of a second embodiment of a modular barrier system according to the present invention. 
         FIG. 8  is a perspective view of a plurality of modular barrier systems according to the present invention used together to form a barrier. 
         FIG. 9  is a perspective view of a plurality of modular barrier systems according to the present invention used together to form a barrier. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
       FIG. 1  shows a modular barrier system  10  comprising a plurality of adjustable barrier units  20 . In the Figures, showing a preferred embodiment, the modular barrier system  10  is shown having two adjustable barrier units  20 . A plurality of these modular barrier systems  10  (each comprising a pair of adjustable barrier units  20 ) may be used adjacent to one another to form a wider barrier structure (as shown in  FIG. 8 ). Modular barrier systems  10  may be added or removed in order to span the width of the area over which the barrier is being used. 
     Each adjustable barrier unit  20  may be coupled to an adjacent adjustable barrier unit  20  by an upper spacer  50  and a lower spacer  70 . Each adjustable barrier unit  20  may have a pair of slide units  22  and a latch mechanism  40 , as detailed in  FIG. 4A . The features of the slide unit  22  are detailed in  FIG. 4B . Each slide unit  22  may comprise a pair of slide guide panels  23  having a main slide  24  sandwiched therebetween. Each slide guide panel  23  may have (a) a rail system mechanism  25  at a top end portion  23   a , (b) a latch hook  26 , shown in its assembly position, at a substantially central location between the top end portion  23   a  and a bottom end portion  23   b  on a rear surface  23   c , and (c) a vertical spacer aperture  27  extending between a first surface  23   d  and a second surface  23   e  of the slide guide panel  23  near the bottom end portion  23   b . The main slide  24  may be positioned between the pair of slide guide panels  23 , and may have a vertical slide aperture  31  extending substantially along the length of the main slide  24  from near a top end portion  24   a  to near a bottom end portion  24   b . The slide aperture  31  is substantially aligned with the spacer apertures  27  of the slide guide panels  23  when sandwiched together. Each main slide  24  may have a plurality of slide teeth  32  aligned along at least a portion of a front edge  24   c  of the main slide  24 . The slide teeth  32  are preferably equidistant from one another. 
     Each slide unit  22  is held together via the lower spacer  70 , which also connects a first slide unit  22  to its partner slide unit  22  (comprising a first adjustable barrier unit  20 ), as well as connecting a first adjustable barrier unit  20  to an adjacent adjustable barrier unit  20  (comprising a modular barrier system  10 ). As such, the lower spacer  70  may be of an appropriate width to accommodate the pair of adjustable barrier units  20  being used in the modular barrier system  10 , as shown in the preferred embodiments. The lower spacer  70  passes through the spacer aperture  27  of the slide guide panel  23  and the slide aperture  31  of the main slide  24 . 
     The pair of slide units  22  are also held together and spaced apart at a slide distance S by way of a slide spacer  35 . Slide spacer  35  passes through each main slide  24  of the adjustable barrier unit  20  through a horizontal base aperture  34 . 
     The pair of main slides  24  in the adjustable barrier unit  20 , slide uniformly between the slide guide panels  23  to lengthen or shorten the adjustable barrier unit  20 . In this way, adjustable barrier units  20  may be shortened or lengthened to manipulate the height of the modular barrier system  10  and/or accommodate different shaped openings for access to the machine being used. Furthermore, the slide guide panels  23  and/or main slide  24  may be manufactured at any desired length to accommodate different heights of the opening or access area on which the barrier structure is being used. The figures depict one adjustable barrier unit  20  being positioned at a different height than that of an adjacent adjustable barrier unit  20 , which is obtained by manipulating the pair of main slides  24  up or down between the slide guide panels  23 . Thus, as shown, the barrier system  10  provides vertical variability across the infeed area. The ability of the barrier to accommodate varying overall height opening is addressed on page 5, line 5. There is a distinction between the overall length of a barrier and the slide adjustment feature of a barrier. In particular, the barrier of the present invention can have a variable width by providing sliding adjustment, and can also have openings of variable width based on different configurations of the individual components. 
     The main slides  24  are held into vertical position, thereby locking the adjustable barrier unit  20  at the desired height by way of latch  40 . Latch  40  may be substantially u-shaped with a first stem  46  and a second stem  48 , each with latch mechanism apertures  42  having a first end  42   a  and a second end  42   b . The latch mechanism apertures  42  are configured to pass around the slide unit  22  and hook onto the latch book  26  (shown in its assembly position) on the slide guide panel  23 . This is shown particularly in  FIGS. 1 and 2 . The latch mechanism apertures are further sized and configured to latch unto corresponding slide teeth  32  on partnered main slides  24 . In this way, downward movement of the main slide  24  is prohibited by the latch  40 , and further restricted by and around the configured shape of teeth  32 . Additionally, once in place, upwards movement of the main slide  24  may be prohibited by way of a lock hook  44  engaging the latch  40 . Lock hook  44  is preferably coupled to the lower spacer  70  at a hook aperture  71  by securing means  72 , such as by a socket head cap screw and washer, as shown in  FIG. 4A . Hook aperture  71  may be sized and configured to accommodate at least a first released position and a second locked position in which the lock hook  44  is positioned on the lower spacer  70 , to either engage the latch  40  or allow the latch  40  to rotate about a latch hook axis, thereby allowing release of the main slide  24 . Accordingly, latch book  26  (shown in its assembly position) is preferably sized and configured to be such a shape and diameter to accommodate rotational movement of the corresponding portion of latch  40  within latch hook  26 . 
     When the latch  40  is in the locked position, engaging the desired slide teeth  32  and the lock hook  44  is secured by means  72  in a second locked position, engaging the latch  40 , upward movement of the main slide  24  is prohibited. This is accomplished by the ratcheting nature of the slide teeth  32 . Because latch  40  is locked by lock hook  44 , the latch  40  is prohibited from movement away from main slide  24  to such a distance that would allow slide teeth  32  to pass and slide the main slide  24  upwards. 
     Main slide  24  may be released, and therefore moved to accommodate different configurations of the modular barrier system  10  by releasing the securing means  72  that hold the latch hook  44  in the locked position and re-securing the latch hook  44  in a first, (up) position, and then rotating the latch  40  to disengage with the teeth, therefore allowing upward and downward movement of the pair of main slides  24  and the adjustable barrier unit  20  as a whole. 
     As shown in  FIGS. 5-6C , the modular barrier system  10  may be positioned on a rail structure  80 . The rail structure  80  may be an existing structure, such as the B32 Channel that is manufactured by COOPER B-Line. The rail structure  80  is preferably a longitudinal rail, or open channel, of a flattened U-shaped cross-section wherein the exposed edges along the longitudinal direction are hooked inward forming upper form  82   a  and lower form  82   b  that may engage the rail system mechanism  25 . 
     The rail system mechanism  25  is preferably positioned at the top end portion  23   a  of the slide guide panel  23 . As discussed above, two slide guide panels  23  are positioned together to form a portion of the slide unit  22 .  FIG. 6B  shows in detail the features of the rail system mechanism  25 . As shown, the slide guide panel  23  has a notch  84  to receive lower form  82   b , at or near the top end portion  23   a . The rail system mechanism  25  may further comprise a waved portion  86  that curves slightly upwards towards a rail system flange  88 . The waved portion  86  may have an upper spacer aperture  89  formed therein for receiving upper spacer  50  to connect adjacent slide units  22  and adjacent adjustable barrier units  20 . The rail system flange  88  is configured to receive upper form  82   a.    
     The modular barrier system  10 , particularly the slide guide panels  23  may be secured to the rail structure  80  by way of a rail lock  90 . Rail lock  90  may be moveably coupled to at least one slide unit  22  of a modular barrier system  10 , sandwiched between the rail system mechanism  25  of two slide guide panels  23 . Preferably, there is one rail lock  90  for each modular barrier system  10 , as shown in the Figures. As shown, the rail lock  90  has a slide aperture  92  that is configured to allow a slight rotation of the lock  90  about the upper spacer  50 . The rail lock  90  may also have at least two screw apertures  94  to receive a socket head cap screw to lock the rail lock  90  in an open position (as shown in  FIG. 6B ) or in a locked position (as shown in  FIG. 6C ). The rail lock  90  may be secured in either the open/unlocked or the locked position by way of securing means, such as a socket head cap screw  96 . The rail lock  90  may further comprise a locking hook  98  located on a rear edge  90   a  of the rail lock  90  that is configured to engage the lower form  82   b  on the rail structure  80 , as described below. 
     The rail lock is positioned in the open position in order for the barrier system  10  to be rotationally lowered into the rail structure  80 . Once the notch  84  is positioned about the lower form  82   b  and the rail system flange  88  is engaged with the upper form  82   a , the rail lock  90  may be rotated into the locked position (shown in  FIG. 6C ) such that the locking hook  98  engages with the lower form  82   b  and prevents any rotational movement of the rail system mechanism  25 , and thus the adjustable barrier units  20 , out from the rail structure opening  82 . In this way, the modular barrier system  10  is secured in front of or near the piece of machinery on which it is used, providing protection for the user. 
     Each of the spacer devices, such as upper spacer  50 , lower spacer  70 , or slide spacer  35  is secured within the respective apertures (to hold the respective pieces of the modular barrier system  10 , adjustable barrier unit  20 , or slide unit  22 , etc. together) by way of holding flanges  100 . The holding flanges  100  preferably extend from the respective spacer device at a length that is equal to or less than the length of the aperture through which it passes. As shown in the Figures, the holding flanges  100  are configured in sets of 3 flanges: one that is positioned within the respective aperture, and two outer flanges. Alternatively, as shown with respect to the slide spacer  35 , the spacer device may have only one holding flange  100  that is configured to be positioned to the outside of the base aperture  34 . The holding flanges  100  are positioned along the respective spacer device at any distance, determined by the spacing that is desired, by way of example, between adjacent slide units  22  or adjacent main slides  24 , etc. Once the spacer device, such as upper spacer  50 , lower spacer  70 , or slide spacer  35  is positioned with the respective aperture (such as upper spacer aperture  89 , spacer aperture  27 , or base aperture  34 ), the outer flanges may be wedged or otherwise bent, preferably in opposing directions, to secure the spacer device in place and minimize any lateral movement of the spacer device and retain the other pieces of the modular barrier system  10  in place. 
       FIG. 7  illustrates a second embodiment  200  according to the present invention of a static modular barrier unit. The static barrier unit  200  preferably comprises a solid member  210 , a pair of receiving guides  204 , and a pair of containment members  208 . As some of the elements of the static modular barrier unit  200  are consistent with elements of the adjustable modular barrier unit  20 , similar numbers will designate similar elements. 
     The solid member  210  may comprise a transparent material such as an acrylic sheet like a PLEXIGLAS® acrylic sheet or may be made from a non-transparent material, including but not limited to, various types of plastics and/or metals. 
     Each receiving guide  204  has a length L and a receiving guide aperture  206  extending substantially along the length L. The length L may be of any length required depending on the specific application. The receiving guide aperture  206  is preferably sized and configured to receive the solid member  202 . The receiving guides  204  preferably attach to the rail structure  80  ( FIG. 9 ) in a similar manner as the top end portions  23   a ,  24   a  of the slide guide panels and the main slides  23 ,  24 , respectively, described above. 
     The containment members  208  are substantially the same length L as the receiving guides  208  and are positioned to contain the solid member  202  and the receiving guides  204  to reduce the likelihood of the solid member  202  from exiting the receiving guide apertures  206 . The containment members  208  preferably attach to the rail structure  80  ( FIG. 9 ) in a similar manner as the top end portions  23   a ,  24   a  of the slide guide panels and the main slides  23 ,  24 , respectively, described above. 
     A first gap member  212  and a second gap member  214  extend between the pair of receiving guides  204 . The first gap member  212  preferably has recesses  213 . 
     Securing members  218  may be provided to increase stability of the solid member  202  within the static barrier unit  200 . The securing members  218  preferably attach to the rail structure  80  ( FIG. 9 ) in a similar manner as the top end portions  23   a ,  24   a  of the slide guide panels and the main slides  23 ,  24 , respectively, described above. The securing members  218  extend around and beyond the recesses  213  of the first gap member  212  to the solid member  202 . 
     A plurality of shims  216  may also be included to provide spacing between the receiving guides  204  and the containment members  208 , and between adjacent securing members  218 . A rail lock  290  may also be provided, similar to the rail lock  90  described with respect to the adjustable barrier unit  20 . 
     An upper spacer  250  and a static barrier spacer  235  may also be provided. The upper spacer  250  and the static barrier spacer  235  provide a secured inter-connection between the elements of the static barrier unit  200  similar to the upper spacer  50  and the slide spacer  35  of the adjustable barrier unit  20  described above. 
       FIG. 8  illustrates a plurality of adjustable barrier systems  10  installed on a rail structure  80 . Some of the adjustable barrier units  20  are shown oriented at different levels. 
     Similar to  FIG. 8 ,  FIG. 9  illustrates a plurality of adjustable barrier systems  10  with the addition of a static barrier unit  200 .  FIGS. 8 and 9  further demonstrate the adaptability of the modular barrier system  10  according to the present invention. Various combinations of adjustable barrier units  20  may be used on rail structures  80  of various lengths and may also include static barrier units  200  (transparent or non-transparent) in areas in which access is to be discouraged. 
     The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.