Door assembly for storage and dispensing unit

A door assembly including a frame with an opening having a first portion and a second portion. The door assembly includes a first panel movable between a closed position in which the first panel generally covers the first portion of the opening and an open position in which the first panel generally does not cover the first portion. The door assembly has a second panel movable between a closed position in which the second panel generally covers the second portion of the opening and an open position in which the second panel generally does not cover the second portion. The second panel is configured to block the first panel from moving to its open position when the second panel is in its closed position. The door assembly further includes a controller operatively coupled to the second panel to selectively block or enable movement of the second panel from its closed position to its open position or from its open position to its closed position.

The present invention is directed to a door assembly, and more particularly, to a door assembly for a storage and dispensing unit which ensures proper operation and secure closure thereof.

BACKGROUND

Self-service storage and dispensing units often include a door, access panel or the like to provide the user access to an inner storage compartment of the unit. However, existing doors may not provide fail-safe operation in that, for example, the door may not be properly secured in the closed position. In addition, existing doors may provide insufficient security features and be vulnerable to being pried open with a crowbar or the like. Finally, existing door assemblies may be difficult to access for repair, maintenance or the like.

SUMMARY

In one embodiment the present invention is a door assembly including a frame with an opening having a first portion and a second portion. The door assembly includes a first panel movable between a closed position in which the first panel generally covers the first portion of the opening and an open position in which the first panel generally does not cover the first portion. The door assembly has a second panel movable between a closed position in which the second panel generally covers the second portion of the opening and an open position in which the second panel generally does not cover the second portion. The second panel is configured to block the first panel from moving to its open position when the second panel is in its closed position. The door assembly further includes a controller operatively coupled to the second panel to selectively block or enable movement of the second panel from its closed position to its open position or from its open position to its closed position.

DETAILED DESCRIPTION

FIG. 1illustrates a storage cabinet10which can be utilized to store and/or dispense any of a wide variety of products. For example, in one embodiment, the storage cabinet10includes various compartments12, each covered by a door assembly14which can be selectively opened by a user or users in a locker-like configuration. The storage cabinet10can be configured to selectively control access to the compartments12by allowing selective opening of the door assemblies14by users. In one case, the storage cabinet10may have a controller15which a user can interact with to gain access to all or certain ones of the compartments12. The controller may take the form of a processor, CPU, computer or the like, and may include a user interface17in the form of a keypad, touch screen, keyboard, mouse, track ball, audio input device, or the like.

When a user wishes to access and withdraw an item from, or replace/replenish an item to, the storage cabinet10, the user may, in some cases, need to first be identified and/or authenticated (i.e. via an identification system and authentication system/database). The identification/authentication can be implemented or carried out in a variety of manners, including by the use of a user identification and/or password, the use of a key fob or other wireless device which transmits in the radio frequency range, a mechanical or electronic key, the use of a mobile phone or device, a card with a magnetic strip in conjunction with a magnetic strip/card reader, the use of biometrics, or various other means or mechanisms. Moreover, the door assembly14disclosed herein can be used in a variety of other settings in which it is desired to control access to a locker or storage compartment12such as, for example, coin-operated lockers or the like.

FIGS. 2 and 3illustrate a door panel16having a generally rectangular door panel frame18extending about the periphery thereof. The door panel frame18includes two vertically oriented dividers20such that the illustrated door panel16includes three openings22, each opening22being associated with a compartment12of the storage cabinet10. The door panel16ofFIGS. 2 and 3includes three door assemblies14arranged in a side-by side configuration, with each door assembly14extending across and selectively covering an associated opening22of the door panel frame18.

Each door assembly14includes a generally flat, rectangular main panel24which extends across the majority of the opening22/compartment12. As shown inFIG. 4, the main panel24may include a pair of aligned cylindrical protrusions26extending generally outwardly therefrom. Each protrusion26is received in a corresponding opening of the door panel frame18to pivotally mount the main panel24to the door panel frame18. In this manner, when conditions are appropriate (as described below), the main panel24can pivot about a vertical axis between its closed position (shown as all of the main panels24inFIG. 1, except main panel24′) wherein the main panel24is positioned across the opening22/compartment14to block access thereto, and an open position (shown as main panel24′ inFIG. 1) wherein the main panel24is not positioned across the opening22/compartment14to allow access thereto.

However, it should be understood that the main panel24can be pivotally mounted by any of a wide variety of mechanisms, such as by hinges, by reversing the position of the protrusions26and openings (i.e. such that the protrusions26are positioned on the frame18) etc. For example,FIG. 17shows an alternate hinge arrangement in which a block50of the door assembly14includes part of a hinge mechanism33formed therein, and the opposite side of the main panel24includes a corresponding hinge portion35configured to engage the hinge portion33of another door assembly14to form a hinge. In this manner the block50for one door assembly14can form part of the hinge for an adjacent door assembly14.

With reference toFIGS. 4 and 7, it can be seen that each main panel24may include a vertically-extending groove or notch28formed in a front surface thereof, and extending partially therethrough. In the embodiment ofFIGS. 4 and 7, the notch28extends at an acute angle, angling back towards a handle30of the door assembly14. However, the notch28can be positioned at various other angles, including generally perpendicular to the front surface of the main panel24, as shown inFIG. 3.

The door assembly14further includes the handle30mounted to the door panel frame18and positioned adjacent to the main panel24. The handle30includes a generally cylindrical portion32, a rear tab34or kick plate extending generally radially outwardly from the cylindrical portion32and a front tab36extending generally radially outwardly from the cylindrical portion. The front tab36includes a base portion38, extending generally away from the cylindrical portion32, and a locking portion40generally forming an angle with the base portion38. In the embodiment shown inFIG. 4, the locking portion40generally forms an acute angle with the base portion38and angles somewhat back towards the cylindrical portion32, matching the angle of the notch28. If desired, the position of the notch28and locking portion40may be reversed such that the notch28is carried on the handle30and the locking portion40is carried on the main panel24. As shown inFIG. 5, in one embodiment, the rear tab34is discontinuous, and does not extend the entire height of the handle30.

The handle30is pivotally and vertically slidably mounted to the door panel frame18. In particular in one embodiment the cylindrical portion32of the handle30receives a post42therein, which is fixedly coupled to the frame18. In this manner the handle30is pivotally mounted to the frame18such that, when conditions are appropriate (as described below), the handle30can pivot about a vertical axis between its closed position (FIG. 6-10) and its fully open position (FIGS. 13-16). Thus, the handle30and main panel24are pivotable about axes that are generally parallel but spaced apart. However, the handle30can be pivotally and axially slidably mounted to the frame18in any of a wide variety of other manners.

As shown inFIG. 4, the handle30may include a gripping portion29which can include a top portion29aand bottom portion29bseparated by a space31. The gripping portion29is configured such that a user can insert a digit into the space31, and thereby lift the gripping portion29, lifting the handle30vertically.

The cylindrical portion32of the handle30includes a plurality of radially outwardly extending, axially spaced protrusions44. In addition, the cylindrical portion32of the handle includes an open position recess46(FIG. 4) and a closed position recess47(FIG. 5) formed therein, and positioned near a top of the handle30in the illustrated embodiment.

Each door assembly14further includes a block50positioned between the handle30and a divider20of the door panel frame18. In the illustrated embodiment the block50is fixedly coupled to the door panel frame18, and positioned immediately adjacent to the handle30. As best shown inFIGS. 4 and 5, the block50includes a plurality of vertically spaced, circumferentially-extending recesses52formed therein. Each recess52may also be connected to an associated downwardly extending notch53at an end thereof.

Each door assembly14may include a solenoid, transducer or other activatable component54associated therewith and operatively coupled to the controller15. With reference toFIGS. 4 and 5, each solenoid54includes an extendible/retractable plunger56with a pad58at the end thereof. The plunger56and pad58are positioned to extend through an opening60of the block50. In the illustrated embodiment, the solenoid54is configured such that when the solenoid54is activated, the plunger56and pad58are retracted, and when the solenoid54is not activated, the plunger56and pad58are extended.

The door assembly14may include a door position sensor62(seeFIG. 4) configured to sense or detect the position of the main panel24, and more particularly, when the main panel24is at, or relatively close to, its closed position or close to the handle30(in a nearly-closed position). The door position sensor62is operatively coupled to the controller15and/or associated solenoid54. In one particular embodiment, the door position sensor62takes the form of a magnetic switch positioned adjacent to the bottom of the main panel24, with a corresponding component, such as a magnet and/or magnetic switch (not shown) on the frame18. However, the door/position sensor62can take any wide variety of forms, including but not limited to pressure or force sensors, optical sensors, contact sensors, photoelectric sensors, ultrasonic sensors, piezoelectric sensors, proximity sensors, electric field sensors or the like.

Each door assembly14may further include a light source64positioned therein. In the illustrated embodiment, the light source64takes the form of a lighted button or light bar positioned in the handle30such that, when activated, the light source64generally illuminates the entire handle30. However, the light source64can be positioned at different areas within the door assembly14.

Each door panel16can be made from any of a wide variety of materials. In one embodiment, however, the door panel frame18and/or block50are made of a relatively strong, rigid material, such as metal (including aluminum), and the main panel24, handle30and/or block50are made of relatively strong, lightweight material, such as plastic. In one embodiment, the main panel24and/or handle30are each made of a generally clear or transparent material, or a mesh material, to allow the contents of the storage compartment12to be visible through the door assembly14. However, if desired the main panel24and/or handle30may be generally opaque.

When a user first approaches a door assembly14, the door assembly14will typically be locked in its closed position. When the door assembly14is in the closed position the main panel24and handle30are both closed and extend across the opening22, and the locking portion40of the handle30is received in the notch28of the main panel24, as shown inFIG. 6. Thus the interaction of the locking portion40and the notch28helps to couple the handle30and main panel24together when they are in the closed position.

When the user first approaches the door assembly14, the handle30is typically in its lower position. In this case, the protrusions44of the handle30are received in the end notches53, and the protrusions44are misaligned with the recesses52of the block50. In addition, the solenoid54is in its deactivated (i.e. extended) position. When the handle30is in its lower position, any attempted pivoting or opening of the handle30is blocked due to the protrusions44of the handle30engaging the block50. Thus, when the handle30is in its lower position the handle30is blocked from rotating, and the door assembly14is also blocked from rotating. Moreover, as shown inFIGS. 6 and 7, when the solenoid54is deactivated, the pad58is positioned in the recess47of the handle30, and therefore blocks the handle30from being raised.

Thus, in this position the pad58blocks the handle30from being raised, which in turn blocks the handle30from rotating, which in turn prevents the door assembly14from being opened. Various other arrangements may also or instead be utilized for blocking the handle30from being raised. For example, in one case the pad58may be positioned just above the top of the handle30when the handle30is in its lower position. Moreover, if desired, the position of the protrusions44and recesses52can be reversed such that the recesses52are positioned on the handle30, and the protrusions44are positioned on the block50.

When the user is granted access to the door/assembly14/inner compartment12, the solenoid54is activated (i.e. by receipt of an unlock signal from the controller15) and the pad58is retracted out of the recess47(FIGS. 8 and 9). At the same time, the light source64for that door assembly14may be activated so that the user is cued that he or she has access to the door assembly14/inner compartment12. When the solenoid54/pad58is retracted, the user can then engage and lift the handle30to its upper position (FIG. 10), such as by the gripping portion29. When the handle30is lifted, the protrusions44of the handle30become axially/vertically aligned with the recesses52on the block50, thereby allowing the handle30to pivot. If desired, the handle30/block50can be arranged such that the handle30is pressed downwardly (i.e. compressing a spring, in one case) instead of upwardly in order to align the protrusions44with the recesses52.

The handle30can then be pivoted by the user about the post42(counterclockwise in the embodiment shown in the drawings) until the rear tab34of the handle30engages the main panel24, thereby pivoting the main panel24slightly open, as shown inFIGS. 11 and 12. The user can then further manually open the main panel24, thereby gaining access to the associated inner compartment12of the storage cabinet10, as shown inFIGS. 13-15.

When the main panel24is sufficiently opened (e.g. in one case, opened beyond the partially open position shown inFIGS. 11 and 12), such opening may cause (via the kick plate34) the handle30to pivot to its fully open position, as shown inFIGS. 13-16, in which case the handle30is pivoted 90 degrees from its closed position. In one embodiment, when the main panel24is opened in this manner, the door position sensor62may be triggered, thereby causing the solenoid54to switch off. In this case when the solenoid54is in its off state, as shown inFIG. 14, the plunger56returns to its extended/deployed position, pushing the plunger58into the recess46of the handle30, thereby locking the handle30in place and preventing the handle30from pivoting. Thus the handle30is effectively secured in its fully open position. When the handle30is secured in its open position, the handle30blocks the main panel24from being closed, as the handle30(more particularly, the tab34) physically blocks and interferes with attempting closing of the main panel24.

This interaction between the main panel24, door position sensor62, solenoid54and handle30helps to ensure that the handle30is not returned to its closed position unless the main panel24is, also, returned to its closed position. Thus, this arrangement ensures that the door assembly14is not placed into a state wherein the main panel24remains unsecured in its open position when the handle30is closed, and thereby provides improved security.

When the door assembly14is fully opened, as shown inFIGS. 13-15, the user has access to the inner compartment12associated with that door assembly14, and can access the inner compartment12to remove desired items therefrom, and/or place items therein, and freely move the main panel24(but not necessarily the handle30).

When the user desires to close the door assembly14, the main panel24is pivoted back toward its closed position. When the main panel24is sufficiently closed (i.e. in its nearly closed position), the door position sensor62senses that the main panel24is sufficiently closed and/or positioned adjacent to the handle30. The solenoid54is then activated, thereby causing the pad58to be retracted out of the recess46of the handle30. The controller15may have logic/software programmed therein to ensure that the solenoid54is activated at this point. In one embodiment, the solenoid54is activated at this time for a fixed period of time (i.e. about 5 seconds in one embodiment), to allow the user sufficient time to complete closing of the door assembly14. The nearly-closed position can be a position in which the main panel24is less than about 30 degrees, or less than about 15 degrees, or less than about 5 degrees out-of-plane from its fully closed position; or wherein the main panel24is spaced apart from any part of the handle30by less than about two inches, or less than about one inch; or wherein the main panel24has engaged the kick plate34of the handle30.

When the solenoid54is activated and the pad58is retracted out of the recess46the handle30is again free to pivot. The main panel24is then further closed by the user, engaging the rear tab34and causing the handle30to move into its closed position (FIGS. 9 and 10). Once the door assembly14is in the closed position, the handle30drops to its lower position (FIG. 8), and the solenoid54is deactivated (i.e. after the timer expires), thereby locking the handle30and main panel24in their closed positions, and also switching off the light source64. The door assembly14is thus configured such that the main panel24is prevented from moving to its closed position unless the handle30is simultaneously moved to its closed position. In other words, as can be seen in comparing the various dimensions ofFIG. 14, if the main panel24were attempted to be closed, the main panel24would engage the kick plate34; it is only when the handle30is also moved to its closed position that the main panel24can be closed.

Accordingly, the door assembly14, as outlined above, provides easy and intuitive operation by a user, and also provides fail-safe operation to ensure that the handle30is locked in its open position when the main panel24is open, and is locked in its closed position only when the main panel24is also in its closed position. In addition, the door assembly14provides an arrangement which is theft and tamper resistant. In particular, as noted above the locking portion40of the handle30fits into the notch28of the main panel24, generally filling the notch28. The block50also helps to generally cover any gap between the handle30and the frame18. This arrangement helps to reduce or eliminate any crevices, into which a crowbar, pry bar or the like can be wedged to force the door assembly14open. The bottom portion29bof the gripping portion29helps to protect and secure the door assembly14, as it prevents unauthorized entry/breakage of the handle30which can be caused by an upward strike on the bottom surface of the upper portion29b, for example with a heavy tool.

As noted above and shown inFIGS. 2 and 18, in one embodiment, each door assembly14may be part of a door panel16having the door panel frame18and a plurality of door assemblies14mounted thereto. In addition, the solenoid54and door position sensor62for each door assembly is mounted on or to the door panel frame18.

As shown inFIG. 18, each door panel16may be mounted to the frame70of the storage cabinet10by a plurality of fasteners72extending through the frame18and received in the frame70. In one particular embodiment, each fastener72may take the form of a safety fastener, safety screw or the like, which has particular head design such that each fastener72can be screwed and unscrewed, or inserted or retracted, only with a specialized, and not-commonly-available, tool. The use of such safety screws72helps to provide increased security to the storage cabinet10and avoid tampering therewith. In some cases the safety screws72may be of a tamper-evident nature so that the owner/operator can notice when the safety screws72have been removed. The tamper-evident feature can be provided by any wide variety of devices, such as stickers covering the screws, a frangible or easily-removable coating, frangible washers or the like.

In some cases, the owner/operator of the storage cabinet10have an appropriate tool on hand and thus be able to remove a door panel16and gain access to the storage compartments12of the storage cabinet10on, for example, an emergency basis. This feature provides manual override functionality to the system10should the controller15, keypad17or solenoid54malfunction, or in the case of a power loss, etc.

The use of the door panel16also provides a modular arrangement to the storage cabinet10. In particular, in the embodiment shown inFIG. 1it can been seen that the storage cabinet10includes six rows and three columns of openings22/door assemblies14/storage compartments12, and each door panel16provides a row of three door assemblies14. As shown inFIG. 18, in one case, an alternate door panel16′, utilizing door assemblies14that are half the height of the other door assemblies14, can be utilized. In this case, divider panels74can be slid into the appropriate storage compartments12so that the size of the storage compartments12and door assemblies14properly correspond. Of course, the storage compartments12/door assemblies14can take any of a variety of other shapes and configurations.

Each door panel16can be provided with any number of desired door assemblies14, in a desired spacing and configuration, to match the user's desires, as well as the configuration of the frame70/compartments12of the storage cabinet10. The door panels16may also be arranged vertically or in other configurations. Thus it can be seen that the door panels16provide a modular assembly in which the various components can be mixed and matched as desired to provide the desired system.

The door panels16also allow for ease of access for repair and/or replacement. In particular, should the handle30, latch mechanism, solenoid52or other components of a door assembly14require repair, maintenance or replacement, the door panel16can be easily removed, thereby exposing the handle30, latch mechanism, solenoid52and the like for easy access. Once the door assembly14has been repaired, or a replacement door panel16has been is obtained, the door panel16can be easily re-attached to the storage cabinet10.

Although the invention is shown and described with respect to certain embodiments, it should be clear that modifications will occur to those skilled in the art upon reading and understanding the specification, and the present invention includes all such modifications.