Abstract:
A modular equipment console comprising at least one base structure, each base structure having a uniform height and an upper surface with a predetermined depth; at least one turret structure, each turret structure being mountable onto one or more base structures; at least one equipment mount, each equipment mount being connectable to one or more of the turret structures and being adaptable for various types of equipment; and a work area, the work area being mountable on at least one of the base structures; wherein the modular equipment console can be arranged into various configurations using different numbers or types of base structures, turret structures, equipment mounts, and work areas.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to a framework for supporting pieces of work station equipment, and more particularly to a console structure for supporting electronic equipment in the nature of computers, video monitors, control panels and the like.  
         BACKGROUND OF THE INVENTION  
         [0002]    Control consoles of the type described herein generally include a framework for receiving and supporting the necessary pieces of electronic and support equipment including terminals, monitors, keyboards, switch panels, telephone turrets, lighting and so forth, and a planar work surface extending outwardly from the framework at a convenient height. Some of the equipment including video monitors and output displays is supported to be visible above the work surface for convenient viewing and user access. Finishing panels can also be supported by the basic framework.  
           [0003]    To date, many work station consoles have been custom manufactured which in terms of design and construction is both expensive and time consuming. This approach has been necessitated by customer requirements that are often unique in terms of work station size, equipment placement, human engineering and cost considerations. In the result, the completed console structures are not only extremely expensive, but are also difficult if not impossible to subsequently modify for the reconfiguration of existing equipment or to retrofit new equipment. An alternative approach has been to assemble the consoles from fixed size modular sections. This approach can reduce costs, and although there may be some loss of flexibility with respect to subsequent modifications and reconfigurations of equipment within the console, there are simply many instances in which the cost savings outweigh the advantages of a system critically engineered to permit unlimited post-installation reconfiguration. Some flexibility must however remain.  
           [0004]    A need therefore exists for a console structure which overcomes the problems inherent in either the custom design and manufacture or modular assembly of console structures. One such approach has been developed by the Applicant and is described in Canadian Patent 1,291,518 issued Oct. 29, 1991 (equivalent to U.S. Pat. No. 4,836,625).  
           [0005]    The backbone of the console structure shown in the aforementioned patents are the horizontally spaced, vertically upright gable members commonly referred to as G-frames. The gables are interconnected by stringers to provide a rigid framework for the console structure. The spacing between gables is infinitely variable so that the framework as a whole is easily adapted to custom requirements both before and after initial on-site assembly. Because most of the equipment in the console is supported by or suspended from the interconnecting stringers, changing the distance between gables is not in and of itself all that disruptive of the system as a whole and particularly the equipment mounting hardware, and this lends the overall structure enormous flexibility. This flexibility comes however at a cost. The gables themselves are metal fabricated usually from tubular steel and are therefore relatively expensive to manufacture and store. The stringers are typically aluminum extrusions and are therefore relatively inexpensive linear stock easily stored, but a lot of different stringers of different shapes and configurations depending upon function are required and an idea of the number and types of stringers needed can be seen from FIGS.  3  to  9  of the patent. This therefore also adds to cost and the need for significant inventory control. The need for this number of stringers is made necessary in part because the gables, as aforesaid, are almost entirely structural in function and integrate no channels, interlocks or other mechanical means that increase their versatility or allow them to perform multiple tasks.  
           [0006]    The Applicant has found that although there will continue to be a strong demand for the flexibility and retrofit capabilities of its G-frame consoles, and for more modular “discreet logic” systems that cost less, many customers now require accommodation for increasingly large pieces of equipment such as, for example, 26 inch monitors, and computer towers that are increasing particularly in height. To accommodate such items, and to maximize the remaining available space for other pieces of equipment usually mounted below the monitors, it is increasingly desirable to further reduce the number of components making up the console framework. The more vertical and horizontal structural members eliminated, the greater the unimpeded space available for oversized monitors and the like.  
         SUMMARY OF THE INVENTION  
         [0007]    The Applicant has therefore developed a console system which is flexible enough to meet the demands of a custom environment, but wherein the number of components in the system is significantly reduced for cost savings. Many of the remaining components “multi-task”, assembly is made easier and less costly, and structural integrity is maintained.  
           [0008]    The present invention therefore seeks to provide a console structure comprising a relatively few basic components which can be easily assembled into a supporting framework for a wide variety of equipment pieces and shapes without major modifications to the basic components themselves.  
           [0009]    The present invention further seeks to provide a console framework providing as much unimpeded space therein as possible, to maximize the adaptability of the framework for the mounting of different pieces of equipment at different locations, and the ability to meet custom requirements using the same basic components.  
           [0010]    The present invention therefore provides a modular equipment console comprising: (a) at least one base structure, each said base structure having a uniform height and an upper surface with a predetermined depth; (b) at least one turret structure, each said turret structure being mountable onto one or more base structures; (c) at least one equipment mount, each said equipment mount being connectable to one or more of said turret structures and being adaptable for various types of equipment; and (d) a work area, said work area being mountable on at least one of said base structures; wherein said modular equipment console can be arranged into various configurations using different numbers or types of base structures, turret structures, equipment mounts, and work areas. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    Preferred embodiments of the present invention will now be described in greater detail, and will be better understood when read in conjunction with the following drawings in which;  
         [0012]    [0012]FIG. 1 is a perspective view of the console structure in accordance with one embodiment of the present invention;  
         [0013]    [0013]FIG. 2 is a perspective view of the console of FIG. 1 in a partially opened condition;  
         [0014]    [0014]FIG. 3 is a partially exploded view of the console of FIG. 1;  
         [0015]    [0015]FIG. 4 is a rear perspective view of the console of FIG. 1;  
         [0016]    [0016]FIG. 5 is a perspective exploded view of a single module console;  
         [0017]    [0017]FIG. 6 is a schematical side elevational view of the present console with a turret;  
         [0018]    [0018]FIG. 7 is a cross sectional view of the rail extrusion forming part of the present console;  
         [0019]    [0019]FIG. 8 is a side-elevational cross sectional view of a hinge assembly forming part of the present console;  
         [0020]    [0020]FIG. 8 a  is a front elevational view of a locking mechanism forming part of the hinge assembly of FIG. 8;  
         [0021]    [0021]FIG. 9 is a cross-sectional view of one part of the hinge assembly;  
         [0022]    [0022]FIG. 10 is a cross-sectional view of another part of the hinge assembly;  
         [0023]    [0023]FIG. 11 is a plan view of corner modules;  
         [0024]    [0024]FIG. 12 is a side elevational, partially sectional view of a desktop configuration of the present console;  
         [0025]    [0025]FIG. 13 is a side elevational, partially sectional view of the present console with a turret; and  
         [0026]    [0026]FIG. 14 is the console of FIG. 13 with enlargements to show the connection of the turret to the base. 
     
    
     DETAILED DESCRIPTION  
       [0027]    The present invention provides a solution to the shortcomings of the prior art by supplying a modular console structure that is capable of being configured according to a client&#39;s needs, and that can be reconfigured easily and with minimal engineering input when required.  
         [0028]    Reference is now made to FIGS.  1  to  6 , which show a first preferred embodiment of console structure  1 . In this embodiment, console  1  is comprised of four basic elements: base structure  10 ; turret structure  40 ; equipment mount  70 ; and work area  90 . Each element is described in more detail below.  
         [0029]    Base structure  10  is comprised of a defined module of a predetermined width, height and depth. An individual base structure  10  is best seen in FIG. 5. This set height, width and depth creates the advantage that console structure  1  can be configured with various turrets and tops with minimum design or engineering effort by ensuring the top of one base structure  10  is the same as the tops of the other base structures used in console structure  1 . In console structure  1 , multiple base structures  10  can be used side by side, as is best seen in FIGS.  1  to  4 .  
         [0030]    Base structure  10  includes two front frame gables  12  and two rear frame gables  14  and an intermediate spacer  30 . In a preferred embodiment, front and rear gables  12  and  14  and spacers  30  respectively are comprised of formed sheet metal. Front frame gables  12  are laterally offset from each other by a lower front stringer  16  and a front top rail  20 . In a standard, squared base structure, front stringer  16  and front rail  20  are the same length, allowing front frame gables  12  to be parallel to one another and perpendicular to the floor.  
         [0031]    Front stringer  16  is preferably comprised of an aluminium extrusion and can include a PVC baseboard cap  15  disposed on its outer side for aesthetic purposes.  
         [0032]    Front rail  20  has the combined function of structurally separating front frame structural components  12  and providing a flat surface for turret  40  to rest on. Front rail  20  is mounted to front gables  12  so that the top of the rail is flush with the tops of gables  12 . Front stringer  16  and front rail  20  can be connected to frame gables  12  by screws, clips or any other suitable fasteners, welds or adhesive.  
         [0033]    Rear frame gables  14  are laterally separated by a lower rear stringer  22  and a rear top rail  26 . Rear stringer  22  is comprised of extruded aluminium and has the same width as front stringer  16 . Preferably, rear stringer  22  and front stringer  16  are the same, thus creating cost savings in the manufacturing process.  
         [0034]    Rear rail  26 , in a preferred embodiment, is an aluminum extrusion, and serves the dual purpose of structurally separating rear frame structural components  14  and providing a flat surface on which to mount turret  40 . Rear rail  26  is mounted to rear frame gables  14  so that its top surface is flush with the tops of rear gables  14 . Further, the top of rear rail  26  is level with the top of front rail  20 , providing a level frame unit on which to mount turret  40 .  
         [0035]    As shown in FIGS.  1  to  5 , upper rails  20  and  26  are simple extrusions including flat continuous uppersurfaces to support the turrets thereon and to connect to the turrets using screws, clips or any other suitable fasteners. For greater flexibility, and more connecting options, the applicant has developed a modified rail as shown most clearly in the cross-sectional view of FIG. 7.  
         [0036]    Gables  12  and  14  are connected to the rail shown in FIG. 7 by means of screws that pass through their sheet metal into horizontal screw ports  31 . The rail takes the form of an inverted L in shape having a downwardly depending vertical leg  27  and an inwardly projecting horizontal leg  28 . The rail includes threaded or unthreaded longitudinally extending slots  32  adapted to receive fasteners, clips or anchors used to connect additional elements such as cable management clips, brackets, clamps or even connectors for finishing panels. Upper leg  28  is formed with a pocket  38  and a T-slot  34 . The T-slot ran be used for slidably receiving a washer/threaded nut combination for connection to bolts extending from the lower edges of the turrets for a strong fixed connection, or the slot can be used for a snap fit with compressible clips or spring loaded plungers which again are disposed along the turret&#39;s lower edges for a quick release connection as will be described in greater detail below, Pocket  38  can be used for fasteners to connect the turrets, or for other pieces of ancillary equipment. Reference has been made to the use of the rails for mounting the turrets, but the same connecting options are available for connection of work surfaces  54  such as those shown in FIGS. 1 and 3.  
         [0037]    The supporting surfaces of horizontal leg  28  are actually the flanges  37  that define the openings into T slot  34  and pocket  38 . As will be seen most clearly in the views of FIGS. 13 and 14, flanges  37  project slightly above the upper edges of gables  12  and  14 . This exposes the slots  33  (FIG. 7) defined by flanges  37  for a sliding interlock connection between the turrets and rails and facilitates lateral adjustments to the positioning of the turrets relative to the base structures.  
         [0038]    Finally, the rail includes at the intersection of the vertical and horizontal legs a registration flange  35 . This flange can serve a number of purposes, including proper and instantaneous registration of the turrets relative to the base structure. As well, the flange defines a cavity  36  which can be used to hinge the turrets to the base as will be described below. The flange&#39;s upper surface  39  can be used to spot and/or support the inner edge of work surface  90  extending forwardly from the console as shown most clearly in the enlarged section of FIG. 14.  
         [0039]    To interconnect gables  12  and  14 , spacers  30  are provided between the two and are connected by means of screws, spot welds or by any other means known in the art. If preferred, the spacers can be manufactured in a variety of different widths to control the total depth of the present console without varying the widths of gables  12 / 14  themselves.  
         [0040]    Base structure  10  thus provides a support structure with a top that is at a predetermined height, width, and depth, thus facilitating the modular configuration and reconfiguration of the items supported by it.  
         [0041]    Turret structure  40  is best seen in FIGS.  1  to  6  and  13 . Turret structure  40  includes side gables  42 , end gables  44 , a back plate  46 , a cooling fan housing  48  (optional), front connection stringer  50  and hinge mechanism  52 .  
         [0042]    Side gables  42  are comprised of formed sheet metal and are generally triangular in shape to support equipment front  72  at an angle to the viewer. The depth of side gables  42  generally correlates to the depth of base structure  10  or the distance between registration flanges  35  on rails  20 / 26 . Side gables  42  will typically include screw holes to allow multiple turrets  40  to be joined side by side, as required for each project.  
         [0043]    End gables  44  have the same profile as side gables  42  and can be attached to the outer sides of side gables  42  to form a finished surface or they can be spaced from side gables  42  as shown in FIGS. 3 and 4 to elongate the assembled turret structure or to increase the available space within the turret.  
         [0044]    Back plate  46  is comprised of a formed sheet metal structure whose height matches the height of side gable  42 . The width of back plate  46  will be selected to accommodate the width of equipment fronts  72 . The bottom edge of back plate  46  is disposed to rest on the top of rear rail  26  for connection thereto.  
         [0045]    Back plate  46  further includes cooling fan mount housing  48  which allows a fan to be mounted to cool any equipment or electronics located within turret  40  or within the base.  
         [0046]    Front connection stringer  50  is typically formed sheet metal and is shaped to receive and or support the front edge of equipment front  72 .  
         [0047]    Side gables  42 , back plate  46 , and front connecting stringer  50  thus form a rectangular base which is meant to rest on base structure  10  at any point along the base&#39;s length, which can include positions that straddle individual bases  10  as shown in FIGS. 2 and 3. Preferably, the connection of spacers  30  and front gables  12  define a void  13  which provides clearance for the equipment  76  suspended below equipment fronts  72  when the turrets straddle a base  10  or when the turrets are moved from side to side over one or more bases to adjust their position. Normally, equipment fronts  72  will be hinged to the upper edge of back plate  46  for easy access to the equipment  76  mounted beneath the front and the interior of the console. Standard hinge hardware can be used, although the applicant has developed another extrusion that will be described in greater detail below that can be used advantageously for this purpose. The ability of turrets  40  to straddle base structures  10  further allows the widths of turrets  40  and equipment fronts  72  to be customized to meet project requirements.  
         [0048]    Turret  40  may be affixed to base structure  10  by various means which are well known in the art and can include metal screws. In a preferred embodiment, however, it is envisioned that turret  40  will affix to base structure  10  through a sliding interlock or snap fit connection for greater flexibility and adjustability. More specifically, and with particular reference to FIG. 14, each turret will include a small outwardly extending horizontal flange  47  at or along its lower front and rear edges. To connect the turret to the base, rear flange  47  is fully inserted into cavity  36  of the registration flange  35  in rear rail  26 . With the turret in the tilted position as shown in broken lines labelled Stage  1  in FIG. 14, the turret is then pivoted downwardly in the direction of arrow A into the position shown in broken lines labelled Stage  2 . The turret is then moved slightly forwardly into its fixed position shown in solid lines in FIG. 14 and identified as Stage  3 . In Stage  3 , the flange  47  on the forward edge of the turret partially extends into registration cavity  36  in front rail  20 , and the rear flange  47  is still partially inserted into cavity  36  in rear rail  26  so that the turrets cannot move vertically. To prevent the turrets from moving back and forth, each turret is provided with one or more spring loaded pins or plungers  49 . As seen most clearly in the enlarged portion of FIG. 14, the plunger&#39;s pin is in a raised position shown in dotted lines when the turret is positioned at Stage  2 . When the turret is moved to Stage  3 , the pin, which is normally biassed into an outwardly extended position, clicks into slot  34  in rail  20 . To disengage the turret, the pin (or pins if there are multiple plungers) can be pulled up to clear slot  34 , and the turrets can then be slid back into Stage  2  and tilted into Stage  3  for complete the removal from the base.  
         [0049]    Instead of or in addition to turret  40 , a work surface  54  may be disposed on base structure  10 . The lower edges of work surface  54  are disposed to fit onto front and rear rails  20  and  26  and affix to the rails in the same manner as turret  40 . In a preferred embodiment work surface  54  is comprised of a wood or pasteboard material finished with a laminate surface.  
         [0050]    Equipment mount  70  allows a client&#39;s equipment  76  to be mounted to console structure  1 . The mount includes a typically rectangular wood or metal equipment front  72  formed with a rectangular opening  73  for the insertion and installation of the equipment  76  to be supported in the turret. The rear edge of front  72  is advantageously hinged to the upper edge of the turret&#39;s rear surface  46 . This can be done in any conventional way, but the applicant has developed an extruded aluminum hinge  52  that can be substituted for advantage. The hinge itself is shown in FIGS. 8, 9 and  10 , and is shown assembled to the console in FIG. 13.  
         [0051]    Hinge  52  comprises three basic components, namely a pivot hanger  76  shown separately in FIG. 9, a pivot extrusion  77  shown in FIG. 10 and a pivotable lock  78 . Hanger  76  connects to the upper edge of the turret&#39;s back plate  46  as will be described below, pivot extrusion  77  connects to the rear edge of equipment front  72  and lock  78  is pivotably connected adjacent one or both ends of pivot extrusion  77  by means of a pin or screw that is received into longitudinally extending screw port  79 . Each lock is inwardly biassed by a spring  96  located on the pin axis as shown in FIG. 8 a . To connect pivot hanger  76  to the upper edge of plate  46 , the plate&#39;s upper edge is formed with a pair of spaced apart, horizontal inwardly directed, downwardly sloping flanges  48  and  49  seen most clearly in FIG. 13 and also shown in broken lines in FIG. 8. Upper flange  48  slides into registration cavity  80  and can be bonded to hanger  76  by means of glue or very high bond (VHB) tape applied between the flange and the hanger in the area marked with reference numeral  94  in FIG. 8. and lower flange  49  is wide enough to cover a T-slot  86  in the pivot hanger&#39;s lower surface. The T-slot slidingly receives threaded nuts to connect with correspondingly threaded bolts that pass through holes in lower flange  49  to provide a rigid connection between hanger  76  and flanges  48  and  49 . Hanger  76  additionally includes a hanger lip  82  to pivotally support a longitudinally extending hinge bead  84  on pivot extrusion  77 . Bead  84  is formed at the end of an arm  85  that bears against the inner surface of hanger  76  to limit extrusion&#39;s  77  clockwise rotation relative to hanger  76 . Lock  78  is used to prevent bead  84  from separating from lip  82 , and, when equipment front  72  is pivoted open, the lock can be pivoted about lock point  79  to hold the front in its open position.  
         [0052]    Pivot extrusion  77  is additionally formed with a pair of forwardly facing grooves or channels  81  and  87  separated by a removable tab  83 . Channel  81  is for the rear edge of equipment front  72  which is fixedly connected to the extrusion by means of screws that extend through the channel&#39;s lower surface  88  with spotting of the screws aided by a screw registration groove  89 . If the equipment front includes a separate metal or laminate finishing panel, its rearmost edge can be friction fit into upper channel  87 . If the equipment front is, for example, all wood, or is a solid substrate with a finishing laminate permanently glued or connected thereto, tab  83  can be broken off to accommodate the additional full thickness of front  72 .  
         [0053]    Console structure  1  further comprises a work surface  90 . Work surface  90  is disposed forwardly of base  10  and serves as, amongst other things, a writing surface, a keyboard support or as a support for a drawer  260 . The lower inner edge of the work surface can rest atop surface  39  of registration flange  35  and is otherwise mounted to the console using sheet metal brackets  232  that can be screwed to front gables  12  as seen most clearly in FIG. 12.  
         [0054]    The combination of the four basic elements of the present console as described above creates a modular, reconfigurable structure. A variety of turret modules can be variously placed on the base structure without the need to modify its height, width, or depth. This allows flexibility in the composition of console structure  1  without the need for significant re-engineering.  
         [0055]    The rise angles of the turrets will be governed by customer requirements with angles of 25°, 30° and 40° probably being the most common. The nature of the equipment supported by equipment fronts  72  will also vary with each installation, the equipment including the likes of CRT monitors, radar screens, switchgear, communications equipment and so forth. The mounting of the equipment on the equipment fronts is conventional and well known in the art and will not be described in further detail herein. The mountings will include conventional flush mounting of the screens and monitors, and the fronts can also be equipped with monitor jacks or adjustable platforms allowing monitors to be raised or lowered, tilted or moved to meet the operator&#39;s preference.  
         [0056]    In order to accommodate corners, console structure  1  is provided with corner modules as best seen in FIG. 11. FIG. 11 illustrates eight different corner modules in two rows of four. The top row illustrates corner modules with a long apex and the bottom row illustrates corner modules with a short apex.  
         [0057]    Reference is now made to first corner module  150 . First corner module  150  is provided with extended work surface  152  if required for a specific project. First corner module  150  is further provided with a top plate  154  and top plate fasteners  156 . In a preferred embodiment, top plate  154  is comprised of a ⅛″ aluminium sheet with a painted finish. Further, in a preferred embodiment, first corner module  150  had an apex of 8″ (20.32 cm) and a corner angle of 22.5 degrees.  
         [0058]    Similarly, second corner module  160  has an apex of 8″ (20.32 cm) and a corner angle of 30 degrees, third corner module  170  has an apex of 8″ (20.32 cm) and a corner angle of 36 degrees and fourth corner module  180  had an apex of 8″ (20.32 cm) and a corner angle of 45 degrees.  
         [0059]    Fifth corner module  190  is provided with extended work surface  192  if required for a specific project. Fifth corner module  190  is further provided with a top plate  194  and top plate fasteners  196 . Further, in a preferred embodiment, fifth corner module  190  had a pointed apex and a corner angle of 22.5 degrees.  
         [0060]    Similarly, sixth corner module  200  had a pointed apex and a corner angle of 30 degrees, seventh corner module  210  had a pointed apex and a corner angle of 36 degrees and eighth corner module  220  had a pointed apex and a corner angle of 45 degrees.  
         [0061]    More detailed embodiments of the present invention are shown in FIGS. 12 and 13. FIG. 12 shows a configuration of console structure  1  in which a work surface  54  is fitted instead of a turret.  
         [0062]    [0062]FIG. 13 shows a turret  40  installed above base structure  10 .  
         [0063]    The frontal openings of base structure  10  between gables can be closed with a panel or door  236  mounted on hinges  238  to allow easy access.  
         [0064]    The rearward openings of the base are similarly closed with a panel  240  or door using hinges  242 .  
         [0065]    Front and rear stringers  16  and  22  are adapted to support a lower shelf  244  and levelling legs  246  and  248 . The front stringer also supports forwardly extending foot  250  which stabilizes the console against tipping.  
         [0066]    The consoles shown in FIGS. 12 and 13 additionally include mounts  252  for a slidable shelf, and front and rear rack mounts  254  and  256  for racks, shelves or brackets useful for storage or to support other pieces of equipment.  
         [0067]    Also shown is a shelf  260  slidably mounted beneath work surface  90 . The shelf can be useful for a keyboard or for storage.  
         [0068]    The above-described embodiments of the present invention are meant to be illustrative of preferred embodiments and are not intended to limit the scope of the present invention. Various modifications, which would be readily apparent to one skilled in the art, are intended to be within the scope of the present invention. The only limitations to the scope of the present invention are set forth in the following claims appended hereto.