Patent Publication Number: US-2023151833-A1

Title: Coupling Mechanism for a Modular System

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION 
     The present application is a continuation of International Application No. PCT/US2022/080020, filed Nov. 17, 2022, which claims the benefit of and priority to U.S. Provisional Application No. 63/280,923, filed on Nov. 18, 2021, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present disclosure is directed generally to the field of containers and related devices. The present disclosure relates specifically to a coupling mechanism for use with a modular system, such as a modular storage system. 
     Tool storage units are often used to transport tools and tool accessories. Some storage units are designed to incorporate into a modular storage system. Various accessories can be configured to interface with a storage unit in a modular storage system, such as smaller containers that couple to units within the modular storage system. 
     SUMMARY OF THE INVENTION 
     One embodiment of the invention relates to a coupling mechanism configured to mechanically engage and disengage a coupling structure. The coupling mechanism includes a housing defining a lower surface, a projection extending downward from the lower surface of the housing, and a plurality of arms extending away from the projection. The plurality of arms are coupled to the projection such that the arms actuate between an engagement position in which the plurality of arms extend upward and away from the projection, a disengagement position in which the plurality of arms extend downward and away from the projection, and a locked position between the engagement position and the disengagement position. 
     In various embodiments, the coupling mechanism includes a tension mechanism that, when actuated, releases the arms from the locked position thereby permitting the arms to pivot into the disengagement position. In various embodiments, the coupling mechanism includes a button that extends upward from an upper surface of the housing opposite the lower surface, the button actuating the tension mechanism. In various embodiments, the tension mechanism biases the arms to remain in the locked position until the button is actuated. In various embodiments, the plurality of arms include at least four arms extending away from the projection and circumferentially surrounding the projection. In various embodiments, the plurality of arms define a plurality of outer surfaces that collectively circumferentially extend at least 250 degrees around the projection. In various embodiments, the plurality of arms include at least four arms extending away from the projection and circumferentially surrounding the projection. 
     Another embodiment of the invention relates to a coupling mechanism configured to mechanically engage and disengage a coupling structure. The coupling mechanism includes a housing defining a lower surface, a projection extending downward from the lower surface of the housing, and a plurality of arms. Each of the plurality of arms extend away from the projection from an inner end closest to the projection to an opposing outer surface furthest from the projection. The plurality of arms actuate between an engagement position in which a first outer surface of a first arm of the plurality of arms defines a first distance from the lower surface, a disengagement position in which the first outer surface of the first arm defines a second distance greater than the first distance, and a locked position in which the first outer surface of the first arm defines a third distance greater than the first distance and less than the second distance. 
     In various embodiments, the plurality of arms define a plurality of outer surfaces that collectively circumferentially extend at least 270 degrees around the projection. In various embodiments, the plurality of arms include at least four arms extending away from the projection and circumferentially surrounding the projection. In various embodiments, the coupling mechanism includes a tension mechanism that, when actuated, releases the arms from the locked position thereby permitting the arms to pivot into the disengagement position. 
     Another embodiment of the invention relates to a coupling system including an object and a coupling mechanism coupled to the object. The coupling mechanism includes a housing defining a lower surface facing away from the utility module, a projection extending downward from the lower surface of the housing, a plurality of arms extending away from the projection, and a button that, when actuated, permits the plurality of arms to transition from the locked position to the disengagement position. The plurality of arms are coupled to the projection such that the arms actuate between a disengagement position in which the plurality of arms extend downward and away from the projection, and a locked position in which the plurality of arms extend laterally away from the projection. 
     In various embodiments, the plurality of arms define a plurality of outer surfaces that collectively circumferentially extend at least 270 degrees around the projection. In various embodiments, the coupling mechanism includes a tension mechanism that, when actuated, releases the arms from the locked position thereby permitting the arms to pivot into the disengagement position. In various embodiments, the coupling mechanism includes a button coupled to the projection, the button actuating the tension mechanism. 
     Another embodiment of the invention relates to a coupling mechanism configured to mechanically engage and disengage a coupling structure on a modular unit. The coupling mechanism includes a housing defining a lower surface, a projection extending downward from the lower surface of the housing, and a plurality of arms that extend away from the projection. The plurality of arms are coupled to the projection such that the arms actuate between an engagement position in which the arms extend away from the projection and upward towards the housing, a disengagement position in which the arms extend away from the projection and downwards away from the housing, and a locked position in which the arms are oriented between the engagement position and the disengagement position. 
     In various embodiments the coupling mechanism includes an interface that, when actuated, releases the arms from the locked position thereby permitting the arms to pivot into the disengagement position. In various embodiments, the interface includes a button that extends upward from an upper surface of the housing opposite the lower surface. In various embodiments, the coupling mechanism includes a tension mechanism coupled to the button. The tension mechanism biases the arms to remain in the locked position until the interface is actuated. 
     In various embodiments, the coupling mechanism includes at least four arms extending away from the projection and circumferentially surrounding the projection. In various embodiments, a first arm of the plurality of arms includes an end furthest from the projection. When the arm is in the engagement position the end of the arm defines a first distance from the lower surface of the housing. When the arm is in the locked position the end of the arm defines a second distance from the lower surface of the housing that is further than the first distance. When the arm is in the disengagement position the end of the arm defines a third distance from the lower surface of the housing that is further than the second distance. 
     Additional features and advantages will be set forth in the detailed description which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description included, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary. 
     The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which: 
         FIG.  1    is a schematic side view of a coupling mechanism, according to an exemplary embodiment. 
         FIG.  2    is a schematic side view of the coupling mechanism of  FIG.  1   , according to an exemplary embodiment. 
         FIG.  3    is a schematic side view of the coupling mechanism of  FIG.  1   , according to an exemplary embodiment. 
         FIG.  4    is a schematic side view of the coupling mechanism of  FIG.  1   , according to an exemplary embodiment. 
         FIG.  5    is a schematic side view of a coupling mechanism, according to an exemplary embodiment. 
         FIG.  6    is a schematic side view of the coupling mechanism of  FIG.  5   , according to an exemplary embodiment. 
         FIG.  7    is a schematic side view of the coupling mechanism of  FIG.  5   , according to an exemplary embodiment. 
         FIG.  8    is a schematic side view of the coupling mechanism of  FIG.  5   , according to an exemplary embodiment. 
         FIG.  9    is a schematic side view of the coupling mechanism of  FIG.  5   , according to an exemplary embodiment. 
         FIG.  10    is a schematic side view of the coupling mechanism of  FIG.  5   , according to an exemplary embodiment. 
         FIG.  11    is a perspective view of the coupling mechanism of  FIG.  5   , according to an exemplary embodiment. 
         FIG.  12    is a perspective view of the coupling mechanism of  FIG.  5    above a coupling pocket, according to an exemplary embodiment. 
         FIG.  13    is a perspective ghost view of the coupling mechanism of  FIG.  5    disposed within a coupling pocket, according to an exemplary embodiment. 
         FIG.  14    is a perspective view of a tension mechanism, according to an exemplary embodiment. 
         FIG.  15    is a perspective view of a tension mechanism, according to an exemplary embodiment. 
         FIG.  16    is a perspective view from above of a utility module, according to an exemplary embodiment. 
         FIG.  17    is a perspective view from below of the utility module of  FIG.  16   , according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring generally to the figures, various embodiments of a coupling mechanism mechanically engage and disengage with a modular utility module are shown. The coupling mechanism is configured to selectively couple and decouple with units in a modular system, such as a tool storage unit. The coupling mechanism includes an interface to couple to one or more coupling recesses of the tool storage unit. The coupling mechanism provides the ability to quickly couple and decouple utility modules to a modular system. 
     When coupled to the tool storage unit, the coupling mechanism is biased to remain coupled to the tool storage unit when the tool storage unit is being moved, such as being moved around a construction site. In specific embodiments, the coupling mechanism includes arms that actuate vertically to engage or disengage with a coupling pocket. 
     Referring to  FIGS.  1 - 5   , a device to couple a container, unit, device, and/or utility module, shown as coupling mechanism  110 , is shown according to an exemplary embodiment. Coupling mechanism  110  is configured to mechanically engage and disengage a coupling structure, such as pocket  190  with ribs. Coupling mechanism  110  includes a housing  120 , which includes an upper surface  122  and an opposing lower surface  124 . In various embodiments housing  120  is coupled to another object, such as an object to be coupled to the coupling pocket  190  of a utility module. 
     In various embodiments, coupling system  106  includes object  108  and coupling mechanism  110  coupled to the object  108 . The coupling mechanism  110  is coupled to the utility module, such as detachably coupled. The coupling mechanism  110  facilitates securing the object  108  to units in a modular system. In various embodiments, object  108  is a tool, such as a tape measure. 
     In various embodiments, coupling mechanism  110  is initially independent of an object (e.g., battery, battery housing, cup, and/or a tool, shown as object  108 ) to be coupled to a utility module, and the coupling mechanism  110  and the object are subsequently coupled together before coupling mechanism  110  is then coupled to a utility module (thereby also coupling the object to the utility module). In various embodiments, coupling mechanism  110  is formed as part of the object and/or coupled to the object before reaching a consumer, and coupling mechanism  110  is used to engage the object to a utility module. 
     Coupling mechanism  110  includes projection  130  that extends downward from lower surface  124  of housing  120 . Coupling mechanism  110  includes a plurality of arms  150  coupled to projection  130  and extending away from projection  130 , such as laterally and/or radially away from projection  130 . In various embodiments, each of the plurality of arms  150  extend away from the projection  130  from an inner end  162  closest to the projection  130  to an opposing outer surface  152  (e.g., ends of arms  150 ) furthest from the projection  130 . The plurality of arms  150  are coupled to the projection  130  such that the arms  150  actuate between an engagement position in which the plurality of arms  150  extend upward and away from the projection  130 , a disengagement position in which the plurality of arms  150  extend downward and away from the projection  130 , and a locked position between the engagement position and the disengagement position. In various embodiments, the arms  150  are arranged around the projection  130  symmetrically with respect to each other. 
     An interface element, shown as button  134  is coupled to projection  130  and is actuated to adjust an position of arms  150  with respect to projection  130 . Stated another way, button  134  extends upward from an upper surface  122  of the housing  120  opposite the lower surface  124 , the button  134  actuating the tension mechanism  139 . In various embodiments, the button  134  is coupled to projection  130 , and the button  134  actuates the tension mechanism  139 . In various embodiments, the tension mechanism  139  biases the arms  150  to remain in the locked position until the button  134  is actuated. Stated another way, coupling mechanism  110  includes a button  134  that, when actuated, permits the plurality of arms  150  to transition from the locked position to the disengagement position. 
     As will be shown, arms  150  selectively engage, lock, and disengage with ribs  192  of coupling pocket  190 . In particular, arms  150  actuate between an engagement position with respect to projection  130  ( FIG.  2   ), a locked position ( FIG.  3   ), and a disengagement position ( FIG.  4   ). In various embodiments, plurality of arms  150  include at least four arms  150  extending away from the projection  130  and circumferentially surrounding the projection  130 . In various embodiments, the plurality of arms  150  defining a plurality of outer surfaces  152  that collectively circumferentially extend at least 250 degrees around the projection  130  (also see  FIG.  11   ). 
     Coupling mechanism  110  includes a tension mechanism  139  that, when actuated, releases the arms  150  from the locked position thereby permitting the arms to pivot into the disengagement position. Various embodiments of tension mechanisms  140 ,  240 , which coupling mechanism  110  may include, are described below in regard to  FIGS.  14  and  15   . In various embodiments the tension mechanism actuates between holding the arms rigidly against the projection (e.g., such as when in the locked position) and permitting the arms to pivot with respect to the rotation (e.g., such as when in the engagement or disengagement positions). 
     When in the engagement position, the arms  150  are folded upward towards lower surface  124 . In particular, as coupling mechanism  110  is coupled to coupling pocket  190 , outer surfaces  152  of the one or more arms  150  pivot upward towards lower surface  124  until outer surfaces  152  are distance  154  from lower surface  124 . 
     When in the locked position, the arms  150  extend laterally from projection  130  and engage against the underside of ribs  192  to secure coupling mechanism with coupling pocket  190 . In particular, once arms  150  are disposed within coupling pocket  190 , outer surfaces  152  of arms  150  pivot beneath ribs  192  of coupling pocket such that outer surfaces  152  are distance  156  from lower surface  124 , and distance  156  is further than distance  154 . 
     When in the disengagement position, the arms  150  are folded downward away from lower surface  124 . In particular, to remove coupling mechanism  110  from coupling pocket  190 , button  134  is actuated to permit arms  150  to pivot with respect to projection  130  such that outer surfaces  152  of arms  150  pivot to distance  158  from lower surface  124 , and distance  158  is further than both distance  154  and distance  156 . 
     Stated another way, the plurality of arms  150  actuate between an engagement position ( FIG.  2   ) in which a first outer surface  152  of a first arm  150  of the plurality of arms  150  defines a first distance  154  from the lower surface  124 , a disengagement position ( FIG.  4   ) in which the first outer surface  152  of the first arm  150  defines a second distance  158  greater than the first distance  154 , and a locked position ( FIG.  3   ) in which the first outer surface  152  of the first arm  150  defines a third distance  156  greater than the first distance  154  and less than the second distance  158 . 
     Referring to  FIGS.  5 - 13   , coupling mechanism  210  is shown according to an exemplary embodiment. Coupling mechanism  210  is substantially the same as coupling mechanism  110  except for the differences discussed herein. In particular, button  234  extends upwards from housing  220 . 
     Housing  220  includes upper surface  222  and an opposing lower surface  224 . To engage coupling mechanism  210  with coupling pocket  290 , coupling mechanism  210  is moved in direction  226  towards coupling pocket  290 . Arms  250  of coupling mechanism  210  pivot towards lower surface  224  as coupling mechanism  210  is inserted into coupling pocket  290 . Subsequently, arms  250  engage ribs  292  to secure coupling mechanism  210  within coupling pocket  290 . To remove coupling mechanism  210 , first button  234  is actuated to permit arms  250  to pivot downward, and then coupling mechanism  210  is moved upward in direction  238 . 
     Referring to  FIGS.  11 - 13   , as shown coupling mechanism  210  includes four arms  250 . Each arm  250  circumferentially extends angle  260  around projection  230  between 70 degrees and 90 degrees with respect to longitudinal axis  232 , and more specifically 80 degrees. In various embodiments, the plurality of arms  150  a plurality of outer surfaces  252  that collectively circumferentially extend at least 250 degrees around the projection  130 , and more specifically at least 270 degrees around the projection  130 . 
     As shown, one or more of arms  250  engage against ribs  292  of coupling pocket  290 . 
     In a specific embodiment, coupling mechanism  110  and coupling mechanism  210  are compatible with the coupling mechanism(s) described in International Patent International Patent Publication No. WO 2017/191628, which is incorporated herein by reference in its entirety. 
     Referring to  FIG.  14   , various aspects of tension mechanism  140  are shown. Tension mechanism  140  is configured to actuate between rigidly engaging the arms against the projection of a coupling mechanism and thereby locking the arms under the ribs of a coupling pocket, and permitting the arms to pivot with respect to the projection. As shown, tension mechanism  140  includes a pinion gear  142  with teeth that engage with teeth of rack gear  144 . 
     Referring to  FIG.  15   , various aspects of tension mechanism  240  are shown. Tension mechanism  240  actuates between rigidly engaging arms against the projection of a coupling mechanism and thereby locking the arms under the ribs of a coupling pocket, and permitting the arms to pivot with respect to the projection. As shown, tension mechanism  240  includes a biasing element, shown as spring  242 , that maintains tension in a flexible elongate structure  244 . In use, a user presses against spring  242  to remove tension in flexible elongate structure  244 , thereby permitting the arms to pivot with respect to the projection. To secure arms beneath ribs, the user stops pressing against spring  242  and in response flexible elongate structure  244  are tightened to bias arms against the projection, thereby securing the arms under the ribs of a coupling pocket. 
     Referring to  FIGS.  16 - 17   , various aspects of utility module  300  are shown, according to an exemplary embodiment. As will be understood, coupling mechanism  110  is configured to couple an object to utility module  300 . Utility module  300  includes an upper surface  302  and an opposing lower surface  306  facing away from the upper surface  302 . One or more female couplers  304  extend from and/or are defined by upper surface  302  of utility module  300 , and one or more male couplers  208  extend from lower surface  306  of utility module  300 . Utility module  300  includes a latch  310  and a latch recess  312  configured to interface with latch recesses and latches, respectively, to secure utility module  300  to other objects. 
     Female couplers  304  of utility module  300  detachably engage with coupling mechanism  110 . In various embodiments, a system  194  includes utility module  300  including utility module  300  and object  198  coupled to utility module  300 . Object  198  is coupled, such as detachably coupled, to coupler  196 . Coupler  196  may be any of the couplers shown (e.g., coupling mechanism  110 , coupling mechanism  210 ). Coupler  196  is reversibly and detachably mechanically coupled to one of female couplers  304 . 
     It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for description purposes only and should not be regarded as limiting. 
     Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure. 
     Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more component or element, and is not intended to be construed as meaning only one. As used herein, “rigidly coupled” refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force. 
     Various embodiments of the disclosure relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements or components of any of the other embodiments discussed above. 
     For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. 
     While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above. 
     In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.