Patent Publication Number: US-6341511-B1

Title: Workstation lock system

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     The present invention relates to the field of workstations, and more particularly, to an improved workstation lock system. 
     Portable tool chests are known in the art (e.g. U.S. Pat. Nos. 5,549,377 and 4,938,548). However, known tool chests, or workstations, have traditionally been installed with lock systems that are hard to service, require high actuation force, and are not easily installed in workstations of different sizes. The demand for, and cost of, heavy-duty workstations is on the rise. Accordingly, the present invention provides a flexible lock system that may be used in many different types of workstations and with workstations of many sizes. The flexibility of the lock system of the present invention allows easy and costeffective integration in different types of workstations, with workstations of many sizes, and with workstations having various drawer arrangements. 
     The lock system of the present system is designed so as to allow low torque manipulation. The transfer channel of the present invention moves in the horizontal plane to lock and unlock banks of drawers. This horizontal actuation requires much less torque in manipulating the lock system as compared to traditional lock systems which operate in the vertical plane. The horizontally actuated transfer channel makes the lock system comfortable for the user to activate. 
     The lock system of the present invention is also designed to be easily serviced. As key locks are routinely serviced for code changes, the lock system of the present invention is designed with a “hairpin” clip underneath the key lock which provides easy access to the lock system. The lock system of the present invention may also be configured with a remote entry locking mechanism. 
     Accordingly, the present invention provides many advantages over known lock systems. The lock system of the present invention: 
     1.) is designed to allow easy locking and unlocking of multiple banks of drawers using a single keylock; 
     2.) allows manipulation of the lock mechanism by minimal torque making it very comfortable for the user to activate; 
     3.) is easily adapted to virtually any unit size or drawer configuration; 
     4.) is adapted with a keyless entry feature; and 
     5.) is adapted with a “key-alike” lock system that is easily changed without disassembling the entire unit. 
     The present invention is preferably comprised of: 
     a horizontally situated transfer mechanism, the transfer mechanism adapted to move horizontally; a means for actuating the horizontally situated transfer mechanism; and a plurality of vertically situated lock mechanisms, where each of the lock mechanisms corresponds to a bank of drawers, and wherein each of the vertically situated lock mechanisms are actuated by a horizontal movement of the transfer mechanism. 
     In addition to the features mentioned above, objects and advantages of the present invention will be readily apparent upon a reading of the following description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Novel features and advantages of the present invention, in addition to those mentioned above, will become apparent to those skilled in the art from a reading of the following detailed description in conjunction with the accompanying drawings wherein similar reference characters refer to similar parts and in which: 
     FIG. 1 illustrates one embodiment of an assembled workstation; 
     FIG. 2 illustrates an exploded view of one embodiment of a workstation; 
     FIG. 3 illustrates one embodiment of a workstation with exploded views of the uprights; 
     FIG. 4 illustrates one embodiment of a workstation with an exploded view of the top panel; 
     FIG. 5 illustrate alternative upright and drawer configurations of the workstation of FIGS. 1-4; 
     FIG. 6 illustrates an elevational cross-sectional view of the workstation of FIGS. 1-4; 
     FIG. 7 illustrates a perspective view of one embodiment of the lock system of the present invention; 
     FIG. 8 illustrates an exploded view of portions of the lock system of the present invention; 
     FIG. 9 illustrates embodiment of a drawer interface of the present invention; 
     FIGS. 10-11 illustrate one embodiment of the key lock and lockrod of the present invention; 
     FIG. 12 illustrates a perspective view of the lock hinge of the present invention; and 
     FIG. 13 illustrates an embodiment of the workstation having a cable as the transfer mechanism. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) 
     The preferred system herein described is not intended to be exhaustive or to limit the invention to the precise forms disclosed. They are chosen and described to explain the principles of the invention, and the application of the method to practical uses, so that others skilled in the art may practice the invention. 
     FIG. 1 illustrates one embodiment of an assembled workstation  10  to whicb the lock system of the present invention may be installed (although the following description relates to a lock system of the present invention installed on a modular workstation, it should be appreciated that the lock system may also be used with a one-piece workstation). The workstation  10  illustrated in FIG. 1 is a heavy-duty workstation capable of storing large loads and having the flexibility to be custom built for different user specifications. 
     In the preferred embodiment, the workstation  10  resides on spring casters  12 . The casters  12  provide portability to the workstation  10 . The casters  12  are designed to support the large loads the workstation  10  is capable of storing. 
     The workstation  10  illustrated in FIG. 1 depicts a workstation  10  having a first and second upright  40 ,  42  positioned in predetermined positions along the base portion  18  of the workstation  10 . As will be discussed in greater detail below, the uprights  40 ,  42  may be placed in various locations along the base portion  18  to allow for different drawer arrangements. A third upright (not shown in FIG. 1, see FIGS. 5A-5Q) may also be used in conjunction with the first and second uprights  40 ,  42  to provide four banks of drawers across the workstation  10 . 
     Example dime ions have been indicated on FIG.  1 . In another embodiment of the workstation  10  shown it FIG. 1, the width of the workstation  10  is 88¼″, the height of the unit is 38½″ (46⅜″ including the casters  12 ), and the depth of the unit is  27 ″. In this embodiment, the width of the top large drawer is 60{fraction (9/16)}″ and the width of the middle bank of drawers is 38{fraction (15/16)}″. 
     FIG. 2 illustrates an exploded view of the workstation  10 . FIG. 3 illustrates one embodiment of the workstation  10  with exploded views of the uprights  40 ,  42  (the uprights  40 ,  42  may be of a one-piece or a multiple piece construction). FIG. 4 illustrates one embodiment of the workstation  10  with an exploded view of the top panel  38 . In one embodiment, the workstation  10  is comprised of: 
     a.) a first module element  20  having a plurality of grooves  22 , a back panel  24 , a side panel portion  26 , and a base; 
     b.) a second module element  28  having a plurality of grooves  30  corresponding to the grooves  22  of the first module element  20 , a back panel  32 , and a side panel portion  34 , and a base; 
     c.) a plurality of rails  36  inserted into the plurality of grooves  22 ,  30  of the first and second module elements  20 ,  28 ; 
     d.) a top panel  38  secured to the back panels  24 ,  32  and side panel portions  26 ,  34  of the first and second module elements  20 ,  28 ; 
     e.) first and second uprights  40 ,  42  attached to a base portion  44  formed by the connected first and second module elements  20 ,  28 ; 
     f.) a plurality of drawers  46 ; and 
     g.) means for holding the plurality of drawers  46  attached in predetermined positions on the uprights  40 ,  42  and side panel portions  26 ,  34  of the first and second module elements  20 ,  28 . 
     In an alternative embodiment, the first and second module elements  20 ,  28  may be integrated into a one-piece construction. In such an embodiment the base portion  44  and the back panels  20 ,  32  would be of a one-piece construction. 
     In the preferred embodiment, the first module element  20  is wider than the second module element  28 . The corresponding edges  48  of the first and second module elements  20 ,  28  are secured together. The back panels  24 ,  32  of the first and second module elements  20 ,  28  are preferably attached using {fraction (3/16)}″ poprivets  50 . The resulting joint may be concealed using an adhesive backed black bumper molding. FIG. 3 illustrates the first and second module elements  20 ,  28  in an assembled state. 
     In the preferred embodiment, once the first and second module elements  20 ,  28  are attached, a plurality of rails  36  may be placed into the grooves  22 ,  30 . Each rail  36  preferably contains multiple threaded holes for receiving bolts. These bolts secure the module elements  20 ,  28  to the rails  36  and also provide mounting points for the swivel and rigid casters  12 . The rails  36  provide the necessary stiffness to the workstation  10  to ensure the workstation will not sag under heavy loads (i.e. from the drawers, top chest or side cabinqts). The number of rails  36  placed in the workstation may vary depending on the width of the workstation  10  and the maximum load capacity. In the preferred embodiment, the workstation has three rails  36 . 
     The uprights  40 ,  42  may be placed into the base portion  44  by inserting the bottom tabs  52  of the uprights  40 ,  42  into the slots  54  in the base portion  44  of the workstation  10 . These uprights  40 ,  42  are also secured to the base portion  44  using screws along the bottom flanges  56  of the uprights  40 ,  42 , the back flanges  58  of the back panel, and top flanges  60  located on the uprights  40 ,  42 . The uprights  40 ,  42  may be “tall” uprights which extend all the way to the top panel  38  of the workstation  10  or they may be “short” uprights which do not extend to the top panel  38  of the workstation  10 . The short uprights allow for the use of wider drawers  46 . As discussed, in the preferred embodiment, either none, one, two, or three uprights may be used to accomplish various drawer configurations. FIGS. 5A-5Q illustrate elevational cross-sectional views of the workstation  10  of the preferred embodiment depicting various drawer configuration options of the workstation  10 . 
     In the preferred embodiment, it is preferred that the side panel portions  26 ,  34  be constructed of a double-wall construction. As illustrated in FIG. 3, a double-wall side panel  26 ,  34  is comprised of an inner and outer wall  64 ,  66 . 
     For high load bearing applications, it is preferred that a corner reinforcer  62  be inserted into the space formed by the inner and outer walls  64 ,  66  of the side panels  26 , 34 . The corner reinforcement  62  is preferably held in position using sheet metal screws. The corner reinforcements  62  are vertical compression members that span from the top panel  38  to the base portion  44  of the workstation. The corner reinforcements  62  act to transfer top panel loads directly to the casters  12 . 
     Referring to FIG. 4, in the preferred embodiment, bolts are inserted through clearance holes in the inner panel hat section  68  and hand threaded into a weld nut on the back side of the outer walls  66  (see areas identified as “A”). Subsequently, the top panel  38  may be secured to the workstation  10 . It is preferred that the back edge of the top panel  38  contains an open hem flange  70  which hooks over the top edge  72  of the back panels  24 ,  32  of the first and second module elements  20 ,  28 . The top panel  38  also preferably has side flanges  74  which are formed down and engage into wide pockets  76  running the depth of the outer wall  66 . The overlapping of the top panel  38  and the outer wall  66 , identified as Area “A”, is clamped together by wrench tightening the bolts already in place in the clearance holes in the inner panel hat section  68 . The resulting joint appears as a spot welded corner with no visible gap between the top panel  38  and the outer wall  66 . 
     In the preferred embodiment, a facia strip  78  is secured to a front face of the base portion  44  of workstation  10 , preferably using sheet metal screws. The facia strip  78  conceals the joint between the first and second module elements  20 ,  28  and also provides a skirt around the caster plate and mounting bolts. 
     The workstation  10  is preferably constructed from a durable steel material. The top panel  38  is preferably a high strength panel able to accommodate large loads without lock system failure (i.e. 500 lb. minimum). In an alternative embodiment, a work surface, such as a laminated board may be placed on the top of the workstation  10 . 
     The method of construction of the workstation  10  provides modularity and drawer interchangeability. The uprights may be reversed, doubled-up, or eliminated to create many different drawer configurations. FIGS. 5A-5Q illustrate some of the possible drawer configurations. Depending on the upright configuration used, different width drawers can be mounted adjacent to each other. For example, looking at FIG. 6, two narrow width drawers (denoted as A) may be removed and replaced with a wider drawer (denoted as B). Three narrow or one narrow and one wide drawer may be removed and replaced with an extra wide drawer (denote as C). 
     Additionally, different width cabinet modules can be joined together to create unique workstation dimensions and drawer arrangements. For example, two wide module elements may be assembled to create a wider unit. The width of the modules are generally controlled by the dimension of the smallest standard width drawer for a given application. 
     The workstation described above provides the strategic value of custom drawer configurations within a given workstation size. Also, the method of construction, and the modularity of the workstation, offers the capability for infinite workstation sizes. Additionally, by building the modules separately, larger workstation widths are no longer limited by the dimensional capability of the paint and fabrication equipment. Workstations may be produced to larger sizes without demanding capital investments for new painting and sheet metal equipment adapted to larger one-piece welded units. 
     FIG. 7 illustrates a perspective view of the lock system  100  of the present invention installed on the modular workstation  10  described above. (It is again emphasized that the lock system  100  of the present invention may be used with the modular workstation  10  described above, or with various other workstations, including, but not limited to, a one-piece workstation.) The drawer locking system  100  of the present invention is designed to easily lock and unlock multiple banks of drawers using a single key lock  102 . The key lock  102  may easily be serviced based on a “hairpin” clip  104  design. The horizontal actuation of the lock system  100  of the present invention requires minimal torque at the key (e.g. less than 5 in.lbs.) making it very comfortable for the user to activate. Unlike traditional vertical lifting lock systems, the rotary action lock system activates with horizontal movement. As a result, during activation, the system of the present invention does not operate against the force of gravity. Based on this low torque activation, a low power remote entry module  106  may be used to activate the lock system  100 . 
     FIG. 8 illustrates an exploded view of portions of the lock system  100  of the present invention. A lock mechanism  108  acts to engage a retaining means  110  on the back portion of each of the drawers  112 . In one embodiment, each of the lock mechanisms  108  is a lock hinge  114  riveted to a vertical angle  116 , located on the back panel of the workstation (see FIG. 12 for a close-up erspective view of the lock hinges. It is prferred that the lock hinge  114  be comprised of a stationary leaf portion  118  and a moving leaf portion  120 . In the preferred embodiment, the moving leaf portion  120  of the lock mechanism  108  rotates in the counterclockwise direction to unlock the drawers  112 . (FIG. 9 illustrates a top plan view illustrating the lock mechanism  108  and drawer  112  interface details.) It is also preferred that the lock hinge  114  be spring loaded and possess a 90 degree stop angle. As illustrated in FIG. 9, the moving leaf portion  120  of the lock mechanism  108  will rotate approximately 45 degrees counterclockwise (looking down from the top) as the system activates from locked to unlocked position. The moving leaf  120  portion preferably has a series of rectangular slots  150 . These rectangular slots  150  engage the retaining means  110  when the moving leaf portion  120  is in the locked position. 
     Although in FIG. 9, a horsehead retaining means is illustrated, it is appreciated that other retaining means may be used. For example, a hook latch retaining means may be used when the lock mechanism  108  contains hooks as opposed to engaging slots. It is also preferred that the lock mechanism  108  be vertically situated along the back of the unit so that the lock mechanism  108  can simultaneously lock and unlock all the drawers  112  of a bank of drawers. 
     The lock hinges  114  are activated by a transfer mechanism  122  that runs horizontally across the back of the workstation. In the preferred embodiment, the transfer mechanism  122  is a transfer channel  124 . The transfer channel  124  is positioned behind a portion of each of the multiple banks of drawers. Rectangular slots  126  in the transfer channel  124  fit into tabs  128  at the top of the vertical angles  116  located on the back panel of the workstation. The tabs  128  guide the tranfer channel  124  as it moves left to right while preventing the channel  124  from rotating. It is preferred that plastic spacers  130  be screwed to a bottom flange of the transfer channel  124 . These spacers  130  move the moving leaf portion  120  of the lock hinge  114  as the transfer channel  124  moves horizontally to the unlocked position (in an alternative embodiment they may also be configured to move the hinge to a locked position). In the embodiment illustrated in FIGS. 7-11, as the spacers  130  move to the right of the unit, they act to push the moving leaf portion  120  from the locked to the unlocked position. To lock the drawer, the transfer channel  124  is activated to return to the left position, wherein the spacers  130  also move to the left. The moving of the spacers  130  to the left allows the Proving leaf portion  120  of the spring-loaded lock hinge  114  to return to the locked position. It is appreciated that other components, other than spacers  130  may be used to activate the lock hinge  114 . 
     In another embodiment, illustrated in FIG. 13, the transfer mechanism is a cable  152 . In one embodiment, the cable has loops or rings  154  that engage holes placed in the moving leaf portions  120  of the lock hinges  114 . Horizontal movement of the cable  152  acts to move the moving leaf portion  120  from the locked to the unlocked position. 
     The transfer channel  124  is preferably activated to move in the horizontal direction via a lockrod system  132 . FIG. 10 illustrates an exploded view of one embodiment of the lockrod system  132  of the present invention. FIG. 11 illustrates the preferred embodiment of the key lock  102  of the present invention. In the embodiment illustrated in FIGS. 10-11, an offset at the rear of the lockrod  132  rotates 180 degrees when activating the system. The offset in the lockrod  132  applies pressure to a bearing surface on the transfer channel  124 . The transfer channel  124  displaces left to right the horizontal distance traveled by the 180 degrees rotation of offset in the lockrod  132  (approximately 0.54″ in one embodiment, this 0.54″ linear movement generates 45 degrees of rotation in the lock hinges  114 ). In the preferred embodiment, the lockrod  132  and the key lock  102  are connected by a hairpin clip  104 . The hairpin clip  104  may be easily removed allowing the key lock  102  to be removed and replaced. 
     In a preferred embodiment, the lock system  100  of the present invention may be activated by remote entry. The remote entry module  106  is illustrated in FIG.  7 . The remote entry module  106  is preferably a self-contained unit having a DC solenoid, receiver and battery back-up. The solenoid actuator connection to the transfer chamuel  124  is shown generally at  134 . The remote entry module  106  preferably has a DC power line  136  that interfaces to an AC wall outlet  138  via a plug-in AC-DC power converter  140 . The antenna  142  for the receiver may be routed through a knock-out portion  144  of the back panel, or across the inside panel, into the hat section space and through a hole in the base portion to the underside of the unit (see FIG.  7 ). 
     The remote entry module  106  may be mounted to the back panel of the unit via mounting holes provided in an upper portion of the inside of the back panel, top panel hat section and the transfer channel  124 . It is also preferred that the back panel contain a “knock-out” portion which allows for easy access to the remote entry module  106  (the “knock-out” portion may be separately locked). 
     As described, the lock system  100  of the present invention provides an improved lock system that is manipulated by low torque, that is easily serviceable once installed, and which may be easily configured for different types of workstations, of differing size, and/or having different drawer arrangements. For example, the lock system  100  of the present invention may be easily configured for installation into workstations having the various drawer arrangements shown in FIGS. 5A-5Q, and FIG.  6 . E.g., any of the different drawer arrangements shown in FIGS. 5A-5Q may be accommodated by installing a lockrod  132 , a transfer channel  124 , a lock hinge  114 , and by placing vertical lock mechanisms  108  in predetermined locations on the back panel of the modular workstation corresponding to each bank of drawers, as described above. 
     Having shown and described a preferred embodiment of the invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention and still be within the scope of the claimed invention. Thus, many of the elements indicated above may be altered or replaced by different elements which will provide the same result and fall within the spirit of the claimed invention. For example, the number and placement of the uprights may vary, the size of the modules may vary, and the base portion of the invention may be a one-piece construction as opposed to being modular. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.