CROSS REFERENCES TO RELATED APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is for a sign frame alignment system and, more particularly, it is for a precision alignment system for modular frames of an electronic sign where the modular frames serve, in part, as a mounting structure for LED panels. Adjustable precision alignment mechanisms of the present invention are mounted on the modular frames and are pre-adjusted on an external alignment fixture in order to provide for a close tolerance single modular frame alignment prior to the vertical and/or horizontal adjacent positioning of multiple modular frames. Communication of components of the pre-aligned precision alignment mechanisms provide for a true and regular alignment of the modular frames and correspondingly of the LED display panels known in the art which display panels can be secured to the aligned modular frames to collectively form an electronic sign.
2. Description of the Prior Art
The problem with assembling electronic LED displays, especially transportable displays, is that the seams between the LED panels of the vertically and horizontally adjacent LED modular support frames are noticeably visible unless extraordinary procedures or concepts are implemented. The manufacturing process can only be expected to achieve a given tolerance fitting level whereby geometric uneveness will result in undesirable, uneven or unequal gaps between the LED display panels resulting in a poor visual quality. One prior art alignment method involved the placing of shims in between support frame members to consequently provide for an aligned LED display panel spacing, but shims are difficult to place and are labor intensive. Another alignment method involved shifting the LED display panel on the face of a support frame. The display panels have a very limited distance that they can be shifted and such adjustment is very labor intensive. Another method involved the use of field adjustable screws so that an LED display panel could be built in the field and then modified to remove any seams. This also is very time consuming and labor intensive and is not repeatable from setup-to-setup since the locations of various display elements may be different at different venues.
The present invention provides a way for a predetermined, uniformly, dimensioned spacing about a modular frame, thereby providing a precise uniform geometry and a precise uniform dimensioning for each of a plurality of modular frames so that very accurate and precise sign displays can be created without any visible seams. Precision alignment mechanisms of the present invention located on a suitable modular frame are factory set using an alignment fixture of the present invention and require no field adjustment.
SUMMARY OF THE INVENTION
The general purpose of the present invention is to provide a precision alignment system to facilitate the alignment of modular frames for an electronic sign including the use of multiple precision alignment mechanisms and an alignment fixture. According to one or more embodiments of the present invention, there is provided a precision alignment system having a plurality of adjustable precision alignment mechanisms and an alignment fixture for use with the modular frames of an electronic sign. In the use of the present invention, the precision alignment mechanisms are distributed and secured about the modular frames, each modular frame of which can be incorporated into the formation of an electronic sign. Each modular frame can provide a support for one or more LED display modules and associated components known in the art. Modular frames and LED modules mounted thereupon can be situated in intimate vertical and horizontal alignment in order to collectively form an electronic sign. In addition to the plurality of precision alignment mechanisms of the present invention, there is also provided an alignment fixture having components which aligningly communicate during an alignment process with the modular frame mounted precision alignment mechanisms prior to use in association with an electronic sign.
One significant aspect and feature of the present invention is a precision alignment system for modular frames which system can be used in an electronic sign for providing precise uniformity when used in association with a plurality of other like modular frames.
Another significant aspect and feature of the present invention is the use of a plurality of precision alignment mechanisms which can be secured to the periphery of an electronic sign frame.
Still another significant aspect and feature of the present invention is the use of precision alignment mechanisms which are readily adjustable and alignable.
Still another significant aspect and feature of the present invention is the use of precision alignment mechanisms each having a housing, a contact block which is positionable within a cavity of the housing, a spring residing in the cavity of the housing which interacts with the contact block, and fasteners extending through the housing and the contact block for locking the position of the contact block.
Another significant aspect and feature of the present invention is the use of contact blocks which extend beyond the outer surfaces of a modular frame to contact other contact blocks which also extend beyond the outer surfaces of other similar modular frames.
Another significant aspect and feature of the present invention is the use of an alignment fixture having multiple alignment apparatuses in the form of jig towers which interface precisely with the contact blocks of the multiple precision alignment mechanisms.
Another significant aspect and feature of the present invention is a precision alignment system for modular frames of an electronic sign which system is easily and quickly used.
Having thus briefly described one or more embodiments of the present invention, and having mentioned some significant aspects and features of the present invention, it is the principal object of the present invention to provide a precision alignment system for modular frames for use with an electronic sign including precision alignment mechanisms and an alignment fixture.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 is an isometric view of a precision alignment system for use with modular frames of an electronic sign which system comprises major components or assemblies including a plurality of precision alignment mechanisms and an alignment fixture, the present invention;
FIG. 2 is a rear view showing the location of the precision alignment mechanisms in the top panel, the side panels, and the bottom panel of a modular frame;
FIG. 3 is a front view of the modular frame having aligned contact blocks which extend through and beyond the rectangular holes in the top panel, the side panels, and the bottom panel of the modular frame;
FIG. 4 and FIG. 5 are exploded isometric views showing opposing sides of components comprising one or more of the precision alignment mechanisms;
FIG. 6 is an isometric assembled view of one or more of the precision alignment mechanisms;
FIG. 7 is a cross section view of the housing and of the locking fasteners, but not of the contact block and the spring 48 of one or more of the precision alignment mechanisms along line 7-7 of FIG. 6;
FIG. 8 is an end view of one or more of the assembled precision alignment mechanisms;
FIG. 9 is a cutaway partial cross section rear view showing the location of several precision alignment mechanisms;
FIG. 10 is an exploded view of one or more of the plurality of jig towers;
FIG. 11 is an assembled view of the components of FIG. 10;
FIGS. 12, 13 and 14 Illustrate, in part, the mode of operation of the present invention;
FIG. 15 illustrates the use of the precision alignment system with a modular frame where the jig towers contact the precision alignment mechanisms mounted in the modular frame;
FIG. 16 shows an example showing the mating of stacked upper and lower modular frames using the precision alignment mechanism of an upper modular frame and the precision alignment mechanism of a lower modular frame; and,
FIG. 17 is a front view of an assembled example showing the mating of multiple horizontally and vertically adjacent modular frames using the precision alignment mechanisms of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an isometric view of a precision alignment system 10 for use with modular frames of an electronic sign which system comprises major components or assemblies including a plurality of precision alignment mechanisms 12a-12n and an alignment fixture 14. For the purpose of illustration and demonstration, the precision alignment mechanisms 12a-12n are shown outside of the modular frame 16 but, when used, are mounted to the inside of the modular frame 16, as shown in FIG. 2 and in other figures. The precision alignment mechanisms 12a-12n, some of which are shown in exploded view, and the alignment fixture 14 are shown in use with a representative modular frame 16 for the purpose of demonstration and illustration of the present invention.
The representative modular frame 16, which could be one of a number of modular frames which are positionable and which are consistent within the art, includes at least a top panel 18a, opposed side panels 18b and 18c, a bottom panel 18d, a rear panel 20 having multiple cutouts extending between the top panel 18a, side panels 18b and 18c, and the bottom panel 18d, and a front panel 22 which can be a double wall panel having multiple cutouts extending between the top panel 18a, side panels 18b and 18c, and the bottom panel 18d. A mounting hole 24d, one of a plurality of mounting holes 24a-24p, is shown in one corner of the front panel 22. The plurality of mounting holes 24a-24p is illustrated in FIG. 3 and which holes are located at the corners and at other locations of the front panel 22. The plurality of mounting holes 24a-24p is used for engagement of alignment pins extending rearwardly from a plurality of LED display modules. Mounting holes 24a, 24d, 24m and 24p are used during an alignment process to align the modular frame 16 to the pins 32 of standoffs 30a-30n in the alignment fixture, as described later in detail. Other components of the modular frame 16 can include other alignment structure (such as also shown in FIG. 2) such as vertical alignment posts 36 and 38 extending from the top panel 18a which posts align, but not in a precise fashion, to alignment holes 40 and 42 in the bottom panel 18d of another modular frame 16.
The alignment fixture 14, shown in FIG. 1, includes a sturdy base 26 and can include support legs 28. The plurality of precisely located standoffs 30a-30n, each having a round pin 32 extending from the top and along the centerline of the standoffs 30a-30n, is secured by suitable hardware to the upper side of the base 26. Preferably, the standoffs 30a-30d and pins 32 are centered near the apexes of an imaginary square 31 and register with the mounting holes 24a, 24d, 24m and 24p of the front panel 22 in order to align the edges of the top panel 18a, the side panels 18b and 18c, and the bottom panel 18d of the modular frame 16 with the imaginary square 31, but can be located in other configurations to register the with front panel mounting holes arranged in other geometric configurations in other modular frames. A support 33 is centrally located on the base 26. A plurality of precisely located alignment apparatuses in the form of jig towers 34a-34n is secured by suitable hardware to the upper side of the base 26 at locations uniformly spaced outside of, but in close proximity to, the imaginary square 31. Components of the jig towers 34a-34n interface precisely with components of the precision alignment mechanisms 12a-12n, the latter of which are mounted in the representative modular frame 16.
FIG. 2 is a rear view showing the use and location of the precision alignment mechanisms 12a-12n in the top panel 18a, the side panels 18b and 18c, and the bottom panel 18d of a modular frame 16. More precisely, the locations of the precision alignment mechanisms 12a and 12b are shown in the top panel 18a, the locations of the precision alignment mechanisms 12c and 12d are shown in the side panels 18b and 18c, respectively, and the locations of the precision alignment mechanisms 12e and 12n are shown in the bottom panel 18d. When the precision alignment mechanisms 12a-12n are used with multiple modular frames 16 in both vertically and horizontally aligned arrangements, precision alignment mechanisms 12a-12n of one modular frame align to other precision alignment mechanisms 12a-12n of adjacent modular frames 16. For purposes of example and demonstration, and with reference to the vertical stacking of modular frames 16, the precision alignment mechanisms 12a and 12b in the top panel 18a of a bottom modular frame 16 would align with the precision alignment mechanisms 12e and 12n, respectively, in the bottom panel 18d of a top modular frame 16. Such an alignment is shown in FIG. 17. In addition, other nonprecision alignment components of the frame 16, which are used for general alignment of successive vertically aligned frames 16, are shown including tapered alignment posts 36 and 38 extending from the top panel 18a and alignment holes 40 and 42 located in the bottom panel 18d. Transverse panels 41 and 43 are also shown extending between the top panel 18a and the bottom panel 18d. Other components are shown which can be used for securing to horizontally adjacent modular frames 16, including a latch/catch mechanism 44 located in close proximity to the side panel 18c for engagement with a latch/catch 45 mechanism (FIG. 1) located in close proximity to the side panel 18b. A latch/catch mechanism 47 is located near the bottom panel 18d and another latch/catch mechanism 49 is located near the top panel 18a (FIG. 3) and are operated by a handle 51 and associated mechanism to secure the bottom panel 18d of an upper modular frame 16 to the top panel 18a of a lower modular frame 16.
FIG. 3 is a front view of the modular frame 16 having aligned contact blocks 50 which extend through and beyond the rectangular holes 110a-110n (shown in FIGS. 1 and 2) in the top panel 18a, the side panels 18b and 18c, and the bottom panel 18d of the frame 16. This illustrative example showing the use of the present invention with the representative modular frame 16 illustrates a frame which, in this case, is a square frame 16. In the alternative, other shaped modular frames, such as rectangular shaped modular frames, could also be used with the present invention after the relocation of several components of the present invention.
FIG. 4 and FIG. 5 are exploded isometric views showing opposing sides of components comprising one or more of the precision alignment mechanisms 12a-12n. The individual components of the precision alignment mechanisms 12a-12n include a geometrically configured housing 46, a spring 48, a contact block 50, and locking fasteners 52, preferably in the form of a cap screw. The housing 46, preferably of aluminum or other material which is malleable and/or slightly flexible, includes a centrally located generally rectangular shaped cavity 54. Opposed side walls 56 and 58 connecting opposed end walls 60 and 62, a rear wall 64 connected to the side walls 56 and 58 and the end walls 60 and 62 form the cavity 54. Fastener body holes 66, including a recess for accommodation of a fastener head, extend through the sidewall 56. Threaded holes 68 in the sidewall 58 oppose the body holes 66 in the side wall 56 for accommodating the threads of the locking fasteners 52. Mounting holes 70 are located at the corners of the junctions of the sidewalls 56 and 58 with the end walls 60 and 62, respectively, of the housing 46. Bevels 72 and 74 at the ends of the housing 46 truncate the cavity 54 and are included to minimize interference with any other components which may be associated with the modular frames 16 of an LED display structure and to allow access into the cavity 54 in order to insert the spring 48 therein. The one-piece spring 48, which aligns within the cavity 54 of the housing 46 and against an inner contact surface 88 of the contact block 50, includes an arcuate section 76 having opposed planar ends 78 and 80 extending at an angle therefrom. The intersection of the planar end 78 with the arcuate section 76 forms a contact edge 82 and the intersection of the planar end 80 with the arcuate section 76 forms a contact edge 84. The contact edges 82 and 84 slidingly contact the inner contact surface 88 of the contact block 50. The one-piece contact block 50, which aligns within a greater portion of the cavity 54 in the housing 46, is substantially rectangular in shape having intersecting surfaces including an outer contact surface 86, an inner contact surface 88 opposing the outer contact surface 86, a side surface 90 and an opposing side surface 92, and an end surface 94 and an opposing end surface 96. Spacer pads 98 and 100 extend outwardly from the side surface 90 of the contact block 50 and spacer pads 102 and 104 extend outwardly from the side surface 92 of the contact block 50. The spacer pads 98-104 provide for spacing between the side surfaces 90 and 92 of the contact block 50 with the inwardly facing surfaces of the side walls 56 and 58 of the cavity 54 and for slideable or fixed surface contact between the inwardly facing surfaces of the side walls 56 and 58. An elongated hole 106 extends through the spacer pad 98, the main body of the contact block 50, and through the spacer pad 102. Another elongated hole 108 extends through the spacer pad 100, the main body of the contact block 50, and through the spacer pad 104. The locking fasteners 52 extend through the body holes 66, the spacer pads 98 and 100, elongated holes 106 and 108, the spacer pads 102 and 104, and into the threaded holes 68, respectively, whereby the contact block 50 can be slideably and adjustably captured within the cavity 54 of the housing 46, as shown in FIG. 7. The spring 48 is located between the inner contact surface 88 of the contact block 50 and the rear wall 64 of the housing 46 to maintain an outward loaded force on the contract block 50. The spring 48 can be loaded prior to or subsequent to placement of the contact block 50 within the cavity 54.
FIG. 6 is an isometric assembled view of one or more of the precision alignment mechanisms 12a-12n, and FIG. 7 is a cross section view of the housing 46 and of the locking fasteners 52, but not of the contact block 50 and the spring 48 of one or more of the precision alignment mechanisms 12a-12n along line 7-7 of FIG. 6. In each figure, a portion of the contact block 50, i.e., the outer contact surface 86, is shown adjustably extended and positionally fixed beyond the inner edges of the side walls 56 and 58 and the end walls 60 and 62 of the housing 46. FIG. 7 also shows the alignment of the spring 48 and the contact block 50 within the cavity 54 of the housing 46. The arcuate section 76 of the spring 48 intimately contacts the rear wall 64 of the cavity 54 of the housing 46. The contact edges 82 and 84 of the spring 48 intimately and slidingly contact the inner contact surface 88 of the contact block 50. The spring 48 always exerts and maintains pressure between the inner contact surface 88 of the contact block 50 and the rear wall 64 of the cavity 54, whereby the contact block 50 is spring loaded outwardly. During alignment, the contact blocks 50 are laterally positionable outwardly or inwardly against the spring force of the spring 48 within the cavities 54 of the housings 46 along a path defined and limited by the relationship of the locking fasteners 52 within the elongated holes 106 and 108 of the contact blocks 50 until secured by the locking fasteners 52. The precision alignment mechanisms 12a-12n are aligned by using the jig towers 34a-34n of the alignment fixture 14, as later described in detail. Any position of the spring loaded contact block 50 within the cavities 54 can be fixed by tightening the locking fasteners 52 once alignment is achieved. The locking fasteners 52 are tightened sufficiently to cause flexing of the side walls 56 and 58 inwardly to frictionally engage and fix the position of the spacer pads 98-104 of the contact block 50.
FIG. 8 is an end view of one or more of the assembled precision alignment mechanisms 12a-12n showing the alignment and clearance of the side surfaces 90 and 92 of the contact block 50 within the cavity 54 of the housing 46 as provided for by the use of the spacer pads 98-104. Engagement of the spacer pads 98-104 with the inner surfaces of the side walls 56 and 58 is also shown. Alignment of the locking fasteners 52 is also shown.
FIG. 9 is a cutaway, partial cross section, rear view of a modular frame 16 showing the locations of several precision alignment mechanisms 12a-12n. Shown in particular are precision alignment mechanisms 12a, 12b, 12c, 12e and 12n secured to the top panel 18a and the bottom panel 18d, respectively, such as by the use of rivets, machine screws or other suitable fastening means which secure through the top panel 18a, the side panel 18b, and the bottom panel 18d, respectively, to engage the mounting holes 70 in the respective precision alignment mechanisms 12a-12n. Also shown are rectangular holes 110e and 110n of a plurality of rectangular holes 110a-110n (not all of which are shown) distributed along the top panel 18a, the side panels 18b and 18c, and the bottom panel 18d to which the precision alignment mechanisms 12a-12n align in order to allow for protrusion of the contact blocks 50 through and beyond the top panel 18a, the side panels 18b and 18c, and the bottom panel 18d.
FIG. 10 is an exploded view of one or more of the plurality of jig towers 34a-34n which are secured to the base 26 of the alignment fixture 14. The jig towers 34a-34n are generally comprised of two larger components including a geometrically configured housing 112 and a geometrically configured positionable alignment tool 114, the latter of which aligns within the housing 112 and is operated therewithin to provide for interaction with the contact blocks 50 of the precision alignment mechanisms 12a-12n, as described later in detail. FIG. 11 is an assembled view of the components of FIG. 10. The housing 112 includes a centrally located slot 116 which is open on two sides and extends along the major length of the housing 112. The slot 116 delineates panels 118 and 120 and extends along nearly the major height of the housing 112. The panel 118 includes a geometrically configured major guide track 122 extending therethrough and opening into the slot 116. The major guide track 122 is comprised of and includes connected and continuous sections having a disengage section 124, a transition section 126, and an engage and lock section 128. The opposing panel 120, which substantially mirrors and aligns distantly to the panel 118, is also comprised of and includes like features including a geometrically configured major guide track 122a extending therethrough and opening into the slot 116. The major guide track 122a is comprised of and includes connected and continuous sections having a disengage section 124a, a transition section 126a, and an engage and lock section 128a. The panel 118 also includes a geometrically configured minor guide track 130 extending therethrough and opening into the slot 116. The minor guide track 130 is comprised of and includes connected and continuous sections having a transition section 132 and an engage and lock section 134. The opposing panel 120, which substantially mirrors and aligns distantly to the panel 118, is also comprised of and includes like features including a geometrically configured minor guide track 130a extending therethrough and opening into the slot 116. The minor guide track 130a is comprised of and includes connected and continuous sections having a transition section 132a and an engage and lock section 134a. The engage and lock sections 128, 128a, 134 and 134a have a parallel relationship to the front panel surfaces 118a and 120a, respectively, of the panels 118 and 120. The transition sections 132 and 132a and the transition sections 126 and 126a have an angular relationship to the front panel surfaces 118a and 120a, respectively, of the panels 118 and 120. The disengage sections 124 and 124a have an angular relationship to the front panel surfaces 118a and 120a, respectively, of the panels 118 and 120. The major guide tracks 122 and 122a, the minor guide tracks 130 and 130a, and the associated sections involved therewith provide for controlling, positioning, maneuvering and locking the of the positionable alignment tools 114, as later described in detail. The positionable alignment tool 114 is directly associated with the housing 112 and is accommodated by the slot 116 of the housing 112 for positioning therein. The positionable alignment tool 114 includes a bar 136 having a contact surface 138 which is planar and which is located at one edge of the bar 136, a handle 140 in the form of a dowel or pin at one end of the bar 136 extends through the sides 142 and 144 at the upper region of the bar 136, a pin 146 passing through a mid-location of the bar 136 and extending beyond the sides 142 and 144 of the bar 136, and another pin 148 passing through the lower region of the bar 136 and extending beyond the sides 142 and 144 of the bar 136. The positionable alignment tool 114 is accommodated by the slot 116 of the housing 112, whereby the pin 146 aligns in the opposed major guide tracks 122 and 122a and the pin 148 aligns in the opposed minor guide tracks 130 and 130a.
Mode of Operation
FIGS. 12, 13 and 14 illustrate, in part, the mode of operation of the present invention where one of the jig towers 34b is shown in alignment with one of the precision alignment mechanisms 12b mounted to the top panel 18a of a modular frame 16 of an electronic sign and the mechanical relationship involved therein. Operation of the jig towers 34a-34n and the precision alignment mechanisms 12a-12n are similar to the mode described herein and only a portion of the invention components and the relationship to part of the modular frame 16 are shown. The modular frame 16 with the precision alignment mechanisms 12a-12n secured thereto is first aligned face down to the alignment fixture 14. More precisely, the mounting holes 24a in the front panel 22 of the modular frame 16 aligns over and about the pin 32 of the standoff 30a, the mounting hole 24d aligns to the pin 32 of the standoff 30b, the mounting hole 24m aligns to the pin 32 of the standoff 30c, and the mounting hole 24p aligns to the pin 32 of the standoff 30n, and preferably, are held in place by gravity on the upper surface of each of the annular standoffs 30a-30n, respectively, whereby the modular frame 16 and the mounted precision alignment mechanisms 12a-12n are located and positionally fixed for interaction with the jig towers 34a-34n of the alignment fixture 14, as now described.
As shown in FIG. 12, the precision alignment mechanism 12b is in alignment with and in close proximity to the jig tower 34b in order that the contact surface 138 of the positionable alignment tool 114 can be positioned to come into intimate contact with the outer contact surface 86 of the contact block 50 in the precision alignment mechanism 12b. All of the positionable alignment tools 114 of all the jig towers 34a-34n are positioned in the disengaged position, as shown, in order that the modular frame 16 with the precision alignment mechanisms 12a-12n can be placed without interference on the pins 32 of the standoffs 30a-30n, as previously described. In the disengaged position, the pin 146 of the positionable alignment tool 114 is assisted by gravity and is aligned at rest in the innermost low end of the disengage sections 124 and 124a of the major guide track 122 and 122a, respectively, and the pin 148 of the positionable alignment tool 114 is aligned in the upper region of the transition sections 132 and 132a of the minor guide track 130 and 130a, respectively. Thus, the lower region of the bar 136 of the positionable alignment tool 114 remains within the confines of the slot 116 of the housing 112 and does not extend beyond the plane formed by the front panel surfaces 118a and 120a of the housing 112 in a position of non-interference with respect to the contact block 50, which is spring loaded in an outward direction from the precision alignment mechanism 12b.
As shown in FIG. 13, the handle 140 of the positionable alignment tool 114 is manually actuated simultaneously to the right and in a downward directed motion as partially assisted by gravity to cause the contact surface 138 of the bar 136 to extend beyond the plane formed by the front panel surfaces 118a and 120a of the housing 112 to intimately and uniformly contact the outer contact surface 86 of the contact block 50 in the precision adjustment mechanism 12b. During such transition actuation, the pin 146 of the positionable alignment tool 114 is moved from the disengaged position, shown in FIG. 12, and thence along the transition sections 126 and 126a of the major guide tracks 122 and 122a, respectively, and the pin 148 of the positionable alignment tool 114 is moved along the transition section 132 and 132a of the minor guide tracks 130 and 130a, respectively. Thus, the contact surface 138 at the lower region of the bar 136 on the positionable alignment tool 114 is positioned beyond the confines of the slot 116 of the housing 112 and extends beyond the plane formed by the front panel surfaces 118a and 120a of the housing 112 to intimately engage the outer contact surface 86 of the spring loaded block 50 located in the precision alignment mechanism 12b. Further, downward actuation of the handle 140 causes the pin 146 and the pin 148 to move along the transition sections 126 and 126a, respectively, and the transition sections 132 and 132, respectively, and then to progressively and slidingly urge the contact surface 138 along and with increasing pressure against the contact surface 86 of the contact block 50. During this action, the elongated holes 106 and 108 of the contact block 50 guide the contact block 50 along the central portion of the horizontally oriented locking fasteners 52 until reaching an aligned mid-position, such as shown in FIG. 14. Also during this action, the spring 48 offers resistance and is partially compressed and loaded and still maintains a spring force against the positionable alignment tool 114. Subsequently, the pins 146 and 148 enter the engage and lock sections 128 and 128a and the engage and lock sections 134 and 134a, respectively, as shown and described with reference to FIG. 14.
As shown in FIG. 14, the handle 140 of the positionable alignment tool 114 is fully moved in a downwardly directed motion, as partially assisted by gravity, in order to fully position the pin 146 into the engage and lock sections 128 and 128a and to fully position the pin 148 into the engage and lock sections 134 and 134a. Upon entry of the pins 146 and 148 into the engage and lock sections 128 and 128a and into the engage and lock sections 134 and 134a, respectively, tension by the spring 54 against the contact block 50 is established at a constant force and is maintained as the positionable alignment tool 114 is urged downwardly along therein and into the lowermost position of the engage and lock sections 128 and 128a and 134 and 134a. The engage and lock section 128 and the engage and lock section 134 in the panel 118 are each parallel to and at a uniform predetermined distance from the front panel surface 118a of the housing 112 and correspondingly and in an opposed mirror-like image, the engage and lock section 128a and the engage and lock section 134a in the panel 120 are each parallel to and at the same uniform predetermined distance from the front panel surface 120a of the housing 112. For example, the engage and lock sections 128 and 128a and 134 and 134a are similarly sized, configured, oriented and arranged in order to provide for motion of the pins 146 and 148 and thus of the positionable alignment tool 114 uniformly with respect to a plane associated along corresponding features of the engage and lock sections 128 and 128a and 134 and 134a. Furthermore, the vertical axis of each of the engage and lock sections 128, 128a, 134 and 134a is in perpendicular alignment to the base 26 of the alignment fixture 14 and each of the bases 26 is aligned at a common distance from a reference, such as, but not limited to, the imaginary square 31 shown in FIG. 1. When the positionable alignment tools 114 are positioned along the engage and lock sections 128, 128a, 134 and 134a, the contact surfaces 138 of the positionable alignment tools 114 are also in perpendicular alignment to the base 26 which is common to each of the precision alignment mechanisms 12a-12n. The alignment relationship of the contact faces 86 of the contact blocks 50 against the perpendicularly oriented contact surfaces 138 of the positionable alignment tools 114 provides a plurality of contact surfaces 138 extending slightly beyond the surfaces of the top panel 18, the side panels 18a-18b, and the bottom panel 18d, respectively, and requires only the locking of the contact blocks 50 in jigged vertically aligned orientation by the tightening of the locking fasteners 52 to secure the contact blocks 50 within the cavities 54 of each of the housings 46 located in the precision alignment mechanisms 12a-12n. Tightening of the locking fasteners 52 slightly deforms the side walls 56 and 58 such that the inner surfaces of the side walls 56 and 58 are drawn against the outwardly facing surfaces of the closely spaced spacer pads 98-104, respectively, to frictionally engage and to positionally fix the position of the perpendicularly aligned contact blocks 50 within the cavities 54.
FIG. 15 illustrates the use of the precision alignment system 10 with a modular frame 16 where components of the jig towers 34a-34n contact the precision alignment mechanisms 12a-12n mounted in the modular frame 16. The positionable alignment tools 114 are shown in the engage and lock mode. Subsequent to tightening of the locking fasteners 52 to fix the vertical alignment of the contact blocks 50 in each of the precision alignment mechanisms 12a-12n, the positionable alignment tools 114 can be retractingly repositioned from the engage and lock sections 128 and 128a of the jig towers 34a-34n to the disengage sections 124 and 124a of the jig towers 34a-34n, thereby discontinuing intimate contact of the contact surfaces 138 of the positionable alignment tools 114 with the outer contact surface 86 of the contact blocks 50 in order to remove the modular frame 16 from the alignment fixture 14. The modular frame 16, having the aligned and positionally fixed contact blocks 50, can then be used with other similarly constructed and similarly aligned and positionally fixed contact blocks 50, as shown in FIGS. 16 and 17.
FIG. 16 shows an example mating of stacked upper and lower modular frames 16 using the precision alignment mechanism 12n of an upper frame 16 and the precision alignment mechanism 12b of a lower frame 16 subsequent to the alignment by use of the respective jig towers 34a-34n and associated components thereof. The outer contact surface 86 of the contact block 50 (precision alignment mechanism 12n) used in the upper modular frame 16 is shown in intimate contact with the outer contact surface 86 of the contact block 50 (precision alignment mechanism 12b) used in the lower modular frame 16. A space 150 is shown generally located and extending between the bottom panel 18d and the top panel 18a of the upper and lower modular frames 16, respectively. The space 150 can be constant or can be unequal or irregular within the limits of formation. The horizontally aligned space 150 extends along the depth and width of the modular frames 16 in accordance with acceptable nonprecision manufacturing tolerance therebetween as the modular frames 16 are not fashioned according to precision standards, but are fashioned within nonprecision tolerances suitable for general alignment without mutual interference. A vertically aligned space 152 (FIG. 17) corresponding to the horizontally aligned space 150 is generally located between the side panel 18b and the side panel 18c of horizontally adjacent modular frames 16, respectively. The vertically aligned space 152 can be constant or can be unequal or irregular. The vertically aligned space 152 extends along the depth and height of the modular frames 16. The precision alignment of multiple modular frames 16 is provided by the mating of the precisely aligned and oriented multiple contact blocks 50 of the invention. The multiple contact blocks 50 only are used for the precise and close tolerance mating between adjacent horizontally and vertically situated and aligned modular frames 16 and none of the top panels 18a, side panels 18b and 18c or bottom panels 18d are in contact with each other, but are aligned across the spaces 150 and 152.
FIG. 17 is a front view showing the mating of multiple, horizontally and vertically, adjacently stacked modular frames 16, herein identified as modular frames 16a, 16b, 16c and 16d, using the precision alignment mechanisms 12a-12n of the present invention subsequent to the alignment by using the respective jig towers 34a-34n and associated components thereof. The previously described spaces 150 and 152 are shown which are generally horizontally or vertically oriented, respectively, and are not contactingly involved with the precision mating of the multiple, horizontally and vertically, adjacently positioned modular frames 16. Common outer precise dimensions, as measured with reference to the outer contact surfaces 86 along the height and length of the modular frames 16, are beneficial to the alignment of modular frames 16a-16d. For example, with respect to modular frame 16a, a common dimension 154a, as measured between the outer contact surface 86 of the precision alignment mechanism 12c and the contact surface 86 of the precision alignment mechanism 12d, is the same as the corresponding dimensions 154b, 154c and 154d with respect to modular frames 16b, 16c and 16d. Provided that the modular frames 16a-16d are configured as perfect squares, the same and common dimension 154e, as measured between the outer contact surface 86 of the precision alignment mechanism 12a and the contact surface 86 of the precision alignment mechanism 12e, is the same as the dimensions 154f, 154g and 154h with respect to modular frames 16b, 16c and 16d, respectively. Then, in this example, the dimensions 154a, 154b, 154c and 154d are the same as dimensions 154e, 154f, 154g and 154h and the alignment of modular frames 16a-16d results in a combined frame structure also being perfectly square. The use of rectangular shaped modular frames would, of course, have other dimensional qualities and aspects.
Various modifications can be made to the present invention without departing from the apparent scope thereof.
PRECISION ALIGNMENT SYSTEM
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PARTS LIST
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10
precision alignment system
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12a-n
precision alignment mechanism
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14
alignment fixture
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16
modular frame
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16a-d
modular frames
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18a
top panel
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18b-c
side panels
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18d
bottom panel
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20
rear panel
|
22
front panel
|
24a-p
mounting holes
|
26
base
|
28
legs
|
30a-n
standoffs
|
31
imaginary square
|
32
pin
|
33
center support
|
34a-n
jig tower
|
36
alignment post
|
38
alignment post
|
40
alignment hole
|
41
transverse panel
|
42
alignment hole
|
43
transverse panel
|
44
latch/catch mechanism
|
45
latch/catch mechanism
|
46
housing
|
47
latch/catch mechanism
|
48
spring
|
49
latch/catch mechanism
|
50
contact block
|
51
handle
|
52
locking fasteners
|
54
cavity
|
56
side wall
|
58
side wall
|
60
end wall
|
62
end wall
|
64
rear wall
|
66
body holes
|
68
threaded holes
|
70
mounting holes
|
72
bevel
|
74
bevel
|
76
arcuate section
|
78
planar end
|
80
planar end
|
82
contact edge
|
84
contact edge
|
86
outer contact surface
|
88
inner contact surface
|
90
side surface
|
92
side surface
|
94
end surface
|
96
end surface
|
98
spacer pad
|
100
spacer pad
|
102
spacer pad
|
104
spacer pad
|
106
elongated hole
|
108
elongated hole
|
110a-n
rectangular holes
|
112
housing
|
114
positionable alignment tool
|
116
slot
|
118
panel
|
118a
front panel surface
|
120
panel
|
120a
front panel surface
|
122
major guide track
|
122a
major guide track
|
124
disengage section
|
124a
disengage section
|
126
transition section
|
126a
transition section
|
128
engage and lock section
|
128a
engage and lock section
|
130
minor guide track
|
130a
minor guide track
|
132
transition section
|
132a
transition section
|
134
engage and lock section
|
134a
engage and lock section
|
136
bar
|
138
contact surface
|
140
handle
|
142
side
|
144
side
|
146
pin
|
148
pin
|
150
space
|
152
space
|
154a-d
dimensions
|
|
Patent Grant
8194385
