Note: Descriptions are shown in the official language in which they were submitted.
CA 02408583 2002-10-17
CONSOLE WITH POSITIONALLY INDEPENDENT
UPPER AND LOWER HALVES
FIELD OF THE INVENTION
The present invention relates to a framework for supporting pieces of work
station equipment, and more particularly to a console structure for supporting
electronic equipment in the nature of computers, video monitors, control
panels and
the like.
BACKGROUND OF THE INVENTION
Control consoles of the type described herein generally include a framework
for receiving and supporting the necessary pieces of electronic and support
equipment including terminals, monitors, keyboards, switch panels, telephone
turrets,
lighting and so forth, and a planar work surface extending outwardly from the
framework at a convenient height. Some of the equipment including video
monitors
and output displays is supported to be visible above the work surface for
convenient
viewing and user access. Attractive finishing panels are also usually
supported by
the basic framework.
To date, many work station consoles have been custom manufactured which
in terms of design and construction is both expensive and time consuming. This
approach has been necessitated by customer requirements that are often unique
in
terms of work station size, equipment placement, human engineering and cost
considerations. In the result, the completed console structures are not only
extremely
expensive, but are also difficult if not impossible to subsequently modify for
the
reconfiguration of existing equipment or to retrofit new equipment. An
alternative
approach has been to assemble the consoles from fixed size modular sections.
This
approach can reduce costs, and although there may be some loss of flexibility
with
respect to subsequent modifications and reconfigurations of equipment within
the
console, there are simply many instances in which the cost savings outweigh
the
advantages of a system critically engineered to permit unlimited post-
installation
reconfiguration. Some flexibility must however remain.
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CA 02408583 2005-10-25
A need therefore exists for a console structure which overcomes the problems
inherent in either the custom design and manufacture or completely modular
assembly of console structures. One such approach has been developed by the
Applicant and is described in Canadian Patent 1,291,518 issued October 29,
1991
(equivalent to U.S. Patent 4,836,625).
The backbone of the console structure shown in the aforementioned patents
are the horizontally spaced, vertically upright gable members 1. The gables
are
interconnected by stringers 2 to provide a rigid framework for the console
structure.
The spacing between gables is infinitely variable so that the framework as a
whole
is easily adapted to custom requirements both before and after initial on-site
assembly. Because most of the equipment in the console is supported by or
suspended from the interconnecting stringers, changing the distance between
gables
is not in and of itself all that disruptive of the system as a whole and
particularly the
equipment mounting hardware, and this lends the overall structure enormous
flexibility. This flexibility comes however at a cost. The gables are metal
fabricated
usually from tubular steel and are therefore relatively expensive to
manufacture and
store. The stringers are typically aluminum extrusions and are therefore
relatively
inexpensive linear stock easily stored, but significant numbers of different
stringers
of different shapes and configurations depending upon function are required
and an
idea of the number and types of stringers needed can be seen from Figures 3 to
9
of the patent. This therefore also adds to cost and the need for significant
inventory
control. The need for this number of stringers is made necessary in part
because the
gables, as aforesaid, are almost entirely structural in function and integrate
no
channels, interlocks or other mechanical means that increase their versatility
or allow
them to perform multiple tasks.
The Applicant has found that although there will continue to be a strong
demand for the flexibility and retrofit capabilities of its customized
consoles, and for
modular "discreet logic" systems that cost less, many customers now demand
both
flexability and lower cost. To achieve these objects, it is increasingly
desirable to
further reduce the number of components making up the console framework but in
a way that the remaining components are analogous to building blocks that can
be
configured, assembled together and reconfigured for maximum design flexibility
and
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CA 02408583 2002-10-17
adaptability. Taking this a step further, one way to reduce product cost is to
reduce
the cost of sales. Particularly in respect of customized product, an intense
collaboration is normally required between the customer and the manufacturer,
the
customer and the sales agent or all three to conceive, design and implement
the final
system. This is an extremely expensive process. However, by applying
relatively few
easily understood and manipulated standard elements, the dealer and/or client
can
achieve near instantaneous design capabilities. Moreover, it is contemplated
that
customers and/or dealers will be given on-line access to a computer
implemented
layout and quoting system that is expected to significantly decrease the time
and cost
to configure the consoles to the customer's requirements, transmit the order
to the
factory and deliver the system to the client for assembly.
SUMMARY OF THE INVENTION
The Applicant has therefore developed a console system which is flexible
enough to meet the demands of a custom environment, but wherein the number of
components in the system is significantly reduced for cost savings. Many of
the
remaining components "multi-task", assembly is made easier and less costly,
and
structural integrity is maintained.
The underlying concept of the present console system is that by dividing the
console into positionally independent upper and lower halves, the level of
variability
and flexibility of configuration is substantially increased. This is achieved
through the
application of standard elements.
It is an object of the present invention therefore to provide a console
structure
comprising a relatively few basic components which can be easily assembled
into a
supporting framework for a wide variety of equipment pieces and shapes without
modifications to the basic components themselves.
It is a further object of the present invention to provide a console framework
providing as much unimpeded space therein as possible to maximize the
adaptability
of the framework for the mounting of different pieces of equipment at
different
locations, and the ability to meet custom requirements using the same basic
components.
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CA 02408583 2005-10-25
It is a further object of the present invention to provide a console framework
upper turret half of the console that is independently positionable relative
to the lower
base half of the console.
According to the present invention then there is provided a console structure
for supporting equipment thereon, comprising a lower base structure comprising
at
least one base module, each base module comprising two spaced apart frame
ends,
an upper stringer connected to and disposed between said frame ends and a
lower
stringer connected to and disposed between said frame ends to be substantially
parallel to and below said upper stringer, said at least one base module being
adapted for connection to another said base module for increasing the length
of said
console structure; an upper turret structure supported on said base structure
said
turret structure comprising two spaced apart upper frame ends, each upper
frame
end having an upper and a lower end and a beam member connected to and
disposed between said upper frame ends adjacent said upper ends thereof; said
turret structure being independently laterally positionable relative to said
base
structure wherein said lower end of each upper frame end is connectable to
said
upper stringer of said base module anywhere along the length of said upper
stringer
between said frame ends whereby said turret structure can be supported by a
single
said base module or by separate base modules connected end to end.
According to the present invention then there is further provided a method of
positioning a turret structure relative to one or more base structures, said
turret and
base structures forming part of an equipment console used to support pieces of
work
station equipment, comprising the steps of forming the turret and base
structures as
discrete modules, said base structure comprising at least one base module,
each
base module comprising two spaced apart frame ends, an upper stringer
connected
to and disposed between said frame ends and a lower stringer connected to and
disposed between said frame ends to be substantially parallel to and below
said
upper stringer, said at least one base module being adapted for connection to
another said base module for increasing the length of said console structure,
said
turret structure comprising two spaced apart upper frame ends, each upper
frame
end having an upper and a lower end and a beam member connected to and
disposed between said upper frame ends adjacent said upper ends thereof; and
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CA 02408583 2005-10-25
forming the turret structure to be connectable to said base structure at any
point
along the length of one of said base structures or straddling base structures
arranged
in end to end alignment with one another, wherein said lower end of each upper
frame end is connectable to said upper stringer of said base module anywhere
along
the length of said upper stringer between said frame ends whereby said turret
structure can be supported by a single said base module or by separate base
modules connected end to end.
According to the present invention then there is still further provided a
method
for the assembly of a framework for a console structure using discrete
modules,
comprising the steps of forming one or more base modules of a predetermined
length, height and depth, each said base module comprising two spaced apart
frame
ends, an upper stringer connected to and disposed between said frame ends and
a
lower stringer connected to and disposed between said frame ends to be
substantially parallel to and below said upper stringer, said at least one
base module
being adapted for connection to another said base module for increasing one or
both
of the length and depth of the said console structure; forming one or more
turret
modules of a predetermined length, height and depth each said one or more
turret
modules comprising two spaced apart upper frame ends, each upper frame end
having an upper and a lower end and a beam member connected to and disposed
between said upper frame ends adjacent said upper ends thereof; assembling
said
base modules into a console base of predetermined length, height and depth;
and
connecting said one or more turret modules anywhere along the length of said
base
modules, wherein said lower end of each upper frame end is connectable to said
upper stringer of said base module anywhere along the length of said upper
stringer
between said frame ends whereby said one or more turret modules can be
supported
by a single base module or by separate base modules connected end to end or
side
by side.
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CA 02408583 2005-10-25
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will now be described in
greater detail, and will be better understood when read in conjunction with
the
following drawings in which:
Figure 1 is a front perspective view of the structural framework of a full
depth
console in accordance with the present invention;
Figure 2 is a front perspective view of the console with finishing panels
applied
to the front rear and upper surfaces of the framework;
Figure 3 is a partially exploded perspective view of the console;
Figure 4 is a partially exploded rear perspective view of the console;
Figure 5 is a front perspective view of the console including some internal
fitments;
Figure 6 is a side elevational partially schematical view of the console;
Figure 7 is a perspective view of a lower frame end forming part of the
present
console;
Figure 8 is a front perspective view of a reduced depth framework for the
present console;
Figure 9 is a partially exploded rear perspective view of the reduced depth
console;
Figure 10 is a side elevational view of the reduced depth ventilation grill;
Figure 11 is a side elevational cross-sectional view of a beam forming part of
the turret structure of the present console;
Figure 12 is a rear perspective view of a full depth console including
finishing
panels thereon;
Figure 13 is a rear perspective view of a reduced depth console including
finishing panels thereon;
Figure 14 is a rear perspective view of a skirt finishing panel;
Figure 15 is a front perspective view of a ventilation grill for the full
depth
console;
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CA 02408583 2002-10-17
Figure 16 is a bottom perspective view of the full depth ventilation grill;
Figure 17 is a front perspective view of a reduced depth ventilation grill for
the
present console; and
Figure 18 is a bottom perspective view of the reduced depth ventilation grill.
DETAILED DESCRIPTION
In order to accommodate various types of equipment and user requirements,
the present invention is provided with a lower frame section and an upper
turret
section which are independently configurable relative to each other. The lower
frame
section can be configured to various lengths and depths to suit a user's
requirements.
Similarly, the upper turret section can also be configured to various lengths
depending on the equipment and user requirements. Further, the length of the
upper
turret section is independent from the length of the lower frame section, and
an upper
turret section may span multiple lower frame sections, or a lower frame
section may
accommodate multiple upper turret sections.
The above flexibility is best illustrated with reference to the drawings.
Figure 1 shows the internal components for a full depth console in accordance
with the present invention. This console includes various structural
subassemblies,
including a base module 10, a turret 40 and a work surface 60. Each of these
components is described in detail below.
One of the objects of the present invention is to provide a modular system in
which the base is independent from the upper turret sections. In order to
accommodate this modularity, base module 10 is assembled from a limited number
of components, each sized and adapted to connect to other components within
the
system.
The core components of the base module are frame ends 12 and upper and
lower stringers 14/16 connected together into a typically rectangular
framework 11.
In the full depth console of Figures 1 to 6, two of these frames 11 are
sistered
together whereas in the reduced depth console of Figures 8 to 10, a single
framework
is used.
More specifically, and with particular reference to Figure 4, each framework
11 includes two frame ends 12 connected typically but not necessarily at
opposite
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CA 02408583 2002-10-17
ends of an upper stringer 14 and a lower stringer 16. Frame end 12 is shown in
isolation in Figure 7. Each frame end 12 is preferably a partially lattice-
like web
defining a number of reinforcing ribs that provide structural strength while
reducing
weight.
Each frame end 12 is shaped to include a pair of upper protrusions 22 and a
pair of slightly longer lower protrusions 24 which define between each pair a
rectangular recess 28 shaped and sized to receive the ends of stringers 14/16
thereinto. A vertical flange 23 is located on each upper protrusion 22 to
extend
towards the centre of recess 28. Similarly, a vertical flange 25 is located on
each
lower protrusion 24 to also extend towards the centre of recess 28. As will be
explained below, these flanges fit into correspondingly sized slits formed
into the
ends of the stringers to quickly and precisely connect the stringers and frame
ends
together.
Each frame end 12 further includes a number of pre-formed screw holes to
accommodate the modularity of the present invention. These include gusset
screw
holes 26, spline plate screw holes 30, and cladding screw holes 31.
As one skilled in the art will appreciate, frame ends 12 can be manufactured
from any structurally sound material, including but not limited to wood or
metal. In
a preferred embodiment however frame ends 12 are injection moulded from
structural foam.
Base module 10 further includes an upper stringer 14 and a lower stringer 16
located between each pair of frame ends 12. Upper and lower stringers 14 and
16
respectively are preferably formed sheet metal channels that are identical to
one
another to save manufacturing and storage costs. Uppers and lower stringers 14
and 16 are best seen in Figures 1 to 4.
For the sake of modularity, upper stringers 14 and lower stringers 16 are
preferably manufactured in predefined discrete lengths of 2, 4 and 6 feet
(approximately 30, 60 and 90 cm).
The ends of upper stringer 14 fit into recesses 28 between upper protrusions
22 of frame ends 12 with slits in the ends of the stringer fitting together
with flanges
23. The height of the rails 15 of upper stringer 14 is the same as the height
of
protrusions 22 for a flush fit with the top of frames 12.
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CA 02408583 2005-10-25
Lower stringer 16 is similarly configured so that its ends fit into the
recesses
28 between protrusions 24 of opposite frame ends 12 for a snap fit with
vertical
flanges 25.
Upper and lower stringers 14 and 16 are more securely and permanently
affixed to frame ends 12 using gussets 18 seen most clearly in Figures 4 and
9.
Each stringer 14 or 16 includes preformed screw holes 17 adjacent its ends for
connection of the gussets to the sides of these stringers. Gussets 18 are then
connected to frame ends 12 by screws or bolts that are threaded into gusset
screw
holes 26.
The stringers are also provided with a number of spaced apart apertures 19
that are particularly useful for the passage of cabling and the like.
In order to prevent deflection and to provide further structural support,
upper
stringer 14 can be supported every two feet by an intermediate column 20. Thus
a four foot stringer 14 will have one intermediate column 20 at its midpoint,
and a six
foot stringer 14 may have two intermediate columns 20 that are located two
feet from
either frame end 12.
Intermediate columns 20 are connected between upper stringer 14 and lower
stringer 16 such as by means of threaded fasteners using screw holes that are
preferably preformed in the stringers as shown in Figure 4. In addition to
providing
structural support, columns 20 also serve as points of connection for doors,
finishing
panels, mounts for fixed and sliding shelves and other fitments as will be
described
below. As seen most clearly in Figure 4, columns 20 are mounted between the
web
portions of stringers 14/16 when intended primarily to provide structural
support or
as connecting points for shelf hardware, and between the rail portions of the
stringers
when they are to serve as supports for doors and panels mounted to the front
of the
base module as seen most clearly in Figure 1.
Base module 10 thus comprises a frame in which the height and depth are
predetermined, but for which the width can be selected to accommodate user
requirements.
In the embodiment of Figure 1, two base frames 11 are sistered together to
create a full depth base module. This is easily accomplished using spline
plates 32
to connect two frame ends 12 together, as best seen in Figures 1 to 6. Spline
plates
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CA 02408583 2002-10-17
32 are attached using screws or bolts which are threaded into spline plate
screw
holes 30. Spline plates 32 can be used on one or both sides of the frame ends.
Full depth modules can be used to accommodate equipment such as full size
video monitors which are deeper than the depth of a single base module.
Levelling screws 39 adjustably screwed into protrusions 24 to allow the base
module 10 to rest squarely on irregular floors. Support feet 34 seen most
clearly in
Figures 1 and 3 are affixed adjacent the ends of lower stringer 16 to provide
stability
to the console and to prevent the console from tipping forwards. Each support
foot
34 preferably includes a bracket 35 which connects to forwardmost lower
stringer 16
such as by means of screws, a forwardly extending foot portion 36 extending
from
bracket 35, and a connecting screw/nut 37 which joins bracket 35 to foot
portion 36.
In some instances, the upper surface of the base module might be finished
very simply with a panel to be used as a work or support surface. In most
instances
however, the base module will support a turret 40 for video and CRT displays,
communications and switch gear and other equipment. There follows therefore a
description of turret 40.
Turret 40 is to be affixed above base module 10. One of the advantages of
the present console structure is that base module 10 and turret 40 do not
necessarily
need to correspond in width with each other. Turret 40 can be wider or
narrower than
base module 10, or a turret can overlap several base modules 10, or multiple
turrets
can fit over a single base module 10. Further, space over a base module 10
that is
unused by a turret 40 can be covered with a work surface.
The basic components of the turret are a pair of upper frame ends 42 and a
beam 44 connected therebetween. Like lower frames 12, the upper frames are
preferably injection moulded from structural foam and are formed with a number
of
reinforcing ribs to provide strength and rigidity.
The lower end of each upper frame 42 is formed with a pair of spaced apart
protrusions 43 that fit between rails 15 of upper stringer 14, and can be
affixed to
upper stringer 14 using bolts or screws. The lower surfaces 44 of the upper
frames
extending laterally outwardly from the upper ends of protrusions 43 rest on
the top
surface of the rails, and can be connected to the rails with bolts or screws
for further
strength and stability. The stringer rails 15 are formed with regularly spaced
detentes
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CA 02408583 2002-10-17
19 and associated preformed screw holes for connection of the upper frame at
selected locations. The spacing between detentes is typically 2 feet but this
can be
varied if required. Each detente is sufficiently wide and includes enough
preformed
screw holes to permit the installation of two side by side upper frames for
turrets of
extended length.
Each upper frame 42 can be moulded with a number of screw holes to
facilitate connection to other components. These will include screw holes 50,
seen
most clearly in Figure 6, used to connect work surface support arms 62 to the
turret.
Between each pair of upper frame ends 42 is affixed beam 44. Beam 44 is
preferably an aluminium extrusion, and like upper and lower stringers 14 and
16 it
can be manufactured in a number of standard lengths of 2, 4 or 6 feet. The
selection
of beam length determines the width of each turret module, and this width can
be
independent from the width of the base module or modules 10 supporting the
turret.
Beam 44 is connected to upper frame ends 42 using valance end caps 48 as
best seen in Figure 1.
Beam 44 is shown in cross-section in Figure 11. The beam is used to support
equipment front panels 140 that fit over monitor screens to trim the space
between
the screens and the console. The beam is adapted as shown in Figure 11 to
engage
the correspondingly shaped upper end of each frame 42.
Beam 44 and end caps 48 are also used to support another aluminum
extrusion 46 which houses a task light (not shown) to illuminate work surface
60.
The present console structure preferably also includes a work surface 60.
Work surface 60 is a flat surface extending forwardly of base module 10 and is
connected to upper frame ends 42 by means of work surface support arms 62 as
described above. Work surface 60 can include a padded nosing 64 for a user's
comfort.
Once base module 10 and turret 40 are configured, various internal fitments
can be added to the console depending on user and equipment requirements.
Examples of fitments are illustrated in Figure 5, which shows a monitor shelf
81,
upper rack mounts 82, a sliding shelf 84, a fixed processor shelf 86 and a
lower rack
mount 88. One skilled in the art will appreciate that other internal fitments
are
possible.
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CA 02408583 2002-10-17
The internal fitments attach to upper and lower stringers 14 and 16 in a like
manner, at discreet intervals. This ability to add different internal fitments
allows the
present console structure to be easily adapted to user requirements and
facilitates
re-engineering and reconfiguration of the console structure if those
requirements
change over time.
Any combination of base modules 10, turrets 40, desk tops and corner units
can be placed together depending on design requirements. The ends of all of
the
modules, including any corners, are consistent, allowing for reconfiguration.
This
flexibility using standard components provides cost savings in the design
stage, as
well as in manufacturing and storage.
Further reconfiguration, which is often necessary, is easier in the present
system, since turret components can be changed without changing the lower base
module 10. Also, a full depth base can be turned into a reduced depth base
easily,
and the reverse is also true. This has the advantage that when migrating or
reconfiguring from a full to a reduced depth console, the omitted frame can be
used
as the base frame for a second reduced depth base module.
The present console is further provided with finishing panels that can be
affixed to the external surface. These finishing panels can best be seen in
Figures
2, 3 and 12 to 18.
The finishing panels comprise a series of standard sized panels, including
skirt
panels 100, ventilation grills 110, and side panels 120.
Skirt panels 100 are affixed to the front and rear surfaces of the present
console structure. In a preferred embodiment, skirt panels 100 are 2 feet wide
and
can be affixed to any base module 10. When base module 10 is wider than two
feet,
the skirt panels are affixed between frame ends 12 and intermediate columns
20.
Panels 100 can be injection moulded to include the internal ribbed structure
shown
in Figure 14 to provide strength and rigidity and various pre-formed screw
holes, slots
and openings for fasteners and to attach hinges, clips, mounting hardware and
so
forth.
The height of skirt panels 100 is slightly less than the height of frame ends
12,
allowing skirt panels 100 to be installed under work surface 60 at the front
of the
present console structure, and allowing two skirt panels 100 to be mounted in
vertical
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CA 02408583 2002-10-17
alignment atop one another, thus covering the entire rear surface of a console
having
a turret structure. Further, to accommodate this panel stacking, the top of
the lower
skirt panel 100 can be adapted to secure against the bottom of the upper skirt
panel
100 by including protrusions in the upper edge of the bottom panel that fit
into
recesses in the lower edge of the upper skirt panel.
Skirt panels 100 can function as doors if connected to base module 10 using
hinges 102, as best seen in Figure 3. Preferred hinges are the European style
zero
clearance hinges such as the BLUM 1090 model. The skirt panels are preformed
with the circular recesses 104 required for this type of hinge, and the hinge
stalks can
be secured to end frames 12 or columns 20, as the case may be using screw
holes
preformed in these components.
The turret portion of the console is enclosed using a skirt panel 100
connected
to a ventilation grill 110. There are two sizes of ventilation grill 110, the
full depth
version illustrated in Figures 3, 15 and 16, and the reduced depth version
shown in
Figures 17 and 18.
With reference to Figures 3 and 6, each grill 110 is respectively connected to
an upper skirt panel 100 using a stiffening bracket 112. Stiffener 112
attaches to
preformed screw holes 114 along the inside edges of grill 110 and to similar
screw
holes 121 in the inner surface of skirt panel 100, holding the two at a pre-
defined
angle to each other. A spacer 119 can be used to keep the correct spacing
between
the cladding but is not essential and this element can be deleted. The forward
edge
of grill 110 is formed into an elongated circular bead 126 that fits into a
correspondingly shaped channel 125 in beam 44 to act as a hinge line so that
each
grill/skirt panel assembly can be pivoted between an open and closed position.
To
hold the assembly in an open position allowing access to the turret's
interior, known
mechanisms such as gas-filled struts can be used or the rachet mechanism 117
shown most clearly in Figure 6. This is a commercially available system and
need
not therefore be described in great detail herein, but the system includes a
first
bracket 113 that connects adjacent to the top of upper frame 42, a second
bracket
116 that connects to stiffener 112 and a rachet 118 that connects between the
two
brackets. The advantage of this system is that it allows the cladding to be
opened
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CA 02408583 2002-10-17
a selected amount and then positively locked into that position for safety.
Gas struts
are however simpler and cheaper and will likely be preferred by many users.
Side panels 120 are used at the ends of the console structure, and are affixed
to end frames 12 and upper end frames 42. Side panels 120 are illustrated in
Figure
12 for a full depth console and in Figure 13 for a reduced depth console.
In an alternative embodiment where a base having a flat work surface is
placed at the end of a console structure having both a base and a turret, side
panel
120 will be split accordingly.
In operation, a console can be quickly and easily designed using the above-
described components. The base modules 10 can be created for optimum layout
and to best use the floor space available in accordance with user requirements
and
turrets can be mounted as needed anywhere along the length of the base
modules.
Further, depending on the type of equipment to be placed within the console,
the
designer can choose a reduced or a full depth structure. Hybrids are also
possible,
for example a full depth base module supporting two oppositely facing turrets.
Further, corners can also be added to the present console structure by using
corner sections in a manner well known in the console art.
Although the present invention has been described in detail with regard to the
preferred embodiment thereof, one skilled in the art will easily realize that
other
versions are possible, and that the invention is only intended to be limited
in scope
by the following claims.
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