U.S. patent application number 10/488395 was filed with the patent office on 2004-11-25 for weldable insulated panel seam.
Invention is credited to Elliott, Michael M., Fiorell, Richard A..
Application Number | 20040231266 10/488395 |
Document ID | / |
Family ID | 23257808 |
Filed Date | 2004-11-25 |
United States Patent
Application |
20040231266 |
Kind Code |
A1 |
Fiorell, Richard A. ; et
al. |
November 25, 2004 |
Weldable insulated panel seam
Abstract
An insulated panel (10) is configured to be welded to another
insulated panel (12), defining a seam with weld material (14)
therebetween. A space or spacer (26, 28) is incorporated into each
panel (10, 12) adjacent the seam so that the welding process can
occur without damaging the insulative core (24) of the panel (10,
12) and offgasing does not occur from heating of the insulative
core (24).
Inventors: |
Fiorell, Richard A.;
(Carmel, IN) ; Elliott, Michael M.; (Carmel,
IN) |
Correspondence
Address: |
BARNES & THORNBURG
11 SOUTH MERIDIAN
INDIANAPOLIS
IN
46204
|
Family ID: |
23257808 |
Appl. No.: |
10/488395 |
Filed: |
March 2, 2004 |
PCT Filed: |
September 17, 2002 |
PCT NO: |
PCT/US02/29336 |
Current U.S.
Class: |
52/459 ;
52/463 |
Current CPC
Class: |
E04C 2/292 20130101;
E04C 2/384 20130101; B32B 3/22 20130101; B32B 15/04 20130101; E04F
13/0889 20130101; E04F 15/02005 20130101; B32B 3/02 20130101 |
Class at
Publication: |
052/459 ;
052/463 |
International
Class: |
E04C 003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 18, 2001 |
US |
60323119 |
Claims
1. An insulated panel configured to connect with other insulated
panels to form a thermally insulated enclosure, the panel
comprising an inner metal skin facing inwardly toward the
enclosure, the inner metal skin having an edge, an outer skin, an
insulative core sandwiched between the inner and outer skins, the
insulative core having an edge positioned to be in substantial
alignment with the inner metal skin edge, a spacer extending along
the edges of the inner metal skin and the insulative core, the
spacer configured to define a space extending longitudinally
between the inner metal skin edge and the insulative core edge.
2. The insulated panel of claim 1, wherein the spacer is a metal
tube.
3. The insulated panel of claim 1, wherein the spacer has a
substantially square cross-section.
4. The insulated panel of claim 1, wherein the spacer is
approximately {fraction (7/8)} inch (2.222 cm) in depth.
5. The insulated panel of claim 1, wherein a second insulated panel
is welded to the edge of the first insulated panel, and the spacer
is configured to separate the insulative core from the welded
edge.
6. The insulated panel of claim 5, wherein the spacer provides a
heat sink thereby allowing the first and second insulated panels to
be welded together without the insulative core becoming overheated
during the welding process.
7. The insulated panel of claim 5, wherein the spacer provides a
heat sink thereby allowing the first and second insulated panels to
be welded together without heating the insulative core such that it
causes offgasing during the welding process.
8. The insulated panel of claim 1, wherein the spacer defines a
slot disposed along the length of the spacer.
9. The insulated panel of claim 1, wherein the spacer is
substantially "J"-shaped.
10. The insulated panel of claim 1, wherein the inner metal skin is
rolled back at the edge such that it forms the spacer.
11. A weldable wall joint comprising a first panel having a metal
skin, a second panel having a metal skin, the second panel being
positioned to substantially abut a portion of the first panel and
define a joint between their metal skins, a first heat sink
configured to extend through the first panel alongside the joint,
and a second heat sink configured to extend through the second
panel alongside the joint.
12. The weldable wall joint of claim 11, wherein the heat sink is
defined by a metal tube.
13. The weldable wall joint of claim 11, wherein the heat sink
defines a substantially square cross-section.
14. The weldable wall joint of claim 11, wherein the heat sink has
a width of at least {fraction (7/8)} inch (2.222 cm).
15. The weldable wall joint of claim 11, wherein the first and
second panels include an insulative core, and the heat sink defines
a space between the joint and the insulative cores.
16. The weldable wall joint of claim 11, wherein the first and
second heat sinks are defined by the metal skins of the respective
first and second panels, the metal skins being formed to roll back
at the joint such that they define the heat sink therebetween.
17. A method of manufacturing a thermally insulative panel
comprising the steps of positioning a first panel such that it
substantially abuts a second panel and forms a weldable joint
therebetween, the first and second panels each including an
insulative core, and providing a space of preselected dimensions in
each of the insulative cores, wherein each of the spaces is
disposed along the weldable joint.
18. The method of claim 17, wherein the space providing step
comprises providing a spacer having walls that define the
preselected space.
19. The method of claim 18, wherein the spacer has a substantially
square-shaped cross-section.
20. The method of claim 18, wherein the spacer is formed from the
respective panel.
21. The method of claim 17, wherein the preselected dimension is a
radius measured from the corner of each respective panel.
Description
FIELD OF THE DISCLOSURE
[0001] The present invention relates to wall, ceiling, or floor
structures comprising a plurality of insulated panels joined
together to form an enclosure, and more particularly to a method
and structure for welding a joint of metal skins of adjacent panels
to provide a sealed enclosure.
BACKGROUND AND SUMMARY
[0002] It is conventional to provide insulated enclosures by
assembling together a plurality of ceiling, wall, and floor panels
with gaskets or caulking between adjacent panels. While such
gaskets or caulking works for various applications, it is desirable
in many applications to have a sealed interior in an enclosure
which is illustratively provided by welding the inner and/or outer
metal skins of adjacent panels together. It should be noted that
although the following description discloses embodiments having the
inner metal skins welded, it is within the scope of the disclosure
to utilize embodiments having the outer skins welded either in
addition to the inner skins, or instead of welding the inner
skins.
[0003] It is desirable to ship these panels made in a factory to an
installation site and to weld the panels on that site. Prior
efforts to weld the metal skins together on the installation site
have created problems with the welding process unduly heating the
insulative core. The welding process has produced offgasing of
materials that safety personnel have found objectionable and in
violation of safety codes. Typically the insulative cores are some
type of organic insulation material, particularly a cellular foam
material such as polyurethane foam or polystyrene foam. When the
welding occurs in close proximity to such materials, the offgasing
or vapors produced by the welding are deemed objectionable or
hazardous. Further, the insulative material in the area of the weld
could ignite, presenting a further hazard.
[0004] In accordance with illustrative embodiments of the present
invention, each panel is provided with an inner metal skin, an
outer skin which may be metal, and an insulative core material
sandwiched between the skins. Each panel provides a side edge
portion which is configured to abut against the side edge portion
of an adjacent panel. When two panels are placed together with
their side edge portions in an abutting relationship, the
insulative cores provide a thermal barrier at the point the panels
abut. The inner metal skins of the adjacent panels are held in
close proximity to be sealed. These inner metal skins may be
abutting together or be spaced apart a small gap up to, for
example, 0.125 inch (0.317 cm).
[0005] It has been found that these metal skins, when held adjacent
each other, can be welded together by conventional TIG or MIG
welding techniques. Typically, an inner metal skin will be a 16
gauge (0.060 inch (0.152 cm) thick) 300 Series stainless steel
sheet. Such inner metal skins may be thinner or thicker depending
upon the application. Such 300 Series stainless steel skins may be
welded together when they are in actual contact, or when a small
gap such as {fraction (1/32)} of an inch up to {fraction (3/16)}
inch (0.079 cm up to 0.238 cm) is provided between the adjacent
skins.
[0006] A space is incorporated into each panel to extend along the
side edge of the panel. The space can illustratively be formed by a
spacer positioned adjacent to the edge of the inner metal skin to
be welded. This spacer, which may take various shapes and forms,
extends inwardly from the edge to be welded a predetermined
distance along the skin surface facing the core. The spacer also
extends a predetermined distance into the core from the skin
surface facing the core. Thus, when two panels are abutted together
with their inner metal skins arranged in close proximity, the
adjacent spacers and the two panels provide a space about and along
the metal skin joint to be welded. When the weld is made at this
joint, the heat produced by the weld will not damage or deteriorate
the insulative core to provide offgasing. It should be understood
that while a spacer is discussed in this disclosure, it is within
the scope of the disclosure to utilize any means for providing a
void between the joint and the insulative material. For example,
the insulative material could instead be cut away to include a
void, rather than using the spacer disclosed within. The spacer
along each inner metal skin edge serves as a heat sink to conduct
away the heat of the weld as well as an insulative gap to protect
the core material from the heat of the welding.
[0007] According to the disclosure, a insulated panel is configured
to connect with other insulated panels to form a thermally
insulated enclosure. The panel comprises an inner metal skin facing
inwardly toward the enclosure, an outer skin, and an insulative
core sandwiched between the inner and outer skins. The inner metal
skin has an edge, and the insulative core has an edge positioned to
be in substantial alignment with the inner metal skin edge. The
panel further includes a spacer extending along the edges of the
inner metal skin and the insulative core. The spacer is configured
to define a space extending longitudinally between the inner metal
skin edge and the insulative core edge.
[0008] In another embodiment of the disclosure, a weldable wall
joint comprises a first panel having a metal skin and a second
panel having a metal skin, the second panel being positioned to
substantially abut a portion of the first panel and define a joint
therebetween. The first panel includes a first heat sink extending
through the first panel alongside the joint, and the second panel
includes a second heat sink configured to extend through the second
panel alongside the joint.
[0009] A method of manufacturing a thermally insulative panel is
also provided. The method includes the steps of positioning a first
panel such that it substantially abuts a second panel and forms a
weldable joint therebetween, and providing a space of preselected
dimensions in each of the panels. Each of the first and second
panels includes an insulative core, and the space is provided along
the weldable joint and defines an area where the insulative core
does not exist.
BRIEF SUMMARY OF THE DRAWINGS
[0010] The detailed description particularly refers to the
accompanying figures in which:
[0011] FIG. 1 is a fragmentary view of an insulated panel seam that
has been welded;
[0012] FIG. 2 is a fragmentary sectional view of one embodiment of
the disclosure, showing square spacers positioned at the weldable
seam;
[0013] FIG. 3 is a fragmentary cross-sectional view of another
embodiment of the spacer;
[0014] FIG. 4 is a fragmentary cross-sectional view of yet another
embodiment of the spacer, wherein the spacer includes a slot;
[0015] FIG. 5 is a fragmentary cross-sectional view of a "J"-shaped
embodiment of the spacer;
[0016] FIG. 6 is a fragmentary cross-sectional view of another
embodiment of the spacer; and
[0017] FIG. 7 is a fragmentary cross-sectional view of a panel
showing the panel skin being used to form the spacer.
DETAILED DESCRIPTION OF THE DRAWINGS
[0018] In the illustrative embodiment, a wall, ceiling, or floor
structure is provided comprising adjacent panels with each panel
having at least one edge configured to abut against at least one
edge of an adjacent panel. Each illustrative panel comprises an
inner metal skin, an outer skin, and an insulative core sandwiched
between the inner and the outer skins. A spacer extends fully along
one edge of the panel. The spacer is configured such that when
adjacent panels are abutted together and their edges of the metal
skins are abutting or slightly spaced apart to provide a gap
therebetween, the insulative cores are spaced from their at least
one edges a distance permitting the edges to be welded without
damage to the insulative cores.
[0019] When the inner metal skins are welded together along their
abutting or adjacent edges, the joint between the adjacent panels
is completely sealed against penetration of gas or vapor and
particularly against penetration by any pathogens. Enclosures
fabricated in such a manner can be held at very low temperatures
and then washed and/or sterilized with live steam at very high
temperatures.
[0020] A method is provided for manufacturing a thermally
insulative wall, ceiling, or floor. A first panel and a second
panel are configured to abut each other such that the metal skins
of the panels are illustratively aligned in a plane and form a
joint therebetween. An insulative core is provided for each panel,
defining a space of predetermined dimensions about the weldable
joint. In illustrative embodiments, a spacer is used to define the
space about the weldable joint. One such spacer may have a
substantially square-shaped cross-section. The spacer can be formed
of extruded or rolled plastic or metal and is positioned to extend
along the joint to be welded.
[0021] The joint is desirably welded such that it is sealed, and
the welding does not cause offgasing or substantial heating of the
insulative core. By providing a space of predetermined dimensions
between the welded joint and the insulative core, offgasing of
harmful vapors is substantially prevented. A distance of
approximately {fraction (7/8)} inch (2.222 cm) between the weldable
joint and the insulative core is illustratively provided, and is
believed to substantially prevent such offgasing. However, while
{fraction (7/8)} inch (2.222 cm) has been determined to be a
sufficient distance for substantially preventing offgasing, it
should be understood that the present disclosure could be applied
with a variety of spacer widths, including from approximately
{fraction (1/2)} inch to more than one inch (approx. 1.27 cm to
more than 2.54 cm).
[0022] An illustrative finished wall panel joint, viewed from the
inside of a refrigerated or thermally insulated room, is shown in
FIG. 1. Panel 10 is welded to panel 12 with weld material 14.
Inside skins 16, 18 of panels 10, 12 are each illustratively a thin
metal sheet formed from 16 gauge (0.060 inch (0.152 cm) thick) 300
Series stainless steel. However, it should be understood that metal
sheets of approximately 18 gauge or thicker would be sufficient for
use as skins 16, 18. As shown in FIG. 1, panels 10, 12 are spaced
apart a distance "C", up to approximately {fraction (3/16)} inch
(0.238 cm). It is also possible, however, to position panels 10, 12
so that the edges of the skins 16, 18 abut each other and no space
is formed between them. The presently preferred spacing distance
"C" is approximately {fraction (3/64)} inch, or 0.045 inch (approx.
0.114 cm).
[0023] A weld between panels 10, 12 is illustratively formed by
heating weld material 14 to a high temperature such that it fills
the space or joint formed between skins 16, 18. During this welding
process, corners 20, 22 of panels 10, 12, respectively, achieve an
elevated temperature similar to that of weld material 14.
[0024] An insulative core 24 thermally insulates panels 10, 12, as
can be seen in FIG. 2. As discussed above, offgasing can occur
during the welding process if the insulative core 24 is proximate
to the weldable joint and corners 20, 22 and is heated to a
substantial temperature as is required by the welding process. The
present invention provides a space between the weldable joint and
the insulative core 24 such that the insulative core 24 is
protected from the elevated temperatures associated with welding,
and therefore offgasing does not occur.
[0025] The welding process ideally provides an air-tight and
durable seal between two abutting panels of ceiling, floor, or
wall. Such an air-tight durable seal is ideally capable of
repeatedly withstanding the 160.degree. F. (71.1.degree. C.) to 270
(132.degree. C.) temperatures typically associated with cleaning
the thermally insulated enclosure.
[0026] In one embodiment, a spacer 26 is positioned adjacent corner
20 of panel 10, as shown in FIG. 1 and in cross-sectional view in
FIG. 2. Another spacer 28 is shown positioned adjacent corner 22 of
panel 12. In the illustrative embodiment, spacers 26, 28 are
aluminum tubes having a square cross-section, wherein the hollowed
regions 30, 32 of the spacers 26, 28 are void of insulating
material. Spacers 26, 28 function to provide a space between the
weldable joint at corners 20, 22 and the insulative core 24. Such a
space is illustratively dimensioned such that width A and depth B
are both approximately {fraction (7/8)} inch (2.22 cm), as this
dimension has been shown to provide sufficient distance between the
weldable joint and insulative core 24. However, as mentioned above,
other depths B and widths A are within the scope of the
disclosure.
[0027] In another embodiment, shown in FIG. 3, spacer 26' is
configured to include a slot 34 extending lengthwise along spacer
26'. Panel 10 includes skin 16 which is configured to form corner
20 and further form a tongue 36. Tongue 36 cooperates with slot 34
to position spacer 26' in an abutting relationship with corner
20.
[0028] Yet another embodiment of panel 10 is shown in FIG. 4,
wherein spacer 26" is substantially an inverse "J" shape. In such
an embodiment, spacer 26" cooperates with inside skin 16 surface
such that neck 38 abuts an inside surface of skin 16, and leg 40
abuts tongue 36.
[0029] Panel 10 can also be formed to have a substantially straight
skin 16 having an edge 42, as shown in FIG. 5, rather than a corner
20 similar to that shown in FIGS. 1-3. In such an embodiment,
spacer 26 is positioned at edge 42 of skin 16.
[0030] Another embodiment is disclosed and shown in FIG. 6, wherein
skin 16 is rolled to substantially form a squared edge which
functions as a spacer. Illustratively, skin 16 is rolled to form a
first side 44 of a dimension B, a second side 46 of a dimension A,
and a third side 48 which substantially abuts the inner surface of
skin 16. Such a configuration permits welding to occur at corner 20
without risk of offgasing occurring due to the space provided by
the rolled skin 16.
[0031] Other configurations for spacers 26, 28 are within the scope
of the invention. Importantly, a spacer 26, 28 provides a heat sink
or sufficient insulative distance between a weldable joint at
corners 20, 22 of panels 10, 12 and the insulative core 24, thereby
preventing offgasing when the joint is welded. It should be
appreciated that spacers 26, 28 can be a quarter-round, square,
rectangle, or any other shape that provides the sufficient distance
between corners 20, 22 and the insulative core 24. It is also
within the scope of the disclosure to provide a space in the
insulative core 24 without the use of spacers 26, 28. Such a
configuration can be formed by cutting away the insulative core 24
in an area proximate to corners 20, 22, thereby providing a heat
sink with the absence of insulative core 24.
[0032] While the disclosure is susceptible to various modifications
and alternative forms, specific exemplary embodiments thereof have
been shown by way of example in the drawings and have herein been
described in detail. It should be understood, however, that there
is no intent to limit the disclosure to the particular forms
disclosed, but on the contrary, the intention is to cover all
modifications, equivalents, and alternatives falling within the
spirit and scope of the invention as defined by the appended
claims.
[0033] There is a plurality of advantages of the present disclosure
arising from the various features of the weldable insulated panel
seam and associated method described herein. It will be noted that
alternative embodiments of the weldable insulated panel seam and
associated method of the present disclosure may not include all of
the features described yet still benefit from at least some of the
advantages of such features. Those of ordinary skill in the art may
readily devise their own implementations of a weldable insulated
panel seam and associated method that incorporate one or more of
the features of the present disclosure and fall within the spirit
and scope of the present disclosure as defined by the appended
claims.
* * * * *