U.S. patent application number 10/955388 was filed with the patent office on 2006-01-05 for frame assembly and environmental enclosure.
Invention is credited to David Buzzard, David J. Cole, Joseph M. Klobucar, Steven Parzuchowski, Claudio Vicente Salzano, Roberto Tkatchuk.
Application Number | 20060000177 10/955388 |
Document ID | / |
Family ID | 34959652 |
Filed Date | 2006-01-05 |
United States Patent
Application |
20060000177 |
Kind Code |
A1 |
Salzano; Claudio Vicente ;
et al. |
January 5, 2006 |
Frame assembly and environmental enclosure
Abstract
A frame assembly for an environmental enclosure including a
plurality of channel-shaped members each including an end wall,
opposed spaced side walls and an opening opposite the end wall
adapted to receive and retain an end cap for retaining a film over
the frame assembly having an integral internal channel which
receives a connector element for interconnecting the frame members
into a rectangular frame assembly and the frame assemblies are then
interconnected to form an environmental enclosure. In one
embodiment, the channel-shaped frame members include a generally
L-shaped connector portion integral with one of the side walls for
interconnecting the frame assemblies in side to side and end to end
relation. In the other embodiment, the rectangular frame assembly
has a height equal to the height of the environmental enclosure and
transverse bracing elements having a U-shaped connector plate
including transverse slots received in the internal channel.
Inventors: |
Salzano; Claudio Vicente;
(Livonia, MI) ; Tkatchuk; Roberto; (Sao Paulo,
BR) ; Klobucar; Joseph M.; (Canton, MI) ;
Cole; David J.; (Ann Arbor, MI) ; Parzuchowski;
Steven; (Livonia, MI) ; Buzzard; David;
(Plymouth, MI) |
Correspondence
Address: |
HOWARD & HOWARD ATTORNEYS, P.C.
THE PINEHURST OFFICE CENTER, SUITE #101
39400 WOODWARD AVENUE
BLOOMFIELD HILLS
MI
48304-5151
US
|
Family ID: |
34959652 |
Appl. No.: |
10/955388 |
Filed: |
September 30, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60579410 |
Jun 14, 2004 |
|
|
|
Current U.S.
Class: |
52/474 |
Current CPC
Class: |
F16B 5/0692 20130101;
E04B 2002/7479 20130101; E04B 2002/7498 20130101; E04B 1/34321
20130101 |
Class at
Publication: |
052/474 |
International
Class: |
E04B 9/00 20060101
E04B009/00 |
Claims
1. A frame assembly for an environmental enclosure, comprising: a
plurality of channel-shaped members, each channel-shaped member
including a first end wall, opposed spaced side walls extending
generally perpendicular to and integral with said first end wall,
an opening opposite said first end wall adapted to receive and
retain an end cap for retaining a film over said frame assembly,
and an integral internal retainer channel including a wall integral
and generally perpendicular to one of said side walls spaced from
said first end wall forming an internal channel with said first end
wall; and said plurality of channel-shaped frame members including
a first channel-shaped frame member in abutting relation with a
second channel-shaped frame member and a retainer element received
in said internal channel of said first channel-shaped frame member
interconnecting said first and second channel-shaped frame
members.
2. The frame assembly as defined in claim 1, wherein said retainer
element includes a first leg portion received in said internal
retainer channel of said first channel-shaped frame member and a
second leg portion received in said internal retainer channel of
said second channel-shaped frame member.
3. The frame assembly as defined in claim 2, wherein said second
channel-shaped frame member extends generally perpendicular to said
first channel-shaped frame member and said retainer element is
generally L-shaped.
4. The frame assembly as defined in claim 1, wherein said first end
wall of said plurality of channel-shaped frame members include an
internal wall integral with and extending generally perpendicular
to said first end wall extending toward said wall integral with and
generally perpendicular to one of said side walls forming said
internal channel.
5. The frame assembly as defined in claim 1, wherein said wall
integral with and generally perpendicular to one of said side walls
is generally L-shaped including an end portion extending toward
said first end wall.
6. The frame assembly as defined in claim 1, wherein said opening
opposite said first end wall includes opposed enlarged parallel
bead-like portions at least one of which extends toward said first
end wall adapted to receive and retain an end cap.
7. The frame assembly as defined in claim 1, wherein one of said
opposed spaced side walls include a U-shaped end portion.
8. The frame assembly as defined in claim 7, wherein said U-shaped
end portions of said opposed spaced side walls include an end
portion extending toward said first end wall.
9. The frame assembly as defined in claim 1, wherein said plurality
of channel-shaped frame members each include an integral connector
portion including an end wall integral with one of said opposed
side walls extending generally parallel to said first end wall
having an end portion extending generally perpendicular to said end
wall of said connector portion spaced from said one of said opposed
side walls forming an L-shaped connector portion, and said
generally L-shaped connector portion of said first channel-shaped
frame member engaging said generally L-shaped connector portion of
a third channel-shaped frame member and a connector element
interconnecting said generally L-shaped connector portions of said
first and third channel-shaped members.
10. The frame assembly as defined in claim 1, wherein one of said
side walls includes an integral end portion extending toward an
opposite side wall having a U-shaped portion extending toward said
first end wall.
11. A frame assembly for an environmental enclosure, comprising: a
plurality of channel-shaped frame members, each of said
channel-shaped frame members including a first end wall, opposed
spaced side wall integral with and extending generally
perpendicular to said first end wall, an opening opposite said
first end wall having parallel sides adapted to receive and retain
an end cap for retaining a film over said frame assembly, and an
integral internal channel within said channel-shaped frame members
including a first generally L-shaped internal channel wall portion
integral with one of said side walls including a first portion
integral with and extending generally perpendicular to said one of
said side walls and an end portion extending toward said first end
wall and a second internal channel wall integral with and extending
generally perpendicular to said first end wall portion extending
toward said second end portion of said first generally L-shaped
internal wall portion.
12. The frame assembly as defined in claim 11, wherein said frame
assembly includes a first channel-shaped frame member in abutting
relation with a second channel-shaped frame member and a retainer
element in one of said internal channels within one of said first
and second channel-shaped members interconnecting said first and
second channel-shaped frame members.
13. The frame assembly as defined in claim 11, wherein said
connector element includes a first leg portion received in said
internal channel of said first channel-shaped frame member and a
second leg portion received in said internal channel of said second
channel-shaped frame member interconnecting said first and second
channel-shaped frame members.
14. The frame assembly as defined in claim 13, wherein said leg
portions of said connector element include a plurality of teeth
forming an interference fit with said internal channels of said
first and second channel-shaped frame members.
15. The frame assembly as defined in claim 11, wherein said opening
opposite said first end wall includes parallel enlarged bead-shaped
portions for retaining an end cap in said opening.
16. The frame assembly as defined in claim 15, wherein said side
walls each include a U-shaped end portion having an said enlarged
bead-shaped portion at an end of said U-shaped portions.
17. The frame assembly as defined in claim 11, wherein said one of
said side walls include a second end wall extending generally
parallel to and opposite said first end wall defining said opening
adjacent the other of said side walls.
18. The frame assembly as defined in claim 17, wherein said opening
is rectangular having parallel enlarged bead-shaped portions for
retaining an end cap.
19. The frame assembly as defined in claim 11, wherein each of said
plurality of channel-shaped frame members includes an integral
retainer portion including a first retainer wall portion integral
with a side wall opposite said one of said side walls extending
generally parallel to said first end wall and a second retainer
wall portion integral and extending generally parallel to said
first wall portion.
20. A frame assembly for an environmental enclosure, comprising: a
plurality of interconnected frame members, each of said frame
members including a channel-shaped portion having a first end wall
portion, opposed spaced side walls extending generally
perpendicular to and integral with said first end wall portion
defining an open end opposite said first end wall portion, said
side walls having opposed inwardly projecting portions adjacent
said open end adapted to receive and retain an end cap, and a
connector portion integral with said channel-shaped portion
including a second end wall portion generally aligned with said
first end wall portion extending generally perpendicular to and
integral with said second end wall portion spaced from an adjacent
side wall portion; said plurality of interconnecting frame members
including two frame members having abutting leg portions; and a
fastener interconnecting said leg portions.
21. The frame assembly as defined in claim 20, wherein said leg
portion has a length less than said side walls.
22. The frame assembly as defined in claim 20, wherein said two
frame members are mirror images of each other.
23. The frame assembly as defined in claim 20, wherein said
inwardly projecting portions of said side walls are
hook-shaped.
24. The frame assembly as defined in claim 23, wherein said
hook-shaped projecting portions are U-shaped each including a first
portion extending generally perpendicular to said side walls and an
end portion extending generally parallel to said side walls.
25. The frame assembly as defined in claim 24, wherein said end
portion of said hook-shaped portion has a greater thickness than
said first portion and rounded end surfaces.
26. The frame assembly as defined in claim 20, wherein said side
walls include an outer side wall and an inner side wall adjacent
said connector portion, and said inner side wall including an
outwardly projecting end portion adjacent said open end overlying
said second bottom wall portion, such that said two side frame
members have opposed projecting end portions adapted to receive a
second end cap.
27. The frame assembly as defined in claim 20, wherein one of said
side walls of said frame members includes an integral generally
L-shaped web portion spaced from said first bottom wall portion
having an end portion extending toward said first bottom wall
portion, and said first bottom wall portion including an opposed
web portion, wherein said web portions are adapted to receive an
L-shaped connector interconnecting said frame members in end to end
relation.
28. A frame assembly for an environmental enclosure, comprising: a
first plurality of frame members each including a channel-shaped
portion having a first end wall portion, a first side wall
extending generally perpendicular to and integral with said first
end wall portion, a second side wall spaced from said first side
wall extending generally perpendicular to and integral with said
first end wall portion, said first side wall including an end
portion extending toward said second side wall and said second side
wall including an end portion extending toward said first side
wall, and a connector portion including a second end wall portion
integral with said second side wall generally aligned with said
first end wall portion and a leg portion spaced from said second
side wall extending generally perpendicular to and integral with
said second end wall portion having a length less than said side
wall; a second plurality of frame members each being a mirror image
of said first plurality of frame members, each including a first
end wall portion, a first side wall extending generally
perpendicular to and integral with said first end wall portion, a
second side wall spaced from said first side wall extending
generally perpendicular to and integral with said first end wall
portion, said first end wall portion including an end portion
extending toward said second side wall, said second side wall
including an end portion extending toward said first side wall and
a connector portion including a second end wall portion integral
with said second side wall aligned with said first end wall portion
and a leg portion spaced from said second side wall extending
generally perpendicular to and integral with said second end wall
portion, wherein said leg portions of one of said first plurality
of frame members and said leg portion of one of said second
plurality of frame members are abutting; and a fastener
interconnecting said leg portions of said one of said first
plurality of frame members to said leg portion of said one of said
second plurality of frame members.
29. The frame assembly as defined in claim 28, wherein said end
portions of said first and second side walls are hook-shaped
adapted to receive and retain an end cap for securing a flexible
film to said frame members.
30. The frame assembly as defined in claim 29, wherein said
hook-shaped portions of said side walls are U-shaped, including a
first portion extending generally perpendicular to said side walls
and an end portion extending generally parallel to said side
walls.
31. The frame assembly as defined in claim 29, wherein said
hook-shaped end portions of said side walls have a greater
thickness than said first portion, and rounded end surfaces.
32. The frame assembly as defined in claim 28, wherein said first
side wall of said first and second plurality of frame members
includes an integral generally L-shaped web portion having an end
portion extending toward said first bottom wall portion and said
first bottom wall portion including an opposed web portion for
receiving an L-shaped connector interconnecting said first and
second plurality of frame members to a third plurality of frame
members in end to end relation.
Description
RELATED APPLICATION
[0001] This application claims priority to Provisional Patent
Application Ser. No. 60/579,410 filed in the U.S. Patent and
Trademark Office on Jun. 14, 2004.
FIELD OF THE INVENTION
[0002] This invention relates to an environmental or contaminant
shield or enclosure which prevents airborne contaminants from
contacting a part received within or transmitted through the
environmental or contaminant enclosure. More particularly, this
invention relates to a frame assembly for an environmental or
contaminant shield or enclosure and the shield or enclosure.
BACKGROUND OF THE INVENTION
[0003] Environmental or contaminant shields or enclosures, commonly
referred to as "clean tunnels," are utilized by many industries to
prevent airborne contaminants from contacting a part received
within or transmitted through the environmental or contaminant
shield or enclosure. Such enclosures are used, for example, in an
automotive paint facility, wherein the vehicle body is conveyed
through clean tunnels between the several steps performed in the
paint shop including, for example, sanding, tack-off (typically
performed by feather dusters), paint booths and ovens to prevent
airborne contaminants, including particulate and waterborne
contaminants, from contacting the vehicle body following sanding,
cleaning, tack-off and painting. A typical automotive paint
facility may include over a mile of clean tunnels. As will be
understood, however, other manufacturing and assembly facilities
also use clean tunnels or enclosures during assembly or
manufacture, including downtime. A typical clean tunnel or
enclosure includes a frame assembly comprised of like
channel-shaped frame members formed from sheet metal, typically
steel, each having an open end, including an end or bottom wall and
opposed side walls having opposed inwardly projecting end portions,
wherein an end cap is received in the opening end of the
channel-shaped frame members which secures a flexible film
stretched over the frame members forming the clean tunnel as
disclosed, for example, in U.S. Pat. Nos. 4,860,778 and
5,906,078.
[0004] As disclosed in such patents, the like channel-shaped frame
members are then interconnected in end to end relation into a
rectangular frame and the flexible sheet is stretched over the
frame members and the rectangular frame members are then
interconnected in side to side or end to end relation to form a
U-shape clean tunnel or enclosure, preventing airborne contaminants
from contacting a part received in the clean tunnel or enclosure.
In a typical application, the frame members are first
interconnected in end to end relation to form a rectangular frame,
a flexible film is stretched over the rectangular frame and secured
by end caps and the rectangular frame members with the flexible
film are then interconnected in end to end and side to side
relation with fasteners or clips. However, because the open ends of
the channel-shaped frame members are closed by the end caps which
secure the flexible film, assembly of the rectangular frame members
with the end caps and flexible film require special clips or
fasteners which penetrate the channel-shaped frame members making
assembly of the frame members difficult, requiring special tools or
parts and potentially reducing the structural integrity of the
frame assembly.
[0005] It would also be desirable to easily remove and replace
damaged flexible film after assembly, which comprises a majority of
the surface area of the clean tunnel or enclosure, without special
tools and to form the frame members from extruded aluminum to form
a light weight, more rigid rugged construction. The environmental
enclosure and frame assembly of this invention solves the problems
associated with the prior art described above, including frame
members which may be easily and securely assembled and wherein the
flexible film may be easily assembled on the frame members or
removed and replaced if damaged.
SUMMARY OF THE INVENTION
[0006] The frame assembly for an environmental enclosure of this
invention includes a plurality of interconnected channel-shaped
frame members, wherein each of the frame members includes a first
end wall, opposed spaced side walls extending generally
perpendicular to and integral with the first end wall and an
opening opposite the first end wall adapted to receive and retain
an end cap for retaining a film over the frame assembly. As thus
far described, the channel-shaped frame members may be generally
similar to the frame members disclosed in the above-referenced U.S.
patents. However, the frame members of this invention further
include an integral internal retainer channel within the
channel-shaped frame members including a retainer wall integral
with and extending generally perpendicular to one of the side
walls, spaced from the end wall, for receiving a connector element
interconnecting the channel-shaped frame members into a rectangular
frame or for interconnecting abutting transverse frame members for
braces or the like. In a preferred embodiment, the internal
retainer wall is generally L-shaped, including a first portion
integral with and extending generally perpendicular to the side
wall and an end portion extending toward the first end wall of the
channel-shaped frame member and in the disclosed embodiment, the
first end wall further includes an internal retainer wall extending
toward the end portion of the generally L-shaped retainer wall,
forming an integral internal channel for receiving a retainer
element as described. In a preferred embodiment, the channel-shaped
frame members are formed from extruded aluminum, forming a light
weight rigid construction.
[0007] In one of the disclosed embodiments of the channel-shaped
members, the first side wall which includes the internal retainer
channel, has a second end wall extending from and integral with the
first side wall and the opening which receives the end cap is
adjacent the second side wall and the opening is defined by
parallel enlarged bead-shaped portions to receive and retain the
end cap which retains a film overlying the frame assembly. In the
other disclosed embodiments, the end portions of the side walls are
U or hook-shaped each having an enlarged bead-shaped portion
extending toward the first end wall.
[0008] In one of the preferred embodiments of the frame assembly of
this invention, the channel-shaped frame members further include an
L-shaped retainer portion including an end wall portion integral
with a side wall, preferably a side wall opposite the integral
internal channel described above, extending parallel to the first
end wall and preferably aligned with the first end wall, and an end
portion integral with and extending generally perpendicular to the
end wall portion of the retainer portion forming a channel-shaped
retainer or connector portion for interconnecting adjacent
channel-shaped members in side to side relation, wherein the
channel-shaped frame members of the frame assembly include a first
plurality of channel-shaped members each having a generally
L-shaped connector portion extending from one side wall and a
second plurality of channel-shaped members which are a mirror image
of the first channel-shaped members, and wherein the L-shaped
retainer portions are aligned in side to side abutting relation and
a fastener interconnects the first and second channel-shaped
members.
[0009] The channel-shaped frame members of this invention are first
assembled into rectangular frame assemblies, wherein the ends are
preferably mitered or cut at a 45 degree angle and an L-shaped
connector element having a first leg portion is received in the
internal retainer channel of one frame member and a second leg
portion is received in an internal channel of a perpendicular
second channel-shaped frame member forming a rectangular frame
assembly. The rectangular frame assembly is then covered with a
thin, preferably transparent film and secured by end caps, such
that each rectangular frame assembly is covered by a thin
transparent film. In the disclosed embodiment of the frame assembly
of this invention having a generally L-shaped retainer portion, the
rectangular frame assemblies are then secured in side to side
relation by a fastener, such as a clip, rivet or the like. In a
preferred alternative embodiment, the frame assemblies are
interconnected in side to side relation by a U-shaped retainer
member having end portions received around the adjacent
channel-shaped frame members and secured by suitable fasteners,
such as screws, bolts, or the like. The frame assemblies may be
rectangular or square. In one preferred embodiment, a rectangular
frame assembly is first formed having a height equal to the desired
height of the environmental enclosure and the rectangular frame
assemblies include cross members having end portions secured to the
rectangular frame assembly by U-shaped retainer members received
within the cross members having slots received in the opposed end
portions of the internal retainer channel, forming a light weight
rigid assembly. The preferred alternative embodiment of the frame
assembly has the advantage that the frame assembly is more rigid
and does not require mirror image channel-shaped frame members and
is thus less expensive to manufacture and assemble.
[0010] In a preferred embodiment of the frame assembly of this
invention, the channel-shaped frame members are extruded,
preferably extruded aluminum, forming a rigid lightweight frame
assembly which is easily assembled or disassembled, as required.
Further, the thin flexible film may be easily secured to or
replaced on the frame assemblies by end caps which, in a preferred
embodiment, includes a planar end portion and projecting generally
parallel outwardly bowed legs which are received between the
parallel enlarged bead-shaped portions defining the opening to the
channel-shaped frame members, securely retaining the flexible
film.
[0011] As will be understood, the disclosed embodiments of the
frame assembly and channel-shaped frame members is provided for
illustrative purposes only and various modifications may be made to
the frame assembly and channel-shaped frame members within the
purview of the appended claims as described further below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a side perspective view of one embodiment of an
environmental enclosure of this invention;
[0013] FIG. 2 is a partial exploded view of the ends of two frame
members, a connector channel, end caps and flexible film
illustrating the assembly of the frame members shown in FIG. 1 in
end to end relation;
[0014] FIG. 3 is a side view of a rectangular frame assembly, which
is a component of the environmental enclosure shown in FIG. 1;
[0015] FIG. 4 is a side cross-sectional view of FIG. 3 in the
direction of view arrows 4-4 with the end cap and film;
[0016] FIG. 5 is a partially exploded top perspective view of two
rectangular frame assemblies shown in FIG. 1 illustrating one means
of interconnecting the frame assemblies further illustrated in FIG.
6;
[0017] FIG. 6 is an end cross-sectional view of two frame members
shown in FIG. 1 interconnected in side to side relation;
[0018] FIG. 7 is a side cross-sectional view similar to FIG. 5 with
an alternative fastener interconnecting the frame members;
[0019] FIG. 8 is a partial side view of an alternative embodiment
of the environmental enclosure of this invention;
[0020] FIG. 9 is a partial side cross-sectional view of FIG. 8 in
the encircled area 9;
[0021] FIG. 10 is a cross-sectional view of FIG. 9, in the
direction of view arrows 10-10;
[0022] FIG. 11 is a perspective view of one embodiment of the
corner connector element illustrated in FIGS. 9 and 10;
[0023] FIG. 12 is a partial side cross-sectional view of FIG. 8 in
the direction of view arrows 12-12;
[0024] FIG. 13 is an end cross-sectional view of FIG. 8 in the
direction of view arrows 13-13;
[0025] FIG. 14 is a side cross-sectional view of FIG. 8 in the
encircled area 14;
[0026] FIG. 15 is as end cross-sectional view of FIG. 14 in the
direction of view arrows 15-15;
[0027] FIG. 16 is a perspective view of the connector element shown
in FIGS. 14 and 15; and
[0028] FIG. 17 is an end cross-sectional view of FIG. 8 in the
direction of view arrows 17-17.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] As will be understood, the embodiments of the frame assembly
and environmental enclosure of this invention disclosed in the
figures are for illustrative purposes only and various
modifications may be made to the frame assembly and environmental
enclosure of this invention with the purview of the appended claims
as described further below.
[0030] The embodiment of the environmental enclosure or clean
tunnel 20 shown in FIG. 1 and FIGS. 2 to 7 includes a plurality of
interconnected rectangular frame assemblies 24 interconnected in
side to side relationship, each including four frame members 26 or
26A interconnected in end to end and side to side relation having a
flexible film 28 preferably stretched between the frame members 26
and 26A. The flexible film 28 may be formed of any suitable
material, including a transparent polymeric film, such as
polyethylene, having a thickness of for example about 0.18 mm and
preferably formed of a polymer, such as polyethylene or a
polyethylene resin which shrinks upon heating, such that the
flexible film 28 may be stretched between the frame members 26 and
26A when heated, providing a smooth and regular surface. As will be
understood, the shape or configuration of the environmental
enclosure or clean tunnel 20 will depend upon the application of
the environmental enclosure. For example, the environmental
enclosure 20 may be in the form of a clean tunnel, as shown in FIG.
1, for enclosing a conveyor (not shown) for conveying a vehicle
body (not shown) between the various work stations in a paint shop
and may include access doors 30. Alternatively, the environmental
enclosure 20 may be in the form of a housing having closed ends
(not shown) for storage of manufactured parts in a manufacturing
facility to prevent contamination of the parts prior to subsequent
manufacturing operations. The disclosed embodiment of the
environmental enclosure 20 and frame assembly of this invention may
be sufficiently rigid to be a free standing structure supported by
the floor or may include additional reinforcement (not shown in
FIG. 1) again depending upon the application.
[0031] FIG. 4 is a cross-section of one preferred embodiment of a
channel-shaped frame member 26 which includes a channel-shaped
portion 32 and an integral connector portion 34. The channel-shaped
portion 32 includes a first end wall portion 36, a first side wall
38 extending generally perpendicular to and integral with the first
end wall portion 36 and a second side wall portion 40 spaced from
the first side wall 38 extending perpendicular to and integral with
the first end wall portion 36 forming a channel-shaped portion 32
having an opening 39 opposite the first end wall 36 as shown in
FIG. 4. In a preferred embodiment, the first side wall 38 includes
an end portion 42 at or adjacent the opening 39 at the open end of
the channel-shaped portion 32 extending toward the second side wall
40 and the second side wall 40 includes an end portion 44 extending
toward the first side wall 38 for receiving and retaining an end
cap 64 as described below. In one preferred embodiment, the second
side wall 40 also includes a second end portion 46 extending away
from the first end portion 44 and overlying the end wall 48 of the
connector portion 34. The disclosed embodiment of the connector
portion 34 includes an end wall portion 48 which is integral with
the second side wall 40 and generally aligned or continuous with
the first wall portion 36. The connector portion 34 further
includes a leg portion 50 which is spaced from the second side wall
40 and preferably extends generally perpendicular to and is
integral with the end wall portion 48 of the connector portion 34
as shown in FIG. 4. In a preferred embodiment, the leg portion 50
has a shorter length than the side walls 38 and 40 of the
channel-shaped portion 32. In a preferred embodiment of the frame
members 26, the end portions 42, 44 and 46 include an enlarged
bead-shaped cap retainer portion 52 which are generally parallel to
the side walls 38 and 40 and extend toward the first end wall 36
and the end wall 48 of the connector portion, respectively, having
an enlarged bead-shaped cross-section and an arcuate outer exterior
surface to receive and retain end caps as described below.
[0032] As set forth below, the frame members 26 are preferably
interconnected in end to end relation to form rectangular frame
assemblies 24 as shown in FIGS. 1 and 3. In a preferred embodiment,
the channel-shaped portion 32 of each of the frame members 26
includes an internal integral channel 55 configured to receive
corner connectors 54, also shown in FIG. 2. In a preferred
embodiment, the internal channels 55 include a generally L-shaped
portion 56 integral with the first side wall 38 having an end
portion 58 extending toward the first bottom portion 36 and the
internal channel 55 may include a second wall portion 60 which
extends generally perpendicular to and is integral with the first
bottom wall portion 36 generally aligned with the end portion 58 of
the generally L-shaped web portion 56, forming an integral internal
channel 55 in the channel-shaped portion 32 having an opening
opposite the second side wall 40 as best shown in FIG. 4. The
generally L-shaped web portion 56 may also be arcuate or J-shaped
to receive an arcuate corner connector channel 54. As discussed
further below, the frame members 26 (and 26A described below) may
be formed of aluminum and extruded forming a light weight
relatively rigid structure at reduced cost. As shown in FIG. 3, the
ends of the frame members 26 may be mitered or cut at a 45 degree
angle, such that the abutting ends interfit as shown in FIG. 3 to
form the rectangular frame assemblies 24 as best shown in FIG. 2.
The corner connectors 54 in this embodiment are preferably L-shaped
having leg portions 62 which are telescopically received in the
internal channels 55 in the channel-shaped portions 32 of the frame
members 26 to complete the assembly of the rectangular frame
assemblies 24. The flexible film 28 may then be received over the
inwardly projecting end portions 42 and 44 of the side walls 38 and
40, respectively, and secured in place by a first end cap 64 as
shown in FIGS. 2 and 4. Alternatively, as described below, the
entire frame assembly may be assembled before application of the
flexible film 28 and end caps 64.
[0033] In one preferred embodiment, the first end caps 64 include a
planar end portion 66 and projecting generally parallel outwardly
bowed legs 68. As best shown in FIG. 4, the legs 68 may include an
arcuate outer surface 70 and the distal ends 70 of the leg portions
68 may be bowed slightly outwardly to interfit with the arcuate cap
retainer portions 52 of the end portions 42 and 44 of the side
walls 38 and 40, respectively, to securely retain the flexible film
28. The first end caps 64 may be formed from an extruded polymer,
such as polyethylene or polypropylene, and the flexible film 28 is
preferably formed of a heat shrinkable polymer, such as
polyethylene, and the flexible film 28 is then preferably heated
following assembly to stretch the film 28 over the rectangular
frame assemblies 24 and 24A.
[0034] Once the rectangular frame assemblies 24 and 24A are
assembled, as described above, the embodiments of the rectangular
frame members 24 and 24A may be interconnected in side to side
relation by the connector portions 34, as now described, with
reference to FIGS. 6 and 7. First, however, it should be noted from
FIGS. 6 and 7 that the frame members include frame members 26 as
just described and frame members 26A which are substantially a
mirror image of the frame members 26, but may be otherwise
identical. That is, the frame members 26A may be identical to the
frame members 26 except that the channel-shaped connector portion
32A is on the right in FIGS. 6 and 7 and the connector portion 34A
is on the left in FIGS. 6 and 7, whereas the channel-shaped portion
32 of frame member 26 is on the left in FIGS. 6 and 7 and the
connector portion 34 of frame member 26 is on the right in FIGS. 6
and 7. Thus, no further description of the frame members 26A is
required for a complete understanding and the elements of the frame
members 26A are numbered the same as the frame members 26 with the
suffix "A." The rectangular frame assemblies 24 and 24A formed from
the frame members 26 and 26A are then assembled in side to side
abutting relation as shown in FIGS. 6 and 7, with the leg portions
50 and 50A of the connector portions 34 and 34A in abutting
relation and the leg portions are then secured together by suitable
fasteners.
[0035] In an embodiment of the frame assembly shown in FIGS. 5 and
6, the rectangular frame members 24 are retained by a U-shaped clip
74 having parallel leg portions 76 received over the leg portions
50 and 50A of the frame members 26 and 26A, respectively, retaining
the rectangular frame members 24 and 24A in side to side abutting
relation. The U-shaped clips may be formed of a metal, such as
aluminum, but are preferably formed of a relatively rigid extruded
plastic, such as polypropylene. The frame assembly shown in FIG. 6,
may thus be assembled without tools or skilled labor. As will now
be understood, the leg portions 50 and 50A preferably have a length
less than the length of the side walls 38, 40, 38A and 40A to
provide easy access to the connector portions 34 and 34A,
respectively, for securement of the frame members 24 and 24A
together as described. FIG. 5 also illustrates the assembly of two
rectangular frame members 24 and 24A with the U-shaped clip 74,
wherein the leg portions 50 and 50A are first aligned and moved
into abutting relation and the U-shaped clip 74 is then received
over the abutting leg portions 50 and 50A. FIG. 7 illustrates an
alternative means of securing the leg portions 50 and 50A using
conventional rivets 78 received through openings 80 in the abutting
leg portions 50 and 50A. The assembly of FIG. 7 is otherwise
identical to the assembly shown in FIG. 6 and thus no further
description is required.
[0036] The embodiment of the frame assemblies shown in FIGS. 6 and
7 may then be finished and sealed with second end caps 82, which
are identical to the first end cap 64, except for size. That is,
the second end caps 82 include a planar end portion 84 and
generally parallel outwardly bowed legs 86 which are received
between the opposed second end portions 46 and 46A of the second
side walls 40 and 40A, respectively, as shown in FIGS. 5, 6 and 7.
Although the second end caps 82 are optional, they prevent the
accumulation of dust or debris in the connector portions 34 and 34A
and provide a more finished assembly.
[0037] It is important to note that the embodiment of the frame
assembly of this invention shown in FIG. 1 and the frame assemblies
described below may be assembled before application of the film 28
which would be difficult, if not impossible, with the frame
assemblies for environmental enclosures disclosed in the above
referenced prior art. That is, the channel-shaped frame members 26
may first be assembled into rectangular frame assemblies 24, as
described above, and the rectangular frame assemblies may then be
assembled into an enclosure, such as the clean tunnel 20 shown in
FIG. 1, before application of the flexible film 28. This is an
important advantage over the prior art because the flexible film 28
may be damaged during assembly. Following assembly of the
rectangular frame assemblies 24 and 24A, the flexible film 28 is
cut to size and applied over the opposed end portions 42 and 44 or
42A and 44A, and secured in place by the first end cap 64 and
preferably heated to stretch the film in place over the rectangular
frame assemblies 24 and 24A. This is a particular advantage where
the flexible film 28 is transparent because this method of assembly
provides a clear view of the interior of the environmental
enclosure 20. Further, the clear film may be damaged or coated with
debris during use and the configuration of the frame members 26 and
26A makes replacement of the flexible film easy and simple without
requiring tools. The first end caps 26 are simply removed and the
flexible film 28 may be easily replaced. It is also important to
note that the frame assemblies of this invention may also be easily
disassembled and changed or stored without special tools,
particularly where the rectangular frame assemblies are secured in
side to side relation with a clip, such as shown at 74 in FIG.
6.
[0038] The alternative preferred embodiment of the environmental
enclosure or clean tunnel 120 shown in FIG. 8 also includes a
plurality of interconnected frame assemblies 124 interconnected in
side to side relation as described below and the rectangular frame
members 124 are covered with a flexible film 128 which is
preferably stretched over the frame assemblies as described above.
However, in this embodiment of the environmental enclosure 120, the
rectangular frame members 124 preferably have a height equal to the
desired height of the environmental enclosure and may include cross
members 122 for rigidity as described below. As set forth above,
the shape or configuration of the environmental enclosure 20 will
depend upon the application of the environmental enclosure. The
embodiment of the rectangular frame assemblies 124 shown in FIG. 8
are formed from a plurality of channel-shaped frame members 132
best shown in cross-section in FIG. 10.
[0039] As shown in FIG. 10, this embodiment of the channel-shaped
members 132 each include a first end wall 136 and opposed first and
second side walls 136 and 138 which are preferably integral with
and extend generally perpendicular to the first end wall 136. The
channel-shaped members 132 further include an opening 139 opposite
the first end wall 136 for receipt of an end cap 164 as described
above. In this embodiment, however, the end portion or second end
wall 142 of the side wall 138 opposite the first end wall 136
extends to the opening 139, such that the opening 139 is spaced
from the integral internal retainer channel 155 formed by the
generally L-shaped wall 156 integral with the first side wall 138
and the wall 160 integral with the first end wall 136. As described
above, the end portion 158 of the L-shaped internal wall 156
preferably extends toward the first end wall 136 and the end wall
136 further includes an integral internal wall 160 which extends
toward the end portion 158, forming an integral internal channel
155 for receipt of a connector element 154 as described below. As
also stated above, the L-shaped wall 156 may also be arcuate. In
this embodiment of the channel-shaped frame members 132, the
opening 139 opposite the first end wall 136 includes parallel
enlarged bead-shaped portions 152 and 153 having an arcuate outer
surface, wherein the bead-shaped portion 152 at the end of the
second end wall 142 extends toward the first end wall 136 and the
enlarged bead-shaped portion 153 at the distal end of the second
side wall 140 extends inwardly from the second side wall 140 as
shown in FIG. 10. As described above, a preferred embodiment of the
end cap 164 includes a planar portion 166 and generally parallel
outwardly bowed leg portions 168 having an outer surface 170 and
bowed end portions 172 which are securely retained between the
parallel bead-shaped end portions 152 and 153, securely retaining
the flexible film 128. As will be noted, the elements of the
channel-shaped frame members 132 are numbered in the same sequence
as the channel-shaped frame members 32 for ease of
understanding.
[0040] As described above, the rectangular frame assemblies 124 may
be formed by mitering the ends of the channel-shaped frame members
132 at a 45 degree angle as shown in FIG. 9 and the connector
element 154 is L-shaped, as best shown in FIG. 11 having
perpendicular end portions 155 preferably including a plurality of
teeth 157 outwardly inclined from the distal ends in a "Christmas
tree" configuration to securely retain the leg portions 155 in the
integral internal channels 155 formed by the L-shaped wall 156
integral with the first side wall 138 and an opposed wall 160
integral with the first end wall 136. The L-shaped connector
element 154 may be an aluminum extrusion. As will be understood
from the above description of the channel-shaped frame members 132,
this embodiment of the frame members does not include an L-shaped
integral connector portion 34, but this embodiment of the
channel-shaped frame members 32 does not require a mirror image
frame member as described above with reference to FIGS. 5 to 7 and
thus results in less cost and a more rigid construction as
described below.
[0041] FIG. 12 illustrates a suitable tie down of the environmental
enclosure 120 to the floor 180, such as the concrete floor of a
manufacturing facility. In the disclosed embodiment shown in FIG.
12, an L-shaped tie down plate having a horizontal portion 182 is
affixed to the floor 180 by a conventional concrete anchor bolt 184
having a nut 186. The vertical leg 188 is attached to the first end
wall 136 of the channel-shaped member 132 by a conventional machine
screw 190 or the like, forming a rigid support for the
environmental enclosure 120 shown in FIG. 8.
[0042] FIG. 13 illustrates a suitable interconnection between
adjacent channel-shaped frame members 132 in side to side abutting
relation with a U-shaped connector plate 192. As shown in FIG. 13,
the U-shaped connector plate 192 includes a planar central portion
194 having a width slightly greater than the combined width of the
first end walls 136 of two abutting channel-shaped frame members
132 and transverse leg portions 196 which receive the second side
walls 140 of the channel-shaped frame members 132 and the central
portion 194 is affixed to the first end wall 136 by machine screws
198 or the like.
[0043] FIGS. 14 and 15 illustrate a suitable connection between the
vertical channel-shaped members 132 and the cross members 122 shown
in FIG. 8. In a preferred embodiment, the cross members 122 are
identical to the channel-shaped frame members 132 and the
horizontal cross members 122 are attached to the vertical
channel-shaped frame members 132 by a U-shaped connector plate 200
best shown in FIG. 16. The connector plate 200 includes a planar
central portion 202 having opposed transverse slots 204 adjacent to
but spaced from one of the perpendicular leg portions 206. As shown
in FIG. 14, the central portion 202 of the U-shaped connector plate
200 is attached to the first end wall 136 of the vertical
channel-shaped frame members 132 by machine screws 208 or the like.
The transverse leg portions 206 of the U-shaped connector plate 200
are then received within the channel-shaped transverse brace member
122 and secured by machine screws 210. In the preferred embodiment,
the leg portion 158 of the L-shaped internal channel portion is
received in one slot 204 and the opposed internal wall 160 is
received in the opposed slot forming a very rigid construction as
shown in FIG. 15.
[0044] FIG. 17 illustrates a suitable interconnection between the
top transverse frame member 132 of the rectangular frame assembly
124 and a channel-shaped frame member 212 of a rectangular frame
assembly which forms the top of the environmental enclosure 120
generally as shown in FIG. 1. In a preferred embodiment, the
channel-shaped frame member 212 is identical to the channel-shaped
frame member 132 and the rectangular frame assemblies which form
the top of the environmental enclosure (not shown) may be identical
to the rectangular frame assemblies 124 described above. In the
disclosed embodiment, the top channel-shaped frame member 132 is
attached to the channel-shaped frame member 212 by an L-shaped
connector plate 214 which is received against the first side wall
138 of the channel-shaped frame members 132 and 212 and secured in
place by machine screws 214 or the like as shown in FIG. 17. As set
forth above, the channel-shaped frame member 212 may be identical
to the channel-shaped frame members 132 and thus the components of
the channel-shaped frame member 212 are numbered the same as the
components of the channel-shaped frame member 132 in FIG. 17. As
shown in FIG. 17, the machine screws 214 are received through the
integral internal channels 155 formed by the opposed walls 158 and
160 and the flexible film 128 secured by end caps 164 are located
on the inside of the environmental enclosure.
[0045] As will be understood from the above description of the
preferred alternative embodiment of the environmental enclosure 120
shown in FIGS. 8 to 17, the assembly of the environmental enclosure
is similar to the environmental enclosure 20 shown in FIGS. 1 to 7.
That is, the rectangular frame assemblies 124 may be first
assembled, as described above, and the rectangular frame members
may then be covered with a flexible, preferably transparent film
128 and secured by end caps 164. As described above, the flexible
film 128 is then preferably heated to stretch the film over the
rectangular frame assemblies 124 and the flexible film 128 may be
easily replaced if damaged following assembly of the environmental
enclosure. As set forth above, the embodiment of the environmental
enclosure 120 and channel-shaped frame members 132, 202 and 212
have several advantages over the environmental enclosure 20 and
channel-shaped frame members 26 described above, including reduced
costs of manufacturing and assembly and increased rigidity.
However, both embodiments provide important advantages over the
prior art, including reduced weight, ease of assembly and easy
replacement of the flexible film. As set forth above, the
channel-shaped frame members may be formed from extruded aluminum
making the environmental enclosure or clean tunnel 20, 120 light in
weight and relatively rigid, but having sufficient flexibility for
ease of assembly. The environmental enclosure or clean tunnel may
be fixed directly to the floor, such as a concrete floor or steel
platform using power actuated fastening systems, such as pins,
anchor bolts or the like. The upper rectangular frame assemblies
may also be supported by the building structure, using brackets,
cables or the like.
[0046] As will be understood from the above description of the
preferred embodiments of the frame assemblies and environmental
enclosures of this invention, various modifications may be made
within the purview of the appended claims. For example, the opening
to the channel-shaped portion or channel-shaped members may be
configured to receive other end caps as disclosed, for example, in
the prior art. Further, any suitable fasteners may be utilized to
interconnect the adjacent the channel-shaped frame members or the
frame members to the connector plates described above., including
machine screws, bolts or the like The frame assemblies shown in
FIGS. 1 to 7 may be square, as shown, or rectangular with
transverse bracing elements as disclosed in FIGS. 8 to 17. Finally,
as described above, the environmental enclosure or clean tunnel of
this invention may have any configuration depending upon the
application. That is, the enclosure may include end walls at
various locations and venting may be provided, as required. Having
described alternative embodiments of the environmental enclosure,
frame assemblies and channel-shaped frame members of this
invention, the invention is now claimed as follows.
* * * * *