U.S. patent application number 10/969483 was filed with the patent office on 2006-04-20 for corner moldings and coolers made therewith.
Invention is credited to Thomas J. Barr.
Application Number | 20060080920 10/969483 |
Document ID | / |
Family ID | 36179269 |
Filed Date | 2006-04-20 |
United States Patent
Application |
20060080920 |
Kind Code |
A1 |
Barr; Thomas J. |
April 20, 2006 |
Corner moldings and coolers made therewith
Abstract
Novel walk-in coolers and other enclosures, which employ novel
elongate extruded, generally non-insulating corner moldings which
receive thereinto wall panels of the enclosures. The elongate
corner moldings have elongate first and second channels which
extend toward an outer corner of the molding, and extend toward
each other along intersecting, non-parallel paths. The channels are
defined at least in part by the inner and outer walls of the
molding. Each channel is defined by an end wall, and first and
second side walls. A web provides a connection between the inner
and outer walls. Also disclosed are methods of fabricating
enclosures.
Inventors: |
Barr; Thomas J.; (Pickett,
WI) |
Correspondence
Address: |
WILHELM LAW SERVICE, S.C.
100 W LAWRENCE ST
THIRD FLOOR
APPLETON
WI
54911
US
|
Family ID: |
36179269 |
Appl. No.: |
10/969483 |
Filed: |
October 20, 2004 |
Current U.S.
Class: |
52/270 |
Current CPC
Class: |
F25D 2201/126 20130101;
F25D 13/00 20130101; F25D 23/063 20130101 |
Class at
Publication: |
052/270 |
International
Class: |
E04B 7/00 20060101
E04B007/00 |
Claims
1. As a unitary article of manufacture, an elongate corner molding
having a length (L), a width (W), and a depth (D), said corner
molding comprising: (a) inner (2) and outer (4) walls defining
inner (6) and outer (8) surfaces of said corner molding; (b)
elongate first (40) and second (42) channels extending into said
molding toward an outer corner (30) of said molding, and being
defined at least in part by said inner (2) and outer (4) walls,
each said channel (40, 42) being defined by an end wall and first
and second side walls extending away from said end wall in a
generally common direction, the first and second channels extending
along intersecting paths; and (c) a web (36) providing a connection
between said inner wall (2) and said outer wall (4).
2. An elongate corner molding as in claim 1 wherein the channels
(40, 42) are defined in part by said web (36).
3. An elongate corner molding as in claim 1 wherein said web
extends along a path and wherein the path, or a projection of a
general direction of the path, intersects said outer wall (4) at a
location displaced from the outer corner (30).
4. An elongate corner molding as in claim 1 wherein the first
channel (40) extends toward the outer corner (30) and ends at a
first end, and the second channel (42) extends toward the outer
corner (30) and ends at a second different end, and wherein one of
the first and second channels extends closer to the outer corner
(30) than the other of the first and second channels.
5. An elongate corner molding as in claim 4 wherein the one of the
first and second channels extends substantially to the outer corner
(30).
6. An elongate corner molding as in claim 1 wherein said corner
molding is made with polymeric material.
7. An elongate corner molding as in claim 6 wherein the polymeric
material is selected from the group consisting of operable
vinylidene chloride homopolymers and copolymers, operable low
density polyethylene homopolymers and copolymers, operable medium
density polyethylene homopolymers and copolymers, operable high
density polyethylene homopolymers and copolymers, operable
polypropylene homopolymers and copolymers, and operable polyamide
homopolymers and copolymers.
8. An elongate corner molding as in claim 6 wherein the polymeric
material comprises vinylidene chloride polymer.
9. An elongate corner molding as in claim 6 wherein the polymeric
material comprises high impact, low temperature, grade vinylidene
chloride polymer.
10. An elongate corner molding as in claim 1 wherein at least one
of the channels is defined by an end wall, and first and second
side walls extending away from said end wall in a generally common
direction, and wherein said first and second side walls, of at
least one of the channels, extend away from said end wall along
converging paths when said corner molding is at rest.
11. An elongate corner molding as in claim 10 wherein the
converging paths define an angle (.alpha.) of about 2 degrees to
about 15 degrees.
12. An elongate corner molding as in claim 10 wherein the
converging paths define an angle (.alpha.) of about 4 degrees to
about 10 degrees.
13. An elongate corner molding as in claim 1 wherein at least one
of said side walls of a respective one of the channels (40, 42) is
resiliently deflectable so as to facilitate resilient flexing of
the side wall outwardly, thereby to accommodate enlarging of the
respective channel at an opening therein so as to receive and grip
a wall panel being inserted into the respective said channel.
14. An elongate corner molding as in claim 1 wherein each of the
channels is defined by an end wall, and first and second side walls
extending away from said end wall, and wherein each of the first
and second channels has a channel width effective to receive, and
to effectively retain, a wall panel having a thickness of between
about 2 inches and about 6 inches.
15. An elongate corner molding as in claim 1 wherein each of the
channels is defined by an end wall, and first and second side walls
extending away from said end wall, and wherein each of the first
and second channels has a channel width effective to receive, and
to effectively retain, a wall panel having a thickness of between
about 3 inches and about 5.5 inches.
16. An elongate corner molding as in claim 1 wherein each of the
channels is defined by an end wall, and first and second side walls
extending away from said end wall, and wherein each of the first
and second channels has a channel width effective to receive, and
to effectively retain, a wall panel having a thickness of between
about 3.5 inches and about 4.1 inches.
17. An elongate corner molding as in claim 1, said outer molding
wall (4) comprising first (28A) and second (28B) legs extending
from the outer corner (30) of said outer molding wall, said inner
molding wall (2) comprising third (32A) and fourth (32B) legs
extending from an inner corner (34) of said inner molding wall,
said web (36) providing a connection between said first leg (28A)
and said inner wall (2), further comprising a second web (36A)
providing a second connection between said second leg (28B) and
said inner wall (2).
18. An elongate corner molding as in claim 17 wherein each of the
channels (40, 42) is further defined in part by at least one of
said first (36) and second (36A) webs.
19. An elongate corner molding as in claim 17 wherein at least one
of said webs (36, 36A) extends along a path wherein the path or a
projection of a general direction of the path, intersects said
outer wall (4) at a location displaced from the outer corner
(30).
20. An elongate corner molding as in claim 1 wherein said corner
molding is asymmetric with respect to an imaginary line (48)
extending through the inner (34) and outer (30) corners.
21. An elongate corner molding as in claim 1 wherein said corner
molding is substantially symmetric with respect to the inner (34)
and outer (30) corners.
22. An elongate corner molding as in claim 17 wherein said corner
molding is substantially symmetric with respect to the inner (34)
and outer (30) corners.
23. An elongate corner molding as in claim 17 wherein said corner
molding is substantially asymmetric with respect to the inner (34)
and outer (30) corners.
24. An elongate corner molding as in claim 1, said corner molding
having a thermal insulation value, between the inner surface (6)
and the outer surface (8), at the first and second channels,
through a combination of walls of said molding, of less than
R4.
25. An elongate corner molding as in claim 17, said corner molding
having a thermal insulation value, between the inner surface (6)
and the outer surface (8), at the first and second channels,
through a combination of walls of said molding, of less than
R4.
26. An elongate corner molding as in claim 1, said corner molding
having no substantial thermal insulating value between the inner
surface (6) and the outer surface (8), at the first and second
channels, through a combination of walls of said molding.
27. A walk-in cooler defining an enclosed and cooled space, said
walk-in cooler having a plurality of upstanding walls, and
comprising: (a) a first said upstanding wall having a first length
and comprising a plurality of first upstanding wall panels joined
to each other in side-by-side relationship, said first upstanding
wall panels having opposing first inner and first outer surfaces,
and first thermally insulating material between the first inner and
first outer surfaces, effective for use as a first thermal
insulating barrier in defining a first outer wall of the cooled
enclosed space, further comprising a first end one of said wall
panels in said first wall; (b) a second said upstanding wall having
a second length and comprising a plurality of second upstanding
wall panels joined to each other in side-by-side relationship, said
second upstanding wall panels having opposing second inner and
second outer surfaces, and second thermally insulating material
between the second inner and second outer surfaces, effective for
use as second thermal insulating barrier in defining a second outer
wall of the cooled enclosed space, further comprising a second end
one of said wall panels in said second wall, adjacent said first
end one of said wall panels in said first wall; (c) an elongate
corner molding having a length (L), and having inner (2) and outer
(4) walls defining inner (6) and outer (8) surfaces, and
corresponding inner (34) and outer (30) corners of said cornier
molding, and first (40) and second (42) elongate channels defined
by channel side walls and channel end walls, the first and second
channels being adapted and configured to receive the first and
second end ones of said wall panels, the first and second channels
extending along the length (L) of the corner molding, and extending
toward each other along intersecting and non-parallel paths.
28. A walk-in cooler as in claim 27, said molding having a thermal
insulation value, between the inner surface and the outer surface,
at the first and second channels, through a combination of walls of
said molding, of less than R4.
29. A walk-in cooler as in claim 27, said corner molding having no
substantial thermal insulating value between the inner surface (6)
and the outer surface (8), at the first and second channels through
a combination of walls of said molding,.
30. A walk-in cooler as in claim 27, said elongate corner molding
further comprising a web (36) providing a connection between said
inner wall (2) and said outer wall (4).
31. A walk-in cooler as in claim 30 wherein at least one of the
channels (40, 42) in said elongate corner molding is further
defined in part by said web (36).
32. A walk-in cooler as in claim 30 wherein said web extends along
a path and wherein the path, or a projection of a general direction
of the path, intersects said outer wall (4) at a location displaced
from the outer corner (30).
33. A walk-in cooler as in claim 27 wherein the first channel
extends toward the outer corner (30) and ends at a first end, and
the second channel extends toward the outer corner (30) and ends at
a second different end, and wherein the distance between one of the
first and second ends and the outer corner is less that the
distance between the other of the first and second ends and the
outer corner.
34. A walk-in cooler as in claim 33 wherein the one of the first
and second ends is located proximate the outer corner (30).
35. A walk-in cooler as in claim 27 wherein said corner molding is
made with polymeric material.
36. A walk-in cooler as in claim 27 wherein corner molding is made
with polymeric material selected from the group consisting of
operable vinylidene chloride homopolymers and copolymers, operable
low density polyethylene homopolymers and copolymers, operable
medium density polyethylene homopolymers and copolymers, operable
high density polyethylene homopolymers and copolymers, operable
polypropylene homopolymers and copolymers, and operable polyamide
homopolymers and copolymers.
37. A walk-in cooler as in claim 27 wherein said corner molding is
made with impact-grade vinylidene chloride copolymer.
38. A walk-in cooler as in claim 27 wherein said corner molding is
made with high impact, low temperature, grade vinylidene chloride
copolymer.
39. A walk-in cooler as in claim 27 wherein at least one of the
channels is defined by an end wall, and first and second side walls
extending away from said end wall in a generally common direction,
and wherein said first and second side walls, of at least one of
the channels, extend away from said end wall along converging paths
when said corner molding is at rest.
40. A walk-in cooler as in claim 39 wherein the converging paths
define an angle (.alpha.) of about 2 degrees to about 15
degrees.
41. A walk-in cooler as in claim 27 wherein at least one of said
side walls of a respective one of the channels resiliently grips a
respective one of said end ones of said wall panels.
42. A walk-in cooler as in claim 27 wherein each of the channels
has a channel width, between the respective side walls, effective
to receive and hold a said one of said wall panels having a
thickness of about 2 inches to about 6 inches.
43. A walk-in cooler as in claim 27 wherein each of the channels
has a channel width, between the respective side walls, effective
to receive and hold a said one of said wall panels having a
thickness of about 3 inches to about 5.5 inches.
44. A walk-in cooler as in claim 27 wherein each of the channels
has a channel width, between the respective side walls, effective
to receive and hold a said one of said wall panels having a
thickness of about 3.5 inches to about 4.1 inches.
45. A walk-in cooler as in claim 27, said first wall having a top
and a bottom, and further comprising an elongate boot having an
upwardly-open channel extending along the first length of the first
wall, and the bottom of the first wall being received in the
upwardly-open channel of the boot and thereby substantially
separating the first wall from an underlying supporting
surface.
46. A walk-in cooler as in claim 27, further comprising a ceiling
spanning respective ones of said upstanding walls and comprising a
plurality of third generally laterally extending wall panels
extending side by side with respect to each other, said third wall
panels having effective thermal insulating properties suitable for
use as thermal insulating barrier in defining a top wall of such
enclosed space, further comprising at least one elongate ceiling
corner molding joining said third wall panels of said ceiling to at
least one of said upstanding side walls.
47. A walk-in cooler as in claim 46, said at least one ceiling
corner molding having a length (L), and inner (2) and outer (4)
walls defining inner (6) and outer (8) surfaces, and first and
second elongate channels extending along the length (L), and having
thermal insulating value, between the inner and outer surfaces, at
the first and second channels, through a combination of walls of
said molding, of less than R4.
48. A walk-in cooler as in claim 47, said at least one ceiling
corner molding having no substantial thermal insulating value
between the inner surface and the outer surface, at the first and
second channels, through a combination of walls of said
molding.
49. A walk-in cooler as in claim 46, said at least one ceiling
corner molding further comprising a web (36) providing a connection
between said inner wall (2) and said outer wall (4).
50. A walk-in cooler as in claim 49 wherein at least one of the
channels in said at least one ceiling corner molding is defined in
part by said web (36).
51. A walk-in cooler as in claim 27 wherein said at least one
ceiling corner molding is made with polymeric material selected
from the group consisting of vinylidene chloride homopolymers and
copolymers, low density polyethylene homopolymers and copolymers,
medium density polyethylene homopolymers and copolymers, high
density polyethylene homopolymers and copolymers, polypropylene
homopolymers and copolymers, and polyamide homopolymers and
copolymers.
52. A method of building a walk-in cooler, defining a cooled
enclosed space inside the cooler, the method comprising: (a)
assembling a plurality of upstanding walls, at least first and
second such walls each comprising a plurality of upstanding wall
panels cooperating with each other in side by side relationship,
the upstanding wall panels having opposing inner and outer
surfaces, and thermally insulating material between the inner and
outer surfaces, the wall panels being effective for use as thermal
insulating barrier between the enclosed space inside the cooler and
an outer ambient environment; and (b) joining respective pairs of
the at least first and second such upstanding walls to each other,
at non-parallel angles, by inserting edge elements of the
respective upstanding walls into a corner molding, the corner
molding having (i) a length (L), (ii) inner (2) and outer (4) walls
defining inner (6) and outer (8) surfaces, and corresponding inner
(34) and outer (30) corners, of the corner molding, and (iii) first
(40) and second (42) elongate channels, defined by channel side
walls and channel end walls, extending along the length of the
corner molding, and defining cross-sectional channel spaces
therein, the edge elements of the respective upstanding walls being
received in the first and second elongate channels.
53. A method as in claim 52, the respective ones of the upstanding
walls substantially filling the cross-sectional spaces defined by
the respective channels at loci along the lengths of such channels
where the wall edges are received.
54. A method as in claim 52, further comprising assembling a
plurality of the panels thereby to define a ceiling, and joining
edges of the ceiling to the upstanding walls by using further such
corner moldings between edges of the ceiling and the upstanding
walls.
55. A method as in claim 52, further comprising employing at least
one such corner molding having no substantial thermal insulating
value between the inner and outer surfaces at the channels, through
a combination of walls of the molding.
56. A method as in claim 52, further comprising employing at least
one such corner molding comprising a web (36) providing a
connection between the inner wall (2) and the outer wall (4).
57. A method as in claim 56, further comprising employing at least
one such corner molding wherein the web (36) extends along a path
and wherein the path, or a projection of a general direction of the
path, intersects the outer wall (4) at a location displaced from an
outer corner (30) of the molding.
58. A method as in claim 57, further comprising employing at least
one such corner molding wherein the first channel (40) extends
toward an outer corner (30) of the molding and ends at a first end,
and the second channel (42) extends toward the outer corner (30)
and ends at a second different end, and wherein the distance
between one of the first and second ends, and the outer corner, is
less that the distance between the other of the first and second
ends, and the outer corner.
59. A method as in claim 52, further comprising employing at least
one such corner molding wherein the corner molding is made with
polymer material selected from the group consisting of operable
vinylidene chloride homopolymers and copolymers, operable low
density polyethylene homopolymers and copolymers, operable medium
density polyethylene homopolymers and copolymers, operable high
density polyethylene homopolymers and copolymers, operable
polypropylene homopolymers and copolymers, and operable polyamide
homopolymers and copolymers.
60. A method as in claim 52, further comprising employing at least
one such corner molding wherein at least one of the channels is
defined by an end wall, and first and second side walls extending
away from the end wall in a generally common direction, and wherein
the first and second side walls, of the respective channel, extend
away from the end wall along converging paths when the corner
molding is at rest.
61. A method as in claim 60 wherein the converging paths define an
angle (.alpha.) of about 2 degrees to about 15 degrees.
62. A method as in claim 61 wherein at least one of the side walls
resiliently grips the respective upstanding wall received in the
respective channel.
63. A method as in claim 61 wherein widths of the respective
channels (40, 42) generally correspond to thicknesses of the
respective edge portions of the upstanding walls, between the inner
and outer surfaces, as received in the respective channels.
Description
BACKGROUND
[0001] This invention relates generally to walk-in refrigerators,
freezers, coolers, such as are used in the grocery business, and to
other types of walled enclosures such as office cubicles, pet
cages, and the like.
[0002] While the description which follows addresses cooling
enclosures specifically, the moldings and enclosure structures of
the invention can also be applied to other enclosure structures
which use a plurality of wall panels joined together by some corner
structure at intersecting, e.g. non-parallel walls.
[0003] In the art of walk-in coolers, refrigerators, and freezers,
such as are used in the grocery business, flat wall panels are
conventionally joined in edge to edge relationship with built-in
edge locks. Such panels are typically about 24-48 inches wide,
about 6-8 feet long and anywhere from 2 inches thick to about 8
inches thick. Common thicknesses range from about 3.5 inches to
about 4.2 inches.
[0004] Such panels are commonly oriented in an upright manner,
joined edge to edge, in alignment with each other so as to define a
wall of a desired length. Multiple such walls are set up about a
space to be enclosed. Where two walls meet, a special insulating
corner panel is inserted at the corner location and is joined to
end panels of each of the two side walls.
[0005] For new construction, the proper number of panels can be
specified according to the space to be enclosed. However, separate
inventory must be kept of the corner panels relative to the flat
wall panels.
[0006] Where a e.g. cooler is no longer needed, the e.g. cooler can
be disassembled, and the materials saved for use to make another
cooler. While such used materials can well be used to make other
coolers, the number of flat panels on hand relative to the number
of corner panels on hand is a function of the sizes of the e.g.
coolers which have been so disassembled. Where e.g. larger coolers
have been disassembled, and smaller coolers are desired to be
built, the builder experiences a relatively larger number of flat
panels and a relatively lower number of corner panels, whereby the
flat panels can be used only by purchasing new corner panels. But
such corner panels are relatively expensive, negating a primary
benefit of employing used materials to save on cost.
[0007] Accordingly, there is a need for elongate corner panels
which are compatible for use with such flat wall panels, so as to
build enclosures therewith without having to purchase or warehouse
additional new elongate corner panels.
[0008] There is further a need for novel methods of fabricating,
e.g. erecting, walk-in and other enclosures which can benefit from
use of an elongate e.g. extruded corner molding having first and
second elongate channels which receive the edges of wall panels
thereinto.
SUMMARY
[0009] The invention provides novel walk-in coolers and other
enclosures, which employ novel elongate extruded, non-insulating
corner moldings to receive thereinto e.g. insulating wall panels of
the enclosures. The elongate corner moldings have elongate first
and second channels which extend toward an outer corner of the
molding, and extend toward each other along intersecting,
non-parallel paths. The channels are defined at least in part by
the inner and outer walls of the molding. Each channel is defined
by an end wall, and first and second side walls. A web provides a
connection between the inner and outer walls.
[0010] Use of the extruded corner moldings obviates need for more
expensive insulating corner panels in making such walk-in
coolers.
[0011] In a first family of embodiments, the invention comprehends,
as a unitary article of manufacture, an elongate corner molding
having a length, a width, and a depth. The corner molding comprises
inner and outer walls defining inner and outer surfaces of the
corner molding; elongate first and second channels extending into
the molding toward an outer corner of the molding, and is defined
at least in part by the inner and outer walls, each channel being
defined by an end wall and first and second side walls extending
away from the end wall in a generally common direction, the first
and second channels extending along intersecting paths; and a web
providing a connection between the inner wall and the outer
wall.
[0012] In some embodiments the channels are further defined in part
by the web.
[0013] In some embodiments, the web extends along a path and the
path, or a projection of a general direction of the path,
intersects the outer wall at a location displaced from the outer
corner.
[0014] In some embodiments, the first channel extends toward the
outer corner and ends at a first end, and the second channel
extends toward the outer corner and ends at a second different end,
and one of the first and second channels extends closer to the
outer corner than the other of the first and second channels.
[0015] In some embodiments, one of the first and second channels
extends substantially to the outer corner.
[0016] In some embodiments, the corner molding is made with
polymeric material, optionally polymeric material selected from the
group consisting of operable vinylidene chloride homopolymers and
copolymers, operable low density polyethylene homopolymers and
copolymers, operable medium density polyethylene homopolymers and
copolymers, operable high density polyethylene homopolymers and
copolymers, operable polypropylene homopolymers and copolymers, and
operable polyamide homopolymers and copolymers.
[0017] In some embodiments, the polymeric material comprises
vinylidene chloride polymer, optionally high impact, low
temperature, grade vinylidene chloride polymer.
[0018] In some embodiments, at least one of the channels is defined
by an end wall, and first and second side walls extending away from
the end wall in a generally common direction, and the first and
second side walls, of at least one of the channels, extend away
from the end wall along converging paths when the corner molding is
at rest.
[0019] In some embodiments, the converging paths define an angle of
about 2 degrees to about 15 degrees, optionally about 4 degrees to
about 10 degrees.
[0020] In some embodiments, at least one of the side walls of a
respective one of the channels is resiliently deflectable so as to
facilitate resilient flexing of the side wall outwardly, thereby to
accommodate enlarging of the respective channel at an opening
therein so as to receive and grip a wall panel being inserted into
the respective channel.
[0021] In some embodiments, each of the channels is defined by an
end wall, and first and second side walls extending away from the
end wall, and each of the first and second channels has a channel
width effective to receive, and to effectively retain, a wall panel
having a thickness of between about 2 inches and about 6 inches,
optionally about 3 inches and about 5.5 inches, further optionally
about 3.5 inches and about 4.1 inches.
[0022] In some embodiments, the outer molding wall comprises first
and second legs extending from the outer corner of the outer
molding wall, the inner molding wall comprising third and fourth
legs extending from an inner corner of the inner molding wall, the
web providing a connection between the first leg and the inner
wall, further comprising a second web providing a second connection
between the second leg and the inner wall.
[0023] In some embodiments, each of the channels is further defined
in part by at least one of the first and second webs.
[0024] In some embodiments, at least one of the webs extends along
a path wherein the path or a projection of a general direction of
the path, intersects the outer wall at a location displaced from
the outer corner.
[0025] In some embodiments, the corner molding is asymmetric with
respect to an imaginary line extending through the inner and outer
corners.
[0026] In some embodiments, the corner molding is substantially
symmetric with respect to the inner and outer corners.
[0027] In other embodiments the corner molding is substantially
asymmetric with respect to the inner and outer corners.
[0028] In some embodiments, the corner molding has a thermal
insulation value, between the inner surface and the outer surface,
at the first and second channels, through a combination of walls of
the molding, of less than R4.
[0029] In some embodiments, the corner molding has no substantial
thermal insulating value between the inner surface and the outer
surface, at the first and second channels, through a combination of
walls of the molding.
[0030] In a second family of embodiments, the invention comprehends
a walk-in cooler defining an enclosed and cooled space. The walk-in
cooler has a plurality of upstanding walls, and comprises a first
such upstanding wall having a first length and comprising a
plurality of first upstanding wall panels joined to each other in
side-by-side relationship, the first upstanding wall panels having
opposing first inner and first outer surfaces, and first thermally
insulating material between the first inner and first outer
surfaces, effective for use as a first thermal insulating barrier
in defining a first outer wall of the cooled enclosed space,
further comprising a first end one of the wall panels in the first
wall; a second such upstanding wall having a second length and
comprising a plurality of second upstanding wall panels joined to
each other in side-by-side relationship, the second upstanding wall
panels having opposing second inner and second outer surfaces, and
second thermally insulating material between the second inner and
second outer surfaces, effective for use as second thermal
insulating barrier in defining a second outer wall of the cooled
enclosed space, further comprising a second end one of the wall
panels in the second wall, adjacent the first end one of the wall
panels in the first wall; an elongate corner molding having a
length, and having inner and outer walls defining inner and outer
surfaces, and corresponding inner and outer corners of said cornier
molding, and first and second elongate channels defined by channel
side walls and channel end walls, the first and second channels
being adapted and configured to receive the first and second end
ones of the wall panels, the first and second channels extending
along the length of the corner molding, and extending toward each
other along intersecting and non-parallel paths.
[0031] In some embodiments, at least one of the side walls of a
respective one of the channels resiliently grips a respective one
of the end ones of the wall panels.
[0032] In some embodiments, the first wall has a top and a bottom,
and the cooler further comprises an elongate boot having an
upwardly-open channel extending along the first length of the first
wall, the bottom of the first wall being received in the
upwardly-open channel of the boot and thereby substantially
separating the first wall from an underlying supporting
surface.
[0033] In some embodiments the walk-in cooler further comprises a
ceiling spanning respective ones of the upstanding walls and
comprising a plurality of third generally laterally extending wall
panels extending side by side with respect to each other, the third
wall panels optionally having effective thermal insulating
properties suitable for use as thermal insulating barrier in
defining a top wall of such enclosed space, the walk-in cooler
further comprising at least one elongate ceiling corner molding
joining the third wall panels of the ceiling to at least one of the
upstanding side walls.
[0034] In some embodiments, the at least one ceiling corner molding
further comprises a web providing a connection between the inner
wall and the outer wall.
[0035] In a third family of embodiments, the invention comprehends
a method of building a walk-in cooler, defining a cooled enclosed
space inside the cooler. The method comprises assembling a
plurality of upstanding walls, at least first and second such walls
each comprising a plurality of upstanding wall panels cooperating
with each other in side by side relationship, the upstanding wall
panels having opposing inner and outer surfaces, and thermally
insulating material between the inner and outer surfaces, the wall
panels being effective for use as thermal insulating barrier
between the enclosed space inside the cooler and an outer ambient
environment; and joining respective pairs of the at least first and
second such upstanding walls to each other, at non-parallel angles,
by inserting edge elements of the respective upstanding walls into
a corner molding. The corner molding has a length, inner and outer
walls defining inner and outer surfaces, and corresponding inner
and outer corners, of the corner molding, and first and second
elongate channels, defined by channel side walls and channel end
walls, extending along the length of the corner molding, and
defining cross-sectional channel spaces therein, the edge elements
of the respective upstanding walls being received in the first and
second elongate channels.
[0036] In some embodiments, the respective ones of the upstanding
walls substantially fill the cross-sectional spaces defined by the
respective channels at loci along the lengths of such channels
where the wall edges are received.
[0037] In some embodiments, the method comprises assembling a
plurality of the panels thereby to define a ceiling, and joining
edges of the ceiling to the upstanding walls by using further such
corner moldings between edges of the ceiling and the upstanding
walls.
[0038] In some embodiments, the method comprises employing at least
one such corner molding having no substantial thermal insulating
value between the inner and outer surfaces at the channels, through
a combination of walls of the molding.
[0039] In some embodiments, the method comprises employing at least
one such corner molding comprising a web providing a connection
between the inner wall and the outer wall.
[0040] In some embodiments, the method comprises employing at least
one such corner molding wherein the web extends along a path and
wherein the path, or a projection of a general direction of the
path, intersects the outer wall at a location displaced from an
outer corner of the molding.
[0041] In some embodiments the method comprises employing at least
one such corner molding wherein the first channel extends toward an
outer corner of the molding and ends at a first end, and the second
channel extends toward the outer corner and ends at a second
different end, and wherein the distance between one of the first
and second ends, and the outer corner, is less that the distance
between the other of the first and second ends, and the outer
corner.
[0042] In some embodiments the method comprises employing at least
one such corner molding wherein the corner molding is made with
polymer material selected from the group consisting of operable
vinylidene chloride homopolymers and copolymers, operable low
density polyethylene homopolymers and copolymers, operable medium
density polyethylene homopolymers and copolymers, operable high
density polyethylene homopolymers and copolymers, operable
polypropylene homopolymers and copolymers, and operable polyamide
homopolymers and copolymers.
[0043] In some embodiments, the method comprises employing at least
one such corner molding wherein at least one of the channels is
defined by an end wall, and first and second side walls extending
away from the end wall in a generally common direction, and wherein
the first and second side walls, of the respective channel, extend
away from the end wall along converging paths when the corner
molding is at rest.
[0044] In some embodiments, widths of the respective channels
generally correspond to thicknesses of the respective edge portions
of the upstanding walls, between the inner and outer surfaces, as
received in the respective channels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 shows a pictorial representation of a walk-in cooler
of the invention with parts cut away, and parts in exploded
perspective.
[0046] FIG. 1A shows a cross-section of a prior art construction of
corners of walk-in coolers.
[0047] FIG. 2 shows a cross-section of a corner molding of the
invention.
[0048] FIG. 2A shows a cross-section of a corner molding of the
invention, which is a mirror image of the cross-section of FIG.
2.
[0049] FIG. 3 shows a cross-section of a floor boot molding of the
invention.
[0050] FIG. 4 shows a cross-section of a further embodiment of
corner moldings of the invention.
[0051] The invention is not limited in its application to the
details of construction or the arrangement of the components set
forth in the following description or illustrated in the drawings.
The invention is capable of other embodiments or of being practiced
or carried out in other various ways. Also, it is to be understood
that the terminology and phraseology employed herein is for purpose
of description and illustration and should not be regarded as
limiting. Like reference numerals are used to indicate like
components.
DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0052] Referring first to FIGS. 1, 1A, 2, and 2A, FIG. 1
illustrates the basic concept of a walk-in cooler 10 of the
invention, having four side walls 12A, 12B, 12C, and 12D, and a
ceiling 12E. One of the side walls 12A includes an access door 14.
Side walls 12A, 12B, 12C, and 12D are shown generally in their
normal configurations. Ceiling 12E is shown with the moldings as
solid line drawings, and the ceiling panels 16E in dashed line
representation of where the ceiling panels would be if shown in
detail.
[0053] In such coolers, the side walls and the ceiling each
comprise multiple panels 16 such as those shown in FIG. 1, locked
together edge-to-edge by a well-known toggle locking system (not
shown) whereby any two panels can be brought together in edge to
edge relationship, and readily and quickly locked to each other
using common tools. Each panel is e.g. 3.5 inches to 3.75 inches
thick. The core of the panel is a thermally insulating foamed
plastic such as urethane foam, covered on both sides by a skin of
e.g. aluminum sheet.
[0054] FIG. 1A shows a conventional prior art corner panel 20
having left and right legs 22A, 22B. The corner panel is
constructed of the same materials as side wall panels 16, only in a
right angled corner configuration defined by legs 22A and 22B which
meet at outer corner 30 of the cooler at a right angle. Thus, the
outer skins 24 of both flat wall panels 16 and corner panel 20 are
aluminum sheeting, enclosing a urethane foam core 25 of e.g. about
4 pcf density having known substantial thermal insulating value.
Conventional wall panels 16 are mounted in edge-to-edge
relationship to corner panel 20 in FIG. 1A using the conventional
toggle connections, which can also be thought of as cam
connectors.
[0055] Returning to the invention, FIG. 2 shows a cross-section of
a plastic extrusion/molding 26 which is used as a corner molding in
the inventive cooler of FIG. 1. Molding 26 has comparatively little
thermal insulating value relative to the foam-core panels 16, less
than R4 through the webs and walls of the molding, collectively,
between the inner 6 and outer 8 surfaces of the molding.
[0056] The flat side wall panels 16 used in the invention are, or
can be, the same as the panels used in FIG. 1 and FIG. 1A. The
toggle method of joining panel-to-panel is, or can be, the same in
FIG. 1 and FIG. 1A.
[0057] One of the differences between known technology and the
invention is in the construction of the corner of the cooler. The
conventional corner structure of FIG. 1A is essentially an "angle"
insulating panel 20 which forms the corner. Think "angle iron", but
different, lighter weight, materials. The corner structure of the
invention does not use an "angle" insulating panel. Rather, the
cooler structure of FIG. 1 does not need, does not use, any corner
"corner panels". Rather, the structure of the invention uses only
conventional flat side, non-corner, panels; and joins the
non-corner, flat side panels at wall corners using an elongate
molding of the nature of the cross-section seen in FIG. 2. FIG. 2A
is the mirror image of FIG. 2 and can be used equally as well
according to the specific implementation of the invention.
[0058] The elongate expression of corner molding 26 of FIG. 2 is
shown in FIG. 1. As seen in FIGS. 1 and 2, molding 26 has an outer
wall 4, having an outer surface 8, defined by first and second
outer legs 28A and 28B, joined at a first corner 30, and an inner
wall 2, having an inner surface 6, defined by third and fourth
inner legs 32A and 32B joined at a second corner 34, and a
connecting web 36. Web 36 extends from corner 34 at the inner legs
to an intermediate-locus line 38 along the cross-dimension "D" of
outer leg 28A, at a location substantially displaced from outer
corner 30.
[0059] Outer leg 28B, the adjoining portion of outer leg 28A
between loci 30 and 38, and web 36 form a first channel 40 which
receives a first one of the side panels 16, shown in dashed outline
in FIG. 2. Inner leg 32A, web 36, and that portion of outer leg 28A
to the left of line 38 form a second channel 42 which receives a
second one of the side panels 16, also shown in dashed outline in
FIG. 2.
[0060] Corner 30 represents the outer corner of the cooler where
walls 12A and 12B come together on the outer surface of the cooler
in FIG. 1. Corner 34 represents the corresponding inner corner
where walls 12A and 12B come together on the inner surface of the
cooler in FIG. 1. Accordingly, the outer corner portion of the
corner wall structure is occupied generally by side wall 12B in the
embodiment illustrated in FIG. 1 and, correspondingly, not by side
wall 12A. Rather, side wall 12A stops short of the outer corner of
the side wall structure at web 36. Web 36 is the only connection
between the outer legs 28A, 28B and the inner legs 32A, 32B. In the
embodiments illustrated inner legs 32A and 32B share equally in
forming the inner surface of the corner on the interior of the
cooler. Such equal sharing is not a limitation of the
invention.
[0061] The widths of the channels 40, 42 generally correspond to
the thicknesses of the edge portions of the panels which are to be
inserted into the channels. Stated another way, the widths of the
channels, between the respective channel side walls, generally
correspond to the thicknesses of the panels which are contemplated
as being suitable for use with such moldings. Channels 40, 42 are
slightly oversized so as to readily receive panels which are
slightly thicker than anticipated, such as within normal
manufacturing tolerances for such panels.
[0062] Outer leg 28A is much longer (Dimension D) than outer leg
28B. Outer leg 28B and that portion of outer leg 28A which is to
the left of line 38 are optionally, at rest, biased inwardly so as
to form acute angles .alpha. about corner 30 and line 38
respectively. Thus, the side walls e.g. 28B and 36, of a channel,
e.g. 40, extend away from the end wall e.g. 28A along converging
paths when the molding is at rest. That way, if a side wall panel
16 is a bit under-sized, e.g. thinner than the nominal width of the
channel at the end of the channel, the respective outer leg 28A or
28B will still be forced outwardly, thus to expand the channel
opening, as the panel is inserted into the channel, whereby the
respective leg 28A or 28B resiliently grips the wall panel,
anyway.
[0063] Angle .alpha. can desirably be any angle which enables the
respective channel side wall to effectively resiliently grip a wall
panel. To that end, at least one of the side walls of each channel
40, 42 is resiliently deflectable in a channel-widening direction,
so as to facilitate flexing the channel side wall outwardly,
thereby to accommodate enlarging the channel at the channel
openings, so as to receive and grip a wall panel being inserted
into the respective channel. Typical magnitudes of angles a are
about 2 degrees to about 15 degrees, optionally about 4 degrees to
about 10 degrees.
[0064] In FIGS. 1 and 2, end ones of the wall panels in a given
wall e.g. 12A, 12B are received in channels 40, 42, whereby the end
wall panels of the adjacent walls extend toward each other along
intersecting, e.g. non-parallel paths. Pop-riveting or the like
(not shown) can be used to secure the panels 16 in channels 40 and
42 if and as desired. The end result is a secure corner which
enables construction of coolers/cold rooms without the need to
separately stock and inventory any insulating corner panels.
[0065] Exemplary materials for making molding 26 are various of the
plastics such as various of the vinylidene chlorides, various of
the polyolefins such as low density polyethylenes, medium density
polyethylenes, high density polyethylenes, and polypropylenes, as
well as various ones of the polyamides. As referred to herein, such
polymers are intended to include all operable homopolymers and
copolymers, and blends, of the recited materials.
[0066] Exemplary vinylidene chloride copolymer (PVC) material is
available from e.g. PolyOne Corporation, Avon Lake, Ohio. As a
first exemplary PVC from PolyOne, there can be mentioned grade
L0676, which is approved for incidental food contact, and has low
temperature impact capability. Another exemplary PolyOne PVC
material is grade 87416, which has corresponding cold tolerance but
which is not approved for incidental food contact. Still another
exemplary PolyOne PVC material is grade 8700 which has approval for
incidental food contact but does not have specific low
temperature-impact strength. However, a material such as grade 8700
can be used in a low temperature environment where no, or only
rare, impact is anticipated during the anticipated normal use life
of the molding.
[0067] Molding 26 can be fabricated by e.g. extrusion, using
conventional extrusion machines, and conventional extrusion
processes. For a walk-in cooler as illustrated in FIG. 1, each of
legs 28A, 28B, 32A, 32B, and webs 36, optionally 36A, can have the
same cross-sectional thickness. In the alternative, the thicknesses
can differ. A thickness of about 0.08 inch has been found to be
acceptable. A range of thicknesses of about 0.05 inch to about 0.13
inch is contemplated as being operable and economically feasible,
depending on the strength requirements of the specific
implementation. Leg and/or web thicknesses can be increased or
decreased from those recited, to correspond with the strength
requirements of the specific implementation. Such strength
requirements may, for example, depend on size of the enclosure
being built. In light of the disclosure herein, those skilled in
the art are well able to determine the strength requirements, and
to specify leg and/or web thickness accordingly.
[0068] At the base of each side wall 12, the bottom portions of the
side panels 16 are received in an elongate bottom boot 43
illustrated in FIG. 3, having an upwardly-open channel extending
along the length of the wall. The bottom of the wall is received in
the boot channel, whereby the boot separates the wall form the
underlying floor or other underlying support.
[0069] In the alternative, the bottoms of the side panels can be
set directly on the concrete or other floor, or can be recessed
into the floor, both of these latter two bottom mountings being
conventional in the industry where conventional cooler construction
is used.
[0070] FIG. 4 illustrates a second embodiment 26A of the Molding
wherein outer leg 28B is extended in length to equal the length of
leg 28A, and a second web 36A extends from inner corner 34 to a
mid-point 44 on outer leg 28B. In such structure, the outer corner
of the cooler, where side walls e.g. 12A, 12B meet, is represented
by a hollow chamber 46 which spaces both respective panels 16 in
side walls e.g. 12A and 12B from outer corner 30 of the molding. In
such case, only that portion of outer leg 28B which is distal from
locus 44 is biased inwardly, and molding 26A is symmetric about
imaginary line 48 which extends through corners 30 and 34, as
compared to the asymmetry of molding 26 in e.g. FIG. 2.
[0071] In an embodiment not shown, each web 36 and/or 36A can be
independently relocated closer to, or farther away from, outer
corner 30, as desired by design criteria, whereby the resulting
molding, having both webs 36 and 36A, is asymmetric with respect to
imaginary line 48.
[0072] A similar set of panels 16E and molding 26E can be used in
assembling the ceiling. In a first embodiment of the method of
assembling the ceiling to the side walls, the entire ceiling is
assembled, including assembling corner moldings 26 about the edges
of the ceiling assembly, and then the ceiling is set on the tops of
the side walls, with the corner moldings of the ceiling extending
down over the tops of the side walls. In such embodiment,
downwardly-extending channels 40 or 42, typically channel 42,
receive the upwardly-extending tops of the wall panels 26 which
form the respective side walls 12. Such method is generally
illustrated in FIG. 1, with the exception that moldings 26E2 and
26E3 are each represented as two pieces 26E2A, 26E2B and 26E3A,
26E3B. In such method, moldings 26E2 and 26E3 are single moldings
which engage all of the ceiling panels which reach that respective
side/end of the ceiling.
[0073] In an alternative embodiment of assembling the ceiling to
the side walls, and considering a rectangular cooler design when
considered in top view as in FIG. 1, corner moldings 26E, such as
26E1, 26E2A and 26E3A are first assembled e.g. downwardly onto the
tops of three of the side walls, with respective e.g. channels 40
directed toward the center of the cooler enclosure which is in the
process of being constructed. At least first and second such corner
moldings, e.g. 26E2A and 26E3A, on opposing sides of the cooler
extend less than the full length of the inside surfaces of their
respective side walls, by the width of e.g. one of panels 16.
[0074] With the respective corner moldings in place on the tops of
the three side walls, beginning at one end of a pair of opposing
moldings, on opposing side walls, an individual ceiling panel 16E1
is then slid, in a generally horizontal direction, into place in
the channels 40 of the respective moldings which are directed
toward the center of the cooler, thus to assemble the first ceiling
panel 16E1 to the opposing side walls and extending over an edge of
the upwardly-open space which is to be enclosed by the ceiling. A
second ceiling panel 16E2 is then slid into place in the channels
and in side-by-side relationship to the first ceiling panel, and
over the upwardly-open space being enclosed by the ceiling. Third
and subsequent ceiling panels 16E3 and 16E4 are sequentially added
to the ceiling assembly until the remaining ceiling opening
represents the width of a single ceiling panel.
[0075] A final ceiling panel 16E5 is selected. Corner moldings
26E2B, 26E3B, 26E4 are assembled to three of the four edges of the
rectangular ceiling panel 16E5 to make a ceiling panel assembly,
wherein one of the elongate sides of the ceiling panel 16E5 does
not have a corner molding assembled thereto. Each of the three
corner moldings 26E2B, 26E3B, 26E4 has a length which generally
corresponds to the length of that edge of the panel 16E5 to which
it is assembled. Thus, the corner molding 26E4 which extends along
the length of the panel generally corresponds in length to the
length of the panel, allowing for wall corner set-back as shown in
FIG. 1. The two corner moldings 26E2B and 26E3B which extend along
the ends of the panel generally correspond in length to the width
of the panel, again allowing for wall corner set-back.
[0076] With the final ceiling panel assembly thus having the three
corner moldings assembled thereto, the assembly is positioned over
the remaining opening in the ceiling and moved in a downward
direction over the opening. As the ceiling panel assembly is moved
downwardly, the downwardly-extending channels 42 in the ceiling
panel assembly are guided over the upwardly-extending top edges of
the respective side walls 16 which underlie the ceiling panel
assembly. The corner moldings of the ceiling panel assembly thus
move downwardly over, and receive, the upwardly-extending top edges
of the respective portions of the respective side walls while the
long edge of panel 16E5 which has no molding mounted thereto, which
faces panel 16E4, is slid into abutting engagement with the facing
edge of panel 16E4.
[0077] Such assembly process thus completes generally closing off
the ceiling of the enclosed space of the cooler. The respective
ceiling panels 16E1-16E5 are optionally locked to each other using
the locks which are incorporated into each of the respective
ceiling panels.
[0078] As illustrated in describing assembly of the ceiling, any of
the corner moldings can be any desired length such as to facilitate
assembly. Any corner moldings which collectively define a
particular corner can be designed, as desired to overlap or
otherwise engage each other so as to make a continuous closure of
the enclosed space at the respective corner. Further, any of the
corners where e.g. a side wall corner meets a ceiling corner can be
closed off with an additional 3-way corner molding (not shown).
[0079] Those skilled in the art will now see that certain
modifications can be made to the apparatus and methods herein
disclosed with respect to the illustrated embodiments, without
departing from the spirit of the instant invention. And while the
invention has been described above with respect to the preferred
embodiments, it will be understood that the invention is adapted to
numerous rearrangements, modifications, and alterations, and all
such arrangements, modifications, and alterations are intended to
be within the scope of the appended claims.
[0080] To the extent the following claims use means plus function
language, it is not meant to include there, or in the instant
specification, anything not structurally equivalent to what is
shown in the embodiments disclosed in the specification.
Claims Strategy--Summarize Point of Novelty For Each Independent
Claim
[0081] 1. Corner moldings [0082] 27. Walk-in coolers [0083] 52.
Method of making a walk-in cooler
Numbering Set for Case No. 29808
[0083] [0084] 2 inner wall of molding [0085] 4 outer wall of
molding [0086] 6 inner surface of molding [0087] 8 outer surface of
molding [0088] 10 walk-in cooer [0089] 12A, 12B, 12C, 12D side
walls of cooler 10 [0090] 14 access door [0091] 16 side wall panels
in walls 12 [0092] 18 [0093] 20 conventional corner panel (FIG. 1A)
[0094] 22A, 22B legs of panels 16 [0095] 23A, 23B legs of
conventional panel 20 [0096] 24 outer skins of conventional panel
20 [0097] 25 urethane foam core of panels 16, 20 [0098] 26 plastic
extrusion molding [0099] 28A, 28B outer legs of molding 26 [0100]
30 outer corner of molding [0101] 332A, 32B inner legs of molding
26 [0102] 34 inner corner of molding 26 [0103] 36, 36A web [0104]
38 intermediate locus along leg 28A where web 36 joins leg [0105]
40 first channel [0106] 42 second channel [0107] 44 intermediate
locus on leg 28B where web 36A joins leg [0108] 46 hollow chamber
(FIG. 4) [0109] 48 imaginary line through corners 30, 34
* * * * *