U.S. patent application number 15/815364 was filed with the patent office on 2018-03-15 for butyl-free multi-gasket panel joint.
This patent application is currently assigned to KPS Global LLC. The applicant listed for this patent is KPS Global LLC. Invention is credited to James M. Costanza, Ali Taqi.
Application Number | 20180073797 15/815364 |
Document ID | / |
Family ID | 61559701 |
Filed Date | 2018-03-15 |
United States Patent
Application |
20180073797 |
Kind Code |
A1 |
Taqi; Ali ; et al. |
March 15, 2018 |
Butyl-Free Multi-Gasket Panel Joint
Abstract
An insulated panel system includes a joint disposed between two
insulated panels. The joint includes a gasket for increasing the
efficiency of walk-in refrigerator and freezer spaces. A butyl-free
gasket having a plurality of protrusions may be disposed between a
first insulated panel, having a male portion, and a second
insulated panel, having a female portion. A latch mechanism,
disposed in part in the two insulated panels, operably engages to
bring the male portion of the first insulated panel into a sealing
engagement with the female portion of the second insulated panel,
with the gasket disposed therebetween. The plurality of protrusions
of the gasket are compressed between the male and female portions
of the first and second panels, such that a plurality of sealing
junctions are formed between the first and second panels.
Inventors: |
Taqi; Ali; (Southlake,
TX) ; Costanza; James M.; (Flower Mound, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KPS Global LLC |
Fort Worth |
TX |
US |
|
|
Assignee: |
KPS Global LLC
Fort Worth
TX
|
Family ID: |
61559701 |
Appl. No.: |
15/815364 |
Filed: |
November 16, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15248098 |
Aug 26, 2016 |
|
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|
15815364 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25D 23/087 20130101;
E04C 2/38 20130101; E04C 2/292 20130101; E04B 1/6141 20130101; F25D
23/063 20130101; E04B 1/6116 20130101; F25D 23/065 20130101; E04C
2002/004 20130101; E04C 2/526 20130101 |
International
Class: |
F25D 23/06 20060101
F25D023/06; E04C 2/292 20060101 E04C002/292; E04B 1/61 20060101
E04B001/61 |
Claims
1. An insulated panel system, comprising: a butyl-free gasket
having a plurality of protrusions; a first insulated panel having a
male portion with a first part of latch mechanism disposed within
the first insulated panel; a second insulated panel having a female
portion with a second part of latch mechanism disposed within the
second insulated panel, wherein the first part of the latch
mechanism in the first insulated panel operably engages with the
second part of the latch mechanism in the second insulated panel to
bring the male portion of the first insulated panel into a sealing
engagement with the female portion of the second insulated panel,
with the gasket disposed therebetween, and wherein the plurality of
protrusions of the gasket are compressed between the male and
female portions of the first and second panels, such that a
plurality of sealing junctions are formed between the male portion
of the first panel and the female portion of the second panel.
2. The insulated panel system of claim 1, wherein the butyl-free
gasket includes three or more protrusions.
3. The insulated panel system of claim 1, wherein the protrusions
are rounded.
4. The insulated panel system of claim 1, wherein the protrusions
are pointed.
5. The insulated panel system of claim 1, wherein the butyl-free
gasket is operably secured to the male portion of the first
insulated panel.
6. The insulated panel system of claim 1, wherein the butyl-free
gasket is operably secured to the female portion of the second
insulated panel.
7. The insulated panel system of claim 1, wherein the butyl-free
gasket is operably secured to both the female portion of the second
insulated panel and the male portion of the first insulated
panel.
8. The insulated panel system of claim 7, wherein the protrusions
of the butyl-free gasket on the female portion of the second
insulated panel are offset between the protrusions of the
butyl-free gasket on the male portion of the first insulated
panel.
9. The insulated panel system of claim 1, wherein the first part of
the latch mechanism of the first insulated panel extends into an
opening in the second insulated panel to operably engage the second
part of the latch mechanism disposed within the second insulated
panel to bring the male portion of the first insulated panel into a
sealing engagement with the female portion of the second insulated
panel.
10. The insulated panel system of claim 1, wherein the second part
of the latch mechanism of the second insulated panel extends into
an opening in the first insulated panel to operably engage the
first part of the latch mechanism disposed within the first
insulated panel to bring the male portion of the first insulated
panel into a sealing engagement with the female portion of the
second insulated panel.
11. A locking joint for securing insulated veneer panels to an
existing structural panel wall, comprising: a butyl-free gasket
having a plurality of protrusions; a male portion and a female
portion, wherein the male portion comprises a top plate that
terminates at its edge with a sealing flange, and a strut operable
to be inserted into the female portion; the female portion
comprises a flange, sidewall, and base, and wherein the flange of
the female portion is operable to overlap an edge of an adjacent
veneer panel, and the sidewall is operable to abut the edge of the
adjacent veneer panel, and the base is operable to rest against an
existing insulated structural panel, and wherein the gasket is
disposed on the flange of the female portion such that the
plurality of protrusions of the gasket are adapted to sealably
compress between the flange and the veneer panel.
12. The locking joint of claim 11, wherein the butyl-free gasket
includes three or more protrusions.
13. The locking joint of claim 11, wherein the protrusions are
rounded.
14. The locking joint of claim 11, wherein the protrusions are
pointed.
15. The locking joint of claim 11, wherein the male strut comprises
louvres operable to securely engage louvres disposed on the surface
of the sidewall of the female portion to secure the male portion to
the female portion.
16. A sealing joint for use with an insulated structural panel
wall, comprising: a butyl-free gasket having a plurality of
protrusions; and two lateral plate members connected by a vertical
member that runs longitudinally between the lateral members, with
an opening disposed in the vertical member operable to allow a
latch mechanism disposed within the body of a first insulated
structural panel to protrude therethrough to engage a latch bar
disposed within a second insulated structural panel to secure the
two insulated structural panels together, and wherein the
engagement of the latch and latch bar brings the first and second
insulated structural panels in sealing engagement with the gasket
disposed on one or more sides of the vertical member such that the
plurality of protrusions of the gasket sealably couple the vertical
member between the first and second insulated structural
panels.
17. The sealing joint of claim 11, wherein the butyl-free gasket
includes three or more protrusions.
18. The sealing joint of claim 11, wherein the protrusions are
rounded.
19. The sealing joint of claim 11, wherein the protrusions are
pointed.
20. The sealing joint of claim 11, wherein the vertical member is
shaped to engage contours of the first and second insulated
structural panels.
21. A sealing joint for use with an insulated structural panel
wall, comprising: two lateral plate members connected by a vertical
member that runs longitudinally between the lateral members, an
opening disposed in the vertical member operable to allow a latch
mechanism disposed within the body of an insulated structural panel
to protrude therethrough to engage a latchbar disposed within an
adjacent insulated structural panel to secure the two insulated
structural panels together, and wherein the engagement of the latch
and latch bar brings the adjacent insulated structural panels in
sealing engagement with the sealing joint disposed therebetween,
and wherein the lateral plate members contact the surface of the
insulated structural panel.
22. The sealing joint of claim 21, further comprising, a sealing
flange disposed at the edge of the plate member, wherein the
sealing flange is operable to engage the surface of one of the
insulated structural panels.
23. The sealing joint of claim 21, wherein the lateral plate
members are of substantially similar dimensions.
24. The sealing joint of claim 18, wherein the lateral plate member
in contact with an exterior surface of the insulated structural
member is wider than the lateral plate member in contact with an
interior surface of the insulated structural member.
25. A method for sealing a joint between two insulated structural
panel walls, comprising: disposing a sealing joint between two
adjacent insulated structural panels; and actuating a latch
mechanism disposed within one of the adjacent insulated structural
panels such that it engages a latch bar of the adjacent structural
panel, wherein the sealing joint comprises two lateral members
connected by a vertical member that extends the length of the
lateral members, an opening in the vertical member operable to
allow the latch mechanism to engage the latch bar.
26. The method of claim 25, wherein the sealing joint further
comprises a sealing flange at an edge of at least one of the
lateral members operable to sealably contact the surface of at
least one of the insulated structural panels.
27. The method of claim 25, wherein the opening is created by the
actuation of the latching mechanism.
28. The method of claim 25, wherein the engagement of the latch bar
by the latching mechanism draws the adjacent insulated structural
panels in to sealed contact with the sealing joint.
Description
[0001] This application is a Continuation-in-Part of U.S.
application Ser. No. 15/248,098, filed Aug. 26, 2016, which is
hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates generally to structural
insulated panels for use in custom-design and prefabricated walk-in
refrigerator and freezer spaces. More specifically, the present
invention relates to a multi-gasket insulated panel system for
increasing the efficiency of walk-in refrigerator and freezer
spaces.
2. Background of the Invention
[0003] Walk-in refrigerator and freezer spaces are typically
manufactured and assembled using pre-fabricated insulated
structural panels joined together to define the refrigerated space.
The structural panels provide insulation to maintain the
temperature inside the walk-in space using as little energy as
possible. The most vulnerable areas of the insulated space or
located at the joints of the structural panels. Because the air
inside a refrigerated area is often at a lower pressure than the
ambient air outside of the area, the resultant pressure gradient
causes warm air to attempt ingress through the joints between the
panels. This vulnerability inevitably leads to some amount of warm
(and moist) air moving into the joints between panels. As the warm
air cools to at or below the dew point as it moves closer to the
enclosed refrigerated area, condensate may form in the joint, which
in turn may freeze if the pressure gradient is such that the warm
air moves quickly into the joint past the point at which freezing
temperatures are found. In the case of walk-in freezer spaces, this
condensation can freeze in the joint between structural insulated
panels. The ice, warmed by the condensation, can further expand the
joint between the structural panels, causing an additional loss of
thermal insulation, and additional ingress of relatively warm,
moist air, which in turn may result in degradation of the overall
efficacy of the refrigerated space. This degradation can result in
a dramatic increase in the amount of energy required to maintain
the refrigerated walk-in at a suitable temperature for storing
perishable goods. In the case of insulated structural panel freezer
systems, condensation formed at a joint can result in the formation
of ice, which, when formed in, or within the joint can expand the
joint. Expansion of this joint further degrades the efficacy of the
insulated structural panel system, especially at the joint.
[0004] In addition to the problem with existing structural panel
refrigeration systems noted above, over time the structural panels
lose insulative properties around the edges of the structural
members as a function of the type of structural and insulation
materials used, inadvertent damage caused to the exterior surfaces
of the structural panels, and the natural degradation of sealants
used between the joints. Generally, the useful life of a structural
panel refrigerated space is limited to based on the factors listed
above, and can reach an unacceptable level of insulation within a
matter of 7 to 10 years from the original installation.
Accordingly, it would be desirable to have a system that
effectively extends the life of a pre-existing structural
panel-based walk-in refrigerated space. It would also be desirable
to have a system for sealing the joints of structural panel-based
walk-in refrigerated spaces upon original
construction/installation.
SUMMARY OF THE INVENTION
[0005] One embodiment of the invention includes a two-piece locking
insert operable to secure insulated veneer panels to a pre-existing
insulated structural panel wall structure. A female locking insert
has a flange that overlaps the insulated veneer and is secured to
the structural wall with a fastener, which may or may not be
integral to the female portion. A male locking insert is inserted
into the female portion such that it has flanges that overlap the
female locking insert flanges and provide a seal against the face
of the veneer panels. The veneer panels may be configured such that
the seams of the veneers are located along the mid-line of the
insulated structural panels to reduce the amount of refrigerated
air from inside the insulated structural panels from coming into
contact with outside ambient air. The flanges may be of a
dual-density material whereby the edges of the male flanges are
softer than the body of the male insert, thereby permitting a
better seal between the male flange and the surface of the
insulated veneer. In another embodiment, an insulated panel system
for increasing the efficiency of walk-in refrigerator and freezer
spaces. A butyl-free gasket having a plurality of protrusions is
disposed between a first insulated panel, having a male portion,
and a second insulated panel, having a female portion. A latch
mechanism, disposed in part in the two insulated panels, operably
engages to bring the male portion of the first insulated panel into
a sealing engagement with the female portion of the second
insulated panel, with the gasket disposed therebetween. The
plurality of protrusions of the gasket are compressed between the
male and female portions of the first and second panels, such that
a plurality of sealing junctions are formed between the first and
second panels. Certain commercial embodiments of the invention have
already been certified for use by NSF International in applications
that involve the refrigeration of perishable goods.
[0006] Another embodiment includes an I-beam shaped seal that is
inserted between standard structural panels. The I-beam shaped seal
is inserted between standard insulated structural panels. The
I-beam shaped seal includes a flange in accordance with the present
invention that is shaped to create a seal between the flange and
the exterior surface of the insulated structural wall. In one
embodiment, the central portion includes a butyl-free gasket,
having a plurality of protrusions, and openings, such as slits,
slots, or gaps that allow for locking mechanisms to join adjacent
panels together. When the lock mechanism is tightened, the panels
compress the I-beam shaped seal and the plurality of protrusions of
the gasket between the adjacent panels to create an air-tight, or
near air-tight, seal to prevent mitigate the formation of ice
between the panels caused by the ingress of warm air
therethrough.
[0007] Other embodiments in accordance with the spirit and scope of
the invention will become apparent to those of skill in the
art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1A shows traditional insulated structural in accordance
with the prior art;
[0009] FIG. 1B shows traditional insulated structural panels joined
together to form an insulated structural wall;
[0010] FIG. 1C shows a latch and latch bar mechanism used to joint
together insulated structural panels;
[0011] FIG. 1D is a perspective component view of a deconstructed
insulated structural panel system, with a butyl-free gasket having
a plurality of protrusions, in accordance with the claimed
invention;
[0012] FIG. 2A shows an insulated veneer system installed on the
exterior surface of a traditional insulated structural panel
wall;
[0013] FIG. 2B shows the locking joint used to secure insulated
veneer panels to the exterior surface of an insulated structural
panel wall;
[0014] FIG. 3A shows the components of a locking joint to secure
the insulated veneer panels;
[0015] FIG. 3B shows the locking joint of FIG. 3A installed on an
exterior surface of an insulated structural panel;
[0016] FIG. 3C is a cross-sectional view of the components of a
locking joint, with a butyl-free gasket;
[0017] FIG. 4 shows an alternative embodiment of a locking
joint;
[0018] FIG. 4A is a cross-sectional view of the components of an
alternative embodiment of a locking joint with a butyl-free
gasket;
[0019] FIG. 5 shows a perspective view of an I-beam insulator seal
in accordance with an embodiment of the present invention;
[0020] FIG. 5A is a perspective view of the I-beam insulator seal
shown in FIG. 5, with a butyl-free gasket, in accordance with an
embodiment of the present invention;
[0021] FIG. 6 shows a cross-sectional view of the I-beam insulator
seal shown in FIG. 5, in accordance with an embodiment of the
present invention;
[0022] FIG. 6A shows a cross-sectional view of an I-beam insulator
seal shown in FIG. 6, with a butyl-free gasket, in accordance with
an embodiment of the present invention;
[0023] FIG. 7 shows an insulator seal installed between the joints
of insulated structural panels;
[0024] FIG. 8A is a perspective view of a portion of butyl-free
gasket having a plurality of substantially rounded protrusions;
[0025] FIG. 8B is a perspective view of a portion of a butyl-free
gasket having a plurality of substantially triangular protrusions;
and
[0026] FIG. 8C is a perspective view of a portion of a butyl-free
gasket having a plurality of substantially rectangular
protrusions.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention is directed to systems and methods of
maintaining the insulative properties of insulated structural
panels. FIGS. 1A and 1B FIG. 1 generally shows an insulated
structural panel system that, when joined together, form a wall for
a pre-defined or custom-built refrigerated space. In FIG. 1, for
example, two un-joined insulated structural panels 20 are shown as
part of an insulated structural wall 10. Each structural panel 20
is constructed of vertical structural members 22 and horizontal
structural members 24. The structural members 22 and 24 may be
constructed of wood, a composite, metal, or any other suitable
structural material as would be understood by one of ordinary skill
in the art. Structural panels 20 are typically constructed using
sheathing 26, which may be steel, aluminum, or other suitable
sheathing material, which is held into place while an insulating
material, such as closed-cell polyurethane foam (not shown) is
injected between the sheathing 26. The insulated structural panel
is primarily assembled by virtue of the closed-cell polyurethane
foam 28 acting as an adhesive to hold the sheathing and structural
members in place. Insulated structural panels 20 are further
typically design such that the polyurethane foam 28 securely bonds
to metal the sheathing 26, the vertical structural members 22, and
horizontal structural members 24, creating a rigid structural panel
20. The vertical structural members 22 can include male and female
portions to form a tongue-in-groove design. A latch 30 and
latch-bar 32, or other suitable connecting hardware is typically
disposed within the panel to facilitate joining the panels
together. When the latch 30 is actuated to engage the latch-bar 32,
for example, the insulated structural panels are drawn tightly
together, as shown in FIGS. 1B and 1C.
[0028] The width of the structural panel 20 may be determined by
the application for which the insulated structural panels are to be
used. The insulated polyurethane structural panels 20 have a
typical thermal resistance ("R-value") of R-8 per inch. Typically,
insulated structural panels that are 3 to 6 inches in width, have
corresponding R-values of R-24 to R-48. The structural members 22
and 24, however, when constructed of wood, only have a total
R-value of R-3 to R-6. Because of the poor insulative properties of
structural panels manufactured with wood structural members 22,
more warm air moves toward the lower-pressure refrigerated space
predominantly at joint between the structural panels 20. The
warming of the refrigerated space causes the cooling system to work
harder and expend more energy, while the frost between the joints
may ultimately result in the structural panels 20 being pushed
apart or the structural members them self otherwise degraded. In
the case of an insulated structural panel system used for
refrigeration, this condensation may remain in liquid form and
become a source of potential mold or bacterial growth.
[0029] In the embodiment shown in FIG. 1D, the insulated structural
panel system includes a butyl-free gasket 16 having a plurality of
protrusions. In a preferred embodiment, gasket 16 is made out of a
resilient polyether urethane material, but gasket 16 can also be
made of polyester urethane material. The gasket 16 is also
preferably resistant to chemical corrosion and ultraviolet
radiation. The plurality of protrusions of gasket 16 can have
substantially rounded, triangular, rectangular, or other suitable
profiles, as shown in FIGS. 8A, 8B, and 8C, respectively. The
gasket 16 is disposed between the structural panels 20 to mitigate
water vapor permeability therebetween. In a preferred embodiment,
the gasket 16 runs the length of both sides of a male portion of a
vertical structural member to compressably seal between two
structural panels 20 together to form the structural wall 10.
Advantageously, due to the plurality of protrusions of the gasket
16, a plurality of sealing junctions are formed to provide multiple
junctions to prevent the ingress of ambient air or liquid into the
joint. The gasket 16 can be placed along any portion of the
structural panel 20, where a seal is desired. The gasket 16 is
preferably disposed onto the vertical structural members 22 with
adhesive or other suitable material. The gasket 16 can have the
adhesive pre-applied to minimize the mess and waste associated with
manual adhesive application methods.
[0030] FIGS. 2A and 2B show an embodiment of the veneer system in
accordance with the present invention. Veneer panels 50 are
preferably overlayed the existing structural panels 20. Once in
place, the veneer panels 50 are secured in place by locking joints
60. Additionally, veneer panels may be secured to structural panels
20 through the use of an appropriate adhesive, such as construction
adhesive, epoxy, or other suitable gluing substance (not shown).
Preferably, the locking joints 60 are off-set from the joints of
structural members 22. This off-set protects the joints at
structural members 22 from exposure to ambient air, thus reducing
the likelihood of the formation of condensate at the joint. The
veneer panels 50 may be of any desired thickness. Preferably, the
locking joint 60 (as described below) is of substantially similar
depth as the thickness of veneer panels 50.
[0031] FIGS. 3A and 3B illustrate the locking joints in accordance
with one embodiment of the invention. The locking joint 60 is
comprised of a capped male insert 100 and a flanged female joint
200. The capped male insert 100 preferably includes a top plate
110, struts 112, and locking louvres 116. Additionally, the capped
male insert includes seals 114 at the lateral edges of capped top
plate 110. Seals 114 are preferably designed to fit against veneer
panels 50 to reduce the amount of outside air that ingresses
through the joint between veneer panels 50 and within the locking
joint 60. The seals 114 also provide a barrier that reduces the
likelihood that water or cleaning materials will enter the system,
e.g., through high pressure spraying and washing. The seals 114 may
be of the same material as the top plate 110 and struts 112, or may
be of a softer material. In various embodiments, the seals may be
constructed so that, when pressed against the face of veneer panels
50, the seals 114 deform to provide a tighter seal from the ingress
of water and ambient air.
[0032] Flanged female joint 200 is constructed to fit between two
veneer panels 50. In practice, it is preferable, though
unnecessary, for the joint 200 to abut the edges of veneer panels
50. In one embodiment, the base 214 of flange joint 200 is
sufficiently wide to allow a fastener 220 to secure the flange
joint 200 to a structural panel 20. In the embodiment shown, the
fastener 220 is a screw, though other suitable fasteners will be
apparent to one of ordinary skill in the art. In the embodiment
shown, the flanged female joint 200 is constructed as a single
piece, including flanges 210, sidewalls 212, and base 214.
Sidewalls 212 include integral louvres 216 designed to lockably
engage louvres 116 of struts 112 of capped male insert 100. While
locking louvres 116, 216 are shown, other suitable methods to join
parts 100 and 200 may be used, such as other mechanical joints,
adhesive, or fasteners, such as clips or screws.
[0033] The veneer panels 50 are positioned such that they are
adjacent to flanges 210 and sidewalls 212. When the female flanged
joint 200 is fastened to a structural panel 20, with veneer panels
50 fully inserted behind the flange, the female flange joint 200
holds the veneer panels in place. Capped male insert 100 is then
inserted into the flanged female joint 200 such that louvres 116
engaged louvres 216 to lock the capped male insert in place, and so
that seals 114 are in contact with the surface of veneer panels 50
to prevent ambient air or liquid from ingress into the joint
between the veneer panels 50 or structural panels 20.
[0034] As shown in FIG. 3C, a butyl-free gasket 16 may be disposed
to the underside of flanges 210. The gasket is preferably disposed
onto the flanges 210 with adhesive or other suitable material. The
gasket 16 can have the adhesive pre-applied to minimize the mess
and waste associated with manual adhesive application methods. The
pre-applied adhesive allows for ease of application, dry-joint
application, and no wasted time to allow for adhesive drying. When
female joint 200 is secured to structural panel 20 to hold the
veneer panels 50 in place, the gasket 16 is compressed between the
veneer panel 50 and the flange 210. Due to the plurality of
protrusions of the gasket, a plurality of sealing junctions are
formed to prevent the ingress of ambient air or liquid into the
joint. The gasket 16 can be placed along any portion of the female
flanged joint 200, where a seal is desired. Alternatively, the
gasket 16 can be placed on the bottom side of capped male insert
100.
[0035] FIG. 4 shows a cross-sectional view of the components of an
alternative embodiment of a locking joint. In this embodiment,
locking joint 70 includes a prefabricated fastener 220' that
protrudes beyond base 214' to fit into a pre-fabricated receptacle
or pre-drilled hole in structural panel 20. The capped male insert
100' includes a top plate 110', a strut 112', and seals 114'.
Additionally, the strut 112' includes locking louvres 116' on both
sides of the strut 112'. The flanged female joint 200' includes a
narrower space sized to accept the strut 112', and includes locking
louvres 216' similar to the louvres 216 of FIGS. 3A and 3B. The
design of FIG. 4 has the advantage of eliminating the air gap
between struts 112 of FIGS. 3A and 3B.
[0036] As shown in FIG. 4A, a butyl-free gasket 16 can be disposed
to the underside of flanges 210'. The gasket 16 is preferably
disposed onto the flanges 210' with adhesive or other suitable
material. When female joint 200' is secured to structural panel 20
to hold the veneer panels 50 in place, the gasket 16 is compressed
between the veneer panel 50 and the flange 210'. Due to the
plurality of protrusions of the gasket, a plurality of sealing
junctions are formed to prevent the ingress of ambient air or
liquid into the joint. The gasket 16 can be placed along any
portion of the female flanged joint 200', where a seal is desired.
Alternatively, the gasket 16 can be placed on the bottom side of
capped male insert 100'.
[0037] In another embodiment of the present invention, a structural
seal 300 is provided in FIGS. 5 through 7 for disposition between
structural panels 20 to further reduce the loss of refrigeration
from inside a refrigerated enclosure bounded by insulated
structural panels 20 and to prevent condensation from contact from
cooler air leaking through the joint with warmer ambient air on the
outside of such structure.
[0038] As shown in FIGS. 5 and 6, the structural seal 300 of the
present embodiment includes lateral members 310 that terminate on
either end at sealing edges 314. A vertical member 312 is disposed
between the lateral members 310. Preferably, the depth of the
vertical member 310 is such that the interior portions of lateral
members 310 are in contact with the sheathing 26 of insulated
structural panels 20. Additionally, an opening or slit 316 is
disposed within the vertical member 312 that corresponds to the
location of the one or more latches 30 and latch-bars 32 that
connect structural panels 20 to one another. During operation, the
structural seal 300 is disposed between two insulated structural
panels 20. When the latch 30 is engaged with latch-bar 32 to bring
the panel joints snug to one another, the panels are brought into
sealing contact with vertical member 312 to reduce the likelihood
of refrigerated air from within a refrigerated space bounded by
structural panels 20 coming into contact with ambient air on the
exterior, and to prevent unwanted condensation from forming between
the structural panels 20. The lateral members 310 are preferable
disposed directly against the sheathing 26 to extend the portion of
the seal beyond the joint between structural members 22 to move the
potential for leaked air further from the joint itself.
[0039] FIGS. 5A and 6A show that a butyl-free gasket 16 may be
disposed to the underside of flanges 210'. The gasket 16 is
preferably disposed onto the flanges 210' with adhesive or other
suitable material. When the structural seal 300 is inserted between
two structural panels 20, as the latch 30 is engaged with latch-bar
32 to bring the structural panels 20 into sealing contact with one
another, the gaskets 16 disposed on either or both sides of
vertical member 312 are compressed to form a plurality of sealing
junctions therebetween. Due to the plurality of protrusions of the
gasket, a plurality of sealing junctions are formed to prevent the
ingress of ambient air or liquid into the joint. The gasket 16 can
be placed along any portion of the structural seal 300, where a
seal is desired.
[0040] FIGS. 8A, 8B, and 8C show alternative embodiments of the
gasket 16 protrusions. The protrusions can have identical
dimensions or varying dimensions to suit a specific requirement. 6A
shows a cross-sectional view of a butyl-free gasket having a
plurality of substantially rounded protrusions. 6B shows a
cross-sectional view of a butyl-free gasket having a plurality of
substantially triangular protrusions. 6C shows a cross-sectional
view of a butyl-free gasket having a plurality of substantially
rectangular protrusions.
[0041] The present invention achieves several advantages over the
prior art. First, butyl has to be mechanically applied as a 3/8''
bead to the panel, otherwise there will be frost and icing issues.
If frost enters a joint, the cooled space must be defrosted and
resealed. Importantly, the cooled space is never the same. The
present invention simplifies the application process to save time
and money and prevent downtime. Second, over time, the butyl bead
dries out and thins allowing the ingress of air and liquid. The
present invention overcomes those issues via its gasket
composition. Perhaps most importantly, the present invention
provides multiple sealing joints to mitigate the ingress of air and
liquids. Should air or liquid penetrate the first sealing joint,
additional sealing joints remain between the air or liquid and the
joint.
[0042] Any of the inventions disclosed herein, such as locking
joints 100 and 100' or structural seal 300 may be constructed of
any number of deformable polymers with varying degrees of
stiffness. Examples of polymers that may be used in accordance with
the present invention include, but are not limited to, PVC,
plastics, nylons, or other suitable materials that are deformable
when placed under a stress load.
[0043] While the present invention has been described in detail, it
is not intended to be limited. Accordingly, various changes,
variations, and substitutions may be made without departing with
the scope of the invention as disclosed.
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