U.S. patent number 3,729,889 [Application Number 05/071,735] was granted by the patent office on 1973-05-01 for modular insulated panel system.
This patent grant is currently assigned to Pet Incorporated. Invention is credited to Gino L. Baruzzini.
United States Patent |
3,729,889 |
Baruzzini |
May 1, 1973 |
MODULAR INSULATED PANEL SYSTEM
Abstract
A modular insulated panel system in which a series of panels are
assembled together with panel locking and sealing members to form
an enclosed insulated space adapted for different environmental
conditioning than the contiguous area.
Inventors: |
Baruzzini; Gino L. (O'Fallon,
MO) |
Assignee: |
Pet Incorporated (St. Louis,
MO)
|
Family
ID: |
22103239 |
Appl.
No.: |
05/071,735 |
Filed: |
September 14, 1970 |
Current U.S.
Class: |
52/264; D25/33;
D25/1; 52/396.04; 52/396.05; 52/396.06 |
Current CPC
Class: |
E04B
1/6162 (20130101); E04H 5/10 (20130101); E04B
2/7409 (20130101); E04B 1/62 (20130101); F25D
23/063 (20130101); E04B 2002/7468 (20130101) |
Current International
Class: |
E04B
1/61 (20060101); E04B 2/74 (20060101); F25D
23/06 (20060101); E04B 1/62 (20060101); E04H
5/00 (20060101); E04H 5/10 (20060101); E04b
001/343 (); E04b 001/38 () |
Field of
Search: |
;52/264,272-275,396,401,578,582,584,479-481,417,461,465,463,586,620,627,36,307
;248/243 ;264/171 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
46,857 |
|
Aug 1936 |
|
FR |
|
761,444 |
|
Jan 1934 |
|
FR |
|
769,067 |
|
Jun 1934 |
|
FR |
|
775,877 |
|
Oct 1934 |
|
FR |
|
1,336,243 |
|
Jul 1963 |
|
FR |
|
1,452,891 |
|
Aug 1966 |
|
FR |
|
1,354,946 |
|
Feb 1964 |
|
FR |
|
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Ridgill, Jr.; James L.
Claims
What is claimed is:
1. A panel module for a panel system of the type described
comprising an edge forming member including a base wall having
laterally spaced outer edges, and adjacent flanges connected to
said base wall in opposed spaced-apart relation and being
relatively angularly related to each other defining a wedge-shaped
channel therebetween, a liner member having an edge margin disposed
between said flanges and being in surface abutment with one of said
flanges and spaced from the other of said flanges, and bonding
means comprising foam insulation material that is expanded into
said channel between the other of said flanges and said liner
member and hardened in bonding engagement therein to maintain said
edge forming and liner members together.
2. The panel module according to claim 1, wherein said spaced-apart
flanges include a first flange extending from adjacent to one
lateral edge of said base wall substantially in the plane of said
liner member and a second flange extending from said base wall
angularly and adjacent to said first flange.
3. The panel module according to claim 2, including another pair of
angularly disposed spaced flanges formed adjacent to the other
lateral edge of said base wall to define another wedge-shaped
channel, and another second liner member positioned in surface
abutment with the outermost of said other pair of flanges and
maintained therein by said bonding means.
4. The panel module according to claim 3, in which said liner
members extend from said first-mentioned and other wedge-shaped
channels in predetermined spaced parallel planes forming opposite
and substantially planar surface walls of said panel module, and
said foam insulation material forms the sole means for interlocking
said edge forming and liner members together.
5. The panel module according to claim 1, wherein said base wall of
said edge forming member is separated into laterally spaced
segments, and opposed walls being formed on said base wall segments
and extending normal thereto to define an elongated recessed
central channel extending substantially throughout the length of
said edge forming member.
6. The panel module according to claim 5, in which a rigid strip of
reinforcing material is positioned within each of said opposed
channel forming walls.
7. The panel module according to claim 5, in which a cross wall
interconnects said channel forming walls and defines the bottom of
said central channel, and said cross wall is provided with lateral
protrusions extending beyond said spaced channel forming walls
toward said pairs of flanges and in spaced relation with said base
wall segments.
8. The panel module according to claim 5, in which said opposed
walls have laterally aligned openings, and a plurality of laterally
extending pin means being positioned in said openings in
predetermined longitudinally spaced relationship across the central
channel of said edge forming member.
9. The panel module according to claim 8, in which said edge
forming member is T-shaped in cross-section and said opposed
channel walls extend perpendicularly from said base wall segments
to define said central channel, and said spaced-apart flanges being
formed on the lateral edge of at least one base wall segment remote
from said central channel.
10. The panel module according to claim 8, in which said edge
forming member is L-shaped in cross-section and said laterally
spaced base wall segments are in the plane of said liner member
with adjacent edges from which opposed walls extend perpendicular
to define said central channel, and an end wall extending normal to
the plane of said liner member from the lateral edge of at least
one base wall segment remote from said central channel.
11. An insulated panel comprising a pair of opposed liner means
each having opposed pairs of marginal edge portions, at least one
edge portion of one of said liner means being juxtaposed with one
edge portion of the other of said liner means, opposed pairs of
edge members connected in end-to-end framing relation between said
liner means in enclosing engagement with said opposed pairs of edge
portions thereof, a body cavity formed between said liner means and
said edge members, at least one of said edge members including a
base wall extending between said liner means and substantially
normal thereto, a pair of opposed side walls integral with said
base wall, a pair of flange means integrally connected with said
base wall adjacent to said side walls and defining therewith a pair
of substantially wedge-shaped channel means open to said body
cavity, one edge portion of said one and other liner means being
respectively received in said channel means and engaged with said
side walls, and an integral mass of insulation material in said
body cavity and extending into said channel means in bonding
relation between said liner means and edge members for preventing
displacement of said one edge member from said panel.
12. An edge member for an insulated panel comprising an extruded
plastic body of preselected length, a base wall on said body having
interior and exterior surfaces and laterally spaced outer margins,
a pair of outer side walls integrally formed on the outer margins
of said base wall defining the width of said edge member, flange
means integrally connected with the interior surface of said base
wall adjacent to each of said side walls and angling from said base
wall toward said side wall to define a wedge-shaped channel
therebetween, said base wall including a pair of opposed second
wall means integrally connected with said base wall adjacent to the
mid-portion thereof and laterally spaced from said outer side
walls, a cross wall integrally connected between said wall means
and spaced from said base wall, said wall means and cross wall
defining a continuous elongated central channel extending
substantially throughout the length of said base wall, a plurality
of opposed and aligned aperture means in said second wall means,
and being predeterminately longitudinally spaced from each other
lengthwise of said body, and a plurality of pin means received in
said plural opposed aperture means and extending across said
central channel.
13. A modular insulated panel enclosure having a controlled
environment, comprising a first series of horizontally disposed
panel members forming a bottom wall, a second series of vertically
disposed panel members forming opposed side and end walls, a third
series of horizontally disposed panel members forming a top wall,
corner members disposed between adjacent side and end walls, door
assembly means in one of said side and end walls, adjacent panel
members in each of said first, second and third series having
continuous opposed channel means with a plurality of longitudinally
spaced pins therein, first spline members having slots engaged with
said pins in opposed channels and interlocking said adjacent panel
members together, second spline members on said corner members in
interlocking relationship between adjacent side and end wall
panels, shelf means including vertical shelf mounting standards
connected with certain of said spline locking members and
positioned adjacent to the interior surfaces of said second series
of panel members substantially at the juncture of adjacent panel
members, yieldable sealing members having plural sealing lips
sealably engaged between adjacent panel members of said first,
second and third series and other sealing means covering said shelf
standards and having spaced wing flanges with sealing lips engaged
against said interior surfaces adjacent to the juncture of adjacent
panel members.
Description
BACKGROUND OF THE INVENTION
The invention relates generally to panel systems forming partition
walls or complete enclosures, and more particularly to insulated or
isolated spaces having a controlled environment.
Many panel systems have been developed for installation in
different types of facilities and for use by a wide variety of
businesses or industries in which prefabricated partition walls or
complete enclosures are required to form separate adjoining areas
such as office cubicles, laboratory and research facilities,
warehousing or storage facilities, production facilities, treatment
rooms and the like. In many cases, it is essential or highly
desirable to sound-proof certain areas or to maintain different
environmental conditions such as temperature, humidity, atmosphere
and the like. It is manifest that the conditions of use will
usually dictate the minimum requirements and specifications of any
panel system and factors of strength, rigidity, durability,
appearance, etc. will thus be determined. In panel systems forming
enclosed spaces in which environmental control is to be effected,
the integrity of the sealing arrangement is a major factor to
maintain a uniform temperature gradient or minimize moisture
migration or other interchange of atmosphere except as may occur
naturally as a result of ingress or egress.
Without limitation upon the scope of the panel system invention to
other applications in different industries, a typical and preferred
embodiment of the present modular insulated panel system invention
hereinafter selected for purposes of illustration and disclosure
comprises a refrigerated enclosure of the type known in the
refrigeration industry as a walk-in cooler. Such coolers may be
installed in supermarkets or numerous other types of businesses for
the storage of merchandise under refrigeration or other
environmental conditioning than the adjoining area in which the
cooler is installed. In the past such walk-in coolers have been
fabricated with wall panels having a wooden frame within which an
insulating material has been packed and covered by outer
porcelainized metallic casing or liner sheets secured by an
adhesive bonding material. These panels were secured together by
spaced cam locking devices recessed into the wooden frame and
accessible through exterior ports, with sealing gaskets being
provided on adjacent abutting surfaces. Conventional wood or metal
flooring has been utilized and ceiling or top panel structures were
similar. Such panel systems, as others used in industry, have been
expensive to build with problems of maintaining manufacturing
tolerances and quality control, have been expensive to ship and
handle due to the weight and bulk thereof, and have been expensive
to install for like reasons.
SUMMARY OF THE INVENTION
Briefly, the invention comprises a novel modular panel system
adapted to form insulated or sound-proof partition walls or an
entire enclosure, such as a self-supporting insulated cooler for
the storage of refrigerated products. The panel system comprises
modular panel members provided with channel means in or adjacent to
the edge margins and being fabricated with "foam" insulation in a
novel manner to unify the component parts, novel panel locking
members insertable into opposed channel means of adjacent panel
members in interlocking relationship, and novel sealing members
applied between adjacent panel members.
The principal object of the present invention is to provide a novel
panel system permitting the orientation and assembly of panel
members into various arrangements of partition walls and complete
enclosures having sound-proof or insulation characteristics
adapting the delimited area for environmental control.
Another object of the invention is to provide a panel system
utilizing panels fabricated in a novel manner and having optimum
strength, rigidity, and insulation characteristics, and which are
light weight and economically manufactured, stored, shipped and
handled. It is also an object to provide a panel system forming a
complete insulated enclosure that may quickly and easily be
assembled with minimum manpower, time and tools.
Another object is to provide a novel panel interlocking arrangement
for positive engagement between adjacent panels and structural
strengthening thereof.
Another object is to provide novel sealing means for a panel system
that is quickly applied and provides positive sealing engagement
between adjacent insulated members to assure the integrity of the
system for environmental conditioning.
A more specific object of the invention is to provide a panel
system forming a refrigerated enclosure or walk-in cooler for the
refrigerated storage of food products or the like in supermarkets
and other stores.
These and still other objects and advantages will become more
apparent hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
For purposes of illustration and disclosure, the invention is
embodied in the parts and in the arrangements and combinations of
parts hereinafter described and claimed.
In the accompanying drawings which form part of the specification
and wherein like numerals refer to like parts wherever they
occur:
FIG. 1 is a perspective view, partly broken away, of an insulated
cooler cabinet embodying the modular insulated panel system of the
present invention,
FIG. 2 is a fragmentary perspective view of a typical side or end
panel module,
FIG. 3 is a greatly enlarged cross-sectional view taken along line
3--3 of FIG. 2,
FIG. 4 is a fragmentary perspective view of a typical bottom or top
panel module,
FIG. 5 is a greatly enlarged cross-sectional view taken along line
5--5 of FIG. 4,
FIG. 6 is a fragmentary plan view of one form of panel locking
spline embodied in the invention,
FIG. 7 is a fragmentary plan view of another form of panel locking
spline embodied in the invention,
FIG. 8 is a fragmentary perspective view of another form of panel
locking spline embodied in the invention,
FIG. 9 is an enlarged cross-sectional view taken along line 9--9 of
FIG. 8,
FIG. 10 is a fragmentary perspective view of a corner post and a
corner locking spline embodied in the invention,
FIG. 11 is an enlarged cross-sectional view taken along line 11--11
of FIG. 10,
FIG. 12 is a fragmentary perspective view of a corner post and
another corner locking spline arrangement embodied in the
invention,
FIG. 13 is an enlarged cross-sectional view taken along line 13--13
of FIG. 12,
FIG. 14 is a plan view of another panel locking form of spline
embodied in the invention,
FIG. 15 is a plan view of still another form of panel locking
spline embodied in the invention,
FIG. 16 is a fragmentary perspective view of one form of sealing
gasket embodied in the invention,
FIG. 17 is an enlarged cross-sectional view taken along line 17--17
of FIG. 16,
FIG. 18 is a fragmentary perspective view of another form of
sealing gasket embodied in the invention,
FIG. 19 is an enlarged cross-sectional view taken along line 19--19
of FIG. 18,
FIG. 20 is an enlarged cross-sectional view taken along line 20--20
of FIG. 1,
FIG. 21 is an enlarged cross-sectional view taken along line 21--21
of FIG. 1,
FIG. 22 is an enlarged cross-sectional view taken along line 22--22
of FIG. 1,
FIG. 23 is an enlarged cross-sectional view taken along line 23--23
of FIG. 1,
FIG. 24 is an enlarged cross-sectional view taken along line 24--24
of FIG. 1,
FIG. 25 is an enlarged cross-sectional view taken along line 25--25
of FIG. 1,
FIG. 26 is an enlarged cross-sectional view taken along line 26--26
of FIG. 1,
FIG. 27 is an enlarged cross-sectional view taken along line 27--27
of FIG. 1,
FIG. 28 is an enlarged cross-sectional view taken along line 28--28
of FIG. 1,
FIG. 29 is an enlarged cross-sectional view taken along line 29--29
of FIG. 1,
FIG. 30 is an exploded perspective view illustrating the assembly
procedure of the bottom panels,
FIG. 31 is an exploded perspective view showing the initial
assembly procedure of the side and end panels with the bottom and
corner post,
FIG. 32 is an exploded perspective view showing further assembly
procedure of the side or end panels with the bottom,
FIG. 33 is an exploded perspective view of the side panel and door
frame assembly procedure,
FIG. 34 is a greatly enlarged fragmentary elevational detail of the
door frame side and header panel assembly,
FIG. 35 is an exploded perspective view of the assembly procedure
of the top panels,
FIG. 36 is an enlarged fragmentary perspective view illustrating
application of a typical sealing gasket,
FIG. 37 is a perspective view of a special tool used in assembling
the modular insulated panel system embodying the present
invention,
FIG. 38 is a fragmentary perspective view of still another form of
sealing gasket embodied in the invention, and
FIG. 39 is an enlarged cross-sectional view taken along line 39--39
of FIG. 38.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As previously indicated, a preferred embodiment of the modular
insulated panel system invention herein selected for disclosure
purposes comprises a complete refrigerated enclosure of the type
known in the refrigeration trade as a walk-in cooler, generally
designated by reference numeral C in FIG. 1. The cooler C may be
installed in a Room R or suitable space such as the backroom or
processing area of a supermarket having a floor RF and side walls
RS as shown in FIG. 1. The cooler C includes a bottom section or
floor CF, a top section or ceiling CC and opposed side and end
sections or walls CS and CE, respectively, defining the enclosure
and forming an internal storage space or area CA accessible through
the cooler door CD. Although not shown in the drawings, it will be
readily apparent that the area CA is provided with a suitable
source of refrigeration which may be a conventional evaporator unit
usually suspended from the ceiling CC and operated from a remote
condensing unit or refrigerated air may be ducted into the cooler
area CA from a remote evaporator unit.
Still referring to FIG. 1, the walk-in cooler C is provided with a
plurality of groups or series of insulated modules, partitions or
panel members of novel and like construction. The bottom section CF
comprises a first series of sequential panel module or members B1
through B6 and the top section CC comprises a series of similar
sequentially arranged panel module or members T1 through T6,
although the top panel members are oriented in an inverted position
relative to the bottom panels as will be described more fully.
While each of the side and end wall sections CS and CE comprises a
second series of vertical panel module or members (and in other
installations, such as partition walls, such a straight line series
may comprise the entire panel system), the panel members of the
side and end walls are sequentially designated as SE1 through SE12
in a counterclockwise order to correlate with a typical assembly
procedure hereinafter described. In addition, one side or end wall
section includes closure panels D1, D2 and D3 defining an opening
in which door assembly DA for the cooler door CD is mounted. The
side and end panels SE1-SE12 are sequentially assembled with corner
posts P1 through P4 to form the rectangular vertical walls of the
cooler cabinet. The cooler C may also be provided with a shelf
assembly SA, which will be described more fully hereinafter as will
the novel locking members for interlocking the panel system in
assembled relation and the sealing members for sealing between
adjacent panel members.
Referring now to FIGS. 2 and 3 wherein a typical side or end panel
module or member SE (1-12) is illustrated, each of these panels SE
is of predetermined dimension to accommodate the modular aspect of
the panel system. For instance, a standard side or end panel may
have an 8-foot vertical dimension and a width of 4 feet, except
that the panels Se abutting the corner posts P1-P4 will be narrower
by the lateral dimension of the corner post, i.e., a 2-inch post
will require adjacent panels of 46 inches.
Each panel member SE (1-12) comprises inner and outer surface
casings or liners 2,2a of rectangular configuration and having
peripheral edges or margins 2b, the liners 2,2a being spaced apart
by peripherally aligned end caps or edge channel members 3 of
generally T-shaped configuration to define a central cavity filled
with and providing a foam insulation body 4 of polyurethane or the
like. The liners 2,2a are preferably formed of cold rolled
commercial quality sheet steel or the like, and the edge or channel
members 3 are preferably formed of extruded plastic, such as
Acrylonitrile Butadine Styrene (ABS).
As shown best in FIG. 3, the edge or channel members 3 extend
longitudinally along each peripheral margin of the panel member SE
or, in other words, the panel member is enclosed by opposed pairs
of lengthwise and laterally extending members 3 of identical
configuration arranged in overlapping and contiguous relationship
with the juxtaposed marginal edges 2b of the liners 2,2a. The edge
or channel members 3 are provided with spaced apart base portions
5,5a having exterior and interior sides or surfaces 5x,5i and first
or liner abutment flanges 6,6a are integrally formed on the base
portions 5,5a to define the lengthwise side edges thereof and
extend normal to the base portions substantially parallel with the
liners 2,2a. Closely adjacent to and extending in a parallel
direction with the outer liner abutment flanges 6,6a are another
set of locking flanges 7,7a, these second flanges 7,7a being
integrally formed with the base interior surface 5i at a slight
outward angle therewith to define with the adjacent side flange
6,6a wedge or key-stone shaped channels 8,8a therebetween extending
lengthwise of the edge members 3. A pair of opposed, spaced channel
walls 9,9a are also integrally formed with base portions 5,5a
adjacent to the mid-portion thereof to form the T-shaped
configuration and define an elongated spline receiving groove, slot
or channel 10 lengthwise of the base extending peripherally around
the entire side or end wall panel SE. A base or cross wall 11 is
integrally formed across the walls 9,9a to close the groove 10 and
includes integrally formed extensions 11a for displacement
preventing bonding engagement with the insulation body 4. If
desired, strengthening or reinforcing members 12,12a, such as rigid
nylon or metallic strips, may be extruded into the channel walls
9,9a or may be bonded to either surface of the channel walls 9,9a.
A plurality of opposed aligned pin receiving bores or apertures
13,13a are provided through the groove walls 9,9a and reinforcing
members 12,12a in predetermined spaced relation lengthwise of the
edge members SE, and a plurality of spline locking lugs or pins 14
are pressed into and fixedly received in said opposed apertures
13,13a extending across the groove 10. It should be noted that the
location and spacing of pins 14 in the respective panel members SE,
B and T are specific in order to assure closely adjacent or
abutting interlocking engagement therebetween by the locking
members to be described. As shown in FIG. 2, the lateral or shorter
ends of a typical standard panel SE are provided with four pins,
and the longitudinal or vertical sides are provided with seven pins
14, although other pin locking arrangements may be provided. In
addition, longitudinally extending serrations or grooves 15,15a are
provided lengthwise of the base portions 5,5a in the exterior
surface 5x thereof intermediate to the flanges 6,6a and central
channel 10 for sealing purposes, as described hereinafter.
Still referring to FIGS. 2 and 3, in the assembled relationship of
the components of the side and end panels SE, the extruded channel
or first members 3 are provided with the reinforcing strip elements
12,12a and the pins 14 are pressed into the opposed openings 13,13a
in channel walls 9,9a. The channel members 3 are cut to end and
side length with mitered ends and the liner or second members 2,2a
are positioned with the margins 2b in the wedge-shaped channels
8,8a in abutment with the outer flanges 6,6a. A specific or
predetermined amount of polyurethane or like plastic is provided
for each panel module SE and, in applying the froth foaming
process, the plastic expands to completely fill the interior panel
space to surround the pins 14 and channel walls 9,9a, 11,11a and
extend into the wedge-shaped channels 8,8a to firmly hold the liner
margins 2b against flanges 6,6a. It should be noted that no other
fastening means or the like are utilized in forming the panel
members SE.
Referring now to FIGS. 4 and 5 wherein a typical intermediate
bottom panel module or member B (2-5) or top panel T (2-5) is
illustrated, each of these panels is of similar construction to the
side and end panels SE and of predetermined dimension to
accommodate the modular aspect of the panel system. For instance, a
standard intermediate panel may have an 8-foot length to correspond
to the width of two end panels SE and two corner post P and the
lateral or end dimension similarly will be 4 feet.
The end or closure bottom panel members B1 and B6 (or top panels T1
and T6) are also of similar construction, but are dimensioned with
shorter lateral ends, such as 2 feet to provide an overlapping or
offset relationship between the joints of the bottom and top walls
CF and CC relative to the joints of the side and end walls SE.
Still referring to FIGS. 4 and 5, each of the intermediate panel
members B (or top panels T) comprises inner and outer surface
casings or liners 16,16a having peripheral edges or margins 16b,
but the inner liner 16 is predeterminately shorter than the outer
liner 16a. The bottom panel member B (or top panel T) is provided
with the T-shaped edge channel members 3 (identical to those
described with reference to side panels SE in FIGS. 2 and 3)
extending along its outer longitudinal sides to adjacent the ends.
The lateral ends of the intermediate panels B are provided with
L-shaped channel members 17 engaged in overlapping contiguous
relationship with the juxtaposed marginal edges 16b of the liners
16,16a as described hereinafter, with insulation material 4 being
formed into the interior chamber of the panel B in bonding relation
with the liners 16,16a and edge members 3,17.
The L-shaped edge or channel members 17 are formed of extruded
plastic, such as Acrylonitrile Butadine Styrene (ABS), and comprise
spaced apart channel forming walls or legs 18,18a including first
or liner abutment flanges and an end wall or leg 19 formed at right
angles thereto, the base walls 18,18a extending in the plane of the
short liner 16 and the end walls 19 extending normal thereto and
defining the lateral end margins of the panel B. The spaced base
walls 18,18a have exterior and interior sides or surfaces 18x,18i
and the inner surfaces 18i of base walls 18 adjacent the free
margin thereof form abutment surfaces for the end margins 16b of
the shorter panel liner 16. Locking or second flanges 20 are
angularly formed from these inner surfaces 18i to define wedge or
keystone-shaped channels 21 with the base walls 18. Similarly, the
end walls 19 of the channel members 17 are provided with
right-angle edge flanges 19a extending in the plane of the other
liner 16a and forming a surface abutment with the end margins 16b
thereof, and locking flanges 20b are formed from the end walls 19
extending in a parallel direction with the edge flanges 19a and
defining therebetween wedge or keystone-shaped channels 21a.
Each of the L-shaped channel members 17 is also provided with a
pair of opposed spaced channel walls 22,22a integrally formed with
the base wall portions 18,18a to form a T-shaped configuration
similar to the channel members 3 and define an elongated spline
receiving groove, slot or channel 23 lengthwise of the base walls
18,18a extending parallel with and adjacent to the end wall 19 at
each lateral end of the panel member B. A cross wall 24
interconnects the inner ends of the channel walls 22,22a to close
the channel 23, but does not extend laterally beyond into the body
cavity in order to facilitate the flow of plastic into the end
channel members 17 during fabrication. The channel walls 22,22a may
also be provided with reinforcing strip members 25,25a extruded
therein or bonded thereto, and spline locking lugs or pins 26 are
pressed into opposed openings 27,27a in predetermined spaced
relation along the channel 23 and project outwardly of the channel
walls 22,22a into the body cavity. These pins 26 are also
specifically located to assure positive interlocking relationship
between panel members. A series of adjacent serrations or grooves
28 are formed in the exterior surface 18x of the base wall portion
18a adjacent to the outer end wall 19 for sealing purposes. In
addition, the L-shaped channel members 17 are provided with end
caps 29 of rectangular shape and bonded to the base walls 18,18a
and end wall 19 to close the ends of the channel members when
assembled with the liners 16,16a and side channel members 3, the
end caps 29 having grooves 29a conterminous with the channels 23.
It will thus be apparent that the channel means 23,29a extend
across the end portions of the inner panel member surfaces and are
open whereas the channels 10 of the channel members 3 forming the
longitudinal sides of the intermediate panel members B terminate at
the end caps 29 and are closed by a suitable cap to retain the
insulation material in the body cavity.
The assembled relationship of the components of the intermediate
bottom panel modules or members B (or top panels T) is similar to
that previously described with respect to the side and end panels
SE, and the foam insulation comprises the means for holding these
components together without other fastening means being needed. It
should be noted that the wedge-shaped channels accommodate a
sufficient tapering body of foam material to prevent the edge
channel or first members 3,17 from pulling loose from the
peripheral margins 2b,16b of the liner or second members and also
provide a bonding continuity with the main body of insulation 4. It
will also be understood that the so-called wedge-shaped channels
may be different configurations, and the term "wedge or
keystone-shaped channels" is intended to cover all such alternate
configurations.
Referring now to FIGS. 30 and 31 which illustrate steps in an
assembly procedure for the panel system, it will be noted that the
end or closure bottom panel members B1 and B6 (and, similarly, the
top panels T1 and T6) are formed differently than the intermediate
bottom panels B2-5 (and top panels T2-5). Only one longitudinal
edge of the panel member B6 (FIGS. 30 and 31) has a T-shaped
channel member 3 extending between L-shaped channel members 17 at
the short lateral ends of the panel B6, and the other side is
provided with an L-shaped channel member 17 formed with mitered
corners to form a continuous upwardly opening connecting channel 23
in the upper panel surface (16) extending along the two short ends
and outer longitudinal side. The door panels D1, D2 and D3 are
similar in construction to the other side and end wall panel
members SE, but the dimensions thereof will be determined by the
width and height of the door CD.
The assembly or fabrication procedure for all panel modules (SE, B,
T and D) is similar and, accordingly, the fabrication of only one
such panel member SE will now be described. The edge channel or
first members 3 are arranged in a suitable fixture or jig (not
shown) to form the rectangular edge framing of the panel SE with
the liner or second members 2,2a being positioned between the
opposed flanges 6,8 and 6a,8a, respectively. The liners 2,2a are
positioned and held against the outer flanges 6 and 6a such as by
an opposed vacuum-type supporting platen (not shown) in surface
contact therewith and forming a vacuum on the surfaces of the
liners 2,2a while completing the supporting fixture to maintain the
liners in spaced parallel planes during the foaming process. An
aperture (not shown) is formed in one edge member 3 to receive the
injection nozzle of conventional froth foaming equipment, and a
regulated and predetermined amount of raw polyurethane or like
plastic insulation material is injected into the body cavity of the
panel member SE according to conventional froth foaming techniques.
The nozzle is then removed and the aperture plugged during the
period that the expanding foam material essentially fills the voids
in, around and between the liners 2,2a and channel members 3 and
cures to form a solid bond with the liners and channel members to
set the pins 14 in the channel walls 9,9a and form locking wedges
in the keystone channels 8,8a to firmly engage the liner margins 2b
against the outer edge member lips or flanges 6,6a. When the
insulation is cured or set, the plug (not shown) is removed and the
aperture may be filled or dressed in a suitable manner.
The respective panel members herein disclosed are assembled
together to form the panel system of the walk-in cooler C with the
use of spline connecting or locking members S1 (FIG. 6), S2 (FIG.
15), S3 (FIG. 7) and S4 (FIG. 14). The splines S1-S4 are each
provided with a body 30 of flat strip steel or the like having a
predetermined width, length and thickness adapted to be received in
the panel grooves or channels 10,23, the outer edges or margins
30a,30b being provided on the body. As shown in FIG. 6, the spline
S1 is provided with a plurality of like pin receiving bayonet slots
31,31a in predetermined spaced relation in the opposed edges
30a,30b thereof, respectively, for guiding and locking engagement
with the cooperating pins 14 of certain channel members 3 of the
panel members SE, B, T and D, and the spline S3 is provided with
similar pin receiving bayonet slots 32,32a in its opposed edges
30,30a. The spline member S3 is used for locking engagement between
cooperating pins 14 of side and end panels SE with cooperating pins
26 of bottom panels B, but not the top panels T.
The bayonet slots 31,31a and 32,32a of splines S1 and S3 each
comprises an entry opening 33a to an elongated slot 33b extending
lengthwise of the spline members S1,S3 to a rounded pin abutment or
seating surface 33c, the entry opening 33a being defined on one
side of an angular cam surface 33d connecting with the inner side
of the slot 31,32 and the other side of the entry opening 33a has a
rounded and inwardly sloping guide surface 33e. In addition, tool
slots 34 are centrally positioned adjacent each end of the splines
S1 and S3 for use in assembly procedures and using a tool 35, FIG.
37. The tool 35 is formed of rigid sheet steel and has a
keystone-shaped working portion 35b with inwardly converging
margins 35b for positive engagement in slots 34, and a body 35c
with end striking margins 35d for hammer actuation of the tool 35
and the spline member being driven thereby. It will be noted that
the slots 31,32 on both splines S1 and S3 are formed on the
opposite margins 30a,30b with the pin abutment margins 33c in
lateral orientation for direct opposed or lateral alignment of pins
14,26 as will be described, and that the bayonet slots 31 of the
spline S1 formed in each margin 30a,30b are oriented in the same
longitudinal relationship whereas the slots 32 in spline S3 are
offset and reversely formed on opposite sides thereof.
Referring to FIG. 15, the spline locking member S2 is adapted for
cooperation only in conjunction with the spline S1 in certain panel
installations in which a structural supporting or reinforcing
spline is required. The spline S2 is provided with opposed pairs of
U-shaped openings or pin receiving slots 36,36a extending laterally
inwardly in predetermined longitudinally spaced relationship for
releasably securing or locking engagement with the cooperating pins
14 of the panels. Elongated key-ways or slots 36b are provided in
the body 30 of the spline member S2 and is of sufficient length to
permit relative longitudinal movement of splines S1 into locking
engagement.
Referring to FIG. 14, the spline S4 comprises a special final panel
locking spline for the header panel member D3 over the door
assembly DA illustrating one final closure arrangement for a panel
system forming a complete enclosure, such as the cooler C. The
spline S4 is a short locking member having only single bayonet
slots 37,37a formed in each outer margin 30a,30b thereof similar to
the slots 32,32a of the spline S3 and having similar numerals for
like identifying parts. However, the slot (37a) on one side of the
spline member S4 is extended from the pin abutment margin 33c to
the end of the spline to form a marginal edge 30c adapted for end
entry into a channel 10 rather than laterally through an entry
opening 33a as in splines S1 and S3.
Referring to FIGS. 10, 11 and 22 wherein a typical corner post P is
shown, the post P is a square (2.times.2) wooden center post 40
provided with a suitable outer casing 40a compatible with the panel
system finish and, preferably, a plastic casing is extruded
directly onto the post 40. The casing 40a has smooth exterior
surfaces 40b on diagonally opposite corners 40c, and a plurality of
parallel vertical serrations 40d are formed in each exterior
surface immediately adjacent to the other diagonal corners 40e for
sealing purposes to be described. The post P is provided with a
corner spline locking or connecting member S5 of generally W-shaped
configuration utilized for interlocking engagement between adjacent
corner-defining panel members SE, the spline S5 having right
angularly disposed base walls 41,41a in abutting relation on one of
the diagonal corners 40c and being secured to the post P by screws
41b or like fasteners. Rigid steel flange or spline walls 42,42a
are formed integral with the base walls 41,41a; respectively, and
extend outwardly at right angles thereto centrally of the sides of
post P and have free outer margins 43,43a in which a plurality of
vertically spaced bayonet slots 44,44a are formed. The slots 44,44a
are identical to the slots 31,31a of spline S1 (FIG. 6) and are
also laterally aligned and longitudinally oriented in the same
direction. It should be noted that the base walls 41,41a of the
spline S5 may extend to the ends of the post P, but the ends of
spline flanges 42,42a are spaced from each end of the post to
obviate interference with the relative sliding locking action of
splines S1 and S3 during assembly.
As indicated, the cooler C may include a shelf assembly SA, as
shown in FIG. 1, which will comprise at least one shelf 45
supported on shelf brackets 45a vertically adjustably mounted on
one or more interior walls of the cooler. It will be understood
that neither of the shelves 45 or shelf supporting brackets 45a
form a part of this invention, but that suitable standards must be
provided to accommodate the attachment to and vertical
adjustability of such shelves and shelf brackets on the interior
walls. Referring to FIGS. 8 and 9, a combination shelf supporting
standard and spline locking member S6 comprises a locking spline or
connecting body portion 46 and shelf standard body portion 47,
which may be formed separately and welded together or which may be
formed as an integral member, as shown. The spline portion 46 is
essentially identical in construction to the spline S1 and
substitutes therefor where shelves 45 may be desired, and includes
outer margins 48,48a in which laterally aligned and longitudinally
oriented bayonet slots 49,49a are formed as in spline S1. The shelf
standard 47 comprises an elongated tubular member 50 having
predeterminately vertically spaced notches 50a adapted to receive
the mounting lugs of a shelf support bracket 45a in a conventional
manner, and the tubular standard member 50 is secured to or formed
with the spline body 46 intermediate to the margins 48,48a by a
connecting web 51 extending normal to the spline flanges on body 47
and of sufficient depth to span one base portion 5,5a from the
channel 10 of a side panel member SE to position the spline body 47
in the channel 10 with the tubular standard 50 projecting beyond
the panel wall 2. It will be noted that the upper and lower ends of
the spline body 46 are shorter than the vertical dimension of the
standard portion 47 as in the configuration of the corner post P
whereby the upper and lower lateral channels of edge members of the
side panels SE interconnected by the spline S6 will not be
obstructed for relative sliding movement of a transversely
extending spline member (S1,S3) crosswise of the ends of spline S6.
In addition, a top wall CC support plate 52 may be welded or
otherwise secured to the upper end of the shelf standard tubular
body 50 and web 51, and is provided with openings 52a for
supplemental attachment to the top wall panel T as with screws or
the like (not shown).
Referring to FIGS. 12 and 13, a similar shelf bracket standard 53
may be provided on a corner post P, the standard having an angular
base wall 54 abutting the base walls 41a,41b of a corner spline S5
and being welded or otherwise attached thereto and the web 50a and
tubular bracket mounting portion 50 projecting at a diagonal angle
to the corner post P.
In connection with the shelf assembly SA and with reference to
FIGS. 27, 28, 38 and 39, a novel sealing gasket or cover member G1
is provided for the shelf bracket standard 47,53 to prevent
entrapment of foreign matter in the tubular portions 50 and to
provide an interior seal of the joints between adjacent side walls
SE interlocked by the spline and bracket standard member 36. The
cover member G1 is preferably extruded from a suitable flexible
plastic, such as Ethylene Vinyl Acetate (EVA), and comprises an
imperforate U-shaped body 56 having an interior wall 56a adapted to
snugly receive and encase the tubular portion 50 of the shelf
standard body 47 and a pair of diverging wing flanges 56b are
formed integral therewith and have converging or tapering walls to
provide longitudinal sealing lips 56c at the free edges. The
U-shaped body 56 and wing flanges 56b are joined by a reduced wall
thickness created by a longitudinal recess in the outer walls 56d
to increase the flexibility and resiliency of the flanges and
sealing lips for firm sealing abutment with the panel member walls
2. The imperforate body 56 is pressed over the tubular standard
body 50 and, when the shelf bracket location is determined, a notch
or kerf 56e (indicated in broken lines in FIG. 38) is made in the
body 56 at the appropriate shelf standard notch 50a.
Referring to FIGS. 16, 17, 22, 23, 24, 26 and 36, the form of novel
sealing or gasket member G2 shown is adapted to be utilized in both
exterior and interior sealing of vertical joints between adjacent
panels and exterior sealing of horizontal joints between adjacent
panels. This gasket member G2 is also extruded from a suitable
flexible plastic, such as Ethylene Vinyl Acetate (EVA) into
elongated sealing strips cut to predetermined length. In
cross-section, the gasket member G2 comprises an arcuate outer
flange or head portion 57 and an inner body portion 58 formed
integral with the head portion 57 at the central portion and
extending normal thereto. The head portion 57 has a thicker central
portion 57a and the arcuate flange walls 57b converge or taper to
form longitudinal sealing lips 57c at the outer free margins. The
body portion 58 is also thicker at its juncture with the head
portion (58b) and has converging or tapering walls 58b, and a
plurality of directly laterally opposed V-shaped sealing lips 58c
are formed on the body 58 at an outward angle extending toward the
head portion 57.
Referring to FIGS. 18, 19, 22 and 25, another form of novel sealing
or gasket member G3 is shown to be utilized in sealing both
horizontally and vertically extending interior corner joints, this
gasket member G3 may also be extruded of EVA or the like. The
gasket member G3 has an arcuate outer flange or head portion 59 and
an inner body portion 60 formed integral with the head portion
intermediate its lateral edges. The head portion has a thicker
central portion 59a and the arcuate, laterally extending flanges
have tapering walls 59b forming longitudinal sealing lips 59c on
the free margins. The body portion 60 has angularly related wall
sections with a thick wall portion 60a connecting with the head
portion 59 and extending normal thereto and a tapering wall portion
60b extending angularly therefrom. A plurality of opposed V-shaped
sealing lips are formed on the body portion 60, but are offset
relative to each other with a single major lip 60c being formed on
the open, obtuse side at the juncture of the wall sections 60a,60b
to extend in a plane substantially parallel with the general plane
of the head portion 59 and a pair of minor lips 60d being formed on
the other side of wall section 60b beyond the major lip 60c from
the head section 59 at an outward angle extending toward the head
section 59.
In addition to the sealing members G1, G2 and G3, conventional
elongated gasket strips or tapes G4 of rectangular cross-section
are utilized on certain joints of the panel members B and SE on the
exterior sides adjacent to the floor RF and side walls RS of the
room and the exterior joints of the ceiling panels T also may be
provided with the gasket strips G4 although in many installations,
where ample overhead clearance is provided, the gasket member G2
may be used.
Referring briefly to FIGS. 1, 20 and 21, the interior floor of the
cooler C may be covered by any suitable planking to prevent
concentrated stresses upon the panel members B and translate any
forces laterally of the centers of such panels through the edge
members 3,17 to the floor RF. For instance, tool grade fiberboard
sheets 61, such as Masonite "Benelex" may be used, and the joints
between panels and around the periphery may be sealed with a
suitable caulking or resilient thermo-expansion material 62.
Referring now to FIGS. 1, 29 and 33, the door assembly DA comprises
a main exterior frame 63 having side and header frame members 63a
and 63b, respectively, formed of extruded fiberglass, plastic or
the like compatible with the cooler panel construction. The frame
members 63a,63b have foam insulation sections 64 and a wooden core
section 64a separated by mullions 64b, the wood core 64a comprising
a mounting post for the door CA, and plural hinge bases 65 being
secured thereto. A peripheral flange 66 is formed to abut the
adjacent door panel D1, D2 or D3 and a rubber adhesive seal tape
66a is provided therebetween. The exterior frame 63 is secured in
place with the panels D1, D2 and D3 by an interior T-shaped frame
67, such as an aluminum extrusion having side and header members
67a and 67b, respectively, with outer peripheral flanges 67c
abutting the panels D1, D2 and D3 in opposed relation with the
flanges 66 and inner flanges 67d secured to the outer frame 63 by
molyjacks and machine screws 68 or the like. Rubber adhesive
sealing tape 68a is also applied between the flanges 67c, 67d and
the panels D and outer frame 63, respectively.
The cooler door CD is similar in construction to the panel members
D, SE, B, and T, comprising spaced casings, or liners 70,70a and
peripheral edge members 71 having spaced outer and inner flanges
72,72a and 73,73a, respectively, and an insulation body 74 of
polyurethane foam or the like. The edge members 71 are
substantially L-shaped forming an outer flange area 71a overlapping
the door frame assembly DA and a main body (74) of substantial
thickness. Rigid plates 75 and 75a are secured together and mounted
in the flange area 71a of the door to provide for mounting either
edge or butt hinge members 76 to the door CD. A flanged recess 77
is formed in the edge members 71 peripherally around the door CD
and a resilient accordian gasket 78 has a wedge or arrow-shaped
mounting element 78a seated in the recess 77 in engagement with the
flange walls 77a. The accordian gasket 78 carries a strip magnet 79
for sealing engagement with a channel member 80 of stainless steel
applied to the opposed wall of door frame 68 and housing anti-sweat
heaters 80a. A handle 81 is provided on the door CD.
ASSEMBLY OF THE PREFERRED EMBODIMENT
Referring now particularly to FIGS. 1, 20-28 and 30-35, an assembly
procedure for the panel system embodied in cooler cabinet C will
now be described although believed to be readily apparent from
these sub-assembly and assembly figures of the drawings. The
assembly of the cooler C preferably begins in the corner of a room
R or along a side wall RS thereof in the desired construction area
and logically would commence with bottom panels B1 and B2, but the
other end closure and bottom panels B6 and B5 are illustrated in
FIG. 30 and description of their assembly will also have reference
to panels B1 and B2, respectively.
In the cooler assembly, the bottom closure panel B6 is positioned
in its desired location on the floor RF with the panel B5 adjacent
thereto and their longitudinal edge members 3 in opposed relation,
and the desired lengths of sealing tape or gasket G4 is applied in
sealing engagement over the serrations 15,15a of the edge members 3
next to the floor (FIG. 20). Spline members S1 and S2 are then
inserted laterally into the groove 10 of the panel B6, spline S2
having its grooves 36a received on the pins 14 and spline S1 having
its access openings 33a oriented on the same pins 14. Although two
short sections of the spline S2 are shown, a single long spline may
be provided as it is laterally engaged with the panels (B) to
stabilize against relative longitudinal movement, whereas two short
sections of spline S1 are used in securing the bottom panels B6 and
B5, etc., together. The panel B5 is then moved laterally against
the panel B6 so that the splines S1 and S2 are received in the
channel 10 thereof and the access openings 33 and grooves 36 are
oriented on the pins 14 therein. The locking tool 35 (FIG. 37) is
inserted in the joint between the panels with its key portion 35a
positioned in the slot 34 of one short spline S1 and slidably
received in the key groove 36b of spline S2, and the tool 35 is
driven longitudinally so that the opposed pins 14 in the slots
31,31a are cammed together along the guide surfaces 33e and
positioned on the pin abutment surfaces 33c. The other spline S1 is
then engaged with pins 14 of the opposed panel members and, as
shown by arrows in FIG. 30, the splines S1 are reversely oriented
to be moved in opposite directions (toward each other) to cooperate
with the spline S2 against racking or relative lateral or
longitudinal movement of the panels B6 and B5. The sealing strips
G4 are thus drawn together into sealing engagement in the locked
condition of the panels B6 and B5.
The remaining bottom panels B4, B3, B2 and B1 are then sequentially
arranged and interlocked with each other in the same manner to form
a first series of panels of the cooler panel system. As indicated
in FIGS. 1 and 31, the assembled floor or bottom wall CF will have
its exterior defined by the edge members 17 thereby forming a
smooth exterior wall surface 19 and a continuous upwardly opening
channel 23 adjacent to the outer wall 19 in the upper surface of
the bottom wall CF about the periphery thereof.
Referring to FIGS. 1 and 31, the side and end walls CS and CE are
assembled on the bottom wall CF beginning in one corner of the
cooler C. The assembly of these panel members SE and posts P will
be described commencing with the panels SE1 and SE2 and the post
P1, and proceeding in a counterclockwise direction, although the
assembly may begin in any corner and preferably will be on the side
or end wall in which the door assembly DA is provided and
preferably will commence on a corner adjacent to a side wall RS of
the room R and the assembly proceed along such side wall RS, as in
a clockwise direction beginning with panels SE 10 and 11 and corner
post P4.
In the assembly of side and end panels SE, short spline members S3
are positioned in the channel means 23 adjacent to and extending
from the corner (P1) with the access openings 33a of the lower
slots 32a being oriented on the pins 26. The panels SE1 and SE2 are
then placed in a vertical position over the splines S3 and the pins
14 of the lower lateral edge members 3 oriented in the access
openings 33a of the offset and reversely formed upper slots 32
whereby the panels SE1 and SE2 are adjacent to, but spaced
laterally away from their final assembled position with the corner
post P1. One of the panels (SE1) is pushed in a direction toward
the corner and such sliding panel movement along the spline S3
causes the pins 14 to be cammed into the upper slots 32 and thus
translate such movement to the spline S3 to cam the pins 26 into
the lower slots 32a and bring the panel member SE1 into its final
assembled position.
The corner post P1 is then held in an elevated position spaced
above the bottom panel B6 and the spline wall 42 of corner spline
S5 inserted into the longitudinal vertical channel 10 of panel SE1
with the access openings 33a of slots 44 being oriented on the pins
14. The corner post P1 is held in this position while end panel SE2
is placed on its spline S3 and moved laterally toward corner post
P1 into final position to be interlocked with the bottom panel B6,
as previously described with respect to side panel SE1, and to
orient its vertically spaced pins 14 in longitudinal channel 10 in
the access openings 33a of the slots 44a of spline wall 42 a. The
corner post P1 is then driven downwardly to cam the pins 14 on
adjacent panels SE1 and SE2 into the bayonet slots 44,44a of the
corner spline S5. It will now be apparent that the cooperable
action of the bayonet slots with the respective pins 14,26 draws
the adjacent panel members firmly together in an interlocked
relationship and that the initial corner assembly of panels SE1 and
SE2 with post P1 is self-supporting so that the sequential assembly
of side and end panel members SE3-SE12 with the corner posts P2-P4
can proceed, as now described.
With reference to FIG. 32, the next end panel SE3 is positioned in
offset relation on another short spline S3 oriented on pins 26 in
the longitudinal channel 23 of bottom panel B6 and long splines S1
and S2 are vertically oriented in the longitudinal channel 10 of
the panel SE2, the spline S2 being moved laterally into final
assembled position with its grooves 36 being received on the pins
14 and the spline S1 being raised to orient the access openings 33a
on the same pins 14. The end panel SE3 is then moved laterally
toward the panel SE2 to cam the short spline S3 into interlocking
relationship between the bottom panel B6 and the end panel SE3, and
the vertical splines S1 and S2 are thus received into the
longitudinal groove 10 and oriented on the pins 14. Spline S1 is
driven downwardly to effect the final interlocking action between
the end panels SE2 and SE3.
As indicated, the same procedure is followed in assemblying corner
post P2, the sequential series of side panels SE4-SE8 of the side
wall CS, the corner post P3, the sequential series of end panels
SE9 and SE10, the corner post P4 and the side wall panels SE11 and
SE12. Similarly, the panel members D1 and D2 are moved laterally
into assembled interlocked position with the adjacent side panels
SE12 and SE1, respectively, leaving only the assembly of panel D3
to complete the side and end wall enclosure of the cooler C.
The panel D3 must be vertically moved into position between panels
D1 and D2 and interlocked therewith and special splines S4, see
FIGS. 14, 33 and 34, illustrate this procedure. As shown, the panel
D3 has short vertical sides with two pins 14 in the channel 10
(although only one such pin may be provided in some panel systems)
and, as in other side and end panels SE and D, all channels 10
extend straight through to the outer edges of the panel to permit a
spline to be inserted from the channel end. Accordingly, the spline
S4 has the "open" slot 37a formed on one side with a straight wall
30c extending to the end of the spline from the pin seating margin
33c. A spline S4 is positioned with its normal slot 37 on the
second pin 14 from the top in vertical groove 10 of each panel D1
and D2 with the open slot 37a facing upwardly to be received in the
opposed vertical channels 10 of panel D3 for engagement with the
lower pin 14 therein. Another spline S4 is inverted or reversely
positioned with its normal slot 37 being received on the upper pin
14 of each side channel 10 of the panel D3, and these splines S4
are held in place as the panel D3 is moved vertically downwardly
between the opposed panels D1 and D2 to bring the oppositely acting
splines into final interlocking orientation between these
panels.
The door assembly DA will usually constitute the last step in the
structural assembly procedure except for application of certain
sealing members G1, G2 and G3 and the top wall CC assembly will
next be described.
Referring to FIGS. 1 and 35, the top panel members T1-T6 are
assembled in a similar sequential series as the bottom panels
B1-B6, and preferably the assembly will commence with the end
closure T1 adjacent to the side wall RS of the room R. However, as
shown in FIG. 35, the procedure will be described beginning with
the panel T6.
Two short splines S1 are oriented in outwardly spaced relation in
the laterally extending end channels 10 of the end panels SE2 and
SE3 with the access openings 33a of lower slots 31a being located
on the pins 14 and longer splines S1 are likewise positioned in the
upper channels 10 of the side panels SE1 and SE4. The panel member
T6 is positioned over these side and end walls with its channel 23
facing downwardly and the upper slots 31 of the splines S1 are thus
directly oriented with the pins 26 therein. The tool 35 is again
used to drive the end wall splines S1 relatively toward each other
(or away from each other) to cam the pins 14 and 26 into the slots
and interlock the top panel T6 with the end wall panels SE2 and
SE3, but the other splines S1 on the side panels SE1 and SE4 are
not set at this time.
The next step in top wall assembly is to position the next set of
splines S1 in the upper channels of side wall panel members and to
position short splines S1 and S2 (or one long spline S2) in the
longitudinal channel 10 of edge member 3 of the panel T6. The panel
member T5 is then positioned with its channels 23 of the lateral
edge members 17 downwardly to receive the side wall splines S1 and
its longitudinal channel 10 being opposed to the corresponding
channel 10 of panel T6 in position to receive the splines S1 and S2
therein. It should be understood that the pins 26 of the top panel
edge members 17 are not oriented with the spline slots 31, but
there is sufficient flexibility that the panel T5 can be moved
laterally to receive the splines S1 and S2 in its channel 10 to
bring the pins 26 into vertical alignment with the access openings
33a of the side wall splines S1. Accordingly, the short splines S1
in the opposed longitudinal channels 10 of the top panels T5 and T6
may be driven toward (or away from) each other using the tool 35
and the first set of side wall splines S1 overlapping the top
panels T5 and T6 can then be driven toward the corner posts P1 and
P2 to cam the pins 14,26 into the slots 31,31a to interlock the
panel T6 and adjacent portion of panel T5 with the side wall panels
SE1 and SE4.
The same procedure is utilized for assembly of the sequential
series of top panels T4, T3, T2 and T1, except that the side wall
splines S1 for the panels T2 and T1 will not be interlocked until
the short end panel splines S1 are oriented into the upper channels
10 of panels SE9 and SE10 so that the final orientation of panel T1
will also bring its longitudinal channel 23 and pins 26 into
alignment with the end splines S1 and slot openings 33a therein.
The last side and end wall splines S1 are set with the tool 35 to
complete the top assembly.
From the foregoing it will be apparent that the basic panel system
includes a series of sequentially positioned and interlocked bottom
panels B1-B6, a series of sequentially positioned and interlocked
side and end panels SE1-SE12 and D1-D3, and a series of
sequentially positioned and interlocked top panels T1-T6. It will
be noted again that the short end closure bottom and top panels B1,
B6, T1 and T6 establish connecting joints in each sequential series
of panels that are laterally offset from the next connecting series
of panels for added strength, and the interlocking spline members
S3 between the bottom wall panels B1-B6 and side wall panels
SE1-SE12 and D1-D3 are longer and traverse the joints to further
stabilize the panel system. As indicated, the splines S5 of the
corner posts P1-P4 have short spline walls 42,42a spaced from the
ends of the posts (P) to permit lateral movement of the splines S3
at the lower ends and the splines S1 at the upper ends. Similarly,
in constructions where shelf assemblies SA are desired, the splines
S6 are shortened at both ends to permit lateral movement of the
splines S3 and S1 at the lower and upper ends thereof. The spline
S2 may be utilized with the splines S6 for shelf assemblies SA as
shown, although usually not required due to the weight factor on
the shelves that obviates racking or lateral stresses in adjacent
panels secured by the splines S6. It will also be apparent that the
sealing gasket G4 will be applied to the appropriate edge members 3
and 17 of bottom, side and end panels to be positioned adjacent to
floor or side walls RF and RS of a room R, and likewise on the top
panels adjacent to the room ceiling and affording limited overhead
clearance for other sealing gaskets.
The floor panels 61 and sealing compound 62 are installed in
appropriate panel systems, preferably before the door assembly DA
is installed and the sealing compound will eliminate the need for
use of sealing gaskets G3 at the bottom inside seams or joints and
the gasket G2 on the bottom panel joints. The door assembly DA is
provided with the resilient seals 66a,68a on the flanges 66 and
67c,67d and is assembled together as previously described and the
door CD mounted on the hinge means 65, 76 to complete the cooler
cabinet C.
Referring again to FIGS. 1, 22-28 and 36, the sealing gasket
members G1-G4 are applied to the assembled cooler cabinet C as
indicated hereinbefore. The sealing strips G4 are applied prior to
assembly of the adjacent panel members for subsequently
inaccessible joints, and the shelf standard gaskets G1 are snapped
into place over the standards 49,53 before setting the shelf
brackets 45b and shelves 45 with the spaced sealing lips 56c
flaring outwardly and yieldably bearing against the adjacent panel
walls 2.
The gaskets G2 are applied to all horizontal and vertical exterior
joints between adjacent panels by pressing the body portion 58
directly into the joint to compress the opposed sealing lips 58c
during application, the lips 58c then resiliently springing
outwardly and being engaged with one of the multiple serrations
15,15a of the edge members 3, the serrations 28 of the edge members
17 or the serrations 40d of the posts P. The outer sealing lips 57c
of the head portion 57 of gasket member G2 bear against the outer
walls 2a,19 of the panels. The gaskets G2 are also applied to the
vertical interior joints of the cooler C in the same manner.
Similarly, the gaskets G3 are applied to interior vertical and
horizontal corner joints by inserting the body portion 60 into the
joint so that the sealing lips 60d are engaged with serrations
15,15d and the major lip 60c bears against the opposed surface of
edge member 17 with the head portion lips 59c being pressed into
yieldable sealing contact with the inner panel liners 2,16 adjacent
thereto.
From the foregoing, the construction and assembly of a typical
panel system embodying the invention will be readily apparent, as
will the fact that partition wall systems and other arrangements
utilizing straight-line or angularly-related wall structures may
also embody the concepts and construction or assembly techniques
herein set forth. For instance, straight or angular channel members
may be provided for direct attachment to floors, walls or ceilings
of a room and similar panels, splines and sealing members applied
thereto. Accordingly, the scope of the invention is only to be
limited by the scope of the claims which follow as such changes,
modifications and adaptations will be readily apparent to all
skilled in the art.
* * * * *