MODULAR ENCLOSURE SYSTEM

Abstract

A modular enclosure system and method for forming an enclosure are disclosed. The enclosure system includes a plurality of interchangeable edge rails constructed to engage a plurality of interchangeable corner connectors. The interchangeable edge rails include a flange constructed to engage and secure a plurality of panel sections to the enclosure thereby quickly and efficiently forming a desired volume enclosure.

Description

BACKGROUND OF THE INVENTION

The present invention relates generally to enclosure assemblies and, more particularly, to a flexibly arrangeable modular enclosure system.

Enclosures come in a wide variety of styles and orientations and have applications that vary from storage cabinets to corrosion resistant electrical boxes. These enclosures often come in variety of sizes as well as a variety of materials depending, in part, on the intended use of the enclosure. Indoor, non-corrosive environment enclosures are often fabricated from generally lightweight plastic materials whereas electrical cabinets in corrosive or industrial applications are often constructed from a stainless steel material. Regardless of the intended use of the enclosure, these enclosures often come only in a variety of standard sizes. Requiring an enclosure having dimensions other than the provided standard sizes either requires significant modification of a standard enclosure or ordering an enclosure that is then manufactured with the desired specifications. As such, requiring a custom made enclosure having a size other than a commonly provided enclosure requires either, significant time and labor to modify a common enclosure, or a substantial increase in cost associated with a special order enclosure.

The intended use of an enclosure is an additional consideration of enclosure construction. Enclosures generally referred to as electrical boxes generally provide knock-outs for openings through the enclosure housing to allow wire access therein. Forming the knock-outs increases the production time required to form a single enclosure. The knock-outs are also often provided in a variety of standard configurations. Deviation from the standard knock-out orientation often requires significant in-field modification of the enclosure. As such, in-field modification of the orientation of the knock-outs increases the installation time of the enclosure. Additionally, depending on the material the enclosure is constructed, any modification of the enclosure may require special tooling and/or expertise to modify the enclosure.

Other enclosures, constructed from generally light weight plastic materials, lack a structural stability required for many applications. That is, these enclosures often require being supported on a floor and once loaded or filled, must be unloaded or emptied in order to be moved. These enclosures often require a generally flat and/or smooth footing surface in order to maintain the operability of doors that may be connected thereto. Positioning the enclosure on a footing surface that is even marginally non-planar and/or having a rough surface results in the interconnected components of the enclosure being misaligned which results in improper, if not inoperable, association of the individual components of the enclosure such as moveable shelves and enclosure doors.

It would therefore be desirable to have an enclosure system having a plurality of components that are quickly and efficiently assembled, and easily customized to a variety of user selected dimensions and applications.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a modular enclosure system that solves the aforementioned problems. The enclosure system includes a plurality of interchangeable corner rails connectable to a plurality of interchangeable corner connectors. The interchangeable corner rails and corner connectors form a frame assembly constructed to receive a plurality of panel portions forming an enclosure about the frame assembly.

In accordance with one aspect of the present invention, an enclosure system is disclosed that includes a frame assembly. The frame assembly includes a plurality of edge rails, each edge rail being interchangeable and having a first end and a second end. The frame assembly also includes a plurality of connectors, each connector being interchangeable and having a connector flange extending outwardly therefrom. Each connector is constructed to engage respective ends of a plurality of the edge rails. The enclosure system includes a plurality of side panels constructed to be attached to the frame assembly, each side panel constructed to engage the connector flanges of a plurality of the connectors.

In accordance with another aspect of the present invention, a cabinet system is disclosed that includes an edge component having a generally curved portion and a pair of generally planar portions wherein a shoulder is formed between the generally curved portion and each of the generally planar portions. The cabinet system further includes a corner component having a body and a plurality of generally curved sections extending therefrom. Each generally curved section is constructed to be snuggly received by the edge component between the shoulders formed thereon. Additionally, the cabinet system includes a plurality of side panels constructed to be received by the edge component on a side generally opposite the corner component and oriented to enclose a volume.

In yet another aspect of the present invention, a method of forming an enclosure is disclosed that includes connecting a plurality of interchangeable corners with a plurality of interchangeable frame rails to form an enclosure frame having a plurality of generally uniform panel mounting flanges. The method also includes mounting an enclosure panel to each of the generally uniform panel mounting flanges thereby enclosing a volume.

According to another aspect of the present invention, a modular container kit is disclosed that includes a plurality of corner connectors, a number of edge rails, and at least one sheet of generally planar material. The number of edge rails are of a predetermined length such that each of the edge rails are constructed to be severed to a user desired length wherein each severed end is engageable with a corner connector to form a frame assembly. The at least one sheet of generally planar material is constructed to be severable into a plurality of panels to engage the frame assembly and form the modular container.

Various other features, objects and advantages of the present invention will be made apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate one preferred embodiment presently contemplated for carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of an enclosure assembly according to one embodiment of the present invention.

FIG. 2 is a perspective view of a portion of an edge rail of the enclosure assembly shown in FIG. 1.

FIG. 3 is an end view of the edge rail shown in FIG. 2.

FIG. 4 is a perspective view of one embodiment of a corner connector of the enclosure assembly shown in FIG. 1.

FIG. 5 is a perspective view of another embodiment of a corner connector of the enclosure assembly of FIG. 1.

FIG. 6 is a perspective view of a door corner exploded from a door edge channel of the enclosure assembly shown in FIG. 1.

FIG. 7 is a cross-sectional view of a corner, side panel, and door assembly of the enclosure assembly shown in FIG. 1 taken along line 7-7.

FIG. 8 is a cross-sectional view of a corner assembly with a shelf bracket of the enclosure assembly shown in FIG. 1 taken alone line 8-8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows an enclosure assembly 10 according to the present invention. The enclosure assembly 10 includes a plurality of edge rails 12 and a plurality of corner connectors 14 connected thereto. Edge rails 12 and corner connectors 14 are constructed to be interchangeable with each edge rail 12 and corner connector 14, respectively. Each corner connector 14 engages a plurality of the edge rails 12 such that the plurality of edge rails 12 and plurality of corner connectors 14 cooperate to form a frame assembly 16. A plurality of side panels 18 are connected to frame assembly 16 and enclose a cavity 17 therein. Enclosure assembly 10 includes a door assembly 20 that includes a plurality of door edge channels 22, a plurality of door corner connectors 24, a door panel 25, and a plurality of jam sections 26. Door assembly 20 is pivotably or removeably connected to enclosure assembly 10 by a hinge 27 or the like. A handle 28 provides a user of enclosure assembly 10 with selective access to cavity 17 contained therein. Optionally, door assembly 20 can include a window 30 to allow a user to visually inspect the contents of cavity 17 of enclosure assembly 10 without opening door assembly 20. It is equally understood that window 30 could also be located at any of the plurality of side panels 18 of enclosure assembly 10. Optionally, enclosure assembly 10 includes a plurality of adapters 30 constructed to quickly and efficiently connect to enclosure assembly 10 and allow connectivity with cavity 17 enclosed therein. Passage adapters 30 can be constructed to interconnect with any of a plurality of commonly used electrical, plumbing, gas, or other system lines or connectors. An optional pedestal assembly 32 includes a plurality of corner sections 34 interconnected by a plurality of rail portions 36. Corner sections 34 and rail portions 36 are interchangeable, respectively, and are constructed to be easily cut to user desired dimensions. Preferably, pedestal assembly 32 is constructed of a material similar to the material of enclosure assembly 10 and can be quickly and efficiently connected thereto. Additionally, it is further understood that corner sections 34 can be constructed with a tab (not shown) internal or external thereto for securely mounting pedestal assembly 32 to a supporting surface such as a floor, cat walk, or the like.

FIGS. 2 and 3 show edge rail 12 of enclosure assembly 10. As shown in FIG. 2, edge rail 12 includes a body portion 38 with a pair of edge rail flanges 40 extending at edges 41 thereof. A step, or shoulder 42, is formed at the interface of each edge rail flange 40 and body 38 of each edge rail 12. A channel 44 is formed in each edge rail flange 40 and extends a length therealong, the importance of which is discussed further below with respect to FIG. 7. As shown in FIG. 3, an interior contour 46 of edge rail 12 has a pair of shoulders 48 positioned proximate edge rail flanges 40. Edge rail flanges 40 extend from body 38 in directions generally transverse to one another.

One embodiment of corner connector 14 is shown in FIG. 4. As shown in FIG. 4, corner connector 14 includes a body portion 50 with a plurality of protrusions 52 extending therefrom. Each protrusion 52 is constructed to snugly engage an edge rail 12 of FIG. 1. Referring to FIGS. 3 and 4, an exterior contour 54 of each protrusion 52 of each corner connector 14 is constructed to slidingly engage a respective interior contour 46 of each edge rail 12 between shoulders 48. A shoulder 56 of each protrusion 52 of each corner connector 14 abuts, as shown in FIG. 2, an edge 58 of each edge rail 12. Referring again to FIG. 4, each corner connector 14 includes a plurality of tabs 60 positioned between adjacent protrusions 52 of corner connector 14. Tabs 60 are constructed to generally align with a respective edge rail flange 40 of a respective edge rail 12 that is connected thereto. Such a construction forms what is commonly referred to as a butt joint between associated edge rails 12 and corner connectors 14. An alternate embodiment of corner connector 14 is shown in FIG. 5.

As shown in FIG. 5, corner connector 62 includes a body portion 64 with a plurality of protrusions 66 extending therefrom. Similar to each corner connector 14, an exterior contour 68 of each protrusion 66 of corner connector 62 is constructed to slidingly engage the interior contour 46 of edge rail 12, as shown in FIG. 3, between shoulders 48 of a respective edge rail 12. Referring to FIGS. 3 and 5, body 38 of each edge rail 12 is constructed to abut body portion 64 of a respective corner connector 62. A joint between edge rail flanges 40 of adjacent edge rails 12 forms one of what are commonly referred to as a half lap joint or a miter joint between adjacent edge rail flanges 40. In those enclosure assemblies 10 where increased frame rigidity is desired, it may be preferable to use corner connector 62 with the half lap joint or miter joint between adjacent edge rails 12 as compared to the butt joint formed when using corner connector 14. Regardless of which corner connector is applied, the rigidity of enclosure assembly 10 is further increased with the connection of side panels 18 thereto.

Similar to the engagement of corner connector and edge rail 12 of frame assembly 16, as shown in FIG. 6, door edge channels 22 and door corner connectors 24 of door assembly 20 are slidingly connected. Door corner connectors 24 include a body portion 70 with a pair of protrusions 72 extending therefrom. Protrusion 72 is constructed to slidingly engage a recess 74 formed in door edge channel 22. A tab 76 is formed between protrusions 72 of door corner connector 24 and is constructed to generally align with a door edge channel flange 78 extending from door edge channel 22. A groove 80 extends along a length of door edge channel flange 78 and is constructed to have door panel 25, as shown in FIG. 1, positioned thereacross.

FIG. 7 shows a cross-section of enclosure assembly 10 along line 7-7 shown in FIG. 1. As shown in FIG. 7, protrusion 52, 66 snuggly engages edge rail 12 between shoulders 48 and each side panel 18 traverses groove 44 of edge rail flange 40 and abuts shoulder 42 of edge rail 12. Groove 44 is constructed to allow for the deposition of a bonding agent, such as glue, therein for fastening each side panel 18 to each edge rail 12. Each edge rail 12 is further defined as an outside edge rail such that enclosure assembly 10 includes a plurality of inside edge rails 84 constructed to be attached along a length of edge rail 12. Each inside edge rail 84 includes a pair of inside edge rail flanges 86 positionable along edge rail flanges 40 of outside edge rail. Each inside edge rail flange 86 of inside edge rail 84 includes a pair of grooves 88, 90. Groove 88 of inside edge rail flange 86 faces edge rail flange 40 of outside edge rail 12 and is configured to receive a bonding agent therein thereby securing each inside edge rail 86 to a corresponding outside edge rail 12. Groove 90 of inside edge rail flange 86 is also constructed to receive a bonding agent therein such that an interior panel 92 of enclosure assembly 10 is securable thereacross.

A channel or chase 94 is maintained between inside edge rail 84 and a corresponding outside edge rail 12 and constructed to allow the passage of wiring therethrough. A cavity 96 is maintained between interior panels 92 and an adjacent side panel 18 of enclosure assembly 10. Optionally, an insulative material may be positioned or injected into cavity 96 thereby forming an insulated enclosure assembly. Jam sections 26 of door assembly 20 include a channel 96 formed along a length thereof. Channel 96 of each jam section 26 is constructed to snuggly receive outside edge rail flange 40 and an associated inside edge rail flange 86. Jam sections 26 also include a stop 98 extending therefrom. Stop 98 includes a gasket 100 positioned there at and constructed to sealingly engage door assembly 20 to enclosure assembly 10. Door edge channel 22 engages gasket 100 and seals cavity 17 of enclosure assembly 10 when door assembly 20 is oriented in a closed position. Grooves 80 of door edge channel flange 78 of door edge channel 22 are constructed to receive a bonding agent to secure door panel 25 and an interior door panel 102 about interconnected door edge channels 22. A cavity 106 is formed between door panels 25, 102 and is constructed to optionally receive an insulative material and/or a window 30, as shown in FIG. 1 therebetween.

As shown in FIG. 8, a support bracket 108 is attached to inside edge rail 84. Support bracket 108 includes a pair of grooves 110 formed therein and constructed to receive a bonding agent therein for securing support bracket 108 to enclosure assembly 10. Alternatively, a mechanical fastener 112, such as a bolt, may be used to secure support bracket 108 to inside edge rail 84 of enclosure assembly 10. As such, enclosure assembly 10 forms a sealed and insulated enclosure cavity that does not require any mechanical fasteners in forming the enclosure assembly. Additionally, the enclosure assembly can be formed by a pultrusion process having a plurality of interchangeable components. Alternatively, it is understood and within the scope of the claims that the plurality of interchangeable components of enclosure assembly 10 could be formed by an extrusion process. Regardless of the process applied to form the enclosure assembly, with a minimum of working, a user of the disclosed enclosure system can form an enclosure having multiple applications, sizes, and configurations with a minimum of workability of the individual components of the enclosure system.

In one embodiment of the present invention, an enclosure system includes a frame assembly. The frame assembly includes a plurality of edge rails, each edge rail being interchangeable and having a first end and a second end. The frame assembly also includes a plurality of connectors, each connector being interchangeable and having a connector flange extending outwardly therefrom. Each connector is constructed to engage respective ends of a plurality of the edge rails. The enclosure system includes a plurality of side panels constructed to be attached to the frame assembly, each side panel constructed to engage the connector flanges of a plurality of the connectors.

An alternate embodiment of the present invention has a cabinet system that includes an edge component having a generally curved portion and a pair of generally planar portions wherein a shoulder is formed between the generally curved portion and each of the generally planar portions. The cabinet system also includes a corner component having a body and a plurality of generally curved sections extending therefrom. Each generally curved section is constructed to be snuggly received by the edge component between the shoulders formed thereon. Additionally, the cabinet system includes a plurality of side panels constructed to be received by the edge component on a side generally opposite the corner component and oriented to enclose a volume.

Another embodiment of the present invention includes a method of forming an enclosure that includes connecting a plurality of interchangeable corners with a plurality of interchangeable frame rails to form an enclosure frame having a plurality of generally uniform panel mounting flanges and mounting an enclosure panel to each of the generally uniform panel mounting flanges thereby enclosing a volume.

A further embodiment of the present invention includes a modular container kit having a plurality of corner connectors, a number of edge rails, and at least one sheet of generally planar material. The number of edge rails are of a predetermined length such that each of the edge rails are constructed to be severed to a user desired length wherein each severed end is engageable with a corner connector to form a frame assembly. The at least one sheet of generally planar material is constructed to be severable into a plurality of panels to engage the frame assembly and form the modular container.

The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.

Claims

1. An enclosure system comprising:

a frame assembly comprising:

a plurality of edge rails, each edge rail being interchangeable and having a first end and a second end;

a plurality of connectors, each connector being interchangeable and having a connector flange extending outwardly therefrom and constructed to engage respective ends of a plurality of the edge rails; and

a plurality of side panels constructed to be attached to the frame assembly, each side panel constructed to engage the connector flanges of a plurality of the connectors.

2. The enclosure system of claim 1 wherein each of the edge rails further comprises a rail flange extending therefrom and generally aligned with the connector flange when connected thereto.

3. The enclosure system of claim 2 further comprising a groove formed in the rail flange, the groove traversed by a side panel connected thereto.

4. The enclosure system of claim 1 wherein the edge rails are further defined as an outside edge rail and wherein the system further comprises a plurality of inside corner rails, each inside corner rail being interchangeable and connectable along a length of a corresponding outside edge rail while maintaining a space therebetween.

5. The enclosure system of claim 4 wherein the space forms a wire chase that runs along a length of each of the inside corner rails.

6. The enclosure system of claim 4 wherein the inside corner rail further comprises an inside corner rail flange extending therefrom having a first groove formed therein, the first groove constructed to be traversed by the corresponding outside edge rail connected thereto.

7. The enclosure system of claim 6 further comprising a second groove formed in the inside corner rail flange on a side of the inside corner rail flange generally opposite the first groove and constructed to be traversed by a cavity panel when the cavity panel is connected thereto.

8. The enclosure system of claim 6 further comprising an intermediate panel positioned between a side panel adjacent to a cavity panel.

9. The enclosure system of claim 1 further comprising a door assembly having a plurality of jam sections, each jam section engageable with at least one of a corresponding edge rail, an edge of a side panel, and an edge of a cavity panel.

10. The enclosure system of claim 9 wherein the door assembly further comprises a plurality of door edge channels interconnected by a plurality of door corner connector.

11. The enclosure system of claim 10 wherein the door corner connector further comprises a first tab engageable with a recess formed in one of the plurality of door edge channels and a second tab engageable with a recess formed in another of the plurality of door edge channels.

12. The enclosure system of claim 10 wherein the door assembly further comprises a door panel fixedly connected to the plurality of door edge channels, the door edge channel pivotably connected to at least one of the jam sections.

13. The enclosure system of claim 12 wherein the door assembly further comprises another door panel connected to the plurality of door edge channels and generally parallel to the door panel.

14. The enclosure system of claim 1 further comprising a window fixedly connected to at least one of the plurality of side panels.

15. The enclosure system of claim 1 further comprising a pedestal assembly having a plurality of side sections and a plurality of interchangeable corner connectors, the pedestal assembly constructed to be attached to at least one of a plurality of the edge rails of the frame assembly and a side panel.

16. The enclosure system of claim 1 further comprising an adapter constructed to be connected to a side panel about a corresponding opening formed therethrough.

17. The enclosure system of claim 1 wherein at least one of the edge rails, connectors, and side panels are formed by a pultrusion-type process.

18. A cabinet system comprising:

an edge component having a generally curved portion and a pair of generally planar portions wherein a shoulder is formed between the generally curved portion and each of the generally planar portions;

a corner component having a body and a plurality of generally curved sections extending therefrom, each generally curved section constructed to be snuggly received by the edge component between the shoulders formed thereon; and

a plurality of side panels constructed to be received by the edge component on a side generally opposite the corner component and oriented to enclose a volume.

19. The cabinet system of claim 18 wherein the corner component further comprises a flange extending from the body between a pair of adjacent generally curved portions, the flange constructed to be flush with at least one of the generally planar portions of the edge component when the corner component is connected thereto.

20. The cabinet system of claim 18 wherein the plurality of generally curved sections of the corner component are generally perpendicular to each other.

21. The cabinet system of claim 18 wherein the corner component further comprises a shoulder formed between the body and each of the generally curved portions, the shoulder constructed to abut an end of a corresponding edge component connected thereto.

22. The cabinet system of claim 18 wherein the edge component is further defined as an outside edge component and the system further comprises an inside edge component having a generally curved middle portion and a pair of generally planar end portions wherein each generally planar end portion is constructed to engage a corresponding generally planar portion of the outside edge component.

23. The cabinet system of claim 22 further comprising a chase formed between the generally curved middle portion of the inside edge component and the generally curved portion of a corresponding outside edge component.

24. The cabinet system of claim 22 further comprising an interior panel attached to a corresponding end portion of the inside edge component and extending therebeyond on a side of the corresponding end portion generally opposite the generally planar portion of the outside edge component.

25. The cabinet system of claim 18 wherein at least one of the edge component, the corner component, and at least one of the plurality of side panels are formed by a protrusion-type process.

26. A method of forming an enclosure comprising:

connecting a plurality of interchangeable corners with a plurality of interchangeable frame rails to form an enclosure frame having a plurality of generally uniform panel mounting flanges; and

mounting an enclosure panel to each of the generally uniform panel mounting flanges thereby enclosing a volume.

27. The method of claim 26 wherein connecting each of the plurality of interchangeable corners with each of the plurality of interchangeable frame rails further comprises inserting a protrusion of a respective interchangeable corner into a recess formed in an end of a corresponding interchangeable rail connected thereto.

28. The method of claim 26 further comprising cutting each of the interchangeable frame rails to a user desired length.

29. The method of claim 26 further comprising gluing the enclosure panel to a respective generally uniform panel mounting flange.

30. The method of claim 26 further comprising attaching a door to a respective enclosure panel to provide access to the volume of the enclosure.

31. The method of claim 30 further comprising forming a seal between the door and the respective enclosure panel when the door is in a closed position.

32. The method of claim 26 further comprising attaching a bracket to at least one of the interchangeable frame rails inside the volume.

33. The method of claim 26 further comprising attaching an inside rail along a corresponding interchangeable frame rail inside the volume and maintaining a passage therebetween.

34. The method of claim 26 further comprising mounting another panel along a length of at least one of the interchangeable frame rails and generally parallel to a corresponding enclosure panel and maintaining another volume therebetween.

35. The method of claim 34 further comprising inserting an insulator into the another volume prior to mounting the another panel.

36. The method of claim 26 further comprising attaching at least one adapter to an enclosure panel to allow communication through the enclosure with the volume.

37. A modular container kit comprising:

a plurality of corner connectors;

a number of edge rails of a predetermined length, each of which are constructed to be severed to a user desired length, wherein each severed end is engageable with a corner connector to form a frame assembly; and

at least one sheet of generally planar material that is constructed to be severable into a plurality of panels to engage the frame assembly and form the modular container.

38. The kit of claim 37 further comprising a door assembly having a plurality of door corner connectors and a number of door edge rails of a predetermined length constructed to be cut to a user desired length, wherein each cut end is engageable with a door corner connector to form a door frame assembly.

39. The kit of claim 38 further comprising a number of door jam sections of a predetermined length constructed to be cut to a user desired length and engageable with the frame assembly and constructed to receive the door frame assembly.