Corner moldings and coolers made therewith

Abstract

Novel walk-in coolers and other enclosures, which employ novel elongate extruded, generally non-insulating corner moldings which receive thereinto wall panels of the enclosures. The elongate corner moldings have elongate first and second channels which extend toward an outer corner of the molding, and extend toward each other along intersecting, non-parallel paths. The channels are defined at least in part by the inner and outer walls of the molding. Each channel is defined by an end wall, and first and second side walls. A web provides a connection between the inner and outer walls. Also disclosed are methods of fabricating enclosures.

Description

BACKGROUND

This invention relates generally to walk-in refrigerators, freezers, coolers, such as are used in the grocery business, and to other types of walled enclosures such as office cubicles, pet cages, and the like.

While the description which follows addresses cooling enclosures specifically, the moldings and enclosure structures of the invention can also be applied to other enclosure structures which use a plurality of wall panels joined together by some corner structure at intersecting, e.g. non-parallel walls.

In the art of walk-in coolers, refrigerators, and freezers, such as are used in the grocery business, flat wall panels are conventionally joined in edge to edge relationship with built-in edge locks. Such panels are typically about 24-48 inches wide, about 6-8 feet long and anywhere from 2 inches thick to about 8 inches thick. Common thicknesses range from about 3.5 inches to about 4.2 inches.

Such panels are commonly oriented in an upright manner, joined edge to edge, in alignment with each other so as to define a wall of a desired length. Multiple such walls are set up about a space to be enclosed. Where two walls meet, a special insulating corner panel is inserted at the corner location and is joined to end panels of each of the two side walls.

For new construction, the proper number of panels can be specified according to the space to be enclosed. However, separate inventory must be kept of the corner panels relative to the flat wall panels.

Where a e.g. cooler is no longer needed, the e.g. cooler can be disassembled, and the materials saved for use to make another cooler. While such used materials can well be used to make other coolers, the number of flat panels on hand relative to the number of corner panels on hand is a function of the sizes of the e.g. coolers which have been so disassembled. Where e.g. larger coolers have been disassembled, and smaller coolers are desired to be built, the builder experiences a relatively larger number of flat panels and a relatively lower number of corner panels, whereby the flat panels can be used only by purchasing new corner panels. But such corner panels are relatively expensive, negating a primary benefit of employing used materials to save on cost.

Accordingly, there is a need for elongate corner panels which are compatible for use with such flat wall panels, so as to build enclosures therewith without having to purchase or warehouse additional new elongate corner panels.

There is further a need for novel methods of fabricating, e.g. erecting, walk-in and other enclosures which can benefit from use of an elongate e.g. extruded corner molding having first and second elongate channels which receive the edges of wall panels thereinto.

SUMMARY

The invention provides novel walk-in coolers and other enclosures, which employ novel elongate extruded, non-insulating corner moldings to receive thereinto e.g. insulating wall panels of the enclosures. The elongate corner moldings have elongate first and second channels which extend toward an outer corner of the molding, and extend toward each other along intersecting, non-parallel paths. The channels are defined at least in part by the inner and outer walls of the molding. Each channel is defined by an end wall, and first and second side walls. A web provides a connection between the inner and outer walls.

Use of the extruded corner moldings obviates need for more expensive insulating corner panels in making such walk-in coolers.

In a first family of embodiments, the invention comprehends, as a unitary article of manufacture, an elongate corner molding having a length, a width, and a depth. The corner molding comprises inner and outer walls defining inner and outer surfaces of the corner molding; elongate first and second channels extending into the molding toward an outer corner of the molding, and is defined at least in part by the inner and outer walls, each channel being defined by an end wall and first and second side walls extending away from the end wall in a generally common direction, the first and second channels extending along intersecting paths; and a web providing a connection between the inner wall and the outer wall.

In some embodiments the channels are further defined in part by the web.

In some embodiments, the web extends along a path and the path, or a projection of a general direction of the path, intersects the outer wall at a location displaced from the outer corner.

In some embodiments, the first channel extends toward the outer corner and ends at a first end, and the second channel extends toward the outer corner and ends at a second different end, and one of the first and second channels extends closer to the outer corner than the other of the first and second channels.

In some embodiments, one of the first and second channels extends substantially to the outer corner.

In some embodiments, the corner molding is made with polymeric material, optionally polymeric material selected from the group consisting of operable vinylidene chloride homopolymers and copolymers, operable low density polyethylene homopolymers and copolymers, operable medium density polyethylene homopolymers and copolymers, operable high density polyethylene homopolymers and copolymers, operable polypropylene homopolymers and copolymers, and operable polyamide homopolymers and copolymers.

In some embodiments, the polymeric material comprises vinylidene chloride polymer, optionally high impact, low temperature, grade vinylidene chloride polymer.

In some embodiments, at least one of the channels is defined by an end wall, and first and second side walls extending away from the end wall in a generally common direction, and the first and second side walls, of at least one of the channels, extend away from the end wall along converging paths when the corner molding is at rest.

In some embodiments, the converging paths define an angle of about 2 degrees to about 15 degrees, optionally about 4 degrees to about 10 degrees.

In some embodiments, at least one of the side walls of a respective one of the channels is resiliently deflectable so as to facilitate resilient flexing of the side wall outwardly, thereby to accommodate enlarging of the respective channel at an opening therein so as to receive and grip a wall panel being inserted into the respective channel.

In some embodiments, each of the channels is defined by an end wall, and first and second side walls extending away from the end wall, and each of the first and second channels has a channel width effective to receive, and to effectively retain, a wall panel having a thickness of between about 2 inches and about 6 inches, optionally about 3 inches and about 5.5 inches, further optionally about 3.5 inches and about 4.1 inches.

In some embodiments, the outer molding wall comprises first and second legs extending from the outer corner of the outer molding wall, the inner molding wall comprising third and fourth legs extending from an inner corner of the inner molding wall, the web providing a connection between the first leg and the inner wall, further comprising a second web providing a second connection between the second leg and the inner wall.

In some embodiments, each of the channels is further defined in part by at least one of the first and second webs.

In some embodiments, at least one of the webs extends along a path wherein the path or a projection of a general direction of the path, intersects the outer wall at a location displaced from the outer corner.

In some embodiments, the corner molding is asymmetric with respect to an imaginary line extending through the inner and outer corners.

In some embodiments, the corner molding is substantially symmetric with respect to the inner and outer corners.

In other embodiments the corner molding is substantially asymmetric with respect to the inner and outer corners.

In some embodiments, the corner molding has a thermal insulation value, between the inner surface and the outer surface, at the first and second channels, through a combination of walls of the molding, of less than R4.

In some embodiments, the corner molding has no substantial thermal insulating value between the inner surface and the outer surface, at the first and second channels, through a combination of walls of the molding.

In a second family of embodiments, the invention comprehends a walk-in cooler defining an enclosed and cooled space. The walk-in cooler has a plurality of upstanding walls, and comprises a first such upstanding wall having a first length and comprising a plurality of first upstanding wall panels joined to each other in side-by-side relationship, the first upstanding wall panels having opposing first inner and first outer surfaces, and first thermally insulating material between the first inner and first outer surfaces, effective for use as a first thermal insulating barrier in defining a first outer wall of the cooled enclosed space, further comprising a first end one of the wall panels in the first wall; a second such upstanding wall having a second length and comprising a plurality of second upstanding wall panels joined to each other in side-by-side relationship, the second upstanding wall panels having opposing second inner and second outer surfaces, and second thermally insulating material between the second inner and second outer surfaces, effective for use as second thermal insulating barrier in defining a second outer wall of the cooled enclosed space, further comprising a second end one of the wall panels in the second wall, adjacent the first end one of the wall panels in the first wall; an elongate corner molding having a length, and having inner and outer walls defining inner and outer surfaces, and corresponding inner and outer corners of said cornier molding, and first and second elongate channels defined by channel side walls and channel end walls, the first and second channels being adapted and configured to receive the first and second end ones of the wall panels, the first and second channels extending along the length of the corner molding, and extending toward each other along intersecting and non-parallel paths.

In some embodiments, at least one of the side walls of a respective one of the channels resiliently grips a respective one of the end ones of the wall panels.

In some embodiments, the first wall has a top and a bottom, and the cooler further comprises an elongate boot having an upwardly-open channel extending along the first length of the first wall, the bottom of the first wall being received in the upwardly-open channel of the boot and thereby substantially separating the first wall from an underlying supporting surface.

In some embodiments the walk-in cooler further comprises a ceiling spanning respective ones of the upstanding walls and comprising a plurality of third generally laterally extending wall panels extending side by side with respect to each other, the third wall panels optionally having effective thermal insulating properties suitable for use as thermal insulating barrier in defining a top wall of such enclosed space, the walk-in cooler further comprising at least one elongate ceiling corner molding joining the third wall panels of the ceiling to at least one of the upstanding side walls.

In some embodiments, the at least one ceiling corner molding further comprises a web providing a connection between the inner wall and the outer wall.

In a third family of embodiments, the invention comprehends a method of building a walk-in cooler, defining a cooled enclosed space inside the cooler. The method comprises assembling a plurality of upstanding walls, at least first and second such walls each comprising a plurality of upstanding wall panels cooperating with each other in side by side relationship, the upstanding wall panels having opposing inner and outer surfaces, and thermally insulating material between the inner and outer surfaces, the wall panels being effective for use as thermal insulating barrier between the enclosed space inside the cooler and an outer ambient environment; and joining respective pairs of the at least first and second such upstanding walls to each other, at non-parallel angles, by inserting edge elements of the respective upstanding walls into a corner molding. The corner molding has a length, inner and outer walls defining inner and outer surfaces, and corresponding inner and outer corners, of the corner molding, and first and second elongate channels, defined by channel side walls and channel end walls, extending along the length of the corner molding, and defining cross-sectional channel spaces therein, the edge elements of the respective upstanding walls being received in the first and second elongate channels.

In some embodiments, the respective ones of the upstanding walls substantially fill the cross-sectional spaces defined by the respective channels at loci along the lengths of such channels where the wall edges are received.

In some embodiments, the method comprises assembling a plurality of the panels thereby to define a ceiling, and joining edges of the ceiling to the upstanding walls by using further such corner moldings between edges of the ceiling and the upstanding walls.

In some embodiments, the method comprises employing at least one such corner molding having no substantial thermal insulating value between the inner and outer surfaces at the channels, through a combination of walls of the molding.

In some embodiments, the method comprises employing at least one such corner molding comprising a web providing a connection between the inner wall and the outer wall.

In some embodiments, the method comprises employing at least one such corner molding wherein the web extends along a path and wherein the path, or a projection of a general direction of the path, intersects the outer wall at a location displaced from an outer corner of the molding.

In some embodiments the method comprises employing at least one such corner molding wherein the first channel extends toward an outer corner of the molding and ends at a first end, and the second channel extends toward the outer corner and ends at a second different end, and wherein the distance between one of the first and second ends, and the outer corner, is less that the distance between the other of the first and second ends, and the outer corner.

In some embodiments the method comprises employing at least one such corner molding wherein the corner molding is made with polymer material selected from the group consisting of operable vinylidene chloride homopolymers and copolymers, operable low density polyethylene homopolymers and copolymers, operable medium density polyethylene homopolymers and copolymers, operable high density polyethylene homopolymers and copolymers, operable polypropylene homopolymers and copolymers, and operable polyamide homopolymers and copolymers.

In some embodiments, the method comprises employing at least one such corner molding wherein at least one of the channels is defined by an end wall, and first and second side walls extending away from the end wall in a generally common direction, and wherein the first and second side walls, of the respective channel, extend away from the end wall along converging paths when the corner molding is at rest.

In some embodiments, widths of the respective channels generally correspond to thicknesses of the respective edge portions of the upstanding walls, between the inner and outer surfaces, as received in the respective channels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a pictorial representation of a walk-in cooler of the invention with parts cut away, and parts in exploded perspective.

FIG. 1A shows a cross-section of a prior art construction of corners of walk-in coolers.

FIG. 2 shows a cross-section of a corner molding of the invention.

FIG. 2A shows a cross-section of a corner molding of the invention, which is a mirror image of the cross-section of FIG. 2.

FIG. 3 shows a cross-section of a floor boot molding of the invention.

FIG. 4 shows a cross-section of a further embodiment of corner moldings of the invention.

The invention is not limited in its application to the details of construction or the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways. Also, it is to be understood that the terminology and phraseology employed herein is for purpose of description and illustration and should not be regarded as limiting. Like reference numerals are used to indicate like components.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Referring first to FIGS. 1, 1A, 2, and 2A, FIG. 1 illustrates the basic concept of a walk-in cooler 10 of the invention, having four side walls 12A, 12B, 12C, and 12D, and a ceiling 12E. One of the side walls 12A includes an access door 14. Side walls 12A, 12B, 12C, and 12D are shown generally in their normal configurations. Ceiling 12E is shown with the moldings as solid line drawings, and the ceiling panels 16E in dashed line representation of where the ceiling panels would be if shown in detail.

In such coolers, the side walls and the ceiling each comprise multiple panels 16 such as those shown in FIG. 1, locked together edge-to-edge by a well-known toggle locking system (not shown) whereby any two panels can be brought together in edge to edge relationship, and readily and quickly locked to each other using common tools. Each panel is e.g. 3.5 inches to 3.75 inches thick. The core of the panel is a thermally insulating foamed plastic such as urethane foam, covered on both sides by a skin of e.g. aluminum sheet.

FIG. 1A shows a conventional prior art corner panel 20 having left and right legs 22A, 22B. The corner panel is constructed of the same materials as side wall panels 16, only in a right angled corner configuration defined by legs 22A and 22B which meet at outer corner 30 of the cooler at a right angle. Thus, the outer skins 24 of both flat wall panels 16 and corner panel 20 are aluminum sheeting, enclosing a urethane foam core 25 of e.g. about 4 pcf density having known substantial thermal insulating value. Conventional wall panels 16 are mounted in edge-to-edge relationship to corner panel 20 in FIG. 1A using the conventional toggle connections, which can also be thought of as cam connectors.

Returning to the invention, FIG. 2 shows a cross-section of a plastic extrusion/molding 26 which is used as a corner molding in the inventive cooler of FIG. 1. Molding 26 has comparatively little thermal insulating value relative to the foam-core panels 16, less than R4 through the webs and walls of the molding, collectively, between the inner 6 and outer 8 surfaces of the molding.

The flat side wall panels 16 used in the invention are, or can be, the same as the panels used in FIG. 1 and FIG. 1A. The toggle method of joining panel-to-panel is, or can be, the same in FIG. 1 and FIG. 1A.

One of the differences between known technology and the invention is in the construction of the corner of the cooler. The conventional corner structure of FIG. 1A is essentially an “angle” insulating panel 20 which forms the corner. Think “angle iron”, but different, lighter weight, materials. The corner structure of the invention does not use an “angle” insulating panel. Rather, the cooler structure of FIG. 1 does not need, does not use, any corner “corner panels”. Rather, the structure of the invention uses only conventional flat side, non-corner, panels; and joins the non-corner, flat side panels at wall corners using an elongate molding of the nature of the cross-section seen in FIG. 2. FIG. 2A is the mirror image of FIG. 2 and can be used equally as well according to the specific implementation of the invention.

The elongate expression of corner molding 26 of FIG. 2 is shown in FIG. 1. As seen in FIGS. 1 and 2, molding 26 has an outer wall 4, having an outer surface 8, defined by first and second outer legs 28A and 28B, joined at a first corner 30, and an inner wall 2, having an inner surface 6, defined by third and fourth inner legs 32A and 32B joined at a second corner 34, and a connecting web 36. Web 36 extends from corner 34 at the inner legs to an intermediate-locus line 38 along the cross-dimension “D” of outer leg 28A, at a location substantially displaced from outer corner 30.

Outer leg 28B, the adjoining portion of outer leg 28A between loci 30 and 38, and web 36 form a first channel 40 which receives a first one of the side panels 16, shown in dashed outline in FIG. 2. Inner leg 32A, web 36, and that portion of outer leg 28A to the left of line 38 form a second channel 42 which receives a second one of the side panels 16, also shown in dashed outline in FIG. 2.

Corner 30 represents the outer corner of the cooler where walls 12A and 12B come together on the outer surface of the cooler in FIG. 1. Corner 34 represents the corresponding inner corner where walls 12A and 12B come together on the inner surface of the cooler in FIG. 1. Accordingly, the outer corner portion of the corner wall structure is occupied generally by side wall 12B in the embodiment illustrated in FIG. 1 and, correspondingly, not by side wall 12A. Rather, side wall 12A stops short of the outer corner of the side wall structure at web 36. Web 36 is the only connection between the outer legs 28A, 28B and the inner legs 32A, 32B. In the embodiments illustrated inner legs 32A and 32B share equally in forming the inner surface of the corner on the interior of the cooler. Such equal sharing is not a limitation of the invention.

The widths of the channels 40, 42 generally correspond to the thicknesses of the edge portions of the panels which are to be inserted into the channels. Stated another way, the widths of the channels, between the respective channel side walls, generally correspond to the thicknesses of the panels which are contemplated as being suitable for use with such moldings. Channels 40, 42 are slightly oversized so as to readily receive panels which are slightly thicker than anticipated, such as within normal manufacturing tolerances for such panels.

Outer leg 28A is much longer (Dimension D) than outer leg 28B. Outer leg 28B and that portion of outer leg 28A which is to the left of line 38 are optionally, at rest, biased inwardly so as to form acute angles α about corner 30 and line 38 respectively. Thus, the side walls e.g. 28B and 36, of a channel, e.g. 40, extend away from the end wall e.g. 28A along converging paths when the molding is at rest. That way, if a side wall panel 16 is a bit under-sized, e.g. thinner than the nominal width of the channel at the end of the channel, the respective outer leg 28A or 28B will still be forced outwardly, thus to expand the channel opening, as the panel is inserted into the channel, whereby the respective leg 28A or 28B resiliently grips the wall panel, anyway.

Angle α can desirably be any angle which enables the respective channel side wall to effectively resiliently grip a wall panel. To that end, at least one of the side walls of each channel 40, 42 is resiliently deflectable in a channel-widening direction, so as to facilitate flexing the channel side wall outwardly, thereby to accommodate enlarging the channel at the channel openings, so as to receive and grip a wall panel being inserted into the respective channel. Typical magnitudes of angles a are about 2 degrees to about 15 degrees, optionally about 4 degrees to about 10 degrees.

In FIGS. 1 and 2, end ones of the wall panels in a given wall e.g. 12A, 12B are received in channels 40, 42, whereby the end wall panels of the adjacent walls extend toward each other along intersecting, e.g. non-parallel paths. Pop-riveting or the like (not shown) can be used to secure the panels 16 in channels 40 and 42 if and as desired. The end result is a secure corner which enables construction of coolers/cold rooms without the need to separately stock and inventory any insulating corner panels.

Exemplary materials for making molding 26 are various of the plastics such as various of the vinylidene chlorides, various of the polyolefins such as low density polyethylenes, medium density polyethylenes, high density polyethylenes, and polypropylenes, as well as various ones of the polyamides. As referred to herein, such polymers are intended to include all operable homopolymers and copolymers, and blends, of the recited materials.

Exemplary vinylidene chloride copolymer (PVC) material is available from e.g. PolyOne Corporation, Avon Lake, Ohio. As a first exemplary PVC from PolyOne, there can be mentioned grade L0676, which is approved for incidental food contact, and has low temperature impact capability. Another exemplary PolyOne PVC material is grade 87416, which has corresponding cold tolerance but which is not approved for incidental food contact. Still another exemplary PolyOne PVC material is grade 8700 which has approval for incidental food contact but does not have specific low temperature-impact strength. However, a material such as grade 8700 can be used in a low temperature environment where no, or only rare, impact is anticipated during the anticipated normal use life of the molding.

Molding 26 can be fabricated by e.g. extrusion, using conventional extrusion machines, and conventional extrusion processes. For a walk-in cooler as illustrated in FIG. 1, each of legs 28A, 28B, 32A, 32B, and webs 36, optionally 36A, can have the same cross-sectional thickness. In the alternative, the thicknesses can differ. A thickness of about 0.08 inch has been found to be acceptable. A range of thicknesses of about 0.05 inch to about 0.13 inch is contemplated as being operable and economically feasible, depending on the strength requirements of the specific implementation. Leg and/or web thicknesses can be increased or decreased from those recited, to correspond with the strength requirements of the specific implementation. Such strength requirements may, for example, depend on size of the enclosure being built. In light of the disclosure herein, those skilled in the art are well able to determine the strength requirements, and to specify leg and/or web thickness accordingly.

At the base of each side wall 12, the bottom portions of the side panels 16 are received in an elongate bottom boot 43 illustrated in FIG. 3, having an upwardly-open channel extending along the length of the wall. The bottom of the wall is received in the boot channel, whereby the boot separates the wall form the underlying floor or other underlying support.

In the alternative, the bottoms of the side panels can be set directly on the concrete or other floor, or can be recessed into the floor, both of these latter two bottom mountings being conventional in the industry where conventional cooler construction is used.

FIG. 4 illustrates a second embodiment 26A of the Molding wherein outer leg 28B is extended in length to equal the length of leg 28A, and a second web 36A extends from inner corner 34 to a mid-point 44 on outer leg 28B. In such structure, the outer corner of the cooler, where side walls e.g. 12A, 12B meet, is represented by a hollow chamber 46 which spaces both respective panels 16 in side walls e.g. 12A and 12B from outer corner 30 of the molding. In such case, only that portion of outer leg 28B which is distal from locus 44 is biased inwardly, and molding 26A is symmetric about imaginary line 48 which extends through corners 30 and 34, as compared to the asymmetry of molding 26 in e.g. FIG. 2.

In an embodiment not shown, each web 36 and/or 36A can be independently relocated closer to, or farther away from, outer corner 30, as desired by design criteria, whereby the resulting molding, having both webs 36 and 36A, is asymmetric with respect to imaginary line 48.

A similar set of panels 16E and molding 26E can be used in assembling the ceiling. In a first embodiment of the method of assembling the ceiling to the side walls, the entire ceiling is assembled, including assembling corner moldings 26 about the edges of the ceiling assembly, and then the ceiling is set on the tops of the side walls, with the corner moldings of the ceiling extending down over the tops of the side walls. In such embodiment, downwardly-extending channels 40 or 42, typically channel 42, receive the upwardly-extending tops of the wall panels 26 which form the respective side walls 12. Such method is generally illustrated in FIG. 1, with the exception that moldings 26E2 and 26E3 are each represented as two pieces 26E2A, 26E2B and 26E3A, 26E3B. In such method, moldings 26E2 and 26E3 are single moldings which engage all of the ceiling panels which reach that respective side/end of the ceiling.

In an alternative embodiment of assembling the ceiling to the side walls, and considering a rectangular cooler design when considered in top view as in FIG. 1, corner moldings 26E, such as 26E1, 26E2A and 26E3A are first assembled e.g. downwardly onto the tops of three of the side walls, with respective e.g. channels 40 directed toward the center of the cooler enclosure which is in the process of being constructed. At least first and second such corner moldings, e.g. 26E2A and 26E3A, on opposing sides of the cooler extend less than the full length of the inside surfaces of their respective side walls, by the width of e.g. one of panels 16.

With the respective corner moldings in place on the tops of the three side walls, beginning at one end of a pair of opposing moldings, on opposing side walls, an individual ceiling panel 16E1 is then slid, in a generally horizontal direction, into place in the channels 40 of the respective moldings which are directed toward the center of the cooler, thus to assemble the first ceiling panel 16E1 to the opposing side walls and extending over an edge of the upwardly-open space which is to be enclosed by the ceiling. A second ceiling panel 16E2 is then slid into place in the channels and in side-by-side relationship to the first ceiling panel, and over the upwardly-open space being enclosed by the ceiling. Third and subsequent ceiling panels 16E3 and 16E4 are sequentially added to the ceiling assembly until the remaining ceiling opening represents the width of a single ceiling panel.

A final ceiling panel 16E5 is selected. Corner moldings 26E2B, 26E3B, 26E4 are assembled to three of the four edges of the rectangular ceiling panel 16E5 to make a ceiling panel assembly, wherein one of the elongate sides of the ceiling panel 16E5 does not have a corner molding assembled thereto. Each of the three corner moldings 26E2B, 26E3B, 26E4 has a length which generally corresponds to the length of that edge of the panel 16E5 to which it is assembled. Thus, the corner molding 26E4 which extends along the length of the panel generally corresponds in length to the length of the panel, allowing for wall corner set-back as shown in FIG. 1. The two corner moldings 26E2B and 26E3B which extend along the ends of the panel generally correspond in length to the width of the panel, again allowing for wall corner set-back.

With the final ceiling panel assembly thus having the three corner moldings assembled thereto, the assembly is positioned over the remaining opening in the ceiling and moved in a downward direction over the opening. As the ceiling panel assembly is moved downwardly, the downwardly-extending channels 42 in the ceiling panel assembly are guided over the upwardly-extending top edges of the respective side walls 16 which underlie the ceiling panel assembly. The corner moldings of the ceiling panel assembly thus move downwardly over, and receive, the upwardly-extending top edges of the respective portions of the respective side walls while the long edge of panel 16E5 which has no molding mounted thereto, which faces panel 16E4, is slid into abutting engagement with the facing edge of panel 16E4.

Such assembly process thus completes generally closing off the ceiling of the enclosed space of the cooler. The respective ceiling panels 16E1-16E5 are optionally locked to each other using the locks which are incorporated into each of the respective ceiling panels.

As illustrated in describing assembly of the ceiling, any of the corner moldings can be any desired length such as to facilitate assembly. Any corner moldings which collectively define a particular corner can be designed, as desired to overlap or otherwise engage each other so as to make a continuous closure of the enclosed space at the respective corner. Further, any of the corners where e.g. a side wall corner meets a ceiling corner can be closed off with an additional 3-way corner molding (not shown).

Those skilled in the art will now see that certain modifications can be made to the apparatus and methods herein disclosed with respect to the illustrated embodiments, without departing from the spirit of the instant invention. And while the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted to numerous rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within the scope of the appended claims.

To the extent the following claims use means plus function language, it is not meant to include there, or in the instant specification, anything not structurally equivalent to what is shown in the embodiments disclosed in the specification.

Claims Strategy—Summarize Point of Novelty For Each Independent Claim

• 1. Corner moldings
• 27. Walk-in coolers
• 52. Method of making a walk-in cooler

Numbering Set for Case No. 29808

• 2 inner wall of molding
• 4 outer wall of molding
• 6 inner surface of molding
• 8 outer surface of molding
• 10 walk-in cooer
• 12A, 12B, 12C, 12D side walls of cooler 10
• 14 access door
• 16 side wall panels in walls 12
• 18
• 20 conventional corner panel (FIG. 1A)
• 22A, 22B legs of panels 16
• 23A, 23B legs of conventional panel 20
• 24 outer skins of conventional panel 20
• 25 urethane foam core of panels 16, 20
• 26 plastic extrusion molding
• 28A, 28B outer legs of molding 26
• 30 outer corner of molding
• 332A, 32B inner legs of molding 26
• 34 inner corner of molding 26
• 36, 36A web
• 38 intermediate locus along leg 28A where web 36 joins leg
• 40 first channel
• 42 second channel
• 44 intermediate locus on leg 28B where web 36A joins leg
• 46 hollow chamber (FIG. 4)
• 48 imaginary line through corners 30, 34

Claims

1. As a unitary article of manufacture, an elongate corner molding having a length (L), a width (W), and a depth (D), said corner molding comprising:

(a) inner (2) and outer (4) walls defining inner (6) and outer (8) surfaces of said corner molding;

(b) elongate first (40) and second (42) channels extending into said molding toward an outer corner (30) of said molding, and being defined at least in part by said inner (2) and outer (4) walls, each said channel (40, 42) being defined by an end wall and first and second side walls extending away from said end wall in a generally common direction, the first and second channels extending along intersecting paths; and

(c) a web (36) providing a connection between said inner wall (2) and said outer wall (4).

2. An elongate corner molding as in claim 1 wherein the channels (40, 42) are defined in part by said web (36).

3. An elongate corner molding as in claim 1 wherein said web extends along a path and wherein the path, or a projection of a general direction of the path, intersects said outer wall (4) at a location displaced from the outer corner (30).

4. An elongate corner molding as in claim 1 wherein the first channel (40) extends toward the outer corner (30) and ends at a first end, and the second channel (42) extends toward the outer corner (30) and ends at a second different end, and wherein one of the first and second channels extends closer to the outer corner (30) than the other of the first and second channels.

5. An elongate corner molding as in claim 4 wherein the one of the first and second channels extends substantially to the outer corner (30).

6. An elongate corner molding as in claim 1 wherein said corner molding is made with polymeric material.

7. An elongate corner molding as in claim 6 wherein the polymeric material is selected from the group consisting of operable vinylidene chloride homopolymers and copolymers, operable low density polyethylene homopolymers and copolymers, operable medium density polyethylene homopolymers and copolymers, operable high density polyethylene homopolymers and copolymers, operable polypropylene homopolymers and copolymers, and operable polyamide homopolymers and copolymers.

8. An elongate corner molding as in claim 6 wherein the polymeric material comprises vinylidene chloride polymer.

9. An elongate corner molding as in claim 6 wherein the polymeric material comprises high impact, low temperature, grade vinylidene chloride polymer.

10. An elongate corner molding as in claim 1 wherein at least one of the channels is defined by an end wall, and first and second side walls extending away from said end wall in a generally common direction, and wherein said first and second side walls, of at least one of the channels, extend away from said end wall along converging paths when said corner molding is at rest.

11. An elongate corner molding as in claim 10 wherein the converging paths define an angle (α) of about 2 degrees to about 15 degrees.

12. An elongate corner molding as in claim 10 wherein the converging paths define an angle (α) of about 4 degrees to about 10 degrees.

13. An elongate corner molding as in claim 1 wherein at least one of said side walls of a respective one of the channels (40, 42) is resiliently deflectable so as to facilitate resilient flexing of the side wall outwardly, thereby to accommodate enlarging of the respective channel at an opening therein so as to receive and grip a wall panel being inserted into the respective said channel.

14. An elongate corner molding as in claim 1 wherein each of the channels is defined by an end wall, and first and second side walls extending away from said end wall, and wherein each of the first and second channels has a channel width effective to receive, and to effectively retain, a wall panel having a thickness of between about 2 inches and about 6 inches.

15. An elongate corner molding as in claim 1 wherein each of the channels is defined by an end wall, and first and second side walls extending away from said end wall, and wherein each of the first and second channels has a channel width effective to receive, and to effectively retain, a wall panel having a thickness of between about 3 inches and about 5.5 inches.

16. An elongate corner molding as in claim 1 wherein each of the channels is defined by an end wall, and first and second side walls extending away from said end wall, and wherein each of the first and second channels has a channel width effective to receive, and to effectively retain, a wall panel having a thickness of between about 3.5 inches and about 4.1 inches.

17. An elongate corner molding as in claim 1, said outer molding wall (4) comprising first (28A) and second (28B) legs extending from the outer corner (30) of said outer molding wall, said inner molding wall (2) comprising third (32A) and fourth (32B) legs extending from an inner corner (34) of said inner molding wall, said web (36) providing a connection between said first leg (28A) and said inner wall (2), further comprising a second web (36A) providing a second connection between said second leg (28B) and said inner wall (2).

18. An elongate corner molding as in claim 17 wherein each of the channels (40, 42) is further defined in part by at least one of said first (36) and second (36A) webs.

19. An elongate corner molding as in claim 17 wherein at least one of said webs (36, 36A) extends along a path wherein the path or a projection of a general direction of the path, intersects said outer wall (4) at a location displaced from the outer corner (30).

20. An elongate corner molding as in claim 1 wherein said corner molding is asymmetric with respect to an imaginary line (48) extending through the inner (34) and outer (30) corners.

21. An elongate corner molding as in claim 1 wherein said corner molding is substantially symmetric with respect to the inner (34) and outer (30) corners.

22. An elongate corner molding as in claim 17 wherein said corner molding is substantially symmetric with respect to the inner (34) and outer (30) corners.

23. An elongate corner molding as in claim 17 wherein said corner molding is substantially asymmetric with respect to the inner (34) and outer (30) corners.

24. An elongate corner molding as in claim 1, said corner molding having a thermal insulation value, between the inner surface (6) and the outer surface (8), at the first and second channels, through a combination of walls of said molding, of less than R4.

25. An elongate corner molding as in claim 17, said corner molding having a thermal insulation value, between the inner surface (6) and the outer surface (8), at the first and second channels, through a combination of walls of said molding, of less than R4.

26. An elongate corner molding as in claim 1, said corner molding having no substantial thermal insulating value between the inner surface (6) and the outer surface (8), at the first and second channels, through a combination of walls of said molding.

27. A walk-in cooler defining an enclosed and cooled space, said walk-in cooler having a plurality of upstanding walls, and comprising:

(a) a first said upstanding wall having a first length and comprising a plurality of first upstanding wall panels joined to each other in side-by-side relationship, said first upstanding wall panels having opposing first inner and first outer surfaces, and first thermally insulating material between the first inner and first outer surfaces, effective for use as a first thermal insulating barrier in defining a first outer wall of the cooled enclosed space, further comprising a first end one of said wall panels in said first wall;

(b) a second said upstanding wall having a second length and comprising a plurality of second upstanding wall panels joined to each other in side-by-side relationship, said second upstanding wall panels having opposing second inner and second outer surfaces, and second thermally insulating material between the second inner and second outer surfaces, effective for use as second thermal insulating barrier in defining a second outer wall of the cooled enclosed space, further comprising a second end one of said wall panels in said second wall, adjacent said first end one of said wall panels in said first wall;

(c) an elongate corner molding having a length (L), and having inner (2) and outer (4) walls defining inner (6) and outer (8) surfaces, and corresponding inner (34) and outer (30) corners of said cornier molding, and first (40) and second (42) elongate channels defined by channel side walls and channel end walls, the first and second channels being adapted and configured to receive the first and second end ones of said wall panels, the first and second channels extending along the length (L) of the corner molding, and extending toward each other along intersecting and non-parallel paths.

28. A walk-in cooler as in claim 27, said molding having a thermal insulation value, between the inner surface and the outer surface, at the first and second channels, through a combination of walls of said molding, of less than R4.

29. A walk-in cooler as in claim 27, said corner molding having no substantial thermal insulating value between the inner surface (6) and the outer surface (8), at the first and second channels through a combination of walls of said molding,.

30. A walk-in cooler as in claim 27, said elongate corner molding further comprising a web (36) providing a connection between said inner wall (2) and said outer wall (4).

31. A walk-in cooler as in claim 30 wherein at least one of the channels (40, 42) in said elongate corner molding is further defined in part by said web (36).

32. A walk-in cooler as in claim 30 wherein said web extends along a path and wherein the path, or a projection of a general direction of the path, intersects said outer wall (4) at a location displaced from the outer corner (30).

33. A walk-in cooler as in claim 27 wherein the first channel extends toward the outer corner (30) and ends at a first end, and the second channel extends toward the outer corner (30) and ends at a second different end, and wherein the distance between one of the first and second ends and the outer corner is less that the distance between the other of the first and second ends and the outer corner.

34. A walk-in cooler as in claim 33 wherein the one of the first and second ends is located proximate the outer corner (30).

35. A walk-in cooler as in claim 27 wherein said corner molding is made with polymeric material.

36. A walk-in cooler as in claim 27 wherein corner molding is made with polymeric material selected from the group consisting of operable vinylidene chloride homopolymers and copolymers, operable low density polyethylene homopolymers and copolymers, operable medium density polyethylene homopolymers and copolymers, operable high density polyethylene homopolymers and copolymers, operable polypropylene homopolymers and copolymers, and operable polyamide homopolymers and copolymers.

37. A walk-in cooler as in claim 27 wherein said corner molding is made with impact-grade vinylidene chloride copolymer.

38. A walk-in cooler as in claim 27 wherein said corner molding is made with high impact, low temperature, grade vinylidene chloride copolymer.

39. A walk-in cooler as in claim 27 wherein at least one of the channels is defined by an end wall, and first and second side walls extending away from said end wall in a generally common direction, and wherein said first and second side walls, of at least one of the channels, extend away from said end wall along converging paths when said corner molding is at rest.

40. A walk-in cooler as in claim 39 wherein the converging paths define an angle (α) of about 2 degrees to about 15 degrees.

41. A walk-in cooler as in claim 27 wherein at least one of said side walls of a respective one of the channels resiliently grips a respective one of said end ones of said wall panels.

42. A walk-in cooler as in claim 27 wherein each of the channels has a channel width, between the respective side walls, effective to receive and hold a said one of said wall panels having a thickness of about 2 inches to about 6 inches.

43. A walk-in cooler as in claim 27 wherein each of the channels has a channel width, between the respective side walls, effective to receive and hold a said one of said wall panels having a thickness of about 3 inches to about 5.5 inches.

44. A walk-in cooler as in claim 27 wherein each of the channels has a channel width, between the respective side walls, effective to receive and hold a said one of said wall panels having a thickness of about 3.5 inches to about 4.1 inches.

45. A walk-in cooler as in claim 27, said first wall having a top and a bottom, and further comprising an elongate boot having an upwardly-open channel extending along the first length of the first wall, and the bottom of the first wall being received in the upwardly-open channel of the boot and thereby substantially separating the first wall from an underlying supporting surface.

46. A walk-in cooler as in claim 27, further comprising a ceiling spanning respective ones of said upstanding walls and comprising a plurality of third generally laterally extending wall panels extending side by side with respect to each other, said third wall panels having effective thermal insulating properties suitable for use as thermal insulating barrier in defining a top wall of such enclosed space, further comprising at least one elongate ceiling corner molding joining said third wall panels of said ceiling to at least one of said upstanding side walls.

47. A walk-in cooler as in claim 46, said at least one ceiling corner molding having a length (L), and inner (2) and outer (4) walls defining inner (6) and outer (8) surfaces, and first and second elongate channels extending along the length (L), and having thermal insulating value, between the inner and outer surfaces, at the first and second channels, through a combination of walls of said molding, of less than R4.

48. A walk-in cooler as in claim 47, said at least one ceiling corner molding having no substantial thermal insulating value between the inner surface and the outer surface, at the first and second channels, through a combination of walls of said molding.

49. A walk-in cooler as in claim 46, said at least one ceiling corner molding further comprising a web (36) providing a connection between said inner wall (2) and said outer wall (4).

50. A walk-in cooler as in claim 49 wherein at least one of the channels in said at least one ceiling corner molding is defined in part by said web (36).

51. A walk-in cooler as in claim 27 wherein said at least one ceiling corner molding is made with polymeric material selected from the group consisting of vinylidene chloride homopolymers and copolymers, low density polyethylene homopolymers and copolymers, medium density polyethylene homopolymers and copolymers, high density polyethylene homopolymers and copolymers, polypropylene homopolymers and copolymers, and polyamide homopolymers and copolymers.

52. A method of building a walk-in cooler, defining a cooled enclosed space inside the cooler, the method comprising:

(a) assembling a plurality of upstanding walls, at least first and second such walls each comprising a plurality of upstanding wall panels cooperating with each other in side by side relationship, the upstanding wall panels having opposing inner and outer surfaces, and thermally insulating material between the inner and outer surfaces, the wall panels being effective for use as thermal insulating barrier between the enclosed space inside the cooler and an outer ambient environment; and

(b) joining respective pairs of the at least first and second such upstanding walls to each other, at non-parallel angles, by inserting edge elements of the respective upstanding walls into a corner molding, the corner molding having (i) a length (L), (ii) inner (2) and outer (4) walls defining inner (6) and outer (8) surfaces, and corresponding inner (34) and outer (30) corners, of the corner molding, and (iii) first (40) and second (42) elongate channels, defined by channel side walls and channel end walls, extending along the length of the corner molding, and defining cross-sectional channel spaces therein, the edge elements of the respective upstanding walls being received in the first and second elongate channels.

53. A method as in claim 52, the respective ones of the upstanding walls substantially filling the cross-sectional spaces defined by the respective channels at loci along the lengths of such channels where the wall edges are received.

54. A method as in claim 52, further comprising assembling a plurality of the panels thereby to define a ceiling, and joining edges of the ceiling to the upstanding walls by using further such corner moldings between edges of the ceiling and the upstanding walls.

55. A method as in claim 52, further comprising employing at least one such corner molding having no substantial thermal insulating value between the inner and outer surfaces at the channels, through a combination of walls of the molding.

56. A method as in claim 52, further comprising employing at least one such corner molding comprising a web (36) providing a connection between the inner wall (2) and the outer wall (4).

57. A method as in claim 56, further comprising employing at least one such corner molding wherein the web (36) extends along a path and wherein the path, or a projection of a general direction of the path, intersects the outer wall (4) at a location displaced from an outer corner (30) of the molding.

58. A method as in claim 57, further comprising employing at least one such corner molding wherein the first channel (40) extends toward an outer corner (30) of the molding and ends at a first end, and the second channel (42) extends toward the outer corner (30) and ends at a second different end, and wherein the distance between one of the first and second ends, and the outer corner, is less that the distance between the other of the first and second ends, and the outer corner.

59. A method as in claim 52, further comprising employing at least one such corner molding wherein the corner molding is made with polymer material selected from the group consisting of operable vinylidene chloride homopolymers and copolymers, operable low density polyethylene homopolymers and copolymers, operable medium density polyethylene homopolymers and copolymers, operable high density polyethylene homopolymers and copolymers, operable polypropylene homopolymers and copolymers, and operable polyamide homopolymers and copolymers.

60. A method as in claim 52, further comprising employing at least one such corner molding wherein at least one of the channels is defined by an end wall, and first and second side walls extending away from the end wall in a generally common direction, and wherein the first and second side walls, of the respective channel, extend away from the end wall along converging paths when the corner molding is at rest.

61. A method as in claim 60 wherein the converging paths define an angle (α) of about 2 degrees to about 15 degrees.

62. A method as in claim 61 wherein at least one of the side walls resiliently grips the respective upstanding wall received in the respective channel.

63. A method as in claim 61 wherein widths of the respective channels (40, 42) generally correspond to thicknesses of the respective edge portions of the upstanding walls, between the inner and outer surfaces, as received in the respective channels.