Modular frame and enclosure system

Abstract

The invention is a modular frame system that can be used to construct free-standing enclosures for equipment. The modular system includes interchangeable frame members connected to transition members that can together be arranged to form an orthogonal frame. Other accessory components can be attached to build an enclosure system. The invention envisions utilizing composite materials in constructing enclosures, with such embodiments having an enhanced strength to weight ratio. The frame system is constructed of frame members that facilitate alignment and attachment of other system accessory components through use of regularly spaced upstanding male connectors that engage with regularly spaced depressed female connectors. Thus, there is great flexibility in attachment of components and adapting the enclosure system to particular applications. Frame members of the invention can alternatively be used as construction components in a variety of building systems.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to provisional application Ser. No. 60/581,999 filed Jun. 22, 2004.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not applicable.

BACKGROUND OF THE INVENTION

Enclosures are used for a number of applications, including three general categories: to provide environmental protection of equipment; to provide a rack or mounting space in which to mount equipment such as computer equipment; and to enclose controls for the utility and energy industries. The enclosure industry is very broad in terms of specific enclosure applications and configuration of the enclosure to house particular products. Broad categories of product configurations include large freestanding units, wall mount units, junction boxes, instrument housings, consoles, operator interfaces and kiosks.

The market in the United States alone for industrial enclosure applications is estimated to exceed $1 billion annually, with approximately half of the dollar value consisting of free-standing enclosures. The general form of most enclosures is orthogonal, either square or rectangular in cross section, although for certain applications other cross sectional shapes may be useful, including trapezoidal, hexagonal and octagonal.

Other variations on the basic form of an enclosure embodied by the freestanding enclosure include wall mounted boxes, operator interface cubicles, along with accessory products such as swing frame mounting panels, doors, partitions and wire way. Many enclosure systems are designed to conform to the Electronic Industry Association 310c standard for hole spacing and location to allow for mounting standard 19 inch equipment on rails (EIA rail).

One difficulty for manufacturers is shipping enclosures is that an assembled enclosure has a very high space to weight ratio. Therefore shipping and handling of assembled enclosures is problematic, as shipping assembled enclosures requires substantial volume. As manufacturers attempt to ship more compact, disassembled components to order minimize shipping costs, there is an efficiency trade-off for the end user, who must either pay to have a technician assemble the enclosure, or assemble the enclosure on site, where time, tool availability, and mechanical skill may limit the ability of the end user to configure an enclosure product in an optimal manner.

As many end users who have attempted to assemble an unfamiliar enclosure or other furniture can attest, basic unfamiliarity of the method of assembly of a complex product of many unfamiliar parts can be a frustrating and often laborious process.

For these reasons modular enclosure construction styles have proven popular because of ease of assembly and ready access, flexible configurations, and capability of expansion. Performance of enclosures utilizing modular construction is limited relative to “unibody” free-standing enclosures with regards to structural rigidity, weight capacity, and other logistical requirements. Some of these limitations of modular construction technology can be eliminated by adding structural reinforcements, usually through adding selected accessory products at additional costs in weight, labor and acquisition price.

A variety of materials have been used to construct enclosures. Freestanding enclosures have utilized mild carbon steel, stainless steel, aluminum and fiberglass reinforced polyester. Considerations on determining the material used in an enclosure include the weight of the enclosure, with heavier materials limiting portability; the weight bearing capacity of the enclosures, with steel being typically used for enclosures carrying heavier loads; and corrosion protection, with enclosures being used in corrosive environments being constructed of stainless steel or polyester.

A number of other performance versus cost balancing factors may be considered when determining the material used and the construction method depending on the particular enclosure application These factors include ease of assembly, need for electromagnetic interference (EMI) shielding, shock and vibration resistance, requirement for explosion protection, enclosure accessory requirements, thermal management, vandalism resistance, hygiene, environmental protection ratings, electrical properties, and industry standards and municipal codes.

Recently, hybrid materials have been developed that combine metal support members with integrated plastic reinforcements. See U.S. Pat. No. 5,190,803 and 6,421,979, the disclosures which are incorporated herein by reference.

There is a need in the enclosure industry for enclosures exhibiting high strength to weight ratio, user configurable structure, capacity for environmental protection and environmental control and relative ease of assembly. The invention disclosed herein offers advantages in many areas important for the design and performance of an enclosure system. When embodied through the use of composite construction, including metal/plastic hybrid material, there are advantages in strength to weight ratio and enabling the optimization of material properties for a particular application. Additionally the modularity of construction, ease of alignment, and utilization of materials with a high strength to weight ratio have applications in many areas of the furniture, construction and other industries.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a method for producing modular frames that have wide application in the furniture, enclosure, construction and other industries. One embodiment provides a rigid rack system that can serve as the frame for freestanding enclosures and if used in conjunction with other modular components of the invention, can be used to construct secure freestanding enclosures for electronic and other equipment.

The invention is embodied in a method of making a frame comprising the steps of providing two or more linear frame members exhibiting frame contact peripheries at the ends and a frame cross-section presenting at least one contact edge along the axis of the frame edges. An additional embodiment of the invention are one or more transition members that form a junction and or corner connection between linear frame components. Ideally, the transition member will exhibit a contact periphery in at least two contact planes. The invention is embodied in aligning a frame contact periphery of a frame member with a first edge profile and abutting a linear frame member to a first contact surface of a transition member, aligning a frame contact periphery with a second edge profile and abutting a linear frame member to a second contact surface of a transition member and then aligning a frame contact periphery with a third edge profile and then abutting a linear frame member to a third contact surface of a transition member. By reiterating the aligning and coupling steps, a three dimensional frame can be constructed according to the invention, utilizing transition members with four or more contact surfaces.

The invention is embodied in a means for connecting and aligning transition members and frame members by providing one or more stud connectors each having first and second connector portions in a more or less linear orientation. Linear frame members are provided with two or more with frame connector cavities extending axially and mutually inwardly from the frame contact ends. Another embodiment of the invention is the connection of frame members to transition members each being configured with a transition connector cavity extending axially inwardly from first, second, third and or fourth contact surfaces. Thus the steps of aligning and coupling a transition member with frame members can be carried out by inserting a stud connector first connector portion within a frame connector cavity and inserting said stud connector second connector portion within a said transition connector cavity. Alignment and permanent connection are embodied in the use of connector clips and locking spacer collars.

The invention is also embodied in a transition member or frame member being configured having an outwardly disposed flat surface having one or more frame carrying connectors, or nubs, integrally formed with the flat surface. Frame members can be configured with regularly spaced carrying connectors, with the carrying connectors lending modularity to the frame members of the invention. The steps of aligning and coupling a frame member locates the frame member and or a transition member with the outwardly facing flat surface that is aligned, thus providing for attachment of a corner completing accessory of the invention, in one embodiment having a cross-section of triangular shape to define a corner by interconnecting frame carrying connectors with accessory connectors. The invention is also embodied in a system and method in which one or more frame members with one or more flat surfaces having an array of said frame carrying connectors which are outwardly depending male connectors and providing an accessory component with accessory carrying connectors as inwardly depending female connectors. The invention is furthermore embodied in a system and method in which one or more frame members with one or more flat surfaces having an array of said frame carrying connectors which are inwardly depending female connectors and providing an accessory component with accessory carrying connectors as outwardly depending male connectors.

According to the invention is a method for aligning and coupling two or more frame members or other frame components with one or more transition members carried out to derive a frame structure with two or more adjacent bays where two vertically oriented frame members are located with a linear edge of one frame member abutting a linear edge of the adjacent frame member. Thus, the cross section of each frame is, in a preferred embodiment, generally square to provide two angularly oriented frame faces extending outwardly from the abutting linear edges. The adjoining frames can be sealed by installation of a resilient gasket and by further providing an inter-bay completing accessory having a cross-section of triangular shape and having accessory connectors corresponding with an array of frame carrying connecters, thus coupling the inter-bay completing accessory at the respective side faces to the angularly oriented frame faces by interconnecting frame carrying connectors with accessory connectors.

Another embodiment of the invention is a frame constructed according to the invention that possesses continuous transition edges, capable of forming a tight seal, especially when employed with a gasket of resilient material. Furthermore, frame systems of the invention can be stacked vertically, and connected in a manner analogous to the horizontal connection just described.

The invention is further embodied in frame members whose frame cross-section defines four flat orthogonally disposed surfaces with one or more said flat surfaces having a said frame connecter assemblage comprising an array of frame connectors, with each transition member back surface frame carrying connector assemblage comprises an array of said frame connectors. The frame connectors are embodied as outwardly depending male connectors and the accessory connectors are embodied as inwardly depending female connectors. Additionally, the frame connectors are embodied as inwardly depending female connectors and the accessory connectors are embodied as outwardly depending male connectors. In a preferred embodiment of the invention the frame cross-section is rectangular or substantially square, although other cross-sectional shapes can be used to practice the invention.

The invention is embodied in a frame system, comprising a plurality of linear frame members of given lengths extending along a frame axis between oppositely disposed contact ends, with the contact ends exhibiting frame contact peripheries. The frame system may include a plurality of transition members. The frame possesses a plurality of transition members being designated lower frame transition members, and a plurality being designated upper frame transition members, a plurality of the frame members being designated vertical frame members, and a plurality being designated horizontal frame members. The oppositely disposed contact ends of a plurality of the vertical frame members being coupled between the first contact surface of a plurality of the lower frame transition members and the fourth contact surface of a plurality of the upper frame transition members. The oppositely disposed contact ends of a plurality of the horizontal frame members being coupled between the second contact surfaces and the third contact surfaces of a plurality of lower frame transition members to define a lower frame portion; and the oppositely disposed contact ends of a plurality of the horizontal frame members being coupled between the second contact surfaces and the third contact surfaces of a plurality of upper frame transition members to define the upper frame portion of a frame having a plurality of vertically disposed corner regions extending between oppositely disposed upper frame transition members and lower frame transition members.

Yet another embodiment of the invention are frame members configured having an open channel extending between frame component ends. Frame members can be designed to function independently as modular construction elements, including as conduits, or with a design specialized for construction of a modular frame system. Frame members and transition members can be configured according to the invention having joined open channels with the transition member cavities being generally aligned with a frame cavity when their respective contact peripheries are aligned. The frame system is also embodied in one or more of said frame members comprising a generally U-shaped channel component having an outwardly open cap receiving side and configured with a generally U-shaped reinforcing member having three outwardly disposed frame faces and a reinforcing member cavity extending between the oppositely disposed contact ends. Preferably, a polymeric channel matrix member is located within the reinforcing member cavity configured to define a portion of the frame connector cavities extending inwardly from the frame contact ends and further configured to define a matrix bottom wall and side walls extending outwardly to spaced apart cap engagement ledges adjacent to the outwardly open cap receiving side. A cap component is provided, configured for positioning over the aforementioned channel component open cap receiving side and having a generally flat cap reinforcing member with an outwardly disposed frame face and an inwardly attached polymeric cap matrix member having oppositely and axially disposed spaced apart engagement surfaces engaging said spaced apart cap engagement ledges, the cap matrix member, with the channel matrix member, defining the frame connector cavities. A connector assembly coupling said cap component with said channel component, including manifold blocks to direct airflow and provide access to the frame member cavity are provided. Although a frame member with a square cross-section in mentioned as a preferred embodiment, other cross-section of frame members can be used to practice the invention.

Other objects of the invention will, in part, be obvious and will, in part, appear hereinafter. The invention, accordingly, comprises the apparatus and method possessing the construction, combination of elements, arrangement of parts and steps which are exemplified in the following detailed description.

For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an assembled enclosure incorporating three frames according to the invention with accessory panels and equipment installed on the frame;

FIG. 2 is a perspective view of an assembled enclosure frame;

FIG. 3 is a perspective view of frame members joined by a transition member;

FIG. 4 is a perspective view of a transition member in association with stud connectors;

FIG. 5 is a an exploded view of a transition member and in association with stud connectors;

FIG. 6 is a top view of a transition member is revealed in connection with stud connectors;

FIG. 7 is a sectional view along line 7-7 of FIG. 6 showing a transition member in connection with stud connectors;

FIG. 8 is a perspective exploded view of a frame member and related components;

FIG. 9 is a partial sectional view of an assembled frame, such section being taken across the transition edges of both the transition members and the linear frame members;

FIG. 10 is a perspective view of a manifold screw;

FIG. 11 is a sectional view of the cap component described in connection with FIG. 8;

FIG. 12 is a sectional view of a cap component according to the invention showing an alternate embodiment;

FIG. 13 is a sectional view of a cap component according to the invention showing an alternate embodiment;

FIG. 14 is a sectional view of a cap component according to the invention showing an alternate embodiment;

FIG. 15 is a top view of an assembled enclosure;

FIG. 16 is a perspective view of an accessory component of triangular configuration;

FIG. 17 is a sectional view of a triangular accessory component installed on a frame member;

FIG. 18 is a sectional view of a triangular accessory component installed on a frame member; and retained by screws;

FIG. 19 is a perspective view of an alternative embodiment of an accessory component of triangular configuration with both simple and cammed female connectors;

FIG. 20 is a sectional view of an alternative embodiment of an accessory component of triangular configuration locked on a frame member with a cammed female connector;

FIG. 21 is a bottom view of the locking arrangement of an accessory block with a cammed female connector;

FIG. 22 is a sectional view of a horizontal accessory bar installed between two frame members;

FIG. 23 is an end view of a accessory component with elongated female carrying connectors.

FIG. 24 is a top view of an accessory component exhibiting the capability of modular interconnection;

FIG. 25 is a side view of an accessory component such as that shown in FIG. 24.

FIG. 26 is a top view of a modular accessory component that can connect frame members and that has a locking cam connector;

FIG. 27 is a side view of an accessory component such as that shown in FIG. 26.

DETAILED DESCRIPTION OF THE INVENTION

The invention is embodied in a modular frame system that can be used to construct free standing enclosures for equipment. In the discourse to follow an enclosure is generally described which incorporates the frame system and method of the invention. Then, the uniquely developed frame system is described including the utilization of linear framed members and transition members which function to define corners as well as to evolve continuous transition edge which falls within a common transition plane permitting an ideal sealing of the cavity defined by the enclosure. The discussion then turns to the structuring of the frame and transition members as they are combined to form an enclosure. To achieve a continuous edge within each transition plane the frame members are rotated in effect an amount of about 45°. However, to reconstitute the sides or skin of an enclosure, accessories are provided which, in effect, return frame surfaces to a conventional orientation. The frame system is constructed of frame members that facilitate alignment and attachment of other system components, such as sealing panels, hinged doors, shelves, drawer tracks, or decorative panels.

The modularity of the components of the invention is illustrated by the interchangeability of horizontal and vertical frame members. While it is possible to construct horizontal and vertical frame members of the invention with different cross sections, for instance with rectangular and round cross sections respectively, modularity and interchangeability of system components is enhanced by producing horizontal and vertical frame members with the same cross section, for instance a square cross section.

In a preferred embodiment, all frame members or frame member components are hollow. When a frame is assembled from hollow frame members, studs, and manifold blocks, there will exist a frame cavity that forms a continuous passageway throughout the structure of the assembled frame. This hollow construction facilitates the application of a number of accessory elements to adapt the assembled frame for a particular application.

Frame members can be cast, molded or extruded from a wide range of materials including thermoplastics and thermoset compounds such as polyamides, polyethylene, polysulfones, polycarbonates, polystyrene, polyester or vinyl resins, epoxy resins, and phenolic resins including copolymers and blends and these materials in reinforced or filled form or from other materials known to those skilled in the art, depending on the requirements of a particular application. Materials to fill, reinforce or modify the above materials include fibers or woven fabrics of glass carbon or textiles and modified natural substances such as wood particles and mineral fibers. Frame members or particular components could be milled or formed, including from metals such as steel, stainless steel, aluminum, and titanium and alloys of these or other appropriate metals.

Referring to FIG. 1, an enclosure incorporating three frames is represented in general at 10. Enclosure 10 incorporates three bays represented generally at 12, 14 and 16 formed with a corresponding three internal frames that are interconnected. Some components of the internal frame are seen within the bay 12 that is associated with a door 18 fastened to the frame at hinges 20-22. Portions of the frame revealed in bay 12 are seen to include a vertical frame member 24 as well as horizontal frame members 26 and 28. These frame members generally exhibit a rectangular cross-section which preferably is square. With such an arrangement, two generally horizontally disposed opposite edges when combined with transition members define a continuous transition edge which resides within a transition plane. This permits an ideal sealing such that a seal as shown at 30 mounted upon the inside of door 18 will engage that transition edge in an ideal manner. Portions of the transition edge are seen at 32. Enclosure 10 rests upon a plinth 34 and is configured with lifting eyes certain of which are identified at 36.

Looking to FIG. 2, an illustrative frame is represented in general at 38. Frame 38 is formed with four principal vertical frame members 40-43, and at a lower frame portion represented generally at 44, four horizontally disposed frame members 46-49 are illustrated. Correspondingly, the frame upper portion represented generally at 50 is seen to incorporate four horizontal frame members 60-63. The figure illustrates the unique orientation of the frame members in that they are, in effect, rotated by an amount of 45° from what may be considered a conventional structuring for an enclosure frame. To interconnect these frame members and accomplishing the earlier-noted continuous transition edges, horizontal and vertical components are interconnected by identically structured transition members shown in the figures at 64-71. These transition members are uniquely structured to establish the earlier-described co-planar transition edge profile. In this regard, two outwardly disposed profiles are seen in the figures at 72 and 74. Correspondingly, an inwardly disposed transition profile which is continuous is seen at 76-78. Such profiles are present at each side of the frame 38. With such an arrangement, components of the enclosure may be, in effect, sealed for pressurization and the like. As another feature, the transition members as at 64-71 as well as the frame members are structured, as noted above, to carry cooling fluids or be utilized as a race for carrying wiring and the like. Lower region transition members 46-49 also are seen coupled with respective feet 80-83. These feet may be structured in the same manner as the frame members or may be formed as simple blocks or the like. Note, additionally, that the transition members are configured having a flat back surface, for example, as represented as at 84 in connection with transition member 71, and 86 in connection with transition member 67. Finally, it may be observed that the surfaces of frame members carry frame carrying connectors 88, and the back surfaces, for example, at 84 and 86 of the transition members also carry frame carrying connectors 88.

Referring to FIG. 3, vertical frame member 42, foot 82 and horizontal frame members 48 and 49 are illustrated in perspective fashion in connection with transition member 70. Linear frame member 49 is seen extending to a contact end represented generally at 90; vertical frame member 76 is seen extending to a contact end 92 and foot 82 is seen extending to a contact end 94. Each of those contact ends exhibits a frame contact periphery, here corresponding with a square frame cross-section. Such an arrangement provides two symmetrically opposite linear edges, for example, one such edge is shown at 96 in connection with linear frame member 49. Note that linear edge 96 is outwardly disposed. In similar fashion, an outwardly disposed linear edge is shown at 98 in connection with vertical frame member 42. An outwardly disposed linear edge is shown at foot implemented frame member 82 as at 100. An inwardly disposed linear edge which is symmetrically oppositely disposed from a corresponding outer linear edge is shown at 110 in connection with horizontal frame member 48.

One embodiment of the invention is the relative orientation of the transition edges of different frame members. One advantage of threaded connector studs as in 140 along with locking spacer collars as in 166 is the capability to install frame members in a chosen orientation relative to one another. In a further embodiment of the invention, other shapes of frame members can also be oriented relative to the transition members to expose an outwardly facing transition edge, disposed in a plane. By adjusting the orientation of frame members through use of connector studs and locking spacer collars, frame members of triangular, rectangular, pentagonal, hexagonal, or octagonal cross section can be oriented to expose a sealing edge in a plane. Certain cross sections of frame members can also be oriented to expose an inwardly facing sealing edge.

Now looking to the transition members as at 70, each is typically formed with four cognitively disposed components. The first such component is represented generally at 112 and is seen to be disposed about a vertically oriented first axis identified at 114. Component 112 provides a first contact surface 116 which exhibits an edge profile which corresponds with the earlier-noted frame contact periphery. That edge profile is oriented about the first axis 114 to position two opposite edges within a first plane extending through the axis 114.

Transition member 70 further is configured having a second component 118 extending along a second axis 120 to a second contact surface 122. Surface 122 exhibits an edge profile corresponding with the cross-section of frame member 49 and is oriented about the second axis 120 to position two opposite edges and a second plane normally disposed with respect to the noted first plane. One of those edges has been described at 96. The figure permits the illustration of this second plane as at 124.

Not seen in this figure is a third component extending along a third axis represented at 128. That component is oriented about axis 128 such that two opposite edges, one of which has been described at 110 lie within the earlier-noted second plane 124. Finally, a fourth component is represented generally at 130 extending along the first axis 114 opposite the first component to a fourth contact surface represented generally at 132. Surface 132 exhibits an edge profile corresponding with the cross-section, for example, of foot or frame member 82. Now looking to the transition edges of transition member 70, note that an outermost one of two edges as shown at 134 with respect to the first and second components interact with contact surfaces 122 and 116 in continuous fashion and within a transition plane. Note that this edge exhibits a medial curvature as represented generally at 136. It may be observed that the outermost edges 98 of the first frame member 42 and the corresponding outermost edge 96 of frame member 49 define a continuous transition edge within a common transition plane. A similar geometry is present with respect to each of the four transition member components. In those situations where less than four frame member components are to be joined, transition members can be constructed with two, or three, cognitively disposed components. The figure further reveals the presence of connector screws certain of which are identified at 138.

In a preferred arrangement, the linear frame members are interconnected with the transition members utilizing stud connectors. Looking to FIGS. 4 and 5, transition member 70 again is reproduced but in association with three stud connectors 140-142. In FIG. 5 portions of the first and second contact surfaces 116 and 122 are revealed extending inwardly from each such contact surface as internally threaded opening 144 and 146 which, in combination with the internal openings of the other transition member components define a transition connector cavity providing for the acceptance of cooling fluids or wiring. FIG. 5 reveals that each of the stud connectors 140-142 is configured with a externally threaded first connector portion shown respectively at 148-150 and an integrally formed second connector portion shown respectively at 152-154 exhibiting a square cross section in this embodiment of the invention. An open channel as shown respectively at 156-158 extends through each of the respective stud connectors 140-142. Additionally, a threaded engagement tap is provided within each stud connector, certain of which are revealed at 160. Additionally, the second connector portion of each of the stud connectors is configured with inner and outer connector channels, certain of which are identified at 162 and 164, respectively. When these stud connectors are threadably engaged with the transition member as at 70 they are secured from rotation by locking spacer collars, certain of which are revealed at 166. Locking spacer collars as at 166 are secured in place by machine screws, certain of which are identified at 168. The thickness of locking spacer collar 166 can be adjusted by the user to accommodate tolerances needed to align the assembled frame. The threaded openings in the stud connectors as described at 160 are located to receive connection screws earlier-described in connection with FIG. 3 at 138.

Referring to FIG. 6, a top view of the transition member 70 is revealed in connection with stud connectors 140-142 and their associated locking spacer collars 166, as shown previously in perspective view in FIG. 4. The figure also reveals that the back surface 84 is arranged perpendicularly or normally to an axis 170. Axis 170, in turn, bisects axes 120 and 128. Also identifiable in FIG. 6 is a transition plane 171 as well as a transition plane 172. It may be recalled that the continuous transition edge profile falls within such transition planes.

Looking to FIG. 7, a sectional view along line 7-7 shown in FIG. 6 is revealed. Referring to the sectional view of FIG. 7, the earlier-described transition connector cavity is illustrated and now represented generally at 174. Note that the cavity is formed from four internally threaded openings. In this regard, note that openings 144 and 146 return from FIG. 5. In addition to these openings, note that the figure reveals threaded openings 176 and 178.

Now considering the structuring of the linear frame members, reference is made to the exploded view of FIG. 8. In the figure, an exemplary frame member is represented generally at 190. A preferred embodiment of the invention is utilization of linear frame members in the construction of a modular frame system. An embodiment of the invention are frame members formed from hybrid materials combining a matrix member and a reinforcing member. Polymeric materials which may be employed with the hybrid frame members as well as for the formation of the transition members. The basic principle of utilizing hybrid materials to form composite construction elements is illustrated in U.S. Pat. No. 5,190,803. Typically the body matrix member is formed from some type of polymeric plastic or composite material through molding or extruding. If the reinforcing member is formed from metal, the shape of the reinforcing member can be produced by pressing, rolling or other means. The components of the hybrid material system can be joined together during the forming process, for instance, by inserting the reinforcing member into a mold and then injecting plastic utilized as a matrix member into the mold. One of many alternative means for forming a component of hybrid material is to separately form the body matrix member, and then join the matrix member to the reinforcing member. Such as process is illustrated by U.S. Pat. No. 6,421,979, with said disclosure expressly incorporated herein by reference. Artisans will recognize that the particular materials utilized are highly diverse, and particular materials may be chosen for specialized applications. Thus, although polymeric matrix members formed of plastic are a preferred embodiment, and the matrix element is referred to as a polymeric matrix, as is obvious to artisans, the invention is not limited only to matrix elements of a polymeric or plastic nature.

Another embodiment of the invention is as a hollow construction element. When a hollow construction element is formed from composite materials as described the construction element of the invention can be used to construct wireway conduit that can be used separately, or in conjunction with the frame system and enclosures of the invention. It is apparent that the construction elements shown in FIG. 8 is readily adaptable as a conduit. If the construction element is made with a removable cap, as in FIG. 8, positioning of material within the conduit would be enabled furthermore, a conduit constructed using the composite materials described will have advantages of strength to weight ratio over conventional single material conduit, whether of metal or plastic construction.

Frame member 190 shown in FIG. 8 is formed with regularly spaced male carrying connectors 248 on the outside surfaces. If the frame member is formed of a single material, male connectors can be formed of the same material as the frame member. When employing hybrid materials as described, the advantage of the provision for regularly spaced male connectors is apparent. When forming a composite construction element of hybrid materials, means must be provided for affixing the body matrix element to the reinforcing element. One method that has previously been used to anchor body matrix material to the reinforcing element is to pass body matrix material through perforations in the reinforcing element so that the body matrix material is formed to integrally connect with the reinforcing element. See U.S. Pat. No. 5,190,803. The invention provides for a method for forming a hybrid or composite construction element wherein the body matrix is fixed to the reinforcing element through perforations or indentations that can be used to form regularly spaced male connectors.

Referring to again to FIG. 8, is seen one embodiment of frame members of a hybrid construction, combining a reinforcing member 196 with a polymeric matrix member 208, formed using either injection molding or extrusion as shown. In a preferred embodiment, horizontal and vertical frame members are constructed as shown in FIG. 8. Frame 190 is formed with a generally U-shaped channel component represented generally at 192. Component 192 is configured with an outwardly open cap-receiving side represented generally at 194 and is seen to be configured with a generally U-shaped reinforcing member represented generally at 196. Reinforcing member 196 configured with three outwardly disposed frame faces 198-200 and a reinforcing member cavity represented generally at 202 which extends between oppositely disposed contact ends 204 and 206. A polymeric channel matrix member represented generally at 208 is located within the reinforcing member cavity 202. Matrix component 208 is configured to define a portion of the frame connector cavities extending inwardly from the frame contact ends 204 and 206. That cavity portion is represented in general at 210. Matrix member 208 is seen to be configured to define a matrix bottom wall 212 and oppositely disposed side walls 214 and 216 which extend outwardly to spaced apart cap engagement ledges shown respectively at 218 and 220.

Note that screw ports, certain of which are identified at 222 extend through the sides of the frame member for communication within the frame connector cavity portion 210. Such screws are represented, for example, at 138 and correspond with screws as described at 138 in FIG. 3. Such a connecting arrangement is provided for all four sides of the linear frame member. The spaced apart cap engagement ledges 218 and 220 are operatively associated with a removable cap component represented generally at 224. Component 224 is configured generally for positioning over the channel component open cap receiving side as well as the oppositely disposed cap engagement ledges 218 and 220. Note that the cap member incorporates three cap screw ports 225 analogous to earlier identified screw ports at 222. Screw ports can be formed during the manufacture of frame members and regularly spaced along the walls of the frame members. In the alternative means to produce screw ports can be formed during manufacture of the frame member by providing means for punch out holes by scoring the reinforcing member and or the matrix member. Screw ports 222 and 225 are shown as circular in shape, but other embodiments of screw ports 222 and 225 could be oval, rectangular, or an extended rectangle forming a slot. Those screw ports not in current use could be closed using a plug shaped to fit a particular hole shape.

Certain stud connectors as represented generally at 226 are coupled within the frame connector cavity. In this regard, the first connector portion 228 of stud connectors as at 226 is mounted within the frame connector cavity utilizing generally U-shaped retaining clips. In this regard, two lower disposed such clips are shown at 232 and 234 which are located within respective matrix clip channels 239 and 238. Corresponding matrix clip channels are shown at 240 and 241. Those channels are aligned with the inner and outer stud connector clip channels here identified in connection with stud 226 at 236 and 237. Those channels are seen to be in alignment with inner and outer cap channels 240 and 241. Corresponding inner and outer cap clip channels are shown at 243 and 244. These cap channels receive upper retaining clips 231 while the said channels additionally are retained by lower retainer clips (not shown) but as described above at 232. Retaining clips are shown as separate parts of two pieces, which would allow retaining clips to be made of a different material than the attachment stud. In the alternative, connector stud 226 can be formed with an integral rib shaped to fit the retaining clip channel of frame member channel component 192 and frame member cap component 224.

A manifold block also may be located within the frame cavity. One such manifold block is represented generally at 250 and is shown configured with six mutually communicating threaded openings. Three of those openings are shown at 252-254. Depending on the length of the frame member and any requirements for additional reinforcement or modifications of an assembled frame member, one or more of manifold block 250, when inserted and aligned with one of the screw ports 222 may be connected in position by machine screws as at 138 to provide intermediate structural support for the linear frame member. Manifold block 250 can be made with one or more threaded holes 252, or could be solid.

The frame member shown in FIG. 8 will be hollow when assembled, facilitating the passage of wiring and/or fluids for temperature regulation. This embodiment of a frame member facilitates insertion of wiring harnesses in the frame cavity 210. As an additional function, the manifold blocks as at 250 may permit communication from exterior of the frame members through these screw ports as at 222 and 225. In this regard, for example, wiring harnesses and or cooling fluids may be conveyed through that port arrangement. Before final assembly of a frame, a wiring harness can be inserted into the frame member channel component 192, and threaded through intervening intermediate frame members, connector studs, and manifold blocks. When the wiring harness is located according to the requirements for the particular enclosure, the ends of the wiring harness can be threaded through an screw hole in a frame member, and the frame member cap component 224 secured to frame member channel component 192. Those skilled in the enclosure art can envision other applications for a continuous frame cavity beyond providing a conduit for wiring.

Returning to the cap 224, a configuration is illustrated which includes a generally flat frame cap reinforcing member 256 which preferably is formed of metal and exhibits an outwardly disposed frame face 258 and an inwardly attached polymeric cap matrix member 260. Matrix member 260 is configured having oppositely and axially disposed spaced apart engagement surfaces 262 and 264 configured to engage respective cap engagement ledges 218 and 220. The cap 224 is assembled against the cap receiving sides 194 through the utilization of connector screws, certain of which have been identified at 138 which extend through ports as at 225 extending through the cap. These screws will engage the threaded openings in oppositely disposed stud connectors as described earlier at 160. Frame member channel component 194 will typically have screw holes 222 aligned with the threaded holes 160 of connector stud 226, and screws 138 can likewise be driven into the connector stud to reinforce the retention of the connector stud in the frame member. The frame member channel component, connector stud and frame member cap component can also be assembled alternatively, or additionally, using an adhesive or other joining means. Additionally, intermediately disposed screws may be threadably engaged with one or more interval manifold blocks at 250. When joined, the frame member channel and frame member cap will form a frame member with a rectangular cross section, although the invention can be practiced with frame members of a number of different cross sections.

As described above, the linear frame members as at 190 are of a hybrid nature combining a polymeric matrix with a metal exterior. The members further are configured with an array of outwardly depending polymeric male connectors or nubs, certain of which are identified at 248. These connectors will be seen to be configured in a variety of shapes and materials. The outwardly disposed surfaces of frame members can be embodied to carry nubs or outwardly disposed male frame carrying connectors 248. As explained in greater detail below, the outwardly disposed male connectors will in preferred embodiments serve a dual role, serving both as a means to fix the polymeric matrix component to frame reinforcing members and also as a means of connecting accessory components.

Referring now to FIG. 9, a partial sectional view of an assembled frame of the invention is revealed, such section being taken across the transition edges of both the transition members and the linear frame members. In the figure, upper frame portion is represented generally at 280, while the lower frame portion is represented in general at 282. A vertical linear frame member is represented generally at 284 extending between the upper and lower portions. Frame member 284 is seen to be configured having oppositely disposed transition edges 286 and 288 which are structurally associated with polymeric matrix components as described in connection with FIG. 8 and shown at 290. Thus, a frame connector cavity 292 is developed between oppositely disposed contact ends 294 and 296. As before, those contact ends exhibit frame contact peripheries which exhibit a frame cross-section having noted two symmetrically opposite linear edges 286 and 288. These contact ends are connected in abutting relationship against the contact surfaces 298 and 300 of respective transition members 302 and 304. A stud connector 306 couples transition member 302 to the top of frame member 284, while an oppositely disposed stud connector 308 connects the lower portion of frame member 284 in abuttable relationship against the contact surface of transition member 304. Accordingly, upon assembly, the frame contact periphery of frame member 284 is aligned with the transition member first contact surface in conjunction with a coupling which is carried out with the stud connectors. Two manifold blocks 312 and 314 are seen to be located and fixed within frame connector cavity 292. As discussed in connection with FIG. 8, these blocks are configured with manifold openings that extend through them thus permitting the insertion of the elongated rod portion 316 of a lifting eye represented generally at 318. Note that the rod extends into threaded engagement with a block form of foot represented at 320. At the upper region 280 a horizontal frame member represented generally at 322 is illustrated as having its contact end 324 abuttably coupled to the corresponding contact surface 326 of transition member 302. Connection is provided by a stud connector 328. As before, in the course of assembly, the horizontal frame contact periphery is aligned with the contact surface 326 and secured in that orientation by the engagement of locking spacer collar 329 (seen previously as 166 in FIG. 5-6) with stud connector 328. Note that horizontal frame member 322 is configured with transition edges 330 and 332 which surmount matrix component 334.

The figure reveals that a top panel 336 is affixed over the top of the assemblage. In this regard it extends over the back surface 338 of transition member 302. Note that a polymeric seal 340 has been located between the transition edge 330 and the inward side of top panel 336.

Now looking to the lower portion 282 of the assemblage, a lower horizontal frame member is represented generally at 342. As before, frame member 342 is assembled within the system by aligning its contact end 344 with the corresponding contact surface 346 of transition member 304. A rigid connection is established through the utilization of stud connector 348, which connection can be further secured in a given orientation by the engagement of locking spacer collar 349. As before, the horizontal frame member 342 is shown with transition edges 350 and 352 which surmount polymeric matrix component 354.

In another embodiment of the invention, to facilitate temperature regulation of the enclosure, environmentally conditioned fluids can be introduced into the frame cavity as at 292 in FIG. 9, utilizing the frame cavity as a duct for conducting the conditioned fluids. Conditioned fluids could be directed from the frame cavity to a particular location within an assembled enclosure inserting or removing screws or plugs from different screw holes in the frame members. In another embodiment, access to the frame cavity is provided by use of connector screw 370. Referring to FIG. 10, a manifold screw is represented generally at 370. Screw 370 is formed with an internally disposed port or channel 372 which may be internally threaded to receive a nipple. The screw is formed with a flat head 374 which is integrally formed with an externally threaded stem 376. Hoses or other means to direct fluid flow are inserted into port 372 and extended to a location accessible to the frame to direct the flow of environmentally conditioned fluid. The environmentally conditioned fluid could be variously air, inert gases, or liquids such as water, and could be used to heat, cool or pressurize particular components. It is envisioned by the invention that both wiring and conditioned fluids could be present in the same frame cavity.

Referring to FIG. 11, a section of the cap component 224 described in connection with FIG. 8 is revealed incorporating the earlier-described cap matrix member 260 and frame cap reinforcing member 256. The section of two frame carrying connectors 248 is shown. A feature of the instant arrangement resides in the arrangement wherein these frame carrying connectors as at 248 lock the frame reinforcing member 256 to matrix member 260. The remaining sides of each frame member can be similarly configured. Male connectors can be formed on other components of the invention, including frame member channels components, transition members and accessory members, described below, using this method. Male carrying connector 248 of FIG. 11 is formed of polymeric body matrix 260 that passes through a perforation in cap reinforcing member 256. When male carrying connector 248 possesses a larger diameter than the perforation, polymeric matrix material 260 will be affixed to cap reinforcing member 256. Referring to FIG. 8, male carrying connectors 248 are regularly spaced along the length of frame member cap component 224. In one embodiment of the invention, sufficient male connectors protrude through cap reinforcing member 256 to retain polymeric matrix 256 in contact with cap reinforcing member 256. In another embodiment of the invention, exposed surfaces of frame member cap component 224 and frame member channel component 192 are covered with regularly spaced male connectors. In yet another embodiment of the invention, male carrying connectors protrude from only a portion of the exposed surfaces. Referring to FIG. 2 and FIG. 3, male carrying connectors 88 can protrude from other system components, including transition members, vertical frame members, horizontal frame members and leg frame members.

An advantage of having the frame carrying connectors composed in part of a frame reinforcing member is the increased strength of carrying connectors, and resistance to wear typically found in materials utilized in the frame reinforcing member compared to the polymeric matrix component. Other portions of frame members and accessory members can be similarly configured.

Male connectors 68 can be formed with a variety of other configurations. Referring to FIG. 12, another cap section is represented generally at 378. The architecture represented by this section is one wherein the frame reinforcing member or frame cap reinforcing member 380 is configured having frame carrying connectors represented as male nodes 382. In the male connector configuration of FIG. 12, the surface of the male connector is formed in part by the surface of the reinforcing element. Such a reinforcing element could be cast, molded or pressed, and mated with body matrix. Note that the upper surface of each of these male nodes is configured with a vent hole 384. These vent holes 384 facilitate the fabrication process wherein the polymeric matrix component 386 is mated with the reinforcing member 380. If the reinforcing member 380 of FIG. 12 were used as an insert in a injection mold, and polymeric body matrix was injected into the mold, it may be necessary to provide vent hole 384 in order to limit void formation between the body matrix component and the reinforcing member and assure secure contact between body matrix member and reinforcing member. The vent hole 384 also provides additional bearing surface to retain body matrix in contact with the reinforcing element. Vent hole 384 can in certain applications serve as a hole for insertion of a stud, rivet or self tapping screw. Depending on the properties of the materials forming body matrix and reinforcing members, the male carrying connector FIG. 12 is expected to exhibit greater shear resistance than the male connector in FIG. 11.

The male connector can be formed of a number of shapes, with a preferred embodiment being a cylindrical shape. A cylindrical male carrying connector as shown in FIG. 11 could have a diameter to height ratio of approximately 4 to 1, 2 to 1, 1 to 1, or 1 to 2, with a preferred embodiment having a diameter to height ratio of approximately 2 to 1. The proportions of the male carrying connector can be varied to accommodate different applications, with important factors in determining the proportions including the shear strength of material forming the male carrying connector, the leverage a male carrying connector is expected to experience, and whether the male carrying connector is required primarily as a means for joining the body matrix member to the reinforcing member or whether the male carrying connector is needed as a means for aligning or attaching accessory members.

Looking to FIG. 13, another frame member cap section is represented generally at 388. Cap section 388 resembles FIG. 11 in that it incorporates frame cap reinforcing member 390, a polymeric matrix component 392 and frame carrying connectors of a male variety shown at 394. One variation on the cylindrical shape of a male connector envisioned is a male connector with a cap or lip that can function to increase retention of mounted components. For this embodiment of the invention, however, the top portions of the connectors 394 are configured with an integrally formed disc 396. Disc 396 may be employed for specialized connector configurations wherein a slidably effected engagement is contemplated. Other portions of frame members and accessory members can be similarly configured, or configured to slidably accept carrying connectors such as connector 394.

Referring to FIG. 14, another frame member cap section is revealed in general at 398. Section 398 exhibits a frame cap reinforcing member 400 which is similar to that described in FIG. 12. This member 400 is mated with polymeric matrix component 402. Frame carrying connectors 404 are configured in similar fashion as FIG. 12, each incorporating a vent hole 406. For the instant embodiment, however, carrying connector discs 408 are attached through the vent holes 406 by machine screws as at 410 which extend into the matrix polymeric material. Thusly, the advantages of carrying connectors 382 illustrated in FIG. 12 are combined with the advantages of the carrying connector 394 of FIG. 13. A lipped male connector such as connectors 396 and 404 can also be formed by attaching a connector cap such as connector disc 408 to a male connector as 404 shown in FIG. 14 using glue, welding or other means.

Referring to FIG. 15, a top view of an enclosure represented generally at 420 is revealed. The view of enclosure 420 is shown with the removal of a top panel as described at 336 in FIG. 9. The view in FIG. 15 shows two manners in which the enclosure can be used to house components. Such installations are dependent on the components to be mounted and the flexibility of the frame systems allows wide variation in mounting systems and equipment installation. Enclosure 420 is configured with two adjacent and interconnected bays represented generally at 422 and 424. In this regard, bay 422 is configured with four upstanding vertical frame members 426-429. Seen in the figure is the inverted bottom surface 432-435 of upper transition members. Connecting these inverted upper transition members 432-435 are horizontal frame members. In this regard, horizontal frame member 438 is connected between vertical frame members 429 and 426. Transition edges shown in the figure are represented at 440-442. A horizontal frame member 444 is shown coupled between vertical components 426 and 427. As before, the frame member 444 is illustrated with transition edges 446-448. Finally, a horizontal frame member 450 extends between the vertical supports 429 and 428 and is illustrated with three transition edges 452-454. Frame member 450 is shown with three transition edges, 452-454. Vertical components 426 and 427 are attached to respective corner completing accessories 456 and 458. These accessories have a cross-section of triangular shape with a base surface corresponding with the back surface width of an associated transition member. The length of these accessories as at 456 and 458 whether provided as combinations of components or as a singular member will represent a combination of the upper frame back surfaces and lower frame back surfaces of the associated transition members as well as the vertical frame member extending between them. With the arrangement shown, a front transition plane is defined at 460; a rear transition plane is defined at 462 and a side transition plane is defined at 464. To support electrical equipment within bay 422 a vertically oriented equipment support accessory having a triangular cross section as shown at 466 and 468 are attached to the vertical components of the frame member supports 428 and 427. Note the presence of an electrical chassis 470 within the bay 422. Chassis 470 is attached to these accessories 466 and 468 by a bracket 472. Slide rails as known in the art can be substituted for brackets 472 to enable installation, maintenance and removal of chassis 470. Note that a door 474 is attached to the accessory 458 by a hinge 476. As described in connection with FIG. 1, door 474 carries a continuous seal as represented at 478 which engages the transition edges within forward transition plane 460.

Bay 422 is attached to bay 424. Looking to bay 424 it is seen to be formed of four vertical columnar supports 480-483. In this regard, the inverted back surfaces 486-489 of upper transition members are revealed at the four corners of the bay. Extending between vertical frame member 483 and vertical frame member 480 is an upper horizontal frame member 492. Three of the transition edges of this member 492 are revealed at 493-495. Note that transition edge 493 falls within the transition plane 462.

Extending between vertical supports 480 and 481 is an upper horizontal frame member 498. Three transition edges 499-501 are represented in the figure. Note that transition edge 499 falls within a central transition plane 504. The figure also reveals that transition edge 452 of horizontal member 450 is essentially coplanar with that transition plane. An upper horizontal frame member 506 is seen to extend between vertical supports 483 and 482. Member 506 also is illustrated with three transition edges 507-509. Note that transition edge 507 falls within a side transition plane 512. Finally, an upper horizontal frame member 514 interconnects vertical support 481 and 482. Further, three transition edges 515-517 are revealed and it may be noted that transition edge 515 is coplanar with transition plane 460.

Corner completing accessories 520 and 522 having a triangular cross-section are mounted to the orderly disposed surfaces of vertical supports 482 and 483. These corner accessories provide a flat corner surface. In this regard, the flat surface of accessory 522 is shown supporting a hinge 524 of a door 526. Similar to bay 422, bay 424 incorporates vertical accessory supports 528 and 530 which are attached to one face of the vertical corner supports 480 and 483. Connected to those support accessories 528 and 530 is a vertical support panel 532 upon which is mounted electrical equipment represented at block 534.

The supporting frames of base 422 and 424 are juxtaposed to define those two bays such that the rearward vertically disposed corner region of support 429 abuts a corresponding rearward vertically disposed corner region of support 480. This develops two rearward angularly outwardly oriented frame faces 536 and 538 which define a rearward outwardly extended space of triangular cross-section.

In the same manner the forward vertically disposed corner region of vertical support 428 abuts the forward vertically disposed corner region of support 481. This provides two forward angularly outwardly oriented frame faces 540 and 542 defining another rearward outwardly extending space of triangular cross-section. Coupled between the frame within these spaces are inter-bay completing accessories having a cross-section of triangular shape corresponding with the spaces of triangular cross section. Thus, an inter-bay completing accessory 544 connects vertical components 480 and 429 and a corresponding inter-bay completing accessory 546 connects the vertical supports 428 and 481.

A back panel 548 is seen to extend across the combined bays 422 and 424 and is sealed to the frame members as represented at seal 550 at bay 422. In similar fashion, seal 552 engages back panel 548 at bay 424. In similar fashion, a seal 554 engages a side panel 556 at the right side of the enclosure 420 as represented in the figure. A left side panel 558 is sealed to the bay 424 at seal 560. Next, a seal 562 located at transition plane 504 sealably supports the inter-bay connection. Note, additionally, door 526 contacts a continuous seal as represented at 564 which engages the transition edges adjacent the forward transition plane 460.

As described above, the surfaces of the frame members of the invention can be constructed to expose regularly spaced male carrying connectors, as at 88, on the faces of the frame members. The spacing of male connectors facilitates attachment and alignment of accessory component members female connector sockets.

The accessory components exhibiting a triangular cross-section are of quite simple structure. In this regard, looking at FIG. 16, such an accessory of triangular configuration is revealed in general at 570. Accessory 570 shown having a rectangular base surface 572 extending inwardly from the surface 572 is an array of regularly spaced female carrying connectors, certain of which are identified at 574.

Looking to FIG. 17, a cross section of the accessory 570 connected to a vertical frame member represented generally at 576 is shown. Member 576 is shown having a reinforcing component 578 is described in general in connection with FIG. 8. Internally within that component is matrix component 580 which is integrally formed with frame male carrying connectors 582 which are seen to engage corresponding accessory female carrying connectors 574. The union thus provided may be reinforced with a suitable adhesive. Note that accessory component 570 as shown is not constructed of hybrid materials. Accessory components (and as noted previously, frame member components) can be alternatively constructed of hybrid materials in those situations where the particular requirements of the installation warrant hybrid construction.

Looking to FIG. 18, a cross section of another accessory of triangular cross-section is represented in general at 584 is shown. Accessory 584 is combined with a vertical frame member represented generally at 586. As in FIG. 17 the member 586 is configured with an outwardly disposed reinforcing component which surmounts a polymeric matrix component 590. Connection with this arrangement is reinforced by a sequence of screws, two of which are shown at 592 which extend from the seats of a corresponding sequence of screw retaining cavities as represented at 594 into engagement with the polymeric matrix component 590.

Another form of coupling involves the utilization of a cam locking approach formed in conjunction with the male frame carrying connectors. Looking to FIG. 19, an alternative accessory component is represented generally at 600. Accessory 600 as before, exhibits a triangular cross-section and is a rectangular based surface 602. As in the case of FIG. 16, the accessory 600 is configured with female connectors 604 depending inwardly from the base surface 602. Male carrying connectors 604 assist in aligning and supporting accessory component 600 when installed on a frame member. Additionally extending inwardly from the base surface 602 are locking cavities as at 606 and 608. Within each of these locking cavities there is provided an externally rotatable cam component shown respectively at 610 and 612. The cavities 606 and 608 engage four of the male frame carrying connectors generally at the corners thereof. Thus, by rotating the cam a locking feature is realized. Looking additionally to FIG. 20, a cross section of accessory 600 reappears in conjunction with a vertical frame member represented generally at 614. As before, the frame member 614 incorporates a reinforcing component 616 which surmounts a polymeric matrix component 618. Note that a cavity 620 extends from the apex of the cross-section of accessory 600 which carries a cam actuator head 622 which may be rotated with a suitable tool such as a screwdriver. Looking to FIG. 21, this locking arrangement is represented in general at 624. In the figure, a cam as at 610 reappears within cavity 606. Four frame member carrying connectors of a male structuring are represented in phantom at 626. It may be observed, that by rotating cam 610, a locking action will be realized.

The frame structures of the invention additionally are configured such that horizontal accessory bars may be employed with them. Referring to FIG. 22, a cross section of such a horizontal accessory bar is represented generally at 628. Accessory bar 628 is seen to be coupled between two vertical frame members represented generally at 630 and 632. As before, frame member 630 is configured with an outwardly disposed reinforcing component 634 which surmounts a polymeric matrix component 636. Note that one angularly disposed face 638 of the member 630 functions to support the accessory bar 628. In similar fashion, frame member 632 is configured with an outwardly disposed reinforcing component 640 which surmounts a polymeric matrix component 642. The angularly oriented face 644 of member 632 also is seen to support the opposite end of accessory bar 628. In this regard, the angularly oriented oppositely disposed faces 646 and 648 of accessory bar 628 are configured with elongated female connectors, for instance, connectors 650 extend inwardly from accessory bar face 646, while inwardly depending female connectors 652 extend inwardly from face 648. Because insertion within conventional female connectors would be difficult for the arrangement of FIG. 22, the female connectors are elongated. This feature is illustrated in FIG. 23. Referring to FIG. 23, three bar face 646 reappears in conjunction with elongated female connectors 650.

The accessory components utilized with the instant system and themselves being modularized. For example, one can be stacked atop another utilizing the connector approach illustrated. Looking to FIG. 24, a top view of such a connector is represented in general at 660. Accessory 660 is configured with a top surface 662 from which extend male connectors certain of which are represented at 664. Looking additionally to FIG. 25, a side view of the accessory 660 is presented. Two of these top connectors are represented at 664. Note additionally that oppositely disposed male connectors are provided at a surface 666 from which extend male connectors, two of which are seen at 668. End surface 670 also is configured with inwardly depending female connectors certain of which are represented at 672. These connectors 672 also may be seen in phantom in connection with FIG. 24. Returning to FIG. 25, each side 674 and 676 of accessory 660 is configured with inwardly depending female connectors. In this regard, female connectors certain of which are identified at 678 extend inwardly from side 674, while corresponding female connectors certain of which are identified at 680 extend inwardly from side 676. Turning again to FIG. 24, it may be observed that male connectors, certain of which are identified at 682 extend outwardly from end of surface 684.

Referring to FIGS. 26 and 27, an accessory bar similar to that described in conjunction with FIG. 22 is represented in general at 690. The outwardly disposed surface 692 of accessory 690 is seen to support outwardly depending male connectors certain of which are identified at 694. The opposite surface of accessory 690 at 696 also is seen to support an array of male connectors certain of which are identified at 698. FIG. 26 shows one side surface 700 from which orderly depends an array of male connectors certain of which are identified at 702. Correspondingly, as represented in FIG. 27, the face opposite face 700 as at 704 supports outwardly depending male connectors certain of which are revealed at 706. Alternatively, surface 740 can be configured with inwardly depending female carrying connectors, as at 672 of FIG. 24 to allow modular stacking and interlocking of multiple accessory components 690. As shown in FIG. 26 and 27, accessory 690 further is configured having an annularly disposed connecting surface 708 which incorporates a locking connector represented generally at 710 which includes an inwardly depending locking cavity 712 internally of which a rotatable locking cam 714 is disposed. As seen in FIG. 26, access to the cam 714 is seen in FIG. 26 to be through an access channel represented generally at 716.

Since certain changes may be made to the above-described apparatus and method without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. All terms not defined herein are considered to be defined according to Webster's New Twentieth Century Dictionary Unabridged Second edition.

Claims

1. The method of making a frame comprising the steps of:

providing two or more linear frame members of given length extending along a frame axis between oppositely disposed frame contact ends exhibiting frame contact peripheries and a frame cross-section exhibiting at least two symmetrically opposite linear edges;

providing one or more transition members each with a first component extending along a first axis a length less than said given length to a first contact surface exhibiting a first edge profile corresponding with said frame cross section, said edge profile being oriented about said first axis to position two opposite edges within a first plane extending along said first axis, said transition member having an integrally formed second component extending along a second axis normal to said first axis a length less than said given length to a second contact surface exhibiting a second edge profile corresponding with said frame cross-section and oriented about said second axis to position two opposite edges within a second plane normally disposed with respect to said first plane, and an integrally formed third component extending along a third axis normal to said first and second axes a length less than said given length to a third contact surface exhibiting a third edge profile corresponding with said frame cross-section, said third edge profile being oriented about said third axis to position two opposite edges within said second plane.

aligning a frame contact periphery of a frame member with said first edge profile and abuttably coupling linear frame member to a transition member first contact surface;

aligning a frame contact periphery with said second edge profile and abuttably coupling a linear frame member to a transition member second contact surface;

aligning a frame contact periphery with said third edge profile and abuttably coupling a linear frame member to a transition member third contact surface; and

reiterating said aligning and coupling steps.

2. The method of claim 1 further comprising the step:

providing three or more stud connectors each having oppositely disposed first and second connector portions;

said step providing two or more linear frame members provides said frame members with frame connector cavities extending axially mutually inwardly from said frame contact ends;

said step providing said one or more transition members provides each transition member as being configured having a transition connector cavity extending axially inwardly from said first, second and third contact surfaces; and

said steps of aligning and coupling a transition member with frame members are carried out by inserting a said stud connector first connector portion within a frame connector cavity and inserting said stud connector second connector portion within a said transition connector cavity.

3. The method of claim 1 in which:

said transition member is provided further comprising a fourth component extending along said first axis opposite said first component a length less than said given length to a fourth contact surface exhibiting a fourth edge profile corresponding with said frame cross-section, said fourth edge profile being oriented about said first axis in alignment with said first component edge profile to locate said edge profile to position two opposite edges within said first plane.

4. The method of claim 3 further comprising the step:

aligning a frame contact periphery of a fourth frame member with said translation member fourth component edge profile while abuttably coupling said fourth contact surface with a frame contact end.

5. The method of claim 4 further comprising the step:

providing one or more stud connectors each having oppositely disposed first and second connector portions;

said step providing two or more linear frame members provides said frame members with frame connector cavities extending axially mutually inwardly from said frame contact ends;

said step providing one or more transition members provides each transition member as being configured having a transition connector cavity extending axially inwardly from said first, second, third and fourth contact surfaces; and

said steps of aligning and coupling a transition member with frame members are carried out by inserting a said stud connector first connector portion within a frame connector cavity and inserting said stud connector second connector portion within a said transition connector cavity.

6. The method of claim 1 in which:

one or more of said frame members is configured having a generally axially disposed frame open channel extending between said oppositely disposed frame contact ends; and

one or more said transition members is configured having inwardly depending and commonly joined transition open channels generally disposed about said first, second and third axes, said transition open channels being generally aligned with a said frame open channel when the contact periphery thereof is aligned with a transition member component edge profile.

7. The method of claim 1 in which:

said one or more transition members are provided with a configuration wherein the outwardly disposed one of two edges of said first component extends inwardly from within a first contact surface transition plane;

the outwardly disposed one of two edges of said second component extends inwardly from within said transition plane; and

said first component outwardly disposed edge and said second component outwardly disposed edge being joined in said transition plane as a continuous first transition edge;

8. The method of claim 7 in which:

said continuous transition edge exhibits a medial curvature.

9. The method of claim 1 in which:

said one or more transition members are provided with a configuration wherein the outermost one of said first component two opposite edges located in said first plane extends inwardly from said first contact surface within a transition plane;

the outermost one of said third component two opposite edges extends inwardly from said third contact surface within said transition plane;

said first component outermost edge and said third component outermost edge being joined in said transition plane as a continuous transition edge.

10. The method of claim 9 in which:

said transition edge exhibits a medial curvature.

11. The method of claim 3 in which:

said one or more transition members are provided with a configuration wherein the outermost one of said fourth component two opposite edges located in said first plane extends inwardly from said fourth contact surface within a transition plane;

the outermost one of said two opposite edges of said second component extends inwardly from said second contact surface within said transition plane; and

the outermost one said fourth component edge and the outermost one said second component edge being joined in said transition plane as a continuous transition edge.

12. The method of claim 11 in which:

said transition edge exhibits a medial curvature.

13. The method of claim 3 in which:

said one or more transition members are provided with a configuration wherein the outermost one of said two opposite edges located in said first plane extend inwardly from said fourth contact surface within a transition plane;

the outermost one of said two opposite edges of said third component extends inwardly from said third contact surface within said transition plane; and

said fourth component outermost edge and said third component outermost edge being joined in said transition plane as a continuous fourth transition edge.

14. The method of claim 1 in which:

a said transition member is provided being configured having an outwardly disposed flat back surface of back surface length and width disposed normally to an axis passing through said first axis and bisecting a corner angle defined by said second and third axes and having one or more frame carrying connectors integrally formed with said back surface;

said step providing two or more frame members provides one or more of said frame members with one or more flat surfaces having an array of integrally formed said frame carrying connectors;

said step of aligning and coupling a frame member locates said frame member to be a vertically disposed frame member with said flat surface aligned with said transition member back surface.

said steps of aligning and coupling frame members locates them to define a frame corner;

further comprising the steps:

providing a corner completing accessory having a corner length corresponding with said given length plus said back surface length, a cross-section of triangular shape to provide a base surface with a base width corresponding with said back surface width and extending said corner length and having two oppositely disposed sides extending to define a corner edge, said base surface being configured with accessory connectors corresponding and connectable with said back surface and flat surface connectors; and

coupling said corner completing accessory at said base surface to a frame member flat surface to define a corner by interconnecting said frame carrying connectors with said accessory connectors.

15. The method of claim 14 in which:

said step for providing two or more frame members provides one or more of said frame members with one or more flat surfaces having an array of said frame carrying connectors which are outwardly depending male connectors; and

said step providing a corner completing accessory provides said accessory connectors as inwardly depending female connectors.

16. The method of claim 1 in which:

said steps for aligning and coupling said two or more frame members with said one or more transition members are carried out to derive a frame structure with two adjacent bays wherein two vertically oriented frame members are located in mutual adjacency wherein a linear edge of one frame member abuts a linear edge of the adjacent frame member, said frame cross section of each is generally square to provide two angularly oriented frame faces extending outwardly from said abutting linear edges to define an outwardly extending space of triangular cross section, said frame faces each having an array of integrally formed frame carrying connectors;

further comprising the steps:

providing an inter-bay completing accessory having a cross-section of triangular shape corresponding with said space of triangular cross-section, having an outwardly disposed base face and mutually inwardly angularly extending side faces each being configured with an array of integrally formed accessory connectors corresponding with said array of frame carrying connecters; and

coupling said inter-bay completing accessory at said side faces to said two angularly oriented frame faces by interconnecting said frame carrying connectors with said accessory connectors.

17. The method of claim 16 in which:

said step for providing two or more frame members provides said angularly oriented frame faces with said integrally formed frame carrying connectors as outwardly depending male connectors; and

said step providing an inter-bay completing accessory provides said accessory connectors as inwardly depending female connectors.

18. A frame system, comprising:

a plurality of linear frame members of given lengths extending along a frame axis between oppositely disposed contact ends, said contact ends exhibiting frame contact peripheries, the frame members exhibiting a frame cross-section having at least two symmetrically opposite linear edges extending to two symmetrically opposite corners of said frame contact peripheries;

a plurality of transition members each with a first component extending along a first axis a length less than said given length to a first contact surface exhibiting an edge profile corresponding with a frame contact periphery, said edge profile being oriented about said first axis to position two opposite edges within a first plane extending along said first axis, said transition member having a second component extending along a second axis normal to said first axis a length less than said given length to a second contact surface exhibiting an edge profile corresponding with said frame cross-section and oriented about said second axis to position two opposite edges within a second plane normally disposed with respect to said first plane, said transition member having a third component extending along a third axis normal to said first and second axes a length less than said given length to a third contact surface exhibiting an edge profile corresponding with said frame cross-section, said edge profile being oriented about said third axis to position two opposite edges within said second plane, and said transition member having a fourth component extending along said first axis opposite said first component a length less than said given length to a fourth contact surface exhibiting an edge profile corresponding with said frame cross-section, said edge profile being oriented about said first axis in alignment with said first component edge profile to locate said edge profile to position two opposite edges within said first plane;

a plurality of said transition members being designated lower frame transition members, and a plurality being designated upper frame transition members;

a plurality of said frame members being designated vertical frame members, and a plurality being designated horizontal frame members;

the oppositely disposed contact ends of a plurality of said vertical frame members being coupled between the first contact surface of a plurality of said lower frame transition members and the fourth contact surface of a plurality of said upper frame transition members;

the oppositely disposed contact ends of a plurality of said horizontal frame members being coupled between the second contact surfaces and the third contact surfaces of a plurality of lower frame transition members to define a lower frame portion; and

the oppositely disposed contact ends of a plurality of said horizontal frame members being coupled between the second contact surfaces and the third contact surfaces of a plurality of upper frame transition members to define the upper frame portion of a frame having a plurality of vertically disposed corner regions extending between oppositely disposed upper frame transition members and lower frame transition members.

19. The frame system of claim 18 in which:

said linear frame members are configured with frame connector cavities extending axially mutually inwardly from said frame contact ends;

said transition members are configured having a transition connector cavity extending axially inwardly from said first, second, third and fourth contact surfaces;

said frame system further comprising a plurality of stud connectors each having a first connector portion configured for engagement within a frame connector cavity and an oppositely disposed second connector portion engageable within a transition connector cavity to effect coupling between frame members and transition members.

20. The frame system of claim 18 in which:

said linear frame members are configured having a generally axially disposed frame open channel extending between said oppositely disposed frame contact ends; and

said transition members are configured having inwardly depending and commonly joined transition open channels generally disposed about said first, second, and third axes.

21. The frame system of claim 18 in which:

the outermost one of said two opposite edges of said first component of each said transition member extends inwardly from said first contact surface within a transition plane;

the outermost one of said two opposite edges of said second component of each said transition member extends inwardly from said second contact surface within said transition plane; and

said first component outermost edge and said second component outermost edge being joined in said transition plane as a continuous transition edge.

22. The frame system of claim 21 in which:

said continuous transition edge exhibits a medial curvature.

23. The frame system of claim 18 in which:

the outermost one of said two opposite edges of said first component of each said transition member extends inwardly from said first contact surface within a transition plane;

the outermost one of said two opposite edges of said third component of each said transition member extends inwardly from said third contact surface within said transition plane; and

said first component outermost edge and said third component outermost edge being joined in said transition plane as a continuous transition edge.

24. The frame system of claim 23 in which:

said continuous transition edge exhibits a medial curvature.

25. The frame system of claim 18 in which:

the outermost one of said two opposite edges of said fourth component of each said transition member extends inwardly from said fourth contact surface within a transition plane;

the outermost one of said two opposite edges of said second component of each said transition member extends inwardly from said second contact surface within said transition plane; and

said fourth component outermost edge and said second component outermost edge being joined in said transition plane as a continuous transition edge.

26. The frame system of claim 25 in which:

said continuous transition edge exhibits a medial curvature.

27. The frame system of claim 18 in which:

the outermost one of said two opposite edges of said fourth component of each said transition member extends inwardly from said fourth contact surface within a transition plane;

the outermost one of said two opposite edges of said third component of each said transition member extends inwardly from said third contact surface within said transition plane; and

said fourth component outermost edge and said third component outermost edge being joined in said transition plane as a continuous transition edge.

28. The frame system of claim 27 in which:

said continuous transition edge exhibits a medial curvature.

29. The frame system of claim 18 in which:

each said transition member is configured having an outwardly disposed flat back surface of back surface length and width disposed normally to an axis passing through said first axis and bisecting a corner angle defined by said second and third axes, said back surface facing outwardly at said corner region and having a frame carrying connector assemblage formed with said back surface;

each said vertical frame member coupled between a said upper frame transition member and a said lower frame transition member having a flat surface aligned with the adjacent back surfaces and including a frame carrying connector assemblage;

said frame system further comprising; and

a corner completing accessory having a cross-section of triangular shape with a base surface corresponding with said back surface width and a base surface length substantially coextensive with said upper frame back surface, said lower frame back surfaces and said vertical frame member and having two oppositely disposed sides extending to define a corner edge, said base being configured with an accessory connector assemblage connected with said frame carrying connector assemblages.

30. The frame system of claim 29 in which:

said frame member frame cross-section defines four flat orthogonally disposed surfaces with one or more said flat surfaces having a said frame connecter assemblage comprising an array of frame connectors;

each said transition member back surface frame carrying connector assemblage comprises an array of said frame connectors; and

said corner completing accessory base accessory connector assemblage comprises an array of accessory connectors.

31. The frame system of claim 30 in which:

said frame connectors are outwardly depending male connectors; and

said accessory connectors are inwardly depending female connectors.

32. The frame system of claim 18 in which:

said frame cross-section is substantially square;

two said frames are juxtaposed to define two bays wherein a forward vertically disposed corner region of one frame abuts the forward vertically disposed corner region of the other frame to provide two forward angularly outwardly oriented frame faces defining a forward outwardly extending space of triangular cross-section, said frame faces of said combination each having a frame carrying connector assemblage;

further comprising a forward inter-bay completing accessory having a cross-section of triangular shape corresponding with said space of triangular cross-section, having an outwardly disposed face and mutually inwardly angularly extending side faces each being configured with an accessory connector assemblage; and

said forward inter-bay completing accessory being coupled with said angularly outwardly oriented frame faces by interconnecting said frame carrying connector assemblages with said accessory connector assemblage.

33. The frame system of claim 32 in which:

each said frame connector assemblage comprises an array of outwardly depending male connectors; and

each said accessory connector assemblage comprises an array of outwardly depending female connectors.

34. The frame system of claim 32 in which:

said two frames are juxtaposed to define two bays wherein a rearward vertically disposed corner region of one frame abuts the rearward vertically disposed corner region of the other frame to provide two rearward angularly outwardly oriented frame faces defining a rearward outwardly extending space of triangular cross-section, said frame faces of said combination each having a frame carrying connector assemblage;

further comprising a rearward inter-bay completing accessory having a cross-section of triangular shape corresponding with said space of triangular cross section, having an outwardly disposed face and mutually inwardly angularly extending side faces, each being configured with an accessory connector assemblage; and

said rearward inter-bay completing assembly being coupled with said angularly outwardly oriented frame faces by interconnecting said frame carrying connector assemblages with said accessory connector assemblages.

35. The frame system of claim 34 in which:

each said frame connector assemblage comprises an array of outwardly depending male connectors; and

each said accessory connector assemblage comprises an array of outwardly depending female connectors.

36. The frame system of claim 19 in which:

one or more of said frame members comprise:

a generally U-shaped channel component having an outwardly open cap receiving side and configured with a generally U-shaped reinforcing member having three outwardly disposed frame faces and a reinforcing member cavity extending between said oppositely disposed contact ends;

a polymeric channel matrix member located within said reinforcing member cavity configured to define a portion of said frame connector cavities extending inwardly from said frame contact ends and further configured to define a matrix bottom wall and side walls extending outwardly to spaced apart cap engagement ledges adjacent said outwardly open cap receiving side;

a cap component configured for positioning over said channel component open cap receiving side and having a generally flat cap reinforcing member with an outwardly disposed frame face and an inwardly attached polymeric cap matrix member having oppositely and axially disposed spaced apart engagement surfaces engaging said spaced apart cap engagement ledges, said cap matrix member, with said channel matrix member, defining said frame connector cavities; and

a connector assembly coupling said cap component with said channel component.