ENCLOSURE AND METHOD THEREFOR

Abstract

An enclosure includes a base. A frame includes a plurality of frame members. The frame members are coupled together and to the base using clips. Each clip includes a base coupled to a side surface of a first frame member. The clip further includes at least one lip extending from the base. The lip is sufficiently raised from the side surface of the first frame member to accept at least a portion of a second frame member between the lip and the side surface. A plurality of panels is coupled to the frame members. At least one panel is coupled to the base.

Description

CLAIM OF PRIORITY AND RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/968,254, filed Aug. 27, 2007, entitled ENCLOSURE AND METHOD THEREFOR, the contents of which are incorporated by reference herein.

TECHNICAL FIELD

This document pertains generally to enclosures, and more particularly, but not by way of limitation, to a double-walled enclosure for a rooftop heating, ventilating, and air conditioning (HVAC) system.

BACKGROUND

It is generally known to provide enclosure systems for rooftop HVAC systems. For instance, such systems typically are custom manufactured to accommodate the HVAC system to be installed. Such enclosure systems have several drawbacks. For instance, the known enclosure systems often have moisture problems in that condensation tends to form within the enclosure. For instance, components, in particular, panels of known enclosure systems often “sweat”. This occurrence is often caused, at least in part, by metallic pathways, or through-metal, between an interior surface and an exterior surface of the component of the enclosure system. For instance, a panel or other component of the enclosure system having continuous or abutting metallic portions exposed to both the interior and the exterior of the enclosure system can pose a risk for sweating within the enclosure system. Additionally, such enclosure systems often require relatively extensive measuring, cutting, drilling, etc. of at least some of the components during assembly of the enclosure systems, which could result in an increased amount of time required for assembly, as well as increased costs.

What is needed is an enclosure system that overcomes the shortcomings of previous enclosure systems.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals describe substantially similar components throughout the several views. Like numerals having different letter suffixes represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

FIG. 1 is a perspective view of an example of an enclosure in accordance with an embodiment of the present invention;

FIG. 2 is a perspective view of the enclosure of FIG. 1 having panels removed to expose frame members;

FIG. 3 is a perspective view of an example of a base of the enclosure of FIG. 1;

FIG. 3A is a side view of an example of an end of a cross member of the base of FIG. 3;

FIG. 3B is an enlarged fragmentary view of a joint between base frame members of the base of FIG. 3;

FIG. 4 is a cross-sectional view of an example of a frame member of the base of FIG. 3;

FIG. 5 is a cross-sectional view of an example of a frame member of the base of FIG. 3;

FIG. 6 is a perspective view of the frame members of FIG. 2 having the base removed;

FIG. 7 is an exploded view of an example of a frame member of the enclosure of FIG. 1;

FIG. 8 is a perspective view of the frame member of FIG. 7;

FIG. 9A is a perspective view of examples of first and second frame members of the enclosure of FIG. 1, the first and second frame members shown disengaged from a clip;

FIG. 9B is a perspective view of an example of the clip of FIG. 9A;

FIG. 9C is an end view of an example of the clip of FIG. 9A;

FIG. 10 is a perspective view of the first and second frame members of FIG. 9A; the first frame member engaged with the second frame member.

FIG. 11 is a perspective view of an example of a panel of the enclosure of FIG. 1;

FIG. 12A is a cross-sectional view of the panel of FIG. 11;

FIG. 12B is an enlarged fragmentary view of a portion of the panel of FIG. 12A;

FIG. 13 is a perspective view of an example of a panel of the enclosure of FIG. 1;

FIG. 14 is a cross-sectional view of the panel of FIG. 13;

FIG. 15 is a perspective view of an example of a panel of the enclosure of FIG. 1;

FIG. 16 is a cross-sectional view of the panel of FIG. 15;

FIG. 17 is a perspective view of an example of an electrical panel of the enclosure of FIG. 1;

FIG. 18 is a cross-sectional view of the electrical panel of FIG. 17;

FIG. 19 is a cross-sectional view of the enclosure of FIG. 1;

FIG. 20 is an enlarged fragmentary view of a portion of FIG. 19, the portion denoted by the label “FIG. 20”;

FIG. 21 is an enlarged fragmentary view of a portion of FIG. 19, the portion denoted by the label “FIG. 21”;

FIG. 22 is an enlarged fragmentary view of a portion of FIG. 19, the portion denoted by the label “FIG. 22”;

FIG. 23 is a cross-sectional view of an example of a jig for use in constructing a panel, the panel being shown prior to insertion of insulation therein; and

FIG. 24 is a cross-sectional view of the jig of FIG. 23, the panel being shown after insertion of insulation therein.

DETAILED DESCRIPTION

The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the present subject matter may be practiced. These embodiments, which are also referred to herein as “examples,” are described in enough detail to enable those skilled in the art to practice the present subject matter. The embodiments may be combined, other embodiments may be utilized, or structural changes may be made without departing from the scope of the present subject matter. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present subject matter is defined by the appended claims and their equivalents.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or”, unless otherwise indicated. Furthermore, all publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.

Referring to FIGS. 1-24, there are shown examples of an enclosure system, indicated generally at 10, in accordance with the present invention. The enclosure system 10 can be used, for instance, to enclose a rooftop heating, ventilating, and air conditioning (HVAC) system, although this is not intended to be limiting, as such an enclosure system 10 can be used to enclose other systems or objects and in locations other than rooftops.

Referring initially to FIGS. 1 and 2, the enclosure system 10 includes a frame 30 and a base 20. The base 20 can be anchored, for instance, to a rooftop or other area of a building. The frame 30 is, in one example, attached to the base 20, as will be described in greater detail below. The frame 30 includes a plurality of frame members 32, at least some of which are coupled together or are coupled to the base 20. The frame members 32 can be coupled together or to the base 20 using clips 50 (see FIG. 9A), as will be described in greater detail below. In one example, the frame 30 further includes a plurality of double-walled panels 40 coupled to at least some of the frame members 32. It is also contemplated that at least some of the panels 40 are coupled to the base 20. In one example, the panels 40 are coupled to the frame 30 or the base 20 using self-tapping screws, although it is contemplated that other fasteners or means of fastening, such as welding or gluing, for instance, are used. It is noted that the enclosure system 10 shown in the figures is but one example and that different configurations, sizes, and shapes are contemplated herein and are determined on a case-by-case basis depending upon that which is to be housed, location of the enclosure system, and the like.

Referring now to FIGS. 3-5, in one example, the base 20 includes base frame members 22 configured in a generally closed shape. In one example, the base 20 includes at least four base frame members 22 having miter ends 22A configured in a generally rectangular shape. In other examples, the base 20 can include more or less than four frame members 22 and do not require miter ends 22A, depending upon the desired shape and configuration of the base 20. The base frame members 22, in one example, are attached by welding the base frame members 22 end-to-end to form a generally rectangular shape. Optionally, in one example, at least one of the sides of the base 20 includes more than one base frame member 22 joined together at a joint 23, as shown in phantom in FIGS. 3 and 3B. For instance, if the desired length of a side of the base 20 exceeds the length of the given base frame members 22, two or more base frame members 22 can be joined to form the side. In one example, the ends of the base frame members 22 forming the joint 23 include a tab-in-slot configuration, which is welded to fixedly attach the two base frame members 22. In other examples, the base frame members 22 have ends of different mating configurations or are joined in ways other than by welding. In other examples, the base frame members 22 are joined using other fastening devices, such as, for instance, bolts.

At least some of the base frame members 22, in one example, each have an open G-beam configuration. That is, each of the base frame members 22 are generally shaped like the letter “G” when viewed in cross section, each with a portion 22C extending outwardly from a channel section 22D. In one example, the portion 22C creates a generally flat landing for supporting at least one of a first floor layer 24 and one or more cross members 26. The one or more cross members 26, in one example, have a C-beam configuration, although this is not intended to be limiting, as other configurations of the one or more cross members 26 are contemplated, such as, for instance, I-beam configurations, T-beam configurations, box beam configurations, solid beam configurations, and the like.

The first floor layer 24, in one example, is a generally rectangular piece of metal sized to fit within the base frame members 22, supported by the portions 22C of the base frame members 22. The one or more cross members 26, in this example, are disposed between two opposing base frame members 22 and attached thereto. For example, referring specifically to FIG. 3A, each of the cross members 26 includes a tab 26A at each end thereof, the tabs 26A fitting within corresponding slots 22B in at least some of the base frame members 22, enabling the cross members 26 to be welded in place. Alternatively, or in addition thereto, the cross members 26 can be attached using fasteners such as bolts, screws, and the like or by using some other fastening means, such as adhesive, clamps, or the like. The one or more cross members 26 function to, in one example, structurally strengthen the base 20, making the base 20 more rigid. While the above examples include one or more cross members 26 (three cross members 26 are shown in FIG. 3), it is noted that it is not required to include any cross members 26 in the base 20. As such, it is contemplated that no cross members are used, for instance, in the event that the base 20 is of sufficient structural rigidity or is capable of carrying interior loads without any cross members.

In one example, the base 20 further includes a second floor layer, generally similar to the first floor layer 24. The second floor layer is engaged with the base frame members 22, for instance directly attached to one or more of the base frame members 22 or directly attached to one or more of the cross members 26. In one example, the first and second floor layers include an insulation cavity therebetween. In another example, insulation is disposed between the first floor layer 24 and the second floor layer. The insulation can be made up of any type of insulation material, such as insulating foam, blanket insulation, rigid insulation boards, or a combination thereof. In one example, the insulating foam is polyurethane foam. In some examples, the first floor layer 24 or the second floor layer can include at least one drainage opening, slot, vent, or the like to allow any moisture build-up within the enclosure system 10 to drain from within the interior.

Referring to FIGS. 6-10, in one example, the frame members 32 of the frame 30 are disposed in a box-like configuration of a desired size and shape to accommodate the desired contents, such as an HVAC system. In one example, the frame members 32 are disposed in vertical and horizontal orientations. In other examples, the frame members 32 can be disposed in other orientations, depending upon the application, such as diagonally.

Referring to FIGS. 7 and 8, in one example, the frame members 32 are each formed by two channels, such as two C-channels 32A, 32B, coupled together. While C-channels 32A, 32B are shown, it is contemplated that other types of channels or members are used to form the frame members 32, provided the channels or members are capable of performing as described herein. In one example, first and second C-channels 32A, 32B include at least one engagement feature 34 to couple the first and second C-channels 32A, 32B. In another example, the at least one engagement feature 34 is of a lance-lock configuration having a first engagement portion 34A of the first C-channel 32A configured to interlock with a second engagement portion 34B of the second C-channel 32B. While the frame member 32 shown in FIGS. 7 and 8 includes six engagement features 34 having three engagement features 34 on each side of the frame member 32, it is contemplated that there be more or less than six engagement features 34 arranged in different locations along the first and second C-channels 32A, 32B. Additionally, while the engagement features 34 are shown having the lance-lock configuration, further examples can include a different type of engagement feature, such as, but not limited to a tab-in-slot configuration; a detent configuration other than the above-described lance-lock configuration; a deformable member configuration in which a deformable member is bent into position to attach the first and second C-channels; and a fastener such as a bolt, screw, pin, or the like. In still other examples, the frame members 32 can be retained together using adhesive, foam, or the like. Further examples include frame members 32 having one-piece construction, such as a box beam configuration, an I-beam configuration, or the like.

The frame members 32, in one example, include ends having inwardly bent lips or tabs 32C on two opposing sides. The other two opposing sides of the ends of the frame members 32 do not include such tabs, thereby forming an opening 32D on at least one of the sides. It is noted that one of the sides of the end can be extended to close off one end of a slot formed by the tabs 32C, such that the frame member 32 then has only one opening 32D.

Referring now to FIGS. 9A, 9B, 9C, and 10, an example of engagement of first and second frame members 32 using a clip 50 is shown. The first and second frame members 32 are shown in a generally perpendicular orientation; however, it is contemplated that the first and second frame members 32 are attached in a non-perpendicular orientation. The clip 50 includes a mounting surface or base 52 having at least one fastener hole 56 for affixing the clip 50 to a surface of the first frame member 32 using a fastener such as a bolt, screw, or the like. One example of the clip 50 includes two fastener holes 56. Yet another example of the clip 50 includes one fastener hole 56 and a protrusion extending downwardly from the base 52 to engage within a corresponding hole or divot within the first frame member 32 to inhibit rotation of the clip 50 with respect to the first frame member 32 or to hold frame members 32, coupled together using the clip 50, generally rigidly. Although this example includes a protrusion extending from the clip 50, a further example contemplates a protrusion extending from the surface of the first frame member 32 to engage within a corresponding hole or divot in the clip 50. Still another example contemplates a protrusion extending from each of the clip 50 and the surface of the first frame member 32, the protrusions engaging within corresponding holes or divots in the clip 50 and the surface of the first frame member 32.

The clip 50, in one example, includes at least one formed edge or lip 54 extending from the base 52. When the clip 50 is engaged with the first frame member 32, the lip 54 is sufficiently raised from the side surface of the first frame member 32 to accept the tab 32C of the second frame member 32 between the lip 54 and the side surface. In another example, the clip 50 includes two lips 54, each of which are disposed on opposite sides of the clip 50. In yet another example, the opposite sides of the clip 50 are parallel. In still another example, the lips 54 are disposed on sides of the clip 50 that are tapered, such that the sides are closer to one another at one end of the clip 50 than at the other end of the clip 50 to form a wedge-like configuration to limit sliding motion of the second frame member 32 with respect to the clip 50. In one example, the clip 50 has a generally rectangular configuration with the opposite sides having a length greater than sides of the clip 50 disposed between the opposite sides. The lips 54 in one example are formed edges that are generally parallel to and displaced from a plane X (see FIG. 9C) aligned with the base 52. That is, the lips 54 extend generally within and along a plane Y that is generally parallel and raised from the plane X aligned with the base 52.

The clip 50 can accept one tab 32C of the second frame member 32 between each lip 54 and the side surface of the first frame member 32, as shown in FIG. 10. In this way, the second frame member 32 can be slidably engaged with the clip 50 attached to the first frame member 32. The clip 50 is received through the at least one opening 32D in the end of the second frame member 32 to allow acceptance of the tabs 32C of the second frame member 32 between the lips 54 of the clip 50 and the side surface of the first frame member 32 and, thereby, rigidly engage the end of the second frame member 32 with the lips 54 of the clip 50. While the above describes engagement of two frame members 32, the description is equally applicable to engagement of a frame member 32 with a base frame member 22.

Referring now to FIGS. 11-14, the double-walled panel 40 includes a first shell 42 generally having a box configuration including an interior region and a second shell 44 positioned with respect to the first shell 42. The second shell 44 is sized and shaped to correspond with the box configuration of the first shell 42. In at least one example, the second shell 44 also has a box configuration including an interior region. The first and second shells 42, 44 are configured to cooperatively nest. In one example, the first and second shells 42, 44 include interior walls defining a cavity 45 within the panel 40. In one example, the first and second shells 42, 44 are formed metallic sheets. However, in other examples, it is contemplated that the first and second shells 42, 44 are formed from non-metallic materials, such as, for instance, plastic or some other polymeric material. In one example, the first and second shells 42, 44 are formed such that, when constructed, the panel 40 is hat-shaped. The term hat-shaped is used herein to describe a shape of the panel 40, wherein the panel 40 has a first side and a second side, similarly shaped to the first side, but smaller in area and generally centered with respect to the first side, such that there exists a generally uniformly stepped arrangement around the sides of the panel 40, as shown in FIG. 11.

The panel 40, in one example, includes a port 41 (FIG. 13) for inserting foam 46, such as uncured liquid foam or other such materials, within the cavity 45 of the panel 40. The foam 46 of this example bonds to each of the first and second shells 42, 44, thereby coupling the first and second shells 42, 44. In one example, the foam 46 is encased within at least the interior region of the first shell 42 and bonded to each of the first and second shells 42, 44, with the first shell 42 being substantially held apart from the second shell 44. For example, the foam 46 is interspersed between the first and second shells 42, 44 so that there is little or no direct contact between the first and second shells 42, 44.

The first and second shells 42, 44 are separated by a predetermined distance D. In one example, the first and second shells 42, 44 are insulated from one another. For example, the foam 46 is a urethane foam insulation that is disposed within the cavity 45 and acts to separate the first and second shells 42, 44 at all points so that there is no continuous metallic pathway (e.g., no through-metal) between the outer surfaces of the first and second shells 42, 44. Referring to FIG. 12B, gaps A and B are formed between the first and second shells 42, 44 with the insertion of the foam 46. Because there is no through-metal, the formation of condensation on the surface of the panel 40 interior to the enclosure system 10 is limited, if not eliminated. While the above discusses the use of urethane foam insulation, it is contemplated that there be another type of insulation used, either by itself or in combination with urethane foam insulation or other types of insulation. Other examples further contemplate the use of air as insulation.

Referring specifically to FIG. 14, a panel 40 is shown in a door configuration. The panel 40 of this example is fitted with a hinge 48 and a gasket 49 so that the panel 40 can be used as a door to the enclosure system 10. The hinge 48 enables the panel 40 to be pivoted with respect to the rest of the enclosure system 10 to allow access to the interior of the enclosure system 10 without at least partially disassembling the enclosure system 10. The gasket 49 aids in sealing the panel 40 to the rest of the enclosure system 10 to limit moisture, contaminants, and the like from entering the enclosure system 10.

Referring now to FIGS. 15 and 16, in another example, a double-walled panel 40′ is Z-shaped. The term Z-shaped is used herein to describe a shape of the panel 40′, wherein the panel 40′ has a first side and a second side, each side being generally rectangular in plan view, the panel 40′ having the sides offset such that the second side projects beyond the first side along at least one of the edges of the panel 40′ and the first side projects beyond the second side along at most the three remaining edges of the panel 40′, as shown in FIG. 15. In another example, the first and second sides of the panel 40′ are offset such that the second side projects beyond the first side along two of the edges of the panel 40′ and the first side projects beyond the second side along at the two remaining edges of the panel 40′. The Z-shaped panel 40′ includes generally similar features and elements to those shown and described above with respect to the hat-shaped panel 40. As such, similar features and elements are labeled in the drawings with similar numbers as those shown with respect to the hat-shaped panel 40 in FIGS. 11-13, differing only in that a “prime” symbol has been added after each number. For instance, a port 41′ of the Z-shaped panel 40′ is generally similar to the port 41 of the hat-shaped panel 40. Therefore, because, excluding the shapes thereof, the panels 40, 40′ are generally similar, further description of the features and elements of the panel 40′ is omitted.

Referring to FIGS. 17 and 18, a compartment 60 for the enclosure system 10 includes first and second walls 62, 64, which, in one example, are configured such that there is no through-metal in order to limit condensation formation within the enclosure system 10. In one example, the compartment 60 includes a cavity 65 to receive a foam or other type of insulation between the first and second walls 62, 64. In one example, the second wall 64 includes a flange 64A, through which fasteners are disposed to attach the compartment 60 within the enclosure system 10 by attaching the compartment 60 to frame members 32.

The compartment 60, in one example, is used to house an electrical panel 66. It is contemplated in other examples that the compartment 60 can be used to house or otherwise contain objects other than or in addition to the electrical panel 66. In one example, the compartment 60 includes a door 68 configured to close off the compartment 60 when closed and allow selective access to an interior of the compartment 60 when open. For instance, in one example, the door 68 is hinged to pivot about an axis between open and closed positions, with at least one hinge positioned between the door 68 and the first wall 62. Different examples of the door 68 can be configured to open inwardly or outwardly with respect to the compartment 60 depending upon various factors such as space constraints and location of the enclosure system 10, for instance. In other examples, the door 68 moves in various manners to accomplish open and closed positions, such as, for instance, sliding, being removable, being foldable (a bi-fold door, for instance), or the like.

Referring to FIGS. 19-22, an example of the enclosure system 10 shows the hat-shaped panels 40 attached to the frame members 32. In this example, vertically-oriented frame members 32 are attached to the base frame members 22 (not shown in the figures) or horizontally-oriented frame members 32 using clips 50, as described above and shown in FIGS. 9A and 10. The frame members 32 are spaced to accommodate the panels 40 therebetween, such that the first shell 42 of each panel 40 forms a portion of the exterior of the enclosure system 10 and the second shell 44 of each panel 40 forms a portion of the interior of the enclosure system 10. The panels 40 are positioned such that the stepped edges of the panels 40 partially encompass the respective frame members 32 to which the panels 40 are mounted. In one example, the panels 40 are engaged to the frame members 32 using self-tapping screws, although it is contemplated that the panels 40 are engaged to the frame members 32 in other manners, such as, for instance, bolts or other fasteners, adhesive, snap-in features, or the like. In one example, foam gaskets 33 (see, for example, FIG. 22) or other such insulation members are disposed between each frame member 32 and the respective panels 40 to limit, if not eliminate, any through-metal pathways of the enclosure system 10. As shown in FIG. 20, the compartment 60, in one example, is mounted to the frame member 32 of the enclosure system 10. As shown in FIG. 21, a corner of the enclosure system 10 is formed using two frame members 32 in this example, with one frame member 32 being used to attach the panels 40 and one frame member 32 acting as a filler to fill a gap formed and thereby present a generally flush surface along each side of the enclosure system 10. Referring to FIG. 22, at least one panel 40 can form a door to the enclosure system 10, as described above, the hinge 48 of the panel 40 being mounted to the respective frame member 32 to allow pivoting of the panel 40 (the panel 40 on the left in FIG. 22) with respect to the rest of the enclosure system 10.

It is noted that the Z-shaped panels 41′ can be used to form the enclosure system. However, the Z-panel enclosure system differs from the enclosure system 10 described above at least in that, due to the Z-shaped configuration of the panels 40′, at least some of the interior frame members 32 (e.g., the frame members 32 disposed between the corners of the enclosure system) are eliminated. Depending on the construction and the strength or structural rigidity of the panels 40′, it is contemplated that the corner frame members 32 are eliminated in one example.

Referring now to FIGS. 11-13, 23, and 24, in another example, the present subject matter further includes a method of constructing the panel 40. In this example, the first skin or shell 42 is placed, for instance, on a first surface 102 of a jig 100 or other fixture suitable for use in constructing the panel 40. The first shell 42 includes an interior surface. The second skin or shell 44 is placed, for instance, between the first surface 102 and a second surface 104 of the jig 100 or other fixture suitable for use in constructing the panel 40. The second shell 44 includes an interior surface. In one example, the first and second shells 42, 44 are positioned in a generally nesting configuration. For example, the first and second shells 42, 44 are cooperatively nested in a generally stacked configuration, with one of the first and second shells 42, 44 at least partially positioned within the other of the first and second shells 42, 44.

Uncured foam 46 is inserted within at least the interior region of the first shell 42. In one example, the introduction of the uncured foam 46 causes the first shell 42 to separate from the second shell 44. Spatial positioning of the first and second shells 42, 44 is maintained to inhibit separation of the first and second shells 42, 44 beyond a separation distance, with the foam 46 curing and bonding to each of the first and second shells 42, 44. In one example, the jig 100 or other fixture is provided to limit the separation distance of the first and second shells 42, 44 to the predetermined distance D.

In one example, the first and second shells 42, 44 are positioned in a stacked configuration with the interior walls of the first and second shells 42, 44 defining the cavity 45 or void therebetween. In one example, the foam 46 is inserted or otherwise introduced within the cavity 45 between the first and second shells 42, 44. The foam 46, in one example, bonds with the interior walls of the first and second shells 42, 44 and, in this way, acts to maintain coupling of the first and second shells 42, 44. In one example, the foam 46 is introduced through the port 41 in one of the first and second shells 42, 44. In another example, the foam 46 is placed onto the interior surface of one of the first and second shells 42, 44 and then the other of the first and second shells 42, 44 is positioned in the stacked configuration to confine the foam 46 within the cavity 45. In another example, the foam 46 is uncured when inserted within the cavity 45. In still another example, the uncured foam is introduced in the cavity 45 by coupling a nozzle to the port 41 or orifice disposed in at least one of the first and second shells 42, 44. Once inserted, the foam 46 expands, thus causing the first and second shells 42, 44 to separate. Separation of the first and second shells 42, 44 of this example is constrained by the separation of the first and second surfaces 102, 104 of the jig 100, such that the first and second shells 42, 44 become separated by the predetermined distance D. In this way, spatial positioning of the first and second shells 42, 44 is maintained, and generally uniform width panels 40 can be produced. In one example, once the cavity 45 is sufficiently filled with foam 46, the foam 46 is cured or otherwise allowed to set. In one example, at least one of the first and second surfaces 102, 104 of the jig 100 is adjustable so that the separation distance can be adjusted. Once positioned, however, the first and second surfaces 102, 104 are substantially rigid. Once the foam 46 cures, the panel 40 is removed from the jig 100. Removal of the panel 40, in one example, is accomplished by sliding the panel 40 out from between the first and second surfaces 102, 104. In another example, removal of the panel 40 is accomplished by adjusting one of the first and second surfaces 102, 104 to increase the separation therebetween and then sliding the panel 40 out from between the rigid first and second surfaces 102, 104. It is noted that, although not shown, this method of construction is equally applicable in constructing the Z-shaped panel 40′, as shown in FIGS. 15 and 16.

Referring generally to FIGS. 1-10, in yet another example, the present invention further includes a method of manufacturing the enclosure system 10. A plurality of frame members 32 are received, the frame members 32 including at least first and second frame members 32. At least the first frame member 32 has a hole pattern to receive at least one mounting clip 50 (see FIGS. 9A and 10). The hole pattern, in one example, corresponds to a single configuration of clip locations. The at least one clip 50 is attached to the first frame member 32. As discussed above, the clip 50 has a mounting surface 52 for attaching to the first frame member 32 and a pair of formed edges or lips 54 disposed on opposite sides and displaced from a plane aligned with the mounting surface 52. The second frame member 32 is then coupled to the at least one clip 50 by engaging an end of the second frame member 32 with the pair of lips 54. In one example, the end of the second frame member 32 is engaged to the first frame member 32 by sliding the second frame member 32 in a direction parallel with a longitudinal axis of the first frame member 32. At least one double-walled panel 40 is then attached to at least one of the first and second frame members 32. In one example, at least some of the frame members 32 have alignment marks thereon that indicate to an assembler the correct configuration of joints and, thus, the correct configuration of the assembled enclosure system 10.

Referring now to FIGS. 1-3, the method, in one example, further includes constructing the base 20 by receiving at least four base frame members 22 having miter ends 22A. The base frame members 22 are coupled together to form a generally rectangular shape. Optionally, as discussed above, in one example, at least one of the sides of the base 20 includes more than one base frame member 22 welded or otherwise joined together at a joint 23, as shown in phantom in FIGS. 3 and 3B. At least the first floor layer 24 is positioned on the base frame members 22. In one example, at least one cross member 26 is positioned between two opposing base frame members 22. The at least one cross member 26 of one example has a tab 26A extending from an end of the cross member 26, so that the tab 26A can be disposed within a corresponding slot 22B in the base frame member 22. In another example, constructing the base 20 further includes engaging a second floor layer with the base frame members 22.

It should be understood that other methods of manufacture or construction of the enclosure system 10 or the double-walled panel 40, 40′ are within the spirit and scope of the present invention. For instance, it is contemplated that use of the Z-shaped panels 40′ to construct an enclosure system can eliminate at least some of the frame members 32. That is, the panels 40′, due to their shape, allow for direct panel-to-panel connections in at least some circumstances, thereby limiting, if not eliminating, at least some of the frame members 32.

In one example, the double-walled construction of the panels 40, 40′ and the reduction of through-metal pathways curtail formation of condensation or “sweating.” Also, the components allow for relatively easy, kit-like construction of the enclosure system 10, thereby reducing the need for measuring, cutting, drilling, etc. of at least some of the components during assembly of the enclosure system 10. By limiting or eliminating such extra steps, the amount of time required for assembly of the enclosure system 10 is decreased.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (or aspects thereof) may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together to streamline the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may lie in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.

Claims

1. An enclosure, comprising:

a base;

a frame including a plurality of frame members, the frame members coupled together and to the base using clips, each clip including a base coupled to a side surface of a first frame member, the clip further including at least one lip extending from the base, the lip being sufficiently raised from the side surface of the first frame member to accept at least a portion of a second frame member between the lip and the side surface; and

a plurality of panels coupled to the frame members, at least one panel coupled to the base.

2. The enclosure of claim 1, wherein the base comprises:

base frame members configured in a generally closed shape; and

at least a first floor layer disposed on the base frame members.

3. The enclosure of claim 2, wherein the base comprises at least one cross member disposed between two base frame members.

4. The enclosure of claim 2, wherein the base comprises a second floor layer engaged with the base frame members.

5. The enclosure of claim 4, wherein the base comprises an insulation cavity between the first and second floor layers.

6. The enclosure of claim 1, wherein each of the frame members includes two channels coupled together.

7. The enclosure of claim 6, wherein the channels of each of the frame members are coupled together using at least one engagement feature.

8. A method, comprising:

attaching at least one clip to a first frame member, the clip having a mounting surface for attaching to the first frame member and a pair of formed edges disposed on opposite sides of the clip, the formed edges being generally parallel to and displaced from a plane aligned with the mounting surface; and

coupling a second frame member to the at least one clip by engaging an end of the second frame member with the pair of formed edges.

9. The method of claim 8, wherein engaging the end of the second frame member includes sliding the second frame member in a direction parallel with a longitudinal axis of the first frame member.

10. The method of claim 8, comprising constructing a base, including:

coupling base frame members together to form a generally closed shape; and

positioning at least a first floor layer on the base frame members.

11. The method of claim 10, wherein constructing the base includes attaching at least one cross member between two base frame members.

12. The method of claim 10, wherein constructing the base includes engaging a second floor layer with the base frame members.

13. The method of claim 8, comprising attaching at least one panel to at least one of the first and second frame members.

14. An apparatus, comprising:

a first shell having a box configuration including an interior region;

a second shell sized and shaped to correspond with the box configuration of the first shell, the first and second shells configured to cooperatively nest; and

foam encased within at least the interior region of the first shell and bonded to each of the first and second shells, wherein the first shell is substantially held apart from the second shell.

15. The apparatus of claim 14, wherein the second shell has a box configuration including an interior region.

16. The panel of claim 14, wherein the foam includes urethane foam insulation.

17. The panel of claim 14, wherein the first shell is insulated from the second shell.

18. The panel of claim 14, wherein the panel is hat-shaped.

19. The panel of claim 14, wherein the panel is Z-shaped.

20. The panel of claim 14, wherein the first and second shells are formed metallic sheets.

21. A method, comprising:

positioning first and second shells in a generally nesting configuration, at least the first shell having a box configuration including an interior region, the second shell sized and shaped to correspond with the box configuration of the first shell;

inserting uncured foam within at least the interior region of the first shell, the introduction of the uncured foam causing the first shell to separate from the second shell; and

maintaining spatial positioning of the first and second shells to inhibit separation of the first and second shells beyond a predetermined separation distance, the foam curing and bonding to each of the first and second shells.

22. The method of claim 21, wherein the foam is inserted through a port within at least one of the first and second shells.

23. The method of claim 21, wherein maintaining the spatial position of the first and second shells includes using a jig.

24. A frame portion, comprising:

a first frame member having a side surface;

a second frame member having an end with at least one tab; and

a clip including a base configured for engagement with the side surface of the first frame member, the clip further including at least one lip extending from the base, the lip being sufficiently raised from the side surface of the first frame member to accept the tab of the second frame member between the lip and the side surface.

25. The frame portion of claim 24, wherein the clip has two lips, each of which are disposed on opposite sides of the clip.

26. The frame portion of claim 25, wherein the second frame member includes two tabs, each tab configured to fit between the corresponding lip of the base and the side surface of the first frame member.

27. The frame portion of claim 24, wherein the at least one tab of the second frame member is selectively slidably engaged with the at least one lip of the clip.

28. A clip for assembling a first linear member and a second linear member in perpendicular orientation, the clip comprising:

a mounting surface for attaching to the first linear member; and

a pair of formed edges disposed on opposite sides of the clip, the formed edges being generally parallel to and displaced from a plane aligned with the mounting surface, wherein the pair of formed edges are configured to receive an end of the second linear member.

29. The clip of claim 28, further including at least one fastener hole disposed in the mounting surface.

30. The clip of claim 28, wherein the opposite sides are parallel to each other.

31. The clip of claim 28, wherein the clip has a generally rectangular configuration with the opposite sides having a length greater than sides of the clip disposed between the opposite sides.

32. The clip of claim 28, wherein the pair of formed edges are configured to rigidly engage the end of the second linear member.

33. A method of manufacturing a wall structure, the method comprising:

positioning a first skin and a second skin in a stacked configuration;

providing a fixture to limit a separation distance of the first skin and second skin;

introducing uncured foam in a void between the first skin and the second skin;

allowing the first skin and second skin to separate to the separation distance; and

curing the foam.

34. The method of claim 33, wherein introducing uncured foam in the void includes coupling a nozzle to an orifice disposed in at least one of the first skin and the second skin.

35. The method of claim 33, wherein providing the fixture includes positioning a rigid surface.

36. The method of claim 35, further including displacing the rigid surface and removing the first skin, second skin and the cured foam.