System and Method for an Adjustable Locking Mechanism for Insulated Panels

Abstract

An adjustable panel locking mechanism is disposed in a slot of a structural member of the panel. A cam-strike or latch is disposed through the slot, over a lock plate, and both are covered by a cover plate. When the panel is assembled, and expanding foam is injected into a volume created by a plurality of structural members and exterior sheathing, the foam expands to the cover plate, which exerts a pressure or force on the cam-strike or latch disposed through the slot. The cam-strike or latch is then adjustable based on the friction between the lock plate and the cover plate with the base of the cam-strike or latch there between.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to structural insulated panels for use in custom-designed and prefabricated walk-in refrigerator and freezer spaces. More specifically, the present invention relates to an adjustable cam-strike system and method for manufacturing same, for use in the construction of custom designed walk-in refrigerator and freezer spaces.

2. Background of the Invention

Walk-in refrigerator and freezer spaces, incubating spaces, and prefabricated insulated structures, such as dwellings, are typically manufactured and assembled using pre-fabricated insulated structural panels joined together to define the enclosed space. The structural panels provide insulation to maintain the temperature inside the walk-in space using as little energy as possible. The panels are typically joined together using latches and cam-strikes. Each panel is typically constructed with either a latch or cam-strike on each edge of the panel, so that when the panels are fitted into a structure, the latch of one edge engages the cam-strike of an adjacent panel.

Additionally, wall panels that are typically fastened to floor and ceiling rails also have a cam-strike and/or latch installed. Typically, the panels are manufactured with great precision, such that each panel has the latch and cam-strike in the same position(s) from panel to panel, and the panels are of precisely the same width. In the prior art, each latch and cam-strike are placed in a predetermined position within a slot that is fashioned to house the cam-strike, but no longitudinal movement along the slot is permitted or possible. In such a configuration, once the insulated panel is filled with foam, the cam-strike and latch mechanism are locked in place by the expansion of the foam around the cam-strike and latch devices, in their respective locations. However, when the panel width and/or placement of the latch or cam-strike is out of manufacturing tolerances, continued installation of panels with a consistent width difference may cause the latch and cam-strike to fail in their respective alignment. Additionally, in very large applications, even in which the panels are within tolerances for width, the minute variances in width can cause “stack-ups,” whereby the repeated increased width eventually causes the latch and cam-strike to fail in alignment. For example, if each of a group of 100 panels is only 1/16 of an inch over width in a panel wall structure, by the time the last panel is installed to a floor rail manufactured within tolerances, the alignment will be off by 6.25 inches. In such situations, an adjustable latch or cam-strike is needed to ensure that the panels can be properly installed.

Additionally, consistently misaligned panels can cause premature stress and wear of the latch systems. Slight adjustability of the cam-strike helps to alleviate this problem.

Accordingly, it would be desirable to have a system that effectively accounts for slight variances in panel width from panel to panel, and for slight variances in manufacturing, within or outside of tolerances.

SUMMARY OF THE INVENTION

In one embodiment of the invention, a cam-strike having a striker pin is disposed through a lock plate disposed over a slotted structural member. A cover plate is placed over the cam-strike plate and lock plate against the structural member. The structural member is covered with sheathing on all sides and filled with expanding insulating foam. The expansion of the foam within the space created by the structural members and the sheathing veneer holds the cam-strike in place between the lock plate and the cover plate through friction. In another embodiment, the cam-strike may be replaced by a latch. In one or more additional embodiments, the invention may not include a lock plate, and may further also include a cam-strike or latch having an enlarged flange to disperse force from the insulating foam over a greater surface area of the cover plate.

During operation, the friction mounting of the cam-strike plate between the cover plate and structural member, which, once the foam insulation has cured, is static, allows the cam-strike pin location to be moved along the slot in the structural member.

In another embodiment, the latch, or latch, member, is mounted between a lock plate and a cover plate in the same or similar manner as the cam-strike. In either embodiment, or in others in accordance with the present invention, the location of the cam-strike plate and the latch can be moved longitudinally within the slot of the structural member to provide for the alignment of the cam-strike pin and the latch.

Other embodiments in accordance with the spirit and scope of the invention will become apparent to those of skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows unassembled insulated structural panels in accordance the present invention;

FIG. 1B shows traditional insulated structural panels joined together to form an insulated structural wall;

FIG. 1C shows a latch and cam-strike mechanism used to joint together insulated structural panels;

FIG. 1D shows the components of a cam-strike and latch pair;

FIG. 2A shows the components of an adjustable cam-strike installation with a structural member in accordance with an embodiment of the present invention;

FIG. 2B shows the components of an adjustable latch installation with a structural member in accordance with an embodiment of the present invention;

FIG. 3 shows the components of an adjustable cam-strike installation with a structural member in accordance with an embodiment of the present invention;

FIG. 4 shows the adjustability of an installed cam-strike in accordance with embodiments of the present invention.

FIG. 5 shows a cross-sectional view of an embodiment of the invention that includes an end plate to at least partially support a wall panel attached to a floor panel in accordance with the invention.

FIG. 5A shows a recess cut of the end plate shown in FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to systems and methods of maintaining the insulative properties of insulated structural panels. FIGS. 1A and 1B generally show an insulated structural panel system that, when joined together, form a wall for a pre-defined or custom-built refrigerated space. In FIG. 1A, for example, two un jointed panels 20 are shown as part of an insulated structural wall 10. Each structural panel 20 is constructed of vertical structural members 22M/22F and horizontal structural members 24 (which also may be constructed with male/female configurations, not shown). The structural members 22 and 24 may be constructed of wood, a composite, metal, or any other suitable structural material as would be understood by one of ordinary skill in the art. Structural panels 20 are typically constructed using sheathing 26, which may be steel, aluminum, oriented strand board (OSB), plywood, or other suitable sheathing material, which is held into place so that an insulating material, such as closed-cell polyurethane foam 28 is blown or injected between the sheathing 26.

The insulated structural panel is primarily assembled by virtue of the closed-cell polyurethane foam 28 acting as an adhesive to hold the sheathing and structural members in place. Insulated structural panels 20 are further typically designed such that vertical structural members 22 (and horizontal members 24) include a tongue-in-groove design (not shown for members 24). A latch 30 and cam-strike 32, are typically disposed within the panels to facilitate joining the panels together. When the latch 30 is actuated to engage the cam-strike 32, for example, the insulated structural panels are drawn tightly together, as shown in FIGS. 1B and 1C. Also shown are rails 40M and 40F. Each of structural panels 20 may include a rail 40M configured as a male structural member having a latch 50 disposed therein, and configured to attached to rail 40F having a female groove 42F with a slot 44F disposed there through in a suitable location for disposition of a cam-strike 52. Rail 40F is preferably configured to attach to a floor structure along the bottom edge of the attached structural panels 20 and defines the external boundary of an enclosed structure manufactured using the structural panels 20. Alternatively, and as further shown herein, Rails 40M and 40F may be interchanged, such that the panel 20 includes a female rail 40F which attaches to a rail 40M.

Structural panels 20 are secured to a floor structure via structural members 40M and 40F by engaging latch 50 and cam-strike 52 in a similar manner as the connection between adjacent panels 20 and latch 30 with cam-strike 32.

The width of the structural panel may be determined by the application for which the insulated structural panels are to be used. If a bad seal exists, over time, as the relatively warm and moist outside air travels through the joint 34, condensation may form. In the case of an insulated structural panel system used for refrigeration, this condensation may remain in liquid form and become a source of potential mold or bacterial growth. In the case of insulated structural panel freezer systems, condensation formed a joint 34 can result in the formation of ice, which, when formed in, or within joint 34 can expand the joint. Expansion of this joint 34 further degrades the efficacy of the insulated structural panel system, especially at the joint 34. Accordingly, a secure connection is needed between the adjacent structural panels, as well as the structural panels and the base of the structure.

FIG. 1D shows examples of the latch 50 and cam-strike 52 of FIGS. 1A-1C in greater detail. Latch 500 and Latch 50 are therefore interchangeable as used in this specification. Latch 500 may include a latch arm 502, a housing 504, a plate surface 506 and a hex-key aperture 508. Cam-strike 520 may include a latch pin 522, a housing, 524, and a plate surface 526. In operation, when the latch 500 with its latch arm 502 are aligned opposite cam-strike 520 and latch pin 522, a hex key (not shown) is inserted into the latch key aperture 508 and rotated, the latch arm 502 engages latch pin 522 and draws the latch 500 closer to the cam-strike 520, including whatever devices latch 500 and cam-strike 520 are mounted on or within. The latch and cam-strike shown in FIG. 1D are well known in the art, examples and aspects of which are disclosed in U.S. Pat. Nos. 6,070,919, 6,299,225, 6,386,788, 6,409,235, 6,530,610, and 6,681,471, all assigned to Kason Industries, Inc. It will be apparent in further description below that latch 50 and cam-strike 52 of FIGS. 2A and 2B correspond to latch 500 and cam-strike 520 of FIG. 1D, respectively.

FIGS. 2A and 2B disclose embodiments of the present invention in which the cam-strike 52 and latch 50 are disposed, respectively through slots in members 40F and 40M. A lock plate 54 is placed over a portion of the slot 44. In a preferred embodiment, the lock plate is placed at the center of the slot, but not necessarily required to be centered. As shown in FIG. 2A, cam-strike 52/520 is disposed through the lock plate 54 through an aperture sized to accept the housing 524 of the cam-strike 520. Preferably, the aperture in the lock plate 54 is sized to minimize movement of the latch 50 or the cam-strike 52, so as to prevent unwanted movement within the assembly. A cover plate 56 is then placed over the lock plate 54 or cam-strike 52, so as to completely cover each of the slot 44, the lock plate 54, and the cam-strike 52. In a preferred embodiment, the cover plate extends beyond the ends of slot 44 by at least an inch, but there is no specific dimensional requirement regarding coverage, so long as the coverage is sufficient to prevent expanding insulating foam from entering the slot 44 or contacting lock plate 54 or cam-strike 52.

FIG. 2B is similar to FIG. 2A, except that instead of cam-strike 52 being disposed through the slot 44, it is latch 50/500 that is disposed through the slot. Additionally, the female structural member 40F is replaced by male structural member 40M.

The lock plate 54 and cover plate 56 preferably have smooth surfaces to facilitate the cam-strike 52 (or latch 50) to slide along the abutted face of cover plate 56. The lock plate 54 and cam strike 52 (and flange 526 thereof, per FIG. 1D), distribute the force over a larger surface area of cover plate 56 to facilitate sliding movement of the cam-strike 52 along the slot. In another alternative construction, the cam-strike 52 is inserted through the slot 44 and covered by the cover plate 56 with no lock plate. Alternatively, the cam-strike flange 526 may be made larger to further distribute the force along the cover-plate 56.

For the assemblies shown in both FIGS. 2A and 2B, once the cover plate 56 is placed over the lock plate 54 and either cam-strike 52 or latch 50, respectively, the cover plate 56 is attached to the structural member 40F or 40M with suitable sealing material as shown in FIG. 3 (only shown for FIG. 2A/2B assembly). In the embodiment shown, a sealing membrane 58 is used to cover the cover plate 56 and seal the cover plate 56 to the structural member 40F or 40M from the ingress of the expanding foam. In the embodiment shown, sealing membrane 58 consists of a non-permeable membrane, such as tape, but the cover plate may also be sealed with any suitable material or compound, such as caulk, silicone sealant, glue, cloth, or any combination thereof, which prevents foam 28 from ingress into the space between the cover plate 56, slot 44F, and the lock plate 54. Further shown, for example, is that the tape 58 is even overlapped over the sides of structural member 40F. While not required, this embodiment further ensures that no foam 28 can infiltrate the cover plate/lock plate/cam-strike/latch assembly, slot, and other grooves and cuts in formed in the structural members and/or created by the assembly of the components described herein. After the cover plate 56 is secured to the structural member 40F/M, the structural member is assembled with other structural members 40F/M and 22F/M as required for the shape of the panel. Once the exterior sheathing 26 is affixed to the structural member 22, 40, on both sides of the panel, expanding foam 28 is injected into the panel. The foam 28 expands to fill the volume created by the structural members 22, 40 and the sheathing 26, and applies a force to the cover plate 56, the cam-strike 52 or latch 50, and the lock plate 54, via the plate surface 506 or 526 of the latch 50/500 or cam-strike 52/520, respectively, as shown in FIGS. 1D, and 2A and 2B. The force applied by the foam 28 is related to the density of the foam 28 used. In embodiments used for walk-in freezers and refrigerated spaces, the foam pressure is typically about 6 lbs/in².

Once the foam 28 has cured within the panel 20, the assembly described herein may be adjusted as shown in FIG. 4 by applying force in the longitudinal directions defined by the slot 44, providing adjustment to align latch 50/500 and cam-strike 52/520, as needed. Depending on the density of foam 28 used within the panel, it may be necessary to use additional tools, such as a hammer 48 and drift 46 to precisely adjust the cam-strike 52 (or latch 50) by tapping it into place.

Assembly of the panels in accordance with embodiments of the invention is shown in accordance with FIGS. 1A-1C. Additionally, the rails 40M /40F may be manufactured as part of a floor panel 46 that is manufactured in a similar manner as insulated panels 20, having the configuration shown in FIGS. 5 and 5A. Additionally, an end plate 60 may be included to support the outer edge of rails 40M/40F to provide additional structural support. In such a configuration, the cover plate 56 may protrude beyond the exterior surface of rails 40M/40F, which may create a gap allowing ingress of warmer air, and/or reducing the stability of the structural panels 20. One solution (not shown), is to router a recess into the back of rails 40M/40F so that the cover plate 56 fits flush with the surface of the back of the rails 40M/40F. Alternatively, end plate 60 may be configured with a relief cut 62 as shown in FIG. 5 and FIG. 5A. The depth of relief cut 62 of end plate 60 is sized to accommodate the depth of cover plate 56, as shown in FIG. 5. During assembly, structural member 40F (shown) is positioned atop end plate 60 such that cover plate 56 is accommodated by the relief cut 62. Floor panel 64 with relief 66 is positioned underneath the remainder of structural member 40F, adjacent to end plate 60. The relief 66 in floor panel 64 is preferably of sufficient depth to accommodate the portion of structural member 40F not supported by end plate 60, such that the panel 20 sits substantially level on top of end plate 60 and floor panel 64.

During installation, a panel 20 is positioned with latch 50 to engage cam-strike 52 (in embodiments with the latch 50 in the panel 20 and the cam-strike 52 in the rail 40F). The latch 50 engages the cam-strike 52 by inserting a hex wrench (not shown) into hex slot 508 (FIG. 1D) and rotatably engaging the latch hook 502. Once the first panel 20 is installed, the second and subsequent panels 20 are installed in the same manner. If the latch 50 and cam-strike 52 are not aligned, then the cam-strike 52 may be adjusted along the slot 44 using a drift 46 and hammer 48, or by hand, or by other suitable method sufficient to overcome the friction between the cam-strike 52 and the cover plate 56.

While the present invention has been described in detail, it is not intended to be limited. Accordingly, various changes, variations, and substitutions may be made without departing with the scope of the invention as disclosed. For example, the cover plates, lock plates, and latches may be manufactured from ceramic, or other composite. The size of the flanges of the latches and cam-strikes may be modified to suit specific applications, and the scale of the components may be adjusted. Other variations will be obvious to those of ordinary skill in the art, and remain within the scope of the invention.

Claims

1. An adjustable locking system, comprising:

a cam-strike having a flange;

and

a cover plate, wherein the cam-strike is disposed through a slot in the structural member, and wherein the cover plate is configured to cover the flange of the cam-strike when the cam-strike is disposed through a slot in a structural member, and

wherein the structural member is configured to provide perimeter support for an insulated panel, and wherein the cover plate covers the slot of the structural member, and is secured to the structural member to provide a friction operable to allow a friction-limited adjustability of the cam-strike along the slot.

2. The adjustable locking system of claim 1, further comprising a lock plate having an aperture sized to have at least a portion of the cam-strike disposed therethrough, wherein the lock plate is positioned between the slot and the cover plate.

3. The adjustable locking system of claim 1, further comprising a sealing membrane operable to seal the cover plate to the structural member.

4. The adjustable locking system of claim 3, wherein the sealing membrane is at least one of glue, tape, or caulk.

5. The adjustable locking system of claim 1, wherein the insulated panel further comprises an expanding foam operable to exert a force against the cover plate.

6. The adjustable locking system of claim 5, further comprising a lock plate disposed between the structural member and the cover plate, wherein the lock plate comprises an aperture sized to accept a portion of a cam-strike disposed therethrough, wherein the lock plate is operable to disperse the force applied by the expanding foam along area of the cover plate in contact with the lock plate and the flange of the cam-strike.

7. An adjustable locking system, comprising:

a latch having a flange;

and

a cover plate, wherein the latch is disposed through a slot in the structural member, and wherein the cover plate is configured to cover the flange of the latch when the latch is disposed through a slot in a structural member, and

wherein the structural member is configured to provide perimeter support for an insulated panel, and wherein the cover plate covers the slot of the structural member, and is secured to the structural member to provide a friction operable to allow a friction-limited adjustability of the latch along the slot.

8. The adjustable locking system of claim 7, further comprising a lock plate having an aperture sized to have at least a portion of the latch disposed therethrough, wherein the lock plate is positioned between the slot and the cover plate.

9. The adjustable locking system of claim 7, further comprising a sealing membrane operable to seal the cover plate to the structural member.

10. The adjustable locking system of claim 9, wherein the sealing membrane is at least one of glue, tape, an elastomeric caulk, or silicone caulk.

11. The adjustable locking system of claim 7, wherein the insulated panel further comprises an expanding foam operable to exert a force against the cover plate.

12. The adjustable locking system of claim 11, further comprising a lock plate disposed between the structural member and the cover plate, wherein the lock plate comprises a slot sized to accept a portion of a latch disposed therethrough, wherein the lock plate is operable to disperse the force applied by the expanding foam along area of the cover plate in contact with the lock plate and the flange of the latch.

13. A method for manufacturing an adjustable locking system, the method comprising the steps of:

disposing one of a cam-strike or a latch, each having a flange, through a slot in at least one of a plurality of structural members;

covering the one of a cam-strike or latch and the slot using a cover plate, wherein the plurality of structural members form the perimeter of an insulated panel, and affixing two opposing sheathing sheets to the plurality of structural members, such that the connection of the opposing sheathing sheets to the plurality of structural members creates a volume between the opposing sheathing sheets; and

injecting expanding foam into the volume, such that when the foam expands to fill the volume, the cover plate exerts a force on the flange of the cam strike or latch to hold the cam-strike or latch in place, wherein the force exerted on the flange of the cam-strike or latch creates a friction that creates a friction limited adjustability of the cam-strike along the slot in the structural member.

14. The method of claim 13, further comprising disposing at least a portion of the cam-strike or latch through an aperture in a lock plate, and placing the lock-plate between the cover plate and the slot, such that the expansion of the foam exerts a force on the lock plate, and wherein the surface area of the lock plate is operable to disperse the force along a greater surface area of the cover plate to facilitate smoother movement of the cam-strike or latch along the slot.

15. The method of claim 13, further comprising covering the cover plate with a sealing membrane, wherein the sealing membrane is operable to prevent the expanding foam from ingress into the area between the cover plate and the cam-strike or latch.

16. The method of claim 14, further comprising covering the cover plate with a sealing membrane, wherein the sealing membrane is operable to prevent the expanding foam from ingress into the area between the cover plate, the lock plate, and the cam-strike or latch.

17. A method for assembling structural wall panels, the method comprising the steps of:

positioning an end plate at the base of a plurality of structural panels, each of the plurality of structural panels comprising:

a locking system in accordance with claim 1 or claim 7,

wherein the end plate includes a relief cut in contact with the structural member of the locking system, and wherein the relief cut accommodates the cover plate of the locking system.

18. The method of claim 17, wherein the structural member is manufactured as part of a floor panel, and wherein an expanding foam insulation is injected into a volume defined by the structural member, the end plate, and at least two panel sheaths, such that the expanding foam exerts a force against the cover plate of the locking system, and wherein the structural member is substantially level when placed on a level surface.

19. A method of assembling an insulated structural panel wall, comprising the steps of:

placing a plurality of structural panels, each of the panels comprising a male structural member having a latch disposed therein, in contact with a female rail comprising a plurality of cam-strikes, each of the cam-strikes at least partially disposed through a respective slot formed in the female rail, wherein each of the cam-strikes is friction-adjustable within its respective slot;

aligning the latch of a first of the plurality of insulated structural panels with a first of the plurality of cam-strikes of the female rail, and engaging the aligned first cam-strike with the latch of the first insulated structural panel to bring the panel into sealing engagement with the female rail;

aligning the latch of a second of the plurality of insulated structural panels with a second of the plurality of cam-strikes of the female rail, wherein aligning the cam-strike with the latch comprises adjusting the second cam-strike within the slot, and

engaging the aligned second cam-strike with the latch of the second insulated structural panel to bring the panel into sealing engagement with the rail, adjacent to the first panel.

20. A method of assembling an insulated structural panel wall, comprising the steps of:

placing a plurality of structural panels, each of the panels comprising a female structural member having a cam-strike disposed therein, in contact with a male rail comprising a plurality of latches, each of the latches at least partially disposed through a respective slot formed in the male rail, wherein each of the latches is friction-adjustable within its respective slot;

aligning the cam-strike of a first of the plurality of insulated structural panels with a first of the plurality of latches of the rail, and engaging the aligned first latch with the cam-strike of the first insulated structural panel to bring the panel into sealing engagement with the male rail;

aligning the cam-strike of a second of the plurality of insulated structural panels with a second of the plurality of latches of the rail, wherein aligning the latch with the cam-strike comprises adjusting the second latch within the slot, and

engaging the aligned second cam-strike with the latch of the second insulated structural panel to bring the panel into sealing engagement with the rail, adjacent to the first panel.