Snap-In Edge Trim Design for End Panels

Abstract

An edge trim for display cases, and methods for making edge trim, are described. Instead of using tape or an adhesive to attach trim to the outer rims of end panels, a shape pattern is created in an extruded trim piece. Then polyurethane liquid can be added to the interior of the panel so that it also fills in the shape pattern. When the polyurethane solidifies into foam it will create a tight bond between the panels and the trim pieces.

Claims

1. An end panel for a refrigerated display case comprising: two end sheets being parallel and spaced apart from each other, each end sheet having an outer-facing surface, an inner-facing surface and an end surface, the end surface extending between the outer and inner surfaces; one or more bumpers attached to a periphery of the outer-facing surface of each end sheet proximate the end surface; a snap-in trim connected to the two end sheets, with attached bumper, via an interference fit, wherein the two end sheets and the snap-in trim form a cavity therebetween, the snap-in trim comprising: a trim body comprising two slots, each of the two end sheets and attached bumper positioned in a respective slot via an interference fit, wherein the bumper is configured to create the interference fit of the two end sheets, the trim body further comprising a shape pattern formed in the trim body between the two slots; and a trim skin surrounding substantially the entire circumference of the trim body the trim skin permanently affixed to the trim body; and an insulating, polyurethane foam positioned in the cavity and in the shape pattern of the trim body.

2. The end panel of claim 1 wherein the trim skin comprises virgin PVC.

3. The end panel of claim 1 wherein the trim body comprises recycled PVC.

4. The end panel of claim 1 further comprising a plurality of wood pieces disposed between the two end sheets.

5. The end panel of claim 1 wherein the two end sheets comprise metal.

6. The end panel of claim 1 wherein the shape pattern comprises a plurality of shapes, and wherein at least one of the plurality of shapes is different than another of the plurality of shapes.

7. The end panel of claim 1 wherein the trim body and trim skin are permanently adhered to each other by being co-extruded.

8. (canceled)

9. A temperature cooled display case comprising: a plurality of shelves; a plurality of end panels, each of the plurality of end panels comprising: two end sheets spaced apart from each other in a parallel configuration, each end sheet having an outer surface, and inner surface and an outermost edge; a snap-in trim attached to the two end sheets, the snap-in trim configured to be attached to the two end sheets via a snap-fit, the snap-in trim comprising: a trim body comprising two slots, each of the two end sheets positioned in a respective slot, the trim body further comprising a shape pattern formed in the trim body between the two slots; and a trim skin surrounding substantially the entire circumference of the trim body, the trim skin permanently adhered to the trim body; a cavity formed between the two end sheets and the snap-in trim; an insulating, polyurethane foam positioned in the cavity and in the shape pattern of the trim body; and one or more bumpers bonded to a periphery on the outer surface of each end sheet, wherein the one or more bumpers are positioned in the slots of the trim body such that the snap-in trim is attached to the two end sheets via an interference fit.

10. The display case of claim 9 wherein the trim skin comprises virgin PVC.

11. The display case of claim 9 wherein the trim body comprises recycled PVC.

12. The display case of claim 9 further comprising a plurality of wood pieces disposed between the two end sheets.

13. The display case of claim 9 wherein the two end sheets comprise metal.

14. The display case of claim 9 wherein the shape pattern comprises a plurality of cross shapes.

15. The display case of claim 9 wherein the trim body and trim skin are permanently adhered to each other by being co-extruded.

16. (canceled)

17. A method of constructing an end panel for use in a temperature cooled display case, the method comprising: providing two end sheets, the two end sheets being parallel and spaced apart from each other, each end sheet having an outer-facing surface, an inner-facing surface and an end surface; attaching a bumper to one or both of the outer-facing surface or the inner-facing surface of each end sheet; co-extruding a trim body and a trim skin such that the trim body and trim skin are permanently affixed, the trim body comprising a plurality of slots formed therein, the plurality of slots configured to receive the two end sheets and respectively attached bumper, the trim body comprising a shape pattern formed therein, the shape pattern formed between the two end sheets; inserting the two end sheets with attached bumper into respective slots in the trim body such that the end sheets with attached bumper are secured in the respective slot by interference fit, wherein the trim body and two end sheets form a cavity therebetween; injecting insulating, polyurethane liquid into the cavity such that the insulating, polyurethane liquid fills the cavity and the shape pattern; and allowing the insulating, polyurethane liquid to solidify into an insulating, polyurethane foam, to bond the two end sheets together and to further secure the trim body to the two end sheets.

18. The method of claim 17 further comprising placing a plurality of wood pieces between the two end pieces.

19. (canceled)

20. The method of claim 17 wherein the shape pattern comprises a cross.

21. The end panel of claim 1 wherein the shape pattern extends into the trim body to a greater depth than the two slots such that the insulating foam extends into the trim body beyond the end surface of the two sheets.

22. The display case of claim 9 wherein the insulating, polyurethane foam extends into the trim body beyond the two end sheets.

23. The method of claim wherein the trim body extends laterally beyond the outer-facing surface of each of the end sheets, wherein the shape pattern extends vertically into the trim body to a greater depth than the plurality of slots.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0008] FIG. 1 is a diagram of an embodiment of a display case.

[0009] FIG. 2 is a diagram of an embodiment of an end panel during construction.

[0010] FIG. 3 is a diagram of an embodiment of a prior art end panel.

[0011] FIG. 4 is a diagram of an end panel embodiment under the present disclosure.

[0012] FIGS. 5A-5D are diagrams of shape pattern embodiments under the present disclosure.

[0013] FIG. 6 is a diagram of an end panel embodiment under the present disclosure.

[0014] FIG. 7 is a diagram of a method embodiment under the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0015] A variety of display cases are used in stores and other retail establishments. The display cases can take a variety of forms, shapes, sizes, and dimensions. One type of display case is the refrigerated display case. These display cases can be refrigerated themselves, or can merely reside within a refrigerated environment. Refrigerated display cases can at times be subject to unique stresses that non-refrigerated display cases are not subject to. Temperature changes can cause a cycle of expanding and shrinking materials and different materials can expand and shrink at different rates and total amounts. Refrigeration cases can also contain machinery that cause vibrational stresses. Because of these stresses, refrigerated cases can wear down quicker than non-refrigerated embodiments. Innovations that lead to cheaper manufacturing of display cases, especially refrigerated ones, can be of great value.

[0016] One part of a display case is the trim. A display case can have the appearance of case 100 in FIG. 1. A case 100 can have end panels 160 and front 170 and back panels 180. Shelves 110, 120 can be positioned between the end panels 160. There may even be a freezer section 140, with a sliding lid. Items 130 (such as food, drinks, etc.) can be stored on the shelves 110, 120 or in the freezer section 140 for display to the public. End panels 160 typically comprise a trim 155 along their outer edges. Trim 155 can have decorative purposes, but it also has functional purposes due to the manufacturing process for end panels 160. For a refrigerated unit, end panels 160 may conceal refrigeration equipment (not shown) within case 100.

[0017] In general, embodiments of an end panel under the present disclosure and under the prior art, comprise two end sheets, joined along their perimeter by some form of end trim, the end sheets and trim forming a cavity. A foam (such as polyurethane foam) is then injected into the cavity. The term end panel generally refers to an entire end panel comprising two end sheets, trim, and foam. The term end sheets refers to the two sheets (often metal) that go into forming a single end panel.

[0018] FIG. 2 displays an embodiment of an end panel 200 midway through construction. End sheet 240 (preferably metal but can be a different material) sits underneath a frame 210. Frame 210 has a C-shaped cross section with the C open toward the interior of the structure. Also shown is a close-up of a side view of frame 210. Double sided tape 220, or another adhesive, is attached to side wings 214, 216 of the C-shaped frame 210 such that it adheres to end sheet 240. End sheet 240 is attached to wing 214 of frame 210 by adhesive 220. Later in the construction process another end sheet 240 will be applied to wing 216 by adhesive 220. A close-up view is shown of frame 210, showing adhesive 220 applied to the face of wing 216. Wooden blocks 230 are often adhered to the end sheets 240 and can be used to receive attachment bolts or other attachment components when connecting neighboring display cases together, or attaching shelving or other components. After applying end sheets 240 to each side of the frame 210, a V-shaped application machine will close on the panel 200 and hold it in place while liquid polyurethane (PU) is injected into the interior region of panel 200 through an aperture. The aperture can be located in a corner, along a side, along a face, and can be of various sizes or shapes. The aperture can be fitted with various nozzles, fittings or attachments for interoperability with other components, such as the injector. The polyurethane dries and hardens into PU foam, an insulator.

[0019] FIG. 3 shows a portion of a typical prior art end panel 200. PU foam 250 sits between end sheets 240 and C-shaped frame 210. Tape/adhesive 220 helps adhere end sheets 240 to frame 210. Trim 245 is attached to the top edge of frame 210 by tape/adhesive 220. Trim 245 is typically made of extruded PVC (polyvinyl chloride). End panel 200 can be attached to the end of a display case, such as display case 100 of FIG. 1.

[0020] There are several problems with the current process of constructing end panels. One is a lot of waste material. The process can also be labor intensive. Previous end panels tend to break down quickly as the attachment mechanisms for the PVC trim (usually tape) tend to be weak. Many warranty claims are made to end panel manufacturers because of end panels that break at the trim, usually when an employee is carrying or adjusting an end panel by holding onto the trim. Thus an end panel trim is needed that is stronger and less expensive to manufacture with less waste.

[0021] FIG. 4 displays one embodiment of end panel 200 under the present disclosure. Snap-in trip 280 can comprise a shape pattern 270, skin 284, and body 286. Skin 284 is virgin PVC in a preferred embodiment while body 286 can comprise recycled PVC. Trim 280 can be snapped onto end sheets 240. Polyurethane liquid is then injected into the space between the end sheets 240 via a small aperture somewhere along the trim 280 or end sheets 240. As the liquid is injected it will fill the entire cavity defined by the end sheets 240 and the trim 280, and fill shape pattern 270. As the liquid solidifies it will harden into foam 250 and create a tight connection between the foam 250 and trim 280. End panel 200 will then comprise two end sheets 240, PU foam 250, and trim 280. One end panel 200 can be placed on each end of a display case.

[0022] Skin 284 in FIG. 4 can be, in a preferred embodiment, virgin PVC. This is because skin 284 will be seen by customers and therefore should have a good appearance. Various colors or finishes can be applied as desired. In other embodiments, possibly a recycled PVC can be used, or other materials such as metals, plastics, and any appropriate material. Trim body 286 in FIG. 4 can be, in a preferred embodiment, recycled PVC. Trim body 286 will not be seen by the public/customers so its appearance is not as important as skin 284. Therefore recycled PVC is a good option. However, other embodiments can comprise virgin PVC, or other materials, such as metals, plastics or other materials as desired.

[0023] Foam 250 in FIG. 4 has been described as polyurethane foam. This is a preferred embodiment. However, other embodiments may comprise different foams or different materials as appropriate.

[0024] End sheets 240 of FIG. 4 can be comprised of metal in a preferred embodiment (such as galvanized aluminum). However, other embodiments can comprise other metals, plastics or other materials.

[0025] Shape pattern 270 in FIG. 4 can take a variety of forms. FIGS. 5A-5D display a variety of embodiments that the shape pattern 270 can take. FIGS. 5A-5D display end panel embodiments 200, comprising end sheets 240, trim 280 (comprising skin 284 and trim body 286), foam 250, and shape pattern 270. As can be seen, shape pattern 270 can take a variety of forms, shapes and sizes. The pattern can be repeating, or it can be several different shapes, or just a single shape. What is desired is that polyurethane liquid flow into the shape pattern 270 during pouring/injection, and that when the polyurethane dries into a foam that a strong connection be formed between end sheets 240, foam 250, and trim 280. Interlocking parts and interference fits can be created by this process.

[0026] Another embodiment under the present disclosure can comprise additional features to seal or protect the bond between the trim and the end sheets. Such an embodiment can be seen in FIG. 6. End panel trim 200 comprise end sheets 240, trim 280 (comprising skin 284 and trim body 286), foam 250, and shape pattern 270. Bumpers 290 can be disposed along the outer edge of the end sheets 240 such that they abut the trim body 286 and/or skin 284. Bumpers 290 can be located inside or outside of trim body 286 and skin 284. When located inside, bumpers 290 can provide an interference fit, so that the bond between the trim body 286 (and skin 284) and the end sheets 240 is strengthened. Bumpers can also help prevent the entry of foreign substances, such as water, into the trim 280. Bumpers located outside of the trim body 286, abutting the skin 284, can also help protect against the entry of foreign substances. Bumpers 290 can comprise a rubber, plastic, or another appropriate material for sealing the trim 280.

[0027] The polyurethane foam used within the panels of the present disclosure can comprise standard polyurethane than can be poured and/or injected in liquid form, as known in the prior art. The liquid then cools and forms a foam. Other materials with similar properties (e.g. a hard setting foam/liquid) could also be used.

[0028] The trim skin and trim body can comprise PVC. In a preferred embodiment the skin is virgin PVC and the trim body is recycled PVC. The combined skin and body can be constructed through a co-extrusion process. Other embodiments could use virgin PVC for both the skin and body, or recycled PVC for both the skin and body. Such embodiments could use a single extrusion process.

[0029] FIG. 8 displays a possible method embodiment 800 for creating an end panel under the present disclosure. At 810, two end sheets are provided. At 820, a trim piece is extruded that comprises a body portion and a skin portion, and further comprises receiving recesses for end sheets and also a shape pattern. At 830, the trim piece is attached to the two end sheets by inserting the end sheets into the recesses, and surrounding substantially all of the end sheets' perimeter with the trim piece to create a hollow panel. At 840, polyurethane liquid is poured or injected into the hollow panel such that the shape patterns are filled. At 850, the polyurethane liquid is allowed to solidify into foam.

[0030] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.