Butyl-Free Multi-Gasket Panel Joint

Abstract

An insulated panel system includes a joint disposed between two insulated panels. The joint includes a gasket for increasing the efficiency of walk-in refrigerator and freezer spaces. A butyl-free gasket having a plurality of protrusions may be disposed between a first insulated panel, having a male portion, and a second insulated panel, having a female portion. A latch mechanism, disposed in part in the two insulated panels, operably engages to bring the male portion of the first insulated panel into a sealing engagement with the female portion of the second insulated panel, with the gasket disposed therebetween. The plurality of protrusions of the gasket are compressed between the male and female portions of the first and second panels, such that a plurality of sealing junctions are formed between the first and second panels.

Claims

1. An insulated panel system, comprising: a butyl-free gasket having a plurality of protrusions; a first insulated panel having a male portion with a first part of latch mechanism disposed within the first insulated panel; a second insulated panel having a female portion with a second part of latch mechanism disposed within the second insulated panel, wherein the first part of the latch mechanism in the first insulated panel operably engages with the second part of the latch mechanism in the second insulated panel to bring the male portion of the first insulated panel into a sealing engagement with the female portion of the second insulated panel, with the gasket disposed therebetween, and wherein the plurality of protrusions of the gasket are compressed between the male and female portions of the first and second panels, such that a plurality of sealing junctions are formed between the male portion of the first panel and the female portion of the second panel.

2. The insulated panel system of claim 1, wherein the butyl-free gasket includes three or more protrusions.

3. The insulated panel system of claim 1, wherein the protrusions are rounded.

4. The insulated panel system of claim 1, wherein the protrusions are pointed.

5. The insulated panel system of claim 1, wherein the butyl-free gasket is operably secured to the male portion of the first insulated panel.

6. The insulated panel system of claim 1, wherein the butyl-free gasket is operably secured to the female portion of the second insulated panel.

7. The insulated panel system of claim 1, wherein the butyl-free gasket is operably secured to both the female portion of the second insulated panel and the male portion of the first insulated panel.

8. The insulated panel system of claim 7, wherein the protrusions of the butyl-free gasket on the female portion of the second insulated panel are offset between the protrusions of the butyl-free gasket on the male portion of the first insulated panel.

9. The insulated panel system of claim 1, wherein the first part of the latch mechanism of the first insulated panel extends into an opening in the second insulated panel to operably engage the second part of the latch mechanism disposed within the second insulated panel to bring the male portion of the first insulated panel into a sealing engagement with the female portion of the second insulated panel.

10. The insulated panel system of claim 1, wherein the second part of the latch mechanism of the second insulated panel extends into an opening in the first insulated panel to operably engage the first part of the latch mechanism disposed within the first insulated panel to bring the male portion of the first insulated panel into a sealing engagement with the female portion of the second insulated panel.

11. A locking joint for securing insulated veneer panels to an existing structural panel wall, comprising: a butyl-free gasket having a plurality of protrusions; a male portion and a female portion, wherein the male portion comprises a top plate that terminates at its edge with a sealing flange, and a strut operable to be inserted into the female portion; the female portion comprises a flange, sidewall, and base, and wherein the flange of the female portion is operable to overlap an edge of an adjacent veneer panel, and the sidewall is operable to abut the edge of the adjacent veneer panel, and the base is operable to rest against an existing insulated structural panel, and wherein the gasket is disposed on the flange of the female portion such that the plurality of protrusions of the gasket are adapted to sealably compress between the flange and the veneer panel.

12. The locking joint of claim 11, wherein the butyl-free gasket includes three or more protrusions.

13. The locking joint of claim 11, wherein the protrusions are rounded.

14. The locking joint of claim 11, wherein the protrusions are pointed.

15. The locking joint of claim 11, wherein the male strut comprises louvres operable to securely engage louvres disposed on the surface of the sidewall of the female portion to secure the male portion to the female portion.

16. A sealing joint for use with an insulated structural panel wall, comprising: a butyl-free gasket having a plurality of protrusions; and two lateral plate members connected by a vertical member that runs longitudinally between the lateral members, with an opening disposed in the vertical member operable to allow a latch mechanism disposed within the body of a first insulated structural panel to protrude therethrough to engage a latch bar disposed within a second insulated structural panel to secure the two insulated structural panels together, and wherein the engagement of the latch and latch bar brings the first and second insulated structural panels in sealing engagement with the gasket disposed on one or more sides of the vertical member such that the plurality of protrusions of the gasket sealably couple the vertical member between the first and second insulated structural panels.

17. The sealing joint of claim 11, wherein the butyl-free gasket includes three or more protrusions.

18. The sealing joint of claim 11, wherein the protrusions are rounded.

19. The sealing joint of claim 11, wherein the protrusions are pointed.

20. The sealing joint of claim 11, wherein the vertical member is shaped to engage contours of the first and second insulated structural panels.

21. A sealing joint for use with an insulated structural panel wall, comprising: two lateral plate members connected by a vertical member that runs longitudinally between the lateral members, an opening disposed in the vertical member operable to allow a latch mechanism disposed within the body of an insulated structural panel to protrude therethrough to engage a latchbar disposed within an adjacent insulated structural panel to secure the two insulated structural panels together, and wherein the engagement of the latch and latch bar brings the adjacent insulated structural panels in sealing engagement with the sealing joint disposed therebetween, and wherein the lateral plate members contact the surface of the insulated structural panel.

22. The sealing joint of claim 21, further comprising, a sealing flange disposed at the edge of the plate member, wherein the sealing flange is operable to engage the surface of one of the insulated structural panels.

23. The sealing joint of claim 21, wherein the lateral plate members are of substantially similar dimensions.

24. The sealing joint of claim 18, wherein the lateral plate member in contact with an exterior surface of the insulated structural member is wider than the lateral plate member in contact with an interior surface of the insulated structural member.

25. A method for sealing a joint between two insulated structural panel walls, comprising: disposing a sealing joint between two adjacent insulated structural panels; and actuating a latch mechanism disposed within one of the adjacent insulated structural panels such that it engages a latch bar of the adjacent structural panel, wherein the sealing joint comprises two lateral members connected by a vertical member that extends the length of the lateral members, an opening in the vertical member operable to allow the latch mechanism to engage the latch bar.

26. The method of claim 25, wherein the sealing joint further comprises a sealing flange at an edge of at least one of the lateral members operable to sealably contact the surface of at least one of the insulated structural panels.

27. The method of claim 25, wherein the opening is created by the actuation of the latching mechanism.

28. The method of claim 25, wherein the engagement of the latch bar by the latching mechanism draws the adjacent insulated structural panels in to sealed contact with the sealing joint.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1A shows traditional insulated structural in accordance with the prior art;

[0009] FIG. 1B shows traditional insulated structural panels joined together to form an insulated structural wall;

[0010] FIG. 1C shows a latch and latch bar mechanism used to joint together insulated structural panels;

[0011] FIG. 1D is a perspective component view of a deconstructed insulated structural panel system, with a butyl-free gasket having a plurality of protrusions, in accordance with the claimed invention;

[0012] FIG. 2A shows an insulated veneer system installed on the exterior surface of a traditional insulated structural panel wall;

[0013] FIG. 2B shows the locking joint used to secure insulated veneer panels to the exterior surface of an insulated structural panel wall;

[0014] FIG. 3A shows the components of a locking joint to secure the insulated veneer panels;

[0015] FIG. 3B shows the locking joint of FIG. 3A installed on an exterior surface of an insulated structural panel;

[0016] FIG. 3C is a cross-sectional view of the components of a locking joint, with a butyl-free gasket;

[0017] FIG. 4 shows an alternative embodiment of a locking joint;

[0018] FIG. 4A is a cross-sectional view of the components of an alternative embodiment of a locking joint with a butyl-free gasket;

[0019] FIG. 5 shows a perspective view of an I-beam insulator seal in accordance with an embodiment of the present invention;

[0020] FIG. 5A is a perspective view of the I-beam insulator seal shown in FIG. 5, with a butyl-free gasket, in accordance with an embodiment of the present invention;

[0021] FIG. 6 shows a cross-sectional view of the I-beam insulator seal shown in FIG. 5, in accordance with an embodiment of the present invention;

[0022] FIG. 6A shows a cross-sectional view of an I-beam insulator seal shown in FIG. 6, with a butyl-free gasket, in accordance with an embodiment of the present invention;

[0023] FIG. 7 shows an insulator seal installed between the joints of insulated structural panels;

[0024] FIG. 8A is a perspective view of a portion of butyl-free gasket having a plurality of substantially rounded protrusions;

[0025] FIG. 8B is a perspective view of a portion of a butyl-free gasket having a plurality of substantially triangular protrusions; and

[0026] FIG. 8C is a perspective view of a portion of a butyl-free gasket having a plurality of substantially rectangular protrusions.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The present invention is directed to systems and methods of maintaining the insulative properties of insulated structural panels. FIGS. 1A and 1B FIG. 1 generally shows an insulated structural panel system that, when joined together, form a wall for a pre-defined or custom-built refrigerated space. In FIG. 1, for example, two un-joined insulated structural panels 20 are shown as part of an insulated structural wall 10. Each structural panel 20 is constructed of vertical structural members 22 and horizontal structural members 24. 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, or other suitable sheathing material, which is held into place while an insulating material, such as closed-cell polyurethane foam (not shown) is 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 design such that the polyurethane foam 28 securely bonds to metal the sheathing 26, the vertical structural members 22, and horizontal structural members 24, creating a rigid structural panel 20. The vertical structural members 22 can include male and female portions to form a tongue-in-groove design. A latch 30 and latch-bar 32, or other suitable connecting hardware is typically disposed within the panel to facilitate joining the panels together. When the latch 30 is actuated to engage the latch-bar 32, for example, the insulated structural panels are drawn tightly together, as shown in FIGS. 1B and 1C.

[0028] The width of the structural panel 20 may be determined by the application for which the insulated structural panels are to be used. The insulated polyurethane structural panels 20 have a typical thermal resistance (R-value) of R-8 per inch. Typically, insulated structural panels that are 3 to 6 inches in width, have corresponding R-values of R-24 to R-48. The structural members 22 and 24, however, when constructed of wood, only have a total R-value of R-3 to R-6. Because of the poor insulative properties of structural panels manufactured with wood structural members 22, more warm air moves toward the lower-pressure refrigerated space predominantly at joint between the structural panels 20. The warming of the refrigerated space causes the cooling system to work harder and expend more energy, while the frost between the joints may ultimately result in the structural panels 20 being pushed apart or the structural members them self otherwise degraded. 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.

[0029] In the embodiment shown in FIG. 1D, the insulated structural panel system includes a butyl-free gasket 16 having a plurality of protrusions. In a preferred embodiment, gasket 16 is made out of a resilient polyether urethane material, but gasket 16 can also be made of polyester urethane material. The gasket 16 is also preferably resistant to chemical corrosion and ultraviolet radiation. The plurality of protrusions of gasket 16 can have substantially rounded, triangular, rectangular, or other suitable profiles, as shown in FIGS. 8A, 8B, and 8C, respectively. The gasket 16 is disposed between the structural panels 20 to mitigate water vapor permeability therebetween. In a preferred embodiment, the gasket 16 runs the length of both sides of a male portion of a vertical structural member to compressably seal between two structural panels 20 together to form the structural wall 10. Advantageously, due to the plurality of protrusions of the gasket 16, a plurality of sealing junctions are formed to provide multiple junctions to prevent the ingress of ambient air or liquid into the joint. The gasket 16 can be placed along any portion of the structural panel 20, where a seal is desired. The gasket 16 is preferably disposed onto the vertical structural members 22 with adhesive or other suitable material. The gasket 16 can have the adhesive pre-applied to minimize the mess and waste associated with manual adhesive application methods.

[0030] FIGS. 2A and 2B show an embodiment of the veneer system in accordance with the present invention. Veneer panels 50 are preferably overlayed the existing structural panels 20. Once in place, the veneer panels 50 are secured in place by locking joints 60. Additionally, veneer panels may be secured to structural panels 20 through the use of an appropriate adhesive, such as construction adhesive, epoxy, or other suitable gluing substance (not shown). Preferably, the locking joints 60 are off-set from the joints of structural members 22. This off-set protects the joints at structural members 22 from exposure to ambient air, thus reducing the likelihood of the formation of condensate at the joint. The veneer panels 50 may be of any desired thickness. Preferably, the locking joint 60 (as described below) is of substantially similar depth as the thickness of veneer panels 50.

[0031] FIGS. 3A and 3B illustrate the locking joints in accordance with one embodiment of the invention. The locking joint 60 is comprised of a capped male insert 100 and a flanged female joint 200. The capped male insert 100 preferably includes a top plate 110, struts 112, and locking louvres 116. Additionally, the capped male insert includes seals 114 at the lateral edges of capped top plate 110. Seals 114 are preferably designed to fit against veneer panels 50 to reduce the amount of outside air that ingresses through the joint between veneer panels 50 and within the locking joint 60. The seals 114 also provide a barrier that reduces the likelihood that water or cleaning materials will enter the system, e.g., through high pressure spraying and washing. The seals 114 may be of the same material as the top plate 110 and struts 112, or may be of a softer material. In various embodiments, the seals may be constructed so that, when pressed against the face of veneer panels 50, the seals 114 deform to provide a tighter seal from the ingress of water and ambient air.

[0032] Flanged female joint 200 is constructed to fit between two veneer panels 50. In practice, it is preferable, though unnecessary, for the joint 200 to abut the edges of veneer panels 50. In one embodiment, the base 214 of flange joint 200 is sufficiently wide to allow a fastener 220 to secure the flange joint 200 to a structural panel 20. In the embodiment shown, the fastener 220 is a screw, though other suitable fasteners will be apparent to one of ordinary skill in the art. In the embodiment shown, the flanged female joint 200 is constructed as a single piece, including flanges 210, sidewalls 212, and base 214. Sidewalls 212 include integral louvres 216 designed to lockably engage louvres 116 of struts 112 of capped male insert 100. While locking louvres 116, 216 are shown, other suitable methods to join parts 100 and 200 may be used, such as other mechanical joints, adhesive, or fasteners, such as clips or screws.

[0033] The veneer panels 50 are positioned such that they are adjacent to flanges 210 and sidewalls 212. When the female flanged joint 200 is fastened to a structural panel 20, with veneer panels 50 fully inserted behind the flange, the female flange joint 200 holds the veneer panels in place. Capped male insert 100 is then inserted into the flanged female joint 200 such that louvres 116 engaged louvres 216 to lock the capped male insert in place, and so that seals 114 are in contact with the surface of veneer panels 50 to prevent ambient air or liquid from ingress into the joint between the veneer panels 50 or structural panels 20.

[0034] As shown in FIG. 3C, a butyl-free gasket 16 may be disposed to the underside of flanges 210. The gasket is preferably disposed onto the flanges 210 with adhesive or other suitable material. The gasket 16 can have the adhesive pre-applied to minimize the mess and waste associated with manual adhesive application methods. The pre-applied adhesive allows for ease of application, dry-joint application, and no wasted time to allow for adhesive drying. When female joint 200 is secured to structural panel 20 to hold the veneer panels 50 in place, the gasket 16 is compressed between the veneer panel 50 and the flange 210. Due to the plurality of protrusions of the gasket, a plurality of sealing junctions are formed to prevent the ingress of ambient air or liquid into the joint. The gasket 16 can be placed along any portion of the female flanged joint 200, where a seal is desired. Alternatively, the gasket 16 can be placed on the bottom side of capped male insert 100.

[0035] FIG. 4 shows a cross-sectional view of the components of an alternative embodiment of a locking joint. In this embodiment, locking joint 70 includes a prefabricated fastener 220 that protrudes beyond base 214 to fit into a pre-fabricated receptacle or pre-drilled hole in structural panel 20. The capped male insert 100 includes a top plate 110, a strut 112, and seals 114. Additionally, the strut 112 includes locking louvres 116 on both sides of the strut 112. The flanged female joint 200 includes a narrower space sized to accept the strut 112, and includes locking louvres 216 similar to the louvres 216 of FIGS. 3A and 3B. The design of FIG. 4 has the advantage of eliminating the air gap between struts 112 of FIGS. 3A and 3B.

[0036] As shown in FIG. 4A, a butyl-free gasket 16 can be disposed to the underside of flanges 210. The gasket 16 is preferably disposed onto the flanges 210 with adhesive or other suitable material. When female joint 200 is secured to structural panel 20 to hold the veneer panels 50 in place, the gasket 16 is compressed between the veneer panel 50 and the flange 210. Due to the plurality of protrusions of the gasket, a plurality of sealing junctions are formed to prevent the ingress of ambient air or liquid into the joint. The gasket 16 can be placed along any portion of the female flanged joint 200, where a seal is desired. Alternatively, the gasket 16 can be placed on the bottom side of capped male insert 100.

[0037] In another embodiment of the present invention, a structural seal 300 is provided in FIGS. 5 through 7 for disposition between structural panels 20 to further reduce the loss of refrigeration from inside a refrigerated enclosure bounded by insulated structural panels 20 and to prevent condensation from contact from cooler air leaking through the joint with warmer ambient air on the outside of such structure.

[0038] As shown in FIGS. 5 and 6, the structural seal 300 of the present embodiment includes lateral members 310 that terminate on either end at sealing edges 314. A vertical member 312 is disposed between the lateral members 310. Preferably, the depth of the vertical member 310 is such that the interior portions of lateral members 310 are in contact with the sheathing 26 of insulated structural panels 20. Additionally, an opening or slit 316 is disposed within the vertical member 312 that corresponds to the location of the one or more latches 30 and latch-bars 32 that connect structural panels 20 to one another. During operation, the structural seal 300 is disposed between two insulated structural panels 20. When the latch 30 is engaged with latch-bar 32 to bring the panel joints snug to one another, the panels are brought into sealing contact with vertical member 312 to reduce the likelihood of refrigerated air from within a refrigerated space bounded by structural panels 20 coming into contact with ambient air on the exterior, and to prevent unwanted condensation from forming between the structural panels 20. The lateral members 310 are preferable disposed directly against the sheathing 26 to extend the portion of the seal beyond the joint between structural members 22 to move the potential for leaked air further from the joint itself.

[0039] FIGS. 5A and 6A show that a butyl-free gasket 16 may be disposed to the underside of flanges 210. The gasket 16 is preferably disposed onto the flanges 210 with adhesive or other suitable material. When the structural seal 300 is inserted between two structural panels 20, as the latch 30 is engaged with latch-bar 32 to bring the structural panels 20 into sealing contact with one another, the gaskets 16 disposed on either or both sides of vertical member 312 are compressed to form a plurality of sealing junctions therebetween. Due to the plurality of protrusions of the gasket, a plurality of sealing junctions are formed to prevent the ingress of ambient air or liquid into the joint. The gasket 16 can be placed along any portion of the structural seal 300, where a seal is desired.

[0040] FIGS. 8A, 8B, and 8C show alternative embodiments of the gasket 16 protrusions. The protrusions can have identical dimensions or varying dimensions to suit a specific requirement. 6A shows a cross-sectional view of a butyl-free gasket having a plurality of substantially rounded protrusions. 6B shows a cross-sectional view of a butyl-free gasket having a plurality of substantially triangular protrusions. 6C shows a cross-sectional view of a butyl-free gasket having a plurality of substantially rectangular protrusions.

[0041] The present invention achieves several advantages over the prior art. First, butyl has to be mechanically applied as a bead to the panel, otherwise there will be frost and icing issues. If frost enters a joint, the cooled space must be defrosted and resealed. Importantly, the cooled space is never the same. The present invention simplifies the application process to save time and money and prevent downtime. Second, over time, the butyl bead dries out and thins allowing the ingress of air and liquid. The present invention overcomes those issues via its gasket composition. Perhaps most importantly, the present invention provides multiple sealing joints to mitigate the ingress of air and liquids. Should air or liquid penetrate the first sealing joint, additional sealing joints remain between the air or liquid and the joint.

[0042] Any of the inventions disclosed herein, such as locking joints 100 and 100 or structural seal 300 may be constructed of any number of deformable polymers with varying degrees of stiffness. Examples of polymers that may be used in accordance with the present invention include, but are not limited to, PVC, plastics, nylons, or other suitable materials that are deformable when placed under a stress load.

[0043] 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.