Modular frame and enclosure system

Abstract

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

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to provisional application Ser. No. 60 / 581,999 filed Jun. 22, 2004.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH [0002] Not applicable. BACKGROUND OF THE INVENTION [0003] Enclosures are used for a number of applications, including three general categories: to provide environmental protection of equipment; to provide a rack or mounting space in which to mount equipment such as computer equipment; and to enclose controls for the utility and energy industries. The enclosure industry is very broad in terms of specific enclosure applications and configuration of the enclosure to house particular products. Broad categories of product configurations include large freestanding units, wall mount units, junction boxes, instrument housings, consoles, operator interfaces and kiosks. [0004] The market in the United States alone for industrial enclosure applications is estimated to exceed $1 billion annually, with ...

AI Technical Summary

Benefits of technology

[0014] The invention is embodied in a method of making a frame comprising the steps of providing two or more linear frame members exhibiting frame contact peripheries at the ends and a frame cross-section presenting at least one contact edge along the axis of the frame edges. An additional embodiment of the invention are one or more transition members that form a junction and or corner connection between linear frame components. Ideally, the transition member will exhibit a contact periphery in at least two contact planes. The invention is embodied in aligning a frame contact periphery of a frame member with a first edge profile and abutting a linear frame member to a first contact surface of a transition member, aligning a frame contact periphery with a second edge profile and abutting a linear frame member to a second contact surface of a transition member and then aligning a frame contact periphery with a third edge profile and then abutting a linear frame member to a third contact surface of a transition member. By reiterating the aligning and coupling steps, a three dimensional frame can be constructed according to the invention, utilizing transition members with four or more contact surfaces.

[0015] The invention is embodied in a means for connecting and aligning transition members and frame members by providing one or more stud connectors each having first and second connector portions in a more or less linear orientation. Linear frame members are provided with two or more with frame connector cavities extending axially and mutually inwardly from the frame contact ends. Another embodiment of the invention is the connection of frame members to transition members each being configured with a transition connector cavity extending axially inwardly from first, second, third and or fourth contact surfaces. Thus the steps of aligning and coupling a transition member with frame members can be carried out by inserting a stud connector first connector portion within a frame connector cavity and inserting said stud connector second connector portion within a said transition connector cavity. Alignment and permanent connection are embodied in the use of connector clips and locking spacer collars.

[0016] The invention is also embodied in a transition member or frame member being configured having an outwardly dis

Problems solved by technology

One difficulty for manufacturers is shipping enclosures is that an assembled enclosure has a very high space to weight ratio.

Therefore shipping and handling of assembled enclosures is problematic, as shipping assembled enclosures requires substantial volume.

As manufacturers attempt to ship more compact, disassembled components to order minimize shipping costs, there is an efficiency trade-off for the end user, who must either pay to have a technician assemble the enclosure, or assemble the enclosure on site, where time, tool availability, and mechanical skill may limit the ability of the end user to configure an enclosure product in an optimal manner.

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

Performance of enclosures utilizing modular construction is limited relative to “unibody” free-standing enclosures with regards to structural rigidity, weight capacity, and other logistical requirements.

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