Note: Descriptions are shown in the official language in which they were submitted.
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MOLDED WALL UNIT INCLUDING A CORNER BRACKET
Background and Summary
[0001] The present invention relates generally to molded wall panels and,
more
particularly, to molded wall panels with connecting brackets for use in
bathroom tub and shower
installations.
[0002] It is well known to provide tub and shower wall panels molded from
a polymer to
simulate ceramic tile. More particularly, such wall panels typically include
indentations between
adjacent rectangular raised portions to simulate grout lines between adjacent
tiles. However,
such molded wall panels often fail to closely resemble ceramic tiles with
conventional grout
lines. Additionally, such molded wall panels typically provide a limited
number of design
options.
[0003] Consumers would like to have the ability to customize their tub and
shower walls,
but often cannot afford a complete tile installation. While many consumers
would prefer to have
ceramic tile installations, this is often prohibitive due to cost and
installation time.
[0004] As such, it is desired to provide cost effective, molded wall
panels that more
closely resemble the appearance of traditional ceramic tile and authentic
grout lines, and that are
simple to install. Additionally, it is desired to provide such molded wall
panels that include a
variety of design options that may be customized by the user.
[0005] According to an illustrative embodiment of the present disclosure,
a corner
bracket for a shower enclosure includes an outer receiver including an outer
receiver body
defining first outer recess configured to receive a first wall panel, a second
outer recess
configured to receive a second wall panel, and a center recess positioned
intermediate the first
outer recess and the second outer recess. An insert is operably coupled to the
outer receiver, the
insert including an inner sealing body received within the center recess of
the outer receiver
body. A locking device is supported by the outer receiver body and the inner
sealing body, the
locking device configured to secure the inner sealing body to the outer
receiver body.
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[0006] According to another illustrative embodiment of the present
disclosure, a corner
bracket for a shower enclosure includes an outer receiver coupled to a first
mounting stud and a
second mounting stud. A body of the outer receiver is formed of a first
material and includes a
first inner arm, a first middle arm, and a first outer arm. The body also
includes a second inner
arm, a second middle arm, and a second outer arm. The first outer arm and the
first middle arm
define a first recess, the second outer arm and the second middle arm define a
second recess, and
the first inner arm and the second inner arm define a third recess. Both the
first inner arm and
the second inner arm have a plurality of raised surfaces extending into the
third recess. The
corner bracket also includes a first wall panel received within the first
recess, a second wall panel
received within the second recess, and an inner sealing body including a
locking device that is
received within the third recess and coupled to the body by the plurality of
raised surfaces.
[0007] In a further illustrative embodiment of the present disclosure, a
method of
forming a bathroom wall unit includes the steps of mounting a corner bracket
to a wall stud,
coupling a first wall panel to the corner bracket within a first recess of the
corner bracket, and
coupling a sealing body to the corner bracket and the first wall panel such
that a fluid tight seal
exists at the interface of the first wall panel and the sealing body.
[0008] Additional features and advantages of the present invention will
become apparent
to those skilled in the art upon consideration of the following detailed
description of the
illustrative embodiment exemplifying the best mode of carrying out the
invention as presently
perceived.
Brief Description of the Drawings
[0009] The detailed description of the drawings particularly refers to the
accompanying
figures in which:
[0010] FIG. 1 is a perspective view of an illustrative shower enclosure
including wall
units of the present disclosure;
[0011] FIG. 2 is a perspective view, with partial cut-aways, of a wall
unit of FIG. 1;
[0012] FIG. 3 is an exploded perspective view, with partial cut-aways, of
the wall unit of
FIG. 2;
[0013] FIG. 4A is a flow chart of an illustrative method of manufacturing
the wall unit of
FIG. 2;
[0014] FIG. 4B is a flow chart of an illustrative casting method of FIG.
4A;
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[0015] FIG. 5 is a perspective view of a further illustrative shower
enclosure including
wall units of the present disclosure;
[0016] FIG. 6 is an exploded perspective view of the shower enclosure of
FIG. 5;
[0017] FIG. 7 is a perspective view of the top corner between the wall
units of FIG. 5;
[0018] FIG. 8 is an exploded perspective view of the top corner of FIG. 7;
[0019] FIG. 9 is a top plan view of the top corner of FIG. 7;
[0020] FIG. 10 is a perspective view, in partial cross-section, of the
upper end of the
corner bracket of FIG. 7;
[0021] FIG. 11 is a top plan view of a further illustrative corner bracket
for use with the
shower enclosure of FIG. 5;
[0022] FIG. 12 is an exploded perspective view of a further illustrative
corner bracket for
use with a shower enclosure;
[0023] FIG. 13 is a cross-sectional view of the corner bracket of FIG.12
as used in a
shower enclosure;
[0024] FIG. 14 is a cross-sectional view of the outer receiver of the
corner bracket of
FIG. 12 as used in a shower enclosure;
[0025] FIG. 15 is a cross-sectional view of the outer receiver of a corner
bracket of FIG.
14 with mounted wall panels coupled thereto; and
[0026] FIG. 16 is a cross-sectional view of an inner sealing body being
inserted into the
outer receiver of the corner bracket of FIG. 12 in a shower enclosure.
Detailed Description of the Drawings
[0027] The embodiments of the invention described herein are not intended
to be
exhaustive or to limit the invention to precise forms disclosed. Rather, the
embodiments selected
for description have been chosen to enable one skilled in the art to practice
the invention.
[0028] Referring initially to FIG. 1, a shower enclosure 10 including
illustrative
bathroom wall units 12a, 12b of the present disclosure is shown. The shower
enclosure 10
supports a faucet 14 for controlling water flow through a showerhead 16. The
wall units 12a,
12b are illustratively supported by a wall 18 including mounting studs 20.
While the wall units
12 are shown for use with a shower enclosure 10, it should be appreciated that
the wall units 12
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may be used in a variety of installations, such as in connection with bath
tubs, vanities and
kitchens.
[0029] With reference to FIGS. 1-3, each wall unit 12 includes a molded
wall panel 22
including a front surface 24, a rear surface 26, a first side edge 28, a
second side edge 30, an
upper edge 32 and a lower edge 34. The front surface 24 and the rear surface
26 extend between
the first and second side edges 28 and 30. The front and rear surfaces 24 and
26 also extend
between upper and lower edges 32 and 34.
[0030] The molded wall panel 22 may be formed from a polymer,
illustratively a
thermoplastic such as acrylonitrile butadiene styrene (ABS). In certain
illustrative embodiments,
the front surface 24 may be generally smooth or planar. In other illustrative
embodiments, a
plurality of linear indentations 36 may be formed in the front surface 24. In
such embodiments,
a plurality of raised portions 38, illustratively of a polygonal shape, are
formed intermediate the
linear indentations 36. The linear indentations 36 are configured to simulate
grout lines, while
the raised portions 38 are configured to simulate conventional ceramic tile.
[0031] The linear indentations 36 illustratively include a plurality of
horizontal
indentations 36a and a plurality of vertical indentations 36b. As such, the
raised portions 38 are
illustratively of a rectangular shape. In one illustrative embodiment, the
raised portions 38 are
squares, such as 4 inch x 4 inch squares or 6 inch x 6 inch squares to
simulate conventional
ceramic tile dimensions. The polymer of the wall panel 22 may also be capped
with a patterned
film (e.g., marble, etc.) to create a more realistic tile-like appearance.
[0032] In the illustrative embodiment, a recessed pocket 40 is formed
within the wall
panel 22. The recessed pocket 40 illustratively includes a rear wall 42, a
bottom wall 44 and a
top wall 46. The recessed pocket 40 illustratively has a depth (d) of
approximately 0.38 inches
to receive conventional ceramic tiles, such as a mosaic tile assembly 50. The
tile assembly 50
illustratively includes individual ceramic tiles 52 of conventional size and
shape, as further
detailed herein. While ceramic tiles are illustratively used in the tile
assembly 50, other
materials may be substituted therefor, such as glass or stone.
[0033] The height (h) of the recessed pocket 40 may vary depending upon
the size, shape
and number of mosaic tiles 52 to be inserted within the pocket 40. In an
illustrative embodiment,
the height (h) of the recessed pocket 40 is between 3 inches and 6 inches.
Illustratively, the
pocket 40 has a height (h) of approximately 6 inches to facilitate insertion
of conventional
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mosaic tile sheets (typically 12 inches by 12 inches). The mosaic tile sheets
would illustratively
be cut in half to a length of 12 inches and a height of 6 inches for insertion
within the pocket 40.
[0034] Illustratively, the pocket 40 extends the full width of the wall
panel 22 between
the first and second side edges 28 and 30 (i.e., open ends). In alternative
embodiments, the
pocket 40 may not extend the full width of the wall panel 22 and terminate
prior to one or both of
the side edges 28 and 30 (i.e., closed end(s)).
[0035] Illustratively, the mosaic tiles 52 are supported on a flexible
substrate, such as a
mesh backing 54. The mesh backing 54 and tiles 52 are adhered to the rear wall
42 of the
recessed pocket 40 through conventional means, such as an adhesive 56. Once in
position, a
finish grout 58, such as an acrylic, may be used to fill in the gaps between
adjacent mosaic tiles
52. The tile assembly 50 may be provided with the wall panel 22 as a kit.
Alternatively, the tile
assembly 50 may be acquired separately by the installer to facilitate
customization as desired by
the end user.
[0036] Reinforcing ribs 60 may be supported by the rear surface 26 of the
wall panel 22
to further support the wall panel 22 and provide additional rigidity. The ribs
60 may be spaced at
various locations to align with mounting studs 20. In one illustrative
embodiment, the ribs 60
may be integrally molded with the wall panel 22. Inserts 62, such as Styrofoam
panels may be
coupled to the rear surface 62 of the wall panel 22 for additional support
through contact with
wall studs 20. In one illustrative embodiment, the inserts 62 may be
positioned intermediate the
ribs 60.
[0037] In certain illustrative embodiments, inwardly extending pockets may
be formed
within the linear indentations 36 of the wall panel 22 to receive conventional
grout (not shown).
For example, the installer may fill the pockets with grout in a manner similar
to conventional
ceramic tile.
[0038] In other illustrative embodiments, simulated grout 64 may be formed
within the
front surface 66 of linear indentations 36 between adjacent raised portions 38
in the wall panel
22. More particularly, the linear indentations 36 may be surfaced treated in
order to provide for
the appearance of simulated grout 64. As further detailed herein, in one
illustrative embodiment
the surface 66 is treated through a laser etching process. In another
illustrative embodiment, the
surface 66 is treated through a sand blasting process. In yet another
illustrative embodiment, a
polymeric colored film may be applied to the surface 66 to define the
simulated grout 64.
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[0039] In the laser etching process, the surface 66 of linear indentations
36 are etched
with a laser to turn the simulated grout 64 a different color. The settings of
the laser (e.g.,
intensity, duration) may be modified or varied to obtain different colors of
the simulated grout
64. For example, the simulated grout 64 may be gray, brown or black depending
upon the laser
settings. Additives may be added to the polymer of the wall panel 22 to cause
the laser to change
the simulated grout 64 to a variety of different colors, such as red, blue,
etc. Additionally, the
laser may be adjusted to create textures within the polymer of the wall panel
22. In other words,
the surface 66 may be roughened by the laser in order to provide a grout-like
texture.
[0040] In the sand blasting process, a sand or bead blast is utilized to
create a grout
pattern in the linear indentations 36 of the wall panel 22. Areas of the wall
panel 22 that should
not be affected (e.g., raised portions 38) may be masked with a fixture. The
sand or beads
etched/embed within the polymer of the indentations 36 and turn it to a
different color. By
changing the color of the sand, different grout colors may be provided (e.g.,
black, gray, brown,
etc.). The size of the sand/bead grains may also be adjusted to create
different textures.
[0041] With reference to FIGS. 1, 4A and 4B, in an illustrative method of
manufacturing
100, the wall panel 22 is formed at block 102, illustratively through applying
a thermoplastic,
such as ABS, within a mold. The wall panel 22 is molded to define the linear
indentations 36
and raised portions 38, along with the recessed pocket 40. In one illustrative
embodiment, the
wall panel 22 may be molded through a thermoforming process.
[0042] With reference to the illustrative panel molding process of FIG.
4B, the mold for
forming the wall panel 22 may be formed by using a traditional ceramic tile
assembly or wall as
a pattern or template. More particularly, at block 112 a ceramic tile assembly
or wall is
illustratively formed by setting and grouting individual ceramic tiles on a
horizontal support
surface. A mold is illustratively cast at step 114. More particularly, a fluid
material, such as a
resin, urethane, aluminum, etc. is cast over the finished ceramic tile
assembly at block 114a. The
fluid material then sets or hardens at block 114b. The ceramic tile assembly
is removed from the
set or hardened material at block 114c. The resulting "negative" impression
defined by the set
material defines a mold used for forming the wall panel 22. Any additional
desired details (e.g.,
recessed pocket 40) may be created within the mold, illustratively through
machining, at block
114d.
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[0043] In an illustrative thermoforming process at block 116, the wall
panel 22 is formed
from polymer applied to the mold to capture the shape, form and texture
(including surface
irregularities and/or cavities) of the ceramic tile assembly. The result is a
formed wall panel 22
that looks like the original pattern with all of the irregularities or
imperfections of the ceramic
tile assembly, including the tiles, grout and the human interaction in laying
the tile.
[0044] At block 104 of FIG. 4A, surface treatment is applied to the front
surface 66 of
linear indentations 64 to define simulated grout 64. Such surface treatment
may be sand blasting
and/or laser etching, as further detailed herein.
[0045] At block 106 of FIG. 4A, adhesive 56 is applied to the rear wall 42
of the recessed
pocket 40 and the tile assembly 50 is secured to the rear wall 42. At block
108, finish grout 58,
such as acrylic, may be applied to the tile assembly 50 after it has set to
the rear wall 42.
[0046] The rear surface of the wall panel 22 illustratively includes
mounting members,
such as the ribs 60, to bring the panel 22 equal to the wall studs 20 for
direct mounting to the
studs 20. A hole may be drilled through the rear wall 42 of the recessed
pocket 40 at the center
of the stud 20. The wall panel 22 is then secured to the stud 20 to provide
additional rigidity to
the recessed pocket 40. A silicone is illustratively applied to seal the
opening. Conventional
mounting flanges proximate upper and lower edges 32 and 34 may receive
fasteners to secure the
wall panel 22 to wall studs 20.
[0047] With further reference to FIGS. 5-10, a further illustrative shower
enclosure 210
is shown as including many similar components as the shower enclosure 10
detailed above. As
such, similar components will be identified with like reference numbers. The
illustrative shower
enclosure 210 includes bathroom wall units 212a, 212b illustratively supported
by wall 18 above
a base 213 having a drain 215. Translucent shower partitions (not shown) may
be supported
above the base 213. Mounting channels 217 may receive edges of the shower
partitions.
[0048] Each wall unit 212 includes a molded wall panel 222 including a
front surface
224, a rear surface 226, a first side edge 228, a second side edge 230, an
upper edge 232 and a
lower edge 234. The front surface 224 and the rear surface 226 extend between
the first and
second side edges 228 and 230 and the upper and lower edges 232 and 234. A
first mounting
flange 236 is supported by the first side edge 228, and a second mounting
flange 238 is
supported by the second side edge 230. Similarly, a third or upper mounting
flange 239 is
supported by the upper edge 232. The first mounting flange 236, the second
mounting flange
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238 and the upper mounting flange 239 are recessed from the front surface 224
of each wall
panel 222.
[0049] First and second wall panels 222a and 222b may be coupled together
through a
connecting bracket 240. Illustratively, the connecting bracket 240 includes a
body 242 having a
first pair of arms 244 and a second pair of arms 246. The first pair of arms
244 includes a first
inner arm 244a and a second outer arm 244b defining a first recess 248, while
the second pair of
arms 246 includes a second inner arm 246a and a second outer arm 246b defining
a second
recess 250. The first mounting flange 236 of the second wall panel 222b is
received within the
second recess 250, while the second mounting flange 238 of the first wall
panel 222a is received
within the first recess 248.
[0050] Illustratively, at least one seal 252 is supported by the
connecting bracket 240.
For example, at least one seal 252 may be supported by the first pair of arms
244, and at least
one seal 254 may be supported by the second pair of arms 246. A first inner
seal 252a is
illustratively supported by the first inner arm 244a, and a first outer seal
252b is illustratively
supported by the first outer arm 244b. Similarly, a second inner seal 254a may
be supported by
the second inner arm 246a, and a second outer seal 254b may be supported by
the second outer
arm 246b. As further detailed herein, the outer seals 252b and 254b may be
eliminated.
Furthermore, the outer arms 244b and 246b may be eliminated, wherein the inner
arms 244a and
246a trap the respective mounting flanges 238 and 236 of the wall panels 222a
and 222b against
the wall stud 20.
[0051] Illustratively, the body 242 of the connecting bracket 240 is
formed of a first
material, illustratively a polymer such as a polypropylene. The seals 252 and
254 are
illustratively formed of a second material, such as an elastomer or
thermoplastic vulcanizate
(SantopreneTM TPV). The second material is softer than the first material,
such that the seals 252
and 254 frictionally engage and provide effective fluid seals between the
mounting flanges 236
and 238 and the body 242 of the connecting bracket 240, while the body 242 of
the connecting
bracket 240 provides adequate support to the wall panels 222. Illustratively,
the first material
(e.g., polypropylene) has a hardness or durometer of approximately 75 shore D,
while the second
material (e.g., TPV) has a hardness or durometer of approximately 50 shore A.
Illustratively, the
body 242 of the connecting bracket 240 is co-extruded with the seals 252 and
254 to form a dual
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extrusion. More particularly, the polypropylene of the body 242 and the TPV of
the seals 252
and 254 bond together during the extrusion process.
[0052] While the illustrative embodiment details co-extruded body 242 and
seals 252,
254, it should be noted that the body 242 may be formed separately from the
seals 252, 254. For
example, the body 242 may be molded from a polymer or extruded from aluminum
with a pocket
to receive separately extruded seals 252, 254. The seals 252, 254 could then
be pressed into (or
otherwise secured within) the pockets of the body 242.
[0053] In one illustrative embodiment, the first arms 244 extend
substantially
perpendicular to the second arms 246, thereby defining a corner bracket 240. A
plurality of
openings 256 are illustratively formed within the body 242 to receive
fasteners (not shown) for
securing the bracket 240 to the wall 18. The bracket 240 illustratively
extends longitudinally
along the full height of the wall panel 222.
[0054] An upper trim or cap 260 may be secured to the upper end of the
wall panels 212a
and 212b, illustratively through a conventional adhesive. In certain
illustrative embodiments,
molded cooperating portions of the panels 222 may replace the cap 260.
[0055] In certain illustrative embodiments, an outer corner trim (not
shown) may cover
the exposed interface or corner joint between the wall panels 222 and extends
longitudinally
parallel to the corner bracket 240. Alternatively, the corner joint may be
sealed with a
conventional sealant or caulk.
[0056] A further illustrative corner bracket 240' is shown in FIG. 11 as
including many
similar features of corner bracket 240 detailed above. The corner bracket 240'
includes only
inner seals 252a and 254a supported by the inner arms 244a and 246a,
respectively. The inner
arms 244a and 246a include en.Otrant edges 262 and 264, illustratively curved
portions,
configured to assist in guiding the mounting flanges 238 and 236 of the wall
panels 222a and
222b into the recesses 248 and 250. Additionally, the outer arms 244b and 246b
include outer
portions 266 and 268 extending beyond the entrant edges 262 and 264 of the
inner arms 244a
and 246a, and are configured to receive fasteners, such as screws 270 to
secure to studs in the
wall 18.
[0057] Installation of the shower enclosure illustratively begins by
placing the base 213
within the rough-in corner defined by the wall 18. The base 213 is secured to
the wall 18 in a
conventional manner.
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[0058] In one illustrative method of installation, the corner bracket 240,
240' is next
secured to the wall 18, illustratively through an adhesive and/or screws 270.
The first wall panel
222a is secured to the bracket 240, 240', illustratively by lubricating the
mounting flange 238
with soap or lubricant and then sliding the flange 238 into the recess 248 of
the bracket 240,
240'. The wall panel 222a is then secured to the wall 18 by fasteners, such as
screws 270
inserted through upper and side mounting flanges 239 and 236. Next, the
mounting flange 236
of the second wall panel 222b is inserted within the recess 250 of the bracket
240, 240'. This
process is repeated for additional wall panels 222. Sealant or caulk is then
illustratively applied
along the corner and bottom joints.
[0059] In another illustrative method of installation, a user slides the
corner bracket 240,
240' onto the first wall panel 222a and then secures the assembly to the wall
18. More
particularly, the flange 238 is slid into the recess 248 of the bracket 240,
240'. Adhesive is
applied to the desired wall stud 20, and the wall panel 222a and bracket 240,
240' are pushed
into the rough-in corner. The wall panel 222a and bracket 240, 240' are then
secured to the wall
stud 20 illustratively through screws 270. Holes may be drilled through the
wall panel 222a and
bracket 240, 240' to facilitate insertion of the screws 270. Next, the
mounting flange 236 of the
second wall panel 222b is inserted within the recess 250 of the bracket 240,
240'. This process is
repeated for additional wall panels 222. The wall panels 222a and 222b are
then secured to the
wall 18 by fasteners, such as screws 270 inserted through upper and outer side
mounting flanges
239 and 236, 238. Sealant or caulk is then illustratively applied along the
corner and bottom
joints.
[0060] Referring now to FIGS. 12-14, another embodiment of an illustrative
corner
bracket 300 is shown within a shower enclosure 10. Corner bracket 300
illustratively includes an
outer receiver 301 and an insert 303. The illustrative outer receiver 301
includes an outer
receiver body 302 having a first trio of arms 304a-304c and second trio of
arms 306a-306c. First
outer arm 304c and first middle arm 304b define a first outer recess 326 (FIG.
14). Similarly,
second outer arm 306c and second middle arm 306b define a second outer recess
328 (FIG. 14).
The first middle arm 304b is angled away from the first outer arm 304c to
define a lead-in or
enlarged opening for the first outer recess 326, and the second middle arm
306b is angled away
from the second outer arm 306c to define a lead-in or enlarged opening for the
second outer
recess 328.
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[0061] First inner arm 304a and second inner arm 306a extend inwardly from
first middle
arm 304b and second middle arm 306b, respectively. First inner arm 304a and
second inner arm
306a define a center recess 330. The inner arms 304a and 306a angle outwardly
at open end of
center recess 330 to define a lead-in or enlarged channel to assist in
receiving the insert 303. The
first inner arm 304a, the first middle arm 304b, and the first outer arm 304c
are configured to
move or flex independently from each other. Similarly, the second inner arm
306a, the second
middle arm 306b, and the second outer arm 306c are configured to move or flex
independently
from each other.
[0062] First middle arm 304b and second middle arm 306b have seals 327,
329 attached
thereto respectively. Illustratively, body 302 of outer receiver 301 is formed
of a first material,
illustratively a polymer such as a polypropylene. Seals 327 and 329 are
illustratively formed of a
second material, such as an elastomer or thermoplastic vulcanizate
(SantopreneTM TPV). The
second material is softer than the first material, such that the seals 327 and
329 frictionally
engage and provide effective fluid seals between wall panels 340a, 340b and
body 302 of outer
receiver 301, while body 302 of outer receiver 301 provides adequate support
to the wall panels
340a, 340b. Illustratively, the first material (e.g., polypropylene) has a
hardness or durometer of
approximately 75 shore D, while the second material (e.g., TPV) has a hardness
or durometer of
approximately 50 shore A. Illustratively, body 302 of outer receiver 301 is co-
extruded with
seals 327 and 329 to form a dual extrusion. More particularly, the
polypropylene of body 302
and the TPV of seals 327 and 329 bond together during the extrusion process.
[0063] While the illustrative embodiment details co-extruded body 302 and
seals 327,
329, it should be noted that body 302 may be formed separately from the seals
327, 329. For
example, body 302 may be molded from a polymer or extruded from aluminum with
a pocket to
receive separately extruded seals 327, 329. The seals 327, 329 could then be
pressed into (or
otherwise secured within) the pockets of the body 302.
[0064] Illustrative corner bracket 300 also includes an inner sealing body
312 that is
coupled to body 302. More particularly, a locking device 317 is supported by
the outer receiver
body 302 and the inner sealing body 312, and is configured to secure the inner
sealing body 312
to the outer receiver body 302. Extending into recess 330 are a plurality of
raised projections
316a (FIG. 14) extending inwardly from first inner arm 304a and a plurality of
raised projections
316b extending inwardly from second inner arm 306a. The plurality of raised
projections 316a,
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316b of the outer receiver body 302 serve to frictionally engage with a
corresponding plurality of
raised projections 316c, 316d of the inner sealing body 312 and define locking
device 317, as
further described below. In one illustrative embodiment, the plurality of
raised projections 316
includes a plurality of ridges, teeth, or barbs that are angled along an axis
defined by direction A
(FIG. 16). In an alternative embodiment, the plurality of raised projections
316 are
perpendicular with respect to the outer surfaces of first and second inner
arms 304a, 306a.
[0065] Inner sealing body 312 illustratively includes a first body 336 and
a second body
338. Second body 338 of inner sealing body 312 is formed of a first material,
illustratively a
polymer such as a polypropylene. First body 336 is illustratively formed of a
second material,
such as an elastomer or thermoplastic vulcanizate (SantopreneTM TPV). The
second material is
softer than the first material, such that first outer portion 318, second
outer portion 320, third
outer portion 322, and fourth outer portion 324 of first body 336 frictionally
engage and provide
effective fluid seals with wall panels 340a, 340b, while locking device 317 of
second body 338
of inner sealing body 312 frictionally engages with first and second inner arm
304a, 306a of
body 302 as described in further detail below. Illustratively, the first
material (e.g.,
polypropylene) has a hardness or durometer of approximately 75 shore D, while
the second
material (e.g., TPV) has a hardness or durometer of approximately 50 shore A.
Illustratively,
first body 336 of inner sealing body 312 is co-extruded with second body 338
to form a dual
extrusion. More particularly, the polypropylene of second body 338 and the TPV
of first body
336 bond together during the extrusion process.
[0066] While the illustrative embodiment details co-extruded first body
336 and second
body 338, it should be noted that first body 336 may be formed separately from
second body
338. For example, second body 338 may be molded from a polymer or extruded
from aluminum
with a protrusion to be inserted into a pocket of separately extruded first
body 336. Second body
338 could then be pressed into a pocket of first body 336.
[0067] First body 336 includes a first outer portion 318, a second outer
portion 320, a
third outer portion 322, and a fourth outer portion 324. Outer portions 318,
320, 322, 324 are
configured to sealingly engage with wall panels 340a, 340b as described in
further detail below.
[0068] Second body 338 of inner sealing body 312 includes spaced apart
first arm 332
and second arm 334, which are configured to flex independently relative to
each other as they are
received within the recess 330. Plurality of raised projections 316c, 316d are
supported on the
CA 02920956 2016-02-17
13
respective outer surfaces of first arm 332 and second arm 334. Plurality of
raised projections
316c, 316d of locking device 317 extend outwardly from the outer surfaces of
arms 332 and 334
and correspond to the plurality of raised projections 316a, 316b of first
inner arm 304a and
second inner arm 306a as locking device 317 is moved axially along direction
A. In an
illustrative embodiment, plurality of raised projections316c, 316d comprise a
plurality of ridges,
teeth, or barbs that are angled along an axis defined by direction A and form
opposing angles
with the corresponding plurality of raised projections 316a, 316b. In an
alternative embodiment,
the plurality of raised projections 316c, 316d are perpendicular with respect
to the outer surfaces
of first arm 332 and second arm 334 of locking device 317.
[0069] Assembly of the molded wall unit including corner bracket 300 is
shown in FIGS.
14-16. As shown in FIG. 14, first outer arm 304c and second outer arm 306c of
outer receiver
301 are mounted to a pair of mounting studs 400a, 400b by a pair of fasteners
314, such as
screws. In an alternative embodiment, fasteners 314 may also include bolts,
nails, and the like.
Fasteners 314 are inserted through recessed pockets 310 along first outer arm
304c and second
outer arm 306c. Recessed pockets 310 facilitate easy insertion of fasteners
314, and fasteners
314 ensure that corner bracket 300 does not move when corner bracket 300 is
mounted to
mounting studs 400a, 400b. In this configuration, recess 326 is substantially
parallel with
mounting stud 400a, and recess 328 is substantially parallel with mounting
stud 400b.
[0070] As shown in FIG. 15, once first outer arm 304c and second outer arm
306c of
body 302 are mounted to mounting studs 400a, 400b, wall panels 340a, 340b are
coupled to body
302. Wall panel 340a is received within recess 326 (FIG. 14). As an end of
wall panel 340a is
inserted into recess 326, seal 327 resiliently deforms and allows wall panel
340a to enter into
recess 326. Once wall panel 340a is inserted into recess 326, seal 327 applies
an outward force
onto wall panel 340a thereby cooperating with first outer arm 304c to
frictionally engage with
wall panel 340a and hold wall panel 340a in place. The interaction between
seal 327 and wall
panel 340a also provides a fluid tight seal at the interface of the two
surfaces. Similarly, second
wall panel 340b is inserted into recess 328. As wall panel 340b is inserted,
seal 329 resiliently
deforms to allow wall panel 340b to enter into recess 328. Once wall panel
340b is inserted, seal
329 applies a force onto wall panel 340b and cooperates with second outer arm
306c to hold wall
panel 340b in place. Seal 329 also frictionally engages with wall panel 340b
to provide a fluid
tight seal at the interfaces of the two surfaces.
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[0071] As shown in FIG. 16, once wall panels 340a, 340b are inserted into
recesses 326,
328, locking device 317 of inner sealing body 312 is moved along direction A
to be inserted into
recess 330. As locking device 317 moves along direction A, first arm 332 and
second arm 334
are substantially aligned with a portion of first inner arm 304a and second
inner arm 306a.
Specifically, the plurality of raised projections 316c, 316d along arms 332,
334 are substantially
aligned with the plurality of raised projections 316a, 316b along first inner
arm 304a and second
inner arm 306a. Insertion of the second body 338 of inner sealing body 312
within the recess
330 is configured to spread the inner arms 304b and 306b, thereby causing the
seals 327 and 329
to make improved sealing contact the wall panels 340a and 340b.
[0072] Also, first outer portion 318 and second outer portion 320 of first
body 336
resiliently deform and move inwardly toward first body 336 as they engage with
respective
portions of wall panels 340a, 340b. As first and second outer portions 318,
320 move inwardly
towards first body 336, inner sealing body 312 becomes temporarily thinner (by
arms 332 and
334 flexing inwardly) thereby allowing inner sealing body 312 to continue to
advance towards
recess 330 along direction A.
[0073] As inner sealing body 312 continues to move along direction A,
plurality of raised
projections 316c, 316d of locking device 317 frictionally engage with
plurality of raised
projections 316a, 316b of body 302. Inner sealing body 312 is continuously
advanced into
recess 330 until substantially all of the plurality of raised projections
316c, 316d are frictionally
engaged with substantially all of the plurality of raised projections 316a,
316b of first and second
inner arms 304a, 306a. The frictional engagement of 316a-316d operates to
prevent axial
movement of inner sealing body 312 in a direction B, which is defined as the
direction opposite
of direction A.
[0074] In the illustrative embodiment, frictional engagement of the
plurality of raised
projections 316a-316d takes place in the form of a ratcheting mechanism where
a first raised
projection on both of the plurality of raised projections 316c, 316d
frictionally engages with a
first raised projection on both of the plurality of raised projections 316a,
316b within recess 330
so as to permit movement of inner sealing body 312 along direction A while
preventing
movement of inner sealing body 312 along direction B (FIG. 16). As additional
force is applied
onto inner sealing body 312 to further its advancement along direction A,
first raised projection
of the plurality of raised projections 316c, 316d will disengage from first
raised projections of
CA 02920956 2016-02-17
the plurality of raised projections 316a, 316b, and the first raised
projections of 316c, 316d will
continue to move along direction A.
[0075] The first raised projections of 316c, 316d will then frictionally
engage and
subsequently disengage with a second raised projection of the plurality of
raised projections
316a, 316b. This frictional engagement and subsequent disengagement between
the raised
projections of 316c, 316d and the raised projections of 316a, 316b will
sequentially continue
until first raised projections of the plurality of raised projections 316c,
316d reaches the final
raised projection of the plurality of raised projections 316a, 316b. In an
alternate embodiment,
the final raised projections of 316a, 316b are substantially thicker than the
other raised
projections of 316a, b to prevent subsequent disengagement by the first raised
projection of 316c,
316d and continual axial movement along direction A. At this point,
substantially all of the
plurality of raised projections 316c, 316d of locking device 317 should be
frictionally engaged
with the plurality of raised projections 316a, 316b of first inner arm 304a
and second inner arm
306a.
[0076] Once the plurality of raised projections are frictionally engaged
with one another
as shown by 316a, 316c and 316b, 316d (FIG.13), locking device 317 is
substantially within
recess 330, and first outer portion 318 and second outer portion 320 of first
body 336 resiliently
attempt to return to their original configuration of FIG. 16. By doing this,
first outer portion 318
and second outer portion 320 move outwardly from first body 336 and
frictionally engage with
wall panels 340a and 340b, respectively. This engagement results in two
additional seals formed
at the interfaces of the first outer portion 318 and the wall panel 340a and
the interfaces of the
second outer portion 320 and the wall panel 340b.
[0077] In the final configuration of corner bracket 300, third outer
portion 322 and fourth
outer portion 324 also frictionally engage with portions of wall panels 340a
and 340b,
respectively. The frictional engagement between third outer portion 322 and
wall panel 340a
results in an additional seal between first body 336 of inner sealing body 312
and wall panels
340a. Similarly, the frictional engagement between fourth outer portion 324
and wall panel 340b
also results in an additional seal between first body 336 of inner sealing
body 312 and wall panel
340b. In effect, corner bracket 300 provides multiple fluid tight seals with
wall panels 340a,
340b without using caulk or other additional materials for sealing purposes.
In one embodiment,
corner bracket 300 provides 3 pairs of seals to wall panels 340a, 340b.
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16
[0078] Although the invention has been described in detail with reference
to certain
preferred embodiments, variations and modifications exist within the scope of
the invention as
described and defined in the following claims.
