Abstract:
A support adapted for use between first and second panels at a joint includes a distal end including a flange, an anchoring end including a flange and an anchor, and an intermediate section connecting the distal end and the anchoring end. The intermediate section is shaped to mate with adjoining edges of the first and second panels.

Description:
FIELD OF THE INVENTION 
   The present invention relates to a support for securing shelving, particularly cantilevered shelving, to an insulated unit without compromising the insulating properties of the unit. 
   BACKGROUND OF THE INVENTION 
   Insulated units, such as walk-in coolers or freezers, are typically box-like structures of sufficient size to allow an individual to walk around in the unit while standing up. The insulated unit, hereafter referred to as a “walk-in,” may be provided with a refrigeration system, or perhaps in certain applications a heating system, and is used for storing items at either low or high temperatures relative to the outside environment. For example, a walk-in may be used in grocery stores, convenience stores, bars or restaurants to store food products such as meat, cheese, beer, and a variety of other foods that are not immediately needed. Application may also be found in other industries, such as pharmaceutical laboratories. 
   To maximize the use of storage space within the walk-in, interior shelving is typically provided. This shelving may be free-standing or cantilevered. Examples of free-standing shelving are described in U.S. Pat. No. 3,424,111 to Maslow; U.S. Pat. No. 3,874,511 to Maslow; U.S. Pat. No. 4,811,670 to Kolvites; et al. and U.S. Pat. No. 6,017,009 to Swartz, et al. 
   However, cantilevered shelving, such as that shown in U.S. Pat. No. 5,645,257 to Ward, has the advantage of not having front vertical support posts that can hamper access to items on the shelves. Nevertheless, there are significant problems encountered in mounting cantilevered shelves in a walk-in. For example, because of the manner in which walk-ins are constructed, prior art systems that are strong enough to support shelving and the items on them tend to compromise the insulating properties of the walk-ins. 
   For purposes of explanation, the construction of a conventional walk-in cooler is described below with reference to the accompanying drawings. 
   As shown in the perspective view of  FIG. 9 , the walk-in  300  is typically constructed of a plurality of interlocking wall panels  100  and ceiling panels  200 . 
   As shown in the partial plan and partial elevational views, which are respectively  FIGS. 7 and 8 , a conventional wall panel  100  comprises a core  102  of insulation, preferably polyurethane foam. An inner skin  104  and an outer skin  106 , also called inner and outer sidewalls, are disposed on opposite sides of the core  102  and are preferably made of thin sheetmetal. The side edges  108 ,  110  of the wall panels are preferably not covered by sheetmetal except for a small marginal lip  107  formed where the sheetmetal skins  104 ,  106  have been folded inwardly at right angles. An elastomeric seal  109 , made for example of rubber or plastic, is preferably provided on each lip  107  at adjoining edges of the panels to provide a seal between panels when they are assembled as described below. This seal minimizes migration of moisture through the walk-in and into the insulating core. In addition, the edges  108 ,  110  are preferably contoured so that one wall panel  100  can easily mate with an adjacent wall panel  101 . A male-female C- or U-shaped contour is illustrated in  FIG. 7 , but a variety of contours, and even a straight profile, are possible. 
   Ceiling panels  200  are formed from the same components as the wall panels  100 . As shown in  FIG. 9 , however, the assembly of the ceiling panels  200  differs in that the inner skin  204  does not extend all of the way to the side edges  208 . Rather, the core  202  is exposed in a region near each edge  208 . In this way, the ceiling panel  200  can mate with a top edge  110   a  of each wall panel  100  as shown in FIG.  9 . 
   As will be appreciated, each wall panel  100  is formed to include one edge  108  having a female contour and one edge  110  having a male contour. In addition, each panel has an interlocking mechanism on the side of the male-contoured edge  110  to be secured at the female contour of an adjacent panel. The same principle of interchangeability also applies to ceiling panels  200 . Of course, one of ordinary skill will understand that some panels, such as panels that make up corners or the front and back panels of the ceiling, will differ slightly from the wall and ceiling panels  100 ,  200  described above. 
   To form a wall, one wall panel  100  is interlocked with another wall panel  101  so that their edges  108 ,  110  mate, forming a joint. The wall panels house a plurality of interlocking mechanisms at a number of locations  116  along each edge  108 ,  110 , as shown in FIG.  9 . The interlocking mechanism typically comprises a suitable pawl  112  and cam-tightening means (not shown) in one panel and a catch (not shown) in the mating panel. The catch is preferably a metal rod embedded in any suitable fashion in the core  102 . The pawl  112  engages the catch and interlocks the wall panels  100 ,  101  when a user rotates the cam-tightening means by way of a removable allen wrench  114 . The ceiling panels  200  are interlocked together and are interlocked with the side panels in substantially the same manner. 
   In order to construct cantilevered shelving without compromising the insulating properties of the walk-in, a fastener would ideally engage only the inner skin  104  of a wall panel  100 . However, the inner skin  104 , being thin sheetmetal, is incapable of supporting substantial load applied by the shelving and the items placed on it. If the shelving is attached to the sheetmetal with such a fastener, when the shelving is loaded the sheetmetal may bend or the fastener may pull through it. As a result, conventional cantilevered shelving is normally attached to the walls with long bolts that pass through the inner skin  104 , the core  102  and the outer skin  106 . On the outside of the walk-in  300 , a stress plate is generally used at each bolt to distribute the load over a large area to prevent pull-through. These bolts, however, serve as paths for heat transfer and can also allow humidity to enter into the walk-in, thus reducing its insulating properties. 
   Accordingly, there is a need in the art for a support that is strong enough to support loaded shelving, but which does not compromise the insulating properties of the walk-in. 
   SUMMARY OF THE INVENTION 
   According to one aspect of the invention, a support is adapted for use between first and second panels at a joint. The support comprises a distal end, that may include a flange, an anchoring end, that also may include a flange, and an anchor, and an intermediate section connecting the distal end and the anchoring end. The intermediate section is shaped to be congruent to and mate with adjoining edges of the first and second panels. 
   In another aspect of the invention, the anchoring end is formed or otherwise adapted to support at least one shelf directly or through one or more intermediate elements. 
   In yet another aspect of the invention, the intermediate section includes an aperture for allowing the pawl, comprising the interlocking mechanism in the first panel, to pass through the support. 
   In still another aspect of the invention, an apparatus comprises a first panel having an inner and an outer wall, a second panel having an inner and an outer wall and joined to the first panel at a joint, and a support secured between the first and second panels at the joint. The support includes a distal end, an anchoring end, and an intermediate section connecting the distal end and the anchoring end. The distal end is disposed at the outer walls of the first and second panels and the anchoring end is disposed at the inner walls of the first and second panels. 
   In yet another aspect of the invention, an edge of the first panel has a male contour and an edge of the second panel has a congruent female contour such that the male contour can mate with the female contour at the joint. The intermediate section is similarly contoured to mate with adjoining edges of the first and second panels. 
   In still another aspect of the invention, an apparatus comprises a first panel having an inner and an outer wall, a second panel having an inner and an outer wall and joined to the first panel at a joint; means for interlocking the panels at the joint; and a support including a distal end, an anchoring end, and an intermediate section connecting the distal end and the anchoring end. The distal end is disposed at the outer walls of the first and second panels and the anchoring end is disposed at the inner walls of the first and second panels. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a partial perspective view of a support according to a preferred embodiment of the present invention; 
       FIG. 2  is a partial side elevation of the support shown in  FIG. 1 ; 
       FIG. 3  is a partial cross-sectional view of the support taken along plane  3 — 3  in  FIG. 2 ; 
       FIG. 4  is a partial cross-sectional view of the support shown in  FIG. 1  disposed between two interlocked panels of an insulating unit or walk-in; 
       FIGS. 5A  to  5 C are partial cross-sectional views of alternative anchors adapted for use with the support of  FIG. 1 ; 
       FIG. 6  is a cross-sectional view of the present invention adapted for use in a corner, which may be formed at the junction of a side wall panel and ceiling panel of a walk-in; 
       FIG. 7  is a partial plan view of two prior art panels of an insulating unit; 
       FIG. 8  is a partial side elevation view of the two panels of the insulating unit shown in  FIG. 7 ; and 
       FIG. 9  is a perspective view of a partially-assembled insulating unit. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   A support  1  in accordance with a preferred embodiment of the present invention is shown in  FIG. 1  to include a distal end  4 , an intermediate section  6  and an anchoring end  8 . The intermediate section  6  is shaped to be congruent with or match the contour of the edges of the panels described above with reference to  FIGS. 7 and 8  so as to fit within the joint of the interlocked panels. An elongated aperture  12  is provided to allow the pawl  112 , comprising each panel interlocking mechanism, and catch to engage in the conventional manner described above. When the support  1  is installed, the distal end  4  and the anchoring end  8  are disposed on opposite sides of the panel  100 . 
   The distal end  4  preferably includes a flange  10 . The flange  10  prevents the support  1  from slipping into the joint toward the interior of the walk-in when the support and any mounted shelves are loaded. The flange also stiffens the support  1  and distributes load along the outer sidewall  106  of the panel. As shown in  FIG. 1 , the flange  10  preferably extends the entire length of the support  1 . Nevertheless, one of ordinary skill will recognize that the flange  10  may extend less than the entire length of the support, or it may be comprised of discrete members protruding at discrete locations. 
   The intermediate section  6  has two sides  5 ,  7  and, as described above, has a horizontal cross-sectional shape to fit, or be congruent, with the contour of the mating edges  108 ,  110 , of the panels as shown in FIG.  4 . The contour illustrated is generally C- or U-shaped, but other shapes will not depart from the scope of the invention. An important aspect of the invention is the ability of the support  1  to fit between any two interlocking panels without disrupting the way in which the panels are interlocked or compromising the insulating properties of the panels. Accordingly, while the contour of the intermediate section  6  can vary, it is generally chosen to match the contour of the panel edges. 
   The flange  10  on the support may be omitted if the contour of the intermediate section  6  and the mating edges of the panels have sufficient relief to prevent the support from pulling through the panels when mounted shelving is loaded. 
   As shown in  FIGS. 1 and 2 , the elongated aperture  12  is provided to allow the pawl  112 , comprising the interlocking mechanism in one wall panel  100 , to pass through the support  1  and engage the catch in the adjacent wall panel  101 . The size and shape of the aperture  12  can vary without affecting the nature of the invention, provided the aperture  12  is sufficiently large to allow the pawl  112  to move when actuated without hindrance. 
   The anchoring end  8  of the support  1  may also include a flange  14  to help distribute the load on the inner sidewall  104 . Although the flange  14  shown is continuous, the flange  14  on the anchoring end  8  may be embodied by a variety of structures as previously mentioned with regard to the flange  10  on the distal end  4 . Similarly, the flange  14  on the anchoring end of the support  1  can be omitted if sufficient structural support is otherwise provided by the remaining elements of the apparatus. 
   The anchoring end  8  also is integrally formed or otherwise provided with an anchor  16  for receiving a shelf directly or for receiving a shelf-mounting bracket. The particular shape of the anchor can vary and three possible alternative shapes are shown in  FIGS. 5A  to  5 C. U.S. Pat. No. 5,645,257 shows an example of an anchor  16  coupled to a bracket, which is in turn attached to a shelf. These anchors  16  and the shelving systems to be used with them are disclosed in U.S. Pat. Nos. 5,645,257 and 5,592,886. (The disclosures of these and each of the other patents mentioned herein are incorporated herein by reference.) One of ordinary skill will also appreciate that the anchor  16  may be a continuous member extending the length of the support  1  as shown in  FIGS. 5A  to  5 C, or a plurality of discrete members protruding from the anchoring end  8  at specific locations. Other alternative structures are also within the skill in art. 
   It will be appreciated that the support  1  may be a unitary member that extends between the floor and ceiling of the walk-in. Alternatively, the support may comprise discreet stacked sections of, for example, standard length that when so stacked extend between the floor and ceiling of the walk-in. In this way, the support  1  can hold substantial vertical load. In addition it will substantially completely fill the space between adjacent panels when assembled. The seals  109  on lips  107  of the outer and inner sidewalls of each panel will also mate with the sides of the support. Therefore, the insulating and moisture barrier properties of the walk-in are not compromised. 
   Moreover, the structure and configuration of the support, in combination with the structural properties of the joined adjacent panels, provide a substantial bending moment that permit cantilevered shelving mounted on the support to hold significant load. 
   In a modification shown in  FIG. 6 , the support  1  is adapted to fit into a joint between a wall panel  100  and a ceiling panel  200 . In such an embodiment, if utilized the flange  14  is trimmed on one side so that it will not interfere with the mating of the wall panel  100  and the ceiling panel  200 . In addition, rather than an anchor  16  adapted to support a bracket or a shelf, a plate  18  is provided which runs parallel to the ceiling panel  200 . The plate  18  has a securing means for securing a standard, shown as a depending vertical restraining wall  20 . A standard is a vertical post to which a shelf is fastened, either directly or by way of a bracket. U.S. Pat. Nos. 5,592,886 and 5,645,257 show a bracket attached to such a standard. Of course, other types of anchors or plates can be provided without departing from the scope of the invention. 
   The securing means on the plate for holding a standard may include any of the following non-limiting examples: an anchor, a snap-in member having a spring-loaded button which engages an aperture in the standard or shelf, a threaded hole for receiving a screw or bolt, and a hook for engaging an aperture in the standard or shelf. Other securing means are possible, as one of ordinary skill will appreciate. 
   In a further modification, a support  1  as shown in  FIG. 6  can also be fitted between a joint of two wall panels  100  connected at a corner. Of course, the type of anchor would change to accommodate the vertical orientation of the support  1 , and could include the shapes shown in  FIGS. 5A  to  5 C but adapted to fit in a corner. 
   The support  1  is preferably integrally formed of fiber-reinforced thermoset polyester. Fiber-reinforced thermoset polyester is preferred for its low heat transfer, or heat-insulating, properties and strength. Of course, the support  1  may also be formed of other plastics with or without reinforcing fibers, wood, graphite, ceramic, mixtures of one or more of the foregoing, or other materials one of ordinary skill finds suitable to the application. In addition, if reinforcing fibers are used, known fibrous materials such as glass or polymeric compositions are suitable. 
   The preferred fiber-reinforced thermoset polyester support  1  can be formed by a compression molding or a pultrusion process. The compression molding process is preferable because it results in a more random distribution of the reinforcing fibers than the pultrusion process. The pultrusion process, in contrast, tends to align the fibers along the length of the support  1 . 
   While the present invention has been described with respect to what is presently considered to be the preferred embodiments, the present invention is not limited to the disclosed embodiments. Rather, the present invention covers various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the appended claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.