Patent Document

CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application Ser. No. 62/130,737, filed Mar. 10, 2015, which is incorporated in its entirety herein. 
     
    
     FIELD 
       [0002]    The systems and methods relate to an enclosure and a rail for the enclosure, e.g., an enclosure for a generator. 
       BACKGROUND 
       [0003]    To protect objects from the elements, the objects can be enclosed in an enclosure. The enclosure can also attenuate noise coming from the enclosed object. 
       SUMMARY 
       [0004]    According to one aspect, systems and methods include a rail for use in creating an enclosure. The rail includes a horizontal leg configured to alternatively secure with a roof and a skid/tank. A first leg of the rail connects perpendicularly to the horizontal leg and a second leg connected perpendicular to the horizontal leg and opposes the first leg. The first leg and the second leg form a channel to receive a wall forming a part of the enclosure. 
         [0005]    Other systems, methods, features, and advantages will be or will become apparent upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and be protected by the accompanying claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    In association with the following detailed description, reference is made to the accompanying drawings, where like numerals in different figures can refer to the same element. The features of the drawings are not necessarily drawn to scale. 
           [0007]      FIG. 1  is a perspective view of an example rail for creating an enclosure. 
           [0008]      FIG. 2  is a cross sectional side view of the rail of  FIG. 1 . 
           [0009]      FIG. 3  is a partial side view of the rail connected with a roof and a wall. 
           [0010]      FIG. 4  is a partial side perspective view of the rail secured to a wall. 
           [0011]      FIG. 5  is a side perspective view of the rail secured to the wall. 
           [0012]      FIG. 6  is a partial side view of the rail securing the wall to a skid/tank. 
           [0013]      FIG. 7  is a partial perspective view of the rail securing the wall to the skid/tank. 
           [0014]      FIG. 8  is a perspective view of an example panel in which one or more panels can be used to form the wall and/or the roof. 
           [0015]      FIG. 9  is an end elevation view of an example channel portion according to  FIG. 8 . 
           [0016]      FIG. 10  is a sectional view of a channel portion of an example panel in interlocking engagement with interlocking elements of a companion panel. 
           [0017]      FIG. 11  is an end view of an example corner piece for interlocking companion panels at corners of the enclosure. 
           [0018]      FIG. 12  is a cross sectional side view of another example rail. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    While the disclosure may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, a specific embodiment with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that as illustrated and described herein. Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity. It will be further appreciated that in some embodiments, one or more elements illustrated by way of example in a drawing(s) may be eliminated and/or substituted with alternative elements within the scope of the disclosure. 
         [0020]    Referring to  FIGS. 1 and 2 , a rail  10  is provided for creating an enclosure  100 . As shown in  FIGS. 3-5 , the rail  10  can be connected with a roof  30  and one or more walls  32  to form the enclosure  100 . As shown in  FIGS. 5-7 , the rail  10  can be connected to a skid/tank  62 . The rail  10  is manufactured by an extrusion process or other manufacturing processes. If manufactured as an extrusion process, the process can be continuous or semi-continuous, and can be done with the material hot or cold. The material for the rail  10  can include one or more of metals, polymers, ceramics, concrete, etc. 
         [0021]    As best shown in  FIGS. 1 and 2 , the rail  10  has a horizontal base leg  12  having first and second opposite edges and first and second opposite ends, a first vertical leg  14  extending from the base leg  12  at approximately the midpoint of the leg  12 , a second vertical leg  16  extending from the first edge of the leg  12 , and a gusset  20  extending at an angle between the second edge of the leg  12  and the first leg  14 . A length is defined between the opposite ends of the base leg  12 . The second leg  16  can be shorter in length than the longer first leg  14 . The legs  12 ,  14 ,  16  define a channel  18 . The legs  12 ,  14  and gusset  20  defines a hollow opening  22 . The opening  22  is open at both ends of the rail  10 . 
         [0022]    The base leg  12  has a first portion  12   a  which extends between the first leg  14  and the second leg  16 . The base leg  12  further has a second portion  12   b  which extends between the first leg  14  and the gusset  20 . The first portion  12   a  may have a thickness which is less than the thickness of the second portion. At least one aperture  76  is formed through the first portion  12   a  and is in communication with the channel  18 . At least one aperture  34  is formed through the second portion  12   b  and is in communication with the opening  22 . The base leg  12  includes a notch  24  which extends along its length. In one example, the notch  24  includes a generally triangular shape but other shapes can be used including rectangular, circular, oval, etc. 
         [0023]    The first leg  14  has a first portion  14   a  which has a predetermined thickness and which extends from the base leg  12 , a second portion  14   b  which extends from the first portion  14   a  to the end of the gusset  20 , and a third portion  14   c  which extends from the second portion  14   b  to a free end  14   d  of the first leg  14 . The first and third portions  14   a,    14   c  may have a thickness which is less than the second portion  14   b.  At least one aperture  56  is formed through the second portion  14   b  and is in communication with the opening  22 . At least one aperture  72  is formed through the third portion  14   c.    
         [0024]    An undercut  33  is formed between the base leg  12  and each of the first and second legs  14 ,  16 . The undercuts  33  may be generally semi-circular shaped or other shapes. 
         [0025]    A first implementation of the rail  10  is described with the rail  10  being connected to an upper end of a wall  32  as shown in  FIGS. 3-5  to form the enclosure  100 . The upper end of the wall  32  is inserted into the channel  18  such that the outer surface of the wall  32  is proximate to, and may abut against, the first leg  14  and the inner surface of the wall  32  is proximate to, and may abut against, the second leg  16 . The base leg  12  is above the wall  32 . The gusset  20  is on the outside  50  of the wall  32 . The wall  32  is fastened to the rail  10  by passing a fastener  54  through the wall  32  and through each aperture  56 . The thicker second portion  14   b  allows for proper thread engagement of the fastener  54 . The thinner portions  14   a,    14   c  provide support while saving material. The rail  10  acts as a cosmetic cover for raw edges of the wall  32 . The second leg  16  also acts as a hook which holds the wall  32  in place during the fastening of the roof  30  as described herein to the rail  10 . The undercuts  33  provide the rail  10  with clearance for the wall  32  when the wall  32  is inserted into the channel  18 . 
         [0026]    The roof  30  is laid on the upper surface  40  of the base leg  12 . If desired, the notch  24  provides a guide edge for caulking before the roof  30  is placed on the base leg  12 . The roof  30  is fastened to the rail  10  by passing a fastener  36  through the roof  30  and through each aperture  34 . The thicker second portion  12   b  allows for proper thread engagement of the fastener  36 . When the roof  30  is fastened to the rail  10 , the aperture(s)  34  are a possible entry point for water to enter the rail  10 . Since the apertures  34  are located above the hollow opening  22 , and the opening  22  is located on the outside  50  of the enclosure  100 , e.g., outside the wall  32  of the enclosure  100 , water flows through the hollow opening  22  and out an end of the rail  10 , and does not have a path to enter inside  52  the enclosure  100 . The hollow opening  22  allows the rail  10  to act as a gutter allowing rain and other water to drain out of the ends and at unsealed seams of the rail  10 . The hollow opening  22  can also reduce a cost to manufacture the rail  10  by reducing a material to produce the rail  10 . The gusset  20  transfers load from the roof  30  to the wall  32 . 
         [0027]    A second implementation of the rail  10  is described with the rail  10  being connected to a lower end of a wall  32  and to a skid/tank  62  as shown in  FIGS. 5-7 . To do this, the rail  10  is rotated 180 degrees from roof  30  to skid/tank  62  so that the gusset  20  points to the inside  52  of the enclosure  100  acting as a load transfer mechanism from the wall  32  to the skid/tank  62 . The lower end of the wall  32  is inserted into the channel  18  such that the inner surface of the wall  32  is proximate to, and may abut against, the first leg  14  and the outer surface of the wall  32  is proximate to, and may abut against, the second leg  16 . The base leg  12  is below the wall  32 . The gusset  20  is on the inside  52  of the wall  32 . The wall  32  is fastened to the rail  10  by passing a fastener  70  through the wall  32  and through each aperture  72 . The rail  10  acts as a cosmetic cover for raw edges of the wall  32 . The second leg  16  also acts as a hook which holds the wall  32  in place during the fastening of the skid/tank  62  to the rail  10 . The undercuts  33  provide the rail  10  with clearance for the wall  32  when the wall  32  is inserted into the channel  18 . 
         [0028]    The skid/tank  62  abuts against the lower surface of the base leg  12  and is attached thereto by passing fasteners  74  through the skid/tank  62  and through the apertures  76  in the base leg  12 . 
         [0029]    Therefore, the rail  10  is reversible and can be used in two different orientations which are 180 degrees relative to each other. By being reversible, the rail  10  can reduce a number of fasteners utilized in the overall assembly of the enclosure  100 . In addition, the rail  10  allows the placement of fasteners such that the fasteners do not allow water to enter the enclosure  100  due to their through holes, and can reduce the overall cost of the enclosure by using common parts throughout the assembly. 
         [0030]    It is to be noted that the apertures  34 ,  56 ,  72  and  76  can be pre-formed in the rail  10 , or can be tapped when the fastener  36 ,  54 ,  56 ,  70 ,  74  is inserted through the rail  10 . 
         [0031]      FIG. 8  is a perspective view of an example construction panel  110  in which one or more panels  110  can be used to form the wall  32  and/or the roof  30 . The panel  110  includes a longitudinal channel  112 , and a longitudinal lip portion  114  which projects inwardly along channel  112 , lip portion  114  being slightly thicker than the thickness of the balance of panel  110 . Longitudinal lip portion  114  terminates in an outer edge which slopes downwardly and inwardly at an angle of 15° (see  FIG. 9 ). Interior wall  116  of channel  112  slopes downwardly and outwardly, also at an angle of 15°. Wall  124  of channel  112  projects upwardly and outwardly from bottom  118 , at an angle of 15°, and terminates in an inwardly projecting enlarged portion  126  having a flat bottom surface which projects slightly upwardly, and a convex arcuate upper surface, to facilitate interlocking with an adjacent panel. 
         [0032]    The bottom  118  can be tapered, e.g., so that the interior wall  116  end is thicker than the wall  124 . By tapering the bottom  118 , the taper allows the profile to keep the wall  124  thick while still making the profile flexible for assembling. Keeping the wall  124  as thick as possible allows for a consistent, quality extrusion profile to be produced. The tapering can begin about a third of the length of the bottom  116  from the interior wall  116  end at a downward angle of about 2°. A thickness of the bottom  118  is about 2.49 inches at the wall  124 . Other dimensions can be used. The tapering can be accomplished through aluminum extrusion. Molten aluminum is pushed through an extrusion die which shapes the aluminum to the desired profile. Additionally or alternatively, the tapering cab be achieved by machining or casting. 
         [0033]    A longitudinal inwardly projecting finger-like member  128  is integral with wall  116 , finger-like member  128  terminating in a concavely curved portion  128   a.    
         [0034]    The longitudinal edge of panel  110  remote from channel  112  terminates in a downwardly extending, generally circular bead portion  130 , having a forwardly projecting lip portion  130   a.  The portion of bead  130  above lip portion  130   a  extends upwardly and inwardly at an angle of 15°, as is seen most clearly in  FIG. 9 . Inwardly from bead  130 , a longitudinally extending downwardly projecting finger  132  terminates in a thickened portion  132   a  which is generally triangular in cross-section, the bottom of the triangle being slightly rounded, and terminating in a flat surface at the top thereof, projecting inwardly from finger  132  proper. The upper surface of thickened portion  132   a  is flat and is in alignment with the bottom surface of enlarged portion  126  of wall  124 , when in interlocking engagement. 
         [0035]    To assemble a panel  110  into interlocking engagement with another panel  110 , lip portion  130   a  of bead  130  is inserted under longitudinal lip portion  114 , with thickened portion  132   a  of finger  132  being directly above the convex arcuate upper surface of enlarged portion  126  of wall  124 . Manual pressure on the surface of panel  110  above finger  132  will cause the angled wall of finger  132  thereof to slide against the convex arcuate upper surface of enlarged portion  126  until locking is achieved when the panels  110  are interlocked as illustrated in  FIG. 10 . As lip  130   a  of circular bead  130  serves as a fulcrum, as panel  110  is levered downwardly, the circular bottom portion of bead  130  will come to its secure position inside concave trough portion  128   a  of member  128 , as also illustrated in  FIG. 10 . 
         [0036]    While the sizes of panels can be enlarged, pro rata, if the slopes of the channel sections are maintained no less than 15° and no greater than 18° it is possible to avoid a structure which is either too rigid, or too flexible respectively. 
         [0037]    Referring to the convex arcuate upper surface of enlarged portion  126  of wall  124 , it has if this curvature is too great, interlocking engagement with portion  132   a  of finger  132  becomes difficult, or if this curvature is made relatively flat, interlocking proves equally difficult. 
         [0038]    The constructions permits a plurality of panels  110  to be readily enjoined in interlocking relationship such that when assembled, there is no necessity for separate structural frames. The shape of the panel sections disclosed above has been designed in order to achieve strength, economy of manufacture, ease of inter-locking, and permanency of interlocked engagement. 
         [0039]      FIG. 11  is an end view of an example corner piece  200  for interlocking companion panels  110  at corners to create the enclosure. The corner piece  200  includes a longitudinal channel indicated generally at  212 . Corner piece  200  includes a lip portion  214  which projects inwardly along channel  212 . Lip portion  214  being slightly thicker than the thickness of the balance of corner piece  200 . Longitudinal lip  214  terminates in an outer edge which slopes downwardly and inwardly at an angle of 15°. Interior wall  216  of channel  212  slopes downwardly and outwardly, also at an angle of 15°. Wall  224  of channel  212  projects upwardly and outwardly from bottom  218 , at an angle of 15°, and terminates in an inwardly projecting enlarged portion  226  having a flat bottom surface which projects slightly upwardly, and a convex arcuate upper surface, to facilitate interlocking with an adjacent panel. Longitudinal inwardly projecting finger-like member  228  is integral with wall  216 , member  228  terminating in a concavely curved portion  128   a.  In some implementation, the bottom  218  can be tapered 2° as described above for bottom  118 . 
         [0040]    The corner piece includes a 90° bend  202  to form a corner of corner piece  200 . Other angle bends  202  can be used. An edge remote from channel  212  terminates in a downwardly extending, generally circular bead portion  230 , having a forwardly projecting lip portion  230   a.  The portion of bead  230  above lip  230   a  extends upwardly and inwardly at an angle of 15°. Inwardly from bead  230 , a longitudinally extending downwardly projecting finger  232  terminates in a thickened portion  232   a  which is generally triangular in cross-section, the bottom of the triangle being slightly rounded, and terminating in a flat surface at the top thereof, projecting inwardly from finger  232  proper. 
         [0041]    Corner piece  200  can be used to assemble a panel  110  into interlocking engagement with another panel  110  at a corner. Lip  130   a  of bead  130  of panel  110  is inserted under longitudinal lip  214  of corner piece  200 , with thickened portion  132   a  of finger  132  being directly above the convex arcuate upper surface of enlarged portion  226  of wall  224 . Manual pressure on the surface of panel  110  above finger  132  will cause the angled wall of finger  132  thereof to slide against the convex arcuate upper surface of portion  226  of the corner piece  200  until locking is achieved when the panel  110  is interflocked with the corner piece  200 . Likewise, lip  230   a  of bead  230  of corner piece  200  can be inserted under longitudinal lip  114  of another panel  110 , with thickened portion  232   a  of finger  232  being directly above the convex arcuate upper surface of enlarged portion  126  of wall  124 . Manual pressure on the surface of corner piece  200  above finger  232  will cause the angled wall of finger  232  thereof to slide against the convex arcuate upper surface of portion  126  of the other panel  110  until locking is achieved when the corner piece  200  is interlocked with the other panel  110 , to connect two panels  110  at 90° with respect to each other. Other angles can be used. 
         [0042]      FIG. 12  is a cross sectional side view of another example of a reversible rail  10 . At least one aperture  300  can be formed through the vertical leg  14 . In one example, the vertical leg  14  includes a first portion  14   a,  second portion  14   b  and third portion  14   c,  e.g., as in  FIG. 2 . The aperture  300  includes mimicking threads for a fastener to thread into. In one example, the aperture  300  does not extend all the way through the vertical leg  14 . The aperture  300  can replace or be used in addition to the aperture  56  in  FIGS. 1 and 2 . Wall  32  is fastened to the rail  10  by passing a fastener  54  through the wall  32  and threading into the aperture  300 . 
         [0043]    Additionally or alternatively, aperture  301  can replace or be used in addition to aperture  34  in  FIGS. 1 and 2 . Aperture  301  can be formed in the second portion  12   b  of the base leg  12 . In one example, the aperture  301  does not extend all the way through the vertical leg  12 . The roof  30  is fastened to the rail  10  by passing a fastener  36  through the roof  30  and threading into each aperture  301 . By incorporating apertures  300  and  301  into the rail  10 , possible water entry points into the rail  10  can be eliminated. 
         [0044]    Additionally or alternatively, the base leg  12  can include a notch  302  which extends along a length, or portion of the length, of the base leg  12 . For example, the notch  302  can provide a guide edge for caulking before the roof  30  is placed on the base leg  12 , e.g., to provide a seal against the environment. The notch  302  can be any shape, e.g., semi-circular, rectangular, triangular, half a hexagon, an irregular shape, etc. 
         [0045]    Additionally or alternatively, gusset  20  can contain a notch  303  which extends along its length or portion of the length thereof. If desired, the notch  303  provides clip-in location for a cosmetic cover plate to be installed to cover seams which occur when two sections of reversible rail  10  abut each other. Additionally or alternatively, a geometry  304  of the gusset  20  can been modified to incorporate a decorative feature which extends along its length, e.g., a bracket shaped feature. 
         [0046]    Additionally or alternatively, chamfers  305  can be formed at the end of legs  14  and/or  16 . The chamfers  305  can provide a guide edge, e.g., for caulking after assembly to a roof and/or skid. 
         [0047]    As used herein, fasteners can include bolts and nuts or other fasteners including screws, etc. 
         [0048]    While particular embodiments are illustrated in and described with respect to the drawings, it is envisioned that those skilled in the art may devise various modifications without departing from the spirit and scope of the appended claims. It will therefore be appreciated that the scope of the disclosure and the appended claims is not limited to the specific embodiments illustrated in and discussed with respect to the drawings and that modifications and other embodiments are intended to be included within the scope of the disclosure and appended drawings. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the disclosure and the appended claims. 
         [0049]    Many modifications and other embodiments set forth herein will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Technology Category: 0