Enclosure and method therefor

Abstract

An enclosure includes a base. A frame includes a plurality of frame members. The frame members are coupled together and to the base using clips. Each clip includes a base coupled to a side surface of a first frame member. The clip further includes at least one lip extending from the base. The lip is sufficiently raised from the side surface of the first frame member to accept at least a portion of a second frame member between the lip and the side surface. A plurality of panels is coupled to the frame members. At least one panel is coupled to the base.

1 . An enclosure, comprising:
 a base;   a frame including a plurality of frame members, the frame members coupled together and to the base using clips, each clip including a base coupled to a side surface of a first frame member, the clip further including at least one lip extending from the base, the lip being sufficiently raised from the side surface of the first frame member to accept at least a portion of a second frame member between the lip and the side surface; and   a plurality of panels coupled to the frame members, at least one panel coupled to the base.   
   
   
       2 . The enclosure of  claim 1 , wherein the base comprises:
 base frame members configured in a generally closed shape; and   at least a first floor layer disposed on the base frame members.   
   
   
       3 . The enclosure of  claim 2 , wherein the base comprises at least one cross member disposed between two base frame members. 
   
   
       4 . The enclosure of  claim 2 , wherein the base comprises a second floor layer engaged with the base frame members. 
   
   
       5 . The enclosure of  claim 4 , wherein the base comprises an insulation cavity between the first and second floor layers. 
   
   
       6 . The enclosure of  claim 1 , wherein each of the frame members includes two channels coupled together. 
   
   
       7 . The enclosure of  claim 6 , wherein the channels of each of the frame members are coupled together using at least one engagement feature. 
   
   
       8 . A method, comprising:
 attaching at least one clip to a first frame member, the clip having a mounting surface for attaching to the first frame member and a pair of formed edges disposed on opposite sides of the clip, the formed edges being generally parallel to and displaced from a plane aligned with the mounting surface; and   coupling a second frame member to the at least one clip by engaging an end of the second frame member with the pair of formed edges.   
   
   
       9 . The method of  claim 8 , wherein engaging the end of the second frame member includes sliding the second frame member in a direction parallel with a longitudinal axis of the first frame member. 
   
   
       10 . The method of  claim 8 , comprising constructing a base, including:
 coupling base frame members together to form a generally closed shape; and   positioning at least a first floor layer on the base frame members.   
   
   
       11 . The method of  claim 10 , wherein constructing the base includes attaching at least one cross member between two base frame members. 
   
   
       12 . The method of  claim 10 , wherein constructing the base includes engaging a second floor layer with the base frame members. 
   
   
       13 . The method of  claim 8 , comprising attaching at least one panel to at least one of the first and second frame members. 
   
   
       14 . An apparatus, comprising:
 a first shell having a box configuration including an interior region;   a second shell sized and shaped to correspond with the box configuration of the first shell, the first and second shells configured to cooperatively nest; and   foam encased within at least the interior region of the first shell and bonded to each of the first and second shells, wherein the first shell is substantially held apart from the second shell.   
   
   
       15 . The apparatus of  claim 14 , wherein the second shell has a box configuration including an interior region. 
   
   
       16 . The panel of  claim 14 , wherein the foam includes urethane foam insulation. 
   
   
       17 . The panel of  claim 14 , wherein the first shell is insulated from the second shell. 
   
   
       18 . The panel of  claim 14 , wherein the panel is hat-shaped. 
   
   
       19 . The panel of  claim 14 , wherein the panel is Z-shaped. 
   
   
       20 . The panel of  claim 14 , wherein the first and second shells are formed metallic sheets. 
   
   
       21 . A method, comprising:
 positioning first and second shells in a generally nesting configuration, at least the first shell having a box configuration including an interior region, the second shell sized and shaped to correspond with the box configuration of the first shell;   inserting uncured foam within at least the interior region of the first shell, the introduction of the uncured foam causing the first shell to separate from the second shell; and   maintaining spatial positioning of the first and second shells to inhibit separation of the first and second shells beyond a predetermined separation distance, the foam curing and bonding to each of the first and second shells.   
   
   
       22 . The method of  claim 21 , wherein the foam is inserted through a port within at least one of the first and second shells. 
   
   
       23 . The method of  claim 21 , wherein maintaining the spatial position of the first and second shells includes using a jig. 
   
   
       24 . A frame portion, comprising:
 a first frame member having a side surface;   a second frame member having an end with at least one tab; and   a clip including a base configured for engagement with the side surface of the first frame member, the clip further including at least one lip extending from the base, the lip being sufficiently raised from the side surface of the first frame member to accept the tab of the second frame member between the lip and the side surface.   
   
   
       25 . The frame portion of  claim 24 , wherein the clip has two lips, each of which are disposed on opposite sides of the clip. 
   
   
       26 . The frame portion of  claim 25 , wherein the second frame member includes two tabs, each tab configured to fit between the corresponding lip of the base and the side surface of the first frame member. 
   
   
       27 . The frame portion of  claim 24 , wherein the at least one tab of the second frame member is selectively slidably engaged with the at least one lip of the clip. 
   
   
       28 . A clip for assembling a first linear member and a second linear member in perpendicular orientation, the clip comprising:
 a mounting surface for attaching to the first linear member; and   a pair of formed edges disposed on opposite sides of the clip, the formed edges being generally parallel to and displaced from a plane aligned with the mounting surface, wherein the pair of formed edges are configured to receive an end of the second linear member.   
   
   
       29 . The clip of  claim 28 , further including at least one fastener hole disposed in the mounting surface. 
   
   
       30 . The clip of  claim 28 , wherein the opposite sides are parallel to each other. 
   
   
       31 . The clip of  claim 28 , wherein the clip has a generally rectangular configuration with the opposite sides having a length greater than sides of the clip disposed between the opposite sides. 
   
   
       32 . The clip of  claim 28 , wherein the pair of formed edges are configured to rigidly engage the end of the second linear member. 
   
   
       33 . A method of manufacturing a wall structure, the method comprising:
 positioning a first skin and a second skin in a stacked configuration;   providing a fixture to limit a separation distance of the first skin and second skin;   introducing uncured foam in a void between the first skin and the second skin;   allowing the first skin and second skin to separate to the separation distance; and   curing the foam.   
   
   
       34 . The method of  claim 33 , wherein introducing uncured foam in the void includes coupling a nozzle to an orifice disposed in at least one of the first skin and the second skin. 
   
   
       35 . The method of  claim 33 , wherein providing the fixture includes positioning a rigid surface. 
   
   
       36 . The method of  claim 35 , further including displacing the rigid surface and removing the first skin, second skin and the cured foam.