US20200299960A1 - Structurally reinforced insulated panel - Google Patents
Structurally reinforced insulated panel Download PDFInfo
- Publication number
- US20200299960A1 US20200299960A1 US16/654,740 US201916654740A US2020299960A1 US 20200299960 A1 US20200299960 A1 US 20200299960A1 US 201916654740 A US201916654740 A US 201916654740A US 2020299960 A1 US2020299960 A1 US 2020299960A1
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- US
- United States
- Prior art keywords
- frame
- panel
- column
- jacket
- panel body
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/388—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of other materials, e.g. fibres, plastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/18—Filling preformed cavities
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
- E04B1/26—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of wood
- E04B1/2604—Connections specially adapted therefor
- E04B1/2612—Joist hangers
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7604—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only fillings for cavity walls
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
Definitions
- the present disclosure generally relates to insulated panels and, more particularly, to a structurally reinforced insulated panel.
- Freezers or refrigerated enclosures such as refrigerated display cases and storage units, are typically constructed of materials that either have high insulative properties or high structural reliability, but not both.
- structurally reliable materials used for a frame such as wood, steel, and aluminum, have a low R value (i.e., thermal resistivity) and allow heat to enter the refrigerated enclosure through the frame (i.e., panel perimeter).
- R value i.e., thermal resistivity
- many known freezers or refrigerators use multiple studs distributed through a panel body to increase the structural integrity of the insulated panel.
- placing multiple studs within the panel body decreases the amount of insulating material that can be placed within the panel body and increases the number of areas within the panel or enclosure that act as a thermal bridge, which decreases the efficiency of the freezer or refrigerator.
- the thermal resistivity of the panel is traded for the structural performance of the panel or enclosure. That is, structural performance will be optimized, but the thermal resistivity (i.e., R value) of the panel or enclosure would consequently be diminished.
- an insulated panel for a storage unit may include a first frame, a second frame, a third frame, and a fourth frame.
- the first, second, third, and fourth frames may each include an interior surface that forms a cavity of the panel body.
- the second frame is spaced away from the first frame and the third frame is spaced away from the fourth frame.
- a column may be disposed in the cavity and may have a first end coupled to the first frame and a second end coupled to the second frame.
- a foam core may be disposed in the cavity such that the column is embedded with the foam core.
- an insulated panel for a storage unit may include a first frame, a second frame, a third frame, and a fourth frame.
- the first, second, third, and fourth frames may each include an interior surface.
- the panel may also include a cavity defined by the interior surfaces.
- the second frame may be spaced away from the first frame and the third frame may be spaced away from the fourth frame.
- a pocket may be at least partially defined by the first frame and sized to receive a beam.
- a column may be disposed in the cavity and may extend between the first frame and the second frame.
- a foam core may be disposed in the cavity such that the column is embedded with the foam core.
- an insulated panel for a storage unit may include a panel body including a first frame, a second frame, a third frame, and a fourth frame.
- the first, second, third, and fourth frames may each include interior surfaces forming a cavity of the panel body.
- the second frame may be spaced away from the first frame, and the third frame may be spaced away from the fourth frame.
- a pocket may be at least partially defined by the first frame and sized to receive a beam.
- a load-bearing column may be disposed in the cavity and extend between the first frame and the second frame. The load-bearing column may be configured to receive a point load from the beam.
- a foam core may be disposed in the cavity such that the column is embedded with the foam core.
- a method of manufacturing a structurally reinforced insulated panel may include providing a panel body including a first frame, a second frame, a third frame, and a fourth frame.
- the first frame may be spaced away from the second frame and the third frame may be spaced away from the fourth frame.
- the method may include coupling a column to the panel body by coupling a first end of the column to the first frame and a second end of the column to the second frame.
- the method may further include forming a cavity in the panel body.
- the method may include dispensing a foam material in liquid phase into the cavity.
- the method may include curing the foam material to form a foam core such that the column is embedded with the foam material.
- the first frame may define a pocket that is configured to receive a portion of a structural member.
- the pocket may be disposed outside the cavity and adjacent to the column.
- the pocket may include first and second parallel side members and a third member perpendicularly disposed relative to the first and second parallel side members.
- the third member may extend between the first side member and the second side member.
- the panel body may include a fifth frame disposed above the first frame, with respect to gravity, such that the third and fourth frames extend above the first frame and couple to the fifth frame.
- the panel body may include a fifth frame spaced away from the first frame and coupled to the third frame and the fourth frame, such that the pocket is adapted to receive a structural member between the first frame and the fifth frame.
- the third member may be the first end of the column such that the first side member, the second side member, and the first end of the column define an opening that is sized to receive a portion of a structural member.
- the pocket may be a notch disposed on an exterior surface of the first frame, the exterior surface opposite the interior surface of the first frame.
- At least one of the second frame, the third frame, and the fourth frame may define a pocket that is configured to receive a portion of a structural member.
- first frame, the second frame, the third frame, and the fourth frame may include a first material.
- the column may be a second material.
- the first material may be a non-metal and the second material may be a metal.
- the first material may include at least one of wood, PVC, high-density foam, and a composite.
- a width of the column may be greater than a width of the third frame and a width of the fourth frame.
- a length of the column may be less than a length of the third frame and a length of the fourth frame.
- each of the first, second, third, and fourth frames may include a core member of a primary material, a jacket of a secondary material, and a mating surface defined by the jacket.
- the jacket may at least partially enclose the core member such that the core member is embedded with the jacket.
- the mating surface of the third frame may define a groove in the jacket and the mating surface of the fourth frame may define a protruding member extending from the jacket.
- a portion of the jacket of each of the third and fourth frames may be compressible when the protrusion of the fourth frame engages the groove of the third frame.
- the column may be fixedly secured to the first frame and the second frame.
- the second frame may include a first section and a second section.
- the column may extend between the first and second sections of the second frame.
- the second frame may include a notch that is disposed on an exterior surface of the second frame such that the notch receives the second end of the column.
- a first surface of the column may be disposed adjacent the first skin and the foam core may be disposed between a second surface of the column and the second skin, the second surface being opposite the first surface of the column.
- the foam core may encapsulate first and second opposing surfaces of the column.
- the third frame may include a metal column.
- the fourth frame may include a metal column.
- a cover may be releasably secured to the pocket.
- forming a cavity may include fastening a first skin to a first side of the panel body and fastening a second skin to a second side of the panel body.
- FIG. 1 is a perspective, cutaway view of an example insulated panel constructed in accordance with the teachings of the present disclosure
- FIG. 2 is a perspective view of a first exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure
- FIG. 3 is a front view of the panel body of FIG. 2 ;
- FIG. 4 is a front view of a second exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure
- FIG. 5 is a front view of a third exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure
- FIG. 6 is a perspective view of a fourth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure.
- FIG. 7 is a perspective view of a fifth exemplary panel body of an insulted panel constructed in accordance with the teachings of the present disclosure.
- FIG. 8 is a perspective view of a sixth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure.
- FIG. 9 is a partial, front view of a beam disposed in an exemplary pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure.
- FIG. 10 is a front view of a different example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure
- FIG. 11 is a front view of a different example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure
- FIG. 12 is a front view of another example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure.
- FIG. 13 is a front view of another example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure
- FIG. 14 is a front view of a seventh exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure.
- FIG. 15A is a cross-sectional view of a first exemplary configuration of the panel body of FIG. 3 taken at A-A;
- FIG. 15B is a cross-sectional view of a second exemplary configuration of the panel body of FIG. 3 taken at A-A;
- FIG. 15C is a cross-sectional view of a third exemplary configuration of the panel body of FIG. 3 taken at A-A;
- FIG. 16 is a partial, top view of an example frame joint between two insulated panels constructed in accordance with the teachings of the present disclosure
- FIG. 17 is a front view of an eighth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure.
- FIG. 18 is an example method of manufacturing an insulated panel in accordance with the teachings of the present disclosure.
- the present disclosure is generally directed to a structurally reinforced, insulated panel (hereinafter, the “panel”) used to construct storage units (e.g., cold storage units, for example, coolers and freezers) and improve upon thermal performance, structural performance, energy performance, and life cycle of the storage units.
- the panel increases the structural performance by using a single column embedded in a foam core.
- the column more efficiently supports and transfers loads from a first frame of the panel to the ground than a panel having multiple studs spanning the height and width of the panel.
- the panel may increase thermal performance by containing more insulating material of the foam core because there is only one column, rather than multiple columns, embedded in the foam core.
- FIG. 1 depicts a first exemplary panel 100 constructed in accordance with the teachings of the present disclosure.
- the panel 100 includes a panel body 102 having a first frame 104 , a second frame 106 spaced away from the first frame 104 , a third frame 108 , and a fourth frame 110 spaced away from the third frame 108 .
- Each of the first, second, third, and fourth frames 104 , 106 , 108 , 110 includes an interior surface 112 that together partially define a cavity 114 of the panel body 102 .
- the perimeter of the cavity 114 is defined by the interior surface 112 of the first frame 104 , the second frame 106 , the third frame 108 , the fourth frame 110 , and an edge 116 of a pocket 118 .
- a column 120 is disposed in the cavity 114 and has a first end 120 a coupled to the first frame 104 and a second end 120 b coupled to the second frame 106 .
- a foam core 122 is disposed in the cavity 114 of the panel 100 and at least partially encapsulates the column 120 such that the column 120 is embedded with the foam core 122 .
- At least one skin 124 which may take the form of a metal sheet, may be disposed on either side of the panel 100 .
- the panel 100 may include a first skin 124 a coupled to the first side 100 a of the panel 100 and a second skin 124 b coupled to the second side 100 b of the panel 100 .
- the first and second skins 124 a , 124 b may be coupled to the first and second sides 100 a , 100 b of the panel 100 using any fastening mechanism.
- first and second skins 124 a , 124 b can be coupled to the first, second, third, and/or fourth frames 104 , 106 , 108 , 110 of the panel 100 using an adhesive; at least one fastener, such as, a screw, a nail, a staple; at least one latch; or by punching a portion of the first and second skins 124 a , 124 b in the panel body 102 .
- adhesives may be used, but due to thermal fluctuations experienced by the panel 100 , a physical fastener may be preferred to a chemical adhesive.
- the first and second skins 124 a , 124 b may be any material suitable for the purpose of insulating and protecting the panel 100 .
- first and second skins 124 a , 124 b can be metal, plywood, plastic, or oriented strand board (OSB). As shown in FIG. 1 , the first skin 124 a may be rectangular having a U-shaped cut-out to form the pocket 118 .
- the pocket 118 is shaped to receive a portion of a structural member, such as a beam (not shown), and is formed by the panel body 102 .
- the first frame 104 defines the pocket 118 .
- the pocket 118 is defined by the first frame 104 in the example illustrated in FIG. 1
- the pocket 118 can be defined by the second frame 106 , the third frame 108 , or the fourth frame 110 .
- the pocket 118 can be formed in part by the first end 120 a of the column 120 , which will be described in greater detail later.
- a different panel body 202 is constructed in accordance with the teachings of the present disclosure, and may form the structural skeleton of an insulated panel, such as the insulated panel 100 of FIG. 1 .
- the panel body 202 of FIG. 2 is similar to the panel body 102 of the insulated panel 100 of FIG. 1 , except for variations in the first, second, third, and fourth frames 204 , 206 , 208 , 210 .
- the same or similar components of the panel body 202 will retain the same reference numbers as outlined above with respect to the panel body 102 of the panel 100 , although the reference numbers will be increased by 100.
- the panel body 202 includes the first frame 204 , the second frame 206 , the third frame 208 , and the fourth frame 210 .
- the third frame 208 and the fourth frame 210 couple the first frame 204 and the second frame 206 to form a rectangular shape of the panel body 202 .
- the third frame 208 extends a height H 1 of the panel body 202 between the first frame 204 and the second frame 206
- the fourth frame 210 is parallel to the third frame 208 and extends a height H 2 of the panel body 202 between the first frame 204 and the second frame 206 .
- the third frame 208 and the fourth frame 210 can be non-parallel or partially non-parallel for a customized or irregularly shaped panel body 202 .
- the third and fourth frames 208 , 210 may be coupled to the first and second frames 204 , 206 using any suitable attachment mechanism.
- the third and fourth frames 208 , 210 can be coupled to the first and second frames 204 , 206 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint, or a mechanical fastener, such as, a screw, a nail, a staple, or other suitable mechanical fastener.
- the first frame 204 , the second frame 206 , the third frame 208 , and the fourth frame 210 may be any type of material.
- each of the first, second, third, and fourth frames 204 , 206 , 208 , 210 can be a hybrid frame having an insulative component and a structural component, which will be discussed later in more detail, such as the hybrid frames disclosed in U.S. Provisional Application No. 62/751,325 filed Oct. 26, 2018, titled “Hybrid Insulating Panel, Frame, and Enclosure,” which is incorporated herein by reference.
- each of the first, second, third, and fourth frames 204 , 206 , 208 , 210 may instead be composed of one material.
- each of the first, second, third, and fourth frames 204 , 206 , 208 , 210 can be elongated pieces of wood, such as, but not limited to, a two inch (2′′) by four inch (4′′) wooden beam.
- each of the first, second, third, and fourth frames 204 , 206 , 208 , 210 can each be a foam.
- the third and fourth frames 208 , 210 can include a metal column.
- the first frame 204 at least partially defines the pocket 218 that receives a portion of a structural member (e.g., a horizontal beam, not shown).
- the pocket 218 may be centrally disposed between the third and fourth frames 208 , 210 . However, in other examples, the pocket 218 can be disposed closer to either the third frame 208 or the fourth frame 210 .
- the pocket 218 includes a first side member 226 , a second side member 228 , and a third member 230 extending between the first side member 226 and the second side member 228 .
- the first and second side members 226 , 228 are spaced away from each other and extend transversely from the first frame 204 .
- the first and second side members 226 , 228 perpendicularly extend from the first frame 204 and are substantially equal in length. In other examples, however, the first and second side members 226 , 228 perpendicularly extend from the first frame 204 and are not substantially equal in length.
- the pocket 218 also includes the third member 230 that extends between the first side member 226 and the second side member 228 .
- the third member 230 receives a majority of the load transferred from the structural member sitting in the pocket 218 because the structural member sits directly on top of the third member 230 .
- the third member 230 may be made of a material strong enough to withstand and properly transfer the load from the structural member to the column 220 .
- the third member 230 can be a single wooden beam, or a single piece of plywood, coupled to the first and second side members 226 , 228 .
- the third member 230 can be a plurality of wooden beams, or a plurality of pieces of plywood, fixedly secure to one another.
- other materials can be used for the third member 230 , such as, for example, a polymer, a rubber, a carbon fiber, or other suitable material.
- the first and second side members 226 , 228 may be coupled to the first frame 204 using any attachment mechanism.
- the first and second side members 226 , 228 can be coupled to the first frame 204 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint, or a mechanical fastener, such as, a screw, a nail, a staple, or other suitable fastener.
- the first and second side members 226 , 228 may be any type of material.
- the first and second side members 226 , 228 can be elongated pieces of wood, such as, but not limited to, a two inch (2′′) by four inch (4′′) wooden stud, or plywood.
- the first and second side members 226 , 228 may be the same type of material. However, in other examples, the first and second side members 226 , 228 can each be different types of materials. Further, the third member 230 may be coupled to the first and second side members 226 , 228 using any attachment mechanism. For example, the third member 230 can be coupled to the first and second side members 226 , 228 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint, or a mechanical fastener, such as, a screw, a nail, a staple, or other suitable fastener.
- the column 220 extending between and coupled to the first frame 204 and the second frame 206 helps transfer the load from the structural member (e.g., a horizontal beam) to the ground.
- the use of a single column concentrates the load on a single support structure of the panel body 202 , which receives an even distribution of the load because the structural member sits directly above the column 220 .
- the column 220 extends between the second frame 206 and the third member 230 , and is coupled to the interior surface 212 of the second frame 206 at a second end 220 b of the column 220 and is coupled to the third member 230 at a first end 220 a of the column 220 .
- the first end 220 a of the column 220 includes a first plate 232 for attaching the column 220 to the third member 230 and the second end 220 b of the column 220 includes a second plate 234 for attaching the column 220 to the second frame 206 .
- the first and second plates 232 , 234 may be integrally formed with the column 220 . In other examples, the first and second plates 232 , 234 can be secured to the column 220 by welding or through the use of fasteners.
- the first plate 232 and the second plate 234 each includes a fastening mechanism 236 for attaching the first and second plates 232 , 234 to the third member 230 and the second frame 206 , respectively.
- the fastening mechanism 236 may be any mechanism capable of securely fixing the first and second plates 232 , 234 to the third member 230 and the second frame 206 , respectively.
- the fastening mechanism 236 can be a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener.
- a width W 1 of the column 220 is greater than a width W 2 of the third frame 208 and a width W 3 of the fourth frame 210 .
- a height H 3 of the column 220 may be less than a height H 1 of the third frame 208 and a height H 2 of the fourth frame 210 .
- the height H 3 of the column 220 can be greater than the height H 1 of the third frame 208 and the height H 2 of the fourth frame 210 .
- the column 220 may be a material suitably strong enough to effectively transfer the load from the structural member to the ground.
- the column 220 can be made of steel, and in particular, ASTM A500, Grade B steel.
- the column 220 is centrally disposed in the cavity 214 between the third frame 208 and the fourth frame 210 such that a first distance D 1 between the third frame 208 and the column 220 and a second distance D 2 between the fourth frame 210 and the column 220 are substantially equal.
- the column 220 can be disposed off-center (e.g., closer to the third frame 208 or closer to the fourth frame 210 ) depending on the placement of the panel 200 in an enclosure created with multiple structurally reinforced panels 200 or other panels.
- FIG. 4 illustrates a second exemplary panel body 302 constructed in accordance with the teachings of the present disclosure.
- the second exemplary panel body 302 is similar to the panel body 202 of FIGS. 2 and 3 , except that a pocket 318 of the second exemplary panel body 302 is at least partially defined by a first end 320 a of the column 320 .
- the structural member sits directly on the column 320 or on a bracket attached to the column 320 .
- the first and second side members 326 , 328 are coupled directly to the first end 320 a of the column 320 .
- the first end 320 a of the column 320 may be a bracket or flanged member fixed to the column 320 providing the first end 320 a , which may be thicker to accommodate the load placed directly on top of the first end 320 a .
- the first end 320 a of the column 320 may also include a shock absorbing material.
- the first end 320 a can include a piece of rubber that comes into contact with the structural member to facilitate placement and reduce vibrations during assembly.
- FIG. 5 illustrates a third exemplary panel body 402 constructed in accordance with the teachings of the present disclosure.
- the third exemplary panel body 402 of FIG. 5 is similar to the panel body 202 of FIGS. 2 and 3 , except the third exemplary panel body 402 provides a different pocket configuration.
- the same or similar components of the panel body 402 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3 , although the reference numbers will be increased by 200.
- the pocket 418 may be disposed in a cavity 414 of the panel body 402 and is partly defined by a first frame 404 , similar to the pocket 218 illustrated in FIGS. 2 and 3 .
- the panel body 402 of FIG. 5 further includes a fifth frame 438 disposed above the first frame 404 , with respect to gravity.
- the third and fourth frames 408 , 410 extend past the first frame 404 and couple to the fifth frame 438 .
- the fifth frame 438 is similar to the first frame 404 and may be made of the same material as the first frame 404 .
- the fifth frame 438 may be coupled to the third and fourth frames 408 , 410 using any suitable attachment mechanism.
- the fifth frame 438 can be coupled to the third and fourth frames 408 , 410 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint; or a mechanical fastener, such as, a screw, a nail, a staple; or other suitable mechanical fastener.
- the first frame 404 of the third exemplary panel body 402 also differs from the first frame 204 of the first exemplary panel body 202 because the first frame 404 creates a closed pocket 418 ; whereas the first frame 204 of the first exemplary panel body 202 creates an open pocket 218 . As shown in FIG.
- the pocket 418 is entirely disposed within the first cavity 414 of the frame and a second cavity 440 , which is defined by the first frame 404 , the fifth frame 438 , part of the third frame 408 , and part of the fourth frame 410 .
- the second cavity 440 may be filled with foam. However, in other examples, the second cavity 440 does not have foam.
- the pocket 418 illustrated in FIG. 5 is adapted to receive a structural member between the first frame 404 and the third member 430 of the pocket 418 .
- FIG. 6 illustrates a fourth exemplary panel body 502 constructed in accordance with the teachings of the present disclosure.
- the fourth exemplary panel body 502 of FIG. 6 is similar to the panel body 402 of FIG. 5 except the fourth exemplary panel body 502 provides a different pocket configuration.
- the same or similar components of the panel body 502 will retain the same reference numbers as outlined above with respect to the panel body 402 of FIG. 5 , although the reference numbers will be increased by 100.
- the panel body 502 of FIG. 6 includes third and fourth frames 508 , 510 that extend between first and second frames 504 , 506 to form a cavity 514 .
- the fourth exemplary panel body 502 includes sixth and seventh frames 542 , 544 that are disposed in the cavity 514 between the third and fourth frames 508 , 510 , and extend in parallel between the first and second frames 504 , 506 . While the sixth and seventh frames 542 , 544 extend in parallel to one another, as illustrated in FIG.
- the sixth and seventh frames 542 , 544 may be non-parallel or partially non-parallel for a customized or irregularly shaped panel body 502 .
- the sixth and seventh frames 542 , 544 may be coupled to the first and second frames 504 , 506 using any suitable attachment mechanism.
- the sixth and seventh frames 542 , 544 can be coupled to the first and second frames 504 , 506 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint; or a mechanical fastener, such as, a screw, a nail, a staple; or other suitable mechanical fastener.
- Coupling the sixth and seventh frames 542 , 544 to the first and second frames 504 , 506 forms a third cavity 548 between the sixth and seventh frames 542 , 544 and a fourth cavity 550 between the third frame 508 and the sixth frame 542 .
- Disposed in the third cavity 548 is a column 520 having a first end 520 a and a second end 520 b .
- the second end 520 b of the column 520 is coupled to the second frame 506 and the first end 520 a of the column 520 at least partially defines the pocket 518 .
- a structural member may sit directly on the column 520 or on a bracket attached to the column 520 .
- the sixth and seventh frames 542 , 544 are directly coupled to the first end 520 a of the column.
- the first end 520 a of the column 520 may be a bracket or flanged member fixed to the column 520 providing the first end 520 a , which may be thicker to accommodate the load placed directly on top of the first end 520 a .
- the first end 520 a may include, for example, a piece of rubber that comes into contact with the structural member to facilitate placement and to reduce vibrations during assembly.
- a pocket 518 is disposed in the third cavity 548 and above the column 520 of the panel body 502 .
- the pocket 518 is defined by a portion of the sixth frame 542 , a portion of the seventh frame 544 , a fourth member 546 , and the first end 520 a of the column 520 .
- the fourth member 546 is disposed a distance D 3 above the first end 520 a of the column 520 , with respect to gravity, and extends between the sixth and seventh frames 542 , 544 .
- the fourth member 546 may be disposed any distance D 3 above the first end 520 a of the column 520 that allows the pocket 518 to receive a support member.
- FIG. 7 illustrates a fifth exemplary panel body 602 constructed in accordance with the teachings of the present disclosure.
- the fifth exemplary panel body 602 of FIG. 7 is similar to the panel body 202 of FIGS. 2 and 3 , except the fifth exemplary panel body 602 provides a different pocket configuration.
- the same or similar components of the panel body 602 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3 , although the reference numbers will be increased by 400.
- a pocket 618 of the fifth exemplary panel body 602 is defined in part by the first frame 604 .
- the fifth exemplary pocket 618 is formed outside of the cavity 614 and defined by an inner surface 612 of the first side member 626 , second side member 628 , and third member 630 .
- a first side member 626 and a second side member 628 extend above the first frame 604 , with respect to gravity, and a third member 630 extends between the first and second side members 626 , 628 .
- a column 620 passes through the third member 630 and a first end 620 a of the column 620 rests on an exterior surface of the third member 630 .
- the first end 620 a of the column 620 includes a first plate 632 for attaching the column 620 to the third member 630 and the first plate 632 may include a fastening mechanism for attaching the first plate 632 to the third member 630 .
- the fastening mechanism can be a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. While the first plate 632 is illustrated in FIG.
- the first plate 632 can be disposed against the interior surface 612 (i.e., facing the cavity) of the third member 630 .
- the second end 620 b of the column 620 extends through the second frame 606 and is received in a notch disposed in the outer surface of the second frame 606 .
- the notch disposed in the outer surface of the second frame 606 extends through only one side of the second frame 606 .
- FIG. 8 illustrates a sixth exemplary panel body 702 constructed in accordance with the teachings of the present disclosure.
- the sixth exemplary panel body 702 of FIG. 8 is similar to the panel body 402 of FIG. 5 except the sixth exemplary panel body 702 provides a different pocket configuration.
- the same or similar components of the panel body 702 will retain the same reference numbers as outlined above with respect to the panel body 402 of FIG. 5 , although the reference numbers will be increased by 300.
- the sixth exemplary panel body 702 is defined by a first frame 704 , a second frame 706 , a third frame 708 , and a fourth frame 710 .
- a pocket 718 of the sixth exemplary panel body 702 is not defined by the first frame 704 .
- the pocket 718 is defined by a first side member 726 , a second side member 728 , a third member 730 , and a first end 720 a of a column 720 .
- the first and second side members 726 , 728 extend transversely from the first end 720 a of the column 720 and the third member 730 extends between the first and second side members 726 , 728 .
- the first end 720 a of the column 720 includes a first plate 732 for attaching the column 720 to the first and second side members 726 , 728 .
- the first plate 732 may be attached to the first and second side members 726 , 728 using, for example, a fastening mechanism, such as, a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener.
- first and second side members 726 , 728 are coupled to the third member 730 , for example, using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint; a mechanical fastener, such as, a screw, a nail, a staple; or other suitable mechanical fastener.
- FIGS. 9-13 illustrate different examples of pocket configurations.
- the pocket 818 may take additional shapes other than rectangular depending on the shape of the structural member.
- a pocket 818 may take the form of a notch 856 disposed in a first frame 804 of a panel body 802 .
- the notch 856 may be of any depth such that a portion of a structural member 858 is disposed in the notch 856 .
- the notch depth can be equal to a thickness of a portion of the structural member 858 , which in this case is an I-beam. In other examples, the notch depth can be greater than a thickness of a portion of the I-beam.
- the notch 856 may also include at least one blind bore that receives a portion of an attachment mechanism.
- the column extends from a second frame to the first frame.
- the column may extend from the second frame to the first frame such that a first end of the column sits beneath the structural member 858 (e.g., an I-beam).
- the pocket 918 A is defined by a U-shaped bracket instead of first and second parallel side members and third member.
- the pocket 918 B has a V-shaped opening.
- the pocket 918 C defines a narrow groove, similar to the notch 856 discussed above.
- the pocket 918 D may take the shape of a circle or oval.
- a seventh exemplary panel body 1002 is constructed in accordance with the teachings of the present disclosure.
- the seventh exemplary panel body 1002 of FIG. 14 is similar to the panel body 202 of FIGS. 2 and 3 , except the seventh exemplary panel body 1002 provides a different column configuration.
- the same or similar components of the panel body 1002 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3 , although the reference numbers will be increased by 800.
- a column 1020 extends between a first section 1060 and a second section 1062 of a second frame 1006 .
- the first and second sections 1060 , 1062 may be equal lengths when the column 1020 is centrally disposed in the panel body 1002 .
- the first and second sections 1060 , 1062 can vary in length.
- the first section 1060 may be a first length L 1 and the second section 1062 may be a second length L 2 .
- a second end 1020 b of the column 1020 does not include a second plate (as shown in FIG. 3 ).
- an outer surface 1064 of the second frame 1006 can include a notch that is adapted to receive a second plate.
- the frame members 104 , 106 , 108 , 110 enclosed by the first and second skins 124 a , 124 b define the cavity 114 in which an insulting material is disposed.
- the insulating material is inserted into the cavity 114 of the panel body 102 (as well as any of the cavities of the exemplary panel bodies disclosed herein) to improve the insulative properties of the panel 100 (i.e., thermal conductivity and thermal resistivity).
- the insulating material is inserted into the cavity 114 in liquid form and sits until the insulating material cures. After the insulating material cures, it becomes one solid piece of insulation, otherwise known as the foam core 122 of the panel 100 .
- the foam core 122 can be a pre-cured block that is cut, or otherwise trimmed, to the size of the cavity 114 .
- the foam core 122 is inserted into the cavity 114 after the foam core 122 has been cut or trimmed to the size of the cavity 114 .
- the foam core 122 may be any insulating material that improves the insulative properties of the panel 100 .
- the foam core 122 can be asbestos, fiberglass, mineral wool, cellulose, polyurethane foam, polystyrene, or other suitable material.
- the foam core 122 may also have any foam density that properly reduces the thermal conductivity of the panel 100 based on the application.
- the foam core 122 can have a foam density of between 1.0 to 3.0 pounds per cubic foot and, more particularly, 2.2 pounds per cubic foot.
- first, second, and third panel configurations 1102 A, 1102 B, 1102 C having different foam core configurations are constructed in accordance with the teachings of the present disclosure. These configurations illustrate different example iterations of the panel body 202 of FIG. 3 , but may be incorporated into any of the panel body examples disclosed herein.
- the three configurations 1102 A, 1102 B, 1102 C are provided to illustrate variations in which the column 1120 may be embedded within a foam core.
- the column 1120 may include first and second opposing surfaces 1166 , 1168 in which one or both surfaces may be surrounded by insulation foam.
- the column 1120 has a thickness T 1 that is less than a thickness T 2 of the third frame and a thickness T 3 of the fourth frame. Since the thickness T 1 of the column 1120 is less than the thicknesses T 2 , T 3 of the third and fourth frames, at least one gap 1170 is formed between a first surface 1166 and/or a second surface 1168 of the column 1120 and an inner surface of the first and second skins. As best illustrated in FIGS. 15A-C , the at least one gap 1170 allows the insulating material to substantially surround the column 1120 , such that the column 1120 is embedded with the foam core. Such a configuration allows the foam core to include a maximum amount of insulating material giving the panel better insulative properties over known insulation panels.
- At least one gap 1170 may be disposed on either side of the panel.
- the first surface 1166 of the column 1120 is adapted to abut a first skin 1124 a , such as the first skin 124 a of the panel 100 of FIG. 1
- the second surface 1168 of the column 1120 is spaced away from a second skin 1124 b , such as the second skin 124 b of the panel of FIG. 1 , thereby providing the gap 1170 in which insulating foam may be inserted.
- the gap 1170 is disposed on a second side 1172 of the panel body 1102 .
- the column 1120 is disposed between, and spaced from, the first and second skins 1124 a , 1124 b , thereby providing gaps 1170 adjacent to both the first and second surfaces 1166 , 1168 of the column 1120 .
- the second surface 1168 of the column 1120 is adapted to abut a second skin 1124 b , such as the second skin 124 b of the panel 100 of FIG. 1
- the first surface 1166 of the column 1120 is spaced away from a first skin 1124 a , such as the first skin 124 a of the panel 100 of FIG. 1 , thereby providing the gap 1170 in which insulating foam may be inserted.
- the gap 1170 is disposed on a first side 1174 of the panel.
- the panel 200 may include a distribution plate (not shown) coupled to the pocket 218 that helps evenly distribute the load of the structural member, if more than one column 220 is disposed between the first frame 204 and the second frame 206 .
- the distribution plate can be disposed below the pocket 218 and above the at least one column 220 .
- the distribution plate can be fixedly secured to the third member 230 using any of the attachment mechanisms discussed above and each of the at least one column 220 can be fixedly secured to the distribution plate.
- the panel 200 may include a cover (not shown) that is slidably received by the pocket 218 . In other examples, the cover can be press fit into the pocket 218 .
- the first, second, third, and fourth frames of any of the example panel bodies may be hybrid frames.
- FIG. 16 a third frame of the panel 100 of FIG. 1 and a fourth frame of a different, but identical panel 100 , is illustrated in detail.
- the third frame is labeled as 1208 and the fourth frame is labeled as 1210 .
- Each hybrid frame 1208 , 1210 includes a beam 1276 of a primary material and a jacket 1278 , 1280 of a secondary material at least partially enclosing the beam 1276 .
- the beam 1276 of the hybrid frame 1208 , 1210 may be plywood, lumber, magnesium oxide, gypsum, rigid plastic, fiberglass, carbon fiber, Kevlar, fiberglass reinforced plastic resin, PVC, or other rigid material.
- the jacket 1278 of the third frame 1208 defines a first joint member 1282 and the jacket 1280 of the fourth frame 1210 defines a second joint member 1284 .
- the jacket 1278 of the third frame 1208 and the jacket 1280 of the fourth frame 1210 are formed such that the second joint member 1284 receives the first joint member 1282 when coupled.
- the first joint member 1282 defines a protrusion 1286 and the second joint member 1284 defines a groove 1288 for a tongue and groove coupling joint.
- first joint member 1282 of the panel can be coupled to the second joint member 1284 of another panel to form a wall, a ceiling, or a floor.
- first joint member 1282 and the second joint member 1284 can both form protrusions 1286 and, in other examples, the first joint member 1282 and the second joint member 1284 can both form grooves 1288 .
- the illustrated beam 1276 is rectangular, but may have different shapes for structural performance and/or bonding with the material of the jacket. Additionally, the illustrated beam 1276 is one material, however, in other examples, the beam 1276 may be composed of one or more materials.
- the beam 1276 may be a rectangular tube (of any of the rigid materials provided above) that is configured to be filled with polyurethane foam.
- an eighth exemplary panel body 1502 is constructed in accordance with the teachings of the present disclosure.
- the eighth exemplary panel body 1502 of FIG. 17 is similar to the panel body 202 of FIGS. 2 and 3 , except the eighth exemplary panel body provides a different column and pocket configuration.
- the same or similar components of the panel body 1502 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3 , although the reference numbers will be increased by 1300 .
- the first end 1520 a of the column 1520 extends between a first section 1561 of the first frame 1504 and a second section 1563 of the first frame 1504 and the second end 1520 b of the column 1520 extends between the first section 1560 of the second frame 1506 and the second section 1562 of the second frame 1506 .
- the first and second sections 1561 , 1563 of the first frame 1504 and the first and second sections 1560 , 1562 of the second frame 1506 may be equal lengths when the column 1520 is centrally disposed in the panel body 1502 .
- the first and second ends 1520 a , 1520 b of the column 1520 include a first plate 1532 and a second plate 1534 , respectively.
- the first plate 1532 is disposed within the pocket 1518 , which takes the form of a notch disposed in the first frame 1504 .
- the second plate 1534 is disposed within a notch 1557 formed in an exterior surface of the second frame 1506 . So configured, both the first and second frames 1504 , 1506 include a notch formed on an exterior surface of the first and second frames 1504 , 1506 .
- the fastening mechanism 1536 takes the form of a plurality of lag bolts securing the column 1520 to the first and second frames 1504 , 1506 via the first and second plates 1532 , 1534 .
- the fastening mechanism 1536 can be a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener.
- the panel 1502 may also include at least one protrusion 1565 that is adapted to be received by a support member disposed in the pocket 1518 .
- the at least one protrusion 1565 can be disposed on the first plate 1532 and extend away from the first plate 1532 for a distance.
- the example at least one protrusion 1565 takes the form of a threaded cylinder that receives a nut to secure the support member to the panel 1502 .
- the at least one protrusion 1565 may take any shape and form that is complementary to the bore or aperture in the support member that is to receive the at least one protrusion 1565 .
- the second plate 1534 disposed at the second end 1520 b of the column 1520 may have a width that is greater than a width of the second frame 1506 such that the second plate 1534 at least partially extends past the width of the second frame 1506 .
- the panel body 1502 may be secured to a floor using the portion of the second plate 1534 that extends past the width of the second frame 1506 .
- the second plate 1534 can include at least one aperture that is adapted to receive a fastening mechanism that secures the panel body 1502 to the floor.
- FIG. 18 depicts an example method of manufacturing 1300 an insulated panel 100 , such as the panel 100 of FIG. 1 , in accordance with the teachings of the present disclosure.
- the method 1300 includes providing the panel body 102 by coupling the first frame 104 and the second frame 106 via the third frame 108 and the fourth frame 110 , such that the second frame 106 is spaced away from the first frame 104 and the fourth frame 110 is spaced away from the third frame 108 (Step 1392 ).
- the method 1300 then involves coupling the column 120 to the panel body 102 by coupling the first end 120 a of the column 120 to the first frame 104 and the second end 120 b of the column 120 to the second frame 106 (Step 1394 ).
- the method 1300 then involves forming a cavity in the panel body (Step 1396 ), which includes fastening the first skin 124 a to the first side 100 a of the panel 100 and fastening the second skin 124 b to the second side 100 b of the panel 100 .
- a foam material in liquid phase, is dispensed into the cavity 114 (Step 1398 ).
- the foam material is cured and forms the foam core 122 in the cavity 114 , such that the column 120 is embedded with the foam core 122 (Step 1400 ).
- providing the panel body 102 further includes forming the pocket 118 having a U-shaped opening in the first frame 104 , the pocket 118 being sized to receive a beam or support member.
- dispensing the foam material in the cavity 114 further includes injecting the foam material into the cavity 114 via a hole in the panel body 102 .
- the panel may be made from cured foam shaped to the desired panel shape and size.
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Abstract
Description
- This application claims the benefit of the filing date of U.S. Provisional Application No. 62/821,294, filed Mar. 20, 2019, the disclosure of which is hereby incorporated by reference in its entirety.
- The present disclosure generally relates to insulated panels and, more particularly, to a structurally reinforced insulated panel.
- Freezers or refrigerated enclosures, such as refrigerated display cases and storage units, are typically constructed of materials that either have high insulative properties or high structural reliability, but not both. For example, structurally reliable materials used for a frame, such as wood, steel, and aluminum, have a low R value (i.e., thermal resistivity) and allow heat to enter the refrigerated enclosure through the frame (i.e., panel perimeter). Further, many known freezers or refrigerators use multiple studs distributed through a panel body to increase the structural integrity of the insulated panel. However, placing multiple studs within the panel body decreases the amount of insulating material that can be placed within the panel body and increases the number of areas within the panel or enclosure that act as a thermal bridge, which decreases the efficiency of the freezer or refrigerator. In these applications, the thermal resistivity of the panel is traded for the structural performance of the panel or enclosure. That is, structural performance will be optimized, but the thermal resistivity (i.e., R value) of the panel or enclosure would consequently be diminished.
- In accordance with a first exemplary aspect of the present disclosure, an insulated panel for a storage unit is provided. The panel may include a first frame, a second frame, a third frame, and a fourth frame. The first, second, third, and fourth frames may each include an interior surface that forms a cavity of the panel body. The second frame is spaced away from the first frame and the third frame is spaced away from the fourth frame. A column may be disposed in the cavity and may have a first end coupled to the first frame and a second end coupled to the second frame. A foam core may be disposed in the cavity such that the column is embedded with the foam core.
- In accordance with a second exemplary aspect of the present disclosure, an insulated panel for a storage unit is provided. The panel may include a first frame, a second frame, a third frame, and a fourth frame. The first, second, third, and fourth frames may each include an interior surface. The panel may also include a cavity defined by the interior surfaces. The second frame may be spaced away from the first frame and the third frame may be spaced away from the fourth frame. A pocket may be at least partially defined by the first frame and sized to receive a beam. A column may be disposed in the cavity and may extend between the first frame and the second frame. A foam core may be disposed in the cavity such that the column is embedded with the foam core.
- In accordance with a third exemplary aspect of the present disclosure, an insulated panel for a storage unit is provided. The insulated panel may include a panel body including a first frame, a second frame, a third frame, and a fourth frame. The first, second, third, and fourth frames may each include interior surfaces forming a cavity of the panel body. The second frame may be spaced away from the first frame, and the third frame may be spaced away from the fourth frame. A pocket may be at least partially defined by the first frame and sized to receive a beam. A load-bearing column may be disposed in the cavity and extend between the first frame and the second frame. The load-bearing column may be configured to receive a point load from the beam. A foam core may be disposed in the cavity such that the column is embedded with the foam core.
- In accordance with a fourth exemplary aspect of the present disclosure, a method of manufacturing a structurally reinforced insulated panel is provided. The method may include providing a panel body including a first frame, a second frame, a third frame, and a fourth frame. The first frame may be spaced away from the second frame and the third frame may be spaced away from the fourth frame. The method may include coupling a column to the panel body by coupling a first end of the column to the first frame and a second end of the column to the second frame. The method may further include forming a cavity in the panel body. The method may include dispensing a foam material in liquid phase into the cavity. Finally, the method may include curing the foam material to form a foam core such that the column is embedded with the foam material.
- In a preferred aspect, the first frame may define a pocket that is configured to receive a portion of a structural member.
- In a preferred aspect, the pocket may be disposed outside the cavity and adjacent to the column.
- In a preferred aspect, the pocket may include first and second parallel side members and a third member perpendicularly disposed relative to the first and second parallel side members.
- In a preferred aspect, the third member may extend between the first side member and the second side member.
- In a preferred aspect, the panel body may include a fifth frame disposed above the first frame, with respect to gravity, such that the third and fourth frames extend above the first frame and couple to the fifth frame.
- In a preferred aspect, the panel body may include a fifth frame spaced away from the first frame and coupled to the third frame and the fourth frame, such that the pocket is adapted to receive a structural member between the first frame and the fifth frame.
- In a preferred aspect, the third member may be the first end of the column such that the first side member, the second side member, and the first end of the column define an opening that is sized to receive a portion of a structural member.
- In a preferred aspect, the pocket may be a notch disposed on an exterior surface of the first frame, the exterior surface opposite the interior surface of the first frame.
- In a preferred aspect, at least one of the second frame, the third frame, and the fourth frame may define a pocket that is configured to receive a portion of a structural member.
- In a preferred aspect, the first frame, the second frame, the third frame, and the fourth frame may include a first material.
- In a preferred aspect, the column may be a second material.
- In a preferred aspect, the first material may be a non-metal and the second material may be a metal.
- In a preferred aspect, the first material may include at least one of wood, PVC, high-density foam, and a composite.
- In a preferred aspect, a width of the column may be greater than a width of the third frame and a width of the fourth frame.
- In a preferred aspect, a length of the column may be less than a length of the third frame and a length of the fourth frame.
- In a preferred aspect, each of the first, second, third, and fourth frames may include a core member of a primary material, a jacket of a secondary material, and a mating surface defined by the jacket.
- In a preferred aspect, the jacket may at least partially enclose the core member such that the core member is embedded with the jacket.
- In a preferred aspect, the mating surface of the third frame may define a groove in the jacket and the mating surface of the fourth frame may define a protruding member extending from the jacket.
- In a preferred aspect, a portion of the jacket of each of the third and fourth frames may be compressible when the protrusion of the fourth frame engages the groove of the third frame.
- In a preferred aspect, the column may be fixedly secured to the first frame and the second frame.
- In a preferred aspect, the second frame may include a first section and a second section.
- In a preferred aspect, the column may extend between the first and second sections of the second frame.
- In a preferred aspect, the second frame may include a notch that is disposed on an exterior surface of the second frame such that the notch receives the second end of the column.
- In a preferred aspect, a first surface of the column may be disposed adjacent the first skin and the foam core may be disposed between a second surface of the column and the second skin, the second surface being opposite the first surface of the column.
- In a preferred aspect, the foam core may encapsulate first and second opposing surfaces of the column.
- In a preferred aspect, the third frame may include a metal column.
- In a preferred aspect, the fourth frame may include a metal column.
- In a preferred aspect, a cover may be releasably secured to the pocket.
- In a preferred aspect, forming a cavity may include fastening a first skin to a first side of the panel body and fastening a second skin to a second side of the panel body.
-
FIG. 1 is a perspective, cutaway view of an example insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 2 is a perspective view of a first exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 3 is a front view of the panel body ofFIG. 2 ; -
FIG. 4 is a front view of a second exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 5 is a front view of a third exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 6 is a perspective view of a fourth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 7 is a perspective view of a fifth exemplary panel body of an insulted panel constructed in accordance with the teachings of the present disclosure; -
FIG. 8 is a perspective view of a sixth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 9 is a partial, front view of a beam disposed in an exemplary pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 10 is a front view of a different example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 11 is a front view of a different example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 12 is a front view of another example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 13 is a front view of another example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 14 is a front view of a seventh exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; -
FIG. 15A is a cross-sectional view of a first exemplary configuration of the panel body ofFIG. 3 taken at A-A; -
FIG. 15B is a cross-sectional view of a second exemplary configuration of the panel body ofFIG. 3 taken at A-A; -
FIG. 15C is a cross-sectional view of a third exemplary configuration of the panel body ofFIG. 3 taken at A-A; -
FIG. 16 is a partial, top view of an example frame joint between two insulated panels constructed in accordance with the teachings of the present disclosure; -
FIG. 17 is a front view of an eighth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; and -
FIG. 18 is an example method of manufacturing an insulated panel in accordance with the teachings of the present disclosure. - The present disclosure is generally directed to a structurally reinforced, insulated panel (hereinafter, the “panel”) used to construct storage units (e.g., cold storage units, for example, coolers and freezers) and improve upon thermal performance, structural performance, energy performance, and life cycle of the storage units. The panel increases the structural performance by using a single column embedded in a foam core. The column more efficiently supports and transfers loads from a first frame of the panel to the ground than a panel having multiple studs spanning the height and width of the panel. Moreover, the panel may increase thermal performance by containing more insulating material of the foam core because there is only one column, rather than multiple columns, embedded in the foam core.
-
FIG. 1 depicts a firstexemplary panel 100 constructed in accordance with the teachings of the present disclosure. Thepanel 100 includes apanel body 102 having afirst frame 104, asecond frame 106 spaced away from thefirst frame 104, athird frame 108, and afourth frame 110 spaced away from thethird frame 108. Each of the first, second, third, andfourth frames interior surface 112 that together partially define acavity 114 of thepanel body 102. In other words, the perimeter of thecavity 114 is defined by theinterior surface 112 of thefirst frame 104, thesecond frame 106, thethird frame 108, thefourth frame 110, and anedge 116 of apocket 118. Acolumn 120 is disposed in thecavity 114 and has afirst end 120 a coupled to thefirst frame 104 and asecond end 120 b coupled to thesecond frame 106. Afoam core 122 is disposed in thecavity 114 of thepanel 100 and at least partially encapsulates thecolumn 120 such that thecolumn 120 is embedded with thefoam core 122. - At least one
skin 124, which may take the form of a metal sheet, may be disposed on either side of thepanel 100. In particular, thepanel 100 may include afirst skin 124 a coupled to thefirst side 100 a of thepanel 100 and a second skin 124 b coupled to thesecond side 100 b of thepanel 100. The first andsecond skins 124 a, 124 b may be coupled to the first andsecond sides panel 100 using any fastening mechanism. For example, the first andsecond skins 124 a, 124 b can be coupled to the first, second, third, and/orfourth frames panel 100 using an adhesive; at least one fastener, such as, a screw, a nail, a staple; at least one latch; or by punching a portion of the first andsecond skins 124 a, 124 b in thepanel body 102. Alternatively or in addition, adhesives may be used, but due to thermal fluctuations experienced by thepanel 100, a physical fastener may be preferred to a chemical adhesive. The first andsecond skins 124 a, 124 b may be any material suitable for the purpose of insulating and protecting thepanel 100. For example, the first andsecond skins 124 a, 124 b can be metal, plywood, plastic, or oriented strand board (OSB). As shown inFIG. 1 , thefirst skin 124 a may be rectangular having a U-shaped cut-out to form thepocket 118. - The
pocket 118 is shaped to receive a portion of a structural member, such as a beam (not shown), and is formed by thepanel body 102. For example, as illustrated inFIG. 1 , thefirst frame 104 defines thepocket 118. While thepocket 118 is defined by thefirst frame 104 in the example illustrated inFIG. 1 , thepocket 118 can be defined by thesecond frame 106, thethird frame 108, or thefourth frame 110. In yet other examples, however, thepocket 118 can be formed in part by thefirst end 120 a of thecolumn 120, which will be described in greater detail later. - Turning now to
FIGS. 2 and 3 , adifferent panel body 202 is constructed in accordance with the teachings of the present disclosure, and may form the structural skeleton of an insulated panel, such as theinsulated panel 100 ofFIG. 1 . Thepanel body 202 ofFIG. 2 is similar to thepanel body 102 of theinsulated panel 100 ofFIG. 1 , except for variations in the first, second, third, andfourth frames panel body 202 will retain the same reference numbers as outlined above with respect to thepanel body 102 of thepanel 100, although the reference numbers will be increased by 100. - The
panel body 202 includes thefirst frame 204, thesecond frame 206, thethird frame 208, and thefourth frame 210. In particular, thethird frame 208 and thefourth frame 210 couple thefirst frame 204 and thesecond frame 206 to form a rectangular shape of thepanel body 202. As illustrated inFIG. 3 , thethird frame 208 extends a height H1 of thepanel body 202 between thefirst frame 204 and thesecond frame 206, and thefourth frame 210 is parallel to thethird frame 208 and extends a height H2 of thepanel body 202 between thefirst frame 204 and thesecond frame 206. However, in other examples, thethird frame 208 and thefourth frame 210 can be non-parallel or partially non-parallel for a customized or irregularly shapedpanel body 202. The third andfourth frames second frames fourth frames second frames - The
first frame 204, thesecond frame 206, thethird frame 208, and thefourth frame 210 may be any type of material. For example, each of the first, second, third, andfourth frames fourth frames fourth frames fourth frames fourth frames - In the
example panel body 202 illustrated inFIGS. 2 and 3 , thefirst frame 204 at least partially defines thepocket 218 that receives a portion of a structural member (e.g., a horizontal beam, not shown). Thepocket 218 may be centrally disposed between the third andfourth frames pocket 218 can be disposed closer to either thethird frame 208 or thefourth frame 210. Thepocket 218 includes afirst side member 226, asecond side member 228, and athird member 230 extending between thefirst side member 226 and thesecond side member 228. The first andsecond side members first frame 204. More particularly, in this example, the first andsecond side members first frame 204 and are substantially equal in length. In other examples, however, the first andsecond side members first frame 204 and are not substantially equal in length. Thepocket 218 also includes thethird member 230 that extends between thefirst side member 226 and thesecond side member 228. Thethird member 230 receives a majority of the load transferred from the structural member sitting in thepocket 218 because the structural member sits directly on top of thethird member 230. As such, thethird member 230 may be made of a material strong enough to withstand and properly transfer the load from the structural member to thecolumn 220. For example, thethird member 230 can be a single wooden beam, or a single piece of plywood, coupled to the first andsecond side members FIGS. 2 and 3 , thethird member 230 can be a plurality of wooden beams, or a plurality of pieces of plywood, fixedly secure to one another. It will be appreciated that other materials can be used for thethird member 230, such as, for example, a polymer, a rubber, a carbon fiber, or other suitable material. - The first and
second side members first frame 204 using any attachment mechanism. For example, the first andsecond side members first frame 204 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint, or a mechanical fastener, such as, a screw, a nail, a staple, or other suitable fastener. The first andsecond side members second side members second side members second side members third member 230 may be coupled to the first andsecond side members third member 230 can be coupled to the first andsecond side members - The
column 220 extending between and coupled to thefirst frame 204 and thesecond frame 206 helps transfer the load from the structural member (e.g., a horizontal beam) to the ground. The use of a single column concentrates the load on a single support structure of thepanel body 202, which receives an even distribution of the load because the structural member sits directly above thecolumn 220. In particular, as illustrated inFIGS. 2 and 3 , thecolumn 220 extends between thesecond frame 206 and thethird member 230, and is coupled to theinterior surface 212 of thesecond frame 206 at asecond end 220 b of thecolumn 220 and is coupled to thethird member 230 at a first end 220 a of thecolumn 220. The first end 220 a of thecolumn 220 includes afirst plate 232 for attaching thecolumn 220 to thethird member 230 and thesecond end 220 b of thecolumn 220 includes asecond plate 234 for attaching thecolumn 220 to thesecond frame 206. The first andsecond plates column 220. In other examples, the first andsecond plates column 220 by welding or through the use of fasteners. Thefirst plate 232 and thesecond plate 234 each includes afastening mechanism 236 for attaching the first andsecond plates third member 230 and thesecond frame 206, respectively. Thefastening mechanism 236 may be any mechanism capable of securely fixing the first andsecond plates third member 230 and thesecond frame 206, respectively. For example, thefastening mechanism 236 can be a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. Further, as shown inFIG. 3 , a width W1 of thecolumn 220 is greater than a width W2 of thethird frame 208 and a width W3 of thefourth frame 210. Additionally, a height H3 of thecolumn 220 may be less than a height H1 of thethird frame 208 and a height H2 of thefourth frame 210. However, in other embodiments, the height H3 of thecolumn 220 can be greater than the height H1 of thethird frame 208 and the height H2 of thefourth frame 210. Moreover, thecolumn 220 may be a material suitably strong enough to effectively transfer the load from the structural member to the ground. For example, thecolumn 220 can be made of steel, and in particular, ASTM A500, Grade B steel. - In
FIG. 3 , thecolumn 220 is centrally disposed in thecavity 214 between thethird frame 208 and thefourth frame 210 such that a first distance D1 between thethird frame 208 and thecolumn 220 and a second distance D2 between thefourth frame 210 and thecolumn 220 are substantially equal. However, in other examples, thecolumn 220 can be disposed off-center (e.g., closer to thethird frame 208 or closer to the fourth frame 210) depending on the placement of the panel 200 in an enclosure created with multiple structurally reinforced panels 200 or other panels. -
FIG. 4 illustrates a secondexemplary panel body 302 constructed in accordance with the teachings of the present disclosure. The secondexemplary panel body 302 is similar to thepanel body 202 ofFIGS. 2 and 3 , except that apocket 318 of the secondexemplary panel body 302 is at least partially defined by afirst end 320 a of thecolumn 320. In this case, the structural member sits directly on thecolumn 320 or on a bracket attached to thecolumn 320. The first andsecond side members first end 320 a of thecolumn 320. Thefirst end 320 a of thecolumn 320 may be a bracket or flanged member fixed to thecolumn 320 providing thefirst end 320 a, which may be thicker to accommodate the load placed directly on top of thefirst end 320 a. Thefirst end 320 a of thecolumn 320 may also include a shock absorbing material. For example, thefirst end 320 a can include a piece of rubber that comes into contact with the structural member to facilitate placement and reduce vibrations during assembly. - In another aspect,
FIG. 5 illustrates a thirdexemplary panel body 402 constructed in accordance with the teachings of the present disclosure. The thirdexemplary panel body 402 ofFIG. 5 is similar to thepanel body 202 ofFIGS. 2 and 3 , except the thirdexemplary panel body 402 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of thepanel body 402 will retain the same reference numbers as outlined above with respect to thepanel body 202 ofFIGS. 2 and 3 , although the reference numbers will be increased by 200. - The
pocket 418 may be disposed in acavity 414 of thepanel body 402 and is partly defined by afirst frame 404, similar to thepocket 218 illustrated inFIGS. 2 and 3 . However, thepanel body 402 ofFIG. 5 further includes afifth frame 438 disposed above thefirst frame 404, with respect to gravity. The third andfourth frames first frame 404 and couple to thefifth frame 438. Thefifth frame 438 is similar to thefirst frame 404 and may be made of the same material as thefirst frame 404. Thefifth frame 438 may be coupled to the third andfourth frames fifth frame 438 can be coupled to the third andfourth frames first frame 404 of the thirdexemplary panel body 402 also differs from thefirst frame 204 of the firstexemplary panel body 202 because thefirst frame 404 creates aclosed pocket 418; whereas thefirst frame 204 of the firstexemplary panel body 202 creates anopen pocket 218. As shown inFIG. 5 , thepocket 418 is entirely disposed within thefirst cavity 414 of the frame and asecond cavity 440, which is defined by thefirst frame 404, thefifth frame 438, part of thethird frame 408, and part of thefourth frame 410. Thesecond cavity 440 may be filled with foam. However, in other examples, thesecond cavity 440 does not have foam. Additionally, thepocket 418 illustrated inFIG. 5 is adapted to receive a structural member between thefirst frame 404 and thethird member 430 of thepocket 418. - In yet another aspect,
FIG. 6 illustrates a fourthexemplary panel body 502 constructed in accordance with the teachings of the present disclosure. The fourthexemplary panel body 502 ofFIG. 6 is similar to thepanel body 402 ofFIG. 5 except the fourthexemplary panel body 502 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of thepanel body 502 will retain the same reference numbers as outlined above with respect to thepanel body 402 ofFIG. 5 , although the reference numbers will be increased by 100. - Similar to the
panel body 402 ofFIG. 5 , thepanel body 502 ofFIG. 6 includes third andfourth frames second frames cavity 514. However, unlike thepanel body 402 ofFIG. 5 , the fourthexemplary panel body 502 includes sixth andseventh frames cavity 514 between the third andfourth frames second frames seventh frames FIG. 6 , in other examples, the sixth andseventh frames panel body 502. The sixth andseventh frames second frames seventh frames second frames seventh frames second frames third cavity 548 between the sixth andseventh frames fourth cavity 550 between thethird frame 508 and thesixth frame 542. Disposed in thethird cavity 548 is acolumn 520 having afirst end 520 a and a second end 520 b. The second end 520 b of thecolumn 520 is coupled to thesecond frame 506 and thefirst end 520 a of thecolumn 520 at least partially defines thepocket 518. Here, a structural member may sit directly on thecolumn 520 or on a bracket attached to thecolumn 520. The sixth andseventh frames first end 520 a of the column. Further, thefirst end 520 a of thecolumn 520 may be a bracket or flanged member fixed to thecolumn 520 providing thefirst end 520 a, which may be thicker to accommodate the load placed directly on top of thefirst end 520 a. Thefirst end 520 a may include, for example, a piece of rubber that comes into contact with the structural member to facilitate placement and to reduce vibrations during assembly. - A
pocket 518 is disposed in thethird cavity 548 and above thecolumn 520 of thepanel body 502. Thepocket 518 is defined by a portion of thesixth frame 542, a portion of theseventh frame 544, afourth member 546, and thefirst end 520 a of thecolumn 520. Thefourth member 546 is disposed a distance D3 above thefirst end 520 a of thecolumn 520, with respect to gravity, and extends between the sixth andseventh frames fourth member 546 may be disposed any distance D3 above thefirst end 520 a of thecolumn 520 that allows thepocket 518 to receive a support member. - In another aspect,
FIG. 7 illustrates a fifthexemplary panel body 602 constructed in accordance with the teachings of the present disclosure. The fifthexemplary panel body 602 ofFIG. 7 is similar to thepanel body 202 ofFIGS. 2 and 3 , except the fifthexemplary panel body 602 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of thepanel body 602 will retain the same reference numbers as outlined above with respect to thepanel body 202 ofFIGS. 2 and 3 , although the reference numbers will be increased by 400. - Similar to the
pocket 218 of the firstexemplary panel body 202 ofFIGS. 2 and 3 , apocket 618 of the fifthexemplary panel body 602 is defined in part by thefirst frame 604. However, unlike the firstexemplary pocket 218, the fifthexemplary pocket 618 is formed outside of thecavity 614 and defined by aninner surface 612 of thefirst side member 626,second side member 628, andthird member 630. In particular, afirst side member 626 and asecond side member 628 extend above thefirst frame 604, with respect to gravity, and athird member 630 extends between the first andsecond side members FIG. 7 , acolumn 620 passes through thethird member 630 and a first end 620 a of thecolumn 620 rests on an exterior surface of thethird member 630. The first end 620 a of thecolumn 620 includes afirst plate 632 for attaching thecolumn 620 to thethird member 630 and thefirst plate 632 may include a fastening mechanism for attaching thefirst plate 632 to thethird member 630. For example, the fastening mechanism can be a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. While thefirst plate 632 is illustrated inFIG. 7 as resting on the exterior surface of thethird member 630, in other embodiments, for example, thefirst plate 632 can be disposed against the interior surface 612 (i.e., facing the cavity) of thethird member 630. Further, the second end 620 b of thecolumn 620 extends through thesecond frame 606 and is received in a notch disposed in the outer surface of thesecond frame 606. In some examples, the notch disposed in the outer surface of thesecond frame 606 extends through only one side of thesecond frame 606. - In yet another aspect,
FIG. 8 illustrates a sixthexemplary panel body 702 constructed in accordance with the teachings of the present disclosure. The sixthexemplary panel body 702 ofFIG. 8 is similar to thepanel body 402 ofFIG. 5 except the sixthexemplary panel body 702 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of thepanel body 702 will retain the same reference numbers as outlined above with respect to thepanel body 402 ofFIG. 5 , although the reference numbers will be increased by 300. - Similar to the
panel body 402 ofFIG. 5 , the sixthexemplary panel body 702 is defined by afirst frame 704, asecond frame 706, athird frame 708, and afourth frame 710. However, unlike thepanel body 402, apocket 718 of the sixthexemplary panel body 702 is not defined by thefirst frame 704. Instead, thepocket 718 is defined by a first side member 726, asecond side member 728, athird member 730, and afirst end 720 a of acolumn 720. In particular, as illustrated inFIG. 8 , the first andsecond side members 726, 728 extend transversely from thefirst end 720 a of thecolumn 720 and thethird member 730 extends between the first andsecond side members 726, 728. Thefirst end 720 a of thecolumn 720 includes afirst plate 732 for attaching thecolumn 720 to the first andsecond side members 726, 728. Thefirst plate 732 may be attached to the first andsecond side members 726, 728 using, for example, a fastening mechanism, such as, a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. Further, the first andsecond side members 726, 728 are coupled to thethird member 730, for example, using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint; a mechanical fastener, such as, a screw, a nail, a staple; or other suitable mechanical fastener. -
FIGS. 9-13 illustrate different examples of pocket configurations. Thepocket 818 may take additional shapes other than rectangular depending on the shape of the structural member. InFIG. 9 , apocket 818 may take the form of anotch 856 disposed in afirst frame 804 of apanel body 802. Thenotch 856 may be of any depth such that a portion of astructural member 858 is disposed in thenotch 856. For example, the notch depth can be equal to a thickness of a portion of thestructural member 858, which in this case is an I-beam. In other examples, the notch depth can be greater than a thickness of a portion of the I-beam. Thenotch 856 may also include at least one blind bore that receives a portion of an attachment mechanism. Moreover, in theexemplary panel body 802, the column extends from a second frame to the first frame. In particular, the column may extend from the second frame to the first frame such that a first end of the column sits beneath the structural member 858 (e.g., an I-beam). - In
FIG. 10 , thepocket 918A is defined by a U-shaped bracket instead of first and second parallel side members and third member. InFIG. 11 , thepocket 918B has a V-shaped opening. InFIG. 12 , thepocket 918C defines a narrow groove, similar to thenotch 856 discussed above. Finally, as illustrated inFIG. 13 , thepocket 918D may take the shape of a circle or oval. - Turning to
FIG. 14 , a seventhexemplary panel body 1002 is constructed in accordance with the teachings of the present disclosure. The seventhexemplary panel body 1002 ofFIG. 14 is similar to thepanel body 202 ofFIGS. 2 and 3 , except the seventhexemplary panel body 1002 provides a different column configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of thepanel body 1002 will retain the same reference numbers as outlined above with respect to thepanel body 202 ofFIGS. 2 and 3 , although the reference numbers will be increased by 800. - In the example of
FIG. 14 , acolumn 1020 extends between afirst section 1060 and asecond section 1062 of asecond frame 1006. The first andsecond sections column 1020 is centrally disposed in thepanel body 1002. In other examples, the first andsecond sections first section 1060 may be a first length L1 and thesecond section 1062 may be a second length L2. Asecond end 1020 b of thecolumn 1020 does not include a second plate (as shown inFIG. 3 ). As such, thecolumn 1020 is coupled to thesecond frame 1006 in a different manner than how afirst end 1020 a of thecolumn 1020 is coupled to afirst frame 1004. However, in some examples, anouter surface 1064 of thesecond frame 1006 can include a notch that is adapted to receive a second plate. - As illustrated in
FIG. 1 , theframe members second skins 124 a, 124 b define thecavity 114 in which an insulting material is disposed. In particular, the insulating material is inserted into thecavity 114 of the panel body 102 (as well as any of the cavities of the exemplary panel bodies disclosed herein) to improve the insulative properties of the panel 100 (i.e., thermal conductivity and thermal resistivity). The insulating material is inserted into thecavity 114 in liquid form and sits until the insulating material cures. After the insulating material cures, it becomes one solid piece of insulation, otherwise known as thefoam core 122 of thepanel 100. In other examples, however, thefoam core 122 can be a pre-cured block that is cut, or otherwise trimmed, to the size of thecavity 114. In such examples, thefoam core 122 is inserted into thecavity 114 after thefoam core 122 has been cut or trimmed to the size of thecavity 114. - The
foam core 122 may be any insulating material that improves the insulative properties of thepanel 100. For example, thefoam core 122 can be asbestos, fiberglass, mineral wool, cellulose, polyurethane foam, polystyrene, or other suitable material. Thefoam core 122 may also have any foam density that properly reduces the thermal conductivity of thepanel 100 based on the application. For example, thefoam core 122 can have a foam density of between 1.0 to 3.0 pounds per cubic foot and, more particularly, 2.2 pounds per cubic foot. - Turning now to
FIGS. 15A-C , first, second, andthird panel configurations panel body 202 ofFIG. 3 , but may be incorporated into any of the panel body examples disclosed herein. The threeconfigurations column 1120 may be embedded within a foam core. In other words, thecolumn 1120 may include first and second opposingsurfaces - In these examples, the
column 1120 has a thickness T1 that is less than a thickness T2 of the third frame and a thickness T3 of the fourth frame. Since the thickness T1 of thecolumn 1120 is less than the thicknesses T2, T3 of the third and fourth frames, at least onegap 1170 is formed between afirst surface 1166 and/or asecond surface 1168 of thecolumn 1120 and an inner surface of the first and second skins. As best illustrated inFIGS. 15A-C , the at least onegap 1170 allows the insulating material to substantially surround thecolumn 1120, such that thecolumn 1120 is embedded with the foam core. Such a configuration allows the foam core to include a maximum amount of insulating material giving the panel better insulative properties over known insulation panels. At least onegap 1170 may be disposed on either side of the panel. In the first configuration ofFIG. 15A , thefirst surface 1166 of thecolumn 1120 is adapted to abut afirst skin 1124 a, such as thefirst skin 124 a of thepanel 100 ofFIG. 1 , and thesecond surface 1168 of thecolumn 1120 is spaced away from asecond skin 1124 b, such as the second skin 124 b of the panel ofFIG. 1 , thereby providing thegap 1170 in which insulating foam may be inserted. Thegap 1170 is disposed on asecond side 1172 of the panel body 1102. InFIG. 15B , thecolumn 1120 is disposed between, and spaced from, the first andsecond skins gaps 1170 adjacent to both the first andsecond surfaces column 1120. In the third configuration ofFIG. 15C , thesecond surface 1168 of thecolumn 1120 is adapted to abut asecond skin 1124 b, such as the second skin 124 b of thepanel 100 ofFIG. 1 , and thefirst surface 1166 of thecolumn 1120 is spaced away from afirst skin 1124 a, such as thefirst skin 124 a of thepanel 100 ofFIG. 1 , thereby providing thegap 1170 in which insulating foam may be inserted. In this example, thegap 1170 is disposed on afirst side 1174 of the panel. - In another aspect, the panel 200 may include a distribution plate (not shown) coupled to the
pocket 218 that helps evenly distribute the load of the structural member, if more than onecolumn 220 is disposed between thefirst frame 204 and thesecond frame 206. In some examples, the distribution plate can be disposed below thepocket 218 and above the at least onecolumn 220. In particular, the distribution plate can be fixedly secured to thethird member 230 using any of the attachment mechanisms discussed above and each of the at least onecolumn 220 can be fixedly secured to the distribution plate. Moreover, the panel 200 may include a cover (not shown) that is slidably received by thepocket 218. In other examples, the cover can be press fit into thepocket 218. - As briefly mentioned above, the first, second, third, and fourth frames of any of the example panel bodies may be hybrid frames. In
FIG. 16 , a third frame of thepanel 100 ofFIG. 1 and a fourth frame of a different, butidentical panel 100, is illustrated in detail. For ease of reference, the third frame is labeled as 1208 and the fourth frame is labeled as 1210. Eachhybrid frame beam 1276 of a primary material and ajacket beam 1276. Thebeam 1276 of thehybrid frame jacket 1278 of thethird frame 1208 defines a first joint member 1282 and thejacket 1280 of thefourth frame 1210 defines a secondjoint member 1284. Generally speaking, thejacket 1278 of thethird frame 1208 and thejacket 1280 of thefourth frame 1210 are formed such that the secondjoint member 1284 receives the first joint member 1282 when coupled. In particular, the first joint member 1282 defines a protrusion 1286 and the secondjoint member 1284 defines a groove 1288 for a tongue and groove coupling joint. Thus, the first joint member 1282 of the panel can be coupled to the secondjoint member 1284 of another panel to form a wall, a ceiling, or a floor. However, in other examples, the first joint member 1282 and the secondjoint member 1284 can both form protrusions 1286 and, in other examples, the first joint member 1282 and the secondjoint member 1284 can both form grooves 1288. The illustratedbeam 1276 is rectangular, but may have different shapes for structural performance and/or bonding with the material of the jacket. Additionally, the illustratedbeam 1276 is one material, however, in other examples, thebeam 1276 may be composed of one or more materials. For example, thebeam 1276 may be a rectangular tube (of any of the rigid materials provided above) that is configured to be filled with polyurethane foam. - Turning now to
FIG. 17 , an eighthexemplary panel body 1502 is constructed in accordance with the teachings of the present disclosure. The eighthexemplary panel body 1502 ofFIG. 17 is similar to thepanel body 202 ofFIGS. 2 and 3 , except the eighth exemplary panel body provides a different column and pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of thepanel body 1502 will retain the same reference numbers as outlined above with respect to thepanel body 202 ofFIGS. 2 and 3 , although the reference numbers will be increased by 1300. - In the example of
FIG. 17 , thefirst end 1520 a of thecolumn 1520 extends between afirst section 1561 of thefirst frame 1504 and asecond section 1563 of thefirst frame 1504 and thesecond end 1520 b of thecolumn 1520 extends between thefirst section 1560 of thesecond frame 1506 and thesecond section 1562 of thesecond frame 1506. The first andsecond sections first frame 1504 and the first andsecond sections second frame 1506 may be equal lengths when thecolumn 1520 is centrally disposed in thepanel body 1502. Additionally, in the illustrated example, the first andsecond ends column 1520 include afirst plate 1532 and asecond plate 1534, respectively. Thefirst plate 1532 is disposed within thepocket 1518, which takes the form of a notch disposed in thefirst frame 1504. Similarly, thesecond plate 1534 is disposed within anotch 1557 formed in an exterior surface of thesecond frame 1506. So configured, both the first andsecond frames second frames - Once the
first plate 1532 is disposed within thepocket 1518 and thesecond plate 1534 is disposed within thenotch 1557 of thesecond frame 1506, thecolumn 1520 is secured to the first andsecond frames fastening mechanism 1536. In the example illustrated inFIG. 17 , thefastening mechanism 1536 takes the form of a plurality of lag bolts securing thecolumn 1520 to the first andsecond frames second plates fastening mechanism 1536 can be a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. - Moreover, because the
pocket 1518 disposed in thefirst frame 1504 and thenotch 1557 disposed in thesecond frame 1506 reduce the thickness of the first andsecond frames FIG. 17 , include a plurality ofreinforcement members 1559 that provide ample material to securely receive afastening mechanism 1536. The plurality ofreinforcement members 1559 may be disposed on aninner surface 1512 of the first andsecond frames reinforcement members 1559 may also be disposed on aninner surface 1512 of the first andsecond frames pocket 1518 and thenotch 1557. So configured, the plurality ofreinforcement members 1559 ensure thecolumn 1520 is adequately secured to the first andsecond frames - The
panel 1502 may also include at least oneprotrusion 1565 that is adapted to be received by a support member disposed in thepocket 1518. For example, as illustrated inFIG. 17 , the at least oneprotrusion 1565 can be disposed on thefirst plate 1532 and extend away from thefirst plate 1532 for a distance. The example at least oneprotrusion 1565 takes the form of a threaded cylinder that receives a nut to secure the support member to thepanel 1502. In other examples, however, the at least oneprotrusion 1565 may take any shape and form that is complementary to the bore or aperture in the support member that is to receive the at least oneprotrusion 1565. - Further, while not illustrated, the
second plate 1534 disposed at thesecond end 1520 b of thecolumn 1520 may have a width that is greater than a width of thesecond frame 1506 such that thesecond plate 1534 at least partially extends past the width of thesecond frame 1506. So configured, thepanel body 1502 may be secured to a floor using the portion of thesecond plate 1534 that extends past the width of thesecond frame 1506. For example, thesecond plate 1534 can include at least one aperture that is adapted to receive a fastening mechanism that secures thepanel body 1502 to the floor. - Finally,
FIG. 18 depicts an example method of manufacturing 1300 an insulatedpanel 100, such as thepanel 100 ofFIG. 1 , in accordance with the teachings of the present disclosure. Themethod 1300 includes providing thepanel body 102 by coupling thefirst frame 104 and thesecond frame 106 via thethird frame 108 and thefourth frame 110, such that thesecond frame 106 is spaced away from thefirst frame 104 and thefourth frame 110 is spaced away from the third frame 108 (Step 1392). Themethod 1300 then involves coupling thecolumn 120 to thepanel body 102 by coupling thefirst end 120 a of thecolumn 120 to thefirst frame 104 and thesecond end 120 b of thecolumn 120 to the second frame 106 (Step 1394). Themethod 1300 then involves forming a cavity in the panel body (Step 1396), which includes fastening thefirst skin 124 a to thefirst side 100 a of thepanel 100 and fastening the second skin 124 b to thesecond side 100 b of thepanel 100. Once the first andsecond skins 124 a, 124 b are secured to thepanel 100, a foam material, in liquid phase, is dispensed into the cavity 114 (Step 1398). The foam material is cured and forms thefoam core 122 in thecavity 114, such that thecolumn 120 is embedded with the foam core 122 (Step 1400). Additionally, in some examples of themethod 1300, providing thepanel body 102 further includes forming thepocket 118 having a U-shaped opening in thefirst frame 104, thepocket 118 being sized to receive a beam or support member. In yet other examples of themethod 1300, dispensing the foam material in thecavity 114 further includes injecting the foam material into thecavity 114 via a hole in thepanel body 102. In yet other examples, the panel may be made from cured foam shaped to the desired panel shape and size. - The figures and description provided herein depict and describe preferred examples of a structurally reinforced, insulated panel for purposes of illustration only. One skilled in the art will readily recognize from the foregoing discussion that alternative examples of the components illustrated herein may be employed without departing from the principles described herein. Thus, upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs for structurally reinforced, insulated panels that achieve both structural and thermal reliability. Therefore, while particular examples and applications have been illustrated and described, it is to be understood that the disclosed examples are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the methods and components disclosed herein without departing from the spirit and scope defined in the appended claims.
Claims (50)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/654,740 US20200299960A1 (en) | 2019-03-20 | 2019-10-16 | Structurally reinforced insulated panel |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201962821294P | 2019-03-20 | 2019-03-20 | |
US16/654,740 US20200299960A1 (en) | 2019-03-20 | 2019-10-16 | Structurally reinforced insulated panel |
Publications (1)
Publication Number | Publication Date |
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US20200299960A1 true US20200299960A1 (en) | 2020-09-24 |
Family
ID=72515672
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/654,740 Abandoned US20200299960A1 (en) | 2019-03-20 | 2019-10-16 | Structurally reinforced insulated panel |
Country Status (2)
Country | Link |
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US (1) | US20200299960A1 (en) |
WO (1) | WO2020190336A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11214964B2 (en) * | 2019-06-14 | 2022-01-04 | Nexii Building Solutions Inc. | Reinforced structural insulation panel with corner blocks |
US20220034078A1 (en) * | 2019-10-01 | 2022-02-03 | Beam Pocket LLC | Beam pocket kit and assembly |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2023070174A1 (en) * | 2021-11-01 | 2023-05-04 | New Building Solutions Pty Ltd | Building material |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA1287964C (en) * | 1986-06-19 | 1991-08-27 | Sidney K. Tissington | Wall panel with foam insulation |
US6550198B1 (en) * | 2001-08-21 | 2003-04-22 | Youichi Endo | Wall construction |
FR2905710A1 (en) * | 2006-09-13 | 2008-03-14 | Simpex Antilles S A R L Sarl | BUILDING EDIFICE AND METHOD, IN PARTICULAR HOUSING |
US20110047908A1 (en) * | 2009-08-28 | 2011-03-03 | Brusman Bryan Daniel | High-strength insulated building panel with internal stud members |
CN102713099B (en) * | 2009-12-18 | 2015-01-07 | 帕特克有限公司 | Panelized structural system for building construction |
US9702147B2 (en) * | 2013-01-07 | 2017-07-11 | Clifford Eugene Babson | Panels for framing and constructing a building structure |
-
2019
- 2019-10-16 US US16/654,740 patent/US20200299960A1/en not_active Abandoned
- 2019-10-16 WO PCT/US2019/056509 patent/WO2020190336A1/en active Application Filing
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11214964B2 (en) * | 2019-06-14 | 2022-01-04 | Nexii Building Solutions Inc. | Reinforced structural insulation panel with corner blocks |
US20220106791A1 (en) * | 2019-06-14 | 2022-04-07 | Nexii Building Solutions Inc. | Reinforced structural insulation panel with corner blocks |
US20220034078A1 (en) * | 2019-10-01 | 2022-02-03 | Beam Pocket LLC | Beam pocket kit and assembly |
US12012744B2 (en) * | 2019-10-01 | 2024-06-18 | Beam Pocket LLC | Beam pocket kit and assembly |
Also Published As
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WO2020190336A1 (en) | 2020-09-24 |
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