Panel construction for an air handling unit

Abstract

A panel for use in an air handling unit including a skin, a fixture having a base, and the base having a surface. The base is interposed between opposed ends and opposed risers extending from the ends of the base in a direction away from the surface. The risers are secured to the skin to form an enclosed chamber between the skin and the fixture. An insulating material is then injected into the enclosed chamber.

1 . A panel for use in an air handling unit comprising: 
 a skin;    a fixture, the fixture and the skin composed of a metal material, the fixture having: 
 a base; and  
 at least one riser extending substantially perpendicular to the base, the at least one riser being secured to the skin to form an enclosed chamber between the skin and the fixture; and  
   an insulating material disposed in the enclosed chamber.    
   
   
       2 . The panel of  claim 1  wherein the insulating material substantially fills the enclosed chamber.  
   
   
       3 . The panel of  claim 2  wherein the insulating material is a foam.  
   
   
       4 . The panel of  claim 3  wherein the foam adheres to at least one surface of the enclosed chamber to increase the stiffness and strength of the panel.  
   
   
       5 . The panel of  claim 3  wherein the foam is polyurethane foam.  
   
   
       6 . The panel of  claim 5  wherein the polyurethane foam is injected into the enclosed chamber.  
   
   
       7 . The panel of  claim 1  wherein the skin comprises an extended portion extending from the fixture substantially parallel to the base, the extending portion being configured to be secured to a framework for an air handling unit framework.  
   
   
       8 . The panel of  claim 7  wherein the extending portion extends from all sides of the fixture.  
   
   
       9 . The panel of  claim 8  wherein the skin is substantially centered on the fixture.  
   
   
       10 . The panel of  claim 9  wherein the skin and the base each have a substantially rectangular shape.  
   
   
       11 . The panel of  claim 10  wherein areal panel dimensions are up to about 60 inches by about 120 inches.  
   
   
       12 . The panel of  claim 1  wherein the risers being secured to the skin by at least one of a layer of tape adhesively disposed between the risers and the skin.  
   
   
       13 . The panel of  claim 12  wherein the tape is polyethylene tape.  
   
   
       14 . The panel of  claim 1  wherein the risers comprise a pair of flanges extending substantially parallel to the base.  
   
   
       15 . The panel of  claim 14  wherein the pair of flanges extend toward each other.  
   
   
       16 . The panel of  claim 14  wherein the pair of flanges is secured to the skin by at least one of a layer of tape and a plurality of fasteners.  
   
   
       17 . The panel of  claim 1  wherein the metal material is stainless steel.  
   
   
       18 . The panel of  claim 1  wherein the skin is of unitary construction.  
   
   
       19 . The panel of  claim 1  wherein the fixture is of unitary construction.  
   
   
       20 . An air handling unit framework comprising: 
 a plurality of interconnected structural members forming a plurality of interconnected frames, each frame of the plurality of frames receiving a panel, the panel comprising: 
 a skin;  
 a fixture, the fixture having: 
 a base; and  
 at least one riser extending substantially perpendicular to the base, the at least one riser being secured to the skin to form an enclosed chamber between the skin and the fixture; and  
 
 an insulating material disposed in the enclosed chamber; and  
   wherein the plurality of interconnected frames and corresponding panels are configured and disposed to form an air handling unit framework.    
   
   
       21 . The air handling unit framework of  claim 20  wherein the skin and the fixture are composed of a metal material.  
   
   
       22 . The air handling unit framework of  claim 20  wherein the plurality of panels are substantially rectangular.  
   
   
       23 . The air handling unit framework of  claim 20  wherein the plurality of panels are usable as portions of walls, floors and ceilings.  
   
   
       24 . The air handling unit framework of  claim 20  wherein the insulating material substantially fills the enclosed chamber.  
   
   
       25 . The air handling unit framework of  claim 20  wherein the insulating material is a foam.  
   
   
       26 . The air handling unit framework of  claim 25  wherein the foam adheres to at least one surface of the enclosed chamber to increase the stiffness and strength of the panel.  
   
   
       27 . The air handling unit framework of  claim 20  wherein a measured distance of the skin along a first axis is greater than a measured distance along a first axis of the fixture, the skin being disposed on the fixture in mutual alignment with the first axis to form at least one overhang for securing the panel to at least one corresponding interconnected frame.  
   
   
       28 . The air handling unit framework of  claim 27  wherein a measured distance of the skin along a second axis is greater than a measured distance along a second axis of the fixture, the first axis and the second axis being non-coincident, the skin being disposed on the fixture in mutual alignment with the second axis to form at least one overhang for securing the panel to at least one corresponding interconnected frame.  
   
   
       29 . The air handling unit framework of  claim 28  wherein the at least two overhangs and the base adjacent the periphery of the at least two overhangs forming a double seal with the corresponding interconnected frames.  
   
   
       30 . The air handling unit framework of  claim 29  wherein the double seal includes a layer of tape applied between the at least two overhangs and the interconnected frames.  
   
   
       31 . The air handling unit framework of  claim 28  wherein the at least two overhangs extend over the fixture by substantially the same length.  
   
   
       32 . The air handling unit framework of  claim 31  wherein the skin and the base are substantially rectangular.  
   
   
       33 . The air handling unit framework of  claim 31  wherein the fixture is substantially centered on the skin.  
   
   
       34 . A method of assembling a panel for use in an air handling unit, comprising the steps of: 
 providing a skin;    providing a fixture, the fixture having: 
 a base; and  
 at least one riser extending from the base; and  
   bending the at least one riser substantially perpendicular to the base;    securing the at least one riser to the skin to form an enclosed chamber between the skin and the fixture; and    disposing an insulating material in the enclosed chamber.    
   
   
       35 . The method of  claim 34  further including an additional step, before the step of securing the at least one riser, of positioning at least one tape layer between the at least one riser and the skin.  
   
   
       36 . The method of  claim 34  wherein the step of providing a skin includes the skin having an extended portion extending from the fixture substantially parallel to the base, the extending portion being configured to secure a framework for the air handling unit.  
   
   
       37 . The method of  claim 36  wherein the extending portion extends from all sides of the fixture.  
   
   
       38 . The method of  claim 37  wherein the step of securing the at least one riser to the skin includes securing the at least one riser to the skin so that the skin is substantially centered on the fixture.  
   
   
       39 . The method of  claim 34  wherein the step of disposing an insulating material includes the insulating material being a foam.  
   
   
       40 . The method of  claim 39  wherein the foam adheres to at least one surface of the enclosed chamber to increase the stiffness and strength of the panel.  
   
   
       41 . The method of  claim 39  wherein the step of disposing an insulating material includes injecting a polyurethane foam into the enclosed chamber.  
   
   
       42 . The method of  claim 34  wherein the steps of providing a skin and of providing a fixture include providing a skin composed of a metal material and providing a fixture composed of a metal material.  
   
   
       43 . The method of  claim 34  wherein the steps of providing a skin and of providing a fixture include providing a skin of unitary construction and providing a fixture of unitary construction.