Structural insulated panel system

Abstract

A structural insulated panel system includes a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member. A first siding member is attached to one side of the frame and a second siding member is attached to an opposite side of the frame to form a cavity and an insulation material is provided within the cavity. A tongue portion includes a projection formed from the first vertical frame member disposed laterally outward from one vertical edge of the first and second siding members. A groove portion includes a recess formed from the second vertical frame member disposed laterally inward from an opposite vertical edge of the first and second siding members, so that the tongue portion from one panel is configured to mate with the groove portion of another panel to provide an assembly of multiple panels.

1 . A structural insulated panel system, comprising:
 a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member;   a first siding member attached to at least a portion of one side of the frame and a second siding member attached to at least a portion of an opposite side of the frame, the frame and the first and second siding members forming a cavity;   an insulation material within the cavity;   a tongue portion comprising a projection formed from the first vertical frame member disposed laterally outward from one vertical edge of the first and second siding members; and   a groove portion comprising a recess formed from the second vertical frame member disposed laterally inward from an opposite vertical edge of the first and second siding members;   wherein the tongue portion from one panel is configured to mate with the groove portion of another panel to provide an assembly of multiple panels.   
   
   
       2 . The system of  claim 1  further comprising a retractable fastener having a hook portion and a pin portion and wherein the hook portion is disposed within one of the first vertical frame member and the second vertical frame member and the pin portion is disposed within the other of the first vertical frame member and the second vertical frame member. 
   
   
       3 . The system of  claim 1  further comprising a corner panel assembly including a first corner panel and a second corner panel. 
   
   
       4 . The system of  claim 3  wherein the first corner panel includes a groove portion and a tongue portion, and the second corner panel includes a tongue portion and a flat surface. 
   
   
       5 . The system of  claim 4  wherein the flat surface of the second corner panel is configured to mate with the tongue portion of the first corner panel to form the corner panel assembly. 
   
   
       6 . A prefabricated structural insulated panel, comprising:
 a frame;   a first siding member attached to a first side of the frame and a second siding member attached to a second side of the frame;   an insulation material disposed within a cavity formed by the frame and the first and second siding members;   the frame comprising a first vertical member disposed outwardly of a vertical edge on one side of the first and second siding members to form a tongue portion, and a second vertical frame member disposed inwardly of a vertical edge on an opposite side of the first and second siding members to form a groove portion.   
   
   
       7 . The panel of  claim 6  wherein the frame comprises frame members made from a material selected from the group consisting of wood and high density foam. 
   
   
       8 . The panel of  claim 6  wherein the insulation material comprises a polyurethane foam material injected into the cavity. 
   
   
       9 . The panel of  claim 6  further comprising a retractable fastener integrated with the first and second vertical frame members. 
   
   
       10 . The panel of  claim 6  further comprising extension members extending between the first vertical member and the vertical edge on the one side of the first and second siding members. 
   
   
       11 . The panel of  claim 6  first vertical frame member of the tongue portion comprises beveled edges. 
   
   
       12 . A method of making a structural insulated panel system, comprising:
 providing a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member;   attaching a first siding member to at least a portion of one side of the frame and attaching a second siding member to at least a portion of an opposite side of the frame to form a cavity;   injecting an insulation material into the cavity;   positioning the first vertical member outwardly of a vertical edge on one side of the first and second siding members to form a tongue portion, and   positioning a second vertical frame member inwardly of a vertical edge on an opposite side of the first and second siding members to form a groove portion.   
   
   
       13 . The method of  claim 12  further comprising the step of providing a hook portion of a retractable fastener within one of the first vertical frame member and the second vertical frame member and providing a pin portion of the retractable fastener within the other of the first vertical frame member and the second vertical frame member. 
   
   
       14 . The method of  claim 12  further comprising the step of adjusting a width of the panel system by removing a first portion of the tongue portion, and removing a second portion of the first and second siding members along the vertical edge on the opposite side of the first and second siding members; the first portion and the second portion having substantially the same thickness. 
   
   
       15 . The method of  claim 12  further comprising the step of adjusting a width of the panel system by adding a shim to the tongue portion. 
   
   
       16 . The method of  claim 12  further comprising the step of providing a corner panel assembly including a first corner panel and a second corner panel. 
   
   
       17 . The method of  claim 16  wherein the step of providing a corner panel assembly further includes providing a groove portion and a tongue portion on the first corner panel, and providing a tongue portion and a flat surface on the second corner panel, and wherein the flat surface of the second corner panel is configured to mate with the tongue portion of the first corner panel to form the corner panel assembly. 
   
   
       18 . The method of  claim 17  further comprising the step of joining the tongue portion of one panel to the groove portion of the first corner panel, and joining the groove portion of another panel to the tongue portion of the second corner panel assembly. 
   
   
       19 . A walk-in cooler, comprising:
 at least two walls, each wall comprising at least one prefabricated structural insulated panel; and   at least one corner panel assembly joining the at least two walls;   each prefabricated structural insulated panel comprising:
 a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member; 
 a first siding member attached to at least a portion of one side of the frame and a second siding member attached to at least a portion of an opposite side of the frame, the frame and the first and second siding members forming a cavity; 
 an insulation material within the cavity; 
 a tongue portion comprising a projection formed from the first vertical frame member disposed laterally outward from one vertical edge of the first and second siding members; and 
 a groove portion comprising a recess formed from the second vertical frame member disposed laterally inward from an opposite vertical edge of the first and second siding members; 
   the corner panel assembly comprising:
 a first corner panel having a groove portion and a tongue portion; 
 a second corner panel having a tongue portion and a flat surface; 
 wherein the flat surface of the second corner panel mates with the tongue portion of the first corner panel to form the corner panel assembly; 
   wherein the groove portion of the first corner panel mates with a tongue portion of the prefabricated structural insulated panel of one wall, and the tongue portion of the second corner panel mates with the groove portion of the prefabricated structural insulated panel of the other wall.   
   
   
       20 . The walk-in cooler of  claim 19  further comprising a retractable fastener having a hook and a pin and wherein the hook is disposed within the tongue portion of the prefabricated structural insulated panel and the tongue portion of the second corner panel, and the pin is disposed within the groove portion of the prefabricated structural insulated panel and the groove portion of the first corner panel.