System and Method for an Adjustable Locking Mechanism for Insulated Panels

Abstract

An adjustable panel locking mechanism is disposed in a slot of a structural member of the panel. A cam-strike or latch is disposed through the slot, over a lock plate, and both are covered by a cover plate. When the panel is assembled, and expanding foam is injected into a volume created by a plurality of structural members and exterior sheathing, the foam expands to the cover plate, which exerts a pressure or force on the cam-strike or latch disposed through the slot. The cam-strike or latch is then adjustable based on the friction between the lock plate and the cover plate with the base of the cam-strike or latch there between.

What is claimed is: 
     
         1 . An adjustable locking system, comprising:
 a cam-strike having a flange;   and   a cover plate, wherein the cam-strike is disposed through a slot in the structural member, and wherein the cover plate is configured to cover the flange of the cam-strike when the cam-strike is disposed through a slot in a structural member, and   wherein the structural member is configured to provide perimeter support for an insulated panel, and wherein the cover plate covers the slot of the structural member, and is secured to the structural member to provide a friction operable to allow a friction-limited adjustability of the cam-strike along the slot.   
     
     
         2 . The adjustable locking system of  claim 1 , further comprising a lock plate having an aperture sized to have at least a portion of the cam-strike disposed therethrough, wherein the lock plate is positioned between the slot and the cover plate. 
     
     
         3 . The adjustable locking system of  claim 1 , further comprising a sealing membrane operable to seal the cover plate to the structural member. 
     
     
         4 . The adjustable locking system of  claim 3 , wherein the sealing membrane is at least one of glue, tape, or caulk. 
     
     
         5 . The adjustable locking system of  claim 1 , wherein the insulated panel further comprises an expanding foam operable to exert a force against the cover plate. 
     
     
         6 . The adjustable locking system of  claim 5 , further comprising a lock plate disposed between the structural member and the cover plate, wherein the lock plate comprises an aperture sized to accept a portion of a cam-strike disposed therethrough, wherein the lock plate is operable to disperse the force applied by the expanding foam along area of the cover plate in contact with the lock plate and the flange of the cam-strike. 
     
     
         7 . An adjustable locking system, comprising:
 a latch having a flange;   and   a cover plate, wherein the latch is disposed through a slot in the structural member, and wherein the cover plate is configured to cover the flange of the latch when the latch is disposed through a slot in a structural member, and   wherein the structural member is configured to provide perimeter support for an insulated panel, and wherein the cover plate covers the slot of the structural member, and is secured to the structural member to provide a friction operable to allow a friction-limited adjustability of the latch along the slot.   
     
     
         8 . The adjustable locking system of  claim 7 , further comprising a lock plate having an aperture sized to have at least a portion of the latch disposed therethrough, wherein the lock plate is positioned between the slot and the cover plate. 
     
     
         9 . The adjustable locking system of  claim 7 , further comprising a sealing membrane operable to seal the cover plate to the structural member. 
     
     
         10 . The adjustable locking system of  claim 9 , wherein the sealing membrane is at least one of glue, tape, an elastomeric caulk, or silicone caulk. 
     
     
         11 . The adjustable locking system of  claim 7 , wherein the insulated panel further comprises an expanding foam operable to exert a force against the cover plate. 
     
     
         12 . The adjustable locking system of  claim 11 , further comprising a lock plate disposed between the structural member and the cover plate, wherein the lock plate comprises a slot sized to accept a portion of a latch disposed therethrough, wherein the lock plate is operable to disperse the force applied by the expanding foam along area of the cover plate in contact with the lock plate and the flange of the latch. 
     
     
         13 . A method for manufacturing an adjustable locking system, the method comprising the steps of:
 disposing one of a cam-strike or a latch, each having a flange, through a slot in at least one of a plurality of structural members;   covering the one of a cam-strike or latch and the slot using a cover plate, wherein the plurality of structural members form the perimeter of an insulated panel, and affixing two opposing sheathing sheets to the plurality of structural members, such that the connection of the opposing sheathing sheets to the plurality of structural members creates a volume between the opposing sheathing sheets; and   injecting expanding foam into the volume, such that when the foam expands to fill the volume, the cover plate exerts a force on the flange of the cam strike or latch to hold the cam-strike or latch in place, wherein the force exerted on the flange of the cam-strike or latch creates a friction that creates a friction limited adjustability of the cam-strike along the slot in the structural member.   
     
     
         14 . The method of  claim 13 , further comprising disposing at least a portion of the cam-strike or latch through an aperture in a lock plate, and placing the lock-plate between the cover plate and the slot, such that the expansion of the foam exerts a force on the lock plate, and wherein the surface area of the lock plate is operable to disperse the force along a greater surface area of the cover plate to facilitate smoother movement of the cam-strike or latch along the slot. 
     
     
         15 . The method of  claim 13 , further comprising covering the cover plate with a sealing membrane, wherein the sealing membrane is operable to prevent the expanding foam from ingress into the area between the cover plate and the cam-strike or latch. 
     
     
         16 . The method of  claim 14 , further comprising covering the cover plate with a sealing membrane, wherein the sealing membrane is operable to prevent the expanding foam from ingress into the area between the cover plate, the lock plate, and the cam-strike or latch. 
     
     
         17 . A method for assembling structural wall panels, the method comprising the steps of:
 positioning an end plate at the base of a plurality of structural panels, each of the plurality of structural panels comprising:   a locking system in accordance with  claim 1  or  claim 7 ,   wherein the end plate includes a relief cut in contact with the structural member of the locking system, and wherein the relief cut accommodates the cover plate of the locking system.   
     
     
         18 . The method of  claim 17 , wherein the structural member is manufactured as part of a floor panel, and wherein an expanding foam insulation is injected into a volume defined by the structural member, the end plate, and at least two panel sheaths, such that the expanding foam exerts a force against the cover plate of the locking system, and wherein the structural member is substantially level when placed on a level surface. 
     
     
         19 . A method of assembling an insulated structural panel wall, comprising the steps of:
 placing a plurality of structural panels, each of the panels comprising a male structural member having a latch disposed therein, in contact with a female rail comprising a plurality of cam-strikes, each of the cam-strikes at least partially disposed through a respective slot formed in the female rail, wherein each of the cam-strikes is friction-adjustable within its respective slot;   aligning the latch of a first of the plurality of insulated structural panels with a first of the plurality of cam-strikes of the female rail, and engaging the aligned first cam-strike with the latch of the first insulated structural panel to bring the panel into sealing engagement with the female rail;   aligning the latch of a second of the plurality of insulated structural panels with a second of the plurality of cam-strikes of the female rail, wherein aligning the cam-strike with the latch comprises adjusting the second cam-strike within the slot, and   engaging the aligned second cam-strike with the latch of the second insulated structural panel to bring the panel into sealing engagement with the rail, adjacent to the first panel.   
     
     
         20 . A method of assembling an insulated structural panel wall, comprising the steps of:
 placing a plurality of structural panels, each of the panels comprising a female structural member having a cam-strike disposed therein, in contact with a male rail comprising a plurality of latches, each of the latches at least partially disposed through a respective slot formed in the male rail, wherein each of the latches is friction-adjustable within its respective slot;   aligning the cam-strike of a first of the plurality of insulated structural panels with a first of the plurality of latches of the rail, and engaging the aligned first latch with the cam-strike of the first insulated structural panel to bring the panel into sealing engagement with the male rail;   aligning the cam-strike of a second of the plurality of insulated structural panels with a second of the plurality of latches of the rail, wherein aligning the latch with the cam-strike comprises adjusting the second latch within the slot, and   engaging the aligned second cam-strike with the latch of the second insulated structural panel to bring the panel into sealing engagement with the rail, adjacent to the first panel.