Structurally reinforced insulated panel

Abstract

An insulated panel for a storage unit having a panel body that includes a first frame, a second frame, a third frame, and a fourth frame. The first, second, third, and fourth frames 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 disposed in the cavity has a first end coupled to the first frame and a second end coupled to the second frame. A foam core is disposed in the cavity such that the column is embedded with the foam core.

1 . An insulated panel for a storage unit, the panel comprising:
 a panel body including a first frame, a second frame, a third frame, and a fourth frame, the first, second, third, and fourth frames 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 disposed in the cavity having a first end coupled to the first frame and a second end coupled to the second frame; and   a foam core disposed in the cavity such that the column is embedded with the foam core.   
     
     
         2 . The panel of  claim 1 , wherein the first frame defines a pocket that is shaped to receive a portion of a structural member. 
     
     
         3 . The panel of  claim 2 , wherein the pocket includes first and second parallel side members and a third member perpendicularly disposed relative to the first and second parallel side members, the third member extending between the first side member and the second side member such that the first side member, the second side member, and the third member define an opening that is sized to receive the portion of the structural member. 
     
     
         4 . The panel of  claim 3 , wherein the third member is the first end of the column such that the first side member, the second side member, and the first end of the column define the opening that is sized to receive the portion of the structural member. 
     
     
         5 . The panel of  claim 2 , further comprising 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. 
     
     
         6 . The panel of  claim 2 , wherein the pocket is a notch disposed on an exterior surface of the first frame, the exterior surface being opposite the interior surface. 
     
     
         7 . The panel of  claim 2 , wherein the pocket is disposed outside of the cavity and is adjacent to the column. 
     
     
         8 . The panel of  claim 1 , wherein the first frame, the second frame, the third frame, and the fourth frame include a first material and the column is a second material. 
     
     
         9 . The panel of  claim 8 , wherein the first material is a non-metal and the second material is metal. 
     
     
         10 . The panel of  claim 9 , wherein the first material includes at least one of wood, PVC, high-density foam, and a composite. 
     
     
         11 . The panel of  claim 1 , wherein a width of the column is greater than a width of the third frame and a width of the fourth frame. 
     
     
         12 . The panel of  claim 1 , wherein a length of the column is less than a length of the third frame and a length of the fourth frame. 
     
     
         13 . The panel of  claim 1 , wherein the column is fixedly secured to the first frame and the second frame. 
     
     
         14 . The panel of  claim 1 , wherein the second frame includes a first section and a second section, the column extending between the first and second sections of the second frame. 
     
     
         15 . The panel of  claim 1 , wherein the second frame includes a notch disposed on the interior surface of the second frame such that the notch is sized to receive the second end of the column. 
     
     
         16 . The panel of  claim 1 , further comprising a first skin secured to a first side of the panel body and a second skin secured to a second side of the panel body, the first skin and the second skin enclosing the cavity of the panel body. 
     
     
         17 . The panel of  claim 16 , wherein a first surface of the column is disposed adjacent the first skin and the core is disposed between a second surface of the column and the second skin. 
     
     
         18 . The panel of  claim 1 , wherein the third frame includes a metal column. 
     
     
         19 . The panel of  claim 1 , wherein the fourth frame includes a metal column. 
     
     
         20 . The panel of  claim 1 , wherein each of the third and fourth frames includes a core member of a primary material, a jacket of a secondary material, and a mating surface defined by the jacket, the jacket at least partially enclosing the core member such that the core member is embedded in the jacket. 
     
     
         21 . The panel of  claim 20 , wherein the mating surface of the third frame defines a groove in the jacket and the mating surface of the fourth frame defines a protruding member extending from the jacket, and wherein a portion of the jacket of each of the third and fourth frames is compressible when the protrusion of the fourth frame engages the groove of the third frame. 
     
     
         22 . The panel of  claim 20 , wherein the mating surface of the third frame defines a groove in the jacket and the mating surface of the fourth frame defines a groove in the jacket. 
     
     
         23 . The panel of  claim 20 , wherein the mating surface of the third frame defines a protruding member extending from the jacket and the mating surface of the fourth frame defines a protruding member extending from the jacket. 
     
     
         24 . The panel of  claim 1 , wherein the foam core may encapsulate first and second opposing surfaces of the column. 
     
     
         25 . An insulated panel for a storage unit, the panel comprising:
 a panel body including a first frame, a second frame, a third frame, and a fourth frame, the first, second, third, and fourth frames each including an interior surface, the panel body including a cavity defined by the interior surfaces, the second frame is spaced away from the first frame, and the third frame is spaced away from the fourth frame;   a pocket at least partially defined by the first frame and sized to receive a beam;   a column disposed in the cavity and extending between the first frame and the second frame; and   a foam core disposed in the cavity such that the column is embedded with the foam core.   
     
     
         26 . The panel of  claim 25 , wherein the pocket includes first and second parallel side members and a third member extending between the first side member and the second side member such that the first side member, the second side member, and the third member form an opening that is sized to receive the beam. 
     
     
         27 . The panel of  claim 26 , wherein the third member is the first end of the column such that the first side member, the second side member, and the first end of the column define the opening that is sized to receive the portion of the structural member. 
     
     
         28 . The panel of  claim 25 , further comprising a fifth frame spaced away from the first frame and coupled to the third frame and the fourth frame, wherein the pocket is adapted to receive a structural member between the first frame and the fifth frame. 
     
     
         29 . The panel of  claim 25 , wherein the pocket is a notch disposed on an exterior surface of the first frame. 
     
     
         30 . The panel of  claim 25 , wherein the first frame, the second frame, the third frame, and the fourth frame include a first material and the column is a second material. 
     
     
         31 . The panel of  claim 30 , wherein the first material is a non-metal and the second material is metal. 
     
     
         32 . The panel of  claim 31 , wherein the first material includes at least one of wood, PVC, high-density foam, and a composite. 
     
     
         33 . The panel of  claim 25 , wherein a width of the column is greater than a width of the third frame and a width of the fourth frame. 
     
     
         34 . The panel of  claim 29 , wherein a length of the column is greater than a length of the third frame and a length of the fourth frame. 
     
     
         35 . The panel of  claim 25 , further comprising a first skin secured to a first side of the panel body and a second skin secured to a second side of the panel body, the first skin and the second skin enclosing the cavity of the panel body. 
     
     
         36 . The panel of  claim 35 , wherein a first surface of the column is disposed adjacent the first skin and the core is disposed between a second surface of the column and the second skin. 
     
     
         37 . The panel of  claim 25 , wherein the third frame includes a metal column. 
     
     
         38 . The panel of  claim 25 , wherein the fourth frame includes a metal column. 
     
     
         39 . The panel of  claim 25 , wherein the second frame includes a first section and a second section, the column extending between the first and second sections of the second frame. 
     
     
         40 . The panel of  claim 25 , wherein the second frame includes a notch disposed on an interior surface of the second frame such that the notch receives a second end of the column. 
     
     
         41 . The panel of  claim 25 , wherein each of the third and fourth frames includes a core member of a primary material, a jacket of a secondary material, and a mating surface defined by the jacket, the jacket at least partially enclosing the core member such that the core member is embedded in the jacket. 
     
     
         42 . The panel of  claim 41 , wherein the mating surface of the third frame defines a groove in the jacket and the mating surface of the fourth frame defines a protruding member extending from the jacket, and wherein a portion of the jacket of each of the third and fourth frames is compressible when the protrusion of the fourth frame engages the groove of the third frame. 
     
     
         43 . The panel of  claim 41 , wherein the mating surface of the third frame defines a groove in the jacket and the mating surface of the fourth frame defines a groove in the jacket. 
     
     
         44 . The panel of  claim 41 , wherein the mating surface of the third frame defines a protruding member extending from the jacket and the mating surface of the fourth frame defines a protruding member extending from the jacket. 
     
     
         45 . The panel of  claim 25 , wherein the foam core encapsulates at least one of first and second opposing surfaces of the column. 
     
     
         46 . An insulated panel for a storage unit, the panel comprising:
 a panel body including a first frame, a second frame, a third frame, and a fourth frame, the first, second, third, and fourth frames each including interior surfaces forming 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 pocket at least partially defined by the first frame and sized to receive a beam;   a load-bearing column disposed in the cavity and extending between the first frame and the second frame, the load-bearing column configured to receive a point load from the beam; and   a foam core disposed in the cavity such that the column is embedded with the foam core.   
     
     
         47 . A method of manufacturing an insulated panel, the method comprising:
 providing a panel body including a first frame, a second frame, a third frame, and a fourth frame, the first frame spaced away from the second frame and the third frame spaced away from the fourth frame;   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;   forming a cavity in the panel body;   dispensing a foam material in liquid phase into the cavity; and   curing the foam material to form a foam core such that the column is embedded with the foam material.   
     
     
         48 . The method of  claim 47 , wherein providing the panel body includes forming a pocket having a U-shaped opening in the first frame, the pocket sized to receive a beam. 
     
     
         49 . The method of  claim 47 , wherein dispensing the foam material into the cavity includes injecting the foam material into the cavity through a hole in the panel body. 
     
     
         50 . The method of  claim 47 , wherein forming a cavity includes 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.