Sheet/Panel Design for Enclosure Component Manufacture

Abstract

An enclosure component for a building having first and second adjacent metal sheets, with an insertion section on an interior edge of the second metal sheet positioned within a receiver section of an interior edge of the first metal sheet, the first and second metal sheets being bonded to a planar foam panel layer with an edge portion of an exterior edge of the first metal sheet received in a locating slot of an edge seal positioned on the edge of the foam panel layer.

What is claimed is: 
     
         1 . An enclosure component for a building structure comprising:
 a first structural layer including a rectangular first metal sheet having an interior sheet face, an exterior sheet face and a first exterior sheet edge having an elongate edge portion bent to extend away from the interior sheet face;   a planar foam panel layer having a first face, an opposed second face and a first exterior panel edge, the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet; and   a planar elongate first edge seal having a first interior seal face, an opposed first exterior seal face, a first edge and an opposed second edge, the first interior seal face positioned proximate to the exterior panel edge of the foam panel layer, the first edge seal including an elongate first locating slot, defined on the first edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior edge of the first metal sheet.   
     
     
         2 . The enclosure component of  claim 1 , wherein the first exterior seal face of the first edge seal defines an elongate slot. 
     
     
         3 . The enclosure component of  claim 2 , wherein the elongate slot is a seal slot in which is positioned an elongate resilient first compression seal adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal. 
     
     
         4 . The enclosure component of  claim 2 , wherein the elongate slot is an interlock slot positioned distal from the first and second edges, which is adapted to receive an interlock key defined in a second exterior seal face of a second edge seal. 
     
     
         5 . The enclosure component of  claim 4 , wherein the first exterior seal face of the first edge seal defines a first seal slot positioned between the interlock slot and the first edge and a second seal slot positioned between the interlock slot and the second edge, and the enclosure component further comprises an elongate resilient first compression seal positioned in the first seal slot and an elongate resilient second compression seal positioned in the second seal slot, the first and second compression seals adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal. 
     
     
         6 . The enclosure component of  claim 1 , further comprising an interlock key on the first exterior seal face of the first edge seal, which is adapted to be received in an interlock slot defined in a second exterior seal face of a second edge seal. 
     
     
         7 . The enclosure component of  claim 5 , wherein the first exterior seal face of the first edge seal defines a third seal slot positioned between the interlock slot and the first seal slot, and the enclosure component further comprises an elongate resilient third compression seal positioned in the third seal slot and adapted to be positioned in pressing contact with the second exterior seal face of the second edge seal. 
     
     
         8 . The enclosure component of  claim 1 , further comprising a planar protective layer having a thickness and bonded to the exterior sheet face of the first metal sheet, and wherein the first locating slot is defined by a first portion of the first edge seal proximate to its first edge and abutting the first interior seal face and a second portion of the first edge seal proximate its first edge and abutting the first exterior seal face, with the first portion terminated an inset distance from the first edge that is equal to the thickness of the protective layer. 
     
     
         9 . The enclosure component of  claim 1 , further comprising a second structural layer including a rectangular second metal sheet having an interior sheet face, an exterior sheet face and a second exterior sheet edge;
 the second face of the foam panel layer being bonded to the interior sheet face of the second metal sheet;   the second exterior sheet edge of the second metal sheet including an elongate edge portion bent to extend away from the interior sheet face of the second metal sheet; and   the first edge seal including an elongate second locating slot, defined on the second edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior sheet edge of the second metal sheet.   
     
     
         10 . The enclosure component of  claim 1 , further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet. 
     
     
         11 . The enclosure component of  claim 9 , further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet. 
     
     
         12 . The enclosure component of  claim 1 , wherein:
 the first metal sheet has a second exterior sheet edge adjacent its first exterior sheet edge, the foam panel layer has a second exterior panel edge adjacent its first exterior panel edge, the second exterior panel edge has an elongate edge portion bent to extend away from the interior sheet face of the first metal sheet, and the enclosure component further comprises:   a planar elongate second edge seal having a second interior seal face, an opposed second exterior seal face, a third edge and an opposed fourth edge, the second interior seal face positioned proximate to the second exterior panel edge of the foam panel layer, the second edge seal including an elongate second locating slot, defined on the third edge between the second interior seal face and the second exterior seal face, and in which is positioned the elongate edge portion of the second exterior sheet edge of the first metal sheet.   
     
     
         13 . The enclosure component of  claim 12 , wherein:
 the first metal sheet has a third exterior sheet edge adjacent its first exterior sheet edge and opposing its second exterior sheet edge, the foam panel layer has a third exterior panel edge adjacent its first exterior panel edge and opposing its second exterior panel edge, the third exterior sheet edge has an elongate edge portion bent to extend away from the interior sheet face of the first metal sheet, and the enclosure component further comprises:   a planar elongate third edge seal having a third interior seal face, an opposed third exterior seal face, a fifth edge and an opposed sixth edge, the third interior seal face positioned proximate to the third exterior panel edge of the foam panel layer, the third edge seal including an elongate third locating slot, defined on the fifth edge between the third interior seal face and the third exterior seal face, and in which is positioned the elongate edge portion of the third exterior edge of the third metal sheet.   
     
     
         14 . The enclosure component of  claim 1 , wherein the first edge seal is foamed polyvinyl chloride. 
     
     
         15 . The enclosure component of  claim 12 , wherein the first and second edge seals are foamed polyvinyl chloride. 
     
     
         16 . The enclosure component of  claim 13 , wherein the first, second and third edge seals are foamed polyvinyl chloride. 
     
     
         17 . The enclosure component of  claim 1 , further comprising a first edge reinforcement member positioned between the first exterior panel edge of the foam panel layer and the first interior seal face of the first edge seal. 
     
     
         18 . The enclosure component of  claim 12 , further comprising a second edge reinforcement member positioned between the second exterior panel edge of the foam panel layer and the second interior seal face of the first edge seal. 
     
     
         19 . The enclosure component of  claim 13 , further comprising a third edge reinforcement member positioned between the third exterior panel edge of the foam panel layer and the third interior seal face of the first edge seal. 
     
     
         20 . An enclosure component for a building structure comprising:
 a first structural layer including a rectangular first metal sheet and a rectangular second metal sheet; with the first metal sheet having an interior sheet face, a first exterior sheet edge and a first interior sheet edge, and the second metal sheet having an interior sheet face and a second interior sheet edge positioned adjacent the first interior sheet edge of the first metal sheet;   the first interior sheet edge of the first metal sheet including a receiver section comprising a planar elongate first receiver region bent to extend away from the interior sheet face of the first metal sheet, and a planar elongate second receiver region joined by a first receiver bend to the first receiver region to extend toward the interior sheet face of the first metal sheet;   the second interior edge of the second metal sheet including an insertion section comprising a planar elongate first insertion region bent to extend away from the interior sheet face of the second metal sheet, and a planar elongate second insertion region joined by a first insertion bend to the first insertion region to extend toward the interior sheet face of the first metal sheet;   the insertion section of the second metal sheet positioned within the receiver section of the second metal sheet;   the first exterior edge of the first metal sheet including an elongate edge portion bent to extend away from the interior sheet face of the first metal sheet;   a planar foam panel layer having a first face, an opposed second face, and an exterior panel edge, the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet and to the interior sheet face of the second metal sheet, with the first face of the foam panel layer defining a channel in which is received the first receiver section and the first insertion section positioned in the first receiver section; and   a first edge seal having a first interior seal face, an opposed first exterior seal face, a first edge and an opposed second edge, the first interior seal face positioned proximate to the exterior panel edge of the foam panel layer, the first edge seal including an elongate first locating slot, defined on the first edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior edge of the first metal sheet.   
     
     
         21 . The enclosure component of  claim 20 , wherein:
 the receiver section further comprises a planar elongate third receiver region joined by a second receiver bend to the second receiver region distal from the first receiver bend to extend away from the interior sheet face of the first metal sheet, with the second receiver region distal from the second receiver bend terminating at a free edge; and   the insertion section further comprises a second insertion bend joined to the first insertion region distal from the first insertion bend.   
     
     
         22 . The enclosure component of  claim 21 , wherein the second insertion bend terminates at a free edge having a tangent line extending toward the first insertion region. 
     
     
         23 . The enclosure component of  claim 21 , further comprising a third insertion region joined to the second insertion bend with the third insertion region extending toward the first insertion region. 
     
     
         24 . The enclosure component of  claim 20 , wherein the second receiver region distal from the first receiver bend terminates at a free edge, and the second insertion region distal from the second insertion bend terminates at a free edge. 
     
     
         25 . The enclosure component of  claim 20 , further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet and to the exterior sheet face of the second metal sheet. 
     
     
         26 . The enclosure component of  claim 20 , wherein the first exterior seal face of the first edge seal defines an elongate slot. 
     
     
         27 . The enclosure component of  claim 26 , wherein the elongate slot is a seal slot in which is positioned an elongate resilient first compression seal that is adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal. 
     
     
         28 . The enclosure component of  claim 26 , wherein the elongate slot is an interlock slot positioned distal from the first and second edges which is adapted to receive an interlock key defined in a second exterior seal face of a second edge seal. 
     
     
         29 . The enclosure component of  claim 28 , wherein the first edge seal defines a first seal slot positioned between the interlock slot and the first edge and a second seal slot positioned between the interlock slot and the second edge, and the enclosure component further comprises an elongate resilient first compression seal positioned in the first seal slot and an elongate resilient second compression seal positioned in the second seal slot, the first and second compression seals adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal. 
     
     
         30 . The enclosure component of  claim 20 , further comprising an interlock key on the first exterior seal face of the first edge seal which is adapted to be received in an interlock slot defined in a second exterior seal face of a second edge seal. 
     
     
         31 . The enclosure component of  claim 29 , wherein the first edge seal defines a third seal slot positioned between the interlock slot and the first seal slot, and the enclosure component further comprises an elongate resilient third compression seal positioned in the third seal slot and adapted to be positioned in pressing contact with the second exterior seal face of the second edge seal. 
     
     
         32 . The enclosure component of  claim 20 , further comprising a planar protective layer having a thickness and bonded to the exterior sheet face of the first metal sheet, and wherein the first locating slot is defined by a first portion of the first edge seal proximate to its first edge and abutting the first interior seal face and a second portion of the first edge seal proximate its first edge and abutting the first exterior seal face, and the first portion is terminated an inset distance from the first edge that is equal to the thickness of the protective layer. 
     
     
         33 . The enclosure component of  claim 20 , further comprising a second structural layer including a rectangular third metal sheet having an interior sheet face, an exterior sheet face and a second exterior sheet edge;
 the second face of the foam panel layer being bonded to the interior sheet face of the third metal sheet;   the second exterior sheet edge of the third metal sheet including an elongate edge portion bent to extend away from the interior sheet face of the third metal sheet; and   the first edge seal including an elongate second locating slot, defined on the second edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the second exterior sheet edge of the third metal sheet.   
     
     
         34 . The enclosure component of  claim 20 , further comprising an edge reinforcement member positioned between the exterior panel edge of the foam panel layer and the first interior seal face of the first edge seal. 
     
     
         35 . An enclosure component for a building structure comprising:
 a first structural layer including a rectangular first metal sheet and a rectangular second metal sheet; with the first metal sheet having an interior sheet face and a first interior sheet edge, and the second metal sheet having an interior sheet face and a second interior sheet edge positioned adjacent the first interior edge of the first metal sheet;   the first interior sheet edge of the first metal sheet including a receiver section comprising a planar elongate first receiver region bent to extend away from the interior sheet face of the first metal sheet, and a planar elongate second receiver region joined by a first receiver bend to the first receiver region to extend toward the interior sheet face of the first metal sheet, with a portion of the planar elongate second receiver region closest to the interior sheet face of the first metal sheet terminating at a free edge distal from the first receiver bend;   the second interior edge of the second metal sheet including an insertion section comprising a planar elongate first insertion region bent to extend away from the interior sheet face of the second metal sheet, and a planar elongate second insertion region joined by a first insertion bend to the first insertion region to extend toward the interior sheet face of the second metal sheet, with a portion of the planar elongate second insertion region closest to the interior sheet face of the second metal sheet terminating at a free edge distal from the first insertion bend;   the insertion section of the second metal sheet positioned within the receiver section of the first metal sheet; and   a planar foam panel layer having a first face and an opposed second face, the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet and to the interior sheet face of the second metal sheet, with the first face of the foam panel layer including a channel in which is received the first receiver section and the first insertion section positioned in the first receiver section.   
     
     
         36 . The enclosure component of  claim 35 , wherein:
 the receiver section further comprises a planar elongate third receiver region joined by a second receiver bend to the second receiver region distal from the first receiver bend to extend away from the interior sheet face of the first metal sheet, with the second receiver region distal from the second receiver bend terminating at a free edge; and   the insertion section further comprises a second insertion bend joined to the first insertion region distal from the first insertion bend.   
     
     
         37 . The enclosure component of  claim 36 , wherein the second insertion bend terminates at a free edge having a tangent line extending toward the first insertion region. 
     
     
         38 . The enclosure component of  claim 36 , further comprising a third insertion region joined to the second insertion bend with the third insertion region extending toward the first insertion region. 
     
     
         39 . The enclosure component of  claim 35 , wherein the second receiver region distal from the first receiver bend terminates at a free edge, and the second insertion region distal from the second insertion bend terminates at a free edge. 
     
     
         40 . The enclosure component of  claim 35 , further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet and to the exterior sheet face of the second metal sheet.