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.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the filing date of U.S. Provisional Application No. 62/821,294, filed Mar. 20, 2019, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to insulated panels and, more particularly, to a structurally reinforced insulated panel.

BACKGROUND

Freezers or refrigerated enclosures, such as refrigerated display cases and storage units, are typically constructed of materials that either have high insulative properties or high structural reliability, but not both. For example, structurally reliable materials used for a frame, such as wood, steel, and aluminum, have a low R value (i.e., thermal resistivity) and allow heat to enter the refrigerated enclosure through the frame (i.e., panel perimeter). Further, many known freezers or refrigerators use multiple studs distributed through a panel body to increase the structural integrity of the insulated panel. However, placing multiple studs within the panel body decreases the amount of insulating material that can be placed within the panel body and increases the number of areas within the panel or enclosure that act as a thermal bridge, which decreases the efficiency of the freezer or refrigerator. In these applications, the thermal resistivity of the panel is traded for the structural performance of the panel or enclosure. That is, structural performance will be optimized, but the thermal resistivity (i.e., R value) of the panel or enclosure would consequently be diminished.

SUMMARY

In accordance with a first exemplary aspect of the present disclosure, an insulated panel for a storage unit is provided. The panel may include a first frame, a second frame, a third frame, and a fourth frame. The first, second, third, and fourth frames may 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 may be disposed in the cavity and may have a first end coupled to the first frame and a second end coupled to the second frame. A foam core may be disposed in the cavity such that the column is embedded with the foam core.

In accordance with a second exemplary aspect of the present disclosure, an insulated panel for a storage unit is provided. The panel may include a first frame, a second frame, a third frame, and a fourth frame. The first, second, third, and fourth frames may each include an interior surface. The panel may also include a cavity defined by the interior surfaces. The second frame may be spaced away from the first frame and the third frame may be spaced away from the fourth frame. A pocket may be at least partially defined by the first frame and sized to receive a beam. A column may be disposed in the cavity and may extend between the first frame and the second frame. A foam core may be disposed in the cavity such that the column is embedded with the foam core.

In accordance with a third exemplary aspect of the present disclosure, an insulated panel for a storage unit is provided. The insulated panel may include a panel body including a first frame, a second frame, a third frame, and a fourth frame. The first, second, third, and fourth frames may each include interior surfaces forming a cavity of the panel body. The second frame may be spaced away from the first frame, and the third frame may be spaced away from the fourth frame. A pocket may be at least partially defined by the first frame and sized to receive a beam. A load-bearing column may be disposed in the cavity and extend between the first frame and the second frame. The load-bearing column may be configured to receive a point load from the beam. A foam core may be disposed in the cavity such that the column is embedded with the foam core.

In accordance with a fourth exemplary aspect of the present disclosure, a method of manufacturing a structurally reinforced insulated panel is provided. The method may include providing a panel body including a first frame, a second frame, a third frame, and a fourth frame. The first frame may be spaced away from the second frame and the third frame may be spaced away from the fourth frame. The method may include 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. The method may further include forming a cavity in the panel body. The method may include dispensing a foam material in liquid phase into the cavity. Finally, the method may include curing the foam material to form a foam core such that the column is embedded with the foam material.

In a preferred aspect, the first frame may define a pocket that is configured to receive a portion of a structural member.

In a preferred aspect, the pocket may be disposed outside the cavity and adjacent to the column.

In a preferred aspect, the pocket may include first and second parallel side members and a third member perpendicularly disposed relative to the first and second parallel side members.

In a preferred aspect, the third member may extend between the first side member and the second side member.

In a preferred aspect, the panel body may include 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.

In a preferred aspect, the panel body may include a fifth frame spaced away from the first frame and coupled to the third frame and the fourth frame, such that the pocket is adapted to receive a structural member between the first frame and the fifth frame.

In a preferred aspect, the third member may be the first end of the column such that the first side member, the second side member, and the first end of the column define an opening that is sized to receive a portion of a structural member.

In a preferred aspect, the pocket may be a notch disposed on an exterior surface of the first frame, the exterior surface opposite the interior surface of the first frame.

In a preferred aspect, at least one of the second frame, the third frame, and the fourth frame may define a pocket that is configured to receive a portion of a structural member.

In a preferred aspect, the first frame, the second frame, the third frame, and the fourth frame may include a first material.

In a preferred aspect, the column may be a second material.

In a preferred aspect, the first material may be a non-metal and the second material may be a metal.

In a preferred aspect, the first material may include at least one of wood, PVC, high-density foam, and a composite.

In a preferred aspect, a width of the column may be greater than a width of the third frame and a width of the fourth frame.

In a preferred aspect, a length of the column may be less than a length of the third frame and a length of the fourth frame.

In a preferred aspect, each of the first, second, third, and fourth frames may include a core member of a primary material, a jacket of a secondary material, and a mating surface defined by the jacket.

In a preferred aspect, the jacket may at least partially enclose the core member such that the core member is embedded with the jacket.

In a preferred aspect, the mating surface of the third frame may define a groove in the jacket and the mating surface of the fourth frame may define a protruding member extending from the jacket.

In a preferred aspect, a portion of the jacket of each of the third and fourth frames may be compressible when the protrusion of the fourth frame engages the groove of the third frame.

In a preferred aspect, the column may be fixedly secured to the first frame and the second frame.

In a preferred aspect, the second frame may include a first section and a second section.

In a preferred aspect, the column may extend between the first and second sections of the second frame.

In a preferred aspect, the second frame may include a notch that is disposed on an exterior surface of the second frame such that the notch receives the second end of the column.

In a preferred aspect, a first surface of the column may be disposed adjacent the first skin and the foam core may be disposed between a second surface of the column and the second skin, the second surface being opposite the first surface of the column.

In a preferred aspect, the foam core may encapsulate first and second opposing surfaces of the column.

In a preferred aspect, the third frame may include a metal column.

In a preferred aspect, the fourth frame may include a metal column.

In a preferred aspect, a cover may be releasably secured to the pocket.

In a preferred aspect, forming a cavity may include 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.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective, cutaway view of an example insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 2 is a perspective view of a first exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 3 is a front view of the panel body of FIG. 2;

FIG. 4 is a front view of a second exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 5 is a front view of a third exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 6 is a perspective view of a fourth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 7 is a perspective view of a fifth exemplary panel body of an insulted panel constructed in accordance with the teachings of the present disclosure;

FIG. 8 is a perspective view of a sixth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 9 is a partial, front view of a beam disposed in an exemplary pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 10 is a front view of a different example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 11 is a front view of a different example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 12 is a front view of another example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 13 is a front view of another example pocket of a panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 14 is a front view of a seventh exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure;

FIG. 15A is a cross-sectional view of a first exemplary configuration of the panel body of FIG. 3 taken at A-A;

FIG. 15B is a cross-sectional view of a second exemplary configuration of the panel body of FIG. 3 taken at A-A;

FIG. 15C is a cross-sectional view of a third exemplary configuration of the panel body of FIG. 3 taken at A-A;

FIG. 16 is a partial, top view of an example frame joint between two insulated panels constructed in accordance with the teachings of the present disclosure;

FIG. 17 is a front view of an eighth exemplary panel body of an insulated panel constructed in accordance with the teachings of the present disclosure; and

FIG. 18 is an example method of manufacturing an insulated panel in accordance with the teachings of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is generally directed to a structurally reinforced, insulated panel (hereinafter, the “panel”) used to construct storage units (e.g., cold storage units, for example, coolers and freezers) and improve upon thermal performance, structural performance, energy performance, and life cycle of the storage units. The panel increases the structural performance by using a single column embedded in a foam core. The column more efficiently supports and transfers loads from a first frame of the panel to the ground than a panel having multiple studs spanning the height and width of the panel. Moreover, the panel may increase thermal performance by containing more insulating material of the foam core because there is only one column, rather than multiple columns, embedded in the foam core.

FIG. 1 depicts a first exemplary panel 100 constructed in accordance with the teachings of the present disclosure. The panel 100 includes a panel body 102 having a first frame 104, a second frame 106 spaced away from the first frame 104, a third frame 108, and a fourth frame 110 spaced away from the third frame 108. Each of the first, second, third, and fourth frames 104, 106, 108, 110 includes an interior surface 112 that together partially define a cavity 114 of the panel body 102. In other words, the perimeter of the cavity 114 is defined by the interior surface 112 of the first frame 104, the second frame 106, the third frame 108, the fourth frame 110, and an edge 116 of a pocket 118. A column 120 is disposed in the cavity 114 and has a first end 120a coupled to the first frame 104 and a second end 120b coupled to the second frame 106. A foam core 122 is disposed in the cavity 114 of the panel 100 and at least partially encapsulates the column 120 such that the column 120 is embedded with the foam core 122.

At least one skin 124, which may take the form of a metal sheet, may be disposed on either side of the panel 100. In particular, the panel 100 may include a first skin 124a coupled to the first side 100a of the panel 100 and a second skin 124b coupled to the second side 100b of the panel 100. The first and second skins 124a, 124b may be coupled to the first and second sides 100a, 100b of the panel 100 using any fastening mechanism. For example, the first and second skins 124a, 124b can be coupled to the first, second, third, and/or fourth frames 104, 106, 108, 110 of the panel 100 using an adhesive; at least one fastener, such as, a screw, a nail, a staple; at least one latch; or by punching a portion of the first and second skins 124a, 124b in the panel body 102. Alternatively or in addition, adhesives may be used, but due to thermal fluctuations experienced by the panel 100, a physical fastener may be preferred to a chemical adhesive. The first and second skins 124a, 124b may be any material suitable for the purpose of insulating and protecting the panel 100. For example, the first and second skins 124a, 124b can be metal, plywood, plastic, or oriented strand board (OSB). As shown in FIG. 1, the first skin 124a may be rectangular having a U-shaped cut-out to form the pocket 118.

The pocket 118 is shaped to receive a portion of a structural member, such as a beam (not shown), and is formed by the panel body 102. For example, as illustrated in FIG. 1, the first frame 104 defines the pocket 118. While the pocket 118 is defined by the first frame 104 in the example illustrated in FIG. 1, the pocket 118 can be defined by the second frame 106, the third frame 108, or the fourth frame 110. In yet other examples, however, the pocket 118 can be formed in part by the first end 120a of the column 120, which will be described in greater detail later.

Turning now to FIGS. 2 and 3, a different panel body 202 is constructed in accordance with the teachings of the present disclosure, and may form the structural skeleton of an insulated panel, such as the insulated panel 100 of FIG. 1. The panel body 202 of FIG. 2 is similar to the panel body 102 of the insulated panel 100 of FIG. 1, except for variations in the first, second, third, and fourth frames 204, 206, 208, 210. Thus, for ease of reference, and to the extent possible, the same or similar components of the panel body 202 will retain the same reference numbers as outlined above with respect to the panel body 102 of the panel 100, although the reference numbers will be increased by 100.

The panel body 202 includes the first frame 204, the second frame 206, the third frame 208, and the fourth frame 210. In particular, the third frame 208 and the fourth frame 210 couple the first frame 204 and the second frame 206 to form a rectangular shape of the panel body 202. As illustrated in FIG. 3, the third frame 208 extends a height H1 of the panel body 202 between the first frame 204 and the second frame 206, and the fourth frame 210 is parallel to the third frame 208 and extends a height H2 of the panel body 202 between the first frame 204 and the second frame 206. However, in other examples, the third frame 208 and the fourth frame 210 can be non-parallel or partially non-parallel for a customized or irregularly shaped panel body 202. The third and fourth frames 208, 210 may be coupled to the first and second frames 204, 206 using any suitable attachment mechanism. For example, the third and fourth frames 208, 210 can be coupled to the first and second frames 204, 206 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint, or a mechanical fastener, such as, a screw, a nail, a staple, or other suitable mechanical fastener.

The first frame 204, the second frame 206, the third frame 208, and the fourth frame 210 may be any type of material. For example, each of the first, second, third, and fourth frames 204, 206, 208, 210 can be a hybrid frame having an insulative component and a structural component, which will be discussed later in more detail, such as the hybrid frames disclosed in U.S. Provisional Application No. 62/751,325 filed Oct. 26, 2018, titled “Hybrid Insulating Panel, Frame, and Enclosure,” which is incorporated herein by reference. However, each of the first, second, third, and fourth frames 204, 206, 208, 210 may instead be composed of one material. For example, each of the first, second, third, and fourth frames 204, 206, 208, 210 can be elongated pieces of wood, such as, but not limited to, a two inch (2″) by four inch (4″) wooden beam. In other examples, each of the first, second, third, and fourth frames 204, 206, 208, 210 can each be a foam. Further, in some examples, the third and fourth frames 208, 210 can include a metal column.

In the example panel body 202 illustrated in FIGS. 2 and 3, the first frame 204 at least partially defines the pocket 218 that receives a portion of a structural member (e.g., a horizontal beam, not shown). The pocket 218 may be centrally disposed between the third and fourth frames 208, 210. However, in other examples, the pocket 218 can be disposed closer to either the third frame 208 or the fourth frame 210. The pocket 218 includes a first side member 226, a second side member 228, and a third member 230 extending between the first side member 226 and the second side member 228. The first and second side members 226, 228 are spaced away from each other and extend transversely from the first frame 204. More particularly, in this example, the first and second side members 226, 228 perpendicularly extend from the first frame 204 and are substantially equal in length. In other examples, however, the first and second side members 226, 228 perpendicularly extend from the first frame 204 and are not substantially equal in length. The pocket 218 also includes the third member 230 that extends between the first side member 226 and the second side member 228. The third member 230 receives a majority of the load transferred from the structural member sitting in the pocket 218 because the structural member sits directly on top of the third member 230. As such, the third member 230 may be made of a material strong enough to withstand and properly transfer the load from the structural member to the column 220. For example, the third member 230 can be a single wooden beam, or a single piece of plywood, coupled to the first and second side members 226, 228. However, in other examples, as illustrated in FIGS. 2 and 3, the third member 230 can be a plurality of wooden beams, or a plurality of pieces of plywood, fixedly secure to one another. It will be appreciated that other materials can be used for the third member 230, such as, for example, a polymer, a rubber, a carbon fiber, or other suitable material.

The first and second side members 226, 228 may be coupled to the first frame 204 using any attachment mechanism. For example, the first and second side members 226, 228 can be coupled to the first frame 204 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint, or a mechanical fastener, such as, a screw, a nail, a staple, or other suitable fastener. The first and second side members 226, 228 may be any type of material. For example, the first and second side members 226, 228 can be elongated pieces of wood, such as, but not limited to, a two inch (2″) by four inch (4″) wooden stud, or plywood. The first and second side members 226, 228 may be the same type of material. However, in other examples, the first and second side members 226, 228 can each be different types of materials. Further, the third member 230 may be coupled to the first and second side members 226, 228 using any attachment mechanism. For example, the third member 230 can be coupled to the first and second side members 226, 228 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint, or a mechanical fastener, such as, a screw, a nail, a staple, or other suitable fastener.

The column 220 extending between and coupled to the first frame 204 and the second frame 206 helps transfer the load from the structural member (e.g., a horizontal beam) to the ground. The use of a single column concentrates the load on a single support structure of the panel body 202, which receives an even distribution of the load because the structural member sits directly above the column 220. In particular, as illustrated in FIGS. 2 and 3, the column 220 extends between the second frame 206 and the third member 230, and is coupled to the interior surface 212 of the second frame 206 at a second end 220b of the column 220 and is coupled to the third member 230 at a first end 220a of the column 220. The first end 220a of the column 220 includes a first plate 232 for attaching the column 220 to the third member 230 and the second end 220b of the column 220 includes a second plate 234 for attaching the column 220 to the second frame 206. The first and second plates 232, 234 may be integrally formed with the column 220. In other examples, the first and second plates 232, 234 can be secured to the column 220 by welding or through the use of fasteners. The first plate 232 and the second plate 234 each includes a fastening mechanism 236 for attaching the first and second plates 232, 234 to the third member 230 and the second frame 206, respectively. The fastening mechanism 236 may be any mechanism capable of securely fixing the first and second plates 232, 234 to the third member 230 and the second frame 206, respectively. For example, the fastening mechanism 236 can be a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. Further, as shown in FIG. 3, a width W1 of the column 220 is greater than a width W2 of the third frame 208 and a width W3 of the fourth frame 210. Additionally, a height H3 of the column 220 may be less than a height H1 of the third frame 208 and a height H2 of the fourth frame 210. However, in other embodiments, the height H3 of the column 220 can be greater than the height H1 of the third frame 208 and the height H2 of the fourth frame 210. Moreover, the column 220 may be a material suitably strong enough to effectively transfer the load from the structural member to the ground. For example, the column 220 can be made of steel, and in particular, ASTM A500, Grade B steel.

In FIG. 3, the column 220 is centrally disposed in the cavity 214 between the third frame 208 and the fourth frame 210 such that a first distance D1 between the third frame 208 and the column 220 and a second distance D2 between the fourth frame 210 and the column 220 are substantially equal. However, in other examples, the column 220 can be disposed off-center (e.g., closer to the third frame 208 or closer to the fourth frame 210) depending on the placement of the panel 200 in an enclosure created with multiple structurally reinforced panels 200 or other panels.

FIG. 4 illustrates a second exemplary panel body 302 constructed in accordance with the teachings of the present disclosure. The second exemplary panel body 302 is similar to the panel body 202 of FIGS. 2 and 3, except that a pocket 318 of the second exemplary panel body 302 is at least partially defined by a first end 320a of the column 320. In this case, the structural member sits directly on the column 320 or on a bracket attached to the column 320. The first and second side members 326, 328 are coupled directly to the first end 320a of the column 320. The first end 320a of the column 320 may be a bracket or flanged member fixed to the column 320 providing the first end 320a, which may be thicker to accommodate the load placed directly on top of the first end 320a. The first end 320a of the column 320 may also include a shock absorbing material. For example, the first end 320a can include a piece of rubber that comes into contact with the structural member to facilitate placement and reduce vibrations during assembly.

In another aspect, FIG. 5 illustrates a third exemplary panel body 402 constructed in accordance with the teachings of the present disclosure. The third exemplary panel body 402 of FIG. 5 is similar to the panel body 202 of FIGS. 2 and 3, except the third exemplary panel body 402 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of the panel body 402 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3, although the reference numbers will be increased by 200.

The pocket 418 may be disposed in a cavity 414 of the panel body 402 and is partly defined by a first frame 404, similar to the pocket 218 illustrated in FIGS. 2 and 3. However, the panel body 402 of FIG. 5 further includes a fifth frame 438 disposed above the first frame 404, with respect to gravity. The third and fourth frames 408, 410 extend past the first frame 404 and couple to the fifth frame 438. The fifth frame 438 is similar to the first frame 404 and may be made of the same material as the first frame 404. The fifth frame 438 may be coupled to the third and fourth frames 408, 410 using any suitable attachment mechanism. For example, the fifth frame 438 can be coupled to the third and fourth frames 408, 410 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint; or a mechanical fastener, such as, a screw, a nail, a staple; or other suitable mechanical fastener. The first frame 404 of the third exemplary panel body 402 also differs from the first frame 204 of the first exemplary panel body 202 because the first frame 404 creates a closed pocket 418; whereas the first frame 204 of the first exemplary panel body 202 creates an open pocket 218. As shown in FIG. 5, the pocket 418 is entirely disposed within the first cavity 414 of the frame and a second cavity 440, which is defined by the first frame 404, the fifth frame 438, part of the third frame 408, and part of the fourth frame 410. The second cavity 440 may be filled with foam. However, in other examples, the second cavity 440 does not have foam. Additionally, the pocket 418 illustrated in FIG. 5 is adapted to receive a structural member between the first frame 404 and the third member 430 of the pocket 418.

In yet another aspect, FIG. 6 illustrates a fourth exemplary panel body 502 constructed in accordance with the teachings of the present disclosure. The fourth exemplary panel body 502 of FIG. 6 is similar to the panel body 402 of FIG. 5 except the fourth exemplary panel body 502 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of the panel body 502 will retain the same reference numbers as outlined above with respect to the panel body 402 of FIG. 5, although the reference numbers will be increased by 100.

Similar to the panel body 402 of FIG. 5, the panel body 502 of FIG. 6 includes third and fourth frames 508, 510 that extend between first and second frames 504, 506 to form a cavity 514. However, unlike the panel body 402 of FIG. 5, the fourth exemplary panel body 502 includes sixth and seventh frames 542, 544 that are disposed in the cavity 514 between the third and fourth frames 508, 510, and extend in parallel between the first and second frames 504, 506. While the sixth and seventh frames 542, 544 extend in parallel to one another, as illustrated in FIG. 6, in other examples, the sixth and seventh frames 542, 544 may be non-parallel or partially non-parallel for a customized or irregularly shaped panel body 502. The sixth and seventh frames 542, 544 may be coupled to the first and second frames 504, 506 using any suitable attachment mechanism. For example, the sixth and seventh frames 542, 544 can be coupled to the first and second frames 504, 506 using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint; or a mechanical fastener, such as, a screw, a nail, a staple; or other suitable mechanical fastener. Coupling the sixth and seventh frames 542, 544 to the first and second frames 504, 506 forms a third cavity 548 between the sixth and seventh frames 542, 544 and a fourth cavity 550 between the third frame 508 and the sixth frame 542. Disposed in the third cavity 548 is a column 520 having a first end 520a and a second end 520b. The second end 520b of the column 520 is coupled to the second frame 506 and the first end 520a of the column 520 at least partially defines the pocket 518. Here, a structural member may sit directly on the column 520 or on a bracket attached to the column 520. The sixth and seventh frames 542, 544 are directly coupled to the first end 520a of the column. Further, the first end 520a of the column 520 may be a bracket or flanged member fixed to the column 520 providing the first end 520a, which may be thicker to accommodate the load placed directly on top of the first end 520a. The first end 520a may include, for example, a piece of rubber that comes into contact with the structural member to facilitate placement and to reduce vibrations during assembly.

A pocket 518 is disposed in the third cavity 548 and above the column 520 of the panel body 502. The pocket 518 is defined by a portion of the sixth frame 542, a portion of the seventh frame 544, a fourth member 546, and the first end 520a of the column 520. The fourth member 546 is disposed a distance D3 above the first end 520a of the column 520, with respect to gravity, and extends between the sixth and seventh frames 542, 544. In particular, the fourth member 546 may be disposed any distance D3 above the first end 520a of the column 520 that allows the pocket 518 to receive a support member.

In another aspect, FIG. 7 illustrates a fifth exemplary panel body 602 constructed in accordance with the teachings of the present disclosure. The fifth exemplary panel body 602 of FIG. 7 is similar to the panel body 202 of FIGS. 2 and 3, except the fifth exemplary panel body 602 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of the panel body 602 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3, although the reference numbers will be increased by 400.

Similar to the pocket 218 of the first exemplary panel body 202 of FIGS. 2 and 3, a pocket 618 of the fifth exemplary panel body 602 is defined in part by the first frame 604. However, unlike the first exemplary pocket 218, the fifth exemplary pocket 618 is formed outside of the cavity 614 and defined by an inner surface 612 of the first side member 626, second side member 628, and third member 630. In particular, a first side member 626 and a second side member 628 extend above the first frame 604, with respect to gravity, and a third member 630 extends between the first and second side members 626, 628. As illustrated in FIG. 7, a column 620 passes through the third member 630 and a first end 620a of the column 620 rests on an exterior surface of the third member 630. The first end 620a of the column 620 includes a first plate 632 for attaching the column 620 to the third member 630 and the first plate 632 may include a fastening mechanism for attaching the first plate 632 to the third member 630. For example, the fastening mechanism can be a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. While the first plate 632 is illustrated in FIG. 7 as resting on the exterior surface of the third member 630, in other embodiments, for example, the first plate 632 can be disposed against the interior surface 612 (i.e., facing the cavity) of the third member 630. Further, the second end 620b of the column 620 extends through the second frame 606 and is received in a notch disposed in the outer surface of the second frame 606. In some examples, the notch disposed in the outer surface of the second frame 606 extends through only one side of the second frame 606.

In yet another aspect, FIG. 8 illustrates a sixth exemplary panel body 702 constructed in accordance with the teachings of the present disclosure. The sixth exemplary panel body 702 of FIG. 8 is similar to the panel body 402 of FIG. 5 except the sixth exemplary panel body 702 provides a different pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of the panel body 702 will retain the same reference numbers as outlined above with respect to the panel body 402 of FIG. 5, although the reference numbers will be increased by 300.

Similar to the panel body 402 of FIG. 5, the sixth exemplary panel body 702 is defined by a first frame 704, a second frame 706, a third frame 708, and a fourth frame 710. However, unlike the panel body 402, a pocket 718 of the sixth exemplary panel body 702 is not defined by the first frame 704. Instead, the pocket 718 is defined by a first side member 726, a second side member 728, a third member 730, and a first end 720a of a column 720. In particular, as illustrated in FIG. 8, the first and second side members 726, 728 extend transversely from the first end 720a of the column 720 and the third member 730 extends between the first and second side members 726, 728. The first end 720a of the column 720 includes a first plate 732 for attaching the column 720 to the first and second side members 726, 728. The first plate 732 may be attached to the first and second side members 726, 728 using, for example, a fastening mechanism, such as, a lag bolt, a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener. Further, the first and second side members 726, 728 are coupled to the third member 730, for example, using an adhesive to hold a mortise-and-tenon joint, a dovetail joint, a box joint, or a butt joint; a mechanical fastener, such as, a screw, a nail, a staple; or other suitable mechanical fastener.

FIGS. 9-13 illustrate different examples of pocket configurations. The pocket 818 may take additional shapes other than rectangular depending on the shape of the structural member. In FIG. 9, a pocket 818 may take the form of a notch 856 disposed in a first frame 804 of a panel body 802. The notch 856 may be of any depth such that a portion of a structural member 858 is disposed in the notch 856. For example, the notch depth can be equal to a thickness of a portion of the structural member 858, which in this case is an I-beam. In other examples, the notch depth can be greater than a thickness of a portion of the I-beam. The notch 856 may also include at least one blind bore that receives a portion of an attachment mechanism. Moreover, in the exemplary panel body 802, the column extends from a second frame to the first frame. In particular, the column may extend from the second frame to the first frame such that a first end of the column sits beneath the structural member 858 (e.g., an I-beam).

In FIG. 10, the pocket 918A is defined by a U-shaped bracket instead of first and second parallel side members and third member. In FIG. 11, the pocket 918B has a V-shaped opening. In FIG. 12, the pocket 918C defines a narrow groove, similar to the notch 856 discussed above. Finally, as illustrated in FIG. 13, the pocket 918D may take the shape of a circle or oval.

Turning to FIG. 14, a seventh exemplary panel body 1002 is constructed in accordance with the teachings of the present disclosure. The seventh exemplary panel body 1002 of FIG. 14 is similar to the panel body 202 of FIGS. 2 and 3, except the seventh exemplary panel body 1002 provides a different column configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of the panel body 1002 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3, although the reference numbers will be increased by 800.

In the example of FIG. 14, a column 1020 extends between a first section 1060 and a second section 1062 of a second frame 1006. The first and second sections 1060, 1062 may be equal lengths when the column 1020 is centrally disposed in the panel body 1002. In other examples, the first and second sections 1060, 1062 can vary in length. In particular, the first section 1060 may be a first length L1 and the second section 1062 may be a second length L2. A second end 1020b of the column 1020 does not include a second plate (as shown in FIG. 3). As such, the column 1020 is coupled to the second frame 1006 in a different manner than how a first end 1020a of the column 1020 is coupled to a first frame 1004. However, in some examples, an outer surface 1064 of the second frame 1006 can include a notch that is adapted to receive a second plate.

As illustrated in FIG. 1, the frame members 104, 106, 108, 110 enclosed by the first and second skins 124a, 124b define the cavity 114 in which an insulting material is disposed. In particular, the insulating material is inserted into the cavity 114 of the panel body 102 (as well as any of the cavities of the exemplary panel bodies disclosed herein) to improve the insulative properties of the panel 100 (i.e., thermal conductivity and thermal resistivity). The insulating material is inserted into the cavity 114 in liquid form and sits until the insulating material cures. After the insulating material cures, it becomes one solid piece of insulation, otherwise known as the foam core 122 of the panel 100. In other examples, however, the foam core 122 can be a pre-cured block that is cut, or otherwise trimmed, to the size of the cavity 114. In such examples, the foam core 122 is inserted into the cavity 114 after the foam core 122 has been cut or trimmed to the size of the cavity 114.

The foam core 122 may be any insulating material that improves the insulative properties of the panel 100. For example, the foam core 122 can be asbestos, fiberglass, mineral wool, cellulose, polyurethane foam, polystyrene, or other suitable material. The foam core 122 may also have any foam density that properly reduces the thermal conductivity of the panel 100 based on the application. For example, the foam core 122 can have a foam density of between 1.0 to 3.0 pounds per cubic foot and, more particularly, 2.2 pounds per cubic foot.

Turning now to FIGS. 15A-C, first, second, and third panel configurations 1102A, 1102B, 1102C having different foam core configurations are constructed in accordance with the teachings of the present disclosure. These configurations illustrate different example iterations of the panel body 202 of FIG. 3, but may be incorporated into any of the panel body examples disclosed herein. The three configurations 1102A, 1102B, 1102C are provided to illustrate variations in which the column 1120 may be embedded within a foam core. In other words, the column 1120 may include first and second opposing surfaces 1166, 1168 in which one or both surfaces may be surrounded by insulation foam.

In these examples, the column 1120 has a thickness T1 that is less than a thickness T2 of the third frame and a thickness T3 of the fourth frame. Since the thickness T1 of the column 1120 is less than the thicknesses T2, T3 of the third and fourth frames, at least one gap 1170 is formed between a first surface 1166 and/or a second surface 1168 of the column 1120 and an inner surface of the first and second skins. As best illustrated in FIGS. 15A-C, the at least one gap 1170 allows the insulating material to substantially surround the column 1120, such that the column 1120 is embedded with the foam core. Such a configuration allows the foam core to include a maximum amount of insulating material giving the panel better insulative properties over known insulation panels. At least one gap 1170 may be disposed on either side of the panel. In the first configuration of FIG. 15A, the first surface 1166 of the column 1120 is adapted to abut a first skin 1124a, such as the first skin 124a of the panel 100 of FIG. 1, and the second surface 1168 of the column 1120 is spaced away from a second skin 1124b, such as the second skin 124b of the panel of FIG. 1, thereby providing the gap 1170 in which insulating foam may be inserted. The gap 1170 is disposed on a second side 1172 of the panel body 1102. In FIG. 15B, the column 1120 is disposed between, and spaced from, the first and second skins 1124a, 1124b, thereby providing gaps 1170 adjacent to both the first and second surfaces 1166, 1168 of the column 1120. In the third configuration of FIG. 15C, the second surface 1168 of the column 1120 is adapted to abut a second skin 1124b, such as the second skin 124b of the panel 100 of FIG. 1, and the first surface 1166 of the column 1120 is spaced away from a first skin 1124a, such as the first skin 124a of the panel 100 of FIG. 1, thereby providing the gap 1170 in which insulating foam may be inserted. In this example, the gap 1170 is disposed on a first side 1174 of the panel.

In another aspect, the panel 200 may include a distribution plate (not shown) coupled to the pocket 218 that helps evenly distribute the load of the structural member, if more than one column 220 is disposed between the first frame 204 and the second frame 206. In some examples, the distribution plate can be disposed below the pocket 218 and above the at least one column 220. In particular, the distribution plate can be fixedly secured to the third member 230 using any of the attachment mechanisms discussed above and each of the at least one column 220 can be fixedly secured to the distribution plate. Moreover, the panel 200 may include a cover (not shown) that is slidably received by the pocket 218. In other examples, the cover can be press fit into the pocket 218.

As briefly mentioned above, the first, second, third, and fourth frames of any of the example panel bodies may be hybrid frames. In FIG. 16, a third frame of the panel 100 of FIG. 1 and a fourth frame of a different, but identical panel 100, is illustrated in detail. For ease of reference, the third frame is labeled as 1208 and the fourth frame is labeled as 1210. Each hybrid frame 1208, 1210 includes a beam 1276 of a primary material and a jacket 1278, 1280 of a secondary material at least partially enclosing the beam 1276. The beam 1276 of the hybrid frame 1208, 1210 may be plywood, lumber, magnesium oxide, gypsum, rigid plastic, fiberglass, carbon fiber, Kevlar, fiberglass reinforced plastic resin, PVC, or other rigid material. The jacket 1278 of the third frame 1208 defines a first joint member 1282 and the jacket 1280 of the fourth frame 1210 defines a second joint member 1284. Generally speaking, the jacket 1278 of the third frame 1208 and the jacket 1280 of the fourth frame 1210 are formed such that the second joint member 1284 receives the first joint member 1282 when coupled. In particular, the first joint member 1282 defines a protrusion 1286 and the second joint member 1284 defines a groove 1288 for a tongue and groove coupling joint. Thus, the first joint member 1282 of the panel can be coupled to the second joint member 1284 of another panel to form a wall, a ceiling, or a floor. However, in other examples, the first joint member 1282 and the second joint member 1284 can both form protrusions 1286 and, in other examples, the first joint member 1282 and the second joint member 1284 can both form grooves 1288. The illustrated beam 1276 is rectangular, but may have different shapes for structural performance and/or bonding with the material of the jacket. Additionally, the illustrated beam 1276 is one material, however, in other examples, the beam 1276 may be composed of one or more materials. For example, the beam 1276 may be a rectangular tube (of any of the rigid materials provided above) that is configured to be filled with polyurethane foam.

Turning now to FIG. 17, an eighth exemplary panel body 1502 is constructed in accordance with the teachings of the present disclosure. The eighth exemplary panel body 1502 of FIG. 17 is similar to the panel body 202 of FIGS. 2 and 3, except the eighth exemplary panel body provides a different column and pocket configuration. Thus, for ease of reference, and to the extent possible, the same or similar components of the panel body 1502 will retain the same reference numbers as outlined above with respect to the panel body 202 of FIGS. 2 and 3, although the reference numbers will be increased by 1300.

In the example of FIG. 17, the first end 1520a of the column 1520 extends between a first section 1561 of the first frame 1504 and a second section 1563 of the first frame 1504 and the second end 1520b of the column 1520 extends between the first section 1560 of the second frame 1506 and the second section 1562 of the second frame 1506. The first and second sections 1561, 1563 of the first frame 1504 and the first and second sections 1560, 1562 of the second frame 1506 may be equal lengths when the column 1520 is centrally disposed in the panel body 1502. Additionally, in the illustrated example, the first and second ends 1520a, 1520b of the column 1520 include a first plate 1532 and a second plate 1534, respectively. The first plate 1532 is disposed within the pocket 1518, which takes the form of a notch disposed in the first frame 1504. Similarly, the second plate 1534 is disposed within a notch 1557 formed in an exterior surface of the second frame 1506. So configured, both the first and second frames 1504, 1506 include a notch formed on an exterior surface of the first and second frames 1504, 1506.

Once the first plate 1532 is disposed within the pocket 1518 and the second plate 1534 is disposed within the notch 1557 of the second frame 1506, the column 1520 is secured to the first and second frames 1504, 1504, respectively, using the fastening mechanism 1536. In the example illustrated in FIG. 17, the fastening mechanism 1536 takes the form of a plurality of lag bolts securing the column 1520 to the first and second frames 1504, 1506 via the first and second plates 1532, 1534. However, in other examples, the fastening mechanism 1536 can be a fastener, a bolt, a screw, a nail, an adhesive, or other suitable fastener.

Moreover, because the pocket 1518 disposed in the first frame 1504 and the notch 1557 disposed in the second frame 1506 reduce the thickness of the first and second frames 1504, 1506, some examples, such as the one illustrated in FIG. 17, include a plurality of reinforcement members 1559 that provide ample material to securely receive a fastening mechanism 1536. The plurality of reinforcement members 1559 may be disposed on an inner surface 1512 of the first and second frames 1504, 1506. Further, the plurality of reinforcement members 1559 may also be disposed on an inner surface 1512 of the first and second frames 1504, 1506 proximate the pocket 1518 and the notch 1557. So configured, the plurality of reinforcement members 1559 ensure the column 1520 is adequately secured to the first and second frames 1504, 1506.

The panel 1502 may also include at least one protrusion 1565 that is adapted to be received by a support member disposed in the pocket 1518. For example, as illustrated in FIG. 17, the at least one protrusion 1565 can be disposed on the first plate 1532 and extend away from the first plate 1532 for a distance. The example at least one protrusion 1565 takes the form of a threaded cylinder that receives a nut to secure the support member to the panel 1502. In other examples, however, the at least one protrusion 1565 may take any shape and form that is complementary to the bore or aperture in the support member that is to receive the at least one protrusion 1565.

Further, while not illustrated, the second plate 1534 disposed at the second end 1520b of the column 1520 may have a width that is greater than a width of the second frame 1506 such that the second plate 1534 at least partially extends past the width of the second frame 1506. So configured, the panel body 1502 may be secured to a floor using the portion of the second plate 1534 that extends past the width of the second frame 1506. For example, the second plate 1534 can include at least one aperture that is adapted to receive a fastening mechanism that secures the panel body 1502 to the floor.

Finally, FIG. 18 depicts an example method of manufacturing 1300 an insulated panel 100, such as the panel 100 of FIG. 1, in accordance with the teachings of the present disclosure. The method 1300 includes providing the panel body 102 by coupling the first frame 104 and the second frame 106 via the third frame 108 and the fourth frame 110, such that the second frame 106 is spaced away from the first frame 104 and the fourth frame 110 is spaced away from the third frame 108 (Step 1392). The method 1300 then involves coupling the column 120 to the panel body 102 by coupling the first end 120a of the column 120 to the first frame 104 and the second end 120b of the column 120 to the second frame 106 (Step 1394). The method 1300 then involves forming a cavity in the panel body (Step 1396), which includes fastening the first skin 124a to the first side 100a of the panel 100 and fastening the second skin 124b to the second side 100b of the panel 100. Once the first and second skins 124a, 124b are secured to the panel 100, a foam material, in liquid phase, is dispensed into the cavity 114 (Step 1398). The foam material is cured and forms the foam core 122 in the cavity 114, such that the column 120 is embedded with the foam core 122 (Step 1400). Additionally, in some examples of the method 1300, providing the panel body 102 further includes forming the pocket 118 having a U-shaped opening in the first frame 104, the pocket 118 being sized to receive a beam or support member. In yet other examples of the method 1300, dispensing the foam material in the cavity 114 further includes injecting the foam material into the cavity 114 via a hole in the panel body 102. In yet other examples, the panel may be made from cured foam shaped to the desired panel shape and size.

The figures and description provided herein depict and describe preferred examples of a structurally reinforced, insulated panel for purposes of illustration only. One skilled in the art will readily recognize from the foregoing discussion that alternative examples of the components illustrated herein may be employed without departing from the principles described herein. Thus, upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs for structurally reinforced, insulated panels that achieve both structural and thermal reliability. Therefore, while particular examples and applications have been illustrated and described, it is to be understood that the disclosed examples are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the methods and components disclosed herein without departing from the spirit and scope defined in the appended claims.

Claims

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.