Abstract: A method of manufacturing a hybrid insulating panel includes providing a mold of a frame, dispensing a first foam material in a liquid phase in the mold, and placing a beam in the mold. The method includes curing the first foam material to form an integrated frame, in which the integrated frame includes the beam at least partially surrounded by the first foam. Further, the method includes dispensing a second foam material into a panel cavity to form a panel body. The panel cavity is at least partially defined by a side of the integrated frame. The method includes curing the second foam material to form a panel body, wherein the panel body is secured to the integrated frame.

Abstract: An enclosure for use as a walk-in freezer or refrigerator includes a first panel and a second panel connected to the first panel. Each of the first and second panels includes a body having a frame coupled to the body. The frame includes a beam of a first material and a jacket of a second material at least partially enclosing the beam. An interior edge of the frame is adjacent to the body. An exterior edge is defined by the jacket and defines a joint member. The joint member of the first panel defines a groove, and the joint member of the second panel defines a protrusion adapted to engage the groove of the joint member of the first panel. At least one joint member includes a deformable portion that compresses when the joint member of the first panel engages with the joint member of the second panel.

Abstract: An insulated panel system includes a joint disposed between two insulated panels. The joint has a male portion and a female portion. The female portion has a flange, sidewalls, and a base that can be secured to an existing structure. The male portion includes a top plate with sealing sides that rest against the face of the insulated panel when inserted into the female portion. The sealing sides prevent warm air and/or moisture from ingress into a refrigerated space defined by the insulated panels. Also disclosed is a sealing joint for insulated structural panels.

Abstract: A hybrid structural member for an insulated structural panel includes a core member surrounded on at least two sides by a high-density structural foam. The hybrid structural member may be manufactured by placing a core member in a cavity of an injection mold and surrounding the core member by insulating foam on at least two sides. The core member may be held in place by screws, posts, pins, a vacuum, or other suitable means.

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

Abstract: A hybrid structural member for an insulated structural panel includes a core member surrounded on at least two sides by a high-density structural foam. The hybrid structural member may be manufactured by placing a core member in a cavity of an injection mold and surrounding the core member by insulating foam on at least two sides. The core member may be held in place by screws, posts, pins, a vacuum, or other suitable means.

Abstract: An insulated panel system includes a joint disposed between two insulated panels. The joint includes a gasket for increasing the efficiency of walk-in refrigerator and freezer spaces. A butyl-free gasket having a plurality of protrusions may be disposed between a first insulated panel, having a male portion, and a second insulated panel, having a female portion. A latch mechanism, disposed in part in the two insulated panels, operably engages to bring the male portion of the first insulated panel into a sealing engagement with the female portion of the second insulated panel, with the gasket disposed therebetween. The plurality of protrusions of the gasket are compressed between the male and female portions of the first and second panels, such that a plurality of sealing junctions are formed between the first and second panels.