Prefabricated insulated panel and wall structure produced therefrom
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a prefabricated insulated panel which may be assembled with other like panels to form a contiguously extending insulated wall structure and, more particularly, to a panel which is usable in installations where temperatures may range from approximately 0 degrees F. to 1000 degrees F. 
     2. Prior Art 
     Many prefabricated insulated wall panel configurations have been proposed. Two such proposals are presented in U.S. Pat. Nos. 3,961,454 and 3,879,910 dated June 8, 1976 and Apr. 29, 1975, respectively. A problem with these proposals is that, when such panels are assembled to form a wall structure, the capability of the resulting wall structure to prevent or limit heat flow through the wall structure, especially at the junctures of adjacent panels, leaves much to be desired. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the foregoing and other drawbacks of prior proposals by providing a prefabricated insulated panel which may be assembled with like panels to form a particularly effective insulated wall structure. A feature of panels embodying the preferred practice of the present invention is that they may be rapidly and expeditiously assembled to form a contiguously extending wall structure which will effectively insulate an area. 
     Accordingly, a feature of the invention lies in the provision of a novel, prefabricated insulated panel, adapted for assembly with like panels, to form an insulated wall structure. 
     A further feature of the invention lies in the provision of an insulated panel which includes opposed edges having complementary male and female formations for coupling adjacent panels together to form a contiguously extending wall structure. An edge flange is provided along one of the edges of each of the panels for connecting the panels to an associated support. 
     A further feature of the invention lies in the provision of a prefabricated insulated panel of the type described which can be effectively coupled with other like panels to form an insulated wall structure wherein edge junctures of adjacent panels form effective barriers to heat loss. 
     A still further feature of the invention lies in the provision of a prefabricated insulated panel of the aforementioned type having a plurality of insulating mats arranged in a manner which minimizes heat loss through the panel. 
     Other features and advantages of the invention will be apparent from the following description taken in conjunction with the accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a pair of insulated panels assembled side-by-side in accordance with the invention, portions of the panels being broken away and/or removed to permit underlying components to be seen, the view being taken from the rear or insulated sides of the panels. 
     FIG. 2 is a view similar to FIG. 1 but taken from the front or opposite sides of the panels. 
     FIG. 3 is a sectional view on an enlarged scale as seen from a plane indicated by a line 3--3 in FIG. 2. 
     FIG. 4 is a sectional view on an enlarged scale as seen from a plane indicated by a line 4--4 in FIG. 10. 
     FIG. 5 is a foreshortened end elevational view of a face member which differs slightly from that utilized in the embodiments of FIGS. 1 and 2. 
     FIG. 6 is a sectional view on an enlarged scale, the view being similar to FIG. 4 showing the male and female connection which is formed between a pair of adjacent panels formed using the face members of FIG. 5. 
     FIG. 7 is a perspective view on an enlarged scale of one type of fastener clip which may be utilized for securing insulating batt members to the face member of the panel structures illustrated in FIGS. 1 and 3. 
     FIG. 8 is a perspective view similar to FIG. 2, showing a juncture arrangement used between the laterally disposed adjacent panels. 
     FIG. 9 is a top plan view on an enlarged scale of a cap strip utilized in the juncture arrangement of FIG. 8. 
     FIG. 10 is a front elevational view of adjacent panels assembled to form a supported wall structure wherein the cap strip is fastened to the adjacent panels to permit relative movement between the panels without unduly stressing the panels, portions of some of the panels being broken away to permit the viewing of otherwise hidden components. 
     FIGS. 11 and 11A are, respectively, side and front elevational views of another embodiment of fastener clip for securing insulating mat members to the face members of panel structures. 
     FIGS. 12 and 12A are, respectively, side and front elevational views of a further embodiment of fastener clip. 
     FIGS. 13 and 13A are, respectively, elevational and top plan views of a retainer strap used to retain insulation mats in place. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1, 2, 3, 8 and 10, identical prefabricated panels 10, 12 are shown assembled side-by-side. Referring particularly to FIGS 8 and 10, other identical panels 10A, 12A are shown assembled atop the panels 10, 12, while still other identical panels 10B, 12B are shown assembled below the panels 10, 12. The panels 10, 10A, 10B, 12, 12A, 12B cooperate to form a continuously extending insulated wall structure. 
     Each of the identical panels 10, 10A, 10B, 12, 12A, 12B comprises a face member 14 formed of sheet material. In the embodiment illustrated, the sheet member 14 is of generally rectangular configuration. The material used to form the sheet member 14 may comprise, for instance, steel or aluminum. The sheet member 14 preferably is ribbed, corrugated, or formed, as illustrated, to provide generally horizontally extending rigidifying rib sections 18, 18a, 18b. 
     Each face member 14 includes upper and lower opposed edges 20, 22 and spaced side edges 24, 24a. the upper and lower edges 20, 22 are provided with complementary male and female formations 20a, 22a extending therealong for receiving the respective complementary formations of the face members of adjacent panels, as best seen in FIGS. 3, 8 and 10. In the embodiment illustrated, the upper edge 20 is provided with the male formation 20a while the lower edge 22 is provided with the female formation 22a. 
     Referring to FIG. 3, the face member 14 includes a flange portion 26 which projects above the upper edge portion 20 and is offset laterally rearwardly therefrom. The flange portion 26 is connected to the male formation 20a of the upper edge portion 20 by means of a web section 28. The web section 28 cooperates with the flange 26 and with the male portion 20a to define a recess 30 extending along the top of each of the panel structures. 
     Referring to FIGS. 1-3, an insulating pad or mat 32 is attached to the rear surface of the face member 14. The mat 32 may be formed of any suitable insulating material, for instance fiberglass, or mineral wool or urethane. The mat 32 may have its rear face 33 covered with a reflective foil 33a and/or an accoustic treatment, including a lead sheet or a sheet of perforated metal. The mat 32 is of generally rectangular configuration with its upper edge engaging the under surface of the web section 28 and with its lower edge being spaced a predetermined amount above the lower edge 22 of the face member 14. 
     A second batt or mat 34 of insulating material of approximately the same size as the first mat 32 is disposed in abutting relation with the first mat 32 and is offset vertically with respect thereto, as illustrated in FIGS. 1, 2 and 3. The mats 32, 34 may be secured to the front surface of the face member 14 by means of fastener clips 36 of the type shown in FIGS. 1 and 7. The clips 36 may be formed of bendable or maleable metal, such as sheet metal. 
     The clips 36 preferably include a pointed lance section 38, a mounting section 40, and a tab section 42. The tab sections 42 are received in or between the reversely bent sections of the upper and lower edge portions 20, 22, as best shown in FIG. 3. The lance sections 38 of the clips 36 project through the pair of abutting mats 32, 34. The distal ends of the lance sections 38 extend through slit openings 44 formed in a channel-like retainer member 46 as best seen in FIGS. 1 and 13. After the distal ends are passed through the openings 44, they are bent reversely to clamp the retaner member 46 against a wire grid 48. The grid 48 is positioned against the confronting face of the mat 34 to retain the mats 32, 34 in place relative to the face member 14. 
     As can be best seen in FIGS. 2, 8 and 10, the side edges of the mats 32, 34 project laterally of the side edges 24, 24a of the face member 14. When the panels 10, 10A, 10B, 12, 12A, 12B are assembled to form a wall structure, the side edges of the insulating mats 32, 34 are moved into tight engagement with one another but preferably in a manner which will not materially compress or buckle the insulation material. 
     Referring to FIGS. 2, 8, 9 and 10, outer elongate cap members 50 are provided to cover the lines of juncture between laterally adjacent panels. The cap members 50 may be formed of any suitable material such as aluminum or steel or the like. In the embodiment illustrated in FIG. 9, the cap member 50 comprises a U-shaped or channel-shaped member having lateral wing portions 52 adapted to engage the confronting surfaces of the face members 14 of adjacent panels. The cap member 50 is provided with insulation 54 such as fiberglass or mineral wool disposed therein and projecting outwardly thereof, as best shown in FIG. 9. The insulation 54 is compressible and is forced against the adjacent panels to effectively seal the line of juncture between the assembled panels. 
     Referring to FIG. 8, closure strips 56 of flexible neoprene or any other suitable material, can also be provided between the generally resilient wing portions 52 and the confronting face members of adjacent panels. The strips 56 cooperate with inwardly bent end sections 58 of the wing portions 52, as is best seen in FIG. 9, to additionally aid in sealing the cap member 50 to the confronting surfaces of the face members 14. 
     The cap member 50 may be fastened by any suitable means, such as by screws 59, to the confronting surfaces of the face members 14. In preferred practice, the screws 59 are used only at one location on each respective panel, for instance at the situs of the ribs 18. Preferably no fasteners are utilized at the locations of overlap of adjacent panels. Thus, there is no mechanical fastening between panels to retard relative movement between adjacent panels. This absence of constriction aids in allowing freedom of movement of the panels relative to one another during heating and cooling, and helps to minimize panel warpage, thus aiding in maintaining a completely insulated wall structure. 
     As can best be seen in FIGS. 2, 4 and 10, the panels may be secured to upright support members 60. The support members 60 are of hat shape as viewed in transverse section. The panels may be connected to the uprights 60 by means of threaded fasteners 61. As is best seen in FIG. 4, the fasteners 61 extend through openings 62 formed in the flange portion 26. The fasteners 61 extend through the mat 34 and into threaded coaction with the respective upright 60. The uprights 60 may be secured, as by welds or any other suitable means, to stiffener struts 64, as best seen in FIG. 10. 
     Referring to FIG. 3, the top edge of the mat 34 is preferably substantially coplanar with the upper edge of the flange 26. When the panels are assembled vertically with one another, the male formation 20a on the lower panel is received in the female formation 22a on the adjacent upper panel by relative vertical sliding, to couple the panels together. However, as can be readily seen from FIG. 4, relative movement of the panels at such male-female coupling juncture, is still possible. 
     Referring to FIG. 3, the male formation 20a is formed from a reversely bent part of the sheet material of the face member 14. The sheet material of member 14 is reversely bent to form the bottom edge 22 and then is reversely bent again to form the female formation 22a. The female formation 22a is generally vertically aligned with the male formation 20a of the respective face member. The female formation and the association male formation are preferably of such size (or width) as will permit the complementary male and female formations to be snugly received in mating engagement. In the embodiment of FIG. 4, the web 66 of material partially defining female formation 22a terminates above the bottom edge 22, and above the web section 28 of the next vertically adjacent panel when these panels are assembled. 
     The fasteners 61 secure the panels to the support grid member 60, but still permit relative expansion and contraction of the panels. As can be seen from FIG. 4, the lower end of the mat 32 of the upper panel is received in overlapped relation to the mat 34 of the lower panel. The lower end of the upper panel mat 32 also overlaps the associated securing fastener 61 of the lower panel, and thereby provides a tortuous path for the transmission of heat from one surface of the assembled panels to the opposite surface thereof. The fact that the lower end of the innermost mat 32 overlaps the fastener 61 prevents escape of heat along the fastener, thus further enhancing the insulating characteristics of the panel. 
     Referring now to FIGS. 5 and 6, there is shown another embodiment of panel face member 14&#39; which is slightly different than the face member 14 of the first described panel structure. The face member 14&#39; has a web section 28&#39;  which is disposed somewhat lower with respect to a male formation 20a&#39; as compared to the corresponding features of the first described embodiment. The face member 14&#39; forms a somewhat deeper pocket 30&#39; for receiving the inner mat 32 of the next vertically adjacent panel. Also, the female formation 22a&#39; of the face member 14&#39; has a web 66&#39; which is adapted to receive the male formation 20a&#39; on the next vertically adjacent panel. 
     In the embodiment of FIGS. 5 and 6, the female formation 22a&#39; includes a depending, diagonally arranged foot portion 66a&#39; which is adapted to engage the web section 28&#39; of the adjacent panel when coupled thereto. Such an arrangement facilitates the expeditious coupling of vertically arranged panels by guiding the movement of the male formation 20a&#39; relative to the female formation 22a&#39; during assembly. Moreover, the female formation 22a&#39; is preferably provided with a horizontally extending dimple or rib 68 to facilitate clasping the male formation 20a&#39; when received therein. Moreover, the upper end of the female formation 22a&#39; may be beveled outwardly as at 69 and then inwardly to further aid in causing the web 66&#39; to clasp the male formation 20a &#39; when received therein. 
     When the panels are assembled to form a wall structure, the wall structure provides optimum insulating characteristics while, at the same time, providing for relative expansion and contraction of the panels. Such a wall structure may be utilized in high temperature environments, for instance, those utilized to provide insulation in an area having a temperature in the range of, for instance, from 0 degrees F. to 1000 degrees F. 
     Referring now to FIGS. 11, 11A, 12 and 12A, there are illustrated other embodiments of bendable mat fastener clips 36&#39;, 36&#34;. The clip 36&#39; is adapted for use as the lowermost clip in a panel assembly. The clip 36&#34; is adapted for use as the upper clip in a panel assembly. The upper clip 36&#34; will be dispensed closer to the web section 28 of the face member 14 and generally above a diagonal portion 70 of the upper face member rib 18 as best seen in FIG. 3. Both of the clips 36&#39;, 36&#34; include integrally formed stiffener rib formations 72. 
     Wall structures embodying the preferred practice of the present invention provide for weather integrity. All of the anchoring fasteners, such as the fasteners 61, are concealed and do not provide any opportunity for water penetration from the noninsulated surface to the insulated surface. The overlap of metal at the male-female coupling joints precludes any direct water entrance, and the joints between laterally adjacent panels are sealed by the insulated caps 50 and the associated sealing strips 56. One man can handle a panel and install it without the necessity of a second workman to hold the panel in position until it is anchored by the fasteners 61. Since there is no direct heat transmission by the fasteners 61 through the panel wall structure, the surface of the noninsulated side of the panel may be painted using conventional paints without the disadvantage of browned or hot spots occurring on the external panel surface. 
     The face members 14 and 14&#39; are preferably formed from single pieces of metal. While the panels have been illustrated and described as being assembled so that the male-female formations 20a, 22a extend horizontally, it will be understood that the panels could be arranged so that the male-female couplings extend vertically, in which event the ribs 18, 18a, 18b on the face members would be oriented vertically rather than horizontally. Accordingly, it will be understood that the terms &#34;vertically&#34; and &#34;horizontally&#34; as used herein, are simply for descriptive purposes, and are not intended to indicate that the orientation of the panels needs to be as described. 
     From the foregoing description and accompanying drawings, it will be seen that the invention provides a novel prefabricated insulated panel adapted to be assembled with like panels, to form an insulated wall structure. Suitable juncture systems are provided for expeditiously coupling the panels together and for preventing heat transmission through the wall structure from its hot side to its cold side. 
     The terms and expressions which have been used are used as terms of description and not of limitation. It is not intended that the use of such terms and expressions should exclude any equivalents of any of the features shown or described. It is recognized that various modifications are possible within the scope of the invention claimed. It is intended that the appended claims shall cover by suitable expression whatever features of patentable novelty reside in the present invention.