Abstract:
Insulated panel assemblies can be used to construct an air-handling enclosure and the like. The insulated panel assemblies can have the same configuration and fit together to form a substantially sealed, insulated enclosure. The insulated panel assemblies themselves are particularly constructed for ease of formation and construction of the panel assemblies. A method of forming insulated panel assembly is also disclosed.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to air handling enclosures, and more specifically to a thermally insulating panel assembly for forming an air handling enclosure. 
       BACKGROUND 
       [0002]    The use of air handling enclosures for HVAC equipment (e.g., heat exchangers, compressors, blowers, filters, fans, motors, cooling elements, heating elements, humidifying elements) is commonplace. Air handling enclosures are often constructed with panels filled with insulation to minimize the transmission of thermal energy from the interior to the exterior of the enclosure. Typically, the panels include inner and outer (first and second) panel members of metal that are joined together to form a volume that receives the insulation. The panel members can be connected together using plastic components to reduce thermal transmission. However, the inner and outer panel members are often difficult to manufacture, and it can be difficult and time-consuming to attach the panel members with the plastic components. 
       SUMMARY 
       [0003]    In one aspect of the present invention, an insulated panel assembly for use in forming an air handling enclosure generally comprises a first panel member having a base portion. First and second side portions extend from the base portion, and first and second side mounting flanges extend from the respective first and second side portions. A second panel member has a base portion, first and second side portions extending from the base portion, and first and second side mounting flanges extending from the respective first and second side portions. A double-sided adhesive strip attaches the first and second side mounting flanges of the first panel member to the respective first and second side mounting flanges of the second panel member. The first and second panel members are arranged with respect to each other so that at least a portion of the first panel member extends beyond a corresponding portion of the second panel member. 
         [0004]    In another aspect of the present invention, a panel member of an insulated panel assembly generally comprises a base portion and a maximum of two bends on each edge margin of the base portion. 
         [0005]    In yet another aspect of the present invention, a corner jig for use in assembling an insulated panel assembly having a first panel member and a second panel member attached by double-sided adhesive strip. The corner jig generally comprises a first side wall and a first end wall arranged to define a first recess. The first recess is configured to receive a corner of the first panel member. A second side wall and a second end wall are arranged to define a second recess positioned generally above the first recess. The second recess is configured to receive a corner of the second panel member. The first and second recesses are configured such that when the first and second panel members are received in the first and second recesses, at least a portion of one of the first and second panel members extends beyond a corresponding portion of the other of the first and second panel members. 
         [0006]    In a still further aspect of the present invention, a method of assembling an insulated panel assembly for use in forming an air handling enclosure includes the step of placing a second panel member of the insulated panel assembly in a first recess of a corner jig. A double-sided adhesive strip is attached to mounting flanges of the second panel member. A first panel member of the insulated panel assembly is placed in a second recess of the corner jig such that the first panel member is adhered to the second panel member by the double-sided adhesive strip. The corner jig maintains the correct positional relationship between the first and second panel members for attachment by the double-sided adhesive strip. Insulation is provided between the first and second panel members. 
         [0007]    Other objects and features of the present invention will be in part apparent and in part pointed out herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective of an air handling enclosure formed from insulated panel assemblies; 
           [0009]      FIG. 2  is an exploded perspective of the air handling enclosure of  FIG. 1 ; 
           [0010]      FIG. 3  is a section taken along line  3 - 3  of  FIG. 1 ; 
           [0011]      FIG. 4  is an enlarged fragmentary portion of  FIG. 3 ; 
           [0012]      FIG. 5  is a perspective of an insulated panel assembly according to a first embodiment of the present invention; 
           [0013]      FIG. 6  is a perspective of a first panel member of the insulated panel assembly of  FIG. 5 ; 
           [0014]      FIG. 7  is a section taken along line  7 - 7  of  FIG. 6 ; 
           [0015]      FIG. 8  is a section taken along line  8 - 8  of  FIG. 6 ; 
           [0016]      FIG. 9  is a top view of a metal blank for forming a first panel member of an insulated panel assembly according to a first embodiment of the present invention; 
           [0017]      FIG. 10  is a perspective of a second panel member of the insulated panel assembly of  FIG. 5 ; 
           [0018]      FIG. 11  is a section taken along line  11 - 11  of  FIG. 10 ; 
           [0019]      FIG. 12  is a section taken along line  12 - 12  of  FIG. 10 ; 
           [0020]      FIG. 13  is a top view of a stamped metal blank for forming a second panel member of an insulated panel assembly according to a first embodiment of the present invention; 
           [0021]      FIG. 14  is a section taken along line  14 - 14  of  FIG. 5 , illustrating the connection of the first panel member and the second panel member of the insulated panel assembly; 
           [0022]      FIG. 15  is an enlarged fragmentary portion of  FIG. 14 ; 
           [0023]      FIG. 16  is a section taken along line  16 - 16  of  FIG. 5 , illustrating the connection of the first panel member and the second panel member of the insulated panel assembly; 
           [0024]      FIG. 17  is an enlarged fragmentary portion of  FIG. 16 ; 
           [0025]      FIG. 18  is a perspective of an insulated panel assembly according to a second embodiment of the present invention; 
           [0026]      FIG. 19  is a perspective of a first panel member of the insulated panel assembly of  FIG. 18 ; 
           [0027]      FIG. 20  is a section taken along line  20 - 20  of  FIG. 19 ; 
           [0028]      FIG. 21  is a section taken along line  21 - 21  of  FIG. 19 ; 
           [0029]      FIG. 22  is a top view of a stamped metal blank for forming a first panel member of an insulated panel assembly according to a second embodiment of the present invention; 
           [0030]      FIG. 23  is a perspective of a second panel member of the insulated panel assembly of  FIG. 18 ; 
           [0031]      FIG. 24  is a section taken along line  24 - 24  of  FIG. 23 ; 
           [0032]      FIG. 25  is a section taken along line  25 - 25  of  FIG. 23 ; 
           [0033]      FIG. 26  is a top view of a stamped metal blank for forming a second panel member of an insulated panel assembly according to a second embodiment of the present invention; 
           [0034]      FIG. 27  is a section taken along line  27 - 27  of  FIG. 18 , illustrating the connection of the first panel member and the second panel member of the insulated panel assembly; 
           [0035]      FIG. 28  is an enlarged fragmentary portion of  FIG. 27 ; 
           [0036]      FIG. 29  is a perspective of a first corner jig; 
           [0037]      FIG. 30  is a perspective of a second corner jig; 
           [0038]      FIG. 31  is a perspective of a third corner jig; 
           [0039]      FIG. 32  is a perspective of a fourth corner jig; 
           [0040]      FIG. 33  is a perspective of the second panel member of  FIG. 10  being positioned within the corner jigs of  FIGS. 29-32 , illustrating a first step to assembling the insulated panel assembly of  FIG. 5 ; 
           [0041]      FIG. 34  is a perspective similar to  FIG. 33 , with double-sided adhesive foam strip applied to the second panel member, illustrating a second step to assembling the insulated panel assembly of  FIG. 5 ; and 
           [0042]      FIG. 35  is a perspective similar to  FIG. 34 , with the first panel member of  FIG. 6  positioned on top of the double-sided adhesive foam strip, illustrating a third step to assembling the insulated panel assembly of  FIG. 5 . 
       
    
    
       [0043]    Corresponding reference characters indicate corresponding parts throughout the drawings. 
       DETAILED DESCRIPTION 
       [0044]    Referring to  FIGS. 1-3 , an air handling enclosure for housing air-handling equipment (e.g., fans, motors, cooling elements, heating elements, and/or humidifying elements) is shown generally at  10 . The enclosure  10  comprises a number of insulated panel assemblies  12  and insulated panel assemblies  112 . The insulated panel assemblies are attached to each other, as described below, and may also be attached to a frame  14  and a base (not shown) to form the air handling enclosure  10 . The insulated panel assemblies  12 ,  112  form an air handling enclosure  10  that is thermally insulated to minimize heating and cooling losses. 
         [0045]    As seen in  FIGS. 3-5 , each panel assembly  12  includes a first panel member  16 , a second panel member  18 , and a thermal insulating core  20 . Referring to  FIGS. 6-8 , the first panel member  16  includes a base portion  22  having an outer face  24  and an inner face  26 . A top portion  28  extends from a top edge margin of the base portion  22 . The top portion  28  extends generally perpendicular from the base portion  22  in a direction inward away from the inner face  26 . A bottom portion  30  extends from a bottom edge margin of the base portion  22  opposite the top portion  28 . The bottom portion  30  extends generally perpendicular from the base portion  22  in a direction inward away from the inner face  26 , such that the bottom portion and the top portion are generally in spaced parallel alignment. A first side portion  32  extends from a first side edge margin of the base portion  22 . The first side portion  32  extends generally perpendicular from the base portion  22  in a direction inward away from the inner face  26 . A second side portion  34  extends from a second side edge margin of the base portion  22  opposite the first side portion  32 . The second side portion  34  extends generally perpendicular from the base portion  22  in a direction inward away from the inner face  26 , such that the first and second side portions are generally in spaced parallel alignment. 
         [0046]    Referring still to  FIGS. 6-8 , each of the top, bottom, and first and second side portions  28 ,  30 ,  32 ,  34  of the first panel member  16  includes a mounting flange configured for attachment to the second panel member  18 . A top mounting flange  38  extends generally perpendicular from the top portion  28  in a direction toward the bottom portion  30 . A bottom mounting flange  40  extends generally perpendicular from the bottom portion  30  in a direction toward the top portion  28 . A first side mounting flange  42  extends generally perpendicular from the first side portion  32  in a direction toward the second side portion  34 . A second side mounting flange  44  extends generally perpendicular from the second side portion  34  in a direction toward the first side portion  32 . The mounting flanges  38 ,  40 ,  42 ,  44  preferably lie in the same plane for level attachment to the second panel member  18 . 
         [0047]    As seen in  FIG. 9 , the first panel member  16  can be formed as one piece from a metal blank  46  that is stamped from a sheet metal roll and bent into shape. The first panel member  16  can be stamped from galvanized steel, stainless steel, aluminum, or any other suitable material. The first panel member  16  is preferably formed of light gauge metal, such as 14-22 gauge metal. In one embodiment, the first panel member  16  is stamped from 20 gauge galvanized steel, although other thicknesses and other suitable materials are within the scope of the present invention. 
         [0048]    The metal blank  46  includes only two bends on each side of the blank to form the side portions  32 ,  34  and mounting flanges  42 ,  44  of the first panel member  16 . Similarly, only two bends are required at the top and bottom to form the top portion  38  and mounting flange  38 , and bottom portion  30  and mounting flange  40  of the first panel member  16 . This configuration makes the first panel member  16  easier to form in a brake press and increases the accuracy of the bends as compared to panel members requiring more than two bends (e.g., three bends) on each side of the panel member. 
         [0049]    Referring to  FIGS. 10-12 , the second panel member  18  includes a base portion  52  having an outer face  54  and an inner face  56 . A top portion  58  extends from a top edge margin of the base portion  52 . The top portion  58  extends generally perpendicular from the base portion  52  in a direction inward away from the inner face  56 . A bottom portion  60  extends from a bottom edge margin of the base portion  52  opposite the top portion  58 . The bottom portion  60  extends generally perpendicular from the base portion  52  in a direction inward away from the inner face  56 , such that the bottom portion and the top portion  58  are generally in spaced parallel alignment. A first side portion  62  extends from a first side edge margin of the base portion  52 . The first side portion  62  extends generally perpendicular from the base portion  52  in a direction inward away from the inner face  56 . A second side portion  64  extends from a second side edge margin of the base portion  52  opposite the first side portion  62 . The second side portion  64  extends generally perpendicular from the base portion  52  in a direction inward away from the inner face  56 , such that the first and second side portions are generally in spaced parallel alignment. 
         [0050]    Referring still to  FIGS. 10-12 , each of the top, bottom, and first and second side portions  58 ,  60 ,  62 ,  64  of the second panel member  18  includes a mounting flange configured for attachment to the first panel member  16 . A top mounting flange  68  extends generally perpendicular from the top portion  58  in a direction away from the bottom portion  60 . A bottom mounting flange  70  extends generally perpendicular from the bottom portion  60  in a direction away from the top portion  58 . A first side mounting flange  72  extends generally perpendicular from the first side portion  62  in a direction toward the second side portion  64 . A second side mounting flange  74  extends generally perpendicular from the second side portion  64  in a direction away from the first side portion  62 . The mounting flanges  68 ,  70 ,  72 ,  74  of the second panel member  18  preferably lie in the same plane for level attachment to the first panel member  16 . 
         [0051]    As seen in  FIG. 13 , the second panel member  18  can be formed as one piece from a metal blank  76  that is stamped from a sheet metal roll and bent into shape. The second panel member  18  can be stamped from galvanized steel, stainless steel, aluminum, or any other suitable material. The second panel member  18  is preferably formed of light gauge material, such as 14-22 gauge material. In one embodiment, the second panel member  18  is stamped from 18 gauge galvanized steel, although other thicknesses and other suitable materials are within the scope of the present invention. The second panel member  18  and the first panel member  16  may be formed of the same material or different materials and may have the same thickness or different thicknesses. 
         [0052]    The metal blank  76  includes only two bends on each side of the blank to form the second panel member  18 . Similarly, only two bends are required at the top and bottom to form the top portion  58  and mounting flange  68 , and bottom portion  60  and mounting flange  70  of the second panel member  18 . This configuration makes the second panel member  18  easier to form in a brake press and increases the accuracy of the bends as compared to panel members requiring more than two bends (e.g., three bends) on each side of the panel member. 
         [0053]    To form the insulated panel assembly  12 , the first and second panel members  16 ,  18  are attached to each other. In order to maintain thermal efficiency, preferably there is no metal-to-metal contact between the first and second panel members  16 ,  18 . In the illustrated embodiment, the first and second panel members  16 ,  18  are attached with double-sided adhesive strip  80  (see,  FIGS. 14 and 15 ). The double-sided adhesive strip  80  is adhered to the mounting flanges to attach the first and second panel members  16 ,  18 . The double-sided adhesive strip  80  attaches the mounting flanges  38 ,  40 ,  42 ,  44  of the first panel member  16  to the respective mounting flanges  68 ,  70 ,  72 ,  74  of the second panel member  18 . The double-sided adhesive strip  80  also acts as a thermal break between the first and second panel members  16 ,  18 . In one embodiment, the double-sided adhesive strip  80  is heavy duty double-sided foam tape. Preferably, the double-sided adhesive strip  80  has a width that is at least as large as a width of the first panel member mounting flanges  38 ,  40 ,  42 ,  44  to ensure that no portion of the first panel member  16  contacts the second panel member mounting flanges  68 ,  70 ,  72 ,  74  directly. As illustrated, the strip  80  is wider than the mounting flanges  38 ,  40 ,  42 ,  44 . In one embodiment, the heavy duty double-sided foam tape has a width equal to a width of the first panel member mounting flanges  38 ,  40 ,  42 ,  44 . For example, in one embodiment, both the first panel member mounting flanges and the double-sided adhesive strip have a width of about ½ inch. The double-sided adhesive strip  80  has a thickness configured to create a thermal break between the first and second panel members  16 ,  18 . In one embodiment, the double-sided adhesive strip has a thickness of at least about ⅛ inch. For example, the double-sided adhesive strip can be ½ inch wide and ⅛ inch thick. One example of a suitable double-sided adhesive strip is the Double Coated Urethane Foam Tape 4008 sold by 3M. Other suitable double-sided adhesive strips are within the scope of the present invention. 
         [0054]    Referring to  FIGS. 14-17 , the first and second panel members  16 ,  18  are attached together such that the inner face  26  of the first panel member  16  is spaced from and opposes the inner face  56  of the second panel member  18 , forming a cavity  82  that holds the insulated core (not illustrated in  FIGS. 14-17 ). At least one edge margin of the first panel member  16  extends beyond the corresponding edge margin of the second panel member  18 . As seen in  FIGS. 5 and 14-17 , the top edge margin of the first panel member  16  extends beyond the top edge margin of the second panel member  18 , the bottom edge margin of the first panel member extends beyond the bottom edge margin of the second panel member, and the second side edge margin of the first panel member extends beyond the second side edge margin of the second panel member. For example, it may be seen in  FIG. 17  that the top portion  28  of the first panel member  16  is disposed laterally outward from the top portion  58  of the second panel member  18 . In the illustrated embodiment, the top portion  28  is also located above of the top edge of the top mounting flange  68 . Similarly, the bottom portion  30  of the first panel member  16  is disposed laterally outward from the bottom portion  60  of the second panel member  18 . In the illustrated embodiment, the bottom portion  30  of the first panel member  16  is also located below the bottom mounting flange  70  of the second panel member  18 . As shown in  FIG. 14 , the second side portion  34  of the first panel member  16  is disposed laterally outward from the second side portion  64  of the second panel member  18 . In the illustrated embodiment, the second side portion  34  of the first panel member  16  is also located outward to the right of the edge of the second side mounting flange  74  of the second panel member  18 . The second panel member  18  is offset from the first panel member  16  such that the first side edge margin of the second panel member extends beyond the first side edge margin of the first panel member. For example as may be seen in  FIG. 14 , the first side portion  62  of the second panel member  18  is disposed laterally outward from the first side portion  32  of the first panel member  16 . In the illustrated embodiment, the first side portion  62  of the second panel member  18  is also located to the left of both the first side portion  32  and the mounting flange  42  of the first panel member  16 . 
         [0055]    The first and second panel members  16 ,  18  are positioned such that the mounting flanges of the first panel member are generally parallel to and in opposed facing relation to the mounting flanges of the second panel member. The top mounting flange  38  of the first panel member  16  is attached to the top mounting flange  68  of the second panel member  18  with double-sided adhesive strip  80  ( FIGS. 16 and 17 ). The bottom mounting flange  40  of the first panel member  16  is attached to the bottom mounting flange  70  of the second panel member  18  with double-sided adhesive strip  80  ( FIG. 16 ). The first side mounting flange  42  of the first panel member  16  is attached to the first side mounting flange  72  of the second panel member  18  with double-sided adhesive strip  80  ( FIG. 14 ). The first side mounting flange  72  of the second panel member  18  extends laterally outward beyond the first side portion  32  of the first panel member  16 . The second side mounting flange  44  of the first panel member  16  is attached to the second side mounting flange  74  of the second panel member  18  with double-sided adhesive strip  80  ( FIGS. 14 and 15 ). The second side mounting flange  74  of the second panel member  18  does not extend beyond the second side portion  34  of the first panel member  16 . 
         [0056]    Attaching the first panel member  16  to the second panel member  18  with double-sided adhesive strip  80  reduces the time required to assemble the insulated panel assembly  12 . In previous panel assemblies, the first and second panel members were attached by plastic clips to create a thermal break. However, the process of attaching the clips to the first and second panel member was very time consuming and labor-intensive. Forming the panel members as described above and using the double-sided adhesive strip to attach the panel members can reduce the time to assemble the panels by about 85% (e.g., from about 35 minutes to about 5 minutes). 
         [0057]    The thermal insulating core  20  is positioned in the cavity  82  between the inner faces  26 ,  56  of the first and second panel members  16 ,  18 . In one embodiment, after the first and second panel members  16 ,  18  are attached together, foam insulation is injected into the cavity  82  to form the thermal insulating core  20 . For example, in one embodiment, the assembled first and second panel members  16 ,  18  are placed in a heated press and the cavity  82  is injected with urethane foam to form the core  20  having a density of about 2.5 lbs/ft 3  (40.05 kg/m 3 ). The thermal insulating core  20  can comprise other suitable insulating materials or other suitable densities within the scope of the present invention. 
         [0058]    Referring to  FIGS. 18-28 , a second embodiment of the insulated panel assembly is indicated at  112 . As seen in  FIG. 18 , each panel assembly  112  includes a first panel member  116 , a second panel member  118 , and a thermal insulating core (not shown, but corresponding to thermal insulating core  20  shown in  FIG. 3 ). Referring now more specifically to  FIGS. 19-21 , the first panel member  116  is substantially similar to the first panel member  16  as described above. The first panel member  116  includes a base portion  122  having an outer face  124  and an inner face  126 . A top portion  128  extends from a top edge margin of the base portion  122 . The top portion  128  extends generally perpendicular from the base portion  122  in a direction inward away from the inner face  126 . A bottom portion  130  extends from a bottom edge margin of the base portion  122  opposite the top portion  128 . The bottom portion  130  extends generally perpendicular from the base portion  122  in a direction inward away from the inner face  126 , such that the bottom portion and the top portion are generally in spaced parallel alignment. A first side portion  132  extends from a first side edge margin of the base portion  122 . The first side portion  132  extends generally perpendicular from the base portion  122  in a direction inward away from the inner face  126 . A second side portion  134  extends from a second side edge margin of the base portion  122  opposite the first side portion  132 . The second side portion  134  extends generally perpendicular from the base portion  122  in a direction inward away from the inner face  126 , such that the first and second side portions are generally in spaced parallel alignment. 
         [0059]    Each of the top, bottom, and first and second side portions  128 ,  130 ,  132 ,  134  includes a mounting flange configured for attachment to the second panel member  118 . A top mounting flange  138  extends generally perpendicular from the top portion  128  in a direction toward the bottom portion  130 . A bottom mounting flange  140  extends generally perpendicular from the bottom portion  130  in a direction toward the top portion  128 . A first side mounting flange  142  extends generally perpendicular from the first side portion  132  in a direction toward the second side portion  134 . A second side mounting flange  144  extends generally perpendicular from the second side portion  134  in a direction toward the first side portion  132 . The mounting flanges  138 ,  140 ,  142 ,  144  of the first panel member  116  preferably lie in the same plane for level attachment to the second panel member  118 . 
         [0060]    As seen in  FIG. 22 , the first panel member  116  can be formed as one piece from a metal blank  146  that is stamped from a sheet metal roll and bent into shape. The first panel member  116  can be stamped from galvanized steel, stainless steel, aluminum, or any other suitable material. The first panel member  116  is preferably formed of light gauge metal, such as 14-22 gauge metal. In one embodiment, the first panel member  116  is stamped from 20 gauge galvanized steel, although other thicknesses and other suitable materials are within the scope of the present invention. 
         [0061]    The metal blank  146  includes only two bends on each side of the blank and two bends at the top and bottom of the blank to form the first panel member  116 . This configuration makes the first panel member  116  easier to form in a brake press and increases the accuracy of the bends as compared to panel members requiring more than two bends (e.g., three bends) on the top, bottom and each side of the panel member. 
         [0062]    Referring to  FIGS. 23-25 , the second panel member  118  includes a base portion  152  having an outer face  154  and an inner face  156 . A top portion  158  extends from a top edge margin of the base portion  152 . The top portion  158  extends generally perpendicular from the base portion  152  in a direction inward away from the inner face  156 . A bottom portion  160  extends from a bottom edge margin of the base portion  152  opposite the top portion  158 . The bottom portion  160  extends generally perpendicular from the base portion  152  in a direction inward away from the inner face  156 , such that the bottom portion and the top portion are generally in spaced parallel alignment. A first side portion  162  extends from a first side edge margin of the base portion  152 . The first side portion  162  extends generally perpendicular from the base portion  152  in a direction inward away from the inner face  156 . A second side portion  164  extends from a second side edge margin of the base portion  152  opposite the first side portion  162 . The second side portion  164  extends generally perpendicular from the base portion  152  in a direction inward away from the inner face  156 , such that the first and second side portions are generally in spaced parallel alignment. 
         [0063]    Each of the top, bottom, and first and second side portions  158 ,  160 ,  162 ,  164  of the second panel member  118  includes a mounting flange configured for attachment to the first panel member  116 . A top mounting flange  168  extends generally perpendicular from the top portion  158  in a direction away from the bottom portion  160 . A bottom mounting flange  170  extends generally perpendicular from the bottom portion  160  in a direction away from the top portion  158 . A first side mounting flange  172  extends generally perpendicular from the first side portion  162  in a direction away from second side portion  164 . A second side mounting flange  174  extends generally perpendicular from the second side portion  164  in a direction away from the first side portion  162 . The mounting flanges  168 ,  170 ,  172 ,  174  of the second panel member  118  preferably lie in the same plane for level attachment to the first panel member  116 . 
         [0064]    As seen in  FIG. 26 , the second panel member  118  can be formed as one piece from a metal blank  176  that is stamped from a sheet metal roll and bent into shape. The second panel member  118  can be stamped from galvanized steel, stainless steel, aluminum, or any other suitable material. The second panel member  118  is preferably formed of light gauge material, such as 14-22 gauge material. In one embodiment, the second panel member  118  is stamped from 18 gauge galvanized steel, although other thicknesses and other suitable materials are within the scope of the present invention. The inner panel  118  and the outer panel  116  may be formed of the same material or different materials and may have the same thickness or different thicknesses. 
         [0065]    The metal blank  176  includes only two bends on each side of the blank, and two bends at the top and bottom of the blank to form the second panel member  118 . This configuration makes the second panel member  118  easier to form in a brake press and increases the accuracy of the bends as compared to panel members requiring more than two bends (e.g., three bends) on each side, top and bottom of the panel member. 
         [0066]    To form the insulated panel assembly  112 , the first and second panel members  116 ,  118  are attached to each other. In order to maintain thermal efficiency, preferably there is no metal-to-metal contact between the first and second panel members  116 ,  118 . In the illustrated embodiment, the first and second panel members  116 ,  118  are attached with double-sided adhesive strip  180  ( FIGS. 27 and 28 ). The double-sided adhesive strip  180  is adhered to the mounting flanges to attach the first and second panel members  116 ,  118 . The double-sided adhesive strip  180  attaches the mounting flanges  138 ,  140 ,  142 ,  144  of the first panel member  116  to the respective mounting flanges  168 ,  170 ,  172 ,  174  of the second panel member  118 . The double-sided adhesive strip  180  also acts as a thermal break between the first and second panel members  116 ,  118 . In one embodiment, the double-sided adhesive strip  180  is heavy duty double-sided foam tape. Preferably, the double-sided adhesive strip  180  has a width that is at least as large as a width of the first panel member mounting flanges  138 ,  140 ,  142 ,  144  to ensure that no portion of the first panel member  116  contacts the second panel member mounting flanges  168 ,  170 ,  172 ,  174  directly. As illustrated, the strip  180  is wider than the mounting flanges  138 ,  140 ,  142 ,  144 . In one embodiment, the heavy duty double-sided foam tape has a width equal to a width of the first panel member mounting flanges  138 ,  140 ,  142 ,  144 . For example, in one embodiment, both the first panel member mounting flanges and the double-sided adhesive strip have a width of about ½ inch. The double-sided adhesive strip  180  has a thickness configured to create a thermal break between the first and second panel members  116 ,  118 . In one embodiment, the double-sided adhesive strip has a thickness of at least about ⅛ inch. For example, the double-sided adhesive strip can be ½ inch wide and ⅛ inch thick. One example of a suitable double-sided adhesive strip is the Double Coated Urethane Foam Tape 4008 sold by 3M. Other suitable double-sided adhesive strips are within the scope of the present invention. 
         [0067]    Referring to  FIGS. 27 and 28 , the first and second panel members  116 ,  118  are attached together such that the inner face  126  of the first panel member  116  is spaced from and opposes the inner face  156  of the second panel member  118 , forming a cavity  182 . At least one edge margin of the first panel member  116  extends beyond the corresponding edge margin of the second panel member  118 . As seen in  FIGS. 18, 27, and 28 , the top portion  128  of the first panel member  116  is disposed laterally outward from the top portion  158  of the second panel member  118 . In the illustrated embodiment, the top edge margin of the first panel member  116  extends beyond the top edge margin of the second panel member  118 . The bottom portion  130  of the first panel member is disposed laterally outward from the bottom portion  160  of the second panel member. In the illustrated embodiment. In the illustrated embodiment, the bottom edge margin of the first panel member  116  extends beyond the bottom edge margin of the second panel member  118 . The first side portion  132  of the first panel member  116  is disposed laterally outward from the first side portion  162  of the second panel member  118 . In the illustrated embodiment, the first side edge margin of the first panel member  116  extends beyond the first side edge margin of the second panel member  118 . The second side portion  134  of the first panel member  116  is disposed laterally outward from the second side portion  164  of the second panel member  118 . In the illustrated embodiment, and the second side edge margin of the first panel member  116  extends beyond the second side edge margin of the second panel member  118 . The second panel member  118  is substantially centered within the first panel member  116  such that the first panel member extends beyond the second panel member at all four edge margins. 
         [0068]    The first and second panel members  116 ,  118  are positioned such that the mounting flanges of the first panel member are generally parallel to and in opposed facing relation to the mounting flanges of the second panel member. The top mounting flange  138  of the first panel member  116  is attached to the top mounting flange  168  of the second panel member  118  with double-sided adhesive strip  180 . The bottom mounting flange  140  of the first panel member  116  is attached to the bottom mounting flange  170  of the second panel member  118  with double-sided adhesive strip  180 . The first side mounting flange  142  of the first panel member  116  is attached to the first side mounting flange  172  of the second panel member  118  with double-sided adhesive strip  180  ( FIG. 27 ). In this embodiment, the first side mounting flange  172  of the second panel member  118  does not extend beyond the first side portion  132  of the first panel member  116 . The second side mounting flange  144  of the first panel member  116  is attached to the second side mounting flange  174  of the second panel member  118  with double-sided adhesive strip  180  ( FIGS. 27 and 28 ). The second side mounting flange  174  of the second panel member  118  does not extend beyond the second side portion  134  of the first panel member  116 . 
         [0069]    Attaching the first panel member  116  to the second panel member  118  with double-sided adhesive strip  180  reduces the time required to assemble the insulated panel assembly  112 . In previous panel assemblies, the first and second panel members were attached by plastic clips to create a thermal break. However, the process of attaching the clips to the first and second panel members was very time consuming and labor-intensive. Forming the panel members as described above and using the double-sided adhesive strip to attach the panel members can reduce the time to assemble the panels by about 85% (e.g., from about 35 minutes to about 5 minutes). 
         [0070]    The thermal insulating core  120  ( FIG. 3 ) is positioned in the cavity  182  between the inner faces  126 ,  156  of the first and second panel members  116 ,  118 . In one embodiment, after the first and second panel members  116 ,  118  are attached together, foam insulation is injected into the cavity  182  to form the thermal insulating core  120 . For example, in one embodiment, the assembled first and second panel members  116 ,  118  are placed in the heated press and the cavity  182  is injected with urethane foam to form the core  120  having a density of about 2.5 lbs/ft 3  (40.05 kg/m 3 ). The thermal insulating core can comprise other suitable insulating materials or other suitable densities within the scope of the present invention. 
         [0071]    In order to ensure the first panel members  16 ,  116  and second panel members  18 ,  118  are properly aligned for attachment with double-sided adhesive strip  80 ,  180 , one or more corner jigs  86   a,    86   b,    186   a,    186   b  may be used ( FIGS. 29-35 ). The corner jigs  86   a,    86   b,    186   a,    186   b  can remain on the panel assemblies  12 ,  112  during the foam injection to maintain the panel members in position and act as a stop for plates of the heated press. 
         [0072]    Referring to  FIG. 29 , a first corner jig  86   a  is shown. The first corner jig  86   a  is configured for use (by itself or in conjunction with the other corner jigs  86   b,    186   a,    186   b ) in positioning the second side portion  34  of the first panel member  16  and the second side portion  64  of the second panel member  18  such that the side portion  34  of the first panel member is disposed laterally outward from the side portion  64  of the second panel member. The first corner jig  86   a  includes a first recess  88   a  defined by an end wall  90   a  and a side wall  92   a.  The first recess  88   a  is configured to receive the second panel member  18  such that the top portion  58  engages the end wall  90   a  and the second side portion  64  engages the side wall  92   a.  The first corner jig  86   a  further includes a second recess  94   a  positioned above the first recess  88   a  and defined by an end wall  96   a  and a side wall  98   a.  The side wall  92   a  is further from a side edge margin of the first corner jig  86   a  than the side wall  92   a.  The end wall  96   a  is closer to an end edge margin of the corner jig  86   a  than the end wall  90   a.  The second recess  94   a  is configured to receive the first panel member  16  such that the top portion  28  engages the end wall  96   a  and the first side portion  32  engages the side wall  98   a.    
         [0073]    A second corner jig  86   b  is shown in  FIG. 30  to include a first recess  88   b  defined by an end wall  90   b  and a side wall  92   b.  The second corner jig  86   b  can be used by itself or in conjunction with the other corner jigs  86   a,    186   a,    186   b  to position the first and second panel members  16 ,  18  in the offset manner shown in the drawings to form the insulated panel  12 . The first recess  88   b  is configured to receive the second panel member  18  such that the bottom portion  60  engages the end wall  90   b  and the second side portion  64  engages the side wall  92   b.  The second corner jig  86   a  further includes a second recess  94   b  positioned above the first recess  88   b  and defined by an end wall  96   b  and a side wall  98   b.  The side wall  92   b  is further from a side edge margin of the second corner jig  86   b  than the side wall  98   b.  The end wall  96   b  is closer to an end edge margin of the second corner jig  86   b  than the end wall  90   b.  When the second panel member  18  is positioned in the first recess  88   b  as described above, a portion of the second side mounting flange  74  and a portion of the bottom mounting flange  70  extends into the second recess  94   b.  The second recess  94   b  is configured to receive the first panel member  16  such that the bottom portion  30  engages the end wall  96   b  and the second side portion  34  engages the side wall  98   b.    
         [0074]    Referring to  FIG. 31 , a third corner jig  186   a  is shown. The third corner jig  186   a  is configured for use (by itself or in conjunction with the other corner jigs  86   a,    86   b,    186   b ) in positioning the first side portion  32  of the first panel member  16  and the first side portion  62  of the second panel member  18  such that the side portion  62  of the second panel member extends beyond the side portion  32  of the first panel member. The third corner jig  186   a  includes a first recess  188   a  defined by a side wall  190   a  and an end wall  192   a.  The first recess  188   a  is configured to receive the second panel member  18  such that the top portion  58  engages the end wall  192   a  and the first side portion  62  engages the side wall  190   a.  The third corner jig  186   a  further includes a second recess  194   a  positioned above the first recess  188   a  and defined by a side wall  196   a  and an end wall  198   a.  The side wall  190   a  is closer to a side edge margin of the third corner jig  186   a  than the side wall  196   a.  The end wall  198   a  is closer to an end edge margin of the corner jig  186   a  than the end wall  192   a.  The second recess  194   a  is configured to receive the first panel member  16  such that the top portion  28  engages the end wall  198   a  and the first side portion  32  engages the side wall  196   a.    
         [0075]    A fourth corner jig  186   b  is shown in  FIG. 32 . The fourth corner jig  186   a  is configured for use (by itself or in conjunction with the other corner jigs  86   a,    86   b,    186   b ) to position the first and second panel members  16 ,  18  in the offset manner shown to form insulated panel  12 . The fourth corner jig  186   b  includes a first recess  188   b  defined by a side wall  190   b  and an end wall  192   b.  The first recess  188   b  is configured to receive the second panel member  18  such that the bottom portion  60  engages the end wall  192   b  and the first side portion  62  engages the side wall  190   b.  The fourth corner jig  186   b  further includes a second recess  194   b  positioned above the first recess  188   b  and defined by a side wall  196   b  and an end wall  198   b.  The side wall  190   b  is closer to a side edge margin of the third corner jig  186   b  than the side wall  196   b.  The end wall  198   b  is closer to an end edge margin of the corner jig  186   b  than the end wall  192   b.  The second recess  194   b  is configured to receive the first panel member  16  such that the bottom portion  30  engages the end wall  198   b  and the first side portion  32  engages the side wall  196   b.    
         [0076]    To assemble an insulated panel assembly  12 , first and second corner jigs  86   a,    86   b  are placed at the top and the bottom of the second panel member  18  on the second side, and third and fourth corner jigs  186   a,    186   b  are placed at the top and bottom of the second panel member on the first side ( FIG. 33 ). Double-sided adhesive strip  80  is positioned on the mounting flanges of the second panel member  18 . The first panel member  16  is then positioned in each second recess  94   a,    94   b,    194   a,    194   b  as described above, thereby ensuring the double-sided adhesive strip  80  contacts and adheres to the mounting flanges of the first panel member and that the first and second panel members are positioned in the offset arrangement of the insulated panel assembly  12  described above ( FIG. 33 ). The corner jigs  86   a,    86   b,    186   a,    186   b  can be removed after the first and second panel members  16 ,  18  are attached to each other, or they can remain in place during the foam injection process and be removed after the panel assembly is completed. 
         [0077]    To assemble an insulated panel assembly  112 , first and second corner jigs  86   a,    86   b  are placed at the corners of the second panel member  118  (not shown). Double-sided adhesive strip  180  is positioned on the mounting flanges of the second panel member  118 , using the corner jigs  86   a,    86   b  as a guide for positioning the strip by running the strip immediately adjacent the side and end walls of each second recess  94   a,    94   b.  The first panel member  116  is then positioned in each second recess  94   a,    94   b  as described above, thereby ensuring the double-sided adhesive strip  80  contacts and adheres to the mounting flanges of the first panel member and that the first and second panel members are positioned in the arrangement of the insulated panel assembly  112  described above (with the first panel member extending beyond the inner panel member on all four edge margins). The corner jigs  86   a,    86   b  can be removed after the first and second panel members  116 ,  118  are attached to each other, or they can remain in place during the foam injection process and be removed after the panel assembly is completed. 
         [0078]    The insulated panel assemblies  12 ,  112  as described above are easier to manufacture because the first and second panel members  16 ,  116 ,  18 ,  118  have only two bends at each of the edge margins. In addition, the panel assemblies  12 ,  112  are easier and quicker to assemble by using double-sided adhesive strip  80 ,  180 , while still maintaining a thermal break between the first and second panel members  16 ,  116 ,  18 ,  118 . The configuration of the panel assemblies permits simple overlapping arrangement of multiple panel assemblies to create the air handling enclosure  10 . Corner jigs  86   a,    86   b,    186   a,    186   b  further simplify the construction of the panel assemblies  12 ,  112  by maintaining the correct positional relationship between the first and second panel members for attachment by the double-sided adhesive strip. 
         [0079]    As seen in  FIGS. 1-4 , multiple insulated panel assemblies  12 ,  112  are attached together to form the air handling enclosure  10 . As shown in  FIG. 4 , adjacent panel assemblies  12   a  ,  12   b  are positioned in overlapping arrangement and attached with fasteners  84  (e.g., self-drilling and self-tapping screws). The first side portion  32   a  of the first panel member  16   a  of the first panel assembly  12   a  is positioned adjacent the second side portion  34   b  of the first panel member  16   b  of the second panel assembly  12   b,  and the first side portion  62   a  of the second panel member  18   a  of the first panel assembly is positioned adjacent the second side portion  64   b  of the second panel member  18   b  of the second panel assembly. The first side mounting flange  72   a  of the second panel member  18   a  of the first panel assembly  12   a  overlaps the second side mounting flange  44   b  of the first panel member  16   b  of the second panel assembly  12   b.  Fasteners  84  are inserted through the base portion  52   a  of the first panel assembly  12   a  and the second side mounting flange  74   b  of the second panel assembly  12   b  to attach the first and second panel assemblies to each other. The fasteners  84  extend only through the second panel members  18   a,    18   b  and do not extend through or contact the first panel members  16   a,    16   b  to avoid creating a thermal bridge between the inner and first panel members. Panel assemblies  112  can also be attached as described above, by overlapping a portion of the panel assembly and inserting a fastener  84  through only the second panel members of adjacent panel assemblies  12 ,  112 . The panel assemblies  12 ,  112  can be attached to each other such that the first panel members are generally co-planar, or such that the first panel members are angled relative to each other (e.g., at about 90 degrees). 
         [0080]    Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. 
         [0081]    When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, the and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
         [0082]    In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained. 
         [0083]    As various changes could be made in the above products without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.