Patent Publication Number: US-2020299960-A1

Title: Structurally reinforced insulated panel

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  120   a  coupled to the first frame  104  and a second end  120   b  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  124   a  coupled to the first side  100   a  of the panel  100  and a second skin  124   b  coupled to the second side  100   b  of the panel  100 . The first and second skins  124   a ,  124   b  may be coupled to the first and second sides  100   a ,  100   b  of the panel  100  using any fastening mechanism. For example, the first and second skins  124   a ,  124   b  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  124   a ,  124   b  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  124   a ,  124   b  may be any material suitable for the purpose of insulating and protecting the panel  100 . For example, the first and second skins  124   a ,  124   b  can be metal, plywood, plastic, or oriented strand board (OSB). As shown in  FIG. 1 , the first skin  124   a  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  120   a  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 H 1  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 H 2  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  220   b  of the column  220  and is coupled to the third member  230  at a first end  220   a  of the column  220 . The first end  220   a  of the column  220  includes a first plate  232  for attaching the column  220  to the third member  230  and the second end  220   b  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 W 1  of the column  220  is greater than a width W 2  of the third frame  208  and a width W 3  of the fourth frame  210 . Additionally, a height H 3  of the column  220  may be less than a height H 1  of the third frame  208  and a height H 2  of the fourth frame  210 . However, in other embodiments, the height H 3  of the column  220  can be greater than the height H 1  of the third frame  208  and the height H 2  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 D 1  between the third frame  208  and the column  220  and a second distance D 2  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  320   a  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  320   a  of the column  320 . The first end  320   a  of the column  320  may be a bracket or flanged member fixed to the column  320  providing the first end  320   a , which may be thicker to accommodate the load placed directly on top of the first end  320   a . The first end  320   a  of the column  320  may also include a shock absorbing material. For example, the first end  320   a  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  520   a  and a second end  520   b . The second end  520   b  of the column  520  is coupled to the second frame  506  and the first end  520   a  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  520   a  of the column. Further, the first end  520   a  of the column  520  may be a bracket or flanged member fixed to the column  520  providing the first end  520   a , which may be thicker to accommodate the load placed directly on top of the first end  520   a . The first end  520   a  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  520   a  of the column  520 . The fourth member  546  is disposed a distance D 3  above the first end  520   a  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 D 3  above the first end  520   a  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  620   a  of the column  620  rests on an exterior surface of the third member  630 . The first end  620   a  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  620   b  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  720   a  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  720   a  of the column  720  and the third member  730  extends between the first and second side members  726 ,  728 . The first end  720   a  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  918 A is defined by a U-shaped bracket instead of first and second parallel side members and third member. In  FIG. 11 , the pocket  918 B has a V-shaped opening. In  FIG. 12 , the pocket  918 C defines a narrow groove, similar to the notch  856  discussed above. Finally, as illustrated in  FIG. 13 , the pocket  918 D 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 L 1  and the second section  1062  may be a second length L 2 . A second end  1020   b  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  1020   a  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  124   a ,  124   b  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  1102 A,  1102 B,  1102 C 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  1102 A,  1102 B,  1102 C 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 T 1  that is less than a thickness T 2  of the third frame and a thickness T 3  of the fourth frame. Since the thickness T 1  of the column  1120  is less than the thicknesses T 2 , T 3  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  1124   a , such as the first skin  124   a  of the panel  100  of  FIG. 1 , and the second surface  1168  of the column  1120  is spaced away from a second skin  1124   b , such as the second skin  124   b  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  1124   a ,  1124   b , 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  1124   b , such as the second skin  124   b  of the panel  100  of  FIG. 1 , and the first surface  1166  of the column  1120  is spaced away from a first skin  1124   a , such as the first skin  124   a  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  1520   a  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  1520   b  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  1520   a ,  1520   b  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  1520   b  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  120   a  of the column  120  to the first frame  104  and the second end  120   b  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  124   a  to the first side  100   a  of the panel  100  and fastening the second skin  124   b  to the second side  100   b  of the panel  100 . Once the first and second skins  124   a ,  124   b  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.