Patent ID: 8429824

Claim:
A method of forming an insulated panel comprising a first major face, a second major faces, and a plurality of intermediate faces, the method comprising: providing a mold bulkhead comprising an interior mold surface defining an interior mold volume, wherein the interior mold surface comprises a plurality of mold sides; providing at least one sealing strip comprising a first anchor extension, a second anchor extension, and a panel cap, wherein the panel cap comprises an interior face and an exterior face; removably attaching the exterior face of the sealing strip to the interior mold surface on at least one of the plurality of mold sides, wherein the first anchor extension and the second anchor extension project into the interior mold volume, and wherein the sealing strip defines a sealed insulation zone; introducing a curable building material into the interior mold volume to form a first slab, wherein the first slab defines the first major face, wherein the first slab at least partially surrounds the first anchor extension; inserting an insulation material layer into the interior mold volume, wherein the insulation material layer is at least partially within the sealed insulation zone; introducing a curable building material into the interior mold volume adjacent to the insulation material layer to form a second slab, wherein the second slab defines the second major face, wherein the second slab at least partially surrounds the second anchor extension; and allowing the curable building material to cure to provide a cured insulated panel, wherein the panel cap defines at least a portion of at least one of the plurality of intermediate faces.