High performance insulated structural panel

Abstract

An insulated structural panel is made from expanded polystyrene (EPS) panel and a plurality of interior and exterior structural members that are affixed to one another by screws is provided. When assembled, the interior and exterior structural members are flush with the EPS panel. A tongue at one end of the EPS panel engages a grove at another end of another EPS panel, therein permitting interlocking two or more EPS panels. The interior panel is C-shaped and is slid into a C-shaped passage in the EPS panel formed by hot-wire cutting the EPS panel. The exterior structural member is positioned within a channel formed opposite the passage. A top plate connects a plurality of interior structural members. A seam covering member is affixed to the one end of the EPS panel and is flush with the EPS panel. A thermal break is provided between the interior and exterior structural members.

1 . An insulated structural panel, comprising:
 a thermally insulative panel having a first side and an opposing second side, wherein a passage associated with the first side extends from a first end to a second end of the thermally insulative panel, and wherein the passage is generally C-shaped having a clearance width associated therewith, and wherein a channel associated with the second side extends from the first end to the second end of the thermally insulative panel, wherein the channel is located generally opposite to the passage;   a first structural member, wherein the first structural member is comprised of a sheet of material generally formed in a C-shape, wherein the sheet of material has a thickness associated with the clearance width of the passage, and wherein the first structural member is configured to slidingly engage the passage in the thermally insulative panel, wherein the first structural member generally resides within the passage and extends from the first end to the second end of the thermally insulative panel, wherein all but an edge portion of the first structural member is contiguously surrounded by the thermally insulative panel, and wherein the edge portion of the first structural member that is not surrounded by the thermally insulative panel is substantially flush with a plane of the first side of the thermally insulative panel;   a second structural member, wherein the second structural member generally resides within the channel and extends from the first end to the second end of the thermally insulative panel, and wherein a separation between the first structural member and second structural member defines a thermal break; and   a plurality of fasteners, wherein the plurality of fasteners fasten the first structural member to the second structural member, therein providing rigidity to the insulated structural panel.   
   
   
       2 . The insulated structural panel of  claim 1 , wherein the thermally insulative panel is comprised of expanded polystyrene. 
   
   
       3 . The insulated structural panel of  claim 1 , wherein the clearance width is less than or approximately equal to the thickness of the sheet of material. 
   
   
       4 . The insulated structural panel of  claim 1 , wherein the first structural member and second structural member are comprised of one or more of steel and aluminum. 
   
   
       5 . The insulated structural panel of  claim 1 , wherein the plurality of fasteners comprise a plurality of truss screws. 
   
   
       6 . The insulated structural panel of  claim 5 , wherein the plurality of truss screws comprise self-tapping heads, wherein holes are defined in the first structural member and second structural member by the self-tapping heads of the plurality of truss screws. 
   
   
       7 . The insulated structural panel of  claim 1 , wherein the plurality of fasteners are comprised of one or more of steel and aluminum. 
   
   
       8 . The insulated structural panel of  claim 1 , wherein the thermally insulative panel comprises a third side and a fourth side defined between the first side and second side, wherein the third side and fourth side comprise a respective tongue and groove, therein providing a mechanism for coupling of two or more insulated structural panels to one another. 
   
   
       9 . The insulated structural panel of  claim 1 , wherein the first end and second end are generally planar and orthogonal to the first and second sides. 
   
   
       10 . The insulated structural panel of  claim 1 , wherein one or more of the first end and second end are not orthogonal to the first and second sides. 
   
   
       11 . The insulated structural panel of  claim 1 , comprising a plurality of passages and channels in the thermally insulative panel, wherein a respective plurality of first structural members and second structural members are positioned within the plurality of respective passages and channels, wherein the insulated structural panel further comprises:
 a third structural member, wherein the third structural member is fastened to the plurality of first structural members proximate to the first end of the thermally insulative panel, and wherein the third structural member generally extends from a third side to a fourth side of the thermally insulative panel, therein providing further rigidity to the insulated structural panel.   
   
   
       12 . The insulated structural panel of  claim 11 , further comprising:
 a fourth structural member, wherein the fourth structural member is fastened to the plurality of first structural members proximate to the second end of the thermally insulative panel, and wherein the fourth structural member generally extends from a third side to a fourth side of the thermally insulative panel, therein providing further rigidity to the insulated structural panel.   
   
   
       13 . The insulated structural panel of  claim 11 , wherein the third structural member comprises a fastening portion and a seam-covering portion, wherein the fastening portion of the third structural member is generally embedded into the first end of the thermally insulative panel and fastened to the plurality of first structural members, and wherein the seam-covering portion of the third structural member extends generally parallel to the first side of the thermally insulative panel from the first end thereof. 
   
   
       14 . The insulated structural panel of  claim 1 , further comprising:
 a fifth structural member, wherein the fifth structural member generally extends along the third side of the thermally insulative panel from the first end to the second end thereof, wherein the fifth structural member comprises a fastening portion and a seam-covering portion, wherein the fastening portion of the fifth structural member is generally embedded into the third side of the thermally insulative panel, and wherein the seam-covering portion of the fifth structural member extends generally parallel to the first side of the thermally insulative panel from the third side thereof.   
   
   
       15 . A method of forming an insulated structural panel, the method comprising:
 providing a thermally insulative panel having a first side and a second side, wherein a passage associated with the first side extends from a first end to a second end of the thermally insulative panel, and wherein the passage is generally C-shaped having a clearance width associated therewith, and wherein a channel associated with the second side extends from the first end to the second end of the thermally insulative panel;   sliding a first structural member into the passage from the first end of the thermally insulative panel until the first structural member generally extends from the first end to the second end of the thermally insulative panel, wherein all but an edge portion of the first structural member is contiguously surrounded by the thermally insulative panel;   placing a second structural member into the channel, wherein the second structural member generally extends from the first end to the second end of the thermally insulative panel and is separated from the first structural member by a thermal break portion of the thermally insulative panel; and   fastening the first structural member to the second structural member, therein providing rigidity to the insulated structural panel.   
   
   
       16 . The method of  claim 15 , wherein providing the thermally insulative panel comprises providing a foam polymer panel and cutting the passage into the foam polymer panel using a hot wire. 
   
   
       17 . The method of  claim 15 , wherein fastening the first structural member to the second structural member comprises driving a truss screw through the second structural member and at least a portion of the thermally insulative panel and first structural member. 
   
   
       18 . The method of  claim 15 , wherein fastening the first structural member to the second structural member comprises driving a truss screw through the first structural member and at least a portion of the thermally insulative panel and second structural member. 
   
   
       19 . The method of  claim 15 , wherein the thermally insulative panel comprises providing a plurality of passages and channels therein, the method further comprising:
 sliding a plurality of first structural members into the plurality of respective passages;   placing a plurality of second structural members into the plurality of respective channels; and   fastening a third structural member to the plurality of first structural members proximate to the first end of the thermally insulative panel, wherein the third structural member generally extends from a third side to a fourth side of the thermally insulative panel, therein providing further rigidity to the insulated structural panel.   
   
   
       20 . The method of  claim 19 , further comprising:
 fastening a fourth structural member to the plurality of first structural members proximate to the second end of the thermally insulative panel, wherein the fourth structural member generally extends from the third side to the fourth side of the thermally insulative panel, therein providing further rigidity to the insulated structural panel.