System, apparatus and method for forming an insulated cavity within a vehicle chamber

Abstract

An insulated compartment for e.g. van having multiple interconnected plastic panels forming floor, walls and roof of the insulated compartment. Assembled external to the van and inserted after assembly. The panels may be interconnected by protruding engagement tabs and corresponding slots or indents in adjacent panels. The panels may include insulation core and external layer by thermoforming. Panels may include weakened creases 43 enabling panels to flex during insertion. Once in position, the panel may return to its fully expanded position to locate the compartment within the vehicle. The panels may contact the vehicle walls or indirectly via braces 49 (fig 14a). The interior surfaces may be planar and exterior contoured to match the vehicle. Vehicle door may receive correspondingly shaped insulating panels. Shaped insulating panels 60 for insulating wheel arches may be hinged. Tread plates 246 (fig 13b) may interface between floor and door. Also claimed flat pack panel kit and a vehicle. [fig 2a]