Thermal Break Panel Assembly for Air Handler Cabinet

Abstract

The thermal break panel assembly (18) includes a first panel member (26), a second panel member (28), a first insulating member (30), and a second insulating member (32). The first panel member (26) includes a first base member (36), a first wall portion (38) extending outward from an outer edge (36C, 36D, 36E, 36F) of the first base member (36), and a first flange (40) extending inward from an upper end (38A) of the first wall portion (38). The first insulating member (30) is disposed between the first wall portion (38) of the first panel member (26) and the third wall portion of the second panel member (28). The second insulating member (32) is disposed between the first base member (36) of the first panel member (26) and the second base member (42) of the second panel member (28). In the extension direction of the first flange (40), a gap (G1) is disposed between the inner edge of the first flange (40) of the first panel member (26) and the second wall portion (44) of the second panel member (28).

Description

Technical Field

[0001] The present invention generally relates to a thermal break panel assembly that greatly reduces thermal bridging. More specifically, the present invention relates to an air handler cabinet having a thermal break panel assembly that greatly reduces thermal bridging.

Background Art

[0002] Heating, ventilation, and air conditioning (HVAC) equipment is typically housed in an isolated, sealed enclosure such as an air handler unit cabinet. The cabinet guides air to pass through the equipment and provides protection to the components housed therein. Due to the change in the direction of the air and the effect of specific components of the HVAC process, parts with a large difference between positive and negative pressures are formed throughout the cabinet. Since HVAC equipment is placed in various climate conditions, it is necessary to insulate the cabinet to prevent heat loss and heat gain between the processed internal air and the external air.

[0003] Conventional HVAC cabinets are formed using panels composed of a thin sheet metal skin and a foam-like (foamed) insulation core. Conventional cabinets with these conventional panels are prone to thermal bridging. Thermal bridging is the transfer of heat through an object that is more conductive than the surrounding materials. The central part of the conventional panel has a very low thermal transmittance value (due to the foam-like insulation core), but the outer edge of the panel (where the sheet metal covers the edge of the panel) can conduct a greater heat load from the inside of the cabinet to the outside of the cabinet, resulting in a decrease in the overall R-value of the cabinet and the possibility of condensation occurring at the edges of the panel. The R-value is a measure of thermal resistance, and the greater the insulation effect, the larger the R-value. The outer edge of the conventional panel becomes a thermal bridge that forms a low-resistance path for heat flow, reducing the insulation effect of the conventional panel and the cabinet having such a panel.

Summary of the Invention

[0004] An object of the present invention is to provide a thermal break panel assembly that can greatly reduce thermal bridges.

[0005] A further object of the present invention is to provide a structurally sealed enclosure (structural enclosure) such as an air handler cabinet that can withstand high differential pressures while maintaining a low heat transfer rate.

[0006] In view of the state of the art, the thermal break panel assembly according to the first aspect of the present invention has a first panel member, a second panel member, a first heat insulating member, and a second heat insulating member. The first panel member has a first base member, a first wall portion extending outward from the outer edge of the first base member, and a first flange extending inward from the upper end of the first wall portion. The second panel member has a second base member, a second wall portion extending outward from the outer edge of the second base member, a second flange extending inward from the upper end of the second wall portion, and a third wall portion extending outward from the inner edge of the second flange. The first heat insulating member is disposed between the first wall portion of the first panel member and the third wall portion of the second panel member. The second heat insulating member is disposed between the first base member of the first panel member and the second base member of the second panel member. In the extending direction of the first flange, a gap is disposed between the inner edge of the first flange of the first panel member and the second wall portion of the second panel member.

[0007] The thermal break panel assembly according to the second aspect is the thermal break panel assembly according to the first aspect, wherein the first wall portion extends from the entire outer edge of at least one of the first base members, and the first flange extends from the entire upper end of the first wall portion.

[0008] The thermal break panel assembly according to the third aspect is the thermal break panel assembly according to the first or second aspect, wherein the width of the first heat insulating member is larger than the width of the first flange of the first panel member.

[0009] The thermal break panel assembly for the fourth face is any one of the thermal break panel assemblies from the first face to the third face, and a step where the second flange of the second panel member and the third wall contact the first heat insulating member is formed.

[0010] The thermal break panel assembly for the fifth face is any one of the thermal break panel assemblies from the first face to the fourth face, and a cavity is formed by the first base member of the first panel member, the first heat insulating member, the third wall portion of the second panel member, the second flange of the second panel member, the second wall of the second panel member, and the second base member of the second panel member, and the second heat insulating member is disposed in the cavity.

[0011] The thermal break panel assembly for the sixth face is any one of the thermal break panel assemblies from the first face to the fifth face, and the first panel member is integrally formed as a single member from sheet metal having a thickness of 14 gauge or less.

[0012] The thermal break panel assembly for the seventh face is any one of the thermal break panel assemblies from the first face to the sixth face, and a plurality of fastening holes are formed in the first panel member so as to extend from the outer surface to the inner surface of the first flange, and the first heat insulating member covers each of the plurality of fastening holes on the inner surface of the first flange.

[0013] The thermal break panel assembly for the eighth face is any one of the thermal break panel assemblies from the first face to the seventh face, and the height of the third wall portion is smaller than the height of the first heat insulating member.

[0014] The thermal break panel assembly for the ninth face is any one of the thermal break panel assemblies from the first face to the eighth face, and the first heat insulating member extends further outward than the second heat insulating member in the width direction of the thermal break panel assembly.

[0015] The thermal break panel assembly according to the tenth surface is any one of the thermal break panel assemblies from the first surface to the ninth surface, and the upper end of the third wall portion is arranged at a distance from the inner surface of the first base member in the extending direction of the third wall portion.

[0016] In view of the state of the art, the air handler unit according to the eleventh surface of the present invention has a plurality of frame members and a plurality of thermal break panel assemblies. The plurality of frame members form a frame structure. The plurality of thermal break panel assemblies are removably connected to the plurality of frame members so as to form an air handler cabinet. Each of the thermal break panel assemblies has a first panel member, a second panel member, a first heat insulating member, a second heat insulating member, a first gap, and a second gap. The first panel member has a first base member, a first wall portion extending outward from the outer edge of the first base member, and a first flange extending inward from the upper end of the first wall portion. The second panel member has a second base member, a second wall portion extending outward from the outer edge of the second base member, a second flange extending inward from the upper end of the second wall portion, and a third wall portion extending outward from the inner edge of the second flange. The first heat insulating member is disposed between the first wall portion of the first panel member and the third wall portion of the second panel member. The second heat insulating member is disposed between the first base member of the first panel member and the second base member of the second panel member. In the extending direction of the first flange, the first gap is disposed between the inner edge of the first flange of the first panel member and the second wall portion of the second panel member. The second gap is disposed between the upper end of the third wall portion of the second panel member and the first base member of the first panel member.

[0017] The air handler unit according to the twelfth surface is the air handler unit of the eleventh surface, and both the first gap and the second gap are greater than about 3 / 4 inch.

[0018] The air handler unit according to the thirteenth surface is the air handler unit of the eleventh surface or the twelfth surface, and each side of the air handler unit includes at least one of a plurality of thermal break panel assemblies.

[0019] The air handler unit according to the fourteenth surface is the air handler unit of any one of the eleventh surface to the thirteenth surface, and any one of the plurality of thermal panel assemblies is removable from a plurality of frame members so as to be accessible inside the air handler cabinet.

[0020] In view of the state of the art, the method of forming the thermal break panel assembly according to the fifteenth aspect of the present invention includes the step of disposing the outer surface of the first panel member on a support. The first heat insulating member is inserted into a groove formed in the first panel member. The second panel member is disposed on the first heat insulating member. The second panel member does not contact the first panel member. The second heat insulating member is injected into a cavity formed by the first panel member, the first heat insulating member, and the second panel member.

[0021] The method of forming the thermal break panel assembly according to the sixteenth aspect is the method of forming the thermal break panel assembly of the fifteenth aspect, and the positioning of the second panel member in disposing the second panel member on the first heat insulating member includes engaging a step formed in the second panel member with the first heat insulating member.

[0022] The method of forming the thermal break panel assembly according to the seventeenth aspect is the method of forming the thermal break panel assembly of the fifteenth aspect or the sixteenth aspect, and the first heat insulating member covers a plurality of fastening holes of the first panel member, thereby substantially preventing the injected second heat insulating member from leaking through the plurality of fastening holes.

[0023] A method of forming a thermal break panel assembly for the eighteenth face is a method of forming a thermal break panel assembly for any one of the fifteenth face to the seventeenth face, wherein the second panel member is disposed on the first thermal insulation member such that a part of the first thermal insulation member is exposed.

[0024] A method of forming a thermal break panel assembly for the nineteenth face is a method of forming a thermal break panel assembly for any one of the fifteenth face to the eighteenth face, wherein the second panel member is disposed on the first thermal insulation member such that the second panel member is at least 1 inch apart from the first panel member at all points.

[0025] A method of forming a thermal break panel assembly for the twentieth face is a method of forming a thermal break panel assembly for any one of the fifteenth face to the nineteenth face, wherein the first thermal insulation member is inserted such that the entire inner edge of the first panel member is in contact with the first thermal insulation member.

[0026] These and other objects, features, aspects, and advantages will become apparent to those skilled in the art from the following description, which discloses the preferred embodiments of the present invention in combination with the accompanying drawings.

Brief Description of the Drawings

[0027] The following description will be made with reference to the accompanying drawings, which form a part of this disclosure.

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DETAILED DESCRIPTION OF THE INVENTION

[0028] Selected embodiments will be described with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following description of the embodiments is merely exemplary and is not intended to limit the present invention as defined by the appended claims and their equivalents.

[0029] Referring to FIGS. 1-8, an air handler unit 10 includes a plurality of frame members 12 and 14 forming a frame structure 16, and a plurality of thermal break panel assemblies 18 removably connected to the plurality of frame members 12, 14 to form an air handler cabinet 20.

[0030] As shown in FIGS. 1 and 2, the base 22 of the frame structure 16 supports the air handler cabinet 20 on the ground. The plurality of frame members include a plurality of first frame members 12 and a plurality of second frame members 14. The first frame members 12 can connect two thermal break panel assemblies 18 substantially perpendicular to each other at corners or the like of the cabinet 20. The second frame members 14 can arrange two thermal break panel assemblies 18 side by side on the same side of the cabinet 20 and connect them substantially parallel to each other.

[0031] As shown in FIG. 2, the plurality of first frame members 12 include vertical first frame members 12A and horizontal first frame members 12B. The vertical first frame members 12A extend vertically from each corner of the base 22. The lower ends of the vertical frame members 12A are connected to the base 22 by an appropriate method such as a fastener 56. The horizontal first frame members 12B extend horizontally between the upper ends of adjacent vertical first frame members 12A. The horizontal first frame members 12B are connected to the vertical first frame members 12A by an appropriate method such as a fastener 56. As shown in FIG. 20, each first frame member 12 has a first flange 12C and a second flange 12D. The first flange 12C and the second flange 12D have a plurality of fastening openings 12E so that the second frame member 14 can be easily connected as shown in FIGS. 1 and 4. As shown in FIGS. 1 and 20, the first flange 12C and the second flange 12D are substantially perpendicular to each other so that the connected thermal break panel assemblies 18 are arranged perpendicular to each other, such as between two adjacent sides of the cabinet. As shown in FIG. 20, the first flange 12C and the second flange 12D further support the panel assembly 18 to be attached. A gasket (not shown) can be arranged on the first flange 12C and the second flange 12D to make it airtight. As shown in FIGS. 2 to 5, the first frame member 12 has a plurality of fastening holes 12F so that the thermal break panel assembly 18 can be easily connected. The plurality of fastening openings 12E preferably do not completely penetrate the first frame member 12.

[0032] As shown in FIG. 1, the second frame member 14 has a vertical second frame member 14A and a horizontal second frame member 14B. As shown in FIGS. 2, 3, and 4, the vertical second frame member 14A extends vertically between the base 22 and the horizontal first frame member 12B. The vertical second frame member 14A extends vertically from the base 22. The lower end of the vertical second frame member 14A is connected to the base 22 by an appropriate method such as a fastener 56. The upper end of the vertical second frame member 14A is connected to the horizontal first frame member 12B, for example, to a flange 12D as shown in FIG. 4. The horizontal second frame member 12B extends horizontally. The lower horizontal second frame member 14B extends between both side surfaces of the base 22. The upper horizontal second frame member 14B extends between the horizontally opposed first frame members 12B. The horizontal second frame member 14B is connected by an appropriate method such as a fastener 56. As shown in FIGS. 3, 4, and 21, each second frame member 14 has a first flange 14C and a second flange 14D. The first flange 12C and the second flange 12D support the panel assembly 18 to be attached as shown in FIG. 21. In order to achieve an airtight state, a gasket (not shown) can be arranged between the first flange 14C and the second flange 14D. The second frame member 14 has a plurality of fastening holes 14E so that the thermal break panel assembly 18 can be easily connected. The plurality of fastening holes 14E preferably do not completely penetrate the second frame member 14. As shown in FIG. 1, the first flange 14A and the second flange 14B are parallel to each other so that in two thermal panel assemblies adjacent on the same side of, for example, a cabinet, the plurality of thermal break panel assemblies 18 connected thereto are arranged substantially parallel to each other.

[0033] As shown in FIG. 1, the thermal break panel assembly, i.e., panel assembly 18, is connected to the first frame member 12, the second frame member 14, and / or the base 22 based on the position of the panel assembly 18. The base 22 is substantially rectangular and has a first side 22A and a second side 22B. The first side 22A is longer than the second side 22B, but the base can have any suitable configuration, such as being substantially square. As shown in the embodiment of FIG. 1, three panel assemblies 18 are connected to each first side 22A of the base 22, and two panel assemblies 18 are connected to each second side 22B of the base 22. As shown in FIGS. 1 and 8, two panel assemblies 18 are provided on the upper surface of the cabinet 20, and two panel assemblies 18 are provided on the bottom surface of the cabinet 20. The embodiment of the cabinet 20 shown in FIG. 1 has 14 panel assemblies 18, but the cabinet can have any suitable number of panel assemblies according to the exemplary embodiments of the present invention.

[0034] As shown in FIGS. 1 and 3, in one aspect, two panel assemblies 18 are connected to each second side 20B of the cabinet 20. The two panel assemblies 18 are respectively connected between a vertical second frame member 14A and one of the vertical first frame members 12A. The upper and lower ends of the panel assembly 18 are respectively connected to one of the horizontal first frame members 12B and the base 22. The panel assemblies 18 on the second side 20B of the cabinet 20 are substantially parallel to each other.

[0035] As shown in FIGS. 1 and 4, in one aspect, three panel assemblies 18 are connected to each first side surface 20A of the cabinet 20. The central panel assembly 18 is connected between two second vertical frame members 14A. The two outer panel assemblies 18 are respectively connected between one of the second vertical frame members 14A and one of the first vertical frame members 12A. The upper and lower ends of the panel assembly 18 are respectively connected to one of the horizontal first frame members 12B and the base 22. The panel assemblies 18 on the first side surface of the cabinet 20 are substantially parallel to each other.

[0036] As shown in FIGS. 1 and 5, in one aspect, two panel assemblies 18 are provided on the upper side of the cabinet 20. The respective sides of the two panel assemblies 18 are connected between a horizontal second frame member 14B and one of the horizontal first frame members 12B. Each of the ends of the panel assembly 18 is connected to the horizontal first frame member 12B. The panel assemblies 18 on the upper side of the cabinet 20 are substantially parallel to each other. As shown in FIGS. 1, 2, and 12, the upper surface panel assembly 18 can be easily removed so as to access the interior 24 of the cabinet 20. Preferably, either the upper surface or the side surface panel assembly 18 of the cabinet 20 is made easily removable so as to access the interior 24 of the cabinet 20. Preferably, by removing any one panel assembly 18, access to the interior 24 of the cabinet 20 can be achieved without the need to remove the other panel assemblies 18. In one aspect, the floor panel is attached to provide a waterproof floor surface, in which case the floor panel is not made removable for accessing the interior of the cabinet 20. Alternatively, in one aspect, the floor panel is made removable for accessing the interior of the cabinet 20.

[0037] As shown in FIGS. 1 and 6 - 8, in one aspect, two panel assemblies 18 are provided on the bottom surface of the cabinet 20. Each side portion of the two panel assemblies 18 is connected between a horizontal second frame member 14B and an opposing side surface 22A of the base 22. Each end of the panel assembly 18 is connected to an opposing side surface 22B of the base 22. The panel assemblies 18 on the bottom side of the cabinet 20 are substantially parallel to each other.

[0038] Preferably, as shown in FIGS. 1, 2, 7, and 8, at least one thermal break panel assembly 18 is provided on each side surface of the air handler unit 10. As shown in FIGS. 1, 7, and 8, fourteen panel assemblies 18 are connected to a plurality of first frame members 12, second frame members 14, and the base 22, thereby forming the air handler cabinet 20. Preferably, as shown in FIG. 8, the panel assembly 18 is connected by a fastener 56 as shown in FIGS. 1 and 2 so that the panel assembly 18 can be easily removed from the plurality of frame members 14 to provide access to the interior 24 of the cabinet 20. The panel assembly 18 preferably substantially forms most of the exterior of the cabinet 20. Air handler components such as heat exchangers and blowers can be disposed inside the interior 24 of the cabinet 20. By removably connecting the panel assembly 18, access to the air handler components disposed inside the interior 24 of the cabinet 20 can be facilitated. Any number of panel assemblies 18 can be used depending on the desired size of the cabinet 20.

[0039] As shown in FIGS. 9 to 15, FIGS. 20, FIGS. 21 and FIG. 25, the panel assembly 18 has a first panel member 26, a second panel member 28, a first heat insulating member 30, and a second heat insulating member 32. The first heat insulating member 30 is disposed between the first panel member 26 and the second panel member 28. As shown in FIG. 24, a cavity 34 of the panel assembly 18 is formed by the first panel member 26, the second panel member 28, and the first heat insulating member 30. As shown in FIG. 25, the second heat insulating member 32 is injected into the panel assembly 18 so as to substantially fill the entire cavity 34.

[0040] As shown in FIGS. 9, 10, 14 and 15, the first panel member 26 has a first base member 36, a first wall portion 38, and a first flange 40. The first panel member 26 is formed of a suitable material such as steel sheet metal. The sheet metal used to form the first panel member 26 can be of any suitable thickness, such as sheet metal from 26 gauge to 14 gauge (including 26 gauge and 14 gauge), but thicker or thinner sheet metal can also be used. Preferably, the first panel member 26 is integrally formed from a single sheet metal having a thickness of 14 gauge or less. The larger the gauge number, the smaller the thickness of the sheet metal. In other words, the thickness being 14 gauge or less means that the thickness of the sheet metal is less than or equal to the thickness corresponding to 14 gauge, for example, like 26 gauge.

[0041] As shown in FIGS. 10 and 15, the first base member 36 has an outer surface 36A and an inner surface 36B. The first base member 36 is preferably substantially planar. The first base member can have any suitable shape, but is preferably substantially rectangular as shown in FIG. 10. The first base member has opposing first outer edge 36C and second outer edge 36E, and opposing third outer edge 36D and fourth outer edge 36F. The third outer edge 36D and the fourth outer edge 36F are preferably substantially perpendicular to the first outer edge 36C and the second outer edge 36E. When the panel assembly 18 is connected to the frame structure 16 to form the cabinet 20, the outer surface 36A of the first base member 36 faces the outside of the cabinet 20. Since a plurality of fastening holes 36G are formed in the first base member 36, it is easy to connect the first base member 36 to the frame structure 16. The plurality of fastening holes 36G extend from the outer surface 36A to the inner surface 36B of the first base member 36.

[0042] As shown in FIGS. 9 and 15, the first wall portion 38 extends outward from the outer edge 36C of the first base member 36. The first wall portion 38 is preferably extended substantially perpendicular to the outer edge 36C of the first base member 36. The first wall portion 38 extends from at least one entire outer edge 36C of the first base member 36. Preferably, as shown in FIG. 15, the first wall portion 38 extends from the entire outer edges 36C, 36D, 36E, 36F respectively.

[0043] As shown in FIGS. 14 and 15, the first flange 40 extends inward from the upper end 38A of the first wall portion 38. The first flange 40 extends from the entire upper end 38A of the first wall portion 38. A plurality of fastening holes 40A are formed in the first flange 40 of the first panel member 26, whereby the connection of the first flange 40 to the frame structure 16 can be facilitated. The fastening holes 40A extend from the outer surface to the inner surface of the first flange 40. The inner edge 40B of the first flange 40 is spaced inward from the first wall portion 38 of the first panel member 26.

[0044] As shown in FIGS. 15, 16, 18, and 22, a groove 52 is formed in the first panel member 26 by the inner surface 36B of the base member 36, the first wall portion 38, and the first flange 40 of the first panel member 26. As shown in FIG. 16, the groove 52 preferably extends around the entire inner circumference of the first panel member 26.

[0045] As shown in FIGS. 9, 15, 17, 19, and 24, the second panel member 28 has a second base member 42, a second wall portion 44, a second flange 46, and a third wall portion 48. The second panel member 28 is formed of a suitable material such as steel sheet metal. The sheet metal used to form the second panel member 28 can be of any suitable thickness, such as a sheet metal from 26 gauge to 14 gauge (including 26 gauge and 14 gauge), but a thicker or thinner sheet metal can also be used. Preferably, the second panel member 28 is integrally formed from a single sheet metal having a thickness of 14 gauge or less. The larger the gauge number, the smaller the thickness of the sheet metal. In other words, a thickness of 14 gauge or less means that the thickness of the sheet metal is less than or equal to the thickness corresponding to 14 gauge, for example, 26 gauge.

[0046] As shown in FIGS. 9 and 17, the second base member 42 has an outer surface 42A and an inner surface 42B. The second base member 42 is preferably substantially planar. The second base member 42 can have any suitable shape, but is preferably substantially rectangular as shown in FIGS. 9, 14, and 17. The second base member 42 has opposing first outer edge 42C and second outer edge 42E, and opposing third outer edge 42D and fourth outer edge 42F. The third outer edge 42D and the fourth outer edge 42F are preferably substantially perpendicular to the first outer edge 42C and the second outer edge 42E. When the panel assembly 18 is connected to the frame structure 16 to form the cabinet 20, the outer surface 42A of the second base member 42 faces the inside of the cabinet 20 (FIG. 2).

[0047] As shown in FIG. 17, the second wall portion 44 extends outward from the outer edge 42C of the second base member 42. The second wall portion 44 preferably extends substantially perpendicular to the outer edge 42C of the second base member 42. The second wall portion 44 extends from the entire at least one outer edge 42C of the second base member 44. Preferably, as shown in FIGS. 15 and 17, the second wall portion 44 extends from the entire outer edges 42C, 42D, 42E, and 42F. As shown in FIGS. 11 to 13, a plurality of air vent holes 44G are formed in the second wall portion 44 of the second panel member 28 so that air can easily escape from the panel assembly when the second heat insulating member 32 is injected. As shown in FIGS. 12 and 17, an injection port 44H is formed in the second wall portion 44 to facilitate the injection of the second heat insulating member 32.

[0048] As shown in FIG. 17, the second flange 46 extends inward from the upper end 44A of the second wall portion 44. Preferably, the second flange 46 extends from the entire upper end 44A of the second wall portion 44. The second flange 46 is preferably substantially parallel to the second base member 42. The second flange 46 is preferably substantially perpendicular to the second wall portion 44.

[0049] As shown in FIG. 17, the third wall portion 48 extends outward from the inner edge of the second flange 46. The third wall portion 48 is preferably substantially parallel to the second wall portion 44. As shown in FIGS. 17 and 19, a step 54 is formed by the second flange 46 and the third wall portion 48 of the second panel member 28.

[0050] As shown in FIGS. 15, 20, 21, 23 and 24, the first heat insulating member 30 is disposed between the first panel member 26 and the second panel member 28. The first heat insulating member 30 is disposed between the first wall portion 38 of the first panel member 26 and the third wall portion 48 of the second panel member 28 in the width direction of the panel assembly 18. As shown in FIG. 24, the first heat insulating member 30 is disposed between the first base member 36 of the first panel member 26, the first flange 40 of the first panel member 26 and the second flange 46 of the second panel assembly 28 in the height direction of the panel assembly 18. As shown in FIG. 15, the thermal break panel assembly 18 has four first heat insulating members 30. Preferably, each of the first heat insulating members 30 has the same width W1, but may have different lengths. Alternatively, the first heat insulating member 30 may have different widths depending on the position of the panel assembly 18 in the cabinet 20. In FIG. 15, one first heat insulating member 30 is illustrated on each side of the thermal panel assembly, but an appropriate number of first heat insulating members 30 can be used. As shown in FIGS. 1 and 10, when viewed from the outer surface 36A of the first panel member 26, the first heat insulating member 30 is made invisible by the first flange 40. The first heat insulating member 30 can be made of any suitable heat insulating material such as glass fiber.

[0051] As shown in FIG. 25, the second heat insulating member 32 is disposed between the first panel member 26 and the second panel member 28. The second heat insulating member 32 can be made of any suitable heat insulating material such as polyurethane.

[0052] The assembly of the thermal break panel assembly 18 is shown in FIGS. 22 to 25. As shown in FIG. 22, the outer surface 36A of the first base member 18 is disposed on a support portion 50 such as a workbench or the ground.

[0053] As shown in FIG. 23, the first heat insulating member 30 is disposed in a groove 52 formed in the first panel member 26. The groove 52 is formed by the inner surface 36B of the first panel member 26, the first wall portion 38, and the first flange 40. As shown in FIGS. 14, 15, and 17, the width W1 of the first heat insulating member 30 is larger than the width W2 of the first flange 40 of the first panel member 26. As shown in FIG. 15, the first heat insulating member 30 is disposed in the entire groove 52 formed in the first panel member 26. As shown in FIG. 14, the first heat insulating member 30 covers (covers) a plurality of fastening holes 36G of the first base member 36 and a plurality of fastening holes 40A of the first flange 40 of the first panel member 26, thereby substantially preventing the second heat insulating member 32 from leaking through the plurality of fastening holes during the injection of the second heat insulating member 32 (FIG. 25). As shown in FIGS. 14 and 15, the entire inner edge of the first panel member 26 is in contact with the first heat insulating member 30, and as shown in FIG. 23, the first heat insulating member 30 is inserted into the groove 52 so as to cover each fastening hole 40A on the inner surface 40B of the first flange 40. As shown in FIG. 14, the first heat insulating member 30 covers each fastening hole 36G formed in the first base member 36 of the first panel member 26.

[0054] As shown in FIG. 24, the second panel member 28 is disposed on the first heat insulating member 26. The second panel member 28 is disposed on the first heat insulating member 26 by engaging the step 54 of the second panel member 28 with the first heat insulating member 30. The second panel member 28 does not contact the first panel member 26. As shown in FIG. 24, the cavity 34 formed when the second panel member 28 is disposed on the first heat insulating member 30 is formed by the first base member 36 of the first panel member 26, the first heat insulating member 30, the third wall portion 48 of the second panel member 28, the second flange 46 of the second panel member 28, the second wall portion 44 of the second panel member 28, and the second base 42 of the second panel member 28. The height H1 of the third wall portion 48 is smaller than the height H2 of the first heat insulating member 30.

[0055] As shown in FIG. 24, in the extending direction of the first flange 40, a first gap G1 is disposed between the inner edge of the first flange 40 of the first panel member 26 and the second wall portion 44 of the second panel member 28. As shown in FIGS. 14 and 24, the second panel member 38 is disposed on the first heat insulating member 30 such that a part of the first heat insulating member 30 is exposed.

[0056] As shown in FIG. 24, a second gap G2 is disposed between the upper edge of the third wall portion 48 of the second panel member 28 and the first base member 36 of the first panel member 26. The upper edge 48A of the third wall portion 48 is disposed spaced apart from the inner surface 36B of the first base member 36 in the extending direction of the third wall portion 48.

[0057] The first gap G1 and the second gap G2 are of any suitable length, preferably both are greater than about 3 / 4 inch. More preferably, the second panel member 28 is disposed on the first heat insulating member 30 such that the second panel member 28 is spaced apart from the first panel member 26 by at least 1 inch at all points, that is, is disposed with a gap. In other words, when the second panel member 28 is disposed on the first heat insulating member 30, it is preferable that no part of the second panel member 28 is within 1 inch of any part of the first panel member 26.

[0058] The assembled first panel assembly 26, second panel assembly 28, and first heat insulating member 30 are then moved to a normal press, and the second heat insulating member 32 is injected. The press maintains the positions of the first panel assembly 26, second panel assembly 28, and first heat insulating member 30 while the second heat insulating member 32 is being injected. It is not necessary to use an adhesive, tape, or other fixing means to integrally fix the first panel member and the second panel member. As shown in FIG. 25, the second heat insulating member 32 is injected into the cavity 34 formed by the first panel member 26, first heat insulating member 30, and second panel member 28. The second heat insulating member 32 is injected through the injection opening 44h (FIG. 17) in the third wall portion 44 of the second panel member 28. The air vent holes 44G (FIGS. 11 to 15 and FIG. 17) facilitate the escape of air within the panel assembly 18 when the second heat insulating member 32 is injected into the cavity 34. When the second heat insulating member 32 hardens and the first panel assembly 26 and second panel assembly 28 are integrally fixed, the panel assembly 18 is removed from the press. The first heat insulating member 30 extends outward beyond the second heat insulating member 32 in the width direction of the panel assembly 18. Then, by connecting the panel assembly 18 to the frame structure 16, the cabinet 20 of the air handler unit 10 can be formed.

[0059] As shown in FIGS. 20, 21, and 24, the thermal break of the panel assembly 18 is obtained by the gaps G1 and G2. The gaps G1 and G2 interrupt the flow of thermal energy through the panel assembly 18, increase the thermal resistance of the panel assembly 18, and can substantially eliminate thermal loss points that may cause condensation on the outer and inner surfaces of the panel assembly 18. The first heat insulating member 30 reinforces the edge of the panel assembly 18, whereby the panel assembly 18 can withstand the pressure associated with the injection of the second heat insulating member 32 without the need to fit a frame along the outer edge of the panel assembly 18 during the injection of the second heat insulating member 32. For this reason, thin sheet metal can be used for the first panel member 26 and the second panel member 28. This is because the configuration of the panel assembly 18 eliminates the need for edge support to resist the foam pressure associated with the injection of the second heat insulating member 32. The first heat insulating member 30 covers the fastening holes 36G, 40A (FIG. 16) of the first panel member 26 and prevents leakage during the injection and curing of the second heat insulating member 32. The step 54 (FIG. 24) of the second panel member 28 enables the second panel assembly 28 to be easily positioned with respect to the first panel member 26 and the first heat insulating member 30 without the need for tape, adhesive, or positioning tools, and the panel assembly can be assembled quickly and efficiently. The step 54 increases the moment of inertia of the panel assembly 18, and thus can reduce the deflection of the first panel member 26 and the second panel member 28 when there is a high pressure difference associated with the operation of the air handler component (FIG. 1) disposed in the air handler unit 10.

[0060] Then, the assembled panel assembly 18 is connected to the first frame member 12 and the second frame member 14 of the frame structure 16, and the cabinet 20 is assembled. The panel assembly 18 can be assembled at the store and transported to the site where the cabinet 20 is constructed. The first panel member 26 and the second panel member 28 are compatible with an automated bender, and the first panel member 26 and the second panel member 28 can be manufactured quickly and efficiently with minimal manual labor. After connecting the panel assembly 18 to the frame structure 16, the panel assembly 18 can be easily removed, and access to the interior of the cabinet 20 can be obtained. In one aspect, the floor panel 18 is attached to provide a waterproof seal, in which case the floor panel is not removable for accessing the interior of the cabinet 20. Alternatively, in one aspect, some of the panels 18 are made removable for accessing the interior of the cabinet 20.

[0061] <General description of terms> In understanding the scope of the present invention, as used herein, the term "comprising" and its derivatives mean open-ended terms specifying the presence of the recited features, elements, components, groups, entities, and / or steps, and do not preclude the presence of features, elements, components, groups, entities, and / or steps not recited. The above also applies to terms having similar meanings such as the terms "having", "including" and their derivatives. Also, the terms "part", "section", "portion", "member" or "element" used in the singular can have two meanings, a single part or a plurality of parts.

[0062] As used herein to describe the operations or functions performed by components, sections, devices, etc., the term "detect" includes not only components, sections, devices, etc. that do not require physical detection, but also decisions, measurements, modeling, prediction, or calculations, etc. for performing such operations or functions.

[0063] As used herein, the term "configured" when used to describe a component, section of a device, or part / component is intended to include hardware and / or software that is constructed and / or programmed to realize a desired function.

[0064] As used herein, terms indicating degree such as "substantially", "approximately", "about" are used to mean a change amount of appropriate modification conditions such that the final result does not change significantly.

[0065] It should be apparent to those skilled in the art from this disclosure that only some examples have been selected for the description of the present invention, and various changes and modifications can be made without departing from the scope of the present invention described in the appended claims. For example, the size, shape, arrangement, and orientation of various components can be changed as necessary and / or desired. Components shown as being directly connected or in contact with each other can have an intermediate structure therebetween. The function of one element can be achieved by two, and vice versa. The structure and function of one aspect can also be applied to other aspects. It is not necessary that all advantages be brought about simultaneously in a particular aspect. Each feature that differentiates from the prior art is considered incidentally as part of a further invention by the applicant that includes the structural or functional idea implemented by such feature, either alone or in combination with other features. Thus, it should be apparent to those skilled in the art from this disclosure that the foregoing description of the embodiments of the present invention is merely illustrative and does not limit the present invention determined by the appended claims and their equivalents.

Claims

1. A first panel member having a first base member, a first wall portion extending outward from an outer edge of the first base member, and a first flange extending inward from an upper end of the first wall portion; A second panel member having a second base member, a second wall portion extending outward from an outer edge of the second base member, a second flange extending inward from an upper end of the second wall portion, and a third wall portion extending outward from an inner edge of the second flange; A first heat insulating member disposed between the first wall portion of the first panel member and the third wall portion of the second panel member; A second heat insulating member disposed between the first base member of the first panel member and the second base member of the second panel member; A gap in the extending direction of the first flange, disposed between an inner edge of the first flange of the first panel member and the second wall portion of the second panel member; A thermal break panel assembly comprising the above.

2. The first wall portion extends from the entire outer edge of at least one of the first base members, and the first flange extends from the entire upper end of the first wall portion. The thermal break panel assembly according to claim 1. The thermal break panel assembly according to claim 1.

3. The width of the first heat insulating member is larger than the width of the first flange of the first panel member. The thermal break panel assembly according to claim 1 or 2. The thermal break panel assembly according to claim 1 or 2.

4. The second flange and the third wall portion of the second panel member form a step in contact with the first heat insulating member. The thermal break panel assembly according to claim 1 or 2. The thermal break panel assembly according to claim 1 or 2.

5. A cavity is formed by the first base member of the first panel member, the first heat insulating member, the third wall portion of the second panel member, the second flange of the second panel member, the second wall portion of the second panel member, and the second base member of the second panel member, and the second heat insulating member is disposed in the cavity. The thermal break panel assembly according to claim 1 or 2. The thermal break panel assembly according to claim 1 or 2.

6. The first panel member is integrally formed as a single member from sheet metal having a thickness of 14 gauge or less. The thermal break panel assembly according to claim 1 or 2. The thermal break panel assembly according to claim 1 or 2.

7. A plurality of fastening holes are formed in the first panel member so as to extend from an outer surface to an inner surface of the first flange. The first heat insulating member covers each of the plurality of fastening holes on the inner surface of the first flange. The first heat insulating member covers each of the plurality of fastening holes on the inner surface of the first flange. The thermal break panel assembly according to claim 1 or 2.

8. The height of the third wall portion is smaller than the height of the first heat insulating member. The thermal break panel assembly according to claim 1 or 2.

9. The first heat insulating member extends further outward than the second heat insulating member in the width direction of the thermal break panel assembly. The thermal break panel assembly according to claim 1 or 2.

10. The upper end of the third wall portion is spaced apart from the inner surface of the first base member in the extending direction of the third wall portion. The thermal break panel assembly according to claim 1 or 2.

11. A plurality of frame members forming a frame structure; A plurality of thermal break panel assemblies removably connected to the plurality of frame members so as to form an air handler cabinet; An air handler unit comprising: Each of the plurality of thermal break panel assemblies A first panel member having a first base member, a first wall portion extending outward from an outer edge of the first base member, and a first flange extending inward from an upper end of the first wall portion; A second panel member having a second base member, a second wall portion extending outward from an outer edge of the second base member, a second flange extending inward from an upper end of the second wall portion, and a third wall portion extending outward from an inner edge of the second flange; A first heat insulating member disposed between the first wall portion of the first panel member and the third wall portion of the second panel member; A second heat insulating member disposed between the first base member of the first panel member and the second base member of the second panel member; A first gap in the extending direction of the first flange, disposed between an inner edge of the first flange of the first panel member and the second wall portion of the second panel member; A second gap disposed between an upper end of the third wall portion of the second panel member and the first base member of the first panel member; An air handler unit including the same.

12. Both the first gap and the second gap are greater than about 3 / 4 inch. The air handler unit according to claim 11.

13. Each side portion of the air handler unit includes at least one of the plurality of thermal break panel assemblies. The air handler unit according to claim 11 or 12.

14. Any one of the plurality of thermal break panel assemblies is removable from the plurality of frame members so as to be accessible inside the air handler cabinet. The air handler unit according to claim 11 or 12.

15. A method of forming a thermal break panel assembly according to claim 1, comprising: placing an outer surface of a first panel member on a support; inserting a first heat insulating member into a groove formed in the first panel member; placing a second panel member on the first heat insulating member such that the second panel member does not contact the first panel member; injecting a second heat insulating member into a cavity formed by the first panel member, the first heat insulating member, and the second panel member. A method of forming a thermal break panel assembly comprising the above steps.

16. The step of placing the second panel member on the first heat insulating member includes positioning the second panel member by engaging a step formed in the second panel member with the first heat insulating member. The method of forming a thermal break panel assembly according to claim 15.

17. The first heat insulating member covers a plurality of fastening holes of the first panel member, thereby substantially preventing the injected second heat insulating member from leaking through the plurality of fastening holes. The method of forming a thermal break panel assembly according to claim 15 or 16.

18. The second panel member is placed on the first heat insulating member such that a part of the first heat insulating member is exposed. The method of forming a thermal break panel assembly according to claim 15 or 16.

19. The second panel member is placed on the first heat insulating member such that the second panel member is at least 1 inch away from the first panel member at all points. The method of forming a thermal break panel assembly according to claim 15 or 16.

20. The first heat insulating member is inserted such that an entire inner edge of the first panel member contacts the first heat insulating member. The method of forming a thermal break panel assembly according to claim 15 or 16.

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