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A building panel for residential and commercial construction uses a plurality of insulating blocks connected together by adhesive. The insulation blocks are typically made of foam. A plurality of support members are disposed on opposite sides of the insulating blocks and offset with respect to the a

A building panel for residential and commercial construction uses a plurality of insulating blocks connected together by adhesive. The insulation blocks are typically made of foam. A plurality of support members are disposed on opposite sides of the insulating blocks and offset with respect to the adjacent support member. The support member are typically made of metal and can have different shapes including “T” shape, “U” shape, and “L” shape. Each support member has a head portion in contact with a surface of the insulating block and a stem portion extending into the insulating block and having a length less than a width of the insulating block so that a thermal conduction path of the support member is discontinuous across the insulating block. The panel can be used as a curtain wall panel in high-rise construction, as well as bodies for aircraft, automotive, and marine applications.

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1. A method of manufacturing a building panel for use in building a residential or commercial structure off-site at a manufacturing location that is geographically separate from an assembly location where the building panel is incorporated into the residential or commercial structure, said method co

1. A method of manufacturing a building panel for use in building a residential or commercial structure off-site at a manufacturing location that is geographically separate from an assembly location where the building panel is incorporated into the residential or commercial structure, said method comprising: assembling a plurality of panel forms to form a panel mold having a hollow cavity within the panel mold, an overall size and shape of the hollow cavity substantially defining an overall size and shape of the building panel, a width of the hollow cavity and a height of the hollow cavity substantially defining a width of the building panel and a height of the building panel, respectively;providing a first metal sheet;bending the first metal sheet to form a first T-shaped support member having a length that is substantially the same as a length of the first metal sheet, wherein bending the first metal sheet to form the first T-shaped support member consists of: bending the first metal sheet by substantially 90 degrees across the length of the first metal sheet to form a first portion of the first metal sheet and a second portion of the first metal sheet that is substantially perpendicular to the first portion of the first metal sheet, a length of the first portion of the first metal sheet less than the width of the hollow cavity;bending the second portion of the first metal sheet by substantially 180 degrees across the length of the first metal sheet to form a third portion of the first metal sheet that is substantially parallel to the second portion of the first metal sheet; andbending the third portion of the first metal sheet by substantially 180 degrees across the length of the first metal sheet to form a fourth portion of the first metal sheet such that the fourth portion of the first metal sheet is parallel to the third portion of the first metal sheet, and such that an end of the first metal sheet lies proximate to where the first metal sheet was bent by substantially 90 degrees across the length of the first metal sheet to form the first portion of the first metal sheet and the second portion of the first metal sheet;disposing the first T-shaped support member within the hollow cavity such that the length of the first T-shaped support member is substantially parallel to the height of the hollow cavity, such that the third portion of the first metal sheet substantially abuts an interior surface of the panel mold, and such that the first portion of the first metal sheet is substantially parallel to the width of the panel mold;providing a second metal sheet to form a planar support member having a length that is substantially the same as a length of the second metal sheet;disposing the planar support member within the hollow cavity such that the length of the planar support member is substantially parallel to the height of the hollow cavity, such that the planar support member does not contact the interior surface of the panel mold, and such that the planar support member forms a first angle with the interior surface of the panel mold, wherein the first angle is not a right angle;filling an unoccupied space in the hollow cavity of the panel mold with a semi-fluid insulating material; andsolidifying the semi-fluid insulating material to form an insulating material that surrounds and encases at least the first T-shaped support member and the planar support member. 2. The method of claim 1, further comprising: providing a third metal sheet;bending the third metal sheet to form a second T-shaped support member having a length that is substantially the same as a length of the third metal sheet, wherein bending the third metal sheet to form the second T-shaped support member consists of: bending the third metal sheet by substantially 90 degrees across the length of the first metal sheet to form a first portion of the third metal sheet and a second portion of the third metal sheet that is substantially perpendicular to the first portion of the third metal sheet, a length of the first portion of the third metal sheet less than the width of the hollow cavity;bending the second portion of the third metal sheet by substantially 180 degrees across the length of the third metal sheet to form a third portion of the third metal sheet that is substantially parallel to the second portion of the third metal sheet; andbending the third portion of the third metal sheet by substantially 180 degrees across the length of the third metal sheet to form a fourth portion of the third metal sheet such that the fourth portion of the third metal sheet is parallel to the third portion of the third metal sheet, and such that an end of the third metal sheet lies proximate to where the third metal sheet was bent by substantially 90 degrees across the length of the third metal sheet to form the first portion of the third metal sheet and the second portion of the third metal sheet;disposing the second T-shaped support member within the hollow cavity such that the length of the second T-shaped support member is substantially parallel to the height of the hollow cavity, such that the third portion of the third metal sheet substantially abuts another interior surface of the panel mold, and such that the first portion of the third metal sheet is substantially parallel to the width of the panel mold, wherein the interior surface of the panel mold and the another interior surface of the panel mold are opposite to each other. 3. The method of claim 2, wherein the first T-shaped support member and the second T-shaped support member are offset from one another such that a line drawn from where the first portion of the first metal sheet meets the second portion of the first metal sheet to where the first portion of the third metal sheet meets the second portion of the second metal sheet forms a second angle with the interior surface of the panel mold, wherein the second angle is not a right angle. 4. The method of claim 3, wherein the planar support member is disposed in the hollow cavity such that the line drawn from where the first portion of the first metal sheet meets the second portion of the first metal sheet to where the first portion of the third metal sheet meets the second portion of the second metal sheet is substantially perpendicular to the planar support member. 5. The method of claim 2, further comprising disposing the first T-shaped support member and the second T-shaped support member within the hollow cavity such that the first portion of the first metal sheet and the first portion of the second metal sheet are disposed in substantially the same plane. 6. The method of claim 5, further comprising disposing the first T-shaped support member and the second T-shaped support member within the hollow cavity such that the first portion of the first metal sheet and the first portion of the second metal sheet do not touch one another. 7. A method of manufacturing a building panel, comprising: providing an insulating block;providing a first metal sheet;bending the first metal sheet no more than three times to form a first support member consisting of a head portion and a stem portion, the head portion and the stem portion substantially planar in shape, the stem portion disposed substantially perpendicular to the head portion, wherein bending the first metal sheet no more than three times to form the first support member consists of: (a) bending the first portion of the first metal sheet by substantially 180 degrees to form a second portion of the first metal sheet that is substantially parallel to the first portion of the first metal sheet, and(b) bending the second portion of the first metal sheet by substantially 180 degrees to form a third portion of the first metal sheet such that the first, second, and third portions of the first metal sheet form the head portion of the first support member; andattaching the first support member to the insulating block such that a length of the first support member is substantially parallel to a height of the insulating block, such that the head portion abuts a surface of the insulating block and the stem portion partially penetrates the insulating block from the surface of the insulating block, wherein the surface of the insulating block is normal to a thickness of the insulating block, the thickness of the insulating block less than the height of the insulating block and less than a width of the insulating block. 8. The method of claim 7, further comprising: providing a second metal sheet to form a second support member that is substantially planar;encasing the second support member within the insulating block such that a length of the second support member is substantially parallel to the height of the insulating block and such that the second support member is surrounded by the insulating block. 9. The method of claim 8, wherein encasing the second support member within the insulating block comprises disposing the second support member within the insulating block in an angled manner such that a plane containing a width and a length of the second support member and a plane that is parallel to the length of the insulating block forms an angle that is less than ninety degrees.