초록 ▼

Insulated panels and methods of forming insulated panels are provided. According to the method, mold bulkhead and a sealing strip including a first anchor extension, a second anchor extension, and a panel cap are provided. The method also includes removably attaching the exterior face of the sealing

Insulated panels and methods of forming insulated panels are provided. According to the method, mold bulkhead and a sealing strip including a first anchor extension, a second anchor extension, and a panel cap are provided. The method also includes 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. A curable building material is introduced into the interior mold volume to form a first slab. The first slab at least partially surrounds the first anchor extension. The method also includes inserting an insulation material layer into the interior mold volume, wherein the insulation material layer is at least partially within the sealed insulation zone. A curable building material is introduced into the interior mold volume adjacent to the insulation material layer to form a second slab. The second slab at least partially surrounds the second anchor extension. The method also includes the step of 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.

대표청구항 ▼

1. 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 p

1. 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; andallowing 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. 2. The method of claim 1, wherein the first anchor extension and the second anchor extension each comprise a plurality of anchoring apertures. 3. The method of claim 2, wherein the plurality of anchoring apertures comprise round holes having a diameter ranging from approximately 0.5 cm to approximately 3 cm. 4. The method of claim 2, wherein the plurality of anchoring apertures are encompassed by the curable building material. 5. The method of claim 1, wherein the at least one sealing strip is removably attached to at least three mold sides. 6. The method of claim 1, wherein a distal edge of the first anchor extension is provided at a distance greater than approximately 3 cm from the first major face, and wherein a distal edge of the second anchor extension is provided at a distance greater than approximately 3 cm from the second major face. 7. The method of claim 1, wherein the first anchor extension and the second anchor extension each respectively extend at an angle ranging from approximately 45° to approximately 135° relative to the interior face. 8. The method of claim 1, wherein the first anchor extension and the second anchor extension each respectively extend along an anchoring vector selected to ensure that respective distal edges of the first and second anchor extensions are displaced from the major and intermediate faces of the insulated panel by at least approximately 3 cm. 9. The method of claim 1, wherein the sealing strip comprises a polymer. 10. The method of claim 1, wherein the insulation material layer comprises polystyrene. 11. The method of claim 1, wherein the sealing strip is attached to the interior mold surface using a removable adhesive. 12. The method of claim 1, wherein the sealing strip comprises an extruded monolithic structure. 13. The method of claim 1, wherein the mold bulkhead is substantially rectangular. 14. The method of claim 1, further comprising separating the insulated panel from the mold bulkhead to allow the sealing strip to remain integrated within the insulated panel. 15. A method of forming an insulated panel comprising a first major face, a second major face, 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, wherein the first anchor extension and second anchor extension comprise a plurality of anchoring apertures, and wherein the first anchor extension and the second anchor extension respectively extend at an angle ranging from approximately 100° to approximately 135° relative to the interior face;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; andallowing 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.