Insulated building panels and structure constructed therewith

Claim 2

An airtight and sound attenuated enclosure assembled from a plurality of prefabricated wall, ceilinng, floor and septum panels, each of said wall and ceiling panels comprising a solid exterior facing member, a perforated interior facing member formed in a substantially pan shape having bent edges therearound said bent edges extending to and engaging said exterior facing and cooperating with said exterior facing member to define a sound attenuating space therebetween, insulating material carried in said space to provide the sound attenuation, said solid facing member being a continuous sheet and including a solid return face overlapping the edges of said perforated facing member to define an individual panel, each panel providing a portion of the solid return facing extending beyond the facing surface of said perforate member and generally into the interior of said enclosure, the solid return face of one panel cooperating with a like solid return face of an adjoining panel so as to provide a multiplicity of facing members side by side and to define a seam therebetween, and means connecting said projecting faces together along said seam, said connecting means extending continuously along said seam to provide an airtight seam between the adjoining panels wherein individual panels can be removed by removing said connecting means therefrom.

Claim 3

The enclosure as set forth in claim 1 in which said sealing means is a continuous bead of brazing material.

Claim 4

The enclosure as set forth in claim 2 further comprising a corner wall panel, said corner panel including a pan shaped perforated inner facing member, a solid facing member spaced from said perforated member and having a return face extending outwardly from the edge of said pan shaped perforated member and returning to the lower surface of said perforated member to define a substantially rectangular chamber therebetween, insulating material being carried in the space defined between said perforated member and said solid facing member and in the space defined by said solid return face and said perforated member, said solid return face cooperatively receiving the end of an adjoining panel in a manner to be secured thereto.

Claim 5

The enclosure as set forth in claim 2 further comprising a corner ceiling panel in which said corner ceiling panel comprises a pan shaped perforated inner facing member, a solid facing member spaced from said perforated member and having a return face extending outwardly from the edge of said pan shaped perforated member and returning to the lower surface of said perforated member to define a substantially rectangular chamber therebetween, insulating material being carried in the space defined between said perforated member and said solid facing member and in the space defined by said solid return face and said perforated member, said solid return face cooperatively receiving the end of an adjoining panel in a manner to be secured thereto.

Claim 6

The enclosure as set forth in claim 2 comprising a modified wall panel adapted to cooperatively receive a panel perpendicular thereto, said modified panel comprising first and second pan shaped perforated facing members, a solid pan shaped member positioned between said perforated members and separating said members, a solid facing member enclosing said pan shaped members to define three chambers therein, insulating material being carried in said three chambers, said solid facing members having return faces engaging the opposite ends of said pan shaped members and projecting beyond the plane of said members, said solid pan shaped member providing a solid face to cooperatively receive an adjoining panel in perpendicular fashion thereto wherein the perpendicular panel may be sealingly secured to said solid pan shaped member.

Claim 7

The enclosure as set forth in claim 2 further comprising a modified septum panel to cooperatively receive an adjoining panel perpendicular thereto, said modified septum panel comprising first and second pan shaped perforated members, a solid pan shaped member, said first and second members and said solid member lying in a common plane, a third pan shaped perforated facing member having a dimension greater than the combined dimension of said first and second members and said solid pan shaped member wherein the open sides of said members are received within the open side of said third pan shaped open member, a solid facing member positioned between said third pan shaped member and said first and second pan shaped members and said solid pan shaped member, said solid facing members providing a solid return face projecting beyond the plane of said first and second pan shaped members, said solid pan shaped member defining a solid face to cooperatively receive the end of a perpendicularly placed panel wherein said perpendicular panel can be sealingly secured thereto.

Claim 8

The enclosure as set forth in claim 2 further comprising a floor panel adapted to be supported between two vertical wall panels, said floor panel comprising first and second perforated facing members, a solid facing member supported therebetween to define attenuating chambers on each side thereof, first and second pan shaped solid members being mounted on either side of said solid facing member, each pan shaped solid member lying in the plane of said pan shaped perforated members and being secured therein by said solid facing member, said solid pan shaped members providing panel receiving surfaces for receiving said vertical wall panels in sealing fashion thereto.

Claim 9

The enclosure as set forth in claim 2 further comprising a supporting panel, said supporting panel comprising first and second solid facing members defining an enclosed space therebetween, a reinforing support member being secured within said space and engaging the interior surface of both said facing members.

Claim 10

The enclosure as set forth in claim 2 wherein said wall panel houses a rectangular bellmouth therein.

Claim 11

The enclosure as set forth in claim 2 wherein said wall panel houses a round bellmouth.

Claim 12

The enclosure as set forth in claim 2 in which said wall panel houses a window therein.

Claim 13

The enclosure as set forth in claim 11 in which said window comprises a frame secured between said solid facing member and perforated facing member, said frame being shaped to cooperatively receive a gasket on either side thereof, a pane of glass being mounted adjacent each gasket, a second gasket opposite each pane of glass, and an exterior frame formed to urge said gaskets and window glass into engagement with said frame thereby providing an airtight window construction.

Claim 14

The enclosure as set forth in claim 2 in which said wall panel inclues a reinforcing channel for receiving and supporting an angle plate upon which a ceiling support beam can be mounted.

Claim 15

The enclosure as set forth in claim 2 further comprising first, second, third and fourth door jamb panels, said panels defining an enclosed solid door jamb frame when connected one to the other thereby providing door entrance, each of said panels including a perforated facing member mounted within a solid facing member so as to define a chamber therebetween, a door panel pivotally secured to one of said door jambs, gasket means secured to each of said door jambs for cooperative engagement with said door in the closed position to provide an air seal therebetween, and lock means cooperating between a second door jamb and said door panel to lock said door in the closed position and thereby urge said door into sealing engagement with said gasket means.

Claim 16

The enclosure as set forth in claim 14 in which said one door jamb panel includes a backup angle member secured therein, and further comprising means to pivotally secure said door panel to said one door jamb panel.

Claim 17

The enclosure as set forth in claim 15 in which said door panel includes a backup member secured therein and in which said pivotal means is a plurality of hinges, each hinge being permanently secured to said door and one door jamb panel by welding, said weld extending from the hinge into the respective backup member.

Claim 18

An airtight and sound attenuated enclosure assembled from a plurality of prefabricated wall, ceiling, floor and septum panels, each of said wall and ceiling panels comprising a solid exterior facing member, a perforated interior facing member formed in a substantially pan shape having bent edges therearound and cooperating with said exterior facing member to define a sound attenuating space therebetween, insulating material carried in said space to provide the sound attenuation, said solid facing member being a continuous sheet and including a solid return face overlapping the edges of said perforated facing member to define an individual airtight panel, each panel providing a portion of the projecting solid facing extending generally into the interior of said enclosure, the projecting face of one panel cooperating with a like projecting face of an adjoining panel so as to provide multiplicity of facing members side by side and to define a seam therebetween, a continuous bead of brazing material sealing said seam from the interior of the enclosure to provide an airtight seam between the adjoining panels wherein individual panels can be removed by removing said sealing means therefrom, septum panels separating interior chambers of the enclosure, said septum panels comprising first and second pan shaped perforated facing members of different sizes, the open side of the smaller member being complementally received in the open side of the larger member, a solid facing member positioned between said first and second members to define sound attenuation chambers on either side, said solid member having a return face projecting through the space defined by the received first and second member edges and projecting outwardly beyond the plane of the smaller of said members to provide the securing face for said septum panel.

Claim 19

An airtight and sound attenuated enclosure assembled from a plurality of prefabricated wall, ceiling, floor and septum panels, each of said wall and ceiling panels comprising a solid exterior facing member, a perforated interior facing member formed in a substantially pan shape having bent edges therearound and cooperating with said exterior facing member to define a sound attenuating space therebetween, insulating material carried in said space to provide the sound attenuation, said solid facing member being a continuous sheet and including a solid return face overlapping the edges of said perforated facing member to define an individual airtight panel, each panel providing a portion of the projecting solid facing extending generally into the interior of said enclosure, the projecting face of one panel cooperating with a like projecting face of an adjoining panel so as to provide multiplicity of facing members side by side and to define a seam therebetween, a continuous bead of brazing material sealing said seam from the interior of the enclosure to provide an airtight seam between the adjoining panels wherein individual panels can be removed by removing said sealing means therefrom, septum panels separating interior chambers of the enclosure, said septum panels comprising first and second pan shaped perforated facing members of different sizes, the open side of the smaller member being complementally received in the open side of the larger member, a solid facing member positioned between said first and second members to define sound attenuation chambers on either side, said solid member having a return face projecting through the space defined by the received first and second member edges and projecting outwardly beyond the plane of the smaller of said members to provide the securing face for said septum panel.

Claim 20

The enclosure as set forth in claim 17 further comprising corner panels in which the corner panels includes one edge of said pan shaped perforated facing member serving as a stiffening member, the return face of said solid facing member extending outwardly from said edge and returning to the lower surface of said perforated member to define a substantially rectangular chamber, therebetween, insulating material being carried in the space defined therebetween, said solid return face cooperatively receiving the end of an adjoining panel in a manner to be secured thereto.

Claim 21

The panels as set forth in claim 17 in which the corner ceiling panel includes one edge of said pan shaped perforated facing member serving as a stiffening member, the return face extending outwardly from the edge of said perforated member and returning to the lower surface of said perforated member to define a substantially rectangular chamber therebetween, insulating material being carried in the space defined therebetween said solid return face cooperatively receiving the end of an adjoining panel in a manner to be secured thereto.

Claim 22

The panels as set forth in claim 17 wherein the floor panel is adapted to be supported between two vertical wall panels and in which said floor panel comprises first and second pan shaped solid members being mounted on either side of said solid facing member in abutting relationship with said perforated facing members, each pan shaped solid member lying in the plane of said pan shaped perforated members and being secured therein by said solid facing member, said solid pan shaped members providing panel receiving surfaces for receiving said vertical wall panels in sealing fashion thereto.

Claim 23

The panels as set forth in claim 17 further comprising a modified wall panel adapted to cooperatively receive a panel perpendicular thereto wherein said perforated facing member includes first and second pan shaped perforated members, a solid pan shaped member positioned between said perforated members and separating said members, said solid facing members enclosing said pan shaped members to define three chambers therein, insulating material being carried in said three chambers, and said solid pan shaped member providing a solid face to cooperatively receive an adjoining panel in perpendicular fashion thereto wherein the perpendicular panel may be sealingly secured to said solid pan shaped member.

Claim 24

The enclosure as set forth in claim 17 further comprising a modified septum panel to cooperatively receive an adjoining panel perpendicular thereto wherein one of said perforated facing members includes first and second pan shaped perforated members, a solid pan shaped member, said first and second pan shaped members and said solid member lying in a common plane and defining chambers in cooperation with said solid facing member, insulating material being carried in said chambers, and said solid pan shaped member defining a solid face to cooperatively receive the end of a perpendicularly placed panel wherein said perpendicular panel can be sealingly secured thereto.

Claim 25

The panels as set forth in claim 17 further comprising a supporting panel, said supporting panel comprising first and second solid facing members defining an enclosed space therebetween, a reinforcing support member being secured within said space and engaging the interior surface of both said facing members.

Claim 26

The panels as set forth in claim 17 in which the wall panel houses a window therein, said window comprises a frame secured between said solid and perforated facing members, said frame being shaped to cooperatively receive a gasket on either side thereof, a pane of glass being mounted adjacent each gasket, a second gasket opposite each pane of glass, and an exterior frame formed to urge said gaskets and window glass into engagement with said frame thereby providing an airtight window construction.

Claim 27

The panels as set forth in claim 17 further comprising first, second, third and fourth door jamb panels, said panels defining a door entrance, each of said panels including a perforated facing member mounted within a solid facing member so as to define a chamber therebetween, a door panel pivotally secured to one of said door jambs, gasket means secured to each of said door jambs for cooperative engagement with said door in the closed position to provide an air seal therebetween, and lock means cooperating between a second door jamb and said door panel to lock said door in the closed position and thereby urge said door into sealing engagement with said gasket means.

Claim 28

The panels as set forth in claim 17 in which the wall panel further includes a reinforcing channel secured between said facing members for receiving and supporting an angle plate upon which a ceiling support beam can be mounted.

Claim 29

The panels as set forth in claim 17 in which said wall panels houses a rectangular bellmouth therein.

Claim 30

The panels as set forth in claim 17 in which said wall panel houses a round bellmouth therein.