Thermally broken panel assembly for an air handler cabinet

An HVAC unit comprising:

• a plurality of frame members defining a frame structure;
• and
• a plurality of thermally broken panel assemblies connected to the plurality of frame members to define a cabinet;
• each of the plurality of thermally broken panel assemblies including
• a first panel member including
• a first base member;
• and
• a first wall extending outwardly from an outer edge of the first base member;
• a second panel member including
• a second base member;
• a second wall extending outwardly from an outer edge of the second base member;
• and
• a second flange extending from an upper end of the second wall;
• a first insulating member disposed between the first base member of the first panel member and the second flange of the second panel member;
• a second 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 disposed between an edge of the first wall of the first panel member and the second wall of the second panel member;
• and
• a second gap disposed between the second flange of the second panel member and the first base member of the first panel member.

A method of forming a thermally broken panel assembly, comprising the steps of

• inserting a first insulating member in a corner formed in a first panel member;
• disposing a second panel member on the first insulating member, the second panel member not being in contact with the first panel member;
• and
• injecting a second insulating member in a cavity defined by the first panel member, the first insulating member, and the second panel member.