초록 ▼

A door or other structural panel of the type which has a pair of opposed, congruent sheets spaced apart by a frame to define a separation space between the sheets which may be filled with a core, such as foam. The edge of each sheet has a zig-zag portion which defines a ledge on the outer side of th

A door or other structural panel of the type which has a pair of opposed, congruent sheets spaced apart by a frame to define a separation space between the sheets which may be filled with a core, such as foam. The edge of each sheet has a zig-zag portion which defines a ledge on the outer side of the sheet and a ridge on the inner side of the sheet. The frame member between the sheets at each edge has on each of two sides a projecting flange and a projecting hook which interlock with the zig-zag portion of the sheets to create a mechanical engagement between the sheets and the frame member. The flow of liquid foam into the separation space is controlled by a rib projecting inwardly from the sheet and by a resilient foam block slightly compressed between the sheets. Methods of manufacturing such panels are provided, including by sliding the beams onto the sheet edges and tapping the beams into a rigid state, and by employing temporary frame members which can be removed and re-used after the foam hardens.

대표청구항 ▼

A structural panel comprising: (a) a pair of opposed, congruent sheets spaced apart by a frame which includes a beam located longitudinally along an edge of each of the sheets, each sheet having an outer side and an inner side facing the inner side of the other sheet, the sheets defining a separatio

A structural panel comprising: (a) a pair of opposed, congruent sheets spaced apart by a frame which includes a beam located longitudinally along an edge of each of the sheets, each sheet having an outer side and an inner side facing the inner side of the other sheet, the sheets defining a separation space between them; (b) wherein the edge of each of the sheets has an inwardly projecting zig-zag defining a ledge on the outer side of the sheet and a ridge on the inner side of the sheet; (c) wherein along a longitudinal edge of the beam a flange extends from the beam, the flange having a connected leg which is an extension of said beam and is outward of said ledge and having a free leg overlying said ledge and, spaced apart from the flange, a hook projects from the beam into the separation space, the hook including a post projecting inwardly from the beam inward of said ledge and a cross member projecting outwardly from the post inward of said ridge toward the inner side of the sheet; and (d) wherein the sheet and the beam are adapted so that the ledge fits closely between the flange and the hook thereby establishing a mechanical engagement which restrains movement between the edge and the beam in two mutually orthogonal directions.