초록 ▼

An improved truck bed toolbox lid and a method of producing the same. The truck bed toolbox lid includes an outer metallic sheet layer comprising a generally rectangular top sheet member, a longitudinal front edge member, two lateral edge members and a longitudinal rear edge member. A metallic liner

An improved truck bed toolbox lid and a method of producing the same. The truck bed toolbox lid includes an outer metallic sheet layer comprising a generally rectangular top sheet member, a longitudinal front edge member, two lateral edge members and a longitudinal rear edge member. A metallic liner sheet member is disposed inside the top sheet member in edge contact abutment with beveled inside edges of the front and rear longitudinal edge members and the lateral edge members to create an internal cavity in which the liner is by stitch welding. One or more injection ports are provided through the liner sheet member through which a self-expanding and self-curing, relatively high-density, foam is injected. The stitch welded edge contacts leave non-welded, gas permeable junctions along the wedged cavity periphery at a funneled apex of the edge contacted boundary which facilitate expansion of the foam toward the outermost edges of the cavity.

대표청구항 ▼

We claim: 1. A truck bed toolbox lid comprising: a substantially flat metallic top sheet member having a depending front edge member, a depending rear edge member and depending lateral edge members; a substantially flat metallic liner sheet member joined to said top sheet member so as to define an

We claim: 1. A truck bed toolbox lid comprising: a substantially flat metallic top sheet member having a depending front edge member, a depending rear edge member and depending lateral edge members; a substantially flat metallic liner sheet member joined to said top sheet member so as to define an internal cavity; and a rigid, expanded, cured foam disposed within said internal cavity and bonded to said top sheet member and said liner sheet member, characterized in that said foam is injected into said cavity in an uncured, unexpanded state and expands and cures so as to self-bond to the metallic surfaces of said top sheet member and said liner sheet member to form an integral, composite truck bed toolbox lid; said truck bed toolbox lid further comprising a hot melt adhesive sealing member disposed alone the perimeter of said liner sheet member, whereby upon cooling said hot melt adhesive sealing member forms a seal between the inside surface of said top sheet member and the outer edge perimeter of said liner sheet member to retain said foam within said internal cavity. 2. The truck bed toolbox lid of claim 1, further comprising a plurality of stitch weld joints connecting the outer edge perimeter of said liner sheet member to said top sheet member. 3. The truck bed toolbox lid of claim 1, wherein said foam is a high density polyurethane foam. 4. A truck bed toolbox lid comprising: a substantially flat metallic top sheet member having a depending front edge member, a depending rear edge member and depending lateral edge members; a substantially flat metallic liner sheet member joined to said top sheet member so as to define an internal cavity; and a rigid, expanded, cured foam disposed within said internal cavity and bonded to said top sheet member and said liner sheet member, characterized in that said foam is injected into said cavity in an uncured, unexpanded state and expands and cures so as to self-bond to the metallic surfaces of said top sheet member and said liner sheet member to form an integral, composite truck bed toolbox lid; characterized in that said lid remains uncrimped with no permanent set upon deflection up to approximately 6.25 inches under up to approximately 480 psi when said lid is secured on a horizontal platform with approximately half said lid extending beyond said platform and subjected to center pressure adjacent one of said lateral edge members. 5. A truck bed toolbox lid comprising: a substantially flat metallic top sheet member having a depending front edge member, a depending rear edge member and depending lateral edge members; a substantially flat metallic liner sheet member joined to said ton sheet member so as to define an internal cavity; and a rigid, expanded, cured foam disposed within said internal cavity and bonded to said top sheet member and said liner sheet member, characterized in that said foam is injected into said cavity in an uncured, unexpanded state and expands and cures so as to self-bond to the metallic surfaces of said top sheet member and said liner sheet member to form an integral, composite truck bed toolbox lid; characterized in that said lid remains uncrimped with no permanent set upon deflection up to approximately 7.5 inches under up to approximately 490 psi when said lid is secured on a horizontal platform with approximately half said lid extending beyond said platform and subjected to corner pressure adjacent one of said lateral edge members. 6. The truck bed toolbox lid of claim 1, wherein said top sheet member is formed of an aluminum sheet having a thickness of approximately 0.063 mil. 7. The truck bed toolbox lid of claim 1, wherein said liner sheet member is disposed generally parallel to said top sheet member. 8. The truck bed toolbox lid of claim 1, wherein at least one of said front edge member, said depending rear edge member and said depending lateral edge members is a hemmed edge. 9. The truck bed toolbox lid of claim 1, wherein said internal cavity is approximately one half to three quarter inches in depth between said top sheet member and said liner sheet member. 10. A truck bed toolbox lid comprising: a substantially flat metallic top sheet member having a depending front edge member, a depending rear edge member and depending lateral edge members, wherein an edge perimeter is formed along the depending front, rear and lateral edge members; a substantially flat metallic liner sheet member joined to said top sheet member in edge contact abutment with said edge perimeter so as to define an internal cavity having a funneled, gas permeable apex boundary; and a rigid, expanded, cured foam disposed within said internal cavity and bonded to said top sheet member and said liner sheet member, characterized in that said foam is injected into said cavity in an uncured, unexpanded state, expands toward said funneled, gas permeable apex boundary and cures so as to self-bond to the metallic surfaces of said top sheet member and said liner sheet member to form an integral, composite truck bed toolbox lid; further comprising a plurality of stitch weld joints that fixedly couple the perimeter of said liner sheet member with said edge perimeter, such that gas permeable, non-welded gaps remain between said plurality of stitch weld joints. 11. The truck bed toolbox lid of claim 10, wherein said edge perimeter is beveled. 12. The truck bed toolbox lid of claim 4, wherein said liner sheet member is disposed generally parallel to said top sheet member. 13. The truck bed toolbox lid of claim 4, wherein at least one of said front edge member, said depending rear edge member and said depending lateral edge members is a hemmed edge. 14. The truck bed toolbox lid of claim 5, wherein said liner sheet member is disposed generally parallel to said top sheet member. 15. The truck bed toolbox lid of claim 5, wherein at least one of said front edge member, said depending rear edge member and said depending lateral edge members is a hemmed edge. 16. The truck bed toolbox lid of claim 10, wherein said top sheet member is formed of an aluminum sheet having a thickness of approximately 0.063 mil. 17. The truck bed toolbox lid of claim 10, wherein said liner sheet member is disposed generally parallel to said top sheet member. 18. The truck bed toolbox lid of claim 10, wherein at least one of said front edge member, said depending rear edge member and said depending lateral edge members is a hemmed edge. 19. The truck bed toolbox lid of claim 10, wherein said internal cavity is approximately one half to three quarter inches in depth between said top sheet member and said liner sheet member.