Foam core panel with interlocking skins and thermal break

A panel comprising a planar core of generally rectangular configuration formed of resilient polymeric foam and having its opposite faces engaged and covered by a pair of generally planar and rectangular sheet metal skins;

• each skin having a pair of inturned flanges extending generally at right angles to the plane of such skin along opposite longitudinal edges thereof;
• one of the flanges of each skin terminating in an outwardly and reversely turned longitudinally-elongated hook portion and the other of the flanges of such skin terminating in an inwardly and reversely turned longitudinally-elongated hook portion;
• said inwardly-turned and outwardly-turned hook portions of one of said skins being interlocked with the outwardly-turned and inwardly-turned hook portions, respectively, of the other of said skins;
• said resilient core being disposed between said skins and urging said skins outwardly to maintain the respective hook portions thereof in interlocking relation;
• and a pair of elongated thermal barrier members of flexible thermoplastic material interposed between the interlocking hook portions of said skins and preventing direct contact between said interlocking hook portions;
• each thermal barrier member including an elongated, integral, bead portion disposed externally of the interlocking hook portions of said flanges to provide a resilient cushion along each longitudinal edge of said panel.

A method of forming a panel for overhead doors and the like, comprising the steps of pre-forming two generally, flat rectangular, rigid metal skins to provide each with a pair of inturned side flanges along opposite longitudinal edges thereof;

• the flanges of each skin having hook portions capable of interlocking with the hook portions of the other of said skins to define a space between said skins for receiving a thermally-insulating foam core;
• positioning said skins along opposite sides of a resilient, planar foam core having a thickness in an uncompressed state greater than the width of said space;
• urging said skins towards each other to compress said core therebetween and advance the hook portions of said flanges into aligned relation so that upon release of said compressive forces the restorative forces exerted by said resilient foam core will urge said hook portions of the two skins into interlocking relation;
• interposing resilient thermal barrier elements between the hook portions of the two skins to prevent direct contact between said skins when said compressive forces are released;
• and thereafter releasing the compressive forces exerted on the skins so that the restorative forces exerted by said resilient foam core urge and maintain said hook portions in interlocking relation and retain said thermal barrier elements in place.