US 7,152,383 B1 · Joining of foam core panels

Abstract

A blind connection for joining foam core panels which comprise a central sheet of foamed resinous material having top and bottom rails and veneers bonded to opposite sides of the central sheet and the rails. The rails having abutting side edge faces with matching slots formed along the length of the side edges. Te slots have undercut retaining surfaces which are engaged by retaining surfaces formed on a joining member which is inserted into these slots in joining the panels in assembled relation. The use of modified joining members in connecting foam core panels that are in angled relation to each other is also described. Wear resistant retaining surfaces may be provided for slots in the foam core by solid polymer liners. Additionally a method customizing panels on an installation job site is provided through the use of portable electrically powered saw to cut a panel to a desired width and a portable electrically powered router to form and undercut slot for receiving a joining member.

Claims34

Dependent claims

An assembly of foam core panels comprising a pair of panels in joined relation wherein

each panel comprises
a foam slab of foamed plastic material having opposed lateral surfaces spaced apart by the thickness of the slab,
the lateral surface area of the panel being defined at least in part by the lateral surface area of the slab, and
veneers, respectively bonded to the lateral surfaces of the slab, and
each panel has an abutting surface formed and defined by a portion of the its foam slab, and
means for joining said panels with said abutting surfaces held in engaged relation,
characterized in that the joining means comprise
slots formed, respectively, in said foam slabs, said slots extending inwardly from said abutting surfaces,
each slot being undercut to form retaining surfaces facing away from the
abutting surface in which it is formed, and
a joining member inserted into said slots,
said joining member having retaining surfaces
respectively engaging the retaining surfaces of said slots,
thereby maintaining the panels in joined relation with said abutting surfaces maintained in abutting and engaged relation.

11 more elements

A method of forming an assembly of foam core panels comprising a pair of panels in joined relation wherein

each panel comprises
a foam slab of foamed plastic material having opposed lateral surfaces spaced apart by the thickness of the slab,
the lateral surface area of the panel being defined at least in part by the lateral surface area of the slab, and
veneers, respectively bonded to the lateral surfaces of the slab and;
each panel has an abutting surface formed and defined by a portion of its foam slab, characterized in that
the slab of each panel has a slot formed therein and extending inwardly from the abutting surface thereof,
each slot being undercut to form retaining surfaces facing away from the abutting surface in which it is formed,
said method comprising the steps of
bringing the two panels into an assembled relation with said abutting surfaces in abutting and engaged relation and
connecting the two panels in this assembled relation by longitudinally introducing a joining member into said slots so as to bring retaining surfaces on said joining member into engagement with the undercut, retaining surfaces on the respective panels.

7 more elements

Dependencies are inferred from the claim text.

Joining of foam core panels

Life of this patent

Joining of foam core panels

Life of this patent

Abstract

Claims34