Structural foamed panel and method of making the same

Abstract

A panel or multi-panel structure in which each of the panels includes a pair of spaced substantially planar sheets connected with one another by connection members and a foam core.

1 . A structural panel comprising: 
 a first substantially planar sheet having an inner surface and an outer surface;    a second substantially planar sheet having an inner surface and an outer surface, said first and second sheets spaced from one another with their respective inner surfaces facing one another;    the inner surface of one of said first and second sheets including a first connection member extending therefrom and the inner surface of the other of first and second sheets including a second connection member extending therefrom, said first and second connection members being connectable to one another to maintain said first and second sheets in spaced relationship; and    a foam core between said paced first and second sheets.    
   
   
       2 . The panel of  claim 1  wherein one of said first and second connection members includes a plurality of struts extending between said first and second sheets.  
   
   
       3 . The panel of  claim 2  wherein one end of said struts is integrally formed with one of said first and second sheets.  
   
   
       4 . The panel of  claim 3  wherein the other end of said struts includes a head having a pair of connection surfaces.  
   
   
       5 . The panel of  claim 4  wherein the other of said first and second connection members is integrally formed with the other of said first and second sheets.  
   
   
       6 . The panel of  claim 5  wherein one of said first and second connection members includes a pair of connection surfaces facing toward one another and the other of said first and second connection members includes a pair of connection surfaces facing away from one another.  
   
   
       7 . The panel of  claim 6  including an edge extending between said sheets around the periphery of said sheets.  
   
   
       8 . The panel of  claim 1  including an edge extending between said sheets around the periphery of said sheets.  
   
   
       9 . The panel of  claim 1  including a plurality of laterally spaced webs between said sheets.  
   
   
       10 . A method of making a structural panel comprising: 
 providing first and second substantially planar sheets;    connecting said first and second sheets to one another in spaced relationship; and    injecting a foam material between said first and second spaced sheets.    
   
   
       11 . The method of  claim 10  including forming an edge between said sheets and around the periphery of said sheets.  
   
   
       12 . A multi-panel structure comprising: 
 a first foamed panel having a pair of spaced, substantially planar sheets, a plurality of connection members between said first and second sheets to connect said sheets to one another and maintain said sheets in a spaced relationship and a foam core between said sheets;    a second foamed panel having a pair of spaced, substantially planar sheets, a plurality of connection members between said first and second sheets to connect said sheets to one another and maintain said sheets in a spaced relationship and a foam core between said sheets;    one of said first and second panels including an outer surface having a pair of spaced first connection members extending outwardly from said outer surface;    the other of said first and second panels including a panel edge, said edge including spaced second connection members, said first and second connection members connectable to one another to connect the edge of said other panel to the outer surface of said one panel.    
   
   
       13 . The structure of  claim 12  wherein one of said first and second connection members includes a pair of connection surfaces facing toward one another and the other of said first and second connection members includes a pair of connection surfaces facing away from one another.  
   
   
       14 . The structure of  claim 13  wherein said first connection members includes a pair of connection surfaces facing toward one another and said second connection members includes a pair of connection surfaces facing away from one another.  
   
   
       15 . The structure of  claim 14  wherein one of pair of connection surfaces includes a connection rib and the other or said pair of connection surfaces includes a connection recess.  
   
   
       16 . The structure of  claim 15  wherein said connection ribs and said connection recesses are connectable to one another.