James R Tate

US Patent:

55773630, Nov 26, 1996

Filed:

Feb 23, 1995

Appl. No.:

8/392574

Inventors:

James R. Tate - Watertown WI
Allen E. Lee - Brookings SD
Bryan P. Zacher - Brookings SD
Vernon D. Olson - Brookings SD

Assignee:

Menasha Corporation - Neenah WI

International Classification:

E04C 234
E06B 716

US Classification:

5278415

Abstract:

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.