Truck bed toolbox lid having injected foam

摘要

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.

主权项

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 alonealong 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.