Foam laminates

Abstract

A method and apparatus for fabrication of foam laminates suitable for use in the construction of furniture and case goods are provided. The panel has an upper surface formed from a thermoplastic sheet of material such as PVC. A cavity formed by the interior surfaces of the sheet have suspended therein attachment or mounting hardware which is subsequently encapsulated by an in situ structural foaming step. The resulting laminated panel is useful as a table top, shelving, and as a structural component in a variety of case goods and furniture.

That which is claimed is:  
     
         1 . A laminated panel comprising: 
 a sheet molded into a tray configuration having an exterior surface, an interior surface, and a bent edge, an interior of the edge and the interior surface collectively defining a cavity;    an insert positioned at least in part within the cavity space, the insert maintained a spaced distance from the interior sheet surfaces;    a structural foam positioned within the cavity, the foam forming a bond with the interior surfaces of the sheet and forming a further bond with the insert portions suspended within the cavity.    
     
     
         2 . The laminated panel according to  claim 1  wherein the panel further comprises a backing layer secured to an outer surface of the structural foam.  
     
     
         3 . The laminated panel according to  claim 1  wherein the panel further comprises a table top.  
     
     
         4 . The laminated panel according to  claim 1  wherein the panel further comprises a countertop.  
     
     
         5 . The laminated panel according to  claim 1  wherein the insert defines an attachment member for a table leg.  
     
     
         6 . The laminated panel according to  claim 5 , wherein an exposed surface of the foam defines at least one depression.  
     
     
         7 . The laminated panel according to  claim 6 , wherein at least one depression is adapted for receiving therein said table leg when the table leg is in a folded configuration.