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AssigneeHunter Paine Enterprises, LLC
InventorsArthur J. Roth, Patrick H. Winters, Michael H. Clement
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A composite structural material suitable, for example, as a replacement for wooden boards, is disclosed. It comprises a dimensionally stable core material ensheathed in a dimensionally stable, laminar covering that is adherent to the core material. The laminar covering is comprised of at least one layer of parallel cords bonded to at least one layer of a rigidified web material selected from the group consisting of paper and cloth. Suitable core materials include polyurethane foam, optionally filled with granulated rubber and/or expandable polymer beads. The parallel cords preferably are supplied in the form of a strip of polyester cloth, as the warp cords thereof. The web material preferably is kraft paper that is rigidified with an epoxy resin.
An elongated, composite structural material comprised of a dimensionally stable core material ensheathed in a laminar covering that is bonded to the core material, wherein the laminar covering is comprised of at least one band of substantially parallel reinforcing cords bonded to at least one layer of a dimensionally stable web material selected from the group consisting of rigidified paper and rigidified cloth, with the cords being oriented in the longitudinal direction of the structural material and extending substantially the entire length thereof.
A method of making an elongated, composite, structural material, comprising the following steps:
An elongated, four-sided, composite structural material having a substantially uniform, rectangular cross-section throughout its length, the material being comprised of a rigid polyurethane foam core material ensheathed in a laminar covering that is bonded to the core material by a thermosetting resin, wherein the laminar covering is comprised of at least one band of cloth, bonded to a layer of paper that is impregnated with a sufficient amount of a rigidifying thermosetting resin to render the paper dimensionally stable, with the warp of the cloth being oriented in the longitudinal direction of the structural material and extending substantially the entire length thereof, and with said at least one band of cloth substantially covering at least two opposite sides of the structural material, and wherein the core material has a crush resistance of at least about 300 psi.
A shipping pallet comprised of top deck boards, stringers, and bottom deck boards, wherein each of the top and bottom deck boards and the stringers is an elongated, four-sided, composite structural material having a substantially uniform, rectangular cross-section throughout its length, the material being comprised of a rigid polyurethane foam core material ensheathed in a laminar covering that is bonded to the core material by a thermosetting resin, wherein the laminar covering is comprised of at least one band of cloth, bonded to a layer of paper that is impregnated with a sufficient amount of a rigidifying thermosetting resin to render the paper dimensionally stable, with the warp of the cloth being oriented in the longitudinal direction of the structural material and extending substantially the entire length thereof, and with said at least one band of cloth substantially covering at least two opposite sides of the structural material, and wherein the core material has a crush resistance of at least about 300 psi.
Dependencies are inferred from the claim text.