Composite structural material and method of making same

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, by a resin, to at least one layer of a dimensionally stable web material that is exterior to the cords, the web material being selected from the group consisting of rigidified paper and rigidified cloth, with the web material and the cords being impregnated with the same resin that is used to bond the cords to the web material, the amount of the resin being sufficient to render the laminar covering dimensionally stable, and the cords being oriented in the longitudinal direction of the structural material and extending substantially the entire length thereof, wherein the laminar covering comprises a plurality of paper layers and each paper layer is impregnated with a cured epoxy resin that helps bind the cords and the core material to the paper layers.

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, by a rigidifying thermosetting resin, to a layer of paper that is exterior to the cloth, the paper being impregnated with the same rigidifying thermosetting resin that is used to bond the cloth to the paper, the amount of the rigidfying thermosetting resin being sufficient 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, wherein the core material has a crush resistance of at least about 300 psi, and wherein the at least one band of cloth is bonded to the paper layer by an unfoamed resin.

An elongated, composite structural material comprising:

• a core comprised of pieces of a filler solid embedded in a resinous matrix;
• and
• a laminar covering that ensheaths the core, the laminar covering being comprised of a layer of a plurality of substantially parallel reinforcing cords bonded, by an unfoamed resin, to a first layer of rigidified paper that is exterior to the cords, wherein the cords and the first paper layer are impregnated with the same unfoamed resin that is used to bond the cords to the first paper layer, the amount of the unfoamed resin being sufficient to render the laminar covering dimensionally stable, and wherein the cords are oriented in the longitudinal direction of the structural material and extend substantially the entire length thereof.

An elongated, four-sided composite structural material having a substantially uniform, rectangular cross section throughout its length, the material comprising:

• a core comprised of granular pieces of a filler solid embedded in a foamed polyurethane resin, the filler solid comprising at least one solid selected from the group consisting of lignocellulosic materials, cellulosic materials, vitreous materials, cementitious materials, carbonaceous materials, plastics, and rubbers;
• and
• a laminar covering that ensheaths the core and is bonded to the core, the laminar covering including a layer of a plurality of substantially parallel cords bonded, by an epoxy resin, to a layer of rigidified paper that is exterior to the cords, wherein the cords and the paper layer are impregnated with the same epoxy resin that is used to bond the cords to the paper layer, the amount of the epoxy resin being sufficient to render the laminar covering dimensionally stable, and wherein the cords comprise a synthetic fiber or filament and are oriented in the longitudinal direction of the structural material and extend substantially the entire length thereof.