Abstract: A composite structural material suitable, for example, as a replacement for wooden boards, sheets, or posts, is disclosed. It comprises a dimensionally stable core material substantially surrounded by a dimensionally stable, laminar covering that is adherent to the core material. 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. Preferably the band of reinforcing cords is sandwiched between two layers of rigidified paper or cloth. The core material can be, for example, a foamed synthetic resin with or without filler. A continuous process for manufacturing the material is disclosed.

Abstract: 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 (19) bonded to at least one layer of a rigidified web material (10) selected from the group consisting of paper and cloth. Suitable core materials include polyurethane foam (38), optionally filled with particles (32) of granulated rubber, expanded perlite, expandable polymer beads, and/or glass microspheres. The parallel cords (19) preferably are supplied in the form of a strip of polyester cloth, as the warp cords thereof. The web material (10) preferably is kraft paper that is rigidified with an epoxy resin.

Abstract: A composite structural material suitable, for example, as a replacement for wooden boards, sheets, or posts, is disclosed. It comprises a dimensionally stable core material substantially surrounded by a dimensionally stable, laminar covering that is adherent to the core material. 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. Preferably the band of reinforcing cords is sandwiched between two layers of rigidified paper or cloth. The core material can be, for example, a foamed synthetic resin with or without filler. A continuous process for manufacturing the material is disclosed.

Abstract: A shipping pallet comprised of at least one layer of substantially parallel, structural deck boards attached to a plurality of stringers is disclosed. The layer of deck boards defines a three-dimensional, substantially rectilinear deck zone that is defined by a top plane, a bottom plane, and four side-edge planes. The pallet includes at least one non-structural member that carries a readable device within the deck zone of a pallet, in the space between two structural deck boards. The non-structural member has a Modulus of Elasticity and Modulus of Rupture that are both below that of the strongest deck board in the deck zone in which the non-structural member is mounted.

Abstract: 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.

Abstract: In a process of generating a polyurethane foam by forming a mixture including isocyanate and polyol reactants, catalyst, and blowing agent, which mixture reacts exothermically to yield a rigid polyurethane foam, there is included in the mixture expandable polymer beads, made of a thermoplastic polymer (e.g., polystyrene or a polyolefin) that has a softening point at or below the maximum temperature reached during the exothermic reaction. The beads may be added in unexpanded form, partially expanded form, or fully expanded form. The heat of the urethane-forming reaction causes the beads to sinter, creating hollow polymeric spheres in the foam, which are larger than the cells in the polyurethane matrix, and which appear to improve the foam's crush resistance.

Abstract: 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.

Abstract: In a process of generating a polyurethane foam by forming a mixture including isocyanate and polyol reactants, catalyst, and blowing agent, which mixture reacts exothermically to yield a rigid polyurethane foam, there is included in the mixture expandable polymer beads, made of a thermoplastic polymer (e.g., polystyrene or a polyolefin) that has a softening point at or below the maximum temperature reached during the exothermic reaction. The beads may be added in unexpanded form, partially expanded form, or fully expanded form. The heat of the urethane-forming reaction causes the beads to sinter, creating hollow polymeric spheres in the foam, which are larger than the cells in the polyurethane matrix, and which appear to improve the foam's crush resistance.

Abstract: In a process generating a polyurethane foam by forming a mixture including isocyanate and polyol reactants, catalyst, and blowing agent, which mixture reacts exothermically to yield a rigid polyurethane foam, there is included expandable polystyrene beads made of a polystyrene that has a softening point at or below the maximum temperature reached during the exothermic reaction.