IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0813060
(2005-12-29)
|
등록번호 |
US-8181580
(2012-05-22)
|
국제출원번호 |
PCT/US2005/047194
(2005-12-29)
|
§371/§102 date |
20070628
(20070628)
|
국제공개번호 |
WO2006/071920
(2006-07-06)
|
발명자
/ 주소 |
- Roth, Arthur J.
- Palmer, Gregory M.
|
출원인 / 주소 |
- Coda Capital Mangement Group, LLC
|
대리인 / 주소 |
Fitzpartick, Cella, Harper & Scinto
|
인용정보 |
피인용 횟수 :
14 인용 특허 :
77 |
초록
▼
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 coverin
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.
대표청구항
▼
1. A shipping pallet comprising: a plurality of stringer boards or blocks; anda plurality of composite upper-deck boards fastened to the stringer boards or blocks, the composite upper-deck boards including two outside-edge boards that flank a plurality of interior boards, each of the composite upper
1. A shipping pallet comprising: a plurality of stringer boards or blocks; anda plurality of composite upper-deck boards fastened to the stringer boards or blocks, the composite upper-deck boards including two outside-edge boards that flank a plurality of interior boards, each of the composite upper-deck boards comprising a dimensionally stable core material ensheathed in a dimensionally stable covering that is bonded to the core material,wherein the core material of each of the interior deck boards has a lesser crush resistance and lower density than the crush resistance and density of either of the outside-edge boards that flank those interior boards. 2. The shipping pallet of claim 1, wherein each of the outer-edge upper-deck boards has a crush resistance of at least about 750 psi. 3. The shipping pallet of claim 2, wherein each of the interior upper-deck boards has a density of about 30 to 55 lb/ft3. 4. The shipping pallet of claim 3, wherein the core material of each of the interior upper-deck boards comprises at least about 20 volume percent of pumice dispersed in a matrix of a foamed thermosetting resin. 5. The shipping pallet of claim 4, wherein the core material of each of the outside-edge upper-deck boards comprises at least about 15 volume percent of rubber tire particles dispersed in a matrix of a foamed thermosetting resin. 6. The shipping pallet of claim 5, wherein the core material of each of the interior upper-deck boards contains no more than about 10 volume percent of rubber tire particles. 7. The shipping pallet of claim 6, wherein the foamed thermosetting resin matrix in each of the upper-deck boards is a polyurethane resin. 8. The shipping pallet of claim 7, wherein the foamed polyurethane resin in the core material of the interior upper-deck boards has a molded density of about 12 to 17 lb/ft3. 9. The shipping pallet of claim 8, wherein the foamed polyurethane resin in the core material of the outside-edge upper-deck boards has a molded density of about 14 to 34 lb/ft3. 10. The shipping pallet of claim 9, wherein about 40 to 60 percent of the volume of the core material of each of the interior upper-deck boards is occupied by pumice, and about 25 to 35 percent of the volume of the core material of each of the outside-edge upper-deck boards is occupied by rubber tire particles. 11. A method of making an elongated, composite, structural material, comprising the following steps: a) forming a foldable laminate of two strips of porous web material selected from the group consisting of paper and cloth, with at least one strip of a band of reinforcing cords sandwiched there between, with the cords running in the lengthwise direction and with the strips of porous web material and all materials lying between those strips being impregnated with a thermosetting resin-precursor mixture;b) folding the laminate into a trough shape and orienting it horizontally, with one of the strips of porous web material on the top and the other strip of porous web material on the bottom;c) depositing in the trough of the laminate, while still foldable, a fluid matrix-resin-precursor composition that is compatible with the resin-precursor mixture in the laminate and which, when fully reacted, yields a thermoset matrix resin that is at least semi-rigid;d) folding closed and sealing shut the laminate so that it surrounds and defines a core space containing the matrix-resin precursor composition; ande) holding the closed laminate and its contents in a mold under conditions conducive to the setting of both the thermosetting resin in the laminate and the matrix resin in the core space, for a time sufficient for both resins to sufficiently set that (i) the laminate and the matrix resin are both made at least semi-rigid, (ii) the matrix resin, together with any filler solid it may contain, fills the core space, and (iii) the laminate and matrix resin are bonded together,wherein at least one side of the strip of porous web material that is positioned on the bottom is coated with a film of synthetic resin before it is impregnated with the thermosetting-resin-precursor mixture, and the web material is oriented so that its resin-coated side faces down with respect to the horizontal orientation of the trough-shaped laminate during steps b and c, the film of synthetic resin being adequate to substantially prevent any ingredients of the thermosetting-resin-precursor mixture from bleeding through the porous web material. 12. The method of claim 11, wherein the porous web material is paper, the thermosetting-resin-precursor mixture is a mixture that reacts to form an epoxy resin, and the film of synthetic resin is a layer of polypropylene that is about 1 to 5 mils thick. 13. A method of making an elongated, composite, structural material, comprising the following steps: a) forming a foldable laminate of two strips of porous web material selected from the group consisting of paper and cloth, with at least one strip of a band of reinforcing cords sandwiched therebetween, with the cords running in the lengthwise direction and with the strips of porous web material and all materials lying between those strips being impregnated with a thermosetting resin-precursor mixture;b) folding the laminate into a trough shape and orienting it horizontally, with one of the strips of porous web material on the top and the other strip of porous web material on the bottom;c) depositing in the trough of the laminate, while still foldable, a fluid polyurethane-resin-precursor composition that is compatible with the resin-precursor mixture in the laminate and which, when fully reacted, yields a foamed polyurethane resin that is at least semi-rigid;d) folding closed and sealing shut the laminate so that it surrounds and defines a core space containing the polyurethane resin-precursor composition; ande) holding the closed laminate and its contents in a mold under conditions conducive to the setting of both the thermosetting resin in the laminate and the polyurethane resin in the core space, for a time sufficient for both resins to sufficiently set that (i) the laminate and the foamed polyurethane resin are both made at least semi-rigid, (ii) the foamed polyurethane resin, together with any filler solid it may contain, fills the core space, and (iii) the laminate and foamed polyurethane resin are bonded together,wherein the top strip of porous web material is conveyed through a dehumidification zone prior to impregnating it with the thermosetting resin-precursor mixture and prior to forming the foldable laminate in step a. 14. The method of claim 13, wherein the top strip of porous web material is paper, and when said strip of paper exits the dehumidification zone its moisture content is about 5 wt. % or less. 15. The method of claim 14, wherein the top strip of porous web material exits the dehumidification zone at a moisture content in the range of about 1 to 4 wt. %. 16. A shipping pallet comprising: a plurality of stringer boards or blocks; anda plurality of composite upper-deck boards fastened to the stringer boards or blocks, the composite upper-deck boards including two outside-edge boards that flank a plurality of interior boards, each of the composite upper-deck boards comprising a dimensionally stable core material ensheathed in a dimensionally stable covering that is bonded to the core material, the covering comprising rigidified paper with high density polyethylene at a surface of the rigidified paper that is opposite a surface of the rigidified paper that faces the core material,wherein the core material of at least one of the upper-deck boards has a lesser crush resistance and lower density than the crush resistance and density of the stringer boards and blocks. 17. The shipping pallet of claim 1, further comprising at least one upper-deck board made from wood. 18. The shipping pallet of claim 1, wherein the core material includes crumb rubber. 19. The shipping pallet of claim 1, wherein the core material includes recycled high density polyethylene. 20. The shipping pallet of claim 1, wherein the core material includes wax. 21. The shipping pallet of claim 1, wherein the core material includes silicate.
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