Method of making a dunnage platform

Abstract

A dunnage platform is in the general shape of a rectangular slab with legs extending form one side. The dunnage platform is made from an expanded polystyrene core. A chemical combination process is used to chemically combine portion of the core proximal to its surface with high impact polystyrene. In a first of two parts of the combination process, the core is placed in a forming mold with one of its two sides and two thirds of its thickness extending therefrom. A heated sheet of high impact polystyrene is brought into contact with the portion of the core extending from the mold. In a similar manner, the other of the two sides of the core is made to extend from the forming mold for contact with a heated sheet of high impact polystyrene.

1 . A process for making a strengthened polystyrene load bearing structure, comprising the steps of:
 using a forming mold into which can be inserted an expanded polystyrene core;   inserting the expanded polystyrene core in the forming mold, wherein a first side of the expanded polystyrene core and at least half the thickness of the expanded polystyrene core extend from the mold;   heating a high impact polystyrene sheet; and   substantially surrounding the first side of the expanded polystyrene core and at least half the thickness of the expanded polystyrene core with the high impact polystyrene sheet.   
     
     
         2 . The process of  claim 1 , wherein the high impact polystyrene sheet is heated to a temperature in a range of between:
 293° F.; and   375° F.   
     
     
         3 . The process of  claim 1 , further comprising applying reduced pressure to mold the heated high impact polystyrene sheet to the expanded polystyrene core. 
     
     
         4 . The process of  claim 1 , wherein the high impact polystyrene sheet is chemically combined with the expanded polystyrene core. 
     
     
         5 . The process of  claim 1 , further comprising the steps of:
 placing the expanded polystyrene core in proximity of the high impact polystyrene sheets; and moving said expanded polystyrene core into contact with said heated high impact polystyrene sheet; wherein said heated high impact polystyrene sheet remains fixed in position.   
     
     
         6 . The process of  claim 1 , further comprising substantially surrounding a second side of the expanded polymer core and at least half the thickness of the expanded polymer core with a second high impact polystyrene sheet.