Composite structural material

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.

1 - 67 . (canceled) 
   
   
       68 . 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 an amount of resin 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. 
   
   
       69 . The composite structural material of  claim 68 , wherein the core material is comprised of pieces of a filler solid embedded in a resinous matrix. 
   
   
       70 . The composite structural material of  claim 69 , wherein the pieces of filler solid comprise granular pieces of one or more solids selected from the group consisting of lignocellulosic materials, cellulosic materials, vitreous materials, cementitious materials, carbonaceous materials, plastics, and rubbers. 
   
   
       71 . The composite structural material of  claim 68 , wherein the core material includes rubber. 
   
   
       72 . The composite structural material of  claim 71 , wherein the core material includes granulated tire rubber. 
   
   
       73 . The composite structural material of  claim 68 , wherein the core material includes a wood material selected from the group consisting of wood powder, wood flake, and waste wood fiber. 
   
   
       74 . The composite structural material of  claim 68 , wherein the core material includes a thermoplastic resin. 
   
   
       75 . The composite structural material of  claim 74 , wherein the core material includes high density polyethylene. 
   
   
       76 . The composite structural material of  claim 68 , wherein the web material is paper that is impregnated with and stiffened by a rigidifying synthetic resin. 
   
   
       77 . The composite structural material of  claim 76 , wherein the paper is kraft paper. 
   
   
       78 . The composite structural material of  claim 77 , wherein, in the laminar covering, the outermost layer is a paper layer. 
   
   
       79 . The composite structural material of  claim 68 , wherein the laminar covering has a one-piece construction. 
   
   
       80 . The composite structural material of  claim 68 , wherein the cords comprise synthetic fibers or filaments. 
   
   
       81 . The composite structural material of  claim 68 , wherein the cords comprise glass fibers or filaments. 
   
   
       82 . The composite structural material of  claim 68 , wherein the cords comprise polyester fibers or filaments. 
   
   
       83 . The composite structural material of  claim 68 , wherein the cords are nonwoven. 
   
   
       84 . The composite structural material of  claim 68 , wherein the cords are laterally connected to each other. 
   
   
       85 . The composite structural material of  claim 84 , wherein the cords are laterally connected to each other by cross-cording. 
   
   
       86 . The composite structural material of  claim 68 , further comprising a metal embedment. 
   
   
       87 . The composite structural material of  claim 86 , wherein the metal embedment comprises a metal selected from the group consisting of aluminum, copper, gold, nickel, cadmium, zinc, bronze, chromium, cobalt, potassium, chrome, lead, tin, and silver. 
   
   
       88 . The composite structural material of  claim 68 , wherein the core material comprises a resin that is compatible with the resin that impregnates the laminar covering. 
   
   
       89 . The composite structural material of  claim 68 , wherein the resin that is used to impregnate the web material and the cords is compatible with the resin that is used to bond the cords to the web material. 
   
   
       90 . The composite structural material of  claim 89 , wherein the resin that is used to impregnate the web material and the cords is the same resin that is used to bond the cords to the web material. 
   
   
       91 . The composite structural material of  claim 68 , wherein the cords are bonded to the web material by an unfoamed resin. 
   
   
       92 . A shipping pallet comprised of at least one board made of the composite structural material of  claim 68 . 
   
   
       93 . A shipping pallet comprised of stringers and deck boards, wherein at least one of the stringers and deck boards is made of the composite structural material of  claim 68 .