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 method of making a dunnage platform comprising:
 providing a core made from an expanded polymer for defining the shape of the platform, said core having a dimension, a first side and a second side separated by an edge;   heating a first thermoplastic sheet having a dimension larger than the dimension of the core, said thermoplastic sheet being held tautly prior to heating;   placing said first heated thermoplastic sheet on top of said first side of said core while the second side of said core is uncovered by a thermoplastic sheet; and   combining said heated first thermoplastic sheet with at least a region of said first side and at least a part of said edge of said core to form a dunnage platform with sufficient load bearing strength;   wherein said at least a portion of said first side and at least a part of said edge are exposed during placement of said first heated thermoplastic sheet on top of said first side of said core.   
     
     
         2 . The method of  claim 1  wherein said first thermoplastic sheet is heated until it sags prior to being placed on said first side of said core. 
     
     
         3 . The method of  claim 1  wherein said combining comprises applying a vacuum to draw said first heated thermoplastic sheet onto said first side of said core. 
     
     
         4 . The method of  claim 1  wherein said core is retained in a forming mold to expose said first side, and at least part of said edge. 
     
     
         5 . The method of  claim 1  wherein said first thermoplastic sheet is held in a clamping frame. 
     
     
         6 . The method of  claim 1  further comprising:
 retaining said core combined with said first thermoplastic sheet in a forming mold having an interior that is complementary to a shape of said core to expose the second side and at least a portion of said edge of said core; 
 heating a second thermoplastic sheet and placing said heated second thermoplastic sheet on top of said second side of said core. 
 
     
     
         7 . A method of making a dunnage platform comprising:
 providing a core made from an expanded polymer for defining the shape of the platform, said core having a dimension, a first side and a second side separated by an edge;   heating a first thermoplastic sheet having a dimension larger than the dimension of the core, a portion of said first thermoplastic sheet being held by a clamping frame;   placing said first heated thermoplastic sheet on top of said first side of said core while the second side of said core is uncovered by a thermoplastic sheet; and combining said heated first thermoplastic sheet with a region of said first side and a part of said edge;   
       wherein said first side and at least a part of said edge are exposed during placement of said first heated thermoplastic sheet on top of said first side of said core. 
     
     
         8 . The method of  claim 7  wherein said clamping frame comprises an upper frame attached to a lower frame. 
     
     
         9 . The method of  claim 7  wherein said first thermoplastic sheet is heated until it sags prior to combining with said core. 
     
     
         10 . The method of  claim 8  wherein said first thermoplastic sheet is clamped between said upper and said lower frame about its edges. 
     
     
         11 . The method of  claim 7  wherein said combining is effected by heating said first thermoplastic sheet at a temperature range of 293° F. to 375° F. 
     
     
         12 . The method of  claim 7  further comprising:
 retaining said core combined with said first thermoplastic sheet in a forming mold having an interior that is complementary to a shape of said core to expose the second side and at least a portion of said edge of said core; 
 heating a second thermoplastic sheet; and combining said heated second thermoplastic sheet with said second side and a part of said edge of said core. 
 
     
     
         13 . The method of  claim 12  where said second thermoplastic sheet covers said second side of the core and at least a portion of said edge. 
     
     
         14 . A method of making a dunnage platform comprising:
 providing a core made from an expanded polymer for defining the shape of the platform, said core having a dimension, a first side and a second side separated by an edge;   heating a first high impact polystyrene sheet having a dimension larger than the dimension of the core, said high impact polystyrene sheet being held tautly prior to heating;   placing said first heated high impact polystyrene sheet on top of said first side of said core while the second side of said core is uncovered by a thermoplastic sheet; and   combining said heated first high impact polystyrene sheet with said first side and a part of said edge of said core;   
       wherein said first side and at least a part of said edge are exposed during the placement of said first heated high impact polystyrene sheet on top of said first side of said core. 
     
     
         15 . The method of  claim 14  wherein said high impact polystyrene sheet is being held by at least a portion of its edge. 
     
     
         16 . The method of  claim 14  wherein said first high impact polystyrene sheet is heated at a temperature range of 293° F. to 375° F. 
     
     
         17 . The method of  claim 14  wherein said combining comprises applying a vacuum to draw said heated first high impact polystyrene sheet onto said first side of said core. 
     
     
         18 . The method of  claim 14  wherein said first high impact polystyrene sheet is held in a clamping frame about at least a portion of its edges. 
     
     
         19 . The method of  claim 14  wherein said first side of said expanded core and more than half of said edge is covered by said first high impact polystyrene sheet. 
     
     
         20 . The method of  claim 14  wherein said providing comprises providing said core in a forming mold having an interior that is complementary to a shape of said core.