METHOD OF MAKING A DUNNAGE PLATFORM
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.