A pallet made from composite parts having a core with higher crush strength when used on the outside

摘要

A shipping pallet (800) is disclosed. The pallet structure comprises a plurality of stringer boards (802) or blocks and a plurality of composite upper-deck boards (804, 806) fastened to them. The upper-deck boards (804, 806) include two outside-edge boards (806) that flank a plurality of interior boards (804). Each of the upper-deck boards (804, 806) are made from a dimensionally stable core material sheathed in and bonded to a dimensionally stable laminar covering but the core material of the interior deck boards(804) has a lesser crush resistance and lower density than either of the outside edge boards (806). 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.