Patent ID: 7544262

Claim:
A process for making a strengthened polystyrene load bearing structure, comprising the steps of: providing a forming mold adapted to receive an expanded polystyrene core, wherein said polystyrene core has been inserted into the forming mold, where a first side of the expanded polystyrene core and at least half the thickness of the expanded polystyrene core have been combined with a first high impact polystyrene sheet, wherein the polystyrene core has been removed from the forming mold; reinserting the expanded polystyrene core in the forming mold, wherein a second side of the expanded polystyrene core and at least half the thickness of the expanded polystyrene core extend from the mold; heating a second high impact polystyrene sheet; and combining the second side and at least half the thickness of the expanded polystyrene core with the second high impact polystyrene sheet.