Composite panel adapted for point compressive loads and method for making same
First Claim
1. A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:
- positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
fixing a foam core between at least a portion of said fabric layers to form said panel;
defining in at least one of said opposing panel surfaces an elongated channel having a cross-sectional profile;
forming a rigid point compressive load bearing member having a structural foam core, an outer fabric layer including fabric flaps and said cross-sectional profile of said elongated channel;
applying resin to said flaps and mating surfaces of the rigid point oppressive load bearing member and said elongated channel;
positioning said rigid point compressive load bearing member in said elongated channel after said applying step; and
allowing said resin to cure to provide along a length of said rigid point compressive load bearing member a greater resistance to point compression as compared to a remaining portion of said panel exclusive of said rigid point compressive load bearing member.
3 Assignments
0 Petitions
Accused Products
Abstract
A method for making a composite panel includes the step (26) of providing a panel having elongated channels (14) that are positioned along areas of anticipated point compression loading. The panel (10) has a reinforcing fabric layer (41) attached to a non-woven fabric layer (43) forming an outside layer (12). The composite panel has foam core (8,9) within the outside layer. The method further comprises the step (27) of providing structural foam channel inserts (16) having an outer fabric layer (18), wherein the channel inserts have a cross section which matches the cross-sectional profile of each of the elongated channels of the panel. Resin is then applied to the outside layer of the panel and outer fabric layer of the channel inserts such the channel inserts are positioned within the channels of the panel (29 and 31). The resin is then allowed to cure (33) forming a composite structure.
86 Citations
25 Claims
-
1. A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
fixing a foam core between at least a portion of said fabric layers to form said panel;
defining in at least one of said opposing panel surfaces an elongated channel having a cross-sectional profile;
forming a rigid point compressive load bearing member having a structural foam core, an outer fabric layer including fabric flaps and said cross-sectional profile of said elongated channel;
applying resin to said flaps and mating surfaces of the rigid point oppressive load bearing member and said elongated channel;
positioning said rigid point compressive load bearing member in said elongated channel after said applying step; and
allowing said resin to cure to provide along a length of said rigid point compressive load bearing member a greater resistance to point compression as compared to a remaining portion of said panel exclusive of said rigid point compressive load bearing member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
-
-
10. A method for manufacturing a composite boat transom comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing transom surfaces;
positioning elongated rigid channel members between said first and second fabric layers aligned with locations corresponding to areas of anticipated point compressive loading; and
injecting a foam core between said first and second fabric layers. - View Dependent Claims (11, 12, 13, 14, 15, 16)
-
-
17. A method for manufacturing a composite boat transom comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing transom surfaces;
positioning elongated rigid channel members between said first and second fabric layers aligned with locations corresponding to areas of anticipated point compressive loading associated with an outboard motor bracket;
injecting a foam core between said first and second fabric layers; and
causing said foam core to penetrate at least partially into interstices of said fabric layers to bind said foam core to said fabric layers. - View Dependent Claims (18, 19, 20)
-
-
21. A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
fixing a foam core between at least a portion of said fabric layers to form said panel;
positioning at least one rigid point compressive load bearing member between portions of said foam core along areas of anticipated point compression loading in a location to prevent compression of said foam core when a point compressive load is applied to said point compressive load bearing members; and
selecting said point compressive load bearing member to be an elongated channel formed of a material selected from the group consisting of steel, aluminum and a metal alloy.
-
-
22. A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
fixing a foam core between at least a portion of said fabric layers to form said panel;
positioning at least one rigid point compressive load bearing member between portions of said foam core along areas of anticipated point compression loading in a location to prevent compression of said foam core when a point compressive load is applied to said point compressive load bearing members; and
forming at a periphery of said opposing panel surfaces a plurality of fabric tabs attached to at least one of said first and second fabric layers.
-
-
23. A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
fixing a foam core between at least a portion of said fabric layers to form said panel;
positioning at least one rigid point compressive load bearing member between portions of said foam core along areas of anticipated point compression loading in a location to prevent compression of said foam core when a point compressive load is applied to said point compressive load bearing members; and
laminating said panel into a composite boat hull to form a transom.
-
-
24. A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
positioning a rigid point compressive load bearing member between said first and second fabric layers along areas of anticipated point compression loading; and
injecting a foam core between at least a portion of said first and second fabric layers to form said panel, wherein said rigid point compressive load bearing member prevents compression of said foam core when a point compressive load is applied to said point compressive load bearing member; and
injecting a foam core into said rigid point compressive load bearing member.
-
-
25. A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:
-
positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
positioning a rigid point compressive load bearing member between said first and second fabric layers along areas of anticipated point compression loading; and
injecting a foam core between at least a portion of said first and second fabric layers to form said panel, wherein said rigid point compressive load bearing member prevents compression of said foam core when a point compressive load is applied to said point compressive load bearing member; and
selecting said rigid point compressive load bearing member to be an elongated channel formed of a material selected from the group consisting of steel, aluminum and a metal alloy.
-
Specification