RV and trailer composite panel manufacturing process with interlocking connections assembly system

A method for manufacturing a recreational vehicle having a composite structure, comprising:

• (a) forming a first composite component, by
• (i) providing a first multi-layer composite panel comprising a plurality of layers having common length and width dimensions, and comprising, in order:
• (1) a first sheet comprising a pre-preg carbon fiber layer, having a resin-heavy exterior side, and an interior side,
• (2) a second sheet comprising a pre-preg epoxy fiberglass layer, the second sheet pre-preg epoxy fiberglass layer disposed against the interior side of the first sheet,
• (3) a rigid structural foam core, disposed against the second sheet,
• (4) a third sheet comprising a pre-preg epoxy fiberglass layer disposed against the rigid structural foam core, and
• (5) a fourth sheet comprising a pre-preg carbon fiber layer having a resin-heavy exterior side, and an interior side disposed against the third sheet,
• (ii) laying up the first multi-layer composite panel on a mold with the resin-heavy exterior side of the first sheet facing the mold,
• (iii) compressing and curing the first composite component to form a completed, cured first composite component, and
• (iv) removing the first multi-layer composite component from the mold;
• (b) forming a second composite component by repeating steps (a)(i) through (a)(iv) above to produce a cured second composite component;
• (c) cutting the cured first composite component along at least one of its length or width to define a first panel edge portion oriented at selected angle alpha (α);
• (d) cutting the cured second composite component along at least one of its length or width to define a second panel edge portion oriented at an angle complementary to the selected angle alpha (α);
• (e) removing, along the second edge portion of the second composite component the rigid structural foam core to a depth sufficient to create a recessed edge of the rigid structural foam core, and form a channel having opposing flanges, the opposing flanges comprising (i) a first flange defined by cured thicknesses of the first sheet and the second sheet, and (ii) a second flange defined by cured thicknesses of the third sheet and the fourth sheet;
• (f) forming, in the first composite component, at least one a groove oriented at the selected angle alpha (α), the groove extending through the fourth sheet, the third sheet, and the rigid structural foam core, and terminating at an interior side of the second sheet without penetrating the second sheet or the first sheet, thereby defining a flange receiving recess;
• (g) applying an adhesive to the recessed edge of the rigid structural foam core, and the groove;
• (h) joining the second composite component to the first composite component by inserting the first flange into the groove until positioned adjacent the interior side of the second sheet of the first composite component, to form a joint therebetween;
• and
• (i) wherein the first and second composite component comprise (A) a recreational vehicle single-piece composite wall panel and a recreational vehicle single-piece composite roof panel, or (B) a recreational vehicle single-piece composite wall panel and a recreational vehicle single piece composite floor panel, or (C) a recreational vehicle single-piece composite roof panel and a recreational vehicle single piece composite floor panel, and wherein the joint defines an interface between, respectively, the recreational vehicle single piece composite wall panel and the recreational vehicle single-piece composite roof panel, or between the recreational vehicle single-piece composite wall panel and the recreational vehicle single piece composite floor panel, or between the recreational vehicle single-piece composite roof panel and the recreational vehicle single-piece composite floor panel, all of which are configured for highway travel.