Composite structural member with integral load bearing joint-forming structure

A composite structure for forming a corner on an enclosure, said structure comprising;

• a first composite structural member having a first panel portion and a first joint-forming edge structure integrally formed on a first edge thereof, said first joint-forming edge structure includes a first web portion adjacent a first joint forming edge, said first panel portion including a core material sandwiched between a first skin layer of composite material and a second skin layer of composite material with said first web portion extending between said first skin layer and said second skin layer of said first panel portion for carrying a load between said first skin layer and said first joint-forming edge structure includes a first composite flange portion extending from said first skin layer of said first panel portion;
• and
• a second composite structural member having a second panel portion and a second joint forming edge structure integrally formed on a second edge thereof, said second joint-forming edge structure includes a second web portion adjacent to a second joint-forming edge, said second panel portion including a core material sandwiched between a first skin layer of composite material and a second skin layer of composite material with said second web portion extending between said first skin layer and said second skin layer of said second panel portion for carrying a load between said first skin layer and second skin layer, said second joint-forming edge structure includes a second composite flange portion extending from said second skin layer of said second panel portion,
• wherein the first joint-forming edge structure of the first composite members is bonded with a bonding material to the second joint forming edge structure of the second composite member so as to form a corner of said enclosure along a joint axis, such that said first flange portion is bonded to a first flange receiving portion of said first layer of said second panel portion and said second flange portion is bonded to a second flange receiving portion of said second layer of said first panel portion and the first and second web portions of said first and second structural members are bonded together such that a load carried by said second skin of said first panel is carried through said second connecting means to said second layer of said second skin layer of said second panel and said core material of said first and second structural members are not subject to that loading.

A composite structure comprising

• a core having a first side and a second side, said first side being generally parallel with said second side;
• first skin means for transmitting forces attached to said first side of said core;
• second skin means for transmitting forces attached to said second side of said core;
• and
• first web means for transmitting force from said first skin means to said second skin means through said core, said first web means dividing said core into a first core portion and a second core portion and connecting said first skin means to said second skin means,
• wherein said first skin means comprises a first skin portion and a second skin portion, wherein said second skin portion is attached to said first core portion and extends to said first web means and said first skin portion is generally attached to said second core portion and has an overlapping first skin portion extending past said web overlapping said second skin portion for a predetermined distance on a first core side of said first web means and said overlapping first skin portion is connected to said second skin portion by a first connection means,
• wherein said second skin means comprises a third skin portion and a fourth skin portion, wherein said fourth skin portion is attached to said second core portion and extends to said first web means and said third skin portion is generally attached to said first core portion and has an overlapping third skin portion extending past said web overlapping said fourth skin portion for a predetermined distance on a second core side of said first web means and said overlapping third skin portion is connected to said fourth skin portion by a second connecting means,
• wherein said first web means comprises a first core web and a second core web, wherein said first core web is attached to said first core portion and connects said second skin portion with said third skin portion, wherein said second core web is attached to said second core portion and connects said first skin portion with said fourth skin portion.