All composite article of manufacture including first and second composite members joined by a composite hinge

An article of manufacture comprising:

• a. A first rigid composite member comprising a plurality of plies of high tensile strength fibers layed-up one upon the other and bonded together by a first resin matrix,
• b. A second rigid composite member comprising a plurality of plies of high tensile strength fibers laid-up one upon the other and bonded together by a second resin matrix, and
• c. A hinge member joining said first and second members in hinge fashion and comprising,
• 1. At least one hinge ply of high tensile strength fibers extending for at least a portion of the length and width of said first member and forming part thereof within said first resin matrix and further extending for at least a portion of the length and width of such second member and forming part thereof within said second resin matrix and still further including a hinge area extending between said first and second members, the width of the hinge area being determined by the spacing between said first and second members, and
• 2. A protective material cooperating with the hinge area of said hinge ply to provide flexibility thereto and to prevent the resin from said first and second resin matrices of said first and second members from adhering to the hinge areas of the hinge ply during curing, so as to provide a flexible hinge between said first and second members.