Composite structures and method of making composite structures

A method of making a composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, said method comprising the steps of:

• attaching a reinforcing fabric layer to a non-woven fabric layer on one side thereof;
• laying said attached fabric layers into a mold with the non-woven fabric layer facing the interior of the mold;
• filling said mold with a self-expanding, self-curable, uncured structural foam;
• and
• allowing said foam to expand and cure to attach itself to said non-woven fabric layer by filling interstices of said non-woven fabric layer in a manner such that said foam does not penetrate into the reinforcing fabric layer to thereby result in said composite structure, and
• wherein said reinforcing fabric layer of said composite structure is capable of being subsequently saturated with curable resin after said structural foam has been attached to said non-woven fabric layer.

A method of manufacturing a boat, comprising the steps of:

• spraying a layer of gelcoat into a boat-hull mold and allowing said gelcoat layer to cure;
• laying a structural skin coat of fiberglass;
• laying stringers throughout said mold in a reinforcing arrangement on said structural skin coat of fiberglass, said stringers being made as a composite structure comprising, a reinforcing fabric layer, a non-woven fabric layer attached to said reinforcing fabric layer, a structural foam attached to said non-woven fabric layer on the side of said non-woven fabric layer opposite said reinforcing fabric layer by having filled interstices of said non-woven fabric layer, and said stringers having flaps of said attached reinforcing fabric layer and non-woven fabric layer extending therefrom and not attached to said foam, with said stringers being laid so that said flaps lay on said structural skin coat of fiberglass;
• impregnating said structural skin coat of fiberglass and said stringers with curable resin;
• and
• curing said resin to result in a boat hull having said stringers attached thereto.