Composite structures and method of making composite structures

A method of manufacturing an elongated boat hull reinforcing member formed from interlocking composite structures, comprising the steps of:

• attaching a reinforced fabric layer to a non-woven fabric layer on one side thereof;
• laying said attached fabric layers into a plurality of elongated molds with the non-woven fabric layer facing the interior of said plurality of molds, each of said molds being provided with at least one of a male and female interlocking mold structure on an end portion thereof;
• predetermining an amount of foam for said molds to fill interstices of the non-woven fabric layer without penetrating through the reinforced fabric layer;
• pre-setting a dispensing device for a self-expanding, self-curable, uncured structural foam to dispense said amount of said foam;
• filling said molds with said amount of said foam;
• 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 to thereby result in a plurality of elongated reinforcing members having at least one of a male and female interlocking member integrally formed on the end portion thereof;
• positioning said reinforcing members end to end in linear alignment;
• and
• engaging said interlocking member of a first one of said plurality of reinforcing members with an oppositely-sexed interlocking member of a second one of said plurality of reinforcing members, to temporarily maintain said first and second reinforcing members in a stationary position relative to each other within a laminated plastic boat hull until said reinforcing members may be permanently laminated into position therein.