Composite panel adapted for point compressive loads and method for making same

A method for manufacturing a composite boat transom comprising the steps of:

• positioning a first fabric layer spaced from a second fabric layer to form opposing transom surfaces;
• positioning elongated rigid channel members between said first and second fabric layers aligned with locations corresponding to areas of anticipated point compressive loading;
• and
• injecting a foam core between said first and second fabric layers.

A method for manufacturing a composite boat transom comprising the steps of:

• positioning a first fabric layer spaced from a second fabric layer to form opposing transom surfaces;
• positioning elongated rigid channel members between said first and second fabric layers aligned with locations corresponding to areas of anticipated point compressive loading associated with an outboard motor bracket;
• injecting a foam core between said first and second fabric layers;
• and
• causing said foam core to penetrate at least partially into interstices of said fabric layers to bind said foam core to said fabric layers.

A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:

• positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
• fixing a foam core between at least a portion of said fabric layers to form said panel;
• positioning at least one rigid point compressive load bearing member between portions of said foam core along areas of anticipated point compression loading in a location to prevent compression of said foam core when a point compressive load is applied to said point compressive load bearing members;
• and
• selecting said point compressive load bearing member to be an elongated channel formed of a material selected from the group consisting of steel, aluminum and a metal alloy.

A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:

• positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
• fixing a foam core between at least a portion of said fabric layers to form said panel;
• positioning at least one rigid point compressive load bearing member between portions of said foam core along areas of anticipated point compression loading in a location to prevent compression of said foam core when a point compressive load is applied to said point compressive load bearing members;
• and
• forming at a periphery of said opposing panel surfaces a plurality of fabric tabs attached to at least one of said first and second fabric layers.

A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:

• positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
• fixing a foam core between at least a portion of said fabric layers to form said panel;
• positioning at least one rigid point compressive load bearing member between portions of said foam core along areas of anticipated point compression loading in a location to prevent compression of said foam core when a point compressive load is applied to said point compressive load bearing members;
• and
• laminating said panel into a composite boat hull to form a transom.

A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:

• positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
• positioning a rigid point compressive load bearing member between said first and second fabric layers along areas of anticipated point compression loading;
• and
• injecting a foam core between at least a portion of said first and second fabric layers to form said panel, wherein said rigid point compressive load bearing member prevents compression of said foam core when a point compressive load is applied to said point compressive load bearing member;
• and
• injecting a foam core into said rigid point compressive load bearing member.

A method of forming high strength panels suitable for use in applications requiring a capability to withstand point compression loading without deformation, comprising the steps of:

• positioning a first fabric layer spaced from a second fabric layer to form opposing panel surfaces;
• positioning a rigid point compressive load bearing member between said first and second fabric layers along areas of anticipated point compression loading;
• and
• injecting a foam core between at least a portion of said first and second fabric layers to form said panel, wherein said rigid point compressive load bearing member prevents compression of said foam core when a point compressive load is applied to said point compressive load bearing member;
• and
• selecting said rigid point compressive load bearing member to be an elongated channel formed of a material selected from the group consisting of steel, aluminum and a metal alloy.