Panels utilizing a precured reinforced core and method of manufacturing the same

A flooring assembly comprising:

• a plurality of panels, said panels being interconnected and each panel of said plurality of panels including
• a top skin having a thickness,
• a bottom skin having a thickness,
• a core located between the top and bottom skins;
• and
• closeout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the top skin, the bottom skin, and closeout are a phenolic composite.

A flooring assembly for use in mass transit vehicles, wherein the mass transit vehicle includes a car assembly including spaced apart side walls, spaced apart end walls, and a floor support assembly, said composite flooring assembly comprising:

• a plurality of panels interconnected to cover the floor support assembly, and each panel of said plurality of panels including
• a top skin having a thickness,
• a bottom skin having a thickness,
• a core located between the top and bottom skins;
• and
• closeout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core is a precured reinforced core, and wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips.

A method of manufacturing precured reinforced core, said method comprising the steps of:

• providing a foam core to act as a base;
• placing at least one layer of fabric on top of the foam core base;
• fully impregnating each layer of fabric with phenolic resin;
• placing a top layer of foam core on the impregnated fabric to create a bun;
• curing the bun at a requisite temperature and pressure;
• and
• cooling the bun thereby creating a finished laminate between the foam layers of the bun such that the laminate does not allow any additional resin to penetrate between the foam layers.

A panel comprising:

• a top skin;
• a bottom skin;
• and
• a precured reinforced core made by a method including the steps of
• providing a foam core to act as a base,
• placing at least one layer of fabric on top of the foam core base,
• fully impregnating each layer of fabric with phenolic resin,
• placing a top layer of foam core on the impregnated fabric to create a bun,
• curing the bun at a requisite temperature and pressure, and
• cooling the bun thereby creating a finished laminate between the foam layers of the bun such that the laminate does not allow any additional resin to penetrate between the foam layers.

A panel comprising:

• a top skin;
• a bottom skin;
• a core located between the top and bottom skins, wherein the core includes at least one tapping block, the tapping block including
• a fiber reinforced material block and
• a metal plate encapsulated within the block, wherein the tapping block is adapted to be drilled and tapped so as to provide the panel with a mounting area with increased support.

A panel comprising:

• a top skin having a thickness;
• a bottom skin having a thickness;
• a core located between the top and bottom skins;
• and
• closeout contacting the top skin and the bottom skin, wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core is a precured reinforced core, and wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips.

A panel comprising:

• a top skin having a thickness;
• a bottom skin having a thickness;
• a core located between the top and bottom skins;
• and
• closeout contacting the top skin and the bottom skin, wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support.

A flooring assembly comprising:

• a plurality of panels, said panels being interconnected and each panel of said plurality of panels including
• a top skin having a thickness,
• a bottom skin having a thickness,
• a core located between the top and bottom skins;
• and
• closeout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core is a precured reinforced core, and wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips.

A flooring assembly comprising:

• a plurality of panels, said panels being interconnected and each panel of said plurality of panels including
• a top skin having a thickness,
• a bottom skin having a thickness,
• a core located between the top and bottom skins;
• and
• closeout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support.

A flooring assembly for use in mass transit vehicles, wherein the mass transit vehicle includes a car assembly including spaced apart side walls, spaced apart end walls, and a floor support assembly, said composite flooring assembly comprising:

• a plurality of panels interconnected to cover the floor support assembly, and each panel of said plurality of panels including
• a top skin having a thickness,
• a bottom skin having a thickness,
• a core located between the top and bottom skins;
• and
• closeout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support.