Apparatus and methods for reinforcing a structural panel

A frame for inclusion in a structural panel comprising:

• a plurality of framework elements made of a composite material, the framework elements at least generally defining an overall panel shape and defining one or more openings;
• and
• a plurality of attachment members supported by the framework elements for attaching the panel relative to a structure, the attachment members including a framework attachment insert having a head and a shaft substantially concentric with and extending from the head through a hole in one of the framework elements to receive a fastener in the shaft;
• the attachment members further including an attachment blade having an elongated base supported by one of the framework elements and a blade member extending from and generally normal to the base, the supporting framework element, and the overall panel shape, the elongated base and the blade member together forming a T-shaped component;
• wherein the frame is configured to be at least partially covered by a polymeric material injection-molded around the one or more framework elements and into the openings to form the structural panel;
• and wherein the elongated base is completely encapsulated within the polymeric material, and wherein a portion of the blade member is encapsulated within the polymeric material.

A structural panel configured for inclusion in a structure, the panel comprising:

• a frame having one or more composite framework elements;
• and
• a material injection-molded onto at least a portion of the frame that fills one or more openings at least partly defined by the framework elements and defines at least a portion of a shape of the panel, the frame being completely encapsulated within the material during an injection-molding operation and the openings defining transparent sections forming windows;
• the frame further including a plurality of attachment members at least partly embedded in the injection-molded material and supported by the one or more composite framework elements;
• the attachment members including:
• an attachment blade having a base, the base being fully embedded in the injection-molded material so as to be encapsulated therein during the injection-molding operation, and a blade member substantially co-extensive with the base to form a T-shape with the base, a portion of the blade member being encapsulated within the injection-molded material during the injection-molding operation, and a major portion of the blade member extending outwardly from the injection-molded material to receive a plurality of fasteners along the blade member;
• and
• a framework attachment insert having a head and a shaft extending from the head through a hole in one of the one or more framework elements, the shaft configured to be at least partially penetrated by a fastener.