Patent ID: 8042315

Claim:
A reinforced panel which comprises: a base layer made of a composite material, said base layer having a surface; a first elongated stiffening member having a substantially U-shaped cross section with a base portion and a pair of substantially parallel and opposite legs extending from the base portion to a respective edge to define a channel therebetween, wherein each edge of the first elongated stiffening member is integrally affixed to the surface of said base layer to position the base portion of said first elongated stiffening member at a distance “h” from said base layer; a second elongated stiffening member having a substantially U-shaped cross section with a base portion and a pair of substantially parallel and opposite legs extending from the base portion to a respective edge to define a channel therebetween, wherein each edge of the second elongated stiffening member is integrally affixed to the surface of the base layer to position the base portion of said second stiffening member at the distance “h” from said base layer, and wherein the second elongated stiffening member is oriented transverse to the first stiffening member to therewith reinforce the base layer and create the panel; a plurality of flaps formed from the base layer wherein each flap extends from an edge of a respective stiffening member and into the channel thereof, and further wherein each flap is bonded to a leg of the respective stiffening member and further wherein each edge of the respective stiffening member is formed as a foot for the respective legs; and a plurality of overlap layers wherein each overlap layer covers the foot of a each of the respective legs and extends therefrom for contact with the surface of the base layer and with the legs of the respective stiffening member to bond therewith and secure the respective stiffening member to the base layer, and wherein each flap is bonded to each of the respective legs of the respective stiffening member opposite from the overlap layers.