Reinforced bulkheads and methods of making same

Abstract

A reinforced bulkhead and method of manufacturing a reinforced bulkhead are disclosed. The bulkhead includes at least one rod that increases the strength and rigidity of the bulkhead. The rod is inserted during the manufacturing process. The size and shape of the bulkhead may be customized after the rod is inserted into the bulkhead core, allowing a manufacturer to prefabricate a large number of bulkhead cores and then customize the prefabricated cores on an as-needed basis.

1 . A method of manufacturing a bulkhead comprising the steps of:
 a. forming a bulkhead core;   b. creating a cavity in the bulkhead core; and   c. inserting a rod into the cavity.   
   
   
       2 . The method of  claim 1 , further comprising the step of trimming the bulkhead to a desired size. 
   
   
       3 . The method of  claim 1 , further comprising the step of attaching a bumper to the bulkhead core. 
   
   
       4 . The method of  claim 1 , wherein the cavity runs longitudinally down the length of the core. 
   
   
       5 . The method of  claim 1 , wherein the cavity is formed with a hot knife. 
   
   
       6 . The method of  claim 1 , wherein steps (b) and (c) are done simultaneously. 
   
   
       7 . The method of  claim 1 , wherein the bulkhead core comprises a closed cell foam. 
   
   
       8 . A method of manufacturing a bulkhead comprising the steps of:
 a. forming a bulkhead core, wherein the bulkhead core has first and second sides that are substantially parallel to each other and third and forth sides that are substantially perpendicular to the first and second sides, the first side being capable of attachment to a mounting system;   b. creating a plurality of cavities in the bulkhead core, wherein the cavities are substantially parallel to the second and third sides;   c. inserting a plurality of rods into the cavities;   d. placing the bulkhead core with rods into a storage area;   e. retrieving the bulkhead core with rods from the storage area;   f. cutting the bulkhead core to a desired length and width;   
   
   
       9 . The method of  claim 8 , further comprising the steps of:
 g. attaching a bulkhead skin to the bulkhead core;   h. attaching a bumper to the bulkhead core; and   i. attaching a protective wrap to the bulkhead core.   
   
   
       10 . A bulkhead comprising:
 a. a bulkhead core, wherein the bulkhead core comprises a material that is flexible;   b. a rod that is located inside the core, wherein the rod is less flexible than the bulkhead core.   
   
   
       11 . The bulkhead of  claim 10 , wherein the bulkhead includes more than one rod. 
   
   
       12 . The bulkhead of  claim 10 , wherein the rod runs longitudinally along the length of the bulkhead core. 
   
   
       13 . The bulkhead of  claim 10 , wherein the rod comprises a hollow fiberglass tube. 
   
   
       14 . The bulkhead of  claim 10 , wherein the material is a closed cell foam. 
   
   
       15 . The bulkhead of  claim 10 , wherein the bulkhead core comprises at least three layers, each of which comprises a material that is a closed cell foam.