Lightweight flame resistant composite panel and panel attachment system

Abstract

A lightweight flame-resistant composite panel is provided including a body portion and a side portion folded over the body portion. The side portion includes a channel segment adjacent to the body portion, and an overlapping segment adjacent to the channel segment. One or more panel apertures are located in the body portion and the channel segment for receiving bolts through the side of the panel. An edge reinforcement insert can be inserted underneath the channel segment in a channel defined by the folded side portion along an edge of the body portion. The edge reinforcement insert includes one or more insert apertures for receiving the one or more bolts through the panel, thereby increasing the bolt bearing strength of the panel along its edge. The edge reinforcement insert may comprise an elongated strip, a plurality of separated tabs, or an end cap, or may alternatively be contained within the panel.

What is claimed is: 
     
         1 . A lightweight, flame resistant composite panel comprising:
 a body portion and a side portion, the side portion including a channel segment adjacent to the body portion, the channel segment and body portion including a plurality of panel apertures for receiving one or more fasteners, the side portion further including an overlapping segment adjacent to the channel segment, the side portion overlapping the body portion such that the overlapping segment projects toward the body portion and thereby defines a channel underneath the channel segment along an edge of the body portion, the plurality of panel apertures in the channel segment and body portion being aligned to receive the one or more fasteners through the body portion adjacent to the edge.   
     
     
         2 . The lightweight composite panel of  claim 1 , wherein the body portion is of uniform thickness. 
     
     
         3 . The lightweight composite panel of  claim 1 , wherein the side portion is tapered, wherein the body portion has a first thickness, wherein the channel segment has a second thickness greater than the first thickness of the body portion, and wherein the overlapping segment has a third thickness greater than the second thickness of the channel segment. 
     
     
         4 . The lightweight composite panel of  claim 1 , wherein the lightweight composite panel is rigid and is reinforced by a fiber selected from the group consisting of glass fiber and carbon fiber, and wherein the fiber is bound by a polymer resin matrix selected from the group consisting of thermosets and thermoplastics. 
     
     
         5 . The lightweight composite panel of  claim 1 , further comprising an edge reinforcement insert located in the channel and connected to the body portion, the edge reinforcement insert including one or more insert apertures for receiving the one or more fasteners, the edge reinforcement insert being positioned relative to the channel segment and the body portion such that the one or more insert apertures are aligned with a corresponding one or more of the plurality of panel apertures, respectively. 
     
     
         6 . The lightweight composite panel of  claim 5 , wherein the edge reinforcement insert includes an elongated strip, the one or more insert apertures being disposed within the elongated strip, the elongated strip including a material selected from the group consisting of metal, nonmetal, and composite, and the elongated strip having one of a continuous surface or a staggered surface. 
     
     
         7 . The lightweight composite panel of  claim 6 , wherein the edge reinforcement insert includes one or more curved tabs projecting from the elongated strip, the one or more insert apertures being disposed within the one or more curved tabs, the one or more curved tabs including a material selected from the group consisting of metal, nonmetal, and composite. 
     
     
         8 . The lightweight composite panel of  claim 1 , wherein the edge reinforcement insert includes a plurality of separated tabs, the one or more insert apertures being disposed within the plurality of separated tabs, the plurality of separated tabs each including a material selected from the group consisting of metal, nonmetal, and composite. 
     
     
         9 . A lightweight, flame resistant composite panel comprising:
 a body portion and a side portion, the side portion including one or more panel apertures for receiving one or more fasteners, the one or more panel apertures being adjacent to an edge of the body portion; and   an edge reinforcement insert applied to the side portion of the panel body, the edge reinforcement insert including one or more insert apertures for receiving the one or more fasteners, the edge reinforcement insert being positioned relative to the side portion such that the one or more insert apertures are aligned with a corresponding one or more of the panel apertures, respectively.   
     
     
         10 . The lightweight composite panel of  claim 9 , wherein the lightweight composite panel is rigid and is reinforced by a fiber selected from the group consisting of glass fiber and carbon fiber, and wherein the fiber is bound by a polymer resin matrix selected from the group consisting of thermosets and thermoplastics. 
     
     
         11 . The lightweight composite panel of  claim 9 , wherein the edge reinforcement insert is an elongated strip, the one or more insert apertures being disposed within the elongated strip, the elongated strip including a material selected from the group consisting of metal, nonmetal, and composite. 
     
     
         12 . The lightweight composite panel of  claim 11 , wherein the edge reinforcement insert includes one or more curved tabs projecting from the elongated strip, the one or more insert apertures being disposed within the one or more curved tabs. 
     
     
         13 . The lightweight composite panel of  claim 9 , wherein the edge reinforcement insert includes a plurality of separated tabs, the one or more insert apertures being disposed within the plurality of separated tabs. 
     
     
         14 . The lightweight composite panel of  claim 9 , wherein the edge reinforcement insert is an end cap applied to the side portion, the end cap including a front-facing portion and a rear-facing portion covering the side portion of the panel, the end cap including one or more end cap apertures for receiving one or more fasteners, the one or more end cap apertures correspondingly aligned with the one or more panel apertures, respectively. 
     
     
         15 . The lightweight composite panel of  claim 14 , wherein the front-facing portion and the rear-facing portion are of uniform thickness. 
     
     
         16 . The lightweight composite panel of  claim 14 , wherein a thickness of at least one of the front-facing portion or the rear-facing portion varies over the length of the end cap. 
     
     
         17 . The lightweight composite panel of  claim 16 , wherein the thickness of at least one of the front-facing portion or the rear-facing portion peaks at the location of the one or more end cap apertures. 
     
     
         18 . A lightweight, flame resistant composite panel comprising:
 a body portion including one or more panel apertures for receiving one or more fasteners, the body portion being of uniform thickness; and   an edge reinforcement insert contained within the body portion, the edge reinforcement insert including one or more insert apertures for receiving the one or more fasteners, the edge reinforcement insert being positioned relative to an edge of the body portion such that the one or more insert apertures are aligned with a corresponding one or more of the panel apertures, respectively.   
     
     
         19 . The lightweight composite panel of  claim 18 , wherein the edge reinforcement insert is sized to span an entire length of the body portion. 
     
     
         20 . The lightweight composite panel of  claim 18 , wherein the composite panel is flame resistant to a temperature of up to at least one of 900 degrees Centigrade, 1,200 degrees Centigrade, or 1,650 degrees Centigrade.