Composite Structure with U- and Z-Folded Sheets for Load Strength

The patent divides the composite panel into modular components: discrete core elements arranged in parallel rows, and separate fibrous reinforcement elements that can be positioned independently. This segmentation allows each component to be manufactured separately with standard dimensions, then assembled into custom configurations to achieve desired mechanical characteristics without requiring entirely custom-manufactured parts.

The patent enables dynamic adaptation of the composite structure's mechanical properties by allowing variable spacing between core elements, variable orientations of fibrous reinforcement, and selective placement of reinforcements at different locations. This dynamic configurability during assembly allows tailoring of stiffness, strength, and other mechanical characteristics for specific application requirements.

The patent combines two distinct materials with complementary properties: rigid core elements (such as foam or plastic) that provide structural support and shape, and fibrous reinforcement materials (such as fiberglass or carbon fiber) that provide tensile strength and wear resistance. This composite approach creates a panel structure with superior load-bearing capacity and durability compared to single-material constructions.

The patent applies fibrous reinforcement selectively at locations where strength and wear resistance are most needed, such as areas subject to heavy loads, friction, or impact. The reinforcement can be concentrated at edges, corners, or specific load paths while using lighter core material elsewhere, optimizing the strength-to-weight ratio and manufacturing efficiency.