Method of making a fiber reinforced core panel

1. A process for forming a composite structure comprising, in order:

arranging a series of adjacent low density strips, wherein the longitudinal axis of the low density strips are substantially parallel forming a core panel having a first side and an opposing second side, wherein the low density strips have at least three faces and having a length to width aspect ratio of at least 5:1, wherein the cross-section of each strip has a major face, a first edge face, and a second edge face, wherein the major face of each strip is disposed within the first or second side of the core panel, wherein the major face of each strip is disposed within an opposite face of the core panel than the major face of the adjacent strips;

threading a continuous fibrous reinforcement sheet through the low density strips such that the fibrous reinforcement sheet is disposed between adjacent strips and adjacent to the major faces of the low density strips, wherein the reinforcement sheet forms at least about sixty five percent (65%) of the surface area of the first side of the core panel and at least about sixty five percent (65%) of the surface area of the second side of the core panel, wherein the reinforcement sheet is not continuous on the first or second side of the core panel; and,

bonding the continuous fibrous reinforcement sheet to the low density strips with an adhesive.

2. The process of claim 1 , wherein the reinforcement sheet forms at least about eighty percent (80%) of the surface area of the first side of the core panel and at least about eighty percent (80%) of the surface area of the second side of the core panel.

3. The process of claim 1 , wherein the continuous fibrous reinforcement sheet comprises a multi-axial knit fabric.

4. The process of claim 1 , wherein the continuous fibrous reinforcement sheet comprising at least one layer of generally parallel rovings.

5. The process of claim 1 , further comprising placing a first outer skin layer on the first side of the fiber reinforced core panel.

6. The process of claim 5 , further comprising placing a second outer skin layer on the second side of the fiber reinforced core panel.

7. The process of claim 6 , further comprising flowing a polymeric matrix into at least a portion of one of the first outer skin, the second outer skin layer, and the continuous fibrous reinforcement sheet and curing the matrix.

8. The process of claim 1 , wherein the low density strips contain an included angle defined as the angle in the strip created by a first line formed by connecting the ends of one edge face and a second line formed by the major face of the low density strips, wherein the included angle is less than 90 degrees.

9. The process of claim 1 , wherein the low density strips contain:

a first included angle defined as the angle in the strip created by a first line formed by connecting the ends of the first edge face and a second line formed by the major face of the low density strips;

a second included angle defined as the angle in the strip created by a third line formed by connecting the ends of the second edge face and a forth line formed by the major face of the low density strips;

wherein the sum of the first included angle and second included angle is less than 180 degrees.

10. A process for forming a composite structure comprising, in order:

arranging a series of adjacent low density strips, wherein the longitudinal axis of the low density strips are substantially parallel forming a core panel having a first side and an opposing second side, wherein the low density strips have at least three faces and having a length to width aspect ratio of at least 5:1, wherein the cross-section of each strip has a major face, a first edge face, and a second edge face, wherein the major face of each strip is disposed within the first or second side of the core panel, wherein the major face of each strip is disposed within an opposite face of the core panel than the major face of the adjacent strips;

threading a continuous fibrous reinforcement sheet through the low density strips such that the fibrous reinforcement sheet is disposed between adjacent strips and adjacent to the major faces of the low density strips, wherein the reinforcement sheet forms at least about sixty five percent (65%) of the surface area of the first side of the core panel and at least about sixty five percent (65%) of the surface area of the second side of the core panel, wherein the reinforcement sheet is not continuous on the first or second side of the core panel, wherein the reinforcement sheet is not continuous on the first or second side of the core panel;

bonding the continuous fibrous reinforcement sheet to the low density strips with an adhesive;

placing a first outer skin layer on the first side of the fiber reinforced core panel;

flowing a polymeric matrix into at least a portion of one of the first outer skin and the continuous fibrous reinforcement sheet; and,

curing the polymeric matrix.

11. The process of claim 10 , wherein the continuous fibrous reinforcement sheet comprises a multi-axial knit fabric.

12. The process of claim 10 , wherein the continuous fibrous reinforcement sheet comprising at least one layer of generally parallel rovings.

13. The process of claim 10 , further comprising placing a second outer skin layer on the second side of the fiber reinforced core panel.

14. The process of claim 13 , further comprising flowing a polymeric matrix into at least a portion of one of the first outer skin, the second outer skin layer, and the continuous fibrous reinforcement sheet and curing the matrix.