Patent ID: 8663791

Claim:
A composite panel having an upper surface and a lower surface comprising: a plurality of elongated strips of low density cellular material arranged in laterally adjacent relation to form a core panel with the strips having first side surfaces facing the upper surface of the panel, opposite second side surfaces facing the lower surface of the panel, and opposing faces between adjacent elongated strips, wherein each of said elongated strips comprises a series of laterally adjacent blocks, with reinforcing strips of a first continuous flexible fibrous sheet material continuously and completely covering one side surface of the elongated strips forming a first set of double wall pleats between the adjacent blocks and extending at least partially through said thickness of the elongated strips, an additional continuous flexible sheet of fibrous and porous reinforcing material continuously overlying the first side surfaces of said elongated strips, the additional flexible sheet having parallel spaced portions projecting between the adjacent elongated strips and forming a second set of double wall pleats between the opposing faces of the adjacent elongated strips, the second set of double wall pleats extending at least partially through the thickness of the core panel as defined by the opposite side surfaces of the elongated strips, and an adhesive resin attaching the reinforcing strips, the additional flexible material sheet to the elongated strips, the first set of double wall pleats and the second set of double wall pleats cooperating to reinforce said core panel in two directions.