Patent ID: 7749420

Claim:
A method of processing a core structure for a composite structure, comprising the steps: a) providing a folded valley core structure that has opposite first and second major surfaces having a structured shape configured with an open three-dimensionally contoured configuration with continuous transverse fold valley channels extending respectively along each of said major surfaces of said core structure, and that is not a honeycomb core having open cells extending perpendicularly to a major plane of the core, and that alone is not self-supporting due to an insufficient strength and/or stiffness; b) temporarily providing a first support arrangement including at least a first core support arranged form-fittingly on at least a first partial area of said first major surface of said core structure to mechanically support and stabilize said core structure having said three-dimensionally contoured configuration, wherein said first core support form-fittingly fills said fold valley channels at least in said first partial area on only said first major surface and not on said second major surface, wherein said first core support comprises a form-fitting first core impression, and wherein said step b) comprises disposing said first core impression form-fittingly on at least said first partial area of said first major surface of said core structure; c) while said core structure is supported and stabilized by said first support arrangement, subjecting said core structure to a first processing; d) after said first processing, then separating and removing said core structure and said first support arrangement from one another; e) temporarily providing a second support arrangement comprising a form-fitting second core impression on said core structure to mechanically support and stabilize said core structure, by disposing said second core impression form-fittingly on at least a second partial area of said second major surface of said core structure, wherein said second core impression form-fittingly fills said fold valley channels at least in said second partial area on only said second major surface and not on said first major surface; f) while said core structure is supported and stabilized by said second support arrangement, subjecting said core structure to a second processing; and g) after said second processing, separating and removing said core structure and said second support arrangement from one another; and h) after said step d), sandwiching said core structure between two cover layers.