Patent ID: 8440120

Claim:
A method of forming a composite structure comprising the following steps: a) providing at least one core block having a first surface and a second surface and having a thickness (h), a number of first grooves formed in the first surface of the core, the first grooves having a first height (h 1 ) and a bottom, and a number of second grooves formed in the second surface of the core block and having a second height (h 2 ), the first grooves and the second grooves forming part of a resin distribution network in the core block, and the core block bendable about axes extending in the longitudinal direction along the first grooves, b) covering at least a part of the core block with a fiber material, c) placing the covered core block in a forming structure comprising a mold part and a vacuum bag, d) sealing the vacuum bag against the mold part to form an interior part of the forming structure, e) connecting a source of uncured fluid resin to feed uncured resin to the resin distribution network, f) connecting the interior of the forming structure to at least one vacuum outlet, g) forcing the uncured resin from the source of uncured resin through the resin distribution network and to the vacuum outlet in order to fill the interior of the forming structure and to impregnate the fiber material, and h) curing the resin in order to form a composite structure, wherein the sum of the first height and the second height (h 1 +h 2 ) is larger than the thickness (h) of the core block, and wherein at least one of the first grooves in the first surface of the core block crosses at least one of the second grooves in the second surface of the core block, wherein the distance (t) between the bottom of the first grooves and the second surface of the core block is of such a size that the core block is flexible along the first grooves, and wherein the core block is formed as a single integrated block.