Patent ID: 8157937

Claim:
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.