Patent ID: 8419883

Claim:
A method of efficiently producing a continuous composite core panel comprising the steps of: continuously forming an elongated strip of low density cellular material having parallel opposite side surfaces and parallel opposite faces perpendicular to the side surfaces, continuously applying a layer of crossing reinforcement fibers onto the faces of the strip and continuously applying the same layer of crossing reinforcement fibers onto the side surfaces of the strip, wherein said continuous applications are by helical winding with fibrous reinforcements, feeding and cutting the continuous strip into a plurality of strips positioned in adjacent relation into a molding apparatus with the crossing reinforcement fibers on opposing faces forming webs positioned between the adjacent strips, applying a hardenable adhesive resin into the crossing reinforcement fibers forming the webs between the opposing faces while retaining porosity in the crossing reinforcement fibers on the side surfaces for subsequently receiving additional adhesive resin by the molding apparatus, and curing the hardenable adhesive resin on the opposing faces of the strips within the molding apparatus to harden the adhesive resin within the webs between the opposing faces of the strips and to produce a continuous core panel reinforced with adhesively bonded webs between the opposing faces of the strips with porous crossing reinforcement fibers on the side surfaces thereof.