Patent ID: 7824591

Claim:
A method comprising: forming a foam core, the core comprising a first core face, a second core face, a top core edge and a bottom core edge; wrapping the foam core with a first layer of fiber tape, the first layer of fiber tape extending continuously along the first core face, top core edge, second core face and bottom core edge of the foam core, wherein the wrapped core has a first wrapped face, a second wrapped face, a top wrapped edge and a bottom wrapped edge; placing a non-tacky veil on the first wrapped face and the second wrapped face of the wrapped core; stitching the wrapped foam core with a thread, the thread extending between and along the first wrapped face and the second wrapped face; wrapping the stitched wrapped core with a second layer of fiber tape to form a wrapped preform, the second layer of fiber tape extending continuously atop the first layer of fiber tape and along the first wrapped face, the top wrapped edge, the second wrapped face and the bottom wrapped edge; placing the wrapped preform in a mold; heating the mold wherein the thread becomes embedded; cooling the mold; and removing the formed structure from the mold.