Fiber reinforced core panel

Abstract

A fiber reinforced core panel having a first side and an opposing second side. The core panel contains a series of adjacent low density strips having at least three faces and having a length to width aspect ratio of at least 5:1. The core panel also contains a continuous fibrous reinforcement sheet which is threaded through the low density strips. 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.

1 . A fiber reinforced core panel having a first side and an opposing second side comprising:
 a series of adjacent low density strips having at least three faces and having a length to width aspect ratio of at least 5:1, wherein the longitudinal axis of the low density strips are substantially parallel, 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;   a continuous fibrous reinforcement sheet, wherein the continuous fibrous reinforcement sheets is threaded 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 side or second side of the core panel.   
     
     
         2 . A fiber reinforced core panel having a first side and an opposing second side comprising:
 a series of adjacent low density strips having at least three faces and having a length to width aspect ratio of at least 5:1, wherein the longitudinal axis of the low density strips are substantially parallel, 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;   a continuous fibrous reinforcement sheet, wherein the continuous fibrous reinforcement sheets is threaded 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 side or second side of the core panel; and,   a stabilizing layer on at least one of the first and second sides of the fiber reinforced core panel.   
     
     
         3 . The fiber reinforced core panel of  claim 2 , wherein the stabilizing layer is selected from the group consisting of fibrous strands, a scrim, unidirectional fibers, a thermoplastic film, and an adhesive layer. 
     
     
         4 . A composite structure comprising:
 the fiber reinforced core panel of  claim 2 ;   a first outer skin layer located on the first side of the fiber reinforced core panel;   a second outer skin layer located on the second side of the fiber reinforced core panel; and,   a resin impregnating at least a portion of one of the first outer skin, the second outer skin layer, and the continuous fibrous reinforcement sheet.   
     
     
         5 . A fiber reinforced core panel having a first side and an opposing second side comprising:
 a series of adjacent low density strips having at least three faces and having a length to width aspect ratio of at least 5:1, wherein the longitudinal axis of the low density strips are substantially parallel, 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, wherein the low density strips comprise a film or coating on at least one face of strip;   a continuous fibrous reinforcement sheet, wherein the continuous fibrous reinforcement sheets is threaded 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 side or second side of the core panel.   
     
     
         6 . The fiber reinforced core panel of  claim 5 , wherein the film or coating is impervious to resin. 
     
     
         7 . A composite structure comprising:
 the fiber reinforced core panel of  claim 5 ;   a first outer skin layer located on the first side of the fiber reinforced core panel;   a second outer skin layer located on the second side of the fiber reinforced core panel; and,   a resin impregnating at least a portion of one of the first outer skin, the second outer skin layer, and the continuous fibrous reinforcement sheet.   
     
     
         8 . A fiber reinforced core panel having a first side and an opposing second side comprising:
 a series of adjacent low density strips having at least three faces and having a length to width aspect ratio of at least 5:1, wherein the longitudinal axis of the low density strips are substantially parallel, 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, wherein the low density strips comprise a plurality of low density material segments and a plurality of reinforcing planes;   a continuous fibrous reinforcement sheet, wherein the continuous fibrous reinforcement sheets is threaded 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 side or second side of the core panel.   
     
     
         9 . The fiber reinforced core panel of  claim 8 , wherein the reinforcing planes are parallel to the longitudinal axis of the low density strips. 
     
     
         10 . The fiber reinforced core panel of  claim 8 , wherein the reinforcing planes are perpendicular to the longitudinal axis of the low density strips. 
     
     
         11 . The fiber reinforced core panel of  claim 8 , wherein the low density material segments and the plurality of reinforcing planes are adhered with an adhesive. 
     
     
         12 . A composite structure comprising:
 the fiber reinforced core panel of  claim 8 ;   a first outer skin layer located on the first side of the fiber reinforced core panel;   a second outer skin layer located on the second side of the fiber reinforced core panel; and,   a resin impregnating at least a portion of one of the first outer skin, the second outer skin layer, and the continuous fibrous reinforcement sheet.   
     
     
         13 . A composite panel having a top side and a bottom side and comprising at least two adjacent fiber reinforced core panel, wherein each reinforced core panel has a first side and an opposing second side and comprises:
 a series of adjacent low density strips having at least three faces and having a length to width aspect ratio of at least 5:1, wherein the longitudinal axis of the low density strips are substantially parallel, 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;   a continuous fibrous reinforcement sheet, wherein the continuous fibrous reinforcement sheets is threaded 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 side or second side of the core panel.   
     
     
         14 . The composite panel of  claim 13 , wherein the adjacent fiber reinforced core panels are arranges such that the low density strips of one fiber reinforced core panel are parallel to the low density strips of adjacent fiber reinforced core panels. 
     
     
         15 . The composite panel of  claim 13 , wherein the adjacent fiber reinforced core panels are arranges such that the low density strips of one fiber reinforced core panel are at a 90 degree angle to the low density strips of adjacent fiber reinforced core panels. 
     
     
         16 . The composite panel of  claim 13 , wherein the composite panel further comprises an additional layer of reinforcement between the adjacent fiber reinforced core panels. 
     
     
         17 . A composite structure comprising:
 the composite panel of  claim 13 ;   a first outer skin layer located on the top side of the composite panel;   a second outer skin layer located on the bottom side of the composite panel; and,   a resin impregnating at least a portion of one of the first outer skin, the second outer skin layer, and the continuous fibrous reinforcement sheet.   
     
     
         18 . A fiber reinforced core panel having a first side and an opposing second side comprising:
 a series of adjacent low density strips having at least three faces and having a length to width aspect ratio of at least 5:1, wherein the longitudinal axis of the low density strips are substantially parallel, 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, wherein the low density strips comprise channels on the major and minor faces of the strips;   a continuous fibrous reinforcement sheet, wherein the continuous fibrous reinforcement sheets is threaded 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 side or second side of the core panel.   
     
     
         19 . A composite structure comprising:
 the fiber reinforced core panel of  claim 18 ;   a first outer skin layer located on the first side of the fiber reinforced core panel;   a second outer skin layer located on the second side of the fiber reinforced core panel; and,   a resin impregnating at least a portion of one of the first outer skin, the second outer skin layer, and the continuous fibrous reinforcement sheet.