Method of manufacture of a structural polymer core assembly
First Claim
1. A method of utilizing a thermoformable composite structure having a specified width, length, and height defining a top and bottom of said composite structure comprising:
- providing a single thermoformable three dimensional structural core constructed of a fiber infused thermoplastic with a pyramidal geometric pattern repeated along the length thereof, said pyramidal geometric pattern repeated along the width thereof;
forming said pyramidal geometric pattern so that it is symmetric about a neutral axis of said structural core and is comprised of a plurality of pyramidal shapes;
forming each of said pyramidal shapes to have four side faces which intersect to form edges;
forming each of said edges to include a radius;
forming said pyramidal geometric pattern to have a series of peaks and troughs that have flat bottoms and tops;
thermally bonding a thermoformable first reinforcement layer to the top of said structural core wherein said first reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core; and
thermally bonding a thermoformable second reinforcement layer to the bottom of said structural core wherein said second reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core.
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Accused Products
Abstract
A composite structure, and method of manufacturing it, having a specified width, length, and height defining a top and bottom the composite structure. The composite structure includes a three dimensional structural core constructed of a polymer with a first series of a geometric pattern repeated along its length. The structural core also has a second series of the geometric pattern repeated along the width thereof. The geometric patter may be a sinusoidal curve or a substantially pyramidal shape. The composite structure also includes a first reinforcement layer made of a polymer positioned above the structural core and bonded thereto. It also includes a second reinforcement layer made of a polymer that is positioned below the structural core and bonded thereto. The composite structure may also include a decorative layer above the first reinforcement layer, an acoustical batting layer positioned between the first reinforcement layer and the structural core, and may include fire retardant chemicals.
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Citations
15 Claims
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1. A method of utilizing a thermoformable composite structure having a specified width, length, and height defining a top and bottom of said composite structure comprising:
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providing a single thermoformable three dimensional structural core constructed of a fiber infused thermoplastic with a pyramidal geometric pattern repeated along the length thereof, said pyramidal geometric pattern repeated along the width thereof; forming said pyramidal geometric pattern so that it is symmetric about a neutral axis of said structural core and is comprised of a plurality of pyramidal shapes; forming each of said pyramidal shapes to have four side faces which intersect to form edges; forming each of said edges to include a radius; forming said pyramidal geometric pattern to have a series of peaks and troughs that have flat bottoms and tops; thermally bonding a thermoformable first reinforcement layer to the top of said structural core wherein said first reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core; and thermally bonding a thermoformable second reinforcement layer to the bottom of said structural core wherein said second reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of manufacturing a structural composite for use in the interior of a vehicle comprising:
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providing a sheet of a fiber infused thermoplastic; preheating said sheet of fiber infused thermoplastic; forming said sheet into a single thermoformable structural core with a pyramidal geometric pattern repeated along the length thereof and said pyramidal geometric pattern repeated along the width thereof by way of compression; forming said pyramidal geometric pattern so that it is symmetric about a neutral axis of said structural core and is comprised of a plurality of pyramidal shapes; forming each of said pyramidal shapes to have four side faces which intersect to form edges; forming each of said edges to include a radius; forming said pyramidal geometric pattern to have a series of peaks and troughs that have flat bottoms and tops; laminating a thermoformable first reinforcement layer constructed of the same fiber infused thermoplastic as said structural core onto the top of said structural core; laminating a thermoformable second reinforcement layer constructed of the same fiber infused thermoplastic as said structural core onto the bottom of said structural core; affixing a decorative layer to the outer portion of said first reinforcement layer; and forming said structural composite into the shape for which it will be used in said interior of said vehicle. - View Dependent Claims (14, 15)
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Specification