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Method of manufacture of a structural polymer core assembly

  • US 7,857,934 B2
  • Filed: 10/05/2007
  • Issued: 12/28/2010
  • Est. Priority Date: 01/28/2002
  • Status: Expired due to Fees
First Claim
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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:

  • 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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