Method of manufacturing a structural polymer core assembly
First Claim
1. A method of manufacturing a multi-layer composite structure having a width, length, and height, the method comprising:
- heating a sheet of fiber-infused thermoplastic polymer;
forming said heated sheet of fiber-infused thermoplastic polymer into a structural core having a pyramidal geometric pattern, wherein said pyramidal geometric pattern repeats along a length and a width of said structural core, is symmetric about a neutral axis of said structural core, and is comprised of a plurality of pyramidal shapes, and wherein each of said pyramidal shapes has at least four side-faces intersecting at respective edges, each of said edges including a radius;
thermally bonding a first thermoformable reinforcement layer to a top of said structural core, said first reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core; and
thermally bonding a second thermoformable reinforcement layer to a bottom of said structural core, said second reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core.
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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.
39 Citations
8 Claims
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1. A method of manufacturing a multi-layer composite structure having a width, length, and height, the method comprising:
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heating a sheet of fiber-infused thermoplastic polymer; forming said heated sheet of fiber-infused thermoplastic polymer into a structural core having a pyramidal geometric pattern, wherein said pyramidal geometric pattern repeats along a length and a width of said structural core, is symmetric about a neutral axis of said structural core, and is comprised of a plurality of pyramidal shapes, and wherein each of said pyramidal shapes has at least four side-faces intersecting at respective edges, each of said edges including a radius; thermally bonding a first thermoformable reinforcement layer to a top of said structural core, said first reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core; and thermally bonding a second thermoformable reinforcement layer to a bottom of said structural core, said second reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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Specification