Patent ID: 8322037
Filing Date: 2012-12-04
Classification: E04C,Y10T

Abstract:
1. A method of forming a lightweight structural building element for use in supporting loads comprising: forming an aluminum alloy inner structural core constructed from a substantially solid aluminum alloy billet that is shaped to have a hollow inner space; forming a plurality of substantially continuous hollow arms from said substantially solid aluminum alloy billet that extend outwardly from a central portion of said aluminum alloy inner structural core, said central portion extending in a longitudinal direction along a length of said aluminum allow inner structural core; forming lobes at end portions of said substantially continuous hollow arms to enclose areas between said lobes; extruding a thermoplastic layer over said aluminum alloy inner structural core, said plurality of substantially continuous hollow arms and said lobes so that said thermoplastic substantially surrounds exterior surfaces of said aluminum alloy inner structural core, said plurality of substantially continuous hollow arms and said lobes, said thermoplastic layer filling said areas enclosed between said lobes so that said lobes mechanically capture and partially enclose a portion of said thermoplastic layer to secure said thermoplastic layer to said aluminum alloy inner structural core and said plurality of substantially continuous hollow arms to provide a protective layer for said aluminum alloy structural core, said substantially continuous hollow arms and said lobes.