Patent ID: 7857934

Claim:
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.