Patent ID: 7882679

Claim:
A lightweight structural building element suitable for use in supporting loads comprising: an aluminum alloy inner structural core constructed from a substantially solid aluminum alloy sheet that is shaped to form a hollow structure having a hollow inner space; a plurality of continuous hollow arms formed from said substantially solid aluminum alloy sheet that extend outwardly from a center portion of said aluminum alloy inner structural core, said plurality of continuous hollow arms constructed from said substantially solid aluminum alloy sheet, said continuous hollow arms shaped to form a plurality of lobes that enclose areas between said lobes; a thermoplastic layer that is extruded over an outer surface of said aluminum alloy inner structural core and said plurality of continuous hollow arms, said thermoplastic layer substantially surrounding said aluminum alloy inner structural core and said plurality of continuous hollow arms, said thermoplastic layer filling said areas between said plurality of continuous hollow arms and said plurality of lobes so that said plurality of continuous hollow arms and 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 continuous hollow arms, and so that said thermoplastic layer substantially surrounds said aluminum alloy inner structural core and said plurality of continuous hollow arms to provide a protective layer that protects said aluminum alloy inner structural core and said plurality of continuous hollow arms.