Patent ID: 7297390

Claim:
A thermoformable composite structure having a specified width, length, and height defining a top and bottom of said composite structure comprising: 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; said pyramidal geometric pattern being symmetric about a neutral axis of said structural core; said pyramidal geometric pattern comprised of a plurality of pyramidal shapes; each of said pyramidal shapes having four side faces which intersect to form edges; each of said edges including a radius; said pyramidal geometric pattern providing a series of peaks and troughs that have flat tops and bottoms; a thermoformable first reinforcement layer positioned above said structural core and thermally bonded thereto wherein said first reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core; and a thermoformable second reinforcement layer positioned below said structural core and thermally bonded thereto wherein said second reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core.