High strength, light weight composite structure, method of manufacture and use thereof

A composite structure (10) comprising:

• a first outer skin (12);
• a second outer skin (14);
• and a core (16) sandwiched between the first outer skin (12) and the second outer skin (14);
• wherein the core (16) comprises a plurality of spaced apart ridges (18) between the first outer skin (12) and the second outer skin (14), each of the spaced apart ridges (18) extending from one end (20) of the composite structure (10) to an opposite end (22);
• and a plurality of connecting elements (24) between the first outer skin (12) and the second outer skin (14) intersecting with the ridges (18) to form open channels (26) within the core (16);
• wherein each open channel (26) within the core (16) is also sandwiched between the first outer skin (12) and the second outer skin (14);
• wherein the ridges (18) of the core (16) and the connecting elements (24) of the core (16) each comprises a plurality of composite plies including at least a first composite ply and a second composite ply, the first composite ply and the second composite ply each comprising a plurality of unidirectional, continuous fibers in a thermoplastic matrix, the plurality of composite plies being bonded together to form a composite laminate of continuous, substantially parallel fiber reinforcement for the ridges (18) of the core (16) and a composite laminate of continuous, substantially parallel fiber reinforcement of the connecting elements (18) of the core (16);
• and
• at least one of the first outer skin (12) and the second outer skin (14) comprises a plurality of composite plies including at least a first composite ply and a second composite ply, the first composite ply and the second composite ply each comprising a plurality of unidirectional, continuous fibers in a thermoplastic matrix;
• the plurality of composite plies being bonded together to form a composite laminate of continuous substantially parallel fiber reinforcement of the outer skin.