Structural elements made with cores of fiber-reinforced plastic

Structural element core adapted to space apart opposed first and second, laterally and longitudinally extended, generally planar surface structures, said core comprising a closed figure pattern of ribbing defined by a plurality of periodically intersecting laterally or longitudinally disposed and vertically stacked fibers and a fiber supporting plastic matrix, said fibers and matrix being radially deflected at their locus of intersection with oppositely disposed fibers and matrix sufficiently to be vertically stacked to the same height at their locus of intersection as between.

The method of forming a structural element core including the steps of laying a first succession of fibers carrying a bondable plastic matrix in a first direction, laying a second succession of fibers carrying a bondable plastic matrix in a second direction transverse to said first direction in a manner such that said first and second successions of fibers are interleaved and their respective polymers in contact, locally deflecting said first and second successions of fibers at their locus of intersection to reduce the height of the two successions of fibers to about the height the first or second succession of fibers, and replicating these steps in a laterally and longitudinally extended pattern to form a core having a planar surface including across the locus of fiber intersection, and bonding said fibers in their assembled relation with said bondable plastic matrix.

Structural element comprising first and second, laterally and longitudinally extended surface structures and interposed therebetween a fiber reinforced core comprising a closed figure pattern of ribbing defined by a plurality of periodically intersecting laterally or longitudinally disposed and vertically stacked fibers and a fiber supporting plastic matrix, said fibers being deflected at their locus of intersection with intersecting fibers sufficiently to reduce the height of said stacked fibers at their locus of intersection.

Structural element core adapted to space apart opposed first and second, laterally and longitudinally extended surface structures, said core comprising a closed figure pattern of ribbing defined by a plurality of periodically intersecting laterally or longitudinally disposed and vertically stacked fibers and a fiber supporting plastic matrix.

Structural element comprising opposed first and second, laterally and longitudinally extended surface structures and interposed therebetween a fiber reinforced core comprising a closed figure pattern of ribbing defined by a plurality of periodically intersecting laterally or longitudinally disposed and vertically stacked fibers and a fiber supporting plastic matrix.