Multi-layer thermoformable laminates and methods of their manufacture

A thermoformable multi-layer laminate structure having been made by a process comprising the steps of:

• forming a polymer layer of an at least partially molten thermoplastic polymeric material having opposite sides;
• superposing first and second layers of glass cloth materials in confronting relationship with said partially molten thermoplastic polymer layer on the opposite sides thereof;
• and
• passing the superposed layers through a compression nip providing a gap which is less than the combined thickness of the layers and engaging free surfaces of said glass cloth layers with the partially molten thermoplastic polymeric material therebetween whereby the compression nip forces said partially molten thermoplastic polymer layers to flow into and impregnate the first and second glass cloth layers and said free surfaces of said glass cloth layers protrude from said polymer layer to form a core structure.