Pyramid waffle core structure and method of fabrication

A structural core, comprising:

• a plurality of rows bonded together laterally, each row formed from two ribbons, each ribbon having upper and lower edges forming a zig-zag pattern having an upper point and a lower point, each upper point of the zig-zag pattern on the upper edge directly above an adjacent upper point of the zig-zag pattern on the lower edge and each lower point of the zig-zag pattern on the upper edge directly above an adjacent lower point on the lower edge, the two ribbons bonded together along bonding lines running from each lower point of the zig-zag pattern on the upper edge to the two adjacent upper points of the zig-zag pattern on the lower edge, each ribbon having bend lines running from each upper and lower points of the zig-zag pattern on the upper edge to the adjacent respective upper and lower points of the zig-zag pattern on the lower edge, wherein the upper points of the zig-zag pattern on the upper edge and the lower points of the zig-zag pattern on the lower edge expand laterally as the two ends of the row are moved together, forming adjacent hollow pyramid-like structures having alternate upward-facing and downward-facing open bases, each hollow pyramid-like structure formed from four faces having substantially straight edges, each open base in one of the plurality of rows offset with respect to each open base in an adjacent another of plurality of rows, the edges of each adjacent pyramid-like structure combining to form a truss-like structure for providing support against transverse loads applied to the structural core.

A method of forming a structure, comprising the steps of:

• forming a plurality of ribbons, each ribbon having upper and lower edges forming a zig-zag pattern having an upper point and a lower point, each upper point of the zig-zag pattern on the upper edge directly above an adjacent upper point of the zig-zag pattern on the lower edge and each lower point of the zig-zag pattern on the upper edge directly above an adjacent lower point on the lower edge;
• forming a plurality of rows, each row formed from two ribbons bonded together along bonding lines running from each lower point of the zig-zag pattern on the upper edge to the two adjacent upper points of the zig-zag pattern on the lower edge, each ribbon having bend lines running from each upper and lower points of the zig-zag pattern on the upper edge to the adjacent respective upper and lower points of the zig-zag pattern on the lower edge, wherein the upper points of the zig-zag pattern on the upper edge and the lower points of the zig-zag pattern on the lower edge expand laterally as the two ends of the row are moved together, forming adjacent hollow pyramid-like structures having alternate upward-facing and downward-facing open bases, each hollow pyramid-like structure formed from four faces having substantially straight edges, each open base in one of the plurality of rows offset with respect to each open base in an adjacent another of the plurality of rows, the edges of each adjacent pyramid-like structure combining to form a truss-like structure for providing support against transverse loads applied to the structure;
• and
• bonding the plurality of rows together laterally to create a structural core having a plurality of rows and columns of adjacent hollow pyramid-like structures.