Patent ID: 7648058

Claim:
A method of manufacturing a non-honeycomb metal core sandwich structure, comprising: forming first and second non-honeycomb metal core structures, each from a single sheet and having three dimensions of corrugation, the first core structure and the second core structure each having a plurality of inwardly and outwardly projecting bonding lands and each being formed from a single sheet of material, wherein the plurality of the inwardly projecting bonding lands of the first core structure are bonded to the plurality of the inwardly projecting bonding lands of the second core structure, the non-honeycomb metal sheet sandwich structure including a protrusion on at least a portion of the inwardly projecting lands of the first core structure and a channel on at least a portion of the inwardly projecting lands of the second core structure, wherein the forming of the first core structure, the bonding lands of the first core structure and the protrusions takes place in a single pressing operation and the forming of the second core structure, the bonding lands of the second core structure and the channels takes place in a single pressing operation that are formed when the bonding lands are formed; placing a bonding material on both sides of the formed non-honeycomb metal core after the non-honeycomb metal core is formed; placing first and second metal sheets on both sides of the formed non-honeycomb metal core, thereby forming a sandwich structure, wherein the bonding material is positioned between the formed metal core and the first and second metal sheets on each side of the formed metal core; providing first and second metal sheets; heating the sandwich structure to bond the formed metal core to the first and second metal sheets; and creating the non-honeycomb metal core sandwich structure where at least a portion of the non-honeycomb metal core sandwich is configured to be formable into compound curves.