Patent ID: 7459049

Claim:
A method for continuous manufacture of open core elements, comprising the steps of: (1) forming two composite web halves each comprising a smooth web and a fluted web; (2) orienting said composite web halves with the exposed fluted web flutes facing up; (3) applying an adhesive to the exposed flute tips of one web half; (4) adhering the other web half by its smooth web to the glued flute tips of said one web half to form an open face double wall web; (5) slitting the open face double wall web longitudinally to form a plurality of adjacent equal width open face double wall strips; (6) applying an adhesive to the exposed flute tips of said open face double wall strips; (7) cutting said strips transversely to a common selected length, and, (8) upending the strips onto common lateral strip edges and adhering the glued flutes of each strip to the smooth web of the next adjacent strip to form an open core element.