Patent ID: 7753254

Claim:
A method of manufacturing a core sandwich structure, comprising: forming a non-honeycomb core having a first core and a second core each having a plurality of inwardly and outwardly projecting bonding lands and at least two non-parallel directions of corrugation, the first and second cores each being a continuous sheet of material; forming a bulge on at least a portion of the inwardly projecting bonding lands of the first core and forming a dimple on at least a portion of the inwardly projecting bonding lands of the second core, wherein the bulges are configured to be received at least partially within corresponding dimples when the first and second cores contact each other; placing the inwardly projecting bonding lands of the first core in contact with the inwardly projecting bonding lands of the second core; positioning at least a portion of the bulges in corresponding dimples, wherein each of a dimple extends inwardly relative to its bonding land and each of a bulge protudes outwardly relative to its bonding land; and securing first and second sheets to the first and second cores to form the core sandwich structure wherein the first and second cores are continuous sheets in the core sandwich structure.