Patent ID: 7757931

Claim:
A method of manufacturing a non-honeycomb core sandwich structure, comprising: forming a first core having a plurality of inwardly and outwardly projecting bonding lands; forming a second core having a plurality of inwardly and outwardly projecting bonding lands, the first and second cores each being a continuous sheet of material and, the first and second cores together being a non-honeycomb structure each with at least two non-parallel directions of corrugation; forming a bulge on a plurality of inwardly projecting land of the first core and forming a dimple on a plurality of inwardly projecting land of the second core, wherein the bulges are received at least partially within corresponding dimples when the first and second cores contact each other, each dimple extending inwardly relative to its bonding land and each bulge protruding outwardly relative to its bonding land such that the first core and the second core have different shapes; placing the inwardly projecting bonding lands of the first core in contact with the inwardly projecting bonding lands of the second core; placing a first sheet in contact with the outwardly projecting bonding lands of the first core and placing a second sheet in contact with the outwardly projecting bonding lands of the second core, thereby forming a non-honeycomb sandwich structure; and joining the first core, the first sheet, the second core and the second sheet together to form the non-honeycomb core sandwich structure with the first and second cores each being a continuous sheet of material in the non-honeycomb core sandwich structure.