Patent ID: 7698873

Claim:
A method of fabricating a construction module comprising the steps of: assembling together a first plurality of thin sheet layers to form a top panel and applying a heat reactive adhesive between said first plurality of thin sheet layers; assembling together a second plurality of thin sheet layers to form a bottom panel and applying a heat reactive adhesive between said second plurality of thin sheet layers; assembling together a third plurality of thin sheet layers to form an intermediate panel applying a heat reactive adhesive between said third plurality of thin sheet layers; placing said intermediate panel between said top panel and said bottom panel in an aligned position; placing said aligned top, intermediate and bottom panels in a heated press to bond together said first plurality of thin sheet layers, and to bind together said second plurality of thin sheet layers and to bond together said third plurality of thin sheet layers; removing said top panel, said intermediate panel and said bottom panel from said heated press; separating said top panel from said intermediate panel and separating said bottom panel from said intermediate panel; removing a first preselected portion of said intermediate panel to define a first cavity portion extending therethrough bounded by peripheral walls; applying a heat reactive adhesive between an inner surface of said top panel and an upper surface of said intermediate panel; applying a heat reactive adhesive between an inner surface of said bottom panel and a lower surface of said intermediate panel; placing said top panel, said intermediate panel and said bottom panel in a heated press to bond together said top panel said intermediate panel and said bottom panel to form said construction module; and, removing said construction module from said heated press.