Patent ID: 8252137

Claim:
A method of forming a connectable building panel comprising the steps of: providing a first layer of building stock having a length; providing at least a second layer of building stock having a length; connecting said first and second layers of building stock at spaced intervals along said lengths thereof to form a stack; cutting said stack into a plurality of strips; expanding at least one of said strips into a core; anchoring said core in said expanded position of a desired size wherein said layers of building stock are connected to one another at various locations and wherein a plurality of voids are defined between said layers at other locations; providing a top skin and a bottom skin; locating said core between said top skin and said bottom skin; while said core is maintained in said expanded position, adhering said top skin to said core and said bottom skin to said core to form an assembled building panel having a top edge, a bottom edge, a first side edge and a second side edge; forming a first channel in said first side edge of said building panel; locating a first connector anchor in said first side edge of said building panel; forming a second channel in said second side edge of said building panel; and locating a second connector anchor in said second side edge of said building panel.