Patent ID: 6913667

Claim:
A method of fabricating composite structural panels comprising the steps of: (a) inserting a plurality of base sheets into a first adhesive spreader, said base sheets each having a plurality of substantially parallel channels being formed therethrough and extending along a horizontal direction; (b) applying a first adhesive to upper and lower surfaces of each of said plurality of base sheets; (c) stacking said base sheets to form a base block having a plurality of honeycombed substantially box-shaped channels extending therethrough in said horizontal direction; (d) rotating said base block 90° to orient said honeycombed substantially box-shaped channels in a vertical direction; (e) cutting said base block along said horizontal direction to form a plurality of honeycomb layers; (f) sandwiching each said honeycomb layer between upper and lower bonding layers; and, (g) laminating upper and lower support layers to respective ones of said upper and lower bonding layers to form a composite structural panel.