Patent ID: 8668855

Claim:
A process of making a sandwich-like product, said process comprising: extruding a web of material having a generally non-planar profile comprising continuous corrugations with continuous peaks and valleys joined by connecting portions extending in the direction of travel of the web; interrupting the continuous corrugations of the extruded web using movable tools on opposite sides of the extruded web to create non-perforated rectangular flats transversely extending from one side edge of the extruded web to the other side edge of the extruded web to create a plastically deformed web having corrugated regions between the flats; folding the plastically deformed web along transversely extending fold lines along the edges of the flats such that the corrugated regions of the plastically deformed web become sidewalls of a plurality of cells arranged in rows and the flats become tops and bottoms of the plurality of cells, the peaks of one of the corrugated regions contacting the peaks of an adjacent corrugated region to create a honeycomb core; applying generally planar outer skins to the tops and bottoms of the cells of the honeycomb core to create a multi-layered web; and cutting the multi-layered web.