received by the International Bureau on 24 August 2020 (24.08.2020)

[Claim 1] 1 . A method for making a core component for a door or panel

comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevenly intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip, a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing an expanded core within a known art door frame and components having stile and rail members and adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core.

[Claim 2] 2. The method of Claim 1 wherein the disposing step comprises ad hesively affixing sheets with unevenly intersected adhesion points by stacking a plurality of flexible single face sheets to form the said stack, severing a strip or core wherein the arrangement of two specific adhesion points typically 230mm apart but not limited to that distance on a sheet is unevenly intersected by two non corresponding adhesion points of typically 250mm but not limited to that size on the following sheet, method and alternate stacking multiples of said sheets ideally but not limited to twenty two flexible single face corrugated sheets.

[Claim 3] The method of Claim 2 wherein the said first sheet material is also unevenly intersected by a third size of 280mm spaced glue application on second sheet as shown.

[Claim 4] The core and material of Claim 1 comprised of adhesively stacked non rigid flexible single face corrugated sheet material wherein the disposing step Claim 2 and 3 comprises the spatial arrangement of two sets of adhesive points as shown.

[Claim 5] The method utilizing non rigid flexible material of Claims 1 to 3

comprising the step of adhesively securing said expanded core to door rail members and coating edge of said core to bond to said door skins.

[Claim 6] 6. The core Claim 1 to 3 wherein the said central column of lon

gitudinal cells are oblong in shape contract on expansion of said core into said door frame as a direct result of the said non rigid flexible single face corrugated sheet material and method in Claim 2.

[Claim 7] 7. The core of Claim 1 comprising the method utilizing non rigid

flexible sheet material of Claim 1 wherein the cells on expansion of the

1 said core present open cells of multiple shapes both contracting and expanding on expansion of the core disposed of by the nature of the said flexible material introduced to the spatial layout of two sets of glue adhesion point applicators in Claim 2 as shown.

[Claim 8] The core of Claim 1 wherein the method of stacking multiple sets of said sheet material B and C as shown whereby said base sheet A as shown is laid down adhesive free corrugated face up and thereafter sets of sheets B and C alternately stacked adhesively affixed Sheet B as corrugated face down followed by said sheet C adhesively fixed stacked corrugated face down as shown herein thereby sealing the stack with adhesively affixed said sheet B.

[Claim 9] The core of Claim 1, wherein the alternative to Claim 8, is method of stacking multiple sets of said sheet material B and C as shown whereby material B adhesion and corrugation face up as shown is laid down followed by material C adhesion face up corrugation face down as shown whereafter said base sheet A as shown is laid down adhesive free corrugated face down thereby sealing the stack.

[Claim 10] 10. A door Claim 1 comprising inner and outer skin said skins having panels formed wherein each outlined by raised moldings on the interior surface of the skin, a peripheral frame and lock block secured said skins and a core component Claim 1 and method as shown to separate the said door skins in a spatial arrangement.

[Claim 11] A door Claim 1 comprising inner and outer skins said skins having flat interior surfaces, a peripheral frame and lock block secured said skins and a core component Claim 1 and method as shown to separate the said door skins in a spatial arrangement.

[Claim 12] The core method of Claim 1 once severed from stack as herein once expanded is ready to use as a filler material whereby no further tolerance sanding of the severed surface is required.

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