Polycarbonate honeycomb core door and method of making same

A method of making a structural panel which may be used as a door comprising:

• providing first and second exterior panels for a door shell;
• providing frame members for the door shell;
• providing a plurality of polymeric sheets being made of a thermoplastic material and having a plurality of openings through a thickness thereof, the openings being spaced apart by wall portions of each of the polymeric sheets;
• providing a plurality of stiffeners comprising a thermally non-conductive fiber reinforced polymer;
• assembling the first and second exterior panels, frame members and plurality of polymeric sheets to make a shell having spaced first and second exterior panels and frame members adjacent edges of the panels, the plurality of polymeric sheets being disposed between adjacent exterior panels, the wall portions being parallel to the first and second exterior panels, and the plurality of stiffeners being between the polymeric sheets;
• and
• bonding the plurality of polymeric sheets to adjacent exterior panels.