Composite wood panels with corrugated cores and method of manufacturing same

A method of manufacturing a corrugated composite wood web, comprising steps of:

• cutting wood laminae having a length of about 75 mm-150 mm, a width of about 10 mm-50 mm, and a thickness of about 0.25 mm-0.4 mm;
• drying the wood laminae to predetermined moisture content by weight of the wood laminae;
• sorting the wood laminae so that all wood laminae for the composite wood panel have dimensions within a tolerance of 5% in length and thickness and a tolerance of 10% in width;
• adding the dried, sorted wood laminae to a blender;
• applying a first bonding agent to the wood laminae in the blender using a spray applicator;
• applying a second, powdered bonding agent to the wood laminae in the blender after the first bonding agent has been applied to the wood laminae in the blender;
• moving the wood laminae from the blender to a mat former;
• forming the wood laminae into a mat of randomly oriented wood laminae, the mat having a thickness adequate to produce a web of 0.5 mm-3 mm;
• consolidating the mat in a low-temperature, low-pressure consolidation stage of a three-stage corrugation press to form a flat consolidated wood web;
• pre-forming the flat consolidated wood web in a low-temperature pre-forming stage of the three-stage corrugation press to pre-form corrugation bends in the flat consolidated wood web;
• and
• fully corrugating the wood web with pre-formed corrugation bends in a high-pressure corrugating press section of the three-stage corrugation press to produce a corrugated wood web.