Method of making plastic laminated core boxes and patterns

Claim 1

A METHOD OF PRODUCING A CORE BOX FOR USE IN FORMING A SAND CORE OF PRETERMINED CONFIGURATION, SAID METHOD COMPRISING THE STEPS OF PREPARING A MASTER CORE HAVING A SURFACE CONFIGURATION CORRESPONDING TO AT LEAST ONE-HALF OF THE SAND CORE TO BE FORMED, COATING SAID MASTER CORE WITH A SUBSTANTIAL UNIFORM THICKNESS OF REMOVABLE SPACING MATERIAL, SAID THICKNESS BEING NOT LESS THAN 3/32 INCH AND NOT MORE THAN 3/8 INCH, PREPARING A MOLD FROM SAID COATED MASTER CORE, USING SAID MOLD TO PRODUCE A METAL BASE MEMBER WHICH IS IDENTICAL TO SAID MOLD, REMOVING SAID SPACING MATERIAL FROM SAID MASTER CORE, COATING SAID MASTER CORE WITH A PARTING COMPOUND, MOUNTING SAID METAL BASE MEMBER RELATIVE TO SAID MASTER CORE SUCH THAT SAID BASE MEMBER AND SAID MASTER CORE ARE SPACED APART OF DISTANCE EQUAL TO THE THICKNESS OF SAID REMOVABLE SPACING MATERIAL, FILLING SAID SPACE WITH LIQUID EPOXY-RESIN WHILE VIBRATING SAID BASE MEMBER AND SAID MASTER CORE AS AN UNIT TO FREE SAID RESIN OF AIR BUBBLES MAINTAINING SAID BASE MEMBER AND SAID MASTER CORE IN SAID SPACED RELATIONSHIP UNTIL SAID RESIN CURED, AND AFTER THE RESIN IS CURED, REMOVING SAID MASTER CORE TO LEAVE THE RESIN AS A PERMANENT LAMINATE ADHERING TO THE SURFACE TO SAID BASE MEMBER AS A PART THEREOF.

Claim 2

A METHOD OF PRODUCING A CORE BOX FOR USE IN FORMING A SAND CORE OF PRETERMINED CONFIGURATION, SAID METHOD COMPRISING THE STEPS OF PREPARING A MASTER CORE HAVING A SURFACE CONFIGURATION CORRESPONDING TO AT LEAST ONE-HALF OF THE SAND CORE TO BE FORMED, COATING SAID MASTER CORE WITH A SUBSTANTIAL UNIFORM THICKNESS OF REMOVABLE SPACING MATERIAL, SAID THICKNESS BEING NOT LESS THAN 3/32 INCH AND NOT MORE THAN 3/8 INCH, PREPARING A MOLD FROM SAID COATED MASTER CORE, USING SAID MOLD TO PRODUCE A METAL BASE MEMBER WHICH IS IDENTICAL TO SAID MOLD, REMOVING SAID SPACING MATERIAL FROM SAID MASTER CORE, COATING SAID MASTER CORE WITH A PARTING COMPOUND, MOUNTING SAID METAL BASE MEMBER RELATIVE TO SAID MASTER CORE SUCH THAT SAID BASE MEMBER AND SAID MASTER CORE ARE SPACED APART OF DISTANCE EQUAL TO THE THICKNESS OF SAID REMOVABLE SPACING MATERIAL, FILLING SAID SPACE WITH LIQUID EPOXY-RESIN WHILE VIBRATING SAID BASE MEMBER AND SAID MASTER CORE AS AN UNIT TO FREE SAID RESIN OF AIR BUBBLES MAINTAINING SAID BASE MEMBER AND SAID MASTER CORE IN SAID SPACED RELATIONSHIP UNTIL SAID RESIN CURED, AND AFTER THE RESIN IS CURED, REMOVING SAID MASTER CORE TO LEAVE THE RESIN AS A PERMANENT LAMINATE ADHERING TO THE SURFACE TO SAID BASE MEMBER AS A PART THEREOF.