Method of manufacturing hollow bodies having walls of sandwich construction

Claim 1

THE METHOD OF MAKING A HOLLOW BODY HAVING AN OPENING THEREIN AND HAVING WALLS OF SANDWICH CONSTRUCTION COMPRISING A CORE OF EDGEWISE ADJACENT SLABS OF CELLULAR MATERIAL CONFINED BETWEEN AND BONDED TO INNER AND OUTER WALL FORMING LAYERS OF RESIN PERMEATED GLASS FIBERS, WHICH METHOD COMPRISES: (A) SEPARATELY FORMING COMPLEMENTARY BODY PARTS WHICH, IN THE FINISHED BODY COMPRISE ALL OF THE BODY EXCEPT FOR SUBSTANTIALLY NARROW BODY WALL PORTIONS THAT ARE INTEGRATED WITH AND SMOOTHLY CONNECT FREE EDGE PORTIONS OF SAID COMPLEMENTARY BODY PARTS TO PROVIDE CONTINUITY BETWEEN THEM, PROCEEDING, AS TO EACH OF SAID COMPLEMENTARY BODY PARTS, BY (1) SUCCESSIVELY LAYING DOWN ONE OF SAID WALL FORMING LAYERS, THE CORE, AND THEN THE OTHER WALL FORMING LAYER, WITH CORRESPONDING LAYERS AND THE CORES OF THE BODY PARTS, AT THE FREE EDGE PORTIONS THEREOF, ALL STEPPED AN APPRECIABLE DISTANCE IN THE SAME DIRECTION, SO THAT THE CORE OF EACH BODY PART TERMINATES AT A LOCATION INTERMEDIATE THE TERMINAL EDGES OF SAID LAYERS AT THE FREE EDGE PORTIONS OF THE BODY PARTS; (2) MAKING EACH OF SAID WALL FORMING LAYERS BT LAYING DOWN LAMINAE OF MATS OF GLASS FIBER IMPREGNATED AND SATURATED WITH A CURING RESIN, WITH ADJACENT LAMINATIONS OF EACH LAYER STEPPED THE BODY PART A DISTANCE SUFFICIENT TO EXPOSE SUBSTANTIAL SIDE SURFACES OF SAID LAMINATIONS; (B) HOLDING THE COMPLEMENTARY BODY PARTS IN THE POSITIONS THEY ARE TO OCCUPY IN THE FINISHED BODY; AND (C) FROM THE SIDE OF THE BODY HAVING CORRESPONDING WALL FORMING LAYERS SPACED APART THE GREATEST DISTANCE, INTEGRATING THE FREE EDGE PORTONS OF THE BODY PARTS BY

Claim 2

THE METHOD OF MAKING A HOLLOW BODY HAVING AN OPENING THEREIN AND HAVING WALLS OF SANDWICH CONSTRUCTION COMPRISING A CORE OF EDGEWISE ADJACENT SLABS OF CELLULAR MATERIAL CONFINED BETWEEN AND BONDED TO INNER AND OUTER WALL FORMING LAYERS OF RESIN PERMEATED GLASS FIBERS, WHICH METHOD COMPRISES: (A) SEPARATELY FORMING COMPLEMENTARY BODY PARTS WHICH, IN THE FINISHED BODY COMPRISE ALL OF THE BODY EXCEPT FOR SUBSTANTIALLY NARROW BODY WALL PORTIONS THAT ARE INTEGRATED WITH AND SMOOTHLY CONNECT FREE EDGE PORTIONS OF SAID COMPLEMENTARY BODY PARTS TO PROVIDE CONTINUITY BETWEEN THEM, PROCEEDING, AS TO EACH OF SAID COMPLEMENTARY BODY PARTS, BY (1) SUCCESSIVELY LAYING DOWN ONE OF SAID WALL FORMING LAYERS, THE CORE, AND THEN THE OTHER WALL FORMING LAYER, WITH CORRESPONDING LAYERS AND THE CORES OF THE BODY PARTS, AT THE FREE EDGE PORTIONS THEREOF, ALL STEPPED AN APPRECIABLE DISTANCE IN THE SAME DIRECTION, SO THAT THE CORE OF EACH BODY PART TERMINATES AT A LOCATION INTERMEDIATE THE TERMINAL EDGES OF SAID LAYERS AT THE FREE EDGE PORTIONS OF THE BODY PARTS; (2) MAKING EACH OF SAID WALL FORMING LAYERS BT LAYING DOWN LAMINAE OF MATS OF GLASS FIBER IMPREGNATED AND SATURATED WITH A CURING RESIN, WITH ADJACENT LAMINATIONS OF EACH LAYER STEPPED THE BODY PART A DISTANCE SUFFICIENT TO EXPOSE SUBSTANTIAL SIDE SURFACES OF SAID LAMINATIONS; (B) HOLDING THE COMPLEMENTARY BODY PARTS IN THE POSITIONS THEY ARE TO OCCUPY IN THE FINISHED BODY; AND (C) FROM THE SIDE OF THE BODY HAVING CORRESPONDING WALL FORMING LAYERS SPACED APART THE GREATEST DISTANCE, INTEGRATING THE FREE EDGE PORTONS OF THE BODY PARTS BY