http://rdf.ncbi.nlm.nih.gov/pubchem/patent/GB-587282-A

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filingDate 1944-08-11^^<http://www.w3.org/2001/XMLSchema#date>
publicationDate 1947-04-21^^<http://www.w3.org/2001/XMLSchema#date>
publicationNumber GB-587282-A
titleOfInvention Improvements in the moulding of hollow bodies from plastic
abstract 587,282. Compound sheet materials. FORD MOTOR CO., Ltd. Aug. 11, 1944, No. 15372. Convention date, Aug. 11, 1943. [Class 140] [Also in Groups V and XXXIII] A process for moulding a hollow cellular body, e.g., a compound sheet or panel as shown in Figs. 3 and 12, consists in arranging a plurality of rolls, each of which comprises a granular core enclosed in an impermeable tubular sheath which in turn is enclosed in an outer wrapping of resin-impregnated material, between outer laminated sheets of resin-impregnated material, subjecting the whole to heat and pressure, and subsequently removing the granular core. The moulding charge may be built up as shown in Figs. 1 and 2, rolls of resin - impregnated material 15 being placed in juxtaposition between additional sheets of the same material 14 and the whole moulded between shaped platens. The rolls 15 are formed by wrapping resin-impregnated material 20 on mandrels formed of a flexible tube or sheath 17 (of resin-impermeable material, e.g., sized paper; cellulosic film, to prevent the resin seeping through on moulding and binding the core) filled with granular material 18 such as sand, the ends of the tube being sealed or plugged after filling. The cores may be shaped (e.g., tapered) to build up a particular shape of moulding charge which approximates to the shape of the final product, e.g., an aerofoil section. Distortion of the cores under pressure results in uniform pressure distribution throughout the moulding charge and this is stated to result in increased strength as compared with articles moulded with rigid cores. In a modification, Fig. 6, the rolls are built up from sheets of resin-impregnated material enclosing resin-impermeable material between which is injected the granular core material which is then compacted and the whole then sewn into long narrow sections to form a series of adjacent rolls which are then placed between sheets of resin-impregnated material and moulded. It is usually necessary to seal the holes made by the sewing needle in this case. To increase the internal pressure compounds such as ammonium carbonate may be incorporated with the core to give off gases under heat. Metallic powders may also be incorporated and heat generated internally by high frequency currents.
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