Foam-honeycomb shell

A lightweight reinforced shell, comprising:

• a plurality of shell parts that are joined together to form a hollow article, wherein each shell part has inner and outer surfaces and includes a multicell honeycomb sheet structure having inner and outer surfaces, a fibrous outer reinforcing region that covers the outer surface of the corresponding honeycomb-type sheet structure, and foam material that penetrates the honeycomb sheet structure and its corresponding fibrous outer reinforcing region;
• each of said fibrous outer reinforcing regions includes a cloth layer having multiple threads and holes between the threads, and inner and outer tissue layers lying respectively against inner and outer surfaces of said cloth layer with each tissue layer having multiple fibers and pores therebetween, with said holes having an average cross-sectional area greater than twice the cross-sectional area of said pores;
• each of said shell parts has an inner surface that is spaced from the inner surface of the other shell parts to leave a hollow region between them;
• each shell part includes a reinforced fibrous inner region that includes an inner cloth layer with multiple threads and holes therebetween, with each inner cloth layer lying directly against the inner surface of the corresponding honeycomb-type sheet structure, and with the holes of said inner cloth layers having at least twice the cross-sectional area of said pores;
• said foam material forms multiple projections projecting inwardly toward said hollow region from said inner cloth layer.