Patent ID: 7661242

Claim:
A hollow structural component having a prescribed curve or a prescribed non-planar contour in one or more dimensions, comprising: outer cover sheets including first and second cover sheets that are spaced apart from one another with a spatially varying distance at least in a transverse direction of the hollow structural component to form opposite outer surfaces of said hollow structural component, and that each have non-intersecting first and second cover sheet slots therein, wherein said cover sheets define said prescribed curve or said prescribed non-planar contour; a rib framework that is arranged between said first and second cover sheets and that comprises at least one first rib and at least one second rib intersecting and connected to said at least one first rib, wherein said first and second ribs respectively have first and second rib connector tabs provided on two opposite edges thereof, and said first and second rib connector tabs are respectively engaged in said first and second cover sheet slots of said first and second cover sheets; first and second end closure sheets that are arranged between said first and second cover sheets, and that are spaced apart from one another with said rib framework therebetween, and that are arranged at opposite ends of said at least one first rib; and mechanical connections securing together said at least one first rib, said at least one second rib, said first cover sheet, said second cover sheet, said first end closure sheet, and said second end closure sheet, wherein respective ones of said mechanical connections are permanent mechanical connections selected from the group consisting of a soldered joint, a brazed joint, a welded joint, and an adhesive bonded joint, and are provided along said rib connector tabs engaged in said cover sheet slots to secure together said cover sheets and said rib framework.