Methods of forming carvable shell articles
First Claim
1. A process of applying polyurethane foam material comprising:
- (a) placing a generally spherical, hollow mold and a spray nozzle so as to position the nozzle along a central axis of the mold;
(b) spraying polyurethane composites through the nozzle and directing said composites radially at the inside surface of the mold, causing the composites to form a foam material against portions of the inside surface at which the composites are sprayed;
(c) moving the mold and the nozzle relative to each other so as to cause the mold to revolve axially with respect to the nozzle, so that the composite material is sprayed at enough portions of the inside surface to form a hollow, generally spherical polyurethane foam shell;
(d) separating the mold and the formed polyurethane foam shell;
(e) coating the polyurethane foam shell; and
(f) using a pocketknife to carve holes extending through the material of the shell, which holes are shaped and positioned to visually represent a face.
2 Assignments
0 Petitions
Accused Products
Abstract
The invention is in the field of three-dimensional hollow novelty items and their manufacture, particularly items such as artificial pumpkins that the consumer desires to carve or alter after purchase. Disclosed is a carvable novelty article, such as an artificial Halloween pumpkin, comprising a polyurethane shell substantially surrounding an interior volume and having a thin, elastomeric coating, such as an acrylic, on the exterior surface of the shell. The carvable article can be formed by an inventive process in which polyurethane foam material, such as material having a nominal density of about 2.5-3.0 pounds per cubic foot, is sprayed from a nozzle rotating with respect to the inside of a mold. After the polyurethane foam article and the mold are separated, the article is coated with an elastomeric coating, such as an acrylic material that is applied as a liquid. Thus, the inventive articles, including those made in accordance with the inventive process, can be used as three-dimensional hollow novelty items of a variety of shapes. In addition, the inventive articles, such as Halloween pumpkins, are carvable, reusable, and can be used with a light source.
-
Citations
29 Claims
-
1. A process of applying polyurethane foam material comprising:
-
(a) placing a generally spherical, hollow mold and a spray nozzle so as to position the nozzle along a central axis of the mold; (b) spraying polyurethane composites through the nozzle and directing said composites radially at the inside surface of the mold, causing the composites to form a foam material against portions of the inside surface at which the composites are sprayed; (c) moving the mold and the nozzle relative to each other so as to cause the mold to revolve axially with respect to the nozzle, so that the composite material is sprayed at enough portions of the inside surface to form a hollow, generally spherical polyurethane foam shell; (d) separating the mold and the formed polyurethane foam shell; (e) coating the polyurethane foam shell; and (f) using a pocketknife to carve holes extending through the material of the shell, which holes are shaped and positioned to visually represent a face. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
-
-
12. A process of applying polyurethane foam material comprising:
-
(a) placing a generally spherical, hollow mold and a spray nozzle so as to position the nozzle along a central axis of the mold; (b) spraying polyurethane composites through the nozzle and directing said composites radially at the inside surface of the mold, causing the composites to form a foam material against portions of the inside surface at which the composites are sprayed; (c) moving the mold and the nozzle relative to each other so as to cause the mold to revolve axially with respect to the nozzle, so that the composite material is sprayed at enough portions of the inside surface to form a hollow, generally spherical polyurethane foam shell; (d) moving the nozzle and the mold axially relative to each other so as to cause the nozzle to move along the axis of the mold; (e) separating the mold and the formed polyurethane foam shell; and (f) coating the polyurethane foam shell. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19)
-
-
20. A process of applying polyurethane foam material comprising:
-
(a) placing a generally spherical, hollow mold and a spray nozzle so as to position the nozzle along a central axis of the mold; (b) spraying polyurethane composites through the nozzle and directing said composites radially at the inside surface of the mold, causing the composites to form a foam material against portions of the inside surface at which the composites are sprayed; (c) moving the mold and the nozzle relative to each other so as to cause the mold to revolve axially with respect to the nozzle, so that the composite material is sprayed at enough portions of the inside surface to form a hollow, generally spherical polyurethane foam shell; (d) separating the mold and the formed polyurethane foam shell; and (e) coating the polyurethane foam shell; and (f) placing a source of light inside the shell. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29)
-
Specification