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Methods of forming carvable shell articles

  • US 5,624,614 A
  • Filed: 06/07/1995
  • Issued: 04/29/1997
  • Est. Priority Date: 03/11/1993
  • Status: Expired due to Term
First Claim
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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.

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