Method of fabricating a foam play article

• US 8,071,175 B2
• Filed: 02/12/2008
• Issued: 12/06/2011
• Est. Priority Date: 02/12/2008
• Status: Expired due to Fees

• Current Assignee: Inarex USA, Inc.
• Original Assignee: Inarex USA, Inc.
• Inventors: Baik, Heui-Jong
• Primary Examiner(s): FLETCHER III, WILLIAM P
• Application Number:
  US12/029,717
• Publication Number:
  US 20090202765A1
• Time in Patent Office: 1,393 Days
• Field of Search: 264/41, 264 464- 469, 264/51, 427/421.1, 427/430.1, 427/372.2, 427/402, 473/569
• US Class Current: 427/402
• CPC Class Codes: A63B 2037/065 Foam
• CPC Class Codes: A63B 2208/12 specially adapted for children
• CPC Class Codes: A63B 37/06 Elastic cores
• CPC Class Codes: A63B 45/00 Apparatus or methods for manufacturing balls working of plastics or substances in a plastic state B29
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/406 Bright, glossy, shiny surface
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 25/045 of foam
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08G 18/4072 Mixtures of compounds of group C08G18/63 with other macromolecular compounds
• CPC Class Codes: C08G 2101/00 Manufacture of cellular products
• CPC Class Codes: Y10T 428/1376 Foam or porous material containing

Abstract

A foam play article comprises: an elastic tube for forming an elastic rubber layer; a foam formed by foaming polyurethane materials (2) in the elastic tube (1); and a coating layer (7) coated on the elastic rubber layer. The article may be manufactured by a method which comprises: providing polyurethane foam materials; attaching a material injector (5) to an elastic tube (1); injecting a predetermined amount of the polyurethane foam materials to the elastic tube (1) through the material injector (5); placing the elastic tube (5) in a mold (6) to provide a foam therein; applying a coating layer onto an outer surface of the foam; and drying the coated foam. The-thus formed play article has superior surface gloss, improved waterproof, soft tactile sensation, and higher stability.

Claims

1. A method of fabricating a foam play article, the method comprising:

providing polyurethane foam materials;

attaching a material injector to an elastic tube;

injecting a predetermined amount of the polyurethane foam materials to the elastic tube through the material injector;

placing the elastic tube in a mold to form a foam;

applying a coating layer onto an outer surface of the foam; and

drying the coated foam.

2. The method of claim 1, wherein the polyurethane materials include a first material comprising liquid methylene diisocyanate and a second material comprising polypropylene glycol, and polymer polyol.

3. The method of claim 2, wherein the second material further comprises at least one of amine polyol, tri-ethylene diamine, silicone surfactant, diethanol amine, and chlorofluorohydro-carbon (CFC).

4. The method of claim 3, wherein the polyurethane materials include about 10-50 wt % of the first material and about 50-90 wt % of the second material.

5. The method of claim 4, wherein the second material comprises about 50-90% of poly propylene glycol, about 10-50 wt % of polymer polyol, about 0.1-10 wt % of tri-ethylene diamine, about 0.1-10 wt % of silicone surfactant, 0.1-10 wt % of diethanol amine, and 0.1-10 wt % of foaming agent.

6. The method of claim 1, further comprising removing a gas generated during the foam process before applying the coating layer onto the outer surface of the foam.

7. The method of claim 1, further comprising removing the material injector and attaching the foam to a hanger to be fixed on a conveyer before applying the coating layer onto the outer surface of the foam.

8. The method of claim 1, wherein the applying of the coating layer onto the outer surface of the foam is performed by spraying or soaking.

9. The method of claim 1, wherein the drying of the coated foam is performed by passing through a dry chamber.

10. The method of claim 1, further comprising applying an additional coating layer onto the outer surface of the foam after drying the coated foam.

11. The method of claim 10, further comprising removing the hanger, cutting the material injector, attaching a sticker before applying an additional coating layer.

12. The method of claim 11, further comprising drying the coated foam after applying the additional coating layer.

13. The method of claim 1, wherein the mold includes a gas removing hole for removing a gas generated during the foam process, an air band hole for accurately forming an inner surface of the mold, and a cavity for attaching a sticker.

14. The method of claim 13, wherein a portion of the article corresponding to position of the cavity is coated after the sticker is attached so as to close a tube injection hole.