Method for molding artificial urethane rock

Details Method for molding artificial urethane rock Method for molding artificial urethane rock

1989-07-10

1990-07-10

Simmons, David

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

Composite article making

264 464, 264220, 264225, B29C 6722

Patent

active

049405586

ABSTRACT:
A method for producing a simulated rock by spraying a high density polyurethane elastomer in a flexible rubber mold. The rubber may be natural rubber or synthetic rubber. A rock is produced in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of liquid uncured rubber forming materials, such as latex rubber, upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the rubber mold is produced by spraying a low density urethane foam composition over the mold. The mold and cradle are stripped from the rock and are sprayed with a two component structural urethane system employing an isocyanate component and a polyol component with appropriate catalysts, fillers and additives. The structural urethane elastomer is built up to substantial thickness to provide a strong rigid load bearing polyurethane molded rock simulating the original rock surface with curing taking place in a matter of seconds or minutes. After cooling, the molded urethane rock is removed and the mold may be reused for repeated molding operations. Where desired, the molded urethane rock may be reinforced with an inner layer of low density urethane foam to reduce the amount of structural urethane employed.

REFERENCES:
patent: 3703572 (1972-11-01), Bellasalma
patent: 3723584 (1973-03-01), Nussbaum
patent: 3883627 (1975-05-01), Fitts
patent: 3950477 (1976-04-01), Di Giacomo
patent: 4650625 (1987-03-01), Pentlow
patent: 4668451 (1987-05-01), Langson
patent: 4847026 (1989-07-01), Jarboe et al.

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