Method of manufacture of synthetic stone article

Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Composite article making

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264 466, 264 69, 264255, 2642711, 264299, 264311, B29C 3908, B29C 3912, B29C 4406

Patent

active

060600063

ABSTRACT:
A baluster or spindle is formed by a casting method, and has a rigid, dense, hollow outer shell forming a decoratively shaped body portion having closed, planar opposed ends. A conduit extends completely through the baluster, providing attachment means to a railing system. The hollow interior of the baluster is injected with a high density polyurethane foam to increase its weight, density, and resistance to breakage. The method of forming a baluster or spindle includes the combined method steps of placement of a mesh sheet adjacent each end of the mold, and then subsequent agitation of the mold. Agitation includes simultaneous spinning and rocking of the mold about its longitudinal axis. The mesh sheet retains the casting material against the end surfaces of the mold, and is completely encapsulated by the casting material such that the mesh sheet is not visible on the surface of the finished product.

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