Buoys – rafts – and aquatic devices – Swimming aid to increase stroke efficiency – Foot attached
Reexamination Certificate
1999-12-17
2001-09-04
Morano, S. Joseph (Department: 3617)
Buoys, rafts, and aquatic devices
Swimming aid to increase stroke efficiency
Foot attached
C441S061000, C428S322700
Reexamination Certificate
active
06283810
ABSTRACT:
BRIEF SUMMARY OF THE INVENTION
This invention relates to a non-mold method of forming articles and to the articles themselves wherein various configured articles may be fashioned with conformable material which may be easily fabricated as by sewing, or heat, or sonic or radio frequency welding to form the basic shape of or modular elements of a completed article, and wherein a thermal setting, flowable plastic or the like is introduced into the space between layers of the conformable material to thereby form the completed article or modular element thereof.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the method of forming completed articles or in other instances, modular elements that will be assembled to form a completed article.
The prior art has long recognized a method of forming articles using a molding process where expensive molds are machined and a thermal setting material such as plastic or the like is injected into the mold, allowed to set and thereafter, the mold opened to remove a formed article which then requires, in most instances, some finishing before the article is ready for marketing.
This methodology heretofore utilized has been expensive and time consuming, not only with respect to the initial expense of fabricating the mold, which requires highly skilled labor, but also with respect to the manual labor needed in removing slashing, sanding, or otherwise finishing the molded product to make the same, ready for sale. The herein disclosed invention does away with the need of conventional molds and the molding process in order to fabricate finished articles, which articles may be fashioned from conformable materials which are sewn or otherwise sealed together to form an inner space into which a flowable, thermal setting, resin or the like, is introduced so that the form or mold becomes part of the finished product itself. The overall saving in labor, that is sewing and sonic or radio frequency, or heat welding, being much less than labor required in making molds and operating a molding machine, is readily apparent.
In addition, by making modular-type elements, the total of which makes up the whole of a finished article, individual elements of modular construction, employing designs and colors which would otherwise not be employable, may be assembled in order to form desirable, marketable products.
2. Description of the Related Art
As far as is known, there is no prior art directly related to the herein disclosed invention wherein a formed article is either modularly fabricated and later assembled to complete the finished article, or wherein a non-molding process is utilized as contemplated in the carrying out of the method of the invention.
However, the concept, in the broad sense of having inner and outer skins or layers forming a space into which something is injected is relatively old. Such items as inflatable pool toys and inflatable concrete bags for underwater purposes are well known. But in the case of the inflatable pool toy, a fluid such as air is contemplated as opposed to a liquid solid-forming polymer of this invention. Further, the pool toy form does not become part of a complete article, as contemplated in the instant invention.
As regards to the underwater concrete bag, into which concrete is introduced, the final shape, after setting of the concrete of the concrete bag is determined by the ambient surroundings, such as sea floor, as opposed to the instant invention that utilizes a predetermined shape and configuration for the patterns defining the ultimate shape of the completed article.
But, a prior search has been made and the most specific references found are hereinafter enumerated, but none detract from the patentability of the disclosed invention and the articles formed thereby.
3,042,562—Product and Method for Production of Articles Having Compound Curves—N. R. PETERSON
This reference is directed to a product and method for forming articles having compound curves without using a mold. The product can be foamed plastic having slits or grooves extending greater than halfway through the thickness of the sheet. A sheet
10
having slits
12
arranged to form adjacent columns
13
are on the top surface
17
and the bottom surface
18
, with the slits staggered to be midway between those on one surface relative to those on the other surface. This slitting provides for a continuous sheet that is very flexible. The sheet
10
is readily formed into a wide variety of complex shapes. A shaped article
21
shown in
FIG. 7
is fabricated in accordance with this invention. The shaped article
21
comprises a base shape
10
b
having a plurality of slits
12
f
and
12
g.
The sheet is formed into a concave structure and the sheet and slits are filled with a hardenable material
25
. The entire article
21
is then covered with a coating
26
. The completed article
21
is rigid and self-supporting. A self-supporting object is made by applying a hardenable cement, grout, or filler material to the grooves or slits opened by flexure of the sheet into a shape. The material upon hardening provides a permanent means for supporting the board in the formed shape. Articles such as boat hulls are readily fabricated by temporarily supporting the slit sheets of polystyrene on a suitable form, coating the sheets with polyester resin woodflower mixture, or epoxy resin woodflower mixture to fill the fissures and then applying a layer of fibrous glass fabric to the outer surface. The slits in the sheet may be in a variety of patterns, as shown in
FIGS. 2-5
.
RE29, 394—Corrosion Protective Band for Underground Pipe Joints With Metal Parts—Swanson, et al.
This reference is directed to impregnated foam bands for sealing bell and spigot pipe joints. Reinforced concrete pipes
11
,
12
having a steel bell ring
13
and steel spigot ring
14
are telescoped together compressing a rubber sealing gasket
17
. Protection for the steel members
13
,
14
is provided by a pair of bands, a spigot band
21
, and a bell band
19
. The bands are formed from a polyurethane foam impregnated with Portland cement and sealed for shipping and handling by a water soluble membrane
22
. The spigot band
21
is stretched and pulled over the steel spigot ring
14
. The bell band
19
is connected to pipe
11
by means of a suitable adhesive. On insertion of the spigot ring
14
into the bell ring
13
of the next pipe, the outer and inner portions of the joint have the spigot band
21
and bell band
19
positioned respectively to protect the steel bell and spigot rings
13
,
14
. Ground water contacts band
21
and the Portland cement impregnated therein is hydrated. Similarly, the fluid in the pipeline activates the corrosion inhibiting properties of bell band
19
.
5,604,998—Sports Shoe Providing Heel Stabilization—Keijiro Kita
This reference is directed to a heel pad for a sports shoe formed of open cell foam impregnated with bouncing putty. A pad
8
of three-dimensional horseshoe shape may be formed from a stack of parts
12
of polyurethane foam impregnated with bouncing putty. The pad may also be formed from a unitary block of polyurethane foam impregnated with bouncing putty and cut into the three dimensional horseshoe shape or a thermoforming process may also be utilized. The pad may comprise a bag-like sheet of synthetic resin
14
enclosing bouncing putty
13
.
FIG. 11
shows a pad
8
comprising open cell foam
18
impregnated with bouncing putty
17
. The pad
8
will have plastic deformation under heel pressure. It will be the same as the bouncing putty itself and exhibit bounce under the impact force applied during athletic sports.
4,946,726—Orthopedic Splinting Articles and Methods Sandvig, et al
This reference is directed to an orthopedic splint of impregnated foam that can be formed around a body part and hardened. The splinting article
10
, a unitary blank, is a sheet of pliant foam initially formed as a rectangle for trimming to custom fit a patient. The foam sheet of article
10
is open celled, impregnated by a curable resin
Cislo & Thomas LLP
Morano S. Joseph
Olson Lars A.
LandOfFree
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