Material and method for an artificial rock
OwnerSilia Abou Arbidinventor
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Abstract
The invention relates to modifying synthetic fiber sponge, such as polyester or polyurethane foam, with an epoxy-, polyester, or acrylic-resin to induce an engineered rock product for use as stone replacement in a variety of applications. The method for manufacturing comprises: producing a foam block; shaping the foam block into any regular or irregular shape; weathering the shaped foam block; infusing the weathered foam block with a resin; curing the infused foam block; and finishing the cured foam block. The artificial rock comprises a foam block shaped to resemble a rock, an exterior of the foam block infused with a resin.
Claims16
A method for manufacturing an artificial rock comprising:
- providing an open-cell polyurethane foam block;
- impregnating said foam block with a resin which is in a viscous to liquid form, by infusing said resin into said open-cell polyurethane foam block;
- curing said impregnated open-cell polyurethane foam block;
- and
- finishing said cured open-cell polyurethane foam block;
- wherein said infusing comprises:
- pouring batches of said resin onto a plurality of faces of said open-cell polyurethane foam block;
- and
- applying simultaneous sweeping and dabbing actions such that said resin infuses into deeper layers of said open-cell polyurethane foam block by capillarity action.
Dependencies are inferred from the claim text.