Process for fabricating a closed, foam-filled, reinforced polyester resin shell article
OwnerMarcelino Rubio, James A. Mizellinventors
Life of this patent
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Abstract
A process for fabricating hollow, foam-filled, reinforced plastic objects such as surfboards. The process involves disassembling a multi-part mold to expose its inner surface. The inner surface is then coated with a gel coat, resin and reinforcing material and assembled into two mold halves. A prefoam material is injected into each mold half which is then capped with a baffle. The foam is then permitted to rise, and a portion of the foam is forced through the baffle. The baffle is then removed and a certain amount of the foam is removed. The two mold halves are joined and a center joining resin is poured in this depression and allowed to cure.
Claims8
A process for fabricating a closed, foam-filled, reinforced polyester-surfaced object, such as a surfboard, said process comprising the steps of:
- disassembling a mold into at least four parts so that the surface of each part is readily accessible to be sprayed by a resin spray gun the joint between the parts being positioned away from the outer edge of the reinforced polyester-surfaced object;
- coating the surface of each part of the mold with a liquid resin and reinforcing material and allowing the liquid resin to at least partially cure;
- assembling some of the mold parts to form one of the halves of the desired object;
- assembling the remaining mold parts to form the other half of the desired object;
- pouring a prefoam mix into each of the mold halves;
- inserting a baffle member across the entire upper surface of the mold halves before the prefoam has commpletely risen said baffle member having at least one hole therethrough;
- allowing the prefoam to rise and allowing a portion thereof to pass through the hole in the baffle member;
- removing the baffle member;
- cutting out a portion of the upper surface of the foam so that when the two halves are joined, a generally I-beam shaped hollow depression is formed between the mold halves;
- supporting the two mold halves into the desired final orientation while pouring a joining resin into the generally I-beam shaped depression;
- and
- permitting the joining resin to cure to form a final part.
Dependencies are inferred from the claim text.