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US 4,940,558 AGranted
Method for molding artificial urethane rock
AssigneeFutura Coatings, Inc.
InventorsEnos D. Jarboe, Rodney D. Jarboe, Edward M. Barclay
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AssigneeFutura Coatings, Inc.
InventorsEnos D. Jarboe, Rodney D. Jarboe, Edward M. Barclay
Estimating the term…
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.
A method for molding an artificial urethane rock which comprises selecting a rock to be reproduced, creating a flexible rubber mold and supporting cradle having a mold cavity conforming to the exterior of said rock, said mold having a substantial degree of flexibility and being created by applying an uncured liquid rubber forming material to said rock, curing said uncured liquid rubber forming material to produce said rubber mold, said cradle being formed by applying by spraying a low density urethane foam forming mixture to the exterior of the rubber mold to provide a self-supporting cradle, spraying a two sided urethane composition into the mold cavity, said urethane composition comprising an isocyanate side and a polyol side and being mixed in a spray gun in a spray-in-mold process, carrying out said spraying to build up the molded artificial urethane rock to a desired thickness and stripping said cradle and mold from the molded artificial urethane rock after curing.
Dependencies are inferred from the claim text.