Abstract A method and apparatus for forming foam material, such as polyurethane or foam rubber, into any desired shape, including multi-curved objects, e.g. a contoured dress form. A mass of preformed foam material is forced through an opening having a peripheral configuration corresponding to that of the finished article. A die used to force the mass through the opening is of the general contour desired in the end article. After a portion of the original mass is forcibly urged through the opening, such extruded portion is sheared away from the remaining mass in the plane of the opening. After the shearing operation, the cut-away portion of the foam will assume the contours of the die, but in effect be a mirror image thereof. In a second phase of the invention, the article produced in the manner above described is positioned over a die opening having a periphery smaller than the periphery of the article by some predetermined amount. The article is forced through such opening with a flat die which is caused to stop from the plane of the opening by the same amount. The extruded portion is again sheared away in the plane of the opening. After the shearing, the article remaining will have the same peripheral configuration and the same external contours, but will have a thickness corresponding to the aforesaid predetermined amount.
A method of forming foam material which consists of supporting a mass of foam material over an opening having a peripheral configuration corresponding to the desired periphery of the produced article, applying pressure to said mass with a member having a mass-engaging contour corresponding to the desired contour of the produced article and forcing a portion of said mass through said opening, then cutting such portion of the mass away from the remaining mass while maintaining said pressure in the general plane of said opening, supporting said cut portion of the mass over an opening having a peripheral configuration similar to but smaller than the periphery of said cut portion, applying pressure to said portion with a relatively flat element to thereby force some of said cut portion through said smaller opening, and then cutting such forced material from the previously cut portion while maintaining said pressure in the general plane of said smaller opening.
Claim 2
Independent Claim
155 words
A method of forming foam material which consists of supporting a mass of foam material over an opening having a peripheral configuration corresponding to the desired periphery of the produced article, applying pressure to said mass with a member having a mass-engaging contour corresponding to the desired contour of the produced article and forcing a portion of said mass through said opening, then cutting such portion of the mass away from the remaining mass while maintaining said pressure in the general plane of said opening, supporting said cut portion of the mass over an opening having a peripheral configuration similar to but smaller than the periphery of said cut portion, applying pressure to said portion with a relatively flat element to thereby force some of said cut portion through said smaller opening, and then cutting such forced material from the previously cut portion while maintaining said pressure in the general plane of said smaller opening.
Claim 3
Dependent Claim
41 words
A method as set forth in claim 1 including releasing of said pressure on said portion and in which the remaining part of said previously cut portion comprises a shell complementary to and adapted to receive the forced material cut therefrom.