US4847026A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of molding an artifcial urethane rock
Assignee: Illinois Tool Works Inc
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Filing: 1987-12-03
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Granted: 1989-07-11
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Expires: 2007-12-03
Abstract
Abstract A method for producing simulated rocks by spraying a high density polyurethane elastomer in a flexible mold. The method includes reproducing a rock in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of latex rubber upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the latex mold is produced by spraying a low density urethane foam composition over the latex 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 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.
Inventors
- 👤 Enos D. Jarboe
- 👤 Rodney D. Jarboe
- 👤 Edward M. Barclay
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 14:02
CPC Classifications
B; B29; B29C; B29C41/00; B29C41/003; B29C33/00; B29C33/38; B29C33/3842; B29C33/3857; B29C33/40; B29C33/405; B29C33/56; B29C2033/3864; B29C41/02; B29C41/08; B29K; B29K2075/00; B29K2821/00; B29K2875/00
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
145 words
A method for molding an artificial urethane rock which comprises selecting a rock to be reproduced, creating a flexible 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 latex rubber to said rock, curing said latex rubber to produce said mold, said cradle being formed by applying by spraying a low density urethane foam forming mixture to the exterior of the latex rubber mold, spraying a two sided urethane compostion 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.
Claim 2
Independent Claim
145 words
A method for molding an artificial urethane rock which comprises selecting a rock to be reproduced, creating a flexible 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 latex rubber to said rock, curing said latex rubber to produce said mold, said cradle being formed by applying by spraying a low density urethane foam forming mixture to the exterior of the latex rubber mold, spraying a two sided urethane compostion 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.
Claim 3
Dependent Claim
33 words
The method of claim 1 in which the cradle mold is created by applying a latex material on said rock in a multiplicity of layers and a fabric is embedded between said layers.
Claim 4
Dependent Claim
17 words
The method of claim 1 in which selected pigments and fillers are added in the polyol side.
Claim 5
Dependent Claim
35 words
The method of claim 1 in which the artificial rock and latex mold are removed from the cradle, the mold is then removed from the artificial rock and the mold is repositioned in the cradle.
Claim 6
Dependent Claim
30 words
The method of claim 1 in which the low density urethane foam is of two to three pounds per cubic foot and is applied by spraying to a substantial thickness.
Claim 7
Dependent Claim
39 words
The method of claim 1 in which the two sides of the urethane composition are solvent free and are introduced separately into a reaction chamber of a spray gun to provide a 100% solids polyurethane artificial rock mold composition.
Claim 8
Dependent Claim
30 words
The method of claim 6 in which the isocyanate and polyol sides are introduced to the spray gun in a volume ratio of isocyanate to polyol of 1:1 to 1:8.
Claim 9
Dependent Claim
23 words
The method of claim 6 in which the isocyanate side comprises a polymeric 4-4'diphenylmethane diisocyanate having a functionality of free NCO of 28-34%.
Claim 10
Dependent Claim
16 words
The method of claim 6 in which the polyol is a hydroxy containing polyester or polyether.
Claim 11
Dependent Claim
17 words
The method of claim 9 in which the polyol comprises a polyether triol, polyetherdiol and a polyethertetrol.
Claim 12
Dependent Claim
47 words
The method of claim 9 in which the polyol comprises substantially 22% polyethertriol having a hydroxy number of 250, 49% of a polyetherdiol having a hydroxy number of 28, 13% of polyethertetrol having a hydroxy number of 770, a glycol extender and a catalyst of dibutyltin dilaurate.
Claim 13
Dependent Claim
34 words
The method of claim 6 in which the isocyanate side comprises a polymeric 4-4' diphenylmethane diisocyanate having a functionality of free NCO of 28-34% and the polyol is a hydroxy containing polyester or polyether.
Claim 14
Dependent Claim
46 words
The method of claim 12 in which the polyol comprises substantially 22% polyethertriol having a hydroxy number of 250, 49% of a polyetherdiol having a hydroxy number of 28, 13% of polyethertetrol having a hydroxy number of 770, a glycol extender and a catalyst dibutyltin dilaeurate.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-07-10 | 1993-01-09 | 1993-07-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-07-10 | 1997-01-09 | 1997-07-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-07-10 | 2001-01-09 | 2001-07-11 | $7700.00 | Window Closed / Lapsed |