Method and compositions for spray molding polyurethane three dimensional objects

Patent 6362302 Issued on March 26, 2002. Estimated Expiration Date:

November 29, 2019. Estimated Expiration Date is calculated based on simple USPTO term provisions. It does not account for terminal disclaimers, term adjustments, failure to pay maintenance fees, or other factors which might affect the term of a patent.

Abstract Claims Description Full Text

Patent References

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Inventor

Boddie, Carl E.

Application

No. 449871 filed on 11/29/1999

US Classes:

528/73, Reactant contains at least one heterocyclic ring264/309, Spraying or flinging material against a shaping surface264/337, Utilizing particular mold material521/158, With ketone, aldehyde, or aldehyde derivative521/163, With nitrogen containing reactant524/789, Elemental silicon, soil, or inorganic silicon compound as DNRM528/76With ether or thioether compound containing at least two -C-X-C- groups

Examiners

Primary: Gorr, Rachel

Attorney, Agent or Firm

Howrey Simon Arnold & White, Nation; Floyd, White; Carter J.

International Class

C08G 018/32

Abstract

A method of producing three dimensional polyurethane shapes by spray molding a quasi-gel like polymer precursor composition that is first mixed and then sprayed by a spray gun. The spray coating of quasi-gel polymer precursor composition subsequently cures to form a molded polyurethane polymer shape. Such artificial three dimensional shapes may include rocks, rock walls or faces, tree stumps or limbs, animals, architectural features or settings in which a certain visual appearance is desired. The method includes: creating a mold and supporting cradle having a mold cavity conforming to the exterior of shape desired, the mold having a substantial degree of flexibility; spraying a quasi-gel polymer precursor composition into the mold cavity, the quasi-gel polymer precursor composition comprising a mixture of an isocyanate portion and a curative portion and being mixed prior to introduction into a spray gun, carrying out the spraying to build up the molded three dimensional shape to a desired thickness and stripping the cradle and mold from the molded polyurethane three dimensional shape after the curing of the quasi-gel polymer precursor.