U.S. patent application number 09/887451 was filed with the patent office on 2001-11-22 for non-mold method of forming objects and articles formed thereby.
Invention is credited to Evans, Robert B..
Application Number | 20010044247 09/887451 |
Document ID | / |
Family ID | 23852615 |
Filed Date | 2001-11-22 |
United States Patent
Application |
20010044247 |
Kind Code |
A1 |
Evans, Robert B. |
November 22, 2001 |
Non-mold method of forming objects and articles formed thereby
Abstract
This invention relates to a non-mold method of forming articles
and to the articles themselves wherein various configured articles
may be fashioned with conformable material which may be easily
fabricated as by sewing, or heat, or sonic welding to form the
basic shape of or modular elements of a completed article, and
wherein a thermal setting, flowable polymer or the like is
introduced into the space between layers of the conformable
material to thereby form the completed article or modular
element.
Inventors: |
Evans, Robert B.; (Santa
Barbara, CA) |
Correspondence
Address: |
CISLO & THOMAS, LLP
233 WILSHIRE BLVD
SUITE 900
SANTA MONICA
CA
90401-1211
US
|
Family ID: |
23852615 |
Appl. No.: |
09/887451 |
Filed: |
June 21, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09887451 |
Jun 21, 2001 |
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09466657 |
Dec 17, 1999 |
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6283810 |
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09466657 |
Dec 17, 1999 |
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09195596 |
Nov 18, 1998 |
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6241567 |
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Current U.S.
Class: |
441/64 |
Current CPC
Class: |
B29C 70/745 20130101;
B29C 39/126 20130101; A63B 2209/00 20130101; A63B 31/10 20130101;
B29K 2105/0002 20130101; Y10T 428/249999 20150401 |
Class at
Publication: |
441/64 |
International
Class: |
A63B 031/08 |
Claims
I claim:
1. A non-molded formed object of selective configuration
comprising: at least first and second unsupported layers of
resilient material, said first and second layers being joined one
to the other to cooperatively define a compartment therebetween
having a pre-formed element configuration; and, an intermediate
polymer solid disposed in conformed manner within said compartment
to form a completed object maintaining said pre-formed element
configuration.
2. A non-molded swim fin comprising at least first and second
conformable layers of material joined one to the other to define
therebetween a compartment having a pre-formed configuration, and a
solid polymer substantially filling in conformed manner said
compartment between said first and second conformable layers,
wherein foot securing portions of said fin are adapted to be
secured about the foot of a swimmer.
3. In the fabrication of a non-molded object, the improvement which
comprises the non-mold forming of a basic configuration of said
object with at least an inner layer and an outer layer of
conformable material unsupportedly defining and maintaining
therebetween an intermediate compartment having a pre-formed
configuration, and introducing a solid forming polymer material in
conforming manner into said intermediate compartment, thereby
forming a completed object.
Description
RELATION TO OTHER APPLICATIONS
[0001] This is a divisional application of U.S. patent application
Ser. No. 09/466,657 which in turn is a continuation-in-part
application of pending U.S. patent application in the name of the
same inventor entitled NON-MOLD METHOD OF FORMING OBJECTS AND
ARTICLES FORMED THEREBY, application Ser. No. 09/195,596 having a
filing date of Nov. 18, 1998, now U.S. Pat. No. 6,241,567 B11.
BRIEF SUMMARY OF THE INVENTION
[0002] This invention relates to a non-mold method of forming
articles and to the articles themselves wherein various configured
articles may be fashioned with conformable material which may be
easily fabricated as by sewing, or heat, or sonic or radio
frequency welding to form the basic shape of or modular elements of
a completed article, and wherein a thermal setting, flowable
plastic or the like is introduced into the space between layers of
the conformable material to thereby form the completed article or
modular element thereof.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to the method of forming completed
articles or in other instances, modular elements that will be
assembled to form a completed article.
[0005] The prior art has long recognized a method of forming
articles using a molding process where expensive molds are machined
and a thermal setting material such as plastic or the like is
injected into the mold, allowed to set and thereafter, the mold
opened to remove a formed article which then requires, in most
instances, some finishing before the article is ready for
marketing.
[0006] This methodology heretofore utilized has been expensive and
time consuming, not only with respect to the initial expense of
fabricating the mold, which requires highly skilled labor, but also
with respect to the manual labor needed in removing slashing,
sanding, or otherwise finishing the molded product to make the
same, ready for sale. The herein disclosed invention does away with
the need of conventional molds and the molding process in order to
fabricate finished articles, which articles may be fashioned from
conformable materials which are sewn or otherwise sealed together
to form an inner space into which a flowable, thermal setting,
resin or the like, is introduced so that the form or mold becomes
part of the finished product itself. The overall saving in labor,
that is sewing and sonic or radio frequency, or heat welding, being
much less than labor required in making molds and operating a
molding machine, is readily apparent.
[0007] In addition, by making modular-type elements, the total of
which makes up the whole of a finished article, individual elements
of modular construction, employing designs and colors which would
otherwise not be employable, may be assembled in order to form
desirable, marketable products.
[0008] 2. Description of the Related Art
[0009] As far as is known, there is no prior art directly related
to the herein disclosed invention wherein a formed article is
either modularly fabricated and later assembled to complete the
finished article, or wherein a non-molding process is utilized as
contemplated in the carrying out of the method of the
invention.
[0010] However, the concept, in the broad sense of having inner and
outer skins or layers forming a space into which something is
injected is relatively old. Such items as inflatable pool toys and
inflatable concrete bags for underwater purposes are well known.
But in the case of the inflatable pool toy, a fluid such as air is
contemplated as opposed to a liquid solid-forming polymer of this
invention. Further, the pool toy form does not become part of a
complete article, as contemplated in the instant invention.
[0011] As regards to the underwater concrete bag, into which
concrete is introduced, the final shape, after setting of the
concrete of the concrete bag is determined by the ambient
surroundings, such as sea floor, as opposed to the instant
invention that utilizes a predetermined shape and configuration for
the patterns defining the ultimate shape of the completed
article.
[0012] But, a prior search has been made and the most specific
references found are hereinafter enumerated, but none detract from
the patentability of the disclosed invention and the articles
formed thereby.
[0013] U.S. Pat. No. 3,042,562--Product and Method for Production
of Articles Having Compound Curves--N. R. PETERSON
[0014] This reference is directed to a product and method for
forming articles having compound curves without using a mold. The
product can be foamed plastic having slits or grooves extending
greater than halfway through the thickness of the sheet. A sheet 10
having slits 12 arranged to form adjacent columns 13 are on the top
surface 17 and the bottom surface 18, with the slits staggered to
be midway between those on one surface relative to those on the
other surface. This slitting provides for a continuous sheet that
is very flexible. The sheet 10 is readily formed into a wide
variety of complex shapes. A shaped article 21 shown in FIG. 7 is
fabricated in accordance with this invention. The shaped article 21
comprises a base shape 10b having a plurality of slits 12f and 12g.
The sheet is formed into a concave structure and the sheet and
slits are filled with a hardenable material 25. The entire article
21 is then covered with a coating 26. The completed article 21 is
rigid and self-supporting. A self-supporting object is made by
applying a hardenable cement, grout, or filler material to the
grooves or slits opened by flexure of the sheet into a shape. The
material upon hardening provides a permanent means for supporting
the board in the formed shape. Articles such as boat hulls are
readily fabricated by temporarily supporting the slit sheets of
polystyrene on a suitable form, coating the sheets with polyester
resin woodflower mixture, or epoxy resin woodflower mixture to fill
the fissures and then applying a layer of fibrous glass fabric to
the outer surface. The slits in the sheet may be in a variety of
patterns, as shown in FIGS. 2-5.
[0015] U.S. Pat. No. Re 29,394--Corrosion Protective Band for
Underground Pipe Joints with Metal Parts--Swanson, Et Al.
[0016] This reference is directed to impregnated foam bands for
sealing bell and spigot pipe joints. Reinforced concrete pipes 11,
12 having a steel bell ring 13 and steel spigot ring 14 are
telescoped together compressing a rubber sealing gasket 17.
Protection for the steel members 13, 14 is provided by a pair of
bands, a spigot band 21, and a bell band 19. The bands are formed
from a polyurethane foam impregnated with Portland cement and
sealed for shipping and handling by a water soluble membrane 22.
The spigot band 21 is stretched and pulled over the steel spigot
ring 14. The bell band 19 is connected to pipe 11 by means of a
suitable adhesive. On insertion of the spigot ring 14 into the bell
ring 13 of the next pipe, the outer and inner portions of the joint
have the spigot band 21 and bell band 19 positioned respectively to
protect the steel bell and spigot rings 13, 14. Ground water
contacts band 21 and the Portland cement impregnated therein is
hydrated. Similarly, the fluid in the pipeline activates the
corrosion inhibiting properties of bell band 19.
[0017] U.S. Pat. No. 5,604,998--Sports Shoe Providing Heel
Stabilization--Keijiro Kita
[0018] This reference is directed to a heel pad for a sports shoe
formed of open cell foam impregnated with bouncing putty. A pad 8
of three-dimensional horseshoe shape may be formed from a stack of
parts 12 of polyurethane foam impregnated with bouncing putty. The
pad may also be formed from a unitary block of polyurethane foam
impregnated with bouncing putty and cut into the three-dimensional
horseshoe shape or a thermoforming process may also be utilized.
The pad may comprise a bag-like sheet of synthetic resin 14
enclosing bouncing putty 13. FIG. 11 shows a pad 8 comprising open
cell foam 18 impregnated with bouncing putty 17. The pad 8 will
have plastic deformation under heel pressure. It will be the same
as the bouncing putty itself and exhibit bounce under the impact
force applied during athletic sports.
[0019] U.S. Pat. No. 4,946,726--Orthopedic Splinting Articles and
Methods Sandvig, Et Al.
[0020] This reference is directed to an orthopedic splint of
impregnated foam that can be formed around a body part and
hardened. The splinting article 10, a unitary blank, is a sheet of
pliant foam initially formed as a rectangle for trimming to custom
fit a patient. The foam sheet of article 10 is open celled,
impregnated by a curable resin. Before applying article 10 to a
patient, a cast padding 14 is preferably placed on the patient so
as to prevent undesirable adhesion or contact between the splint
and the patient. The foam sheet is preferably impregnated with a
water curable isocyanate functional polyurethane prepolymer
resin.
[0021] U.S. Pat. No. 5,002,047--Orthopedic Pads and
Methods--Sandvig, Et Al.
[0022] This reference is directed to foam materials suitable for
orthotic pads and methods of preparing the pads using the foam
materials. A blank 10 dimensioned as shown to be used as an
orthotic foot pad is generally comprised of a pliant extensible
foam sheet of extensible foam that is open-celled. The orthotic pad
is impregnated with a solventless resin system and then sealed in a
water vapor impermeable package which is opened just prior to use.
In use, the package is opened and the blank is exposed to water.
The patient's foot is positioned on the blank with possibly using
an appropriate interface barrier. The foot is held in place with
sufficient pressure to cause the surface of the pad to conform to
the shape of the bottom of the foot and held until the pad is
secured. The appropriate interface material can be a flexible
stockinet 14.
[0023] U.S. Pat. No. 5,112,663--Method of Manufacturing Composite
Structures Morenz, Et Al.
[0024] This reference is directed to a method of making a composite
structure, such as an aircraft wing, wherein sheets of flexible,
open cell foam are impregnated with a thermo-setting resin. A sheet
of dry fiber reinforced material is placed on one or both sides of
the impregnated foam sheet. The resulting sandwich is wrapped
around a foam core and the assembly is placed in a corresponding
tool cavity. The tool cavity is heated to a curing temperature and
the foam core expands into the confines of the tool.
[0025] U.S. Pat. No. 5,338,024--Golf Club--Charles S. Baum
[0026] This reference is directed to a golf club head which is
formed with a ball impacting face having an outer layer of wood
veneer bonded to an inner layer of synthetic resin reinforced
fibers by a synthetic resin which impregnates both layers. The club
head is formed by an outer shell being positioned over a molded
foam plastic core, wherein the core is covered with a flexible
woven resin reinforced fiber sock and, thereafter the impregnation
of the sock with an uncured synthetic resin is achieved and,
thereafter the composite is cured in forming molds.
[0027] U.S. Pat. No. 5,664,518--Composite Structures and Method of
Making Composite Structures--Lewit. Et Al.
[0028] This appears to be a particularly pertinent patent in the
sense that it describes making composite structures wherein a
reinforcing fabric, such as fiberglass is mechanically attached by
stitching to a non-woven polyester fabric. The attached fabrics are
placed in a mold with non-woven fabric facing inside of the mold. A
soft, expanding, self-curing foam is put into the mold, in an
amount sufficient so that upon expansion in a closed mold, the foam
penetrates into the intricacies of the non-woven fabric, which upon
curing forms a bond therewith. However, note that a forming mold is
required in contradistinction to the instant invention.
DISCLOSURE OF THE INVENTION
[0029] This invention relates to the method of forming composite
objects or articles comprising the combination of forming patterns
of conformable material representative of the component sides of
the final shape of the object to be formed and affixing the formed
patterns of conformable material along conforming lines to thereby
form an intermediate space therebetween, after which a flowable
polymer is introduced into the intermediate space. Thereafter, the
flowable polymer is allowed to polymerize into a solid after which
the formed object is produced whereby the patterns of conformable
material and said polymer are integral.
[0030] In a more basic, general way, the invention is related to
the non-mold method of forming a basic configuration of an article
with at least an inner layer and an outer layer of conformable
material to thereby form an intermediate space therebetween and
introducing a solid forming material into said intermediate space
to thereby form a completed object. The formed object may be of
selected configuration and comprises at least first and second
secured layers of material, having an intermediate polymer solid
therebetween, which comprises a modular element in some instances
or is capable of further additions to form a completed object of
desired shape and in other instances, may be the final object or
article itself.
[0031] It is an important object of the invention to provide a
method of forming objects not requiring molds in the conventional
sense.
[0032] It is another important object of the invention to provide a
method, and articles formed thereby, wherein two layers of material
are fashioned into a desired shape by means of securement along
their periphery by means of sewing or other bonding methods so that
an intermediate space is formed and thereafter, filling said
intermediate space with a thermal setting polymer which after
setting, forms an integral article of desired configuration and
which may be used as a building block or modular element to fashion
a completed article.
[0033] It is still another more important object of the invention
to have a non-mold forming process which does not rely on expensive
machinery or labor-intensive, high priced labor in order to form
completed articles.
[0034] It is still another more important object of the invention
to provide a non-mold forming process which does not require molds,
expensive machinery, or highly talented labor in order to fabricate
or assemble finished articles of desired shape and/or
components.
[0035] It is another even more specific object of the invention to
provide a method of forming objects wherein the pattern or
components themselves used in forming the finished article or
object becomes part, in an integral manner, of the finished article
or object itself.
[0036] It is still another more important object of the invention
to provide a method of forming modular elements using a non-mold
forming process wherein menial labor is utilized for securing
components together to thereby form finished articles of enhanced
functional characteristics, but of relatively low-cost in terms of
tools, jigs, molds, and labor.
[0037] It is still another more important object of the invention
to provide a non-mold forming process wherein articles are
fashioned from conformable material as by sewing, or heat, or sonic
or radio frequency sealing so that at least two layers of the
material form an intermediate space therebetween into which is
introduced, a flowable thermal setting polymer which after setting
up, forms the completed article itself or forms a basic modular
element which may be easily assembled with other modular elements
to provide a finished, fabricated article.
[0038] These and other objects of the invention will become more
apparent from referring to the hereinafter following commentary or
specification taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a perspective view of one type of article or
object that is made in accordance with the invention;
[0040] FIGS. 2, 3, 4, and 5 illustrate, in sequence, the
methodology in one embodiment of the invention in forming the
article depicted in FIG. 1;
[0041] FIG. 6 is a view taken along the line 6-6 of FIG. 5;
[0042] FIG. 7 is a flow chart which schematically illustrates the
general methodology of the invention;
[0043] FIG. 8 illustrates the top view of another embodiment of the
invention wherein individual components or modular units are
utilized to make up the finished article;
[0044] FIG. 9 is a side view of the article shown in FIG. 8;
[0045] FIG. 10 is a top view of another embodiment of the invention
showing the modular concept of the methodology of the invention as
applied to a specific object such as a swim fin;
[0046] FIG. 11 is a schematic illustration of a different type of
formed object, in this case being a knee pad;
[0047] FIG. 12 schematically illustrates still another application
of the invention directed to a filter; and
[0048] FIG. 13 schematically illustrates the application of the
invention to a tennis racquet.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0049] The detailed description set forth below in connection with
the appended drawings is intended as a description of presently
preferred embodiments of the invention and is not intended to
represent the only forms in which the present invention may be
constructed and/or utilized. The description sets forth the
functions and the sequence of steps for constructing and operating
the invention in connection with the illustrated embodiments.
However, it is to be understood that the same or equivalent
functions and sequence may be accomplished by different embodiments
that are also intended to be encompassed within the spirit and
scope of the invention.
[0050] Before going specifically to the drawings illustrating
several of the many embodiments contemplated to which the invention
may be put, a description of the starting materials would be
appropriate.
Polymer
[0051] The type of polymer utilized in the practice of the
invention will, as those of ordinary skill in the art recognize,
depend upon the final products that are to be formed in the
practice of the invention. In all instances, a thermal setting
plastic is contemplated and its characteristics chosen to more
aptly suit the final needs of the product to be formed. That is,
where the end product needs to be more flexible, a polymer will be
chosen that has a durometer rating most compatible with the end
result desired. In other instances where gravity flow, as opposed
to pressure injection of the flowable polymer is contemplated, the
viscosity of the polymer in the fluid state will become important
and those of ordinary skill in the polymer art and in deed,
familiar with the characteristics of the end products desired, will
be able to readily choose the polymers for the characteristics they
possess and which are desired for the final formed product.
[0052] For example, with regard to a swimming fin of the type that
will be discussed hereinafter, a urethane polymer marketed by
Uniroyal Chemical under the trademark VIBRATHANE, has been found to
be suitable. The characteristics of VIBRATHANE, designated by
Uniroyal Chemical as B-625, has been found to be desirable with
regard to its use in the swimming fin used as one example for
practicing the invention.
Urethane Properties
[0053]
1 VIBRATHANE B-625 Prepolymer Property % NCO 6.09-6.56 Amine
equivalent 665 + 25 Appearance @ 75.degree. F. (24.degree. C.)
Liquid Typical Viscosity @ 212.degree. F. 170 (0.75) (100.degree.
C.), cps (pa-s) Processing Information 1,4-butanediol level.sub.1,
pph 6.4 Vibracure 3095 level.sub.1, pph -- Curative temperature,
.degree. F. (.degree. C.) 140 (60) Vibrathane temperature, .degree.
F. (.degree. C.) 200 (93) Pot Life, Min..sub.2 6 Urethane
Properties Shore Hardness 85A 100% Modulus, psi (MPa) 820 (5.6)
300% Modulus, psi (MPa) 1900 (13.1) Tensile, psi (MPa) 5400 (37.2)
Elongation, % 460 Tear Strength (D470), pli (kN/m) 80 (14) Tear
Strength, Die C, pli (kN/m) 540 (94.5) Bashore Rebound, % 64
Compression Set, 22 Hrs./158.degree. F. 29 (70.degree. C.) Method
B, % Bell Brittle Point, .degree. F. (.degree. C.) <-80 (-63)
Specific Gravity 1.09
[0054] While a specific polyurethane formulation is given, it is to
be understood that other specific formulations may be utilized
again, depending upon the end results desired and mere reference to
manufacturer's specifications similar to those given above, will
allow a worker in the art to choose the polymer most suited to
selected applications. For example, liquid polyvinyl chloride could
be utilized with polyvinyl chloride or polyurethane sheet for the
conformable material.
[0055] In some instances where a conformable material, as will be
described, is used having a layer of plastic or polyurethane
thereon, a polymer and catalyst is chosen such that upon
introduction and curing of the polymer, the exothermic reaction
causes introduced polymer and adjacent plastic or polyurethane
layers on the conformable material to coalesce into a single
integrated mass.
Conformable Material
[0056] The type of material that lends itself most readily for the
forming of patterns that are affixed to each other in a sealing
relationship to thereby form an intermediate space to receive the
flowable polymer may take various forms, but generally will be a
polyurethane, polyvinyl chloride or other suitable plastic sheeting
material or a fabric of Nylon, Kevlar, Hypalon and similar such
polyester fabrics ranging in denier from 70 having 108.times.86
threads per inch to 200 denier having 40.times.40 threads per inch.
Again, a worker in the art will select and choose a conformable
material or fabric depending upon the ultimate end use of the
material for the finished article or modular element, keeping in
mind the end use to which the same will be put. In some instances,
where a fabric is indicated, a courser or finer material will be
dictated. as will its being coated with different polymers to aid
in the affixing process, especially where sonic welding is
contemplated and even in those instances where sewing or other
affixing of the materials is employed. In some instance, a
mechanical bond between the pile of the conformable material and
introduced flowable polymer will be desired and thus, the fabric
chosen accordingly. Also, the mesh or scrim of this material will
aid in the bonding process between conformable material and
introduced polymer. Where plastic sheeting material is utilized,
the flexibility or stiffness of the material will dictate its
suitability of use in practice of the invention.
[0057] Several types of materials that have been found particularly
useful for the specific example of a swimming fin, as one of the
described embodiments of the invention, is URETEK 1115 put out by
Uretek, Inc., wherein the fabric is 70 denier nylon having
108.times.86 threads per inch and having a polyether polyurethane
coating. Another suitable material put out by the same company
under URETEK 2651 comprises a Kevlar type 29 material of 200 denier
with 40.times.40 threads per inch and having an aliphatic polyether
polyurethane coating. A suitable plastic sheet material for use in
swimming fins is a polyurethane sheet offered by J. P. Stevens
Company under is designation MP1880. This sheet material is a
general purpose, easily thermo-formable polyether polyurethane
having the necessary degree of stiffness or flexibility for a wide
range of end uses. Also, as previously stated PVC sheet material is
also suitable.
[0058] Other materials that may be useful in the practice of the
invention are offered by Archer Rubber Company and more
specifically by the Coated Fabric Group thereof, such materials are
a basket weave Nylon under style 9312 with a neoprene coating;
style 2163 which is a polyester fabric having a neoprene coating;
style 9333 which is a polyester fabric having a neoprene coating;
style 2141 which is a 420 denier nylon having a hypalon/neoprene
coating; and style 2085 which is 420 denier nylon having a neoprene
coating and all such materials will be found to be satisfactory,
depending upon the end uses to which the formed article will be
put, keeping in mind that the material becomes part of the finished
product and thus, a worker in the art will select both material and
coatings depending upon color, sheen and other esthetic properties
that will be desirable to incorporate into the finished
product.
[0059] Where a polyurethane sheet material is utilized for a swim
fin application, thicknesses in the range of about, by way of
example and not limitation, 0.01-05 inch and a durometer of about
70-95 A have been found useful. Obviously, other materials,
thicknesses and pliability will suggest themselves depending on the
end uses to which the conformable material is to be put.
[0060] It is only important that the conformable material in most
instances be capable of forming bonds with the introduced polymer,
be easy to work with in finishing the articles to be produced and
be impermeable to the introduced flowable polymer so same does not
leak out.
Methods of Forming
[0061] The methods of forming articles of the invention are as
prolific in number as the imagination of a worker in the art
permits. That is, with the simplified mode of fabrication by taking
a conformable material whether sheet or fabric, cutting out a
pattern and affixing two layers together to form an intermediate
space that is filled with a thermal setting plastic, allows for a
wide range of manufacturing techniques. In some instances, an
element of the assemblage comprising the finished product may be
mold formed, as with polyurethane foam, for integration as by
sewing, sonic welding or otherwise with modular elements that will
make up the remaining assemblage of the end product.
[0062] The totality of an article to be formed, where its
configuration permits, may be fashioned from the conformable
material in sheet or fabric form or individual modular elements
thereof may be made and then affixed together, depending upon the
end results desired and as will be seen, fabrication methods permit
the inclusion of padding, reinforcements or similar such additions.
Again, all are dependent upon the final end result to be
attained.
[0063] Generally speaking, the invention contemplates a conformable
fabric material of the type having the characteristic previously
described which is easily cut to a configuration that the final
article will take. In some instances, the two layers of conformable
material or fabric are affixed along their periphery either by
sewing, RF welding, sonic welding or other means, it only being
important that an intermediate space be formed between the two
layers, whether these layers are coated or uncoated, so that the
flowable polymer may be introduced. In some instances, in order to
prevent ballooning or bulging out during the polymer filling step,
seams formed by sewing, RF welding, sonic welding or otherwise may
be utilized to limit the amount of intermediate space into which
the polymer is introduced.
[0064] The simplified method of formation readily lends itself for
modular element formation which elements are subsequently affixed,
sewn or otherwise secured to each other to form a finished article
of desired shape, color and material characteristics.
[0065] Where sewing is contemplated, one need only utilize,
depending upon the fabric or other material chosen, a heavy duty
commercial-type sewing machine in order to provide adequate seaming
for both the periphery and intermediate areas of the patterns being
formed. In other instances, heat welding by means of radio
frequency techniques may be used in which case it becomes important
to utilize a polymer coated material to allow for the affixing of
two layers of material along a periphery or intermediate section
thereof, in order to provide the intermediate spaces into which the
polymer is introduced.
[0066] Those of ordinary skill in the art will of course recognize
other means of formation of a configured article dependant upon the
materials selected and the end result desired.
[0067] Referring now to the drawings wherein like numerals of
reference designate like elements throughout, there will be seen in
FIG. 1, one of the exemplars of the practice of one embodiment of
the invention. Herein depicted, is an aquatic fin 2 having fin
portion 4 and heel portion 6, intermediate of which are upstanding
fastening portions 8 and 10 which may be secured around the foot of
a wearer's foot by means of velcro, snaps, buckles or the like, not
shown.
[0068] In the fabrication of the fin 2 shown in FIG. 1, two pieces
of material 1 and 3, like that heretofore described, are placed in
position as shown in FIG. 2 either in side-by-side relationship or
superimposed one on the other and a line pattern 5 drawn on each as
shown in FIG. 3 in order to obtain two cut-out patterns 20 and 22
which are shown in FIG. 4 and which 20 are superimposed on each
other as shown in FIG. 5. The periphery or outer edge 24 formed as
by sewing, sonic welding or the like, creates a fixed boundary 26
about the periphery of the assemblage 28 with the exception of a
small gap or orifice 30 through which flowable polymer may be
introduced into the inner space 32 formed between layers 20 and
22.
[0069] The assemblage 28, in addition to having the affixed
perimeter 26, is provided with a plurality of spaced seams 34 to
form elongate channels 36 into which polymer may be introduced.
[0070] Once the assemblage 28 has been sewn, fixed or sonic or
radio frequency welded, as heretofore described, polymer 38 such as
one previously described is introduced into the opening 30 by means
of gravity or pressure injection so as to fill the inner space 32
between the layers 20 and 22 formed by reason of affixing of the
perimetric edge 26 and the placement of the seams 34. The formed
polymer 38 is best seen in FIG. 6.
[0071] In its simplest form, the methodology of the practice of the
invention with respect to obtaining the benefits of one embodiment
heretofore described is seen in the flow chart of FIG. 7.
[0072] There follows, by way of example and not limitation, a
specific example of the formation of the fin 2 as shown in FIG. 1
as follows:
EXAMPLE
[0073] 1. Two sheets of polyurethane-backed nylon cloth are cut
according to the fin pattern shape illustrated in FIGS. 24.
[0074] 2. A sheet of nylon mesh is cut according to the same fin
pattern shape.
[0075] 3. The nylon mesh is positioned between two sheets of
polyurethane-backed nylon cloth with the polyurethane backing on
the inside (toward the mesh).
[0076] 4. The three pieces are sewn together to form the shape of
the fin and cavities as shown in FIG. 5. The edge cavities are sewn
to form a cavity or inner space whose cross section starts at one
inch at the foot pocket side of the blade and shrinks to one-half
inch at the tip of the blade. The center cavity also narrows from
one inch to one-half inch, but it only extends half way from the
foot pocket to the end of the blade. The cavities extend to the
heel of the foot pocket base to form an opening to pour thermoset
polyurethane into. The opening extends a minimum of two inches from
where the edge of the final product is to be.
[0077] 5. Thermosetting polyurethane is poured into the heel-end
opening and flows to the tip of the blade through the cavities. The
initial temperature of the polyurethane is 110.degree. F.
[0078] 6. The two-inch long excess length of the assembly is rolled
onto itself, forcing the polyurethane to fill any cavities not
initially filled. This is analogous to rolling the end of a tube of
toothpaste, only the goal here is to fill the cavities, not empty
them.
[0079] 7. The thermosetting polyurethane system is formulated so
that as it sets up, it exothermetically generates heat to a
temperature above 275.degree. F. This melts the polyurethane
coating on the nylon cloth and binds it to the thermosetting
polyurethane.
[0080] 8. Once the thermosetting polyurethane sets up, the rolled
end is cut off, separate foot pocket buckles or straps are
attached, and a completed, non-mold formed fin is obtained.
[0081] Referring to FIGS. 8 and 9, there is shown still another
embodiment of the invention, which in this particular case, is also
directed to the formation of an aquatic fin 50. In the formation of
aquatic fin 50, separate heel receiving portions 52 are formed
which may be of formed polyurethane foam and which may be fashioned
in order to accommodate the human foot and more specifically, the
contours and configuration thereof in both left and right
configurations.
[0082] In the fabrication of fin 50, modular elements 54 and 56 are
formed using the methodology previously described with respect to
fin 2. However, in this particular instance the modular elements 54
and 56 are in elongated form having the polymer introduced therein
and which elements are assembled, as by sewing or other affixing,
to intermediate web portions 58 which may be a singular layer of
material such as semi rigid polyurethane or a composite involving
two layers affixed together having the polymer therebetween. A wide
range of attractive colors may be used for the various components
to make an aesthetically pleasing design. Subsequently, a
previously formed foot receiving portion 51 and a separate foam
heel portion 52 is sewn or otherwise affixed to the two elongate
members 54 and 56 and thereafter, a strap or other affixing means,
not shown, may be secured to the lateral sides of the foot
receiving portion 51 by which the fin 50 may be securely fastened
to the ankle of a wearer of the fin 50.
[0083] In the construction of the fin 52 illustrated, various foam
inserts for example may be placed in the bottom of the heel portion
52 and in deed, separate foam elements may be fastened and secured
into separate upstanding portions 8 and 10 as shown in FIG. 1 for
fin 2. In other words, individual modular elements or components of
the finished article, in this case for example, fin 50 may be
fabricated and easily affixed, one to the other as by sewing,
bonding or other means well known in the art.
[0084] Referring now to FIG. 10, there is shown separate elongate
members 70 and 72 which are fashioned of a plurality of layers of
materials previously described forming the inner space into which a
polymer may be injected or introduced and in this particular
instance, the layers of material may have a plastic coating and the
polymer used may be exothermic so that the heat generated melts the
plastic layer to cause a coalescence or flowing of one material to
the other in order to form an integral mass or assemblage with
respect to the thermal setting polymer and the layers of
material.
[0085] In some instances, those of ordinary skill in the art will
recognize that a polymer layer may be desirable in order to ensure
the integration of polymer and layers of material as a unified
assemblage or mass so that the polymer once set will not move
independent of the encapsulation within which it finds itself. In
some instances, the mesh size or coarseness of a fabric, for
example, may ensure a mechanical attachment or securement between
the polymer and the fabric itself.
[0086] Those of ordinary skill in the art will recognize that the
fin shown in FIG. 1 may have the upstanding portions 8 and 10
separately fashioned, as opposed to being integral as shown and
described, and as previously alluded. In order to make a more
comfortable fit with respect to the foot and ankle of the wearer,
there may be placed between the two layers of material a foam
cushioning pad. The upstanding portions 8 and 10 may be separately
fabricated and later affixed to the remainder of the fin
article.
[0087] Other modifications will present themselves. For example in
FIG. 10, the two elements 70 and 72 may be secured one to the other
to fashion a completed article such as a swim fin wherein elements
70 and 72 are secured to each other by means of an intermediate web
of flexible fabric or material such as previously described, in
which event there would be a single layer as opposed to the dual
layer forming the intermediate web space therebetween in which
case, no polymer would be injected.
[0088] Referring to FIG. 11, there is shown a knee pad 80 with
elastic fastening members 82 to exemplify the type of objects that
may be formed using the methodology of the invention. Following the
methodology of the invention, the knee pad pattern is applied to
two layers of lo fabric. The layers are affixed about their
periphery and along selective cavities to allow the formation of an
intermediate spaces therebetween and thereafter, the introduction
of a thermal setting polymer in order to obtain, after
solidification, a knee pad of a simple and practical design, which
is manufactured in an economical fashion. As those in the art will
recognize appropriate sewing, sealing or sonic or radio frequency
welding will be desirable and necessary to form curves and to
prevent ballooning or bulging.
[0089] There are a whole host of articles that may be fashioned
utilizing the hereindisclosed invention wherein it is desired and
desirable to have material which is utilized to fashion the article
become a part of the article itself without the need of molds or a
molding process.
[0090] For example, referring to FIGS. 12 and 13, an industrial
type filter 84 is illustrated wherein the outer frame 86 is formed
by sewing together two opposed pieces of fabric within which is
secured screen or filter member 88. Likewise, as shown in FIG. 13,
a low cost, easily manufactured tennis racquet 90 has the frame 92
formed as previously described for any article to be formed within
which is secured gut or nylon strings 94.
[0091] While the present invention has been described with regards
to particular embodiments. it should be recognized that additional
variations of the present invention may be devised without
departing from the inventive concept and the appended claims are
intended to cover all such embodiments.
* * * * *