Patent ID: 6555188
Filing Date: 2003-04-29
Classification: A41G,B29C,B44C,Y10T

Abstract:
An article formed by a process comprising:(a) placing a generally spherical, hollow mold and a spray nozzle so as to position the nozzle along a central axis of the mold; (b) spraying components of a rigid polyurethane foam through the nozzle and directing said components radially at the inside surface of the mold, causing the components to form a foam material against portions of the inside surface at which the components are sprayed; (c) moving the mold and the nozzle relative to each other so as to cause the mold to revolve axially with respect to the nozzle, so that the component material is sprayed at enough portions of the inside surface to form a hollow, generally spherical, rigid polyurethane foam shell; (d) separating the mold and the formed polyurethane foam shell; and (e) at some point in the process, forming holes extending through the material of the rigid polyurethane foam shell, which holes are shaped and positioned to visually represent a face.