Patent ID: 8613978
Filing Date: 2013-12-24
Classification: B29C

Abstract:
1. A method of manufacturing a body structure for a door or other furniture, comprising: placing a layer of a release sheet on a surface; depositing an uncured artificial stone mix on said release sheet; placing a skeletal framework on said uncured artificial stone mix; introducing liquid structural foam within said skeletal framework; wrapping said release sheet over said skeletal framework, wherein said deposited uncured artificial stone mix on said release sheet completely covers said skeletal framework; placing said wrapped skeletal framework in a chamber of a defined volume, whereby foaming of said liquid structural foam generates heat that accelerates curing of said uncured artificial stone mix, creates high pressure that compresses said uncured artificial stone mix, and makes said uncured artificial stone mix to conform to shape of said chamber; and curing said uncured artificial stone mix, thereby creating an outer cured artificial stone skin constituting one or more of a top surface, a bottom surface, and side surfaces of said body structure.