Patent ID: 6139786
Filing Date: 2000-10-31
Classification: B28B,B44C,Y10S

Abstract:
A method of forming a flexible mold for use in producing a molded article, including the steps of:(a) providing a model of an article to be produced, said model having top, bottom and side surface area portions forming a predetermined outer contour;(b) providing at least one flexible and liquid impervious layer;(c) partially encapsulating said model within said at least one flexible and liquid impervious layer to form a reverse image of said predetermined outer contour, said partially encapsulated model having a lower portion;(d) providing a container having a floor member;(e) inserting said partially encapsulated model into said container, said lower portion of said partially encapsulated model being placed in contiguous overlaying relationship with said floor member of said container;(f) providing a curable liquid polymer composition;(g) pouring said curable liquid polymer composition into said container for encapsulation of said partially encapsulated model within said curable liquid polymer composition;(h) inserting a pair of handle members into said curable liquid polymer composition to a predetermined depth, said predetermined depth being less than a depth of said liquid impervious layer;(i) curing said curable liquid polymer composition having said pair of said handle members embedded therein to form a solid flexible mold encompassing member adhered to said liquid impervious layer for forming a flexible mold structure;(j) removing said flexible mold structure from said container; and,(k) displacing said handle members each toward the other to release said model from said flexible mold structure to form a cavity therein for use in forming said molded article as a replica of said model.