Patent ID: 7984893
Filing Date: 2011-07-26
Classification: B23C,B23Q,B29C,B29L,Y10T

Abstract:
1. A process for supporting a non-planar contoured surface of a block of polymeric foam material while machining an opposite surface of the block of polymeric foam material, the block having a first face and the opposed second face, the method comprising the steps of: forming a one-piece, substantially solid removable support having a contour that is complementary to a non-planar contoured surface of a block of polymeric foam material to be processed, the one-piece substantially solid removable support configured to support the non-planar contoured surface from an opposite planar surface formed on the removable support, wherein the forming step includes the steps of: a) processing the first face of the block of polymeric foam material by a machine to form a cavity, the cavity having an outer aperture and a region with at least the non-planar contoured surface, the second face of the block of polymeric foam material supported on a surface of the machine; b) introducing an expandable foam material into the cavity formed in the first face of the block of polymeric foam material and allowing the introduced expandable foam material to cure to produce a support, the support having a non-planar contoured surface proximate to the non-planar contoured surface in the formed cavity and a planar support surface, the planar support surface opposed to the non-planar contoured surface located in the cavity of the block of polymeric foam material, wherein curing of the expandable material proceeds with the outer aperture into the cavity open; c) rotating the block of polymeric foam material with the cured expandable foam in the cavity to a second position, wherein the planar support surface defined by the cured expandable foam contacts the support surface on the machine and the opposed second face of the block of polymeric foam is presented for processing by the machine; d) while the block of polymeric foam is in the rotated position, processing the second opposed face of the block of polymeric foam material to form a second contoured surface; and e) removing the cured expandable foam material from contact with the cavity, the removed cured expandable foam material forming a removable support having a contour complementary to the first contoured surface formed in the block of polymeric foam material.