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.

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.