Exothermic reaction closed cavity low pressure dressform molding method and product produced thereby

Abstract

A dress or clothing form apparatus for holding and supporting garments, comprises a shaped solid body of a polymer material having a first density. The solid body is covered by a skin of the polymer material, but of a second density greater than the first density. The skin is functionally enabled for sealing pin holes therein. The body is made using a two-part exothermic reaction in a chilled mold wherein the skin thickness is determined by the temperature of the mold and the size of the chemical charge.

What is claimed is:  
     
         1 . A dress or clothing form apparatus for holding and supporting garments, the apparatus comprising: a shaped solid body including a skin covering, the body made of an aromatic isocyanate combined with a polyurethane, the skin functionally enabled for sealing pin holes therein.  
     
     
         2 . The apparatus of  claim 1  wherein the aromatic isocyanate is polymeric diphenylmethane diisocyanate and the polyurethane is polyol.  
     
     
         3 . The apparatus of  claim 1  wherein the shaped solid body resembles a human form.  
     
     
         4 . The apparatus of  claim 3  wherein the human form is anatomically incomplete.  
     
     
         5 . The apparatus of  claim 1  wherein the skin is between 100 and 120 mils in thickness.  
     
     
         6 . A method for making a dress or clothing form for holding and supporting garments, the method comprising the steps of: preparing a closed mold adapted for receiving a polymeric chemical formulation charge and for retaining an exothermic expansion of the chemical formulation within the closed mold so as to form a shaped solid body form; selecting a formulation charge volume to closed mold volume ratio and mold temperature for producing a skin covering of a selected thickness; and charging the closed mold with the selected formulation charge.  
     
     
         7 . The method of  claim 6  further comprising the step of preparing the chemical formulation to produce a two-part exothermic reaction in a closed mold.  
     
     
         8 . The method of  claim 7  further comprising the step of providing an aromatic isocyanate combined with a polyurethane for use as the polymeric formulation.  
     
     
         9 . The method of  claim 7  further comprising the step of providing polymeric diphenylmethane diisocyanate as one component in the two-part reaction.  
     
     
         10 . The method of  claim 9  further comprising the step of providing polyol as a further component in the two-part reaction.  
     
     
         11 . The method of  claim 6  further comprising the step of shaping the solid body to resemble a human form.  
     
     
         12 . The method of  claim 6  further comprising the step of shaping the human form as anatomically incomplete.  
     
     
         13 . The method of  claim 12  further comprising the step of cooling the mold and setting the charge so as to produce a skin thickness of between 100 and 120 mils.  
     
     
         14 . The method of  claim 13  wherein the mold temperature is between 90 and 110 degrees F.  
     
     
         15 . The method of  claim 13  wherein the charge comprises between 40 and 60 percent of the volume of the mold.  
     
     
         16 . The method of  claim 6  further comprising the step of adding water to the chemical formulation charge.