Foam core cement and urethane shutters

Abstract

A shutter assembly having a foam insert or core enveloped by a cementitious or urethane-based shell. The shell can also be provided with an optional hanger member that allows the shutter assembly to be mounted to a dwelling via a bracket affixed to an exterior wall surface thereof. The assembly can be molded from a cementitious slurry including gypsum cement and water, or alternatively, from a two part urethane filled with lightweight fly ash. An appropriate amount of the slurry or urethane-based material is added onto a bottom mold surface portion to a desired depth. If the hanger member is to be used, it is placed onto the bottom mold surface portion prior to the introduction of the slurry or urethane-based material. The foam insert or core is placed atop the slurry or urethane-based material in a desired orientation, whereupon the top mold surface portion is closed over the bottom mold surface portion. After curing, the shutter assembly is removed from the mold and is ready for immediate use and/or further processing.

1 . A method for forming a molded component, comprising:
 providing a bottom mold surface member;   charging an amount of a urethane-based material onto the bottom mold surface member; and   disposing a foam member into the urethane-based material such that the foam member is at least partially enveloped by the urethane-based material.   
   
   
       2 . The invention according to  claim 1 , further comprising providing an upper mold surface member operably associated with the bottom mold surface member. 
   
   
       3 . The invention according to  claim 2 , wherein the upper mold surface member is selectively operable to cause the foam member to be at least partially submerged within the urethane-based material. 
   
   
       4 . The invention according to  claim 2 , wherein the upper mold surface member includes a surface portion having a plurality of protuberances formed thereon, wherein the protuberances are selectively operable to cause the foam member to be at least partially submerged within the urethane-based material. 
   
   
       5 . The invention according to  claim 1 , further comprising providing an insert selectively operable to be disposed within the bottom mold surface member, wherein the insert includes a surface configuration. 
   
   
       6 . The invention according to  claim 5 , wherein the surface configuration is selectively operable to form a surface of a shutter. 
   
   
       7 . The invention according to  claim 5 , wherein the component is selectively operable to be removed from the insert after the urethane-based material has sufficiently cured. 
   
   
       8 . The invention according to  claim 1 , wherein the component comprises a shutter. 
   
   
       9 . The invention according to  claim 1 , wherein the foam member is completely enveloped by the urethane-based material. 
   
   
       10 . The invention according to  claim 1 , further comprising providing a hangar member disposed within the urethane-based material. 
   
   
       11 . The invention according to  claim 1 , wherein the foam member includes at least one opening formed therein such that the urethane-based material is selectively operable to penetrate therethrough. 
   
   
       12 . The invention according to  claim 1 , wherein the urethane-based material includes a two-part urethane composition. 
   
   
       13 . The invention according to  claim 1 , wherein the urethane-based material includes fly ash. 
   
   
       14 . A molded component, comprising:
 a foam member; and   a shell comprised of a urethane-based material at least partially enveloping the foam member.   
   
   
       15 . The invention according to  claim 14 , wherein the component comprises a shutter. 
   
   
       16 . The invention according to  claim 14 , wherein the foam member is completely enveloped by the urethane-based material. 
   
   
       17 . The invention according to  claim 14 , further comprising a hangar member disposed within the urethane-based material. 
   
   
       18 . The invention according to  claim 14 , wherein the foam member includes at least one opening formed therein such that the urethane-based material is selectively operable to penetrate therethrough. 
   
   
       19 . The invention according to  claim 14 , wherein the component is formed by:
 charging an amount of the urethane-based material onto a bottom mold surface member;   disposing the foam member into the urethane-based material such that the foam member is at least partially enveloped by the urethane-based material; and   allowing the urethane-based material to cure for a sufficient period of time.   
   
   
       20 . The invention according to  claim 19 , further comprising an upper mold surface member operably associated with the bottom mold surface member. 
   
   
       21 . The invention according to  claim 20 , wherein the upper mold surface member is selectively operable to cause the foam member to be at least partially submerged within the urethane-based material. 
   
   
       22 . The invention according to  claim 20 , wherein the upper mold surface member includes a surface portion having a plurality of protuberances formed thereon, wherein the protuberances are selectively operable to cause the foam member to be at least partially submerged within the urethane-based material. 
   
   
       23 . The invention according to  claim 19 , further comprising an insert selectively operable to be disposed within the bottom mold surface member, wherein the insert includes a surface configuration. 
   
   
       24 . The invention according to  claim 23 , wherein the surface configuration is selectively operable to form a surface of a shutter. 
   
   
       25 . The invention according to  claim 23 , wherein the component is selectively operable to be removed from the insert after the urethane-based material has sufficiently cured. 
   
   
       26 . The invention according to  claim 14 , wherein the urethane-based material includes a two-part urethane composition. 
   
   
       27 . The invention according to  claim 14 , wherein the urethane-based material includes fly ash. 
   
   
       28 . A system for forming a molded component, comprising:
 a bottom mold surface member;   wherein an amount of a urethane-based material is charged onto the bottom mold surface member;   wherein a foam member is disposed into the urethane-based material such that the foam member is at least partially enveloped by the urethane-based material.   
   
   
       29 . The invention according to  claim 28 , further comprising an upper mold surface member operably associated with the bottom mold surface member. 
   
   
       30 . The invention according to  claim 29 , wherein the upper mold surface member is selectively operable to cause the foam member to be at least partially submerged within the urethane-based material. 
   
   
       31 . The invention according to  claim 29 , wherein the upper mold surface member includes a surface portion having a plurality of protuberances formed thereon, wherein the protuberances are selectively operable to cause the foam member to be at least partially submerged within the urethane-based material. 
   
   
       32 . The invention according to  claim 28 , further comprising an insert selectively operable to be disposed within the bottom mold surface member, wherein the insert includes a surface configuration. 
   
   
       33 . The invention according to  claim 32 , wherein the surface configuration is selectively operable to form a surface of a shutter. 
   
   
       34 . The invention according to  claim 32 , wherein the component is selectively operable to be removed from the insert after the urethane-based material has sufficiently cured. 
   
   
       35 . The invention according to  claim 28 , wherein the component comprises a shutter. 
   
   
       36 . The invention according to  claim 28 , wherein the foam member is completely enveloped by the urethane-based material. 
   
   
       37 . The invention according to  claim 28 , further comprising a hangar member disposed within the urethane-based material. 
   
   
       38 . The invention according to  claim 28 , wherein the foam member includes at least one opening formed therein such that the urethane-based material is selectively operable to penetrate therethrough. 
   
   
       39 . The invention according to  claim 28 , wherein the urethane-based material includes a two-part urethane composition. 
   
   
       40 . The invention according to  claim 28 , wherein the urethane-based material includes fly ash.