Artificial Carvable Items and Methods of Manufacture

Abstract

Embodiments of the invention described herein thus provide a carvable pumpkin that is durable, can be reused, that has enhanced fire retardance, and that has a bright brilliant color that remains intact upon carving. These improvements help ensure that the pumpkins are safer, such that if they catch fire, they provide a flame barrier and burn out in about a minute or less. The improvements also help provide brightly colored pumpkins that do not have an external coating or layer of paint that can be easily scratched off. Finally, the improvements help provide pumpkins with a substantially uniform skin or otherwise controllable thickness, which can ease carving and provide an enhanced user experience.

1 - 5 . (canceled) 
     
     
         6 . A method of forming an artificial pumpkin, comprising:
 (a) providing a retainer box in the approximate shape of a pumpkin;   (b) inserting a silicone glove mold to the retainer box;   (c) applying a pigment to the silicone release layer to provide a pigmented mold release;   (d) applying foam to the pigmented mold release, wherein the foam comprises from about 1 to about 5% flame retardant;   (e) providing a plug that is smaller than, but similarly shaped to, the silicone mold of the pumpkin;   (f) allowing the foam to expand against the plug, causing an outer surface of the foam to be formed by the silicone glove mold and an inner surface of the foam to be formed by the plug.   
     
     
         7 . The method of  claim 6 , wherein the silicone mold is formed as half of a pumpkin shape, such that two halves may be formed and then adhered together to provide a final pumpkin product. 
     
     
         8 . The method of  claim 6 , wherein the pigment is an orange pigment or any other color desired. 
     
     
         9 . The method of  claim 6 , wherein the flame retardant comprises Tris (2-chloroisopropyl) phosphate, or a similar flame retardant or fire suppressant.