Chemical resistant composite support pad

Abstract

Embodiments of the mold for making the Chemical Resistant Composite Support Pad are comprised of a top and bottom molds where the top mold is comprised of a mold lip, a pneumatic ejection port, a lid aperture, a magnetic cover for the pneumatic ejection port, and a lid. The method of making a chemical resistant composite support pad comprises the steps of spraying a coating of polymer agent into the top mold and the bottom mold. A controlled run of an agent is sprayed into the joined top and bottom molds along the joint of the top mold and the bottom mold. Polymeric foam is injected through the lid aperture, the lid is replaced, and the foam is allowed to cure. The molds are separated, and compressed air is used to eject the support pad out of the mold. Any irregularities are repaired by spraying the coating of polymer agent.

What I claim is: 
     
         1 ) A chemical resistant composite support pad mold comprising a top mold and a bottom mold where the top mold is comprised of a mold lip, a pneumatic ejection port, a lid aperture, a magnetic cover for the pneumatic ejection port, and a lid. 
     
     
         2 ) The chemical resistant composite support pad mold described in  claim 1  comprising the magnetic cover that covers the pneumatic ejection port during the spraying of the coatings inside of the mold as well as injection of the polymer foam. 
     
     
         3 ) The chemical resistant composite support pad mold described in  claim 2  comprising the mold lip used to seal the top mold to the bottom mold and in particular to seal the mated bottom mold and top mold when the controlled run is made to complete the inside coating. 
     
     
         4 ) The chemical resistant composite support pad mold described in  claim 2  comprising wherein the magnetic cover is a thin sheet of magnetic material that is placed over the pneumatic ejection port on the inside of the top mold. 
     
     
         5 ) The chemical resistant composite support pad mold described in  claim 4  wherein the pneumatic ejection port allows the support pad is to be ejected from the mold by inserting compressed air into the pneumatic ejection port to force the support pad out from the mold and wherein the magnetic cover is easily detached from the top mold by the force of the compressed air inserted in the pneumatic ejection port. 
     
     
         6 ) The chemical resistant composite support pad mold described in  claim 1  wherein the lid covers the lid aperture during the spraying of the skin coating and is removed to allow access the interior of the mold when the controlled run is performed and when the foam is added to the inside of the mold. 
     
     
         7 ) A chemical resistant composite support pad made by the process comprising the steps
 a) opening a top mold and a bottom mold so that interior sides of both molds are accessible;   b) spraying a coating of a polymer agent onto the interior sides of the top mold and the bottom mold;   c) allowing the top mold and the bottom mold to cure;   d) placing the top mold and the bottom mold together;   e) removing a lid is along with a portion of the coating;   f) spraying a controlled run of the same polymer coating used in the top mold coating and the bottom mold coating over the top mold coating and along the joint of the top mold coating and the bottom mold coating;   g) allowing the controlled run agent to cure;   h) injecting polymeric foam through the lid aperture;   i) placing the lid over the lid aperture;   j) allowing the foam to rise, harden, and cure;   k) separating the top mold and the bottom mold;   l) compressed air is forced into the pneumatic ejection port forcing the magnetic cover and the support pad out of the top mold;   m) removing the magnetic cover; and   n) repairing any irregularities in the areas covered by the lid or the magnetic cover by spraying the coating of polymer agent.