Life ring and method of manufacture
A life ring includes a cover formed of a knitted back polyester fabric with a top vinyl coating, and a urethane foam core within the cover. The cover and the urethane foam core are formed into a ring shape. By using the noted cover material, the life ring can be manufactured without a painting step, thereby reducing manufacturing costs and improving the consistency of the finished product.
1. A method of manufacturing a life ring comprising:
(a) unrolling a section of a knitted back polyester fabric with a top vinyl coating;
(b) cutting the section into a ring cover with a digital cutter;
(c) securing the ring cover in a ring mold;
(d) injecting the ring mold with urethane foam and permitting the urethane foam to cure;
(e) removing the ring cover with the cured foam from the ring mold and trimming the ring cover with the cured foam; and
(f) applying attachments.
2. A method according to claim 1 , wherein steps (a)-(f) are conducted without painting.
3. A method according to claim 1 , wherein step (e) is practiced by trimming an outside of the ring cover with the cured foam with a band saw and a rotary table.
4. A method according to claim 3 , wherein step (e) is further practiced by trimming an inside of the ring cover with the cured foam with a drum sander.
5. A method according to claim 1 , wherein step (f) is practiced by applying vinyl trim banding to an outside circumference and an inside circumference of the ring cover with the cured foam.
6. A method according to claim 5 , wherein step (f) is further practiced by sewing beckets and rope to the ring cover with the cured foam without painting.
7. A method according to claim 1 , wherein the method consists of steps (a)-(f).
8. A method of manufacturing a life ring without painting, the method comprising:
(a) unrolling a section of a knitted back polyester fabric with a pre-colored top vinyl coating;
(b) cutting the section into a ring cover with a digital cutter;
(c) securing the ring cover in a ring mold;
(d) injecting the ring mold with urethane foam and permitting the urethane foam to cure;
(e) removing the ring cover with the cured foam from the ring mold and trimming the ring cover with the cured foam; and
(f) without painting the ring cover with the cured foam, applying attachments.
9. A method according to claim 8 , wherein step (e) is practiced by trimming an outside of the ring cover with the cured foam with a band saw and a rotary table.
10. A method according to claim 9 , wherein step (e) is further practiced by trimming an inside of the ring cover with the cured foam with a drum sander.
11. A method according to claim 8 , wherein step (f) is practiced by applying vinyl trim banding to an outside circumference and an inside circumference of the ring cover with the cured foam.
12. A method according to claim 11 , wherein step (f) is further practiced by sewing beckets and rope to the ring cover with the cured foam without painting.
13. A method of manufacturing a life ring comprising:
(a) unrolling a section of a knitted back polyester fabric with a top vinyl coating;
(b) cutting the section into a ring cover with a digital cutter;
(c) securing the ring cover in a ring mold;
(d) inserting a foam in the ring mold;
(e) removing the ring cover with the inserted foam from the ring mold and trimming the ring cover with the inserted foam; and
(f) applying attachments.