Covering arrangement for an animatronic or robotic arrangement

Abstract

A covering arrangement for an animatronic arrangement, the covering arrangement having a laminated structure comprising: an outer stretchable polymer layer having a thickness of between 0.5 to 5 mm; and a foam layer configured to provide desired bulk and form to the covering arrangement, wherein the foam layer comprises a shaped foam preform formed from precast flexible foam sheets.

Claims

1. A combination comprising a greater than human sized animatronic arrangement and a covering arrangement having a moulded laminated structure configured to cover the greater than human sized animatronic arrangement, wherein the covering arrangement comprises: an outer stretchable polymer layer having a thickness of between 0.5 to 5 mm; and a foam layer configured to provide desired bulk and form to the covering arrangement, wherein the foam layer comprises a shaped foam preform formed from precast flexible foam sheets, the shaped foam preform comprising a combination of at least two foam layers comprising: at least one body layer comprising a stretchable foam adapted to provide the form and configuration of the foam layer; and at least one contoured foam layer comprising a reticulated polymer foam adapted to provide shape and stiffness to the foam layer; wherein the covering arrangement is configured to be flexed or moved by the greater than human sized animatronic arrangement; and, wherein the out stretchable polymer layer comprises: a tensile strength of 475 psi, as measured according to ASTM D-412; a die B tear strength of 102 pli, as measured according to ASTM D-624; a 100% modulus of 22 psi, as measured according to ASTM D-412; and, and elongation at break of 1000%, as measured according to ASTM D-412.

2. The combination according to claim 1, wherein the outer stretchable polymer layer comprises a silicone material.

3. The combination according to claim 1, wherein the at least one body layer comprising a stretchable foam comprises a polyurethane foam; and the at least one contoured foam layer comprising a reticulated polymer foam comprises a polyurethane foam.

4. The combination according to claim 1, wherein the contoured foam layer comprises at least two or more shaped sections joined together to provide the foam layer with a selected form and configuration.

5. The combination according to claim 1, wherein the contoured foam layer includes at least one articulation aperture located within each shaped section.

6. The combination according to claim 1, wherein the contoured foam layer comprises a laminated structure of two affixed layers comprising an articulation layer formed from reticulated foam including a plurality of articulation apertures, and a backing layer formed from reticulated foam onto which the articulation layer is affixed.

7. The combination according to claim 1, wherein the covering arrangement includes a connection section that is connectable to at least one fastening or manipulation device, the covering arrangement including at least one section of mesh material on the outer stretchable polymer layer positioned in a location that reinforces the portion of the connection section proximate the outer stretchable polymer layer.

8. The combination according to claim 1, further including at least one section of mesh material positioned to reinforce at least one portion of the outer stretchable polymer layer that includes ridges or folds in the outer stretchable polymer layer.

9. The combination of claim 1, wherein the outer stretchable polymer layer comprises one or more peak lines that define lines of articulation of the outer stretchable polymer layer.

10. A method of forming at least one section of a covering arrangement for a greater than human sized animatronic arrangement configured to cover a greater than human sized animatronic arrangement, the method comprising: forming an outer stretchable polymer layer having a thickness of between 0.5 to 5 mm in a mould, the outer stretchable polymer layer having an outer surface and an inner surface; forming a foam preform having a desired form and bulk suitable for a selected section the covering arrangement, the foam layer comprising a shaped foam preform formed from precast flexible foam sheets comprising a combination of at least two foam layers comprising: at least one body layer comprising a stretchable polymer foam adapted to provide the form and configuration of the foam layer; and at least one contoured foam layer foam comprising a reticulated polymer foam adapted to provide shape and stiffness to the foam layer; and adhering the foam preform to the inner surface of the outer stretchable polymer layer, thereby forming a section of the covering arrangement; and wherein forming an outer stretchable polymer layer comprises forming an outer stretchable polymer layer so as to have: a tensile strength of 475 psi, as measured according to ASTM D-412; a die B tear strength of 102 pli, as measured according to ASTM D-624; a 100% modulus of 22 psi, as measured according to ASTM D-412; and, an elongation at break of 1000%, as measured according to ASTM D-412.

11. The method according to claim 10, wherein the mould comprises a textured mould having textured mould surfaces formed which provide desired texture and shape to outer surface of the outer stretchable polymer layer.

12. The method according to claim 10, wherein the stretchable polymer layer is applied to the mould using a spray applicator.

13. The method according to claim 10, wherein the step of forming an outer stretchable polymer layer in a mould comprises: coating the inner mould surface of the mould with a stretchable polymer pigment thereby forming a colour coated mould surface; and applying a stretchable polymer layer to the mould including the colour coated mould surface; and drying the resulting coloured stretchable polymer layer.

14. The method according to claim 10, further including the step of: adhering at least one section of mesh material to the inner surface of the outer stretchable polymer layer positioned to reinforce at least one portion of the outer stretchable polymer layer to form, in combination with the outer stretchable polymer layer, a reinforced outer layer, and thereafter adhering the foam preform to the reinforced outer layer to form a section of the covering arrangement.

15. The method according to claim 14, wherein the step of adhering at least one section of mesh material comprises: infusing the mesh material with stretchable polymer; and mounting the mesh material to at least one portion of the inner surface of the outer stretchable polymer layer.

16. The method according to claim 10, wherein the step of forming the foam preform comprises: laminating together at least one soft foam body layer for providing the form and configuration of the foam layer and at least one contoured foam layer for providing shape and stiffness to the foam layer.

17. The method according to claim 16, wherein the contoured foam layer is formed from a pattern including two or more interconnecting sections which are stitched together to form a contoured layer.

18. The method according to claim 16, wherein the step of forming the foam preform further comprises: forming the contoured foam layer from two or more layers of reticulated foam, the layers including at least one articulation layer including a plurality of articulation apertures, and at least one backing layer onto which the articulation layer is affixed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will now be described with reference to the figures of the accompanying drawings, which illustrate particular preferred embodiments of the present invention, wherein:

(2) FIG. 1 illustrates a cross-section of a covering arrangement according to one embodiment of the present invention.

(3) FIG. 2 illustrates a texture mould with outer stretchable polymer layer applied.

(4) FIG. 3 illustrates the step of applying a mesh reinforcing material to the inner surface of the outer stretchable polymer layer shown in FIG. 2.

(5) FIG. 4 illustrates the step of vacuum bagging the reinforced outer stretchable polymer layer resulting from the step shown in FIG. 3.

(6) FIG. 5 illustrates the step of marking out a pattern on a contoured foam layer.

(7) FIG. 6 illustrates the step of joining two foams comprising the contoured foam layer. It should be noted that the illustrated joining process can be done either inside the mould or outside the mould.

(8) FIG. 7 illustrates the step of stitching the pattern of the contoured foam layer shown in FIG. 6. It should be noted that stitching may not be not appropriate in all situations and adhesives may suffice.

(9) FIG. 8 illustrates the step of applying an adhesive on body foam layer for affixing to the contoured foam layer shown in FIG. 8.

(10) FIG. 9 illustrates the step of placing foam preform into the mould shown in FIGS. 2 to 4.

(11) FIG. 10 illustrates the step of applying masking material/plastic to the relevant layer of covering arrangement when held in a mould.

(12) FIG. 11 provides a cross-sectional view of the covering arrangement with applied masking material/plastic as shown in FIG. 10.

(13) FIG. 12 shows the configuration of open join between two covering arrangement sections.

(14) FIG. 13 shows the configuration of sealed and connected join between two covering arrangement sections.

(15) FIG. 14 provides a photograph of an example of this hair knotting configuration on the outer silicone layer.

(16) FIG. 15 provides a photograph of a sample of repaired three day old creature skin having a configuration according to the present invention.

(17) FIG. 16 provides a photograph of a skin sample mounted between the arms of a durability test rig.

DETAILED DESCRIPTION

(18) The present invention provides a light weight, durable, and flexible covering or skin arrangement for an articulated body such as an animated or animatronic creature or figure used in a display, entertainment show or venue such as a museum or theme park. The system can be used in indoor and outdoor situations and applications. The skin arrangement has a laminated multilayer structure in which each layer has been selected to provide particular advantageous properties to the overall laminated structure.

(19) FIG. 1 shows a cross-section of the laminated layers structure 102 of one embodiment of a covering arrangement 100 according to the present invention. The illustrated laminated layers structure 102 has a multilayer structure.

(20) Starting from the top layer shown in FIG. 1, the multilayer structure comprises an outer stretchable polymer layer 105 which provides the outer visual layer of the covering arrangement 100. This layer provides the external visual aesthetics, and is therefore required to have the desired texture, colour and flexibility to matching the creature or other figure the covering arrangement 100 is designed to clad. In the illustrated embodiment, the outer stretchable polymer layer 105 comprises a thin moulded silicone material, preferably a flexible, stretchy silicone rubber. The outer stretchable polymer layer 105 is a moulded form formed from a curable liquid silicone rubber composition (the process of which is described in more detail below).

(21) The outer surface 107 of this stretchable polymer layer 105 is typically textured, for example to mimic the texture of an animal skin such as an elephant or dinosaur. This texture is taken from the textured surface of a mould from which that layer of the skin is formed. This moulding process will be explained in more detail later in the specification. The outer surface 107 is also has a desired colour, which is imparted using suitable silicone dyes or pigments applied when moulding that layer (again explained in more detail later in the specification). Silicone colour is therefore intrinsically laid into the silicone outer surface 107.

(22) Where applicable, areas of the outer stretchable polymer layer 105 that require extra strength are reinforced using a mesh material layer 110. It should be appreciated this step is optional, as in some cases no reinforcement may be needed. Sections, typically elongate strips of mesh material 112 are positioned ridges or peaks lines (for example 115 in FIGS. 2 and 4) on the inner surface 114 of the outer stretchable polymer layer 105. These ridges or peaks lines may also comprise lines of articulation of the outer stretchable polymer layer 105. For example, a central peak section 115 on the inner surface 114 of the outer stretchable polymer layer 105 can be seen in the section 106 of covering arrangement 100 shown in FIG. 1.

(23) The bulk, form and shape of the covering arrangement 100 are provided by foam layer 120. The illustrated foam layer 120 is a combination of two types of foams laminated together to form a shaped structure. These foams are: At least one body layer 124 for providing the form and configuration of the foam layer. The body layer 124 is typically a soft foam, such as a stretchable polymer foam, for example a flexible polyurethane foam. This soft foam gives a light weight bulk to the covering arrangement 100 (and sections thereof) and also has the required flexibility to allow each particular section of covering arrangement 100 to flex and more when manipulated on the articulated body. For outdoor applications, it is preferred the foam structure does not retain water. In such applications, a pool furniture type reticulated foam that does not retain moisture could possibly be used; and At least one contoured foam layer 126 for providing shape and stiffness to the foam layer. The contoured foam layer is typically a reticulated polymer foam, for example a reticulated polyurethane foam. The contoured foam layer 126 provides a flexible contoured shape to the foam layer 120 which is shaped and formed to hold in specific configuration but can also be flexed and articulated to move.

(24) Each of the body layer 124 and contoured foam layer 126 are formed from precast flexible foam sheets shaped and formed into a specific configuration. It should be appreciated that the choice of foam for the body layer 124 and contoured foam layer 126 can be dependent on the application. For example, it would be desirable to use a non-water retentive foam where the covering arrangement is used in an outdoor setting. Moreover, the use of both a body layer 124 and contoured foam layer 126 is also dependent on the application. In some embodiments, the foam layer 120 may only comprise one or more body layer or layers 124. No contoured foam layer 126 may be used.

(25) The contoured foam layer 126 typically comprises at least two or more shaped sections which are adhered (stitched and glued) together to have a selected topology, form and configuration. The contoured foam layer 126 can also comprise a laminated structure of two layers 128, 129 of reticulated foam. In the illustrated embodiment, the contoured foam layer 126 is formed from an articulation layer 128 comprising reticulated foam which includes a plurality of articulation apertures 130 (known as cheese ghosting, described below), and a backing layer 129 formed from reticulated foam onto which the articulation layer 128 is affixed. However, it should be appreciated that in other embodiments, the contoured foam layer 126 may not include an articulation layer 128. In some embodiments, sections of mesh material (not visible in FIG. 1), preferably power mesh material, is set between the articulation layer 128 and backing layer 129 aligned with connection or manipulation sections of the covering arrangement 100. This laminated structure is more clearly illustrated later in the specification where the process of forming the contoured foam layer 126 is discussed in more detail.

(26) The resultant covering arrangement 100 combines the stretchiness and cast-ability of silicone with a lightweight combination of construction foams and netting for support, body and strength.

(27) These properties are provided by the desired properties of the individual laminated layers:

(28) outer stretchable polymer layer 105—desired to be durable and flexible. It provides the external surface texture and finish. It is the castable layer that will conform to any moulded surface form or texture;

(29) mesh material 112—desired to resists tearing, provide support for stitches and adds strength in high stress areas of the outer stretchable polymer layer 105. Its open weave nature allows it to absorb silicon (important for bonding) and maintain a reasonably high level of stretch once integrated into the other layers

(30) a body foam layer 124—desired to be supple, yielding and have a strong shape memory; and

(31) a contoured foam layer 126—desired to be structural, stitchable and have a strong shape memory.

(32) The foam layers 124 and 126 provide for and assists with the durability of the silicon by sharing any loads, tensions or other forces acting upon it. Additionally it provides structural support to the silicon so that it holds its form more readily.

(33) Whilst a number of materials are available which meet the above structural properties, the layers of the covering arrangement of the present invention may in some embodiments be formed from the following materials:

(34) outer stretchable polymer layer 105—a flexible, stretchy silicon rubber such as the Dragon Skin Series silicones, preferably Dragon Skin shore 10, available from Smooth-On, Easton Pa. 18042, United States of America;

(35) mesh material 112—Power Mesh—a dance wear mesh with four way stretch. However, it should be appreciated that in other cases a less stretchy material may be preferable, such as along the edges of the outer silicone layer;

(36) a body foam layer 124—a flexible polyurethane foam sheet or sheets such as “Econo” Foam from Joyce Foam Products, Moorebank, NSW, Australia (see MSDS provide in Appendix 1); and

(37) a contoured foam layer 126—a reticulated foam sheet or sheets such as Meracell Reticulated Polyester/Polyether Foam from Joyce Foam Products, Moorebank, NSW, Australia (see MSDS provide in Appendix 2).

(38) It should be appreciated that the Dragon Skin Series silicones available from Smooth-On, Easton Pa. 18042, United States of America are high performance platinum cured silicone rubbers that can be mixed 1A:1B by weight or volume and cure at room temperature with negligible shrinkage. The cured silicone material is strong and stretchy. It has a high degree of stretch and will rebound to its original form without distortion over many cycles. This type of silicone rubber is therefore suitable for making high performance moulds and is used in many special effects applications, especially animatronics where repetitive motion is required. The material is water tight translucent and will accept pigments for creating colour effects. This silicone provides the following advantageous properties (Dragon Skin 10—measured after 7 days at 23° C.).

(39) Mix Ratio: 1A: 1B by weight or volume

(40) Mixed Viscosity, cps: 23,000 (ASTM D-2393)

(41) Specific Gravity, g/cc: 1.07 (ASTM D-1475)

(42) Specific Volume, cu. in./lb.: 25.8 (ASTM D-1475)

(43) Color: Translucent

(44) Shore A Hardness: 10 A (ASTM D-2240)

(45) Tensile Strength, psi: 475 (ASTM D-412)

(46) 100% Modulus, psi: 22 (ASTM D-412)

(47) Elongation @ Break: 1000% (ASTM D-412)

(48) Die B Tear Strength, pli: 102 (ASTM D-624)

(49) Shrinkage, in./in.: <0.001 (ASTM D-2566)

(50) Nevertheless, it should be appreciated that other silicone rubbers providing similar properties could equally be used for the outer stretchable polymer layer 105.

(51) Silicone Skin Manufacturing Process

(52) The method of manufacture of the covering arrangement of the present invention is a stepwise process in which each of the individual layers are individual formed and adhered together in a compression mould 140 (FIG. 9) to form the final laminated structure 102 shown in FIG. 1. It should be appreciated that Velcro adhered to the mould can be used to retain the foam in some situations.

(53) It is to be understood that the overall covering arrangement 100 of an articulated or animated body is typically manufactured from a plurality of individually formed sections 106 of covering arrangement 100 which are joined together once formed. Each of these sections 106 of covering arrangement 100 is designed with the required outer surface texture, form and configuration for a designated part of the overall covering arrangement 100. However, each section 106 of the covering arrangement 100 is formed in a generally similar process or method. The method involves the following basic steps: 1. Forming an outer stretchable polymer layer 105 in a mould 140; 2. Optionally, adhering at least one section of mesh material 112 to the inner surface 114 of the outer stretchable polymer layer 105. For example aligned along the at least one line of articulation 116 or along the edges of the covering arrangement 100 to form a reinforced outer layer 160 (FIG. 4); and 3. Forming a foam preform 170 (FIG. 9) having a desired form and bulk suitable for a selected section 106 the covering arrangement 100, and adhering the foam preform 170 to the outer stretchable polymer layer or where appropriate the reinforced outer layer 160.

(54) Each of these three steps will now be described in more detail:

(55) Step One—Forming the Outer Stretchable Polymer Layer

(56) The outer stretchable polymer layer 105 is formed in as a moulded layer in a textured resin and fibreglass mould 140, shown in FIGS. 2 to 4 and 9. As shown in FIGS. 2 and 9, the illustrated mould 140 has two fibreglass mould pieces 142, 144, comprising an outer textured mould 142 in which the silicone outer layer is formed and an interior “press” mould 144 which closes the outer textured mould 142 once all of the layers of the covering arrangement section 106 are placed together in the laminated structure 102, and allows these layers to be pressed together to form the desired contoured shape (as described below). As should be appreciated, a variation on the illustrated two mould 140 structure is where an undercut is placed into the sculpt and another mould is required to achieve the shape. Furthermore, in alternate embodiments a single textured mould could be used, with weights, other bodies of the like used to compress the laminate therein. One of the inner surfaces 152 of the textured mould 142 has a textured surface 154 (FIG. 2—underneath polymer layer 105). This textured surface 154 is contoured to provide the desired skin surface texture and form for a particular covering arrangement section 106, including ridges 115.

(57) The texture and shape of the mould 140 is formed using a negative mould technique, in which the mould 140 is cast from a preformed sculpt (not illustrated in the drawings) providing the desired shape and texture outer surface 107 of that covering arrangement section 106. In this process, the detail of the outer skin texture is typically sculpted in a sculpting material such as plasticine, oil based clay or similar sculpting material. Once the required texture and detail is formed, the approved detail sculpt (again not shown) is walled in a sculpting material, again such as plasticine, to form a desired shaped mould cavity and shaped section 108. A release agent is applied to the textured surface of the sculpt prior to the application of the resin and the fibreglass. The desired colour pigment for the covering arrangement section 106 is either applied as a coloured gel coat layer or incorporated with a resin and applied to the texture side 154 of the moulds 140.

(58) The sculpt is used to form the mould 140 of each covering arrangement section 106. The outer textured mould 142 includes the textured surface 154 providing the desired shape and texture outer surface 107. The outer stretchable polymer layer 105 is therefore formed by painting applying the textured surface 154 of the mould 140 with intrinsic colour using for example an air brush and stippling or paint brush, or pouring. The silicone material can be applied to the textured surface 154 of the textured mould 142 once the intrinsic colour and layer of back up colour is applied. It should however be appreciated that in other embodiments intrinsic silicone painting could alternatively be used. The desired silicone rubber is applied to the outer textured mould 142 as a curable liquid silicone rubber composition using a silicone spraying device. However, it should be appreciated that other techniques could equally be used.

(59) The curable liquid silicone rubber composition is preferably a silicone elastomer known as Dragon skin shore 10 (as discussed previously). For the illustrated embodiment, multiple passes of silicone rubber (with back up colour) was applied using a “silicon III” silicone spray machine (or similar apparatus) to produce the outer layer 105 in the outer textured mould 142 shown in FIG. 2. A number of stretchable polymer layers are sprayed into the textured mould 142. The number of layers is between 1 to 50, though typically more than 2 layers, such as between 3 and 5 layers are applied. The resulting outer stretchable polymer layer had a thickness of between 1 to 3 mm. The outer layer 105 is then allowed to air dry/cure. However, drying/curing could be assisted using heating techniques if desired.

(60) In alternate embodiments, where a silicone sprayer is not available, the silicone could be stippled and/or brushed or poured onto the appropriate surfaces of the textured mould 142.

(61) Step Two—Optionally Adhering the Mesh Material

(62) Strips of mesh material 112, such as power mesh or other suitable mesh are adhered to selected areas on the inner surface 114 of the outer stretchable polymer layer 105. It should be appreciated that power mesh is a lightweight, four-way stretch fabric having strength, body and resilience. Power mesh fabric is formed from a polymer such as nylon or a mixture of polymers such as nylon and spandex (for example 90% nylon and 10% spandex) to provide the required strength, flexibility and elastic properties.

(63) Strips of this mesh material 112 is adhered to the inner surface 114 of the outer stretchable polymer layer 105 aligned along at stress or weak points in the outer stretchable polymer layer 105 for example ridges 115 or folds in the covering arrangement, and/or lines of articulation of the covering arrangement 100. It should be appreciated that typically a single layer of mesh material 112 is applied. However, in alternate embodiments, two or more layers could be applied to provide additional reinforcement. Once applied, the outer layer 150 and reinforcing mesh material combine to form a reinforced outer layer 160 (FIG. 4). Mesh material or other suitable material 112 is also applied to or proximate to any areas where hair knotting and/or reinforcements for fastening and/or manipulation features such as paddles are located and areas for hair application (discussed below).

(64) The mesh reinforcing strips 112 are infused with silicone either before laying or after laying on the outer stretchable polymer layer 105. The reinforced outer layer 160 (FIG. 4) is then placed in a vacuum bag 162 and the air removed from the vacuum bag to apply a uniform pressure on the mesh reinforcing strips 112 whilst the mesh strips 112 dry in place. It is noted that the intrinsic layer with back up colour is left in place on the mould 142, undisturbed during this process. It should be appreciated that vacuum bagging may be required for some applications.

(65) Step 3: Forming and Adhering the Foam Preform

(66) A foam preform 170 for the covering arrangement section 106 is formed whilst the reinforced outer layer 160 is drying. As shown in FIG. 9, the foam preform 170 (FIG. 9) has a desired form and bulk suitable for a selected section 106 the covering arrangement 100.

(67) In the illustrated embodiment, the foam preform 170 is a combination of two types of foams laminated together or applied separately to form a shaped structure. These foams are: 1. at least one soft foam body layer 124 for providing the form and configuration of the foam layer. The body layer 124 is typically a stretchable polymer foam, for example a flexible polyurethane foam; and 2. At least one contoured foam layer 126 for providing shape and stiffness to the foam layer. The contoured foam layer 126 is typically a reticulated polymer foam, for example a reticulated polyurethane foam.

(68) Whilst the illustrated embodiment uses two foam layers, it should be appreciated that in other embodiments as single soft body foam layer 124 could be used. In such an embodiment, no contoured foam layer 126 is used.

(69) The foam preform 170 is patterned or filleted to fit the form of the textured mould 142. Each of the foam body layer 124 and contoured foam layer 126 is formed from planar (for example cardboard) patterned forms 127 (see FIG. 5) created using a patterning process in which the relationship between the foam and the press/texture moulds 142/144 is recorded by way of notches and marks for an accurate fit in the final product. The patterning process employs standard pattern making techniques as would otherwise be engaged in the costume making and millinery trades. In some embodiments during this patterning process that the articulation apertures 130 (known as “cheese ghosting”) of the contoured foam layer 126 is considered in accordance to the direction of anticipated movement of that section 106 of the covering arrangement 100. However, it should be appreciated that articulation apertures 130 may not be required in some applications, and therefore not included in the contoured foam layer 126.

(70) As shown in FIGS. 5 to 7, the illustrated contoured foam layer 126 comprises a laminated structure of two layers 128, 129 of reticulated foam. In the illustrated embodiment, the contoured foam layer 126 is formed from an articulation layer 128 formed from reticulated foam including a plurality of articulation apertures 130 (optional cheese ghosting, described below), and a backing layer 129 formed from reticulated foam onto which the articulation layer 128 is affixed.

(71) The contoured foam layer 126 is formed by firstly marking out a pattern on the articulation layer 128 of reticulated foam (see FIG. 5) including the desired shape for forming the 3D contours of the foam preform 170 and the articulation apertures 130 or “cheese ghosting” of this layer. The articulation apertures 130 of the articulation layer 128 are cut out. The backing layer 129 (having a cooperating outer shape) is then aligned with the articulation layer 128. Where required, silicone infused mesh material (not illustrated in the Figures) is laid between the articulation layer 128 and backing layer 129 as reinforcement for any manipulation paddles and/or tethers that may be connected to that section 106 of the covering arrangement 100. The abutting sides of the articulation layer 128 and backing layer 129 are then sprayed with a light covering of silicone and, before the silicone has cured, laid together and compressed using a manual roller device, for example a rolling pin or similar, to ensure a positive connection. When the silicone has cured, the marked out pattern on the contoured foam layer 126 is cut out using a sharp scalpel, blade or the like.

(72) Once the shape of the contoured foam layer 126 is cut out, the darts and pattern shapes are attended to by sewing or adhering complementary adjoining sections (for example sections 165 and 166 in FIGS. 6 and 7) of the contoured foam layer 126 together with strong thread (see FIG. 7).

(73) The soft foam body layer 124 is then affixed to the contoured foam layer 126 using a contact adhesive 169 or silicone when applied as separates (see FIG. 8) to form the overall laminated foam preform 170. The contact adhesive 169 can comprise any suitable adhesive such as a resin or rubber of one or a combination of silicone, polychloroprene or the like, such as Anchor-weld scraper grade contact adhesive available from Bostik, Australia. The contact adhesive is allowed to fully cure.

(74) Once the contact adhesive has cured, the stitch the foam preform 170 is affixed typically using temporary stitches or Velcro strips adhered to the press mould 144.

(75) A light coat of silicone or other adhesive is applied to the complementary surfaces of the foam preform 170 in the press mould 144 and the reinforced outer layer 160 in the textured mould 142. The textured mould 142 and press mould 144 halves of mould 140 are closed and pressed together. The textured mould 142 and press mould 144 halves are secured together using a fastening arrangement (not illustrated), for the illustrated embodiment bolts (not illustrated) could be used. The laminated arrangement in the mould 140 is then allowed to cure.

(76) Once cured, the laminated structure 105 of the covering arrangement section 106 is removed from the mould 140 by removing the temporary stitches on the press mould, and then releasing the covering arrangement section from the textured mould 142 and press mould 144 halves.

(77) It should be appreciated that in some instances press moulding using the textured mould 142 and press mould 144 halves as a method of foam lamination may be substituted entirely by a vacuum bagging moulding process. Vacuum bagging can apply similar even pressure to the laminated structure 105 of the covering arrangement section 106 during the lamination curing time. However, it is to be understood that such substitution is only suited to shallow open moulds with less complicated contours.

(78) Joining Covering Arrangement Sections

(79) As noted above, the overall covering arrangement 100 of an articulated body/animatronic arrangement is manufactured from a plurality of individually formed sections 106 of covering arrangement 100 which are joined together once formed. Permanent joins are used to connect small sections 106 of the covering arrangement 100 to form larger section of the covering arrangement 100. The permanent joins are preferably located along a wrinkle line to minimise the visual/aesthetic impact of the join.

(80) The construction of the covering arrangement sections 106 follows the same process as discussed previously, up to the point where the textured mould 142 and press mould 144 halves of the mould 140 are closed and pressed together. In this step, a 40 mm wide piece of masking fabric 190 is laid between the textured mould 142 and press mould 144 halves along the cooperating edges as shown in FIGS. 10 and 11. The mould 140 is secured and allowed to cure as noted in the previously described method. In this case, the masking plastic inhibits the bond between the adjoining surface of the foam preform 170 and reinforced outer layer 160. This enables this area to be rolled back revealing the join 199 and join line 205 for next step of joining the two covering arrangement sections 106. As illustrated in sequential FIGS. 11 to 13, this is achieved by:

(81) Joining the two textured mould sections 142 using fasteners (not illustrated), such as bolt 207;

(82) Peel back the area 200 of the foam preform 170 that remained unstuck due to the masking plastic 190 and affix open for example using a pin 201 to reveal the join 199 and associated join line 205 for each covering arrangement section 106 (FIG. 12);

(83) Apply an adhesive 204, such as silicone thickened with “Thi-Vex” (a silicone Thixotropic agent) along the join line 205 of join 199 and allow to cure (FIG. 12);

(84) Place a length of mesh material or net 210 which has been infused with silicone on top of and along the join line 205 to give the join 199 between each covering arrangement section 106 strength (FIG. 12);

(85) Spray the exposed surfaces of the foam preform 170 and reinforced outer layer 160 about join 199 with an adhesive 204, such as silicone thickened with “Thi-Vex” and remove pins and allow the foam to return to join line 205. Press flat the join 199 and associated layers of the foam preform 170 and reinforced outer layer 160 (FIG. 12).

(86) Apply a weight 220 to the join 1999 to ensure positive contact (FIG. 13). Allow to cure.

(87) Glue the adjoining body foam layers 124 together of the join 199 with contact adhesive, such as such as a resin or rubber of one or a combination of silicone, polychloroprene or the like and stitch or adhere the contoured foam layer 126 using a strong thread. Allow glue to cure (FIG. 13).

(88) Release from mould 140.

(89) Fur and Hair Knotting

(90) The covering arrangement 100 of the present invention can be connected or joined to other covering materials. For example, in some embodiments, the covering arrangement 100 could include a fur portion. In some embodiments, the covering arrangement 100 can be connected to a fur material, for example a 4-way stretch fur supplied by National Fibre Technologies supported by power mesh. The fur can be in differing lengths and densities where desired. The connection typically comprises a transition region in the covering arrangement section so the present invention which includes hair fibres 200 implanted into the outer surface 107 of the outer stretchable polymer layer 105. This transition would typically comprise sparse hair knotted into the outer stretchable polymer layer 105. The individual fibres are punched (not stitched) into the silicone and knotted onto a backing fabric, in this case a layer of power mesh imbedded into the outer stretchable polymer layer 105 in the appropriate areas (as previously discussed). An example of this hair knotting configuration on the outer stretchable polymer layer 105 is shown in FIG. 14.

(91) Repairs

(92) The success of the repairs to the covering arrangement 100 of the present invention is due to the unique laminated structure of a thin silicone outer layer 105 (approx. 1 mm) on top of a structural foam sub-structure 120 of soft body foam 124 and contoured reticulated foam 126 which is supported with the optional reinforcing mesh material 112 (power mesh) in areas of high loads.

(93) Tom skin may result from technician carelessness, vandalism or possibly from a mechanical failure. The repair approach to fixing it will vary depending on the extent of damage to the covering arrangement 100. The layers are repaired as follows:

(94) The soft body foam 124 and contoured reticulated foam 126 are both glued together with contact glue.

(95) The silicone outer layer 105 is repaired by applying a small amount of an adhesive such as “silpoxy” (see below) with a spatula or similar to both sides of the damaged silicone. A strong thread can be used to stitch the sides of the silicone together across the damaged section, using a similar technique as a surgeon would use to stitch a patients wound together.

(96) Allow at least fifteen minutes for the adhesive to cure. When the adhesive has cured remove the stitches.

(97) FIG. 15 illustrates the morphology of a three day old sample skin of repaired covering arrangement 100 or sample skin having a structure according to the present invention. The sample skin was cut in the indicated area 210 and repaired from the surface following the method steps described above. Areas to be repaired were cleaned with isopropyl alcohol wipes and shellite to remove grease and dust. All silicone repairs were made using a silicone adhesive. One exemplary adhesive was “Silpoxy” adhesive available from Smooth-On, Easton Pa. 18042, United States of America which was found to be very effective. It should be appreciated that Silpoxy (or Sil-poxy) is a one component silicone adhesive made specifically for bonding RTV silicone rubber to silicone rubber and other substrates including some plastics (urethane), plasters/ceramics, fabrics, etc. Sil-Poxy provides a strong, flexible bond between silicone parts with high elongation. However, it should be appreciated that alternate silicone adhesives could equally be used for repairs.

(98) Durability Testing

(99) The durability of the covering arrangement 100 was tested to determine the impact of constant and continual movement thereon. Stretch, compression and abrasion are the typical areas of concern for longevity of any covering arrangement or skin of an articulated form. Accelerated testing rigs were used to explore the durability of various materials and combinations of materials. An example of a covering arrangement section 106 similar to as shown and described in relation to FIG. 1 is shown in a test rig 300 in FIG. 16. The test rig 300 comprises two spaced apart clamping arms 305 between which a sample is held. The arms 305 move to stretch and move the sample therebetween.

(100) Testing Methodology

(101) The testing method involved the following steps:

(102) Apply stretch control matrix to the test fabric (i.e. covering arrangement 100);

(103) Clamp the top and bottom of the test fabric in the test rig;

(104) Set the speed for test;

(105) Turn off the machine when count cycle has been reached;

(106) Remove the fabric;

(107) Inspect the condition of the test fabric; and

(108) Check stretch control matrix against the matrix dots on fabric.

(109) As can be appreciated, the testing process begins by testing covering arrangement 100 without any attachments before progressing to more complex combinations and variations, progressing from generic testing to testing specific areas of concern presented by the sculptural form and animation of the animated/articulated figure. Tested samples can also incorporate fixing methods to control surfaces, joins, and transitions and repairs systems.

(110) An example test analysis and results is provided below. The aim of the example test run was to identify durability of the proposed skin covering arrangement and the impact of continual stretching by testing the stretch and adhesion capabilities of the composite skin. The test run conditions were as follows:

(111) Apparatus:

(112) Stretch machine (FIG. 19)—applying 25% stretch.

(113) Sample/Test Piece:

(114) A piece of covering arrangement measuring 25 cm×25 cm.

(115) Method/Test Procedure:

(116) These steps test the impact of constant and continual stretching on the composite skin. 1. Clamp the top and bottom of the test fabric in the test rig. 2. Set the speed for test in accordance with test sheet. 3. Run test machine for: Total cycles: 1,429,200 and Total Test Hours: 198.5. 4. Turn off the machine when count cycle has been reached. 5. Remove the fabric from the test rig. 6. Inspect the condition of the test fabric.

(117) The test piece of skin completed 1,429,200 cycles and as shown in FIG. 16 remained of an acceptable show quality (for example for use in an entertainment venue such as a theme park).

(118) Another test piece of skin (not illustrated) completed 4,417,200 cycles and remained of an acceptable show quality. All the individual elements of the tested covering arrangement have performed above initial expectations.

(119) The above described covering arrangement 100 provides a lightweight skin and coverings which provides a more dynamic and lifelike movement to an animatronic figure, as the covering is able to flex and move with more freedom compared to heavier conventional counterparts. The covering arrangement of the present invention also allow lighter and more dynamic underlying articulated bodies and structures to be built as the lightweight of the skin places less load requirement on members and articulation devices of the structure and framework of the articulated figure. Lightweight skins also provide for a much more serviceable Animated Figure (AF).

(120) Moreover, when used in combination with other elements, such as Muscle bags, fur, paddle attachments and other articulated devices, the covering arrangement of the present invention combines to give an articulated or animated body covered with the inventive covering arrangement a light weight and flexible fabrication component thus allowing engineering to produce dynamic lifelike movements.

(121) Furthermore, the described covering arrangement 100 is straightforward to repair if damages, with repairs to the foam layer 120 being glued and/or sewn to repair damage and, the stretchable polymer layer 105 being fixable using adhesive, or adhering a suitable silicone patch to the damaged section of the covering arrangement 100.

(122) Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention.

(123) Where the terms “comprise”, “comprises”, “comprised” or “comprising” are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other feature, integer, step, component or group thereof.