JP3001752B2 - Cushionable container for fluid and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION This invention generally relates to a method of making the same and cushioning container for fluids, more particularly, the composite flexible polymer skin, a relatively rigid base, and the composite outer skin and the base and including cellular foam flexible conjugated with held between the method of manufacturing a cushioning bath and its having a laminated structure.

[0002]

BACKGROUND OF THE INVENTION Cushioning bathroom articles, such as bathtubs, shower stalls, sinks, etc., are made of flexible polymer layers (typically vinyl), bases (typically made of glass fiber reinforced polyester resin). And in the prior art as formed from a laminated structure having a cellular foam sandwiched between a flexible polymer layer and a base.
This type of cushioned bathroom article is comparable in appearance to conventional steel or iron, porcelain-coated bathroom containers, and the foam provides improved thermal and sound insulation over such conventional containers. Is to provide a natural isolation.
Furthermore, when this composite structure is applied to a bathtub, the combination of the outer layer of the flexible polymer and the foam makes it difficult for anyone to slip in the bathtub, and all accidents such as actual dropping and falling down are alleviated. .

[0003] for a number of reasons, cushioning bathroom supplies of this kind, from those that are widely accepted not allowed. Perhaps, for this reason the most important of the cushioning bathroom articles known in the prior art is that they are not capable of withstanding the rigors of practical use. For example, the prior art cushioned bathroom article described in the invention of U.S. Pat. No. 4,289,717 describes a flexible composite polymer shell that includes an outer layer of vinyl. When using vinyl as the outer skin, the physical properties of the flexible skin, such as tensile strength, elongation strength and friction resistance, make the skin relatively susceptible to damage under the rigors of actual use Thus, damage to the outer skin can occur. In addition, vinyl tends to lose plasticizer over time, resulting in a hardened flexible polymer shell. Further, the curing time required for the vinyl resin is significantly related to the length of the processing time.

[0004] Another reason that conventional cushioned bathroom articles have not been found to be widely accepted is due to problems encountered in the manufacturing process. For example, in the method described in the invention of the aforementioned 4,289,717 patent , during the manufacturing process, a large number of defective products were generated due to leakage of the foam between the base and the necessary flexible composite skin. In addition, the seal used to attempt to prevent leakage according to this patented invention included a laborious process. Labor costs associated with attempting to prevent the generation of numerous rejects and foam leakage have significantly affected the cost of manufacturing.

[0005]

To determine so that the fact that the [0008], is the actual physical robustness to charge amount to withstand the conditions of use, over a period of a long time period consistent with the life of the manufactured articles Thus, there is an ongoing need for cushioned containers for fluids such as bathtubs made from materials that maintain their physical properties. As always, to reduce the length of time needed to complete the product, by reducing the number of defective articles produced, there is also a need to improve the economies of manufacture.

[0006]

Shape Narukata method of the present invention for producing a cushioning container for fluid SUMMARY OF THE INVENTION comprises a step of preparing a base having a shape resembling approximate roots such <br/> the shape of the container . A flexible composite skin is formed by applying a first coating of a urethane polymer on a mold having a shape complementary to the container. A second coating of a urethane polymer is applied over the first coating. Preferably, the third film of the expandable polymer resin is coated on the second coating to produce a more "body" to the skin. The resulting composite skin on the mold is mated with the base to create a cavity between the base and the foamable polymer resin. Thereafter, the cavity is filled with a foamable polymer resin according to the present invention. Further, a method formed in accordance with the present invention, as described above, the first coating, comprising applying a second coat and the third coat, in this case, the third than in the above-described manner Make the coating thick. Thereafter, a binder film is applied to the foamable polymer resin to promote the bonding between the foamable polymer resin and the glass fiber applied to the binder film.

[0007] In a preferred aspect, the urethane polymer of the first and second coatings is a non-foamable elastomer.
Urethane.

Furthermore, from a preferred aspect of the process, is formed by the present invention, with sealing the base frame for the base, the use of integrated silicone rubber seal for sealing the frame to the mold elements is there.

In another aspect, the invention relates to a cushioned container for fluids produced by the method of the invention. The container formed according to the present invention comprises a base, an elastomer
Consisting of a first layer of urethane, a second layer of elastomeric urethane applied to the first layer, and a layer of foamed resin between the base and the second layer of elastomeric urethane. Good Mashiku is a third layer of foam urethane coating to the second layer, based is pinched foaming resin between the third layer of foam urethane. In other embodiments, the first, second and third layers of urethane, but is produced as described above, it is thicker than the third layer and the third layer of foam urethane. In another embodiment, a binder layer is applied to a third layer of foamable urethane, followed by providing a layer of glass fibers over the binder layer.

[0010]

By reference to the following portions of the specification in conjunction with EXAMPLES drawings, it is able to best understand the present invention
There will be .

The present invention will be described with reference to the structure of a cushion-type bathtub.
It is to be understood that applications find particular application in the manufacture of objects used in bathrooms, for example, shower cubicles, sinks, "whirlpool" tubs, hot tubs, hot spring baths and the like.

ProductionUpThe first step is to achieve the desired degree of rigidity.
Cushioned bath tub that gives strength and strengthRight
It is a configuration of a base having a similar shape. FIG. 1 and
2 and the conventional two-piece resin injection method,
From polyester resin and reinforced glass fiber fabricBathtubBe
A source B is prepared. In FIG. 1, a female part of a split type
Min 10 is designed to sit on a flat surface
Central wall portion 10 surrounded by flange portion 10b
a. Similarly, the halved male part
12 is a wall portion 10aWhenComplementary center wall portions 12a,
And the flange portion 10bforOutlineRightComplementaryToSurround
An outer peripheral flange portion 12b is provided. Male type for assembly
The part 12 is fitted to the female part 10 and the flange part 12
b and 10b abut at 16 along the circumferencelike
And a cavity 1 between the male part 12 and the female part 10.
8 and its shape is that of the desired bathtub base B.
You.

To manufacture the bathtub base B, a resin transfer molding method is used. The base B can be formed from a polyester resin containing a filler such as a flame retardant. Suitable polyester resins include W1827, commercially available from Gwill Industries, British Columbia, or CC154, commercially available from Raychold of Port Moody, British Columbia.
Included are those sold under the name Bathtub base B
Using a suitable release agent, such as that sold under the name "Frekote 700" by Dexter Adhesives, Seablock, NH, the female part 10 and the male part. The opposite inner surface of the mold part 12 is coated. The glass fiber mat is pre-cut according to a predetermined pattern and then placed in the female mold part 10. Preferably, square feet (92.9c
m ²⁾ per about 2~2.5 oz. A single layer, continuous strand fiberglass mat (available from Owens-Corning), (about 56.7-70.9 g) is used for the side walls. In high stress areas, such as floors and end walls, two-ply glass fiber mats are used. Thereafter, the male part 12 is attached to the female part 10 and secured thereto by a plurality of clamps 14. The polyester resin and a suitable catalyst (both in liquid form) are mixed in a suitable apparatus and force injected into the entire cavity 18 through the opening 20 in the central wall portion 12a of the male part 12. Gas vent holes (not shown) at the corners of the male part 12 allow the cavity 18 to be filled during resin injection.
Allow air to escape from If the actual, suitable catalysts are mainly made of methyl ethyl ketone peroxide, Calif, available from Norakku Company Azusa.

After injection, the polyester resin in the cavity 18 is partially cured for about 10 to 12 minutes, after which the clamp 14 is removed and the male part 12 is removed. 8 to 1
After a lapse 0 minutes, the resin is cured to the charge amount, it is possible to separate the tub base B from the female portion 10. afterwards
Remove the tub base B from female portion 10, rows that have a complete cure was left for about 24 hours, the shape at that time, that generally Teisu appearance as shown in FIG. Typically about 1/4 inch "
A base of about 3/8 "inches thick is preferred.

The base B includes a substantially flat floor 22 of rectangular shape, substantially flat front and side walls 24, 26 and 28 (each standing upright from the floor 22) and rising from the floor 22. Inclined rear wall 30 integral with side walls 26 and 28
Is provided. An outer peripheral flange 34 extends from upper edges of the front wall 24, the side walls 26 , 28 and the rear wall 30 , and is adjacent to the side walls 26 , 28 and the rear wall 30.
Part 4 has an outer peripheral rib 36 thereon.

After hardening, the burrs on the edge of the outer peripheral flange 34 are trimmed and removed. In the foaming process in situ to be described later, for injecting self-foaming resin, the inclined rear wall 3
At 0, a foam injection port 37 is formed. Also, multiple 1/16 "
Inch (0.16 cm) vent vent 39 on floor 22, front wall 2
4 and along the outer circumferential rib 36.

As another example of the resin infusion process, the bathtub base B can be made as a vacuum formed shell from a material such as acrylonitrile-butadiene styrene (ABS) or polyvinyl chloride (PVC).

Referring to FIG. 3, a composite flexible polymer skin S
(Shown in FIG. 4) is formed on the mold 40. Especially mold 4
0 is a base 4 having a substantially flat outer peripheral surface 42a.
2 is provided. Member 44 having a desired internal surface with the same shape of the tub, the base 42 protrudes from, tub base B of the floor 22 and the approximate ne complementary floor surface 44a, front wall 24 and I complementary outline of tub base B front wall surface 44b, tub base B of the side walls 26 and the 28 and I GENERAL complementary side walls surfaces 44c and 44d, and a rear wall 30 of the base B GENERAL
A complementary inclined rear wall surface 44e. Floor surface 44
Projecting from a are projections 44f arranged at desired positions of the drainage of the bathtub. To determine so that the 3, recess 46
Is provided on the member 44 surrounding the base 42, and the arm of the bathtub is cast. The recess 46 includes a bottom floor portion 46a and an outer upright wall portion 46b intermediate the bottom floor portion 46a and the outer peripheral surface 42a. The base 42 includes an upright wall portion 46c extending from the outer peripheral edge of the surface 42a in a direction facing the member 44. Arranged at a plurality of positions on the upright wall portion 46c is a hook 4 that secures the form 40 to the frame 50 for a base, which will be described in more detail below.
7

[0019] In preparation for production of the composite flexible polymer outside skin, the surface and recesses 46 of the total hand of an outer peripheral surface 42a and the member 44, is first cleaned using a solvent such as a clean cloth and methyl ethyl ketone . By cleaning, contaminants total hand and, should the working material roughness loose residual is removed. After cleaning the surface, use a wax such as the one named "Partall No. 2" available from Rexco Chemical Company of Carpenteria, Calif. Preferably, it is glossy. Before waxing,
Preheating the surface to a temperature of 75 ± 10 ° F. (23.9 ± 5.5 ° C.) is also preferred . The resulting waxed surface should have a uniform high gloss with no visible lines or scratches. Surface cleaned after each use, and wax processing when changing at least every cycle.

After cleaning, waxing and heating the surface, a release agent such as polyvinyl alcohol, commercially available from Rexco Chemical Company under the trade name “Partall PVA No. 10”, is used. spraying the first thin dust coating, then coated by applying a second wet film. The resulting film is
There is a glossy, it should be those that do not contain bubbles.

[0021] Referring to FIG. 4, the composite friendly by the following steps
A flexible polymer skin S is formed. In the first step, a first coating U1 of an elastomeric resin, preferably an elastomeric urethane, is formed on the surface of the mold 40 by spraying two layers of elastomeric resin onto the surface of the mold. Elastomer resin, by spraying the mixture onto the surface of the volatile carrier solvent and catalyst, applying a first layer. Before applying the first layer, the mold is conditioned by wet-treating the entire mold with a solvent such as methyl ethyl ketone. Before application of the elastomer resin of the first layer should be completely dry surface of the mold, it should be that there is no certain portions of drops. As described above, a second layer of an elastomeric resin, preferably an elastomeric urethane, is applied to the first layer. Elastomer resin, a wetting agent, with a mixture of volatile carrier solvent and a catalyst, to form the second layer by spraying the first layer. If desired, coloring additives can be added to the second layer of the first coating U1. Coloring additives may also be added to the first layer, it is preferably added only to the second layer. In this way , the first layer adds a deep luster to the surface. In a second step, a second coating U made of an elastomer resin, preferably an elastomer urethane, is sprayed on the first coating U1 with a mixture of an elastomer resin and a catalyst.
2 is formed on the first coating U1. Second coating U2 is
It is the predominant material in the composite polymer shell, which gives it thickness and strength. The thickness of the coating U2 can be varied to provide stiffness and strength to fabricated articles in different areas. The skin at this stage can be used as is , but if a more “substantial”, ie softer feel to the skin is desired, a third coating U3 can preferably be applied. Third coating U
3 comprises a foamable resin, preferably foamable urethane. The coating U3 is formed on the surface of U2 by spraying a mixture of the foamable resin and the catalyst on the surface of U2. The coating U3 does not contribute significantly to the strength of the composite skin S, but imparts a "soft feel" to the composite skin. The composite skin can be provided without the layer U3, but if a "soft feel" is desired, it is preferred to apply the coating U3.

For the coating U1, a suitable elastomer
Urethanes, "Kemugurezu V021" (Chemglaze V
021) and is available from Road Corporation of Erie, PA. This elastomer urethane is "Chem Glaze 9
951 "(Chemglaze 9951) and diluted with a volume ratio of about 6 to 6.25 parts elastomer urethane to about 1 part solvent by volume using a solvent such as that sold by Lord Corporation. A suitable catalyst for use in the first step is Chemglaze 9995
(Chemglaze 9995) and "Chemglaze 999"
2 "(Chemglaze 9992) sold by Road Corporation. A copy of Chemglaze 99
About 3 for 95 and half the Chemglaze 9992
The catalyst is used in a proportion of 7.5 parts of elastomeric urethane. Suitable humectants for use in the first step, under the name "Kemugurezu 9971" (Chemglaze 9971),
Sold by Road Corporation and used at a ratio of about 20.8 parts elastomer urethane to 1 part wetting agent by volume. If a suitable catalyst is used, 9
995 catalyst should be added first, followed by thorough mixing for 1 minute, then 9992 catalyst should be added,
Then mix for another minute. The preferred composition described above is
Only-out based Dzu elastomer urethane component, 4.9 wt%
1 shows a catalyst mixture of Other catalyst levels can be used depending on the resin system used and the surrounding conditions. The above mixture can be applied onto the mold 40 using a conventional air assist spray gun or siphon type spray gun. Preferably, the elastomeric urethane mixture of the first layer of the first coating U1 is sprayed onto the mold 40 in a first thin coating, after which it becomes the second coating. The resulting first layer is preferably about 1-2 mils (about
0.00254 to 0.00508 cm). Coated coating waste that can have defects in the finished product, it should be assumed that substantially does not contain gas bubbles or other foreign matter. The finished coating should be of uniform thickness and free of any visible flow or drops on the exposed surface. The evaporation of the solvent in response to loss of companion a <br/> cormorants thickness, the first application of the first layer, 1
It may be necessary to be more than 2 mils (0.00254 to 0.00508 cm). After the application of the first layer, the volatiles are evaporated. An electric heater and a fan (not shown) are placed under the mold 40 and actuated to increase the temperature of the mold 40,
Of the layer can be accelerated.

As mentioned above, the first layer preferably does not contain any coloring pigment which serves to maintain the amount of pigment used. As described in more detail below, the first coating U1
The second layer comprises a color pigment to provide the required aesthetic appearance.

An elastomer resin, preferably an elastomer urethane, is applied on the surface of the first layer to complete the first coating U1. The purpose of the second layer is to form a colored layer containing urethane colored to a desired color.
Although the first layer of elastomeric urethane can be colored, it is preferred to color the second layer to maintain the required amount of colored urethane.

An elastomeric urethane suitable for use in the second step is Chemglaze V021 (Chemgls V021).
aze V021) sold by Road Corporation. Road Corporation also offers a wide selection of elastomeric urethanes containing coloring components. These elastomeric urethanes are also sold under the name Chemglaze V, and are combined with Chemglaze V021 in approximately equal amounts,
A second layer of elastomeric urethane component can be provided. The solvents, wetting agents and catalysts used in the second layer are the same as those used in the first layer, should be used in approximately equal amounts and should be mixed in a similar manner. The mixture for the second layer can be sprayed onto the first layer using a conventional air assisted spray gun or siphon type spray gun. Preferably, the second layer results in about 4
The elastomer mixture is sprayed onto the first layer in an amount that will have a thickness of mils ± 1 mil (about 0.010 cm ± 0.0025 cm). After applying the mixture, the solvent is evaporated. As described above, this evaporation can be promoted by increasing the temperature of the mold. The resulting second layer should be free of dirt, gas bubbles, or other foreign matter that could cause defects in the finished product. The finished layer should be free of any visible streams or drops on the finished product. This layer was completely cured prior to further processing, and preferably about 4 mils ± 1 mil (about 0.010 cm ± 0.
0025 cm). When the first film U1 is formed using the urethane described above, about 1 to about 2
It can achieve working times of the time, when generating the coated using vinyl resin can be compared with that which can be a two or three times longer processing time. When using a urethane resin that can be used without a volatile carrier, about 1 to
Processing times of less than 2 hours can also be achieved. This type of carrier-free resin is known as a "100% solids" resin.

Following application of the first coating U1 of elastomeric urethane as described above, a second coating U2 of an elastomeric resin, preferably elastomeric urethane, is applied over coating U1. Elastomer urethanes suitable for use in the second step are "Chemglaze M33"
1 "(Chemglaze M331) sold by Road Corporation. "Chem Glaze M40
Mix the elastomer urethane with the catalyst sold by Lord Corporation under the name "2" (Chemglaze M402). The elastomeric urethane is mixed with the catalyst in a ratio of about 3 to about 1 by volume. As a result, about 55
The mixture is applied under conditions that provide a coating thickness of 80 mils (about 0.1397-0.2032 cm). By applying the mixture against a heated mold carries a first coating U1, such a coating can line a Ukoto. Preferably, for the elastomeric urethanes described above, the mold temperature is about 85 ° F.
(29.4 ° C.) to heat the elastomeric urethane mixture, but upon exiting the applicator , this is 105 ° F.
(40.5 ℃) and not to as obtain super. About 15 ~
If avoiding the flow by applying four or more thin coating of 20 mils (about 0.038 ~0.051cm), suitable results were obtained. While during the time of coating is suitably about 5 minutes, in the case of using the elapsed less than or greater, it is possible to use a longer time period than or shorter. After the last coating has been applied, the entire coating should be consolidated and consolidated. Typically, this can take about 45 minutes. Although it is possible to shorten the curing time by using an infrared oven, prior to oven cure, about 10 minutes or more, it should cure the coating under ambient conditions. Curing will be complete when the solvent stops evaporating. The resulting coating is a coating of about 55 to 80 mils (about 0.1397 to 0.2032 cm) of elastomeric urethane. The coating should be free of dirt, clumps or other foreign matter that can cause defects in the finished product. The finished coating should be smooth, glossy, of uniform thickness, and free of any visible drops or drops on the finished product. By taking a cross-section of the skin, the proper hardening of the skin can be tested. A properly cured skin should not be able to be peeled with normal strength. When using such a peeling test, a row of Ubeki this for most central portion of the cutting edge.

Following formation of the second elastomeric resin coating U2, an optional coating U3 of a foamable resin, preferably foamable urethane, is sprayed onto the surface of the coating U2. Suitable foamable urethanes for use in this step are "IPI046
9A and B Spray Urethane Foam "(IPI 04
69A and B Spray Urethane Foam) sold by IPI, Elkton, MD.
IPIO469A and B spray urethane foams
It has a density of about 3.5 to about 5 lb (about 1.59 to about 2.3 kg). A suitable formulation is 3 parts IPI0469B versus 1 part I
This is the capacity ratio of PI0469A. Foamable urethane coating U
The preferred urethanes used in 3 differ from the preferred elastomeric urethanes described above for coatings U1 and U2. Elastomeric urethane can not be foamed, foamable resin for coating U3 are considered self-foaming, which when sprayed or applied to the surface, to generate a matrix of cellular foamed it Becomes

When applied, approximately 1 / inch (2.54 cm)
Preferably, the thickness of the coating U3 is between 8 and about 1/4. Coating the foamable urethane mixture using a spray gun U2
By applying to, an appropriate thickness can be achieved. The mold temperature should be at least about 85 ° F (29.4
° C) and not more than about 120 ° F (48.9 ° C).
The temperature of the foamable urethane mixture as it exits the spray gun ranges from about 140 ° F to about 160 ° F (about 60.0 ° C to about 71.1 ° C).
℃) and it should be that there is no exceeded. The coating should be as smooth as possible without flow. When taken along the tub arm, the surface temperature of the foam skin is about 85
It should be between ° C and 95 ° F. Prior to further processing, the applied foam should be integrated, which can take about 5 minutes. Longer foaming times may be required to achieve the required skin temperature. Typically, the foaming polyurethane resin generates and retains heat as it foams. Thus, the measurement of the skin temperature indicates the completion of foaming. The resulting foam layer should be of uniform thickness, except for the tubing where the thinner skin layer is desired, with the exception of the bathtub wall. The coating should be free of any visible drops on the finished product. When applied, the finished foam can be up to about 1/4 inch (about 0.63
cm) The entire thickness should be covered with a foam layer. There should be no mold surfaces without foam layers, except for the plumbing walls described above, which are intentionally "peeled" rather than foamed. The purpose of the preferred foamable polyurethane coating U3 is to form a more rigid polymer shell S by adding substantial portions to the base elastomeric resin coatings U1 and U2. For satisfactory applications with substantial portions of the composite skin S consisting of the coatings U1 and U2, the coating U3 may not be necessary. On the other hand, if enhanced "substantial" is desired , the coating U3 is preferred.

When the foamable resin coating U3 is applied to the pipe wall, the thickness of the other portion of the coating U3 should be increased to ensure that a space for the foamable resin F, which will be described in more detail below, is provided. It shall be intentionally thin. Foamed urethane layer U3 is formed from a self-foaming polyurethane resin, when sprayed in a thin layer, the resin generates a charge amount of heat to induce a substantial foaming, it does not hold. As a result, the thin layer of foamable polyurethane resin cures, forming a flexible polymer layer having a large number of easily visible micropores at low magnification. The term "skin foam" (commonly referred to as "integral skin foam") is to the surface of the resin is in contact during curing, the foamable resin forming the adhesion of skin that is integrated To mention. This type of resin includes a surfactant that causes the resin to wet the surface and form a "skin" on the surface as the resin foams and cures.

[0030] Polyurethanes are preferred because they cure relatively quickly as compared to other resins such as vinyl resins. Shorter curing time, results in a shorter processing time,
This leads to more economical manufacturing processes. Previous
As noted, the polyurethane is cured within a few minutes is particularly advantageous when preparing a commercial scale. The elastomeric urethane polymer is preferred over other polymers such as vinyl polymers, which are, tensile strength, elongation,
Because of their enhanced physical properties, such as rub resistance , these make them more suitable to withstand the rigors of practical use compared to other polymers, such as vinyl polymers. Become. In addition, urethane polymers do not lose plasticizer and do not become brittle, as was observed with vinyl polymers.

In the next step of the manufacturing process, the bathtub base B is turned over, fixed to the frame 50, placed and fixed on the mold 40, and as a result, a cavity is formed between the base B and the mold 40. A conventional self-expanding polyurethane resin is poured into the resultant, and is expanded and cured to form a cellular foam in the cavity 70. 4 and 5, the frame 50 consists of a frame structure of steel, the internal dimensions are the bath base B
It is Ru determine to ne of the external dimensions as the approximate fit. Frame 50
Has an outer peripheral surface 42a and the frame base 52 ne approximate rectangle having a flange 34 with approximate ne complementary bottom surface 53 of the base B of the mold body 40. As will be described in more detail later, the lower surface 53 is sealed to the flat outer peripheral surface 42a of the mold body 40 and the outer peripheral flange 34 of the bathtub base B. Disposed around the outer periphery of the base 52 is the lower surface 5
3 is a hole 69 passing therethrough. The frame 50 is a base B
Upright frame member 5 complementary to side walls 26 and 28 of
4. It further comprises an angle frame member 56 complementary to the rear wall 30 of the base B, and an upright end member 58 complementary to the front wall 24 of the base B. Further, the cross-top frame members 60 in the rectangular arrangement have the spread of the floor 22 of the bathtub base B.
Straddle the part where Upon completion of the foam injection process to be described later, for sealing the injection port 37, mounting the manual operation closure device 62 between the angle frame members 56.

[0032] Referring to FIG. 5, by reversing the tub base <br/> scan B as shown in FIG. 4, the mounting of the tub base B to the frame 50, a rectangular frame-based as described later 5
The frame 50 is lowered relative to the bathtub base B until the bottom surface 53 of the second is sealed below the outer peripheral flange 34. A bottom surface 53 of the rectangular base 52 is defined by a flat metal gasket 150, which, in cooperation with the integrated silicone rubber seal 152, square on the lower side of the flat outer peripheral surface 42a of the outer peripheral flange 34 and Katatai 40 Base 52
Is sealed. The integral silicone rubber seal 152 has a body 154 formed complementarily with the lower groove of the flange 34. Body portion 15 of integrated silicone rubber seal 152
4 extends along the outer periphery of the bathtub base B within the groove of the outer peripheral flange 34. The integrated silicone rubber seal 152
An outer peripheral flange 156 extends outwardly from the body 154 to extend a seal between the outer peripheral surface 42 a and the metal gasket 150. Before lowering the frame 50 with respect to the base B, the integrated silicone rubber seal 152 is disposed below the flange 34 and in a groove around the base B. Overlaying the integral silicone rubber seal 152 is a flat mounting plate 158 that covers the entire exposed upper surface of the integral silicone rubber seal 152 and separates it from the metal gasket 150. Integrated silicon rubber seal 1
52, the metal gasket 150 and the mounting plate 158 are used at predetermined locations, and the metal gasket 150 is
The frame 50 is lowered relative to the bathtub base B until it engages the upper surface of the frame 8. Thus, bathtub base B
Is sealed in the frame 50 to prevent leakage of the foam during the in-situ foaming process described later. Hole 6 in frame 50
9, and the metal gasket 150, the main body 154 of the silicone rubber seal 152, and the screw 67 arranged through a hole (not shown) of the base B, to the frame 50.
Bathtub base B is firmly held in place. Screw 67
Is fixed by a speed nut 66.

The integrated silicon to under the rubber seal 152 abuts conform to the flat outer circumferential surface 42a, is then lowered a tub base B and frame 50. assembled relative to the mold body 40, member 44 of the tub base B It shall project inside. The lower side of the integrated silicone rubber seal 152 abuts against the surface 42a, and the frame 50 is sealed to the base 42 of the mold 40, so that during the in-situ foaming process described later, the foam resin from the cavity 70 is removed. Prevent leaks. Thereafter , the base 42 and the frame 50 of the mold 40 are fixed to each other using the hooks 47 of the mold 40 and the clamps 160 provided on the frame 50. At this point, it will be appreciated that the bathtub base B is spaced apart from the composite flexible polymer skin S and defines a cavity 70 therebetween (FIG. 5).

[0034] Still referring to FIG. 6, then filling the flexible cellular foam F in the cavity 70 by a foaming process in situ. Preferably, the cellular foam F comprises I
PI1156A and B, a polyurethane foam material such as those available from IPI of Elkton, MD under the name of urethane foam. IPI
1156 A and B urethane foams can be from about 3.5 to about 5
lb. (About 1.59 to about 2.3 kg). 1 in capacity
Mixing the A and B components in a ratio of 1 part A to 1.45 parts B;
Mix in a conventional multiple component system available from Witco Chemical, Wilmington, Del. Preferably, it produces a one inch (2.54 cm) foam core,
Therefore spacing between the tub base B and a composite flexible polymer skin S should be about 1 inch (about 2.54 cm). Although through the inlet 37 in a liquid form over a force injecting urethane foam resin mixture, prior Similarly foam expands across the cavity 70, the air trapped from the venting opening 39 escape. Closing device 6 after injection of liquid
The inlet 39 is closed by 2 to contain the expanding foam. Upon expansion and subsequent curing, the foam F bonds to the interior surface of the base B and the interior surface of the foamable polyurethane coating U3 of the skin S. Preferably, for the foam described above, the surface of the foamable urethane coating U3 is between about 70 ° and 80 ° F. (about 21.1 and 26.7 ° C.) and the temperature of the bathtub base B is between 70 ° and 80 ° F. (21.1 to 26.7 ° C). Temperature of the foamable polyurethane should follow the manufacturer's specification, for the resin is from about 73 ° F. to about 77 ° F (about 22.8～ about 25.0 ° C.) are suitable. After injection of the foamable polyurethane, it should promote the completion of the curing period taking charge amount of time. Generally, for the resin is a delay of approximately 20 minutes is appropriate. The resulting foam layer is not going to contain voids, should that tightly bound to the glass fiber shell and polymer skin. Leakage of the foam around the integral silicone rubber seal should be avoided.

While a particular polyurethane foam material has been described above, it should be understood that other open or closed cell foams may be used.

The amount of foam F, as well as the output speed of the dispenser, is critical for obtaining a finished product with optimal texture and strength. If the actual, with 30% to 40% of the overpack, it is observed that achieved excellent results,
For optimum results, it is preferred to use 35%. An overpack is intended to inject more foam by weight into the cavity 70 (which is then necessary to completely fill the cavity 70 with foam upon complete cure). The use of insufficient overpacked foam may result in the foam not being evenly distributed throughout the cavity 70 and consequently the cavity 70
Gives a large void space inside. If too much foam is used, the cured foam often shows shrinkage,
As a result , the bathtub surface is deformed. After curing (a process that takes about 20 minutes), the clamp 160 is removed and the assembled tub consisting of tub base B, composite flexible polymer skin S, and foam F sandwiched therebetween is molded with frame 50. Removed from the body 40, the surface of the recess 46, the mold body 40
The outer skin S is separated from the member 42 and the surface 42a. Thereafter, the screw 67 is removed, and the frame 50 is separated from the bathtub. To facilitate the opening of the mold 40, compressed air can be injected into the mold until separation is achieved. The resulting bath, and then washed with water to remove polyvinyl alcohol.

The finished tub is thus a stamp so that shapes in FIGS. 7 and 8, the central container portion 80 and an outer laminate periphery arm flange 82, an upper surface covered with the composite flexible polymer skin S, and large moiety is from the bottom surface formed by the tub base B, equipped with a foam F which is sandwiched between the part of substantially all hands. The projection 44f (FIG. 3) of the member 44 results in an opening 84 in the bottom of the bathtub, which is closed by the composite flexible polymer skin S and the bathtub base B, both of which are pierced. setting is removed by other physical that it is necessary to form the bathtub drain outlet
I understand. Similarly, an overflow outlet 86 is formed in the front wall of the bathtub.

The bath shown in FIGS. 7 and 8, by lowering the bath in a suitable frame structure, it can be mounted either in the bathtub is supported by either the flange 82 is placed on a floor or Ru <br/> be held in both. Alternatively, the tub can be free standing and simply placed on the floor , with the exposed side covered with a suitable fascia (not shown) and attached to the lower surface of the flange 82.
One end of the bathtub base B can be inserted into a recess 85 formed by the lower side of the outer peripheral rib 36. As yet another example, it is possible to a tub by 1 to 3 of the wall inserted into the sealed body, in this case, frame structure, the flange 82
Support from these walls, and one or more exposed sides of the bathtub shall be covered by a suitable fascia.

Referring also to FIGS. 4-9, a fluid container formed in accordance with the present invention comprises a polyurethane polymeric sheathing U1 and U2 as described above, and about 1-1.5 inches (about 2.54-3.81 cm). ) Is provided with a coating U3 made of a foamable polymer resin having a thickness of (3). The coating U3 is coated with a binder coating 100 that promotes the binding of the U3 resin to the glass fiber layer 102 applied to the binder coating 100. According to this aspect of the invention, coatings U1, U2 and U3 are provided on a mold similar to mold 40 described above. The foamable polymer resin coating U3 is generally thicker in this embodiment than in the embodiments described above. Such thicknesses can be achieved by applying multiple layers of polymer resin in a manner similar to that of the described coating U3 applied as described above. The binder coating 100 is preferably a urethane-polyester mixture, such as that available from Polymer Development Laboratory, Orange, California, under the name M5 hybrid. The binder coating 100 may be applied by roll over or brushing is applied to a thickness of typically from about 5 to about 100 mils (about 0.013 to about 0.254 cm). After applying the binder coating 100, a layer of glass fibers 102 can be applied by conventional techniques, including spraying. Preferably, the layer of glass fibers 102, about
Apply to a thickness of 1/4 to 5/16 inch (about 0.635 to 0.794 cm). After the glass fibers have set, the entire laminate can be removed from the mold to provide a fluid container according to the present invention.

As indicated above, it should be understood that the cushioned container for a fluid formed in accordance with the present invention may take other forms besides a bathtub. Suitable applications include shower stalls, sinks and hot tubs.

[0041] Although the present invention has been described with reference to preferred embodiments, the invention is not limited thereto, the scope of the invention should be construed only in connection with the claims as set forth Is clearly understood by those skilled in the art. For example, the particular temperature and processing time may vary depending on the particular resin used and ambient conditions.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a split mold used for producing a glass fiber reinforced polyester resin bathtub base by a resin transfer molding method.

FIG. 2 is a slope view of the fabricated bathtub base.

FIG. 3 shows a mold for making a composite flexible polymer skin.
It is a slope view.

[4] within the cavity between the tub base and the mold body, for mounting a cellular foam mold body tub base for the purpose of forming in situ, the mold body provided with a composite polymer skin on its is an exploded slant <br/> view showing the assembly of the tub base and the frame.

FIG. 5 is a sectional view of the assembled mold, bathtub base and frame.

FIG. 6 is a cross-sectional view showing details of a laminated component portion of the composite skin along the arm of the container.

7 is a slant view illustrating the fabricated cushioning container.

FIG. 8 is a cross-sectional view of the cushioned container manufactured along line 8-8 in FIG. 7;

FIG. 9 is a cross-sectional view of a laminate of another embodiment of a container formed according to the present invention.

[Explanation of symbols]

B Base 10 Female part 12 Male part 18 Cavity 20 Opening 22 Floor 24 Front wall 26 Side wall 28 Side wall 30 Rear wall 34 Outer peripheral flange 37 Foam inlet 39 Degassing opening 40 Mold 42 Base 44a Floor Surface 44b Front wall surface 44c Side wall surface 44d Side wall surface 44e Inclined rear wall surface S Composite flexible polymer skin U1 First coating U2 Second coating U3 Third coating 50 Frame 70 Cavity F Bubbles Quality foam

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification code FI B29K 105: 04 105: 06 B29L 22:00 (73) Patent holder 593172197 International Cushioned Products Inc. International Cushioned Products Inc. Canada Country Vy 6 X 3 Sea 7 British Columbia, Richmond, Number 202 Bridgeport Road 8360 (72) Inventor Wayne E. Borts, Jr. United States, 19610 Pennsylvania, Wyomissing, Gerrard Avenue 1307 (72) Inventor Darren M. Wagner Canada, V1X4K4 British Columbia, Kelowna, Comp. 21, Site 13B, R5 (72) Inventor Alan A. Boudin Canada V1 1 6 El 4 British Columbia, Vernon, Comp. 6, Site 8A, R1 1 (56) References JP-A-63-56437 (JP, A) JP-B-49-13072 (JP, B1) JP-B-47-41238 (JP, Y1) U.S. Pat. (US, A) (58) Fields surveyed (Int. Cl. ⁷ , DB name) B29C 39/10-39/12 B32B 1 / 02,5 / 18

Claims (26)

(57) [Claims] 1. A base, a first elastomeric urethane.
A second coating of elastomeric urethane applied to the first coating, and a layer of foamed resin between the base and the second coating of elastomeric urethane , wherein the first coating of elastomeric urethane comprises: , Base and
Opposing the first layer and the second layer adjacent to the second coating
Cushion container for a fluid having . 2. The method according to claim 1 , wherein the first layer opposite to the base comprises a color additive.
And the second layer adjacent to the second coating is substantially free of
The cushioning container for a fluid according to claim 1 , further comprising a coloring additive . 3. The method according to claim 1, wherein the first layer is about 1 to about 2 mils (about 0.001 mil).
254 to about 0.00508 cm), and the second layer is about 3.0 to about 5.0 mils (about 0.0076 to about 0.00 mil).
The cushioning container for fluid according to claim 1, which has a thickness of 0127 cm). 4. The fluid cushioning container of claim 1, wherein the second coating is about 50 to about 80 mils (about 0.127 to about 0.2032 cm) thick. Further comprising a 5. A third coat of the origination Awau urethane coated on the second coating, the third coating, the second to-be
The cushioning container for a fluid according to claim 1, which is between the membrane and the layer of the foamed resin . 6. The container according to claim 1, wherein the foamed resin is polyurethane foam. 7. The cushioning container for a fluid according to claim 1, wherein the base comprises a reinforced polyester resin. 8. The cushioning container for a fluid according to claim 1, wherein the base further comprises a flame retardant. 9. A base comprising: a wall portion, a floor portion, and an outer peripheral flange portion, wherein the wall portion is closed at one end by the floor portion and opened at the other end, and the outer peripheral flange portion is opened by the wall portion. Extending from the end
Cushioning container for fluids according to claim 1 comprising an outer peripheral flange provided with a seat for receiving the sheet <br/> Lumpur elastomer sealing the coating of Awau urethane based. 10. A foamable urethane third coating having a thickness of about 0.5 μm.
125 to 0.25 inch (about 0.317 to about 0.635
The cushioning container for a fluid according to claim 5, which has a thickness of (cm). First coating 11. The elastomeric urethane, a second coat of elastomeric urethane coated on the first coat, a third coat of the origination Awau urethane coated to the second coating, the first 3. A cushioning container for fluids comprising a binder coating applied to the coating of 3 and a base of a glass fiber layer applied to the binder coating. 12. Making a base having a shape substantially similar to the shape of the container, (a) applying a first coating of elastomeric urethane on a mold having a shape complementary to the shape of the container, (b) A second coating of elastomeric urethane over the first coating;
A flexible composite skin is produced by applying a coating of: a base and a mold are paired to form a cavity between the base and the second coating of elastomeric urethane; A method for producing a cushioning container for a fluid, the method including a step of filling a cavity with a liquid. 13. Before the step of applying the first coating, conditioning the mold by applying polyvinyl alcohol to the mold and applying a solvent selected from the group consisting of methyl ethyl ketone and acetone. The method for producing a cushioning container for fluid according to claim 12, further comprising: 14. An elastomer, wherein the first coating comprises a first layer of an elastomeric urethane, and a coloring additive.
The method for producing a cushioning container for a fluid according to claim 12, comprising a second layer of urethane. 15. The method for producing a cushioning container for fluid according to claim 12, wherein the urethane polymer of the second coating is an elastomer urethane. 16. d the expandable polymer resin prior to the pairing step
2. The method according to claim 1, wherein the second coat of last urethane is applied to the second coat.
3. The method for producing a cushioning container for a fluid according to item 2. 17. The method according to claim 12, wherein the foamable polymer resin in the filling step is foamable urethane. 18. A process for pairing a base and a mold body.
The sealing of the base by integrating silicone rubber seal
The base by the frame is supported, manufacturing method of the cushioning container for fluids of the integrated rubber seal according to claim 12, wherein is also sealing frame against the mold thereof. 19. The method for producing a cushioning container for fluid according to claim 12, wherein the base is formed from a polyester resin filled with a flame retardant. 20. About 1 to about 2 mils (about 0.00254 to
About 0.00508 cm) of elastomer in the first layer by spraying urethane onto the mold
Apply urethane and apply about 3 to about 5 mils (about 0.00762
15. The method of claim 14, wherein the second layer of elastomeric urethane is applied by spraying the elastomeric urethane and a color additive over the first layer. 21. About 55 to about 80 mils (about 0.1397
16. The method of claim 15, wherein the second coating of elastomeric urethane is applied by spraying (~ 0.2032 cm) elastomeric urethane on the first coating. 22. The method for producing a cushioning container for fluid according to claim 16, wherein the foamable polymer resin applied to the second film is foamable urethane. 23. A cavity defined between the base and the foamable polymer resin, wherein the cavity is about 1.0 inch (about 2.54 cm).
The method for producing a cushioning container for fluid according to claim 17, wherein the width is m). 24. The foamable urethane is applied by spraying a coating having a thickness of about 0.125 to about 0.25 inches (about 0.317 to about 0.635 cm) over the second coating. 23. The method for producing a cushioning container for fluid according to item 22. 25. (a) applying a first coating of elastomeric urethane on a mold having a shape complementary to the container; and (b) applying a second coating of elastomeric urethane on the first coating.
The coating was applied, coated with the expandable polymer resin on the (c) second coat, originating
Performing a step of preparing a flexible composite skin by foam, comprising the steps of applying a binder coating on the calling Awakasane coalesced resin thus obtained, a coating of glass fibers onto the binder coating And a method for producing a cushioning container for a fluid. 26. Making a base, the base having a wall portion, a floor portion and an outer peripheral flange portion, wherein the wall portion is closed at one end by the floor portion and opened at the other end, and the outer peripheral flange portion is formed by the wall portion. Extending from and integral with the open end of the elastomeric urethane, a liquid mixture of the elastomeric urethane and its volatile carrier is sprayed onto the mold to form a first layer of the elastomeric urethane, the mold having an outer peripheral surface, a recess. A member having a recess, and a wall surface and a floor surface, the member protruding centrally from the outer peripheral surface, the wall surface of the member being generally complementary to a wall portion of the base, and the floor portion of the member being a base portion of the base. The recess is generally complementary to the floor portion of the base, the recess surrounds the wall surface of the member and joins the wall surface and the outer peripheral surface, and the recess is substantially complementary to the outer peripheral flange portion of the base, and is formed of an elastomer. The first coating is formed by rendering the first layer of the urethane tack-free and spraying a liquid mixture of the elastomeric urethane and its volatile carrier onto the first layer to form a second layer of the elastomeric urethane. Completing and applying a first coating of elastomeric urethane to the mold by rendering the second layer of elastomeric urethane tack-free, spraying the elastomeric urethane over the first coating to form a second coating Wherein the elastomeric urethane of the second coating is applied to the first coating on all surfaces of the mold, spraying foamable urethane on the second coating, By forming a composite flexible polymer skin by foaming to form a third coating, and inserting the wall and floor portions of the base into the support frame structure of the frame and securing the base to the frame. Mounting the base to a frame having an outer peripheral frame base, the frame base having a lower surface generally similar in shape to the outer peripheral surface of the mold, and having an inner shape generally similar to the outer shape of the wall and floor portions of the base. Having a similar support frame structure, wherein the frame is attached to the mold such that the base is spaced apart but close to and adjacent to the composite flexible polymer skin, and foamed in liquid form The expandable polymer resin is injected into the cavity to expand the expandable polymer resin throughout the cavity, thereby forming a flexible foam between the base and the flexible composite polymer outer skin, and forming the outer skin into a mold. A method for manufacturing a cushioning container for fluid, comprising removing a frame from a base.