US20050276941A1 - Polymer-based molded article with minimal flame spread and smoke properties - Google Patents
Polymer-based molded article with minimal flame spread and smoke properties Download PDFInfo
- Publication number
- US20050276941A1 US20050276941A1 US10/867,261 US86726104A US2005276941A1 US 20050276941 A1 US20050276941 A1 US 20050276941A1 US 86726104 A US86726104 A US 86726104A US 2005276941 A1 US2005276941 A1 US 2005276941A1
- Authority
- US
- United States
- Prior art keywords
- layer
- molded article
- recited
- intermediate layer
- molded
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K3/00—Baths; Douches; Appurtenances therefor
- A47K3/28—Showers or bathing douches
- A47K3/30—Screens or collapsible cabinets for showers or baths
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
Definitions
- the present invention relates to molded components and more particularly to polymer-based bath fixtures which minimize flame spread and smoke when subjected to combustion.
- Tub surrounds are positioned within a recess built around a bathtub or shower.
- Conventional modular tub/shower units often include a tub portion at the bottom and two or more wall portions. The whole structure is inserted into the wall recess to form a waterproof surround.
- the fully enclosed waterproof structure is highly advantageous in that it prevents the escape of water into the wall cavity despite the shower spraying water onto the surrounding walls.
- Tub and shower surrounds and other such polymer-based bath fixtures are typically molded through an open mold fiberglass reinforced plastic molding system.
- spray stations perform particular spraying operation to produce the molded component.
- Such spray operations typically include an acrylic such as a gelcoat and resin/catalyst/chopped fiberglass fixture application.
- the chopped fiberglass provides a support structure for the component which supports the gelcoat aesthetic surface.
- polystyrene-based components may not meet certain requirements for flame spread and smoke according to particularly strict building codes.
- the polymeric materials are based on benzene ring chemistry, which may generate smoke and support combustion. Because additives that reduce flame spread tend to increase smoke generation and vice-versa, the use of chemical additives to polymer-based components to control these two parameters has had limited success.
- the molded article according to the present invention includes at least three layers: a cosmetic surface layer, an intermediate layer and a backing layer. Each layer is sprayed, in order, onto an open mold to build up the composite material molded article.
- the intermediate layer is an energy absorbing layer between the surface layer and the backing layer. The construction at least partially confines burning to the surface layer where flame spread is controlled and smoke is minimized by the composition of the intermediate layer.
- the present invention therefore provides a polymer-based component, which minimizes flame spread and smoke.
- FIG. 1 is a general perspective view of a molded article according to the present invention.
- FIG. 2 is a sectional view a portion of the molded article.
- FIG. 1 illustrates a general perspective view of a polymer based molded article 20 .
- the molded article 20 is preferably a tub and shower surround, which is formed of multiple portions.
- a tub portion 22 receives wall portions 24 and 26 to form the molded article 20 .
- any number of molded articles of any number of portions such as shower bases, sinks, or other plastic faced components, will benefit from the present invention.
- such components are relatively large bathroom-related fixtures.
- Each portion 22 , 24 , 26 preferably includes at least three layers: a cosmetic surface layer 28 , an intermediate layer 30 , and a backing layer 32 .
- each layer 28 , 30 , 32 is sprayed, in order, onto an open mold to build up the composite material component as generally understood, however, other manufacturing techniques will also benefit from the present invention.
- the cosmetic surface layer 28 is preferably a layer of resin referred herein as “gelcoat”.
- the gelcoat is a hardenable polyester resin that becomes the visible surface of the finished product.
- the backing layer 32 is preferably a sprayed layer of chopped fiberglass known as “chop.” Other chops such as a resin/catalyst/chopped fiberglass mixtures will also benefit from the present invention.
- the intermediate layer 30 is an energy absorbing layer between the cosmetic surface layer 28 and the backing layer 32 .
- the intermediate layer 30 absorbs energy in the form of heat from behind the exposed cosmetic surface layer 28 to delay ignition of the cosmetic surface layer 28 .
- the composition of the intermediate layer 30 reduces the overall generation of smoke.
- the intermediate layer 30 is preferably an aliphatic resin with flame inhibitors such as aluminum trihydrate and other inorganic, non-flammable materials.
- the construction at least partially confines burning to the cosmetic surface layer 28 , where flame spread is controlled, and smoke is minimized by the composition of the intermediate layer 30 .
- Involvement of the backing layer 32 is minimized as the fuel from the cosmetic surface layer 28 , which commonly provides ignition of the backing layer 32 , is segregated therefrom by the intermediate layer 30 .
Landscapes
- Health & Medical Sciences (AREA)
- Public Health (AREA)
- Epidemiology (AREA)
- General Health & Medical Sciences (AREA)
- Bathtubs, Showers, And Their Attachments (AREA)
- Laminated Bodies (AREA)
Abstract
A molded article includes at least three layers: a cosmetic surface layer, an intermediate layer and a backing layer. The intermediate layer is an energy absorbing layer between the surface layer and the backing layer which at least partially confines burning to the surface layer, where flame spread is controlled, and smoke is minimized by the composition of the intermediate layer.
Description
- The present invention relates to molded components and more particularly to polymer-based bath fixtures which minimize flame spread and smoke when subjected to combustion.
- Tub surrounds are positioned within a recess built around a bathtub or shower. Conventional modular tub/shower units often include a tub portion at the bottom and two or more wall portions. The whole structure is inserted into the wall recess to form a waterproof surround. The fully enclosed waterproof structure is highly advantageous in that it prevents the escape of water into the wall cavity despite the shower spraying water onto the surrounding walls.
- Tub and shower surrounds and other such polymer-based bath fixtures are typically molded through an open mold fiberglass reinforced plastic molding system. As the open molds transit the assembly line, spray stations perform particular spraying operation to produce the molded component. Such spray operations typically include an acrylic such as a gelcoat and resin/catalyst/chopped fiberglass fixture application. The chopped fiberglass provides a support structure for the component which supports the gelcoat aesthetic surface.
- Although producing a high quality molded component, such polymer-based components may not meet certain requirements for flame spread and smoke according to particularly strict building codes. The polymeric materials are based on benzene ring chemistry, which may generate smoke and support combustion. Because additives that reduce flame spread tend to increase smoke generation and vice-versa, the use of chemical additives to polymer-based components to control these two parameters has had limited success.
- Accordingly, it is desirable to provide a polymer-based component, which minimizes flame spread and smoke.
- The molded article according to the present invention includes at least three layers: a cosmetic surface layer, an intermediate layer and a backing layer. Each layer is sprayed, in order, onto an open mold to build up the composite material molded article. The intermediate layer is an energy absorbing layer between the surface layer and the backing layer. The construction at least partially confines burning to the surface layer where flame spread is controlled and smoke is minimized by the composition of the intermediate layer.
- The present invention therefore provides a polymer-based component, which minimizes flame spread and smoke.
- The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
-
FIG. 1 is a general perspective view of a molded article according to the present invention; and -
FIG. 2 is a sectional view a portion of the molded article. -
FIG. 1 illustrates a general perspective view of a polymer based moldedarticle 20. The moldedarticle 20 is preferably a tub and shower surround, which is formed of multiple portions. Generally, atub portion 22 receiveswall portions article 20. It should be understood that any number of molded articles of any number of portions, such as shower bases, sinks, or other plastic faced components, will benefit from the present invention. Preferably, such components are relatively large bathroom-related fixtures. - Referring to
FIG. 2 , a sectional view through one of theportions portions portion cosmetic surface layer 28, anintermediate layer 30, and abacking layer 32. - Typically, each
layer - The
cosmetic surface layer 28 is preferably a layer of resin referred herein as “gelcoat”. The gelcoat is a hardenable polyester resin that becomes the visible surface of the finished product. - The
backing layer 32 is preferably a sprayed layer of chopped fiberglass known as “chop.” Other chops such as a resin/catalyst/chopped fiberglass mixtures will also benefit from the present invention. - The
intermediate layer 30 is an energy absorbing layer between thecosmetic surface layer 28 and thebacking layer 32. Theintermediate layer 30 absorbs energy in the form of heat from behind the exposedcosmetic surface layer 28 to delay ignition of thecosmetic surface layer 28. Furthermore, the composition of theintermediate layer 30 reduces the overall generation of smoke. Theintermediate layer 30 is preferably an aliphatic resin with flame inhibitors such as aluminum trihydrate and other inorganic, non-flammable materials. The construction at least partially confines burning to thecosmetic surface layer 28, where flame spread is controlled, and smoke is minimized by the composition of theintermediate layer 30. Involvement of thebacking layer 32 is minimized as the fuel from thecosmetic surface layer 28, which commonly provides ignition of thebacking layer 32, is segregated therefrom by theintermediate layer 30. - Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined, unless otherwise indicated and will still benefit from the present invention.
- The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.
Claims (12)
1. A molded article comprising:
a cosmetic surface layer;
a backing layer; and
an energy absorbing intermediate layer between said cosmetic surface layer and said backing layer.
2. The molded article as recited in claim 1 , wherein said intermediate layer comprises an aliphatic resin.
3. The molded article as recited in claim 2 , wherein said intermediate layer comprises a flame inhibitor.
4. The molded article as recited in claim 3 , wherein said flame inhibitor comprises aluminum trihydrate.
5. The molded article as recited in claim 1 , wherein said cosmetic surface layer comprises an acrylic.
6. The molded article as recited in claim 1 , wherein said backing layer comprises a chopped fiberglass.
7. A molded bathroom fixture comprising:
a cosmetic surface layer;
a backing layer; and
an energy absorbing intermediate layer between said cosmetic surface layer and said backing layer.
8. The molded bathroom fixture as recited in claim 7 , wherein said intermediate layer comprises an aliphatic resin.
9. The molded bathroom fixture as recited in claim 8 , wherein said intermediate layer comprises a flame inhibitor.
10. The molded bathroom fixture as recited in claim 9 , wherein said flame inhibitor comprises aluminum trihydrate.
11. The molded bathroom fixture as recited in claim 7 , wherein said cosmetic surface layer, said backing layer, and said energy absorbing intermediate layer form a wall of a shower surround portion.
12. The molded bathroom fixture as recited in claim 7 , wherein said cosmetic surface layer, said backing layer, and said energy absorbing intermediate layer form a wall of a tub surround portion.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/867,261 US20050276941A1 (en) | 2004-06-14 | 2004-06-14 | Polymer-based molded article with minimal flame spread and smoke properties |
CA002508155A CA2508155A1 (en) | 2004-06-14 | 2005-05-24 | Polymer-based molded article with minimal flame spread and smoke properties |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/867,261 US20050276941A1 (en) | 2004-06-14 | 2004-06-14 | Polymer-based molded article with minimal flame spread and smoke properties |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050276941A1 true US20050276941A1 (en) | 2005-12-15 |
Family
ID=35460882
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/867,261 Abandoned US20050276941A1 (en) | 2004-06-14 | 2004-06-14 | Polymer-based molded article with minimal flame spread and smoke properties |
Country Status (2)
Country | Link |
---|---|
US (1) | US20050276941A1 (en) |
CA (1) | CA2508155A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2012067695A1 (en) * | 2010-11-15 | 2012-05-24 | Masco Bath Corporation | Method for bathing vessel having wood-containing base board |
US20130256949A1 (en) * | 2012-03-30 | 2013-10-03 | Raymond Doss | Mold for Creating Negative Draft Surfaces in Molded Items and Method of Molding |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3139627A (en) * | 1962-08-08 | 1964-07-07 | Rubber And Plastics Compound C | Liner for a shower stall |
US4801493A (en) * | 1980-07-23 | 1989-01-31 | Daniel Ferziger | Coated fabric and mattress ticking |
US4844944A (en) * | 1987-12-18 | 1989-07-04 | American Standard, Inc. | Lightweight, durable plumbing fixture fabricated from a delamination-resistant multilayer polymeric composite |
US4961995A (en) * | 1987-08-10 | 1990-10-09 | Ross Gilbert B | Polishable, flame retarded, synthetic mineral product |
US5494718A (en) * | 1994-01-18 | 1996-02-27 | The Geon Company | Rigidizer for plastic vessels |
US5643652A (en) * | 1994-09-28 | 1997-07-01 | Centura Solid Surfacing, Inc. | Composite panel for toilet and shower partitions |
-
2004
- 2004-06-14 US US10/867,261 patent/US20050276941A1/en not_active Abandoned
-
2005
- 2005-05-24 CA CA002508155A patent/CA2508155A1/en not_active Abandoned
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3139627A (en) * | 1962-08-08 | 1964-07-07 | Rubber And Plastics Compound C | Liner for a shower stall |
US4801493A (en) * | 1980-07-23 | 1989-01-31 | Daniel Ferziger | Coated fabric and mattress ticking |
US4961995A (en) * | 1987-08-10 | 1990-10-09 | Ross Gilbert B | Polishable, flame retarded, synthetic mineral product |
US4844944A (en) * | 1987-12-18 | 1989-07-04 | American Standard, Inc. | Lightweight, durable plumbing fixture fabricated from a delamination-resistant multilayer polymeric composite |
US5494718A (en) * | 1994-01-18 | 1996-02-27 | The Geon Company | Rigidizer for plastic vessels |
US5643652A (en) * | 1994-09-28 | 1997-07-01 | Centura Solid Surfacing, Inc. | Composite panel for toilet and shower partitions |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2012067695A1 (en) * | 2010-11-15 | 2012-05-24 | Masco Bath Corporation | Method for bathing vessel having wood-containing base board |
WO2012067696A1 (en) * | 2010-11-15 | 2012-05-24 | Masco Bath Corporation | Method of forming a bathing vessel |
WO2012067694A1 (en) * | 2010-11-15 | 2012-05-24 | Masco Bath Corporation | Bathing vessel having wall reinforcement panel |
US20140020172A1 (en) * | 2010-11-15 | 2014-01-23 | Masco Bath Corporation | Structural Wall Design of a Composite Bathing Vessel |
US9320393B2 (en) * | 2010-11-15 | 2016-04-26 | Delta Faucet Company | Structural wall design of a composite bathing vessel |
US9648988B2 (en) | 2010-11-15 | 2017-05-16 | Delta Faucet Company | Method for bathing vessel having wood-containing base board |
US9661956B2 (en) | 2010-11-15 | 2017-05-30 | Delta Faucet Company | Method of forming a bathing vessel |
US10213057B2 (en) | 2010-11-15 | 2019-02-26 | Delta Faucet Company | Bathing vessel having wall reinforcement panel |
US20130256949A1 (en) * | 2012-03-30 | 2013-10-03 | Raymond Doss | Mold for Creating Negative Draft Surfaces in Molded Items and Method of Molding |
US9321191B2 (en) * | 2012-03-30 | 2016-04-26 | Raymond Doss | Mold for creating negative draft surfaces in molded items and method of molding |
US10137604B2 (en) | 2012-03-30 | 2018-11-27 | Raymond Doss | Mold for creating negative draft surfaces in molded items and method of molding |
Also Published As
Publication number | Publication date |
---|---|
CA2508155A1 (en) | 2005-12-14 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: MIROLIN INDUSTRIES CORPORATION, CANADA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KAPELANSKI, SCOTT;ZIBRAT, STANISLAV;PRETI, ALFREDO LI;REEL/FRAME:015482/0467;SIGNING DATES FROM 20040512 TO 20040607 |
|
AS | Assignment |
Owner name: MASCO CORPORATION, MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MIROLIN INDUSTRIES CORPORATION;REEL/FRAME:016207/0907 Effective date: 20050110 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |