WO2008087637A2

WO2008087637A2 - Injection-molding process and article manufactured thereby

Info

Publication number: WO2008087637A2
Application number: PCT/IL2008/000067
Authority: WO
Inventors: Rimon Ben-Dor
Original assignee: Lotemplast Plastic Products Ltd
Priority date: 2007-01-16
Filing date: 2008-01-16
Publication date: 2008-07-24
Also published as: WO2008087637A3

Abstract

A hollow article, and a method for producing the same, comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members. Each of the members is formed as a trough-like shell having two rims defining a hollow and an opening therebetween, each of the rims mating with a corresponding rim of another one of the members along longitudinally extending seams. The members are secured together by a secondary injecting molding of a connection material along the seams.

Description

INJECTION-MOLDING PROCESS AND ARTICLE MANUFACTURED

THEREBY

FIELD OF THE INVENTION

This invention relates to injection molding methods, and to articles manufactured thereby, especially to hollow articles, which are non-hollow blown.

BACKGROUND OF THE INVENTION

Injection molding is a well-known and widespread method for forming parts out of meltable materials such as plastics, and so forth. In injection molding, a reciprocating screw or ram injector is used to inject melted material into a mold by force. The material takes on the shape of the mold, thus forming the part.

In particular, injection molding may be used to form hollow parts. For example, a pressurized gas, usually nitrogen, is introduced into a hollow mold into which the melted material has been introduced. The gas forms a gas channel which, upon completion of the part, becomes the hollow. This process is known as a hollow blowing with gas assist.

In any injection molding procedure, when the material cures, that is, solidifies, it contracts slightly. Under ideal conditions, such as uniform temperature of the material and uniform wall thickness of the part, there is no or negligible visual evidence of the contracting on the surface of the part. Different methods of injection molding are known. For example, JP 3544965 discloses a method of injection molding parts of a pair of half hollow bodies molded by primary molding, even if the joining parts are thin, when the joining parts of a pair of the half hollow bodies are joined by secondary molding.

According to the method, a slide mold and a fixed mold are used in primary molding to mold a pair of the half hollow molded articles so as to provide joining parts to the peripheral edges thereof. The slide mold is slid with respect to the fixed mold in secondary molding to abut the joining parts of a pair of the half hollow molded articles. A molten resin for secondary molding is injected in the joining space part of the abutted thin-walled joining parts through a side gate to join a pair of the half hollow molded articles to obtain a hollow molded article. At this time, a property is imparted to the flow of the molten resin injected from the side gate so as to turn the flow of the molten resin toward the joining parts near to the thin-walled joining parts of the joining parts constituting the joining space part to allow the molten resin to flow in the joining space part.

DE 10 2005 062 825 discloses a hollow product which is molded by an internal gas pressure or gas injection process and cooled. At least one layer of a softer thermoplastic, that is, an elastomer, is then applied onto the outside of the molding, using either a two component injection molding process or a coating method. The softer plastic may be injected or coated over the entire outer surface of the hollow molding. Alternatively where a cover is to be attached to the injection molded component, one side remains free of soft polymer. An article produced by securing together injection molded parts is disclosed in US 6,363,641, which discloses a hand-held wafer-like signal, which is essentially flat and octagonally shaped, with a handle at the lower end. It has a front side and a back side. The front side is a unitary construction made by plastic injection molding and has a reflector surface, one-half of a handle and a one-half of a cylindrical light housing, which is essentially perpendicular to the reflective surface.

The back side is also made by injection molding and also has a reflective surface inside an octagonal frame, one-half of a battery container and one-half a cylindrical light housing. The front and back sides are secured together, as by screwing, and when assembled, they become a lightweight weatherproof hand-held signal.

US 4,477, 116 discloses a sun visor body having a flat core, which may be in the form of a plastic material insert, and which has a peripheral molding defined on it. A covering material for covering over the core is fastened to the outwardly facing side surfaces of the peripheral molding by being bonded or welded thereto or being attached by a heat-sensitive bonding agent. Foam padding layers may be placed between the core and the covering material.

SUMMARY

According to one aspect of the present invention, there is provided a method for creating a hollow article comprising at least one elongated portion extending substantially longitudinally, the method comprising the step of: (a) providing at least two injection-molded polymer members, each of the members being formed as a trough-like shell having two rims defining a hollow and an opening there between, the members being correspondingly formed such that they may be brought together so that each of the rims mates with a corresponding rim of another one of the members;

(b) bringing the members together such that each of the rims mates with a corresponding rim of another one of the members along a longitudinally extending seam; and

(c) securing the members together by a secondary injecting molding of a connection material along the seams.

According to an embodiment of the invention, the method provides for the members constituting a closed frame.

In some embodiments of the invention the method may comprise arranging four elongated portions in a substantially rectangular shape, or optionally, forming three elongated members in a substantially C-shape. Optionally, the method comprises extending at least one of the elongated portions at least partially along a curve.

In some embodiments of the invention, the method may comprise forming the article in a substantially elliptical shape, such as a circle. Optionally, at least two of the elongated portions may be formed integrally with each other.

According to some embodiments of the invention, the method provides for the members and/or the connection material to be made of a rigid injectable plastic material. Optionally, the method may comprise attaching a pane to the connection material on one of the seams of each elongated portion. Optionally, at least a portion of the pane may be transparent, translucent, or opaque. Additionally or alternatively, the pane may comprise at least two regions, each being transparent, translucent, or opaque. Optionally, the method may comprise forming the regions integrally with one another. Optionally, the pane may be formed integrally with the connection material. Additionally or alternatively, the method may provide for making the pane from a material selected from the group comprising metal, wood, plastic, glass, and viscoelastic materials.

In some embodiments of the invention, the method may provide for the article being impervious to passage therethrough of non-corrosive liquids. The seams may be formed with recesses, which are larger than an external entrance thereto, and the connection material may be formed with gripping ridges occupying said recesses. Optionally, the method may comprise forming the recesses in a substantially T-like formation, a substantially Y-like formation, or having a circular portion and a narrow neck portion, which is narrower than the diameter of the circular portion at the entrance.

According to some embodiments of the invention, the method may comprise introducing an auxiliary member within the hollow of at least one of said polymer members. Optionally, at least one of the members may comprise grips projecting into the hollow, the grips being adapted to securely hold the auxiliary member, at least when the members are secured together. Optionally, the method may provide for the auxiliary member being a rigid support member, for example to provide rigidity or strength to the article. It may be, for example, a rod or a flat bar or strip, and may be made of metal. Optionally, the method may comprise projecting the auxiliary member beyond the hollow, such that a portion of it is external to the members. The portion which is external to the members may constitute part of a hinge. Since the members are formed before the auxiliary member is introduced, there is no visible manifestation of the material of the members curing on the auxiliary member, such as due to shrinkage during curing, which would appear if the members were formed by injection molding about the auxiliary member.

In some embodiments of the invention, the method may provide for the article comprising two of the members, which may be symmetrical with one another. Optionally, the article may be adapted for use as a construction element.

According to some embodiments of the invention, the method may comprise using the article as at least a part of a chair, table, stool, shelf, closet, door (such as but not limited to, a shower door), partition, wall, dividing wall, ironing board, panel, toy house, swing, see-saw or for any other use.

According to an embodiment of the invention, the method provides for a door comprising at least one hollow article comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members. Optionally, the method may comprise forming each of the members as a trough-like shell having two rims defining a hollow and an opening therebetween. Each of the rims may mate with a corresponding rim of another one of the members along longitudinally extending seams, the members being secured together by a secondary injecting molding of a connection material along the seams. Optionally, the method may comprise adapting the door to be used as a shower door, a partition or both.

According to an embodiment of the invention, the method provides for a shower stall comprising at least one hollow door comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members. Optionally, the method may comprise forming each of the members as a trough-like shell having two rims defining a hollow and an opening therebetween. Each of the rims may mate with a corresponding rim of another one of the members along longitudinally extending seams, the members being secured together by a secondary injecting molding of a connection material along the seams. Optionally, the method may provide for the shower stall further comprising a shower base.

According to another aspect of the present invention, there is provided a hollow article comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members, each of the members being formed as a trough-like shell having two rims defining a hollow and an opening therebetween, each of the rims mating with a corresponding rim of another one of the members along longitudinally extending seams, the members being secured together by a secondary injecting molding of a connection material along the seams.

According to an embodiment of the invention, the members may constitute a closed frame. Four elongated portions may be arranged in a substantially rectangular shape, or three elongated members may be formed in a substantially C-shape.

At least one of the elongated portions may extend at least partially along a curve. The article may be formed in a substantially elliptical shape, such as a circle.

At least two of the elongated portions may be formed integrally with each other.

The members and/or the connection material may be made of a rigid injectable plastic material.

A pane, attached to the connection material on one of the seams of each elongated portion, may be provided.

At least a portion of the pane may be transparent, translucent, or opaque. The pane may comprise at least two regions, each being transparent, translucent, or opaque. The regions may be integrally formed with one another.

The pane may be formed integrally with the connection material. The pane may be made from a material selected from the group comprising metal, wood, plastic, glass, and viscoelastic materials.

The article may be impervious to passage therethrough of non-corrosive liquids.

The seams may be formed with recesses which are larger than an external entrance thereto, and the connection material is formed with gripping ridges occupying said recesses. The recesses may be formed in a substantially T-like formation, a δ substantially Y-like formation, or having a circular portion and a narrow neck portion which is narrower than the diameter of the circular portion at the entrance.

According to some embodiments of the invention, an auxiliary member may be introduced within the hollow of at least one of said polymer members. At least one of the members may comprise grips projecting into the hollow, the grips being adapted to securely hold the auxiliary member, at least when the members are secured together. The auxiliary member may be a rigid support member, for example to provide rigidity or strength to the article. It may be, for example, a rod or a flat bar or strip, and may be made of metal. The auxiliary member may project beyond the hollow, such that a portion of it is external to the members. The portion which is external to the members may constitute part of a hinge. Since the members are formed before the auxiliary member is introduced, there is no visible manifestation of the material of the members curing on the auxiliary member, such as due to shrinkage during curing, which would appear if the members were formed by injection molding about the auxiliary member.

The article may comprise two of the members, which may be symmetrical with one another.

The article may be adapted for use as a construction element.

The article may be adapted for use as at least a part of a chair, table, stool, shelf, closet, door (such as but not limited to, a shower door), partition, wall, dividing wall, ironing board, panel, toy house, swing, see-saw or for any other use.

According to an embodiment of the invention, there is provided a door comprising at least one hollow article comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members. Each of the members may be formed as a trough-like shell having two rims defining a hollow and an opening therebetween. Each of the rims may mate with a corresponding rim of another one of the members along longitudinally extending seams, the members being secured together by a secondary injecting molding of a connection material along the seams. Optionally, the door may be adapted to be used as a shower door, a partition or both.

According to an embodiment of the invention, there is provided a shower stall comprising at least one hollow door comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members. Each of the members may be formed as a trough-like shell having two rims defining a hollow and an opening therebetween. Each of the rims may mate with a corresponding rim of another one of the members along longitudinally extending seams, the members being secured together by a secondary injecting molding of a connection material along the seams. Optionally, the shower stall further comprises a shower base.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting 20 examples only, with reference to the accompanying drawings, in which:

Fig. IA is a perspective view of an article according to the present invention;

Fig. IB is a partial cross-sectional view taken along line H-II in Fig. 1 A;

Fig. 1 C is a partial perspective view of one member of the article illustrated in Fig. 1 A;

Fig. 2 illustrates one member of the article illustrated in Fig. IA, with an embodiment of an auxiliary member placed therein;

Figs. 3 A through 3 C illustrate modification of a recess formed at margins of the article;

Fig. 4 schematically illustrates an exemplary shower stall 400, in accordance with an embodiment of the invention;

Fig. 5 schematically illustrates an exemplary larger size shower stall 500, in accordance with another embodiment of the invention; and

Fig. 6 schematically illustrates an exemplary one door shower stall 600, in accordance with another embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

As illustrated in Fig. IA, there is provided an article, generally designated at 10, in accordance with the present invention. The article 10 comprises a perimeter frame 12 and an interior pane 14. As seen in more detail in Fig, IB, the perimeter frame 12 comprises first and second members 16 A, 16B (hereinafter referred to as 16 when referenced collectively), an auxiliary member 18, and interior and exterior connection elements 20a, 20b (hereinafter referred to as 20 when referenced collectively), made of a connection material. The interior connection element 20a is attached to both the frame 12 and the pane 14.

The article 10 may be, as seen in Fig, IA, in the form of a panel, useful, for example, as a picture or mirror frame, or in construction applications, such as a window, a door, a fixed or sliding construction panel, a shelf, a cover for an electrical panel, a table top, a partition, and so forth. The form and material properties of both the frame 12 and the pane 14 are to be selected accordingly. For example, if intended for use as part of a shower stall, the pane 14 may be formed such that it is translucent. Optionally, pane 14 may comprise a plurality of ridges 14 A. Ridges 14A may be for decorative purposes. Optionally, ridges 14A may be adapted to structurally strengthen pane 14. In addition, the article may be formed without the pane 14, for example, if formed as a linear member such as a beam or shaft.

During manufacture, each of the members 16 is formed by a standard injection molding process, such as is well-known in the art. They may be made of any material appropriate material, such as thermoplastics, resins, and other plastic or plastic-related materials. Each member 16 is formed as a shell, that is, as relatively thin-walled with a hollow 22 therein. Inner edges 24 of the walls, in cross-section such as in Fig. IB, constitute outer boundaries of an opening 26 to the hollow 22. In addition, margins 27 are provided. The margins 27 may be in the form of extensions having a concavity, for example as illustrated in Fig. IB. As further seen in Fig. IB, the margins 27 may be formed with internal recesses 34 which are larger than the entrance 36 thereto. The significance of this will become clear below.

As illustrated in Fig. 1C, the members 16 (only one member is illustrated in

Fig. 1C) may further comprise a plurality of grips 28 formed within the hollow 22 and adapted to retain therewithin the auxiliary member 18. As shown, each grip 28 comprises a plate 30 having a slot 32, sized so as to tightly receive therein a portion of the auxiliary member.

It will be appreciated that in order for the interior of the frame 12 to be in fluid isolation from the exterior of the frame, the inner edges 24 of the first and second members 16 A, 16B are formed such that they are aligned with one another when the openings 26 of the members are brought together. Although in the present example the members 16 are symmetrical, this is not required.

After each of the members 16 has cured, the auxiliary member 18 is placed within the grips 28. One unitary auxiliary member 18 may be provided for the entire article 10, or several individual auxiliary members may be provided. For example, if the frame 12 is generally rectangular in shape, the auxiliary member may be formed as a rectangle, or each side thereof may comprise a linear auxiliary member. By introducing the auxiliary members 18 after the members 16 has cured, no visible manifestation, such as stress marks, of the material of the members shrinking on the auxiliary member will be apparent. As illustrated in Fig. 2, which illustrates one of the members 16 with the auxiliary member 18 placed therein, at least one of the auxiliary members may project beyond the frame 12. In this way, they may constitute functional elements of the article. For example, if the article is to be used as a door, portions of the auxiliary member may serve as parts of hinges thereof.

The members 16 are then brought together, such that each of the inner edge 24 contacts an inner edge of the other member, thus forming a seam. The auxiliary member 18 is received within the grips 28 of both members. Corresponding margins 27 on the two members together form a recess.

The connector elements 20 are now formed. A connection material, which is adapted to bond to the material of the members 16, is injection molded into the recesses formed within the margins. The bonding of each of the members 16 to the connector elements 20 secures them together, thus forming a unitary article. During injection, the connection material occupies the recesses 34 formed within the margins 27. In this way, the connector elements 20 are prevented from being displaced when experiencing a load or force which would otherwise displace it due to shearing of the connection material from the surface of the member 16, to which it is bonded.

The recess 34 may be formed, as illustrated in Figs. 3A through 3C, respectively, as a substantially T-like formation, a substantially Y-like formation, or as a circular portion having a narrow neck portion, which constitutes the entrance 36 to the recess, being narrower than the diameter of the circular portion,

As seen, part of the connector element may project beyond the recess, and may thus constitute a functional element. For example, the interior connector element 20a may also connect to the pane 14, thus fixing it to the frame. The external connector element 20b may be used, for example, as a gasket. Alternatively, one or both of the connection elements 20 may be formed such that it lies flush with the edges of the recess, that is, so that it does not substantially project beyond the frame 12.

Reference is made to Fig. 4 which schematically illustrates an exemplary shower stall 400, in accordance with an embodiment of the invention. Shower stall 400 is assembled from a first article 401, a mirror-image symmetrical second article 402, a shower base 415, a first wall support 408, and a second wall support 409. Shower stall 400 rests on shower base 415, and may be a rectangular enclosure formed by two perpendicularly intersecting walls, 411 and 412, and by the intersection of first article 401 and second article 402 which are parallel to walls 412 and 411, respectively. Optionally, walls 411 and 412 may not form a right angle. Additionally, or alternatively, first article 401 and second article 402 may not be parallel to walls 411 and 412. First article 401 and second article 402, in addition to serving as external partitions to shower stall 400, are further adapted to serve as doors to enter into shower stall 400. For convenience hereinafter, first article 401 and second article 402 may be referred to as shower doors 401 and 402, respectively.

Shower door 401 comprises a closed frame 419 and a pane 403, which may be the same or substantially similar to that shown in Fig. IA and Fig. IB at 12 and 14, respectively. Shower door 402 comprises a closed frame 417 and a pane 420, which may be the same or substantially similar to that shown in Fig. IA and Fig. IB at 12 and 14, respectively. Panes 403 and 420 may be transparent or, optionally, translucent. Optionally, one pane may be translucent and the other pane may be transparent. Alternatively, one pane may be transparent or translucent, and the other pane may be opaque.

Shower doors 401 and 402 additionally comprise handles 414 and 416, respectively, which are used to pull the shower doors open, in a direction away from the walls. Optionally, one or both handles may be used to push one or both door inwardly in a direction towards the walls. Handles 414 and 416 are located on frame 419 and 417 respectively, externally located to the enclosure defined by shower stall 400, in a position which may be easily accessed by a person wishing to enter the shower stall. Shower doors 401 and 402 further comprise a first push bar 413 and a second push bar 418, respectively, which are used to push the shower doors open, in a direction away from the walls. Optionally, one or both handles may be used to pull one or both doors inwardly in a direction towards walls 411 and/or 412. Optionally, push bar 413 and/or push bar 418, may be replaced by handles, for example, the same or similar to 414 and 416, respectively. Push bar 413 and 418 are located on frame 419 and 417 respectively, internally located to the enclosure defined by shower stall 400, in a position which may be easily accessed by a person wishing to exit the shower stall. Additionally or alternatively, handle 414 and/or 416 may be replaced with push bars.

Shower doors 401 and 402 each comprise a gasket 410 along edges of the shower doors which intersect, the gasket adapted to seal an opening at the intersection between the doors. Optionally, only one of the shower doors comprises gasket 410. Optionally, gasket 410 additionally extends along the edges of shower doors 401 and/or 402 in closest proximity to shower base 415. Gasket 410 may comprise a flexible, water resistant material, such as, for example, rubber, silicon, or similar.

Shower doors 401 and 402 are attached to support columns 408 and 409, respectively, along a side of frame 419 and 417, respectively, opposing the intersecting edges of the doors (and comprising gasket 410). Attachment to support columns 408 and 409 is through an upper hinge 404 and 406, respectively, and through a lower hinge 405 and 407, respectively. Optionally, doors 401 and 402 may be attached to support columns 408 and 409, respectively, by more than two hinges. Hinges 404, 405, 406 and 407 are adapted to support a weight of the doors when open and closed, and may be further adapted to allow movement of one or both doors in two directions, when opened in the direction of walls 411 and/or 412, and/or in the direction away from either one or both walls, respectively. Hinges 404, 405, 406 and 407 may be further adapted to withstand exposure to water and to humidity conditions typically encountered in a shower environment.

Support columns 408 and 409 are adapted to be attached to walls 411 and 412, respectively, and to further support the weight of shower doors 401 and/or 402, respectively, when repeatedly opened and closed. Support columns 408 and 409 may be attached to walls 411 and 412 by any means of fixed attachment such as, for example, screws, bolts, and the like. Additionally or alternatively, support columns 408 and 409 may be attached to shower base 415. Support columns 408 and/or 409 may also be produced from plastic through an injection molding process known in the art. Optionally, the support columns may be produced from any material adapted to withstand exposure to water and to humidity conditions typically encountered in a shower environment. Shower base 415 is adapted to serve as the base of shower stall 400. Shower base 415 may comprise a drain (not shown) and/or drain connection (not shown).

Shower base may be fabricated from a porcelain or porcelain related material, plastic, or any material adapted to withstand exposure to water and to humidity conditions typically encountered in a shower environment.

Reference is made to Fig. 5, which schematically illustrates an exemplary larger size shower stall 500, in accordance with another embodiment of the invention. Shower stall 500 is assembled from a shower door 501, a mirror- image symmetrical shower door 502, a shower base 515, a first wall support 508, a second wall support 509, and hinges 504, 505, 506 and 507. Comprised in shower doors 501 and 502 are closed frames 519 and 517; panes 503 and 520; handles 514 and 516; gasket 510, and push bars 513 and 518, respectively. Shower doors 501 and/or 502 optionally comprise ridges 514A in panes 503 and/or 520, respectively. Shower door 501 and 502, including closed frames 519 and 517, panes 503 and 520, handles 514 and 516, gasket 510, push bars 513 and 518; and hinges 504, 505, 506, and 507; are the same or substantially similar to that shown in Fig. 4 at 401, 402, 419, 417, 403, 420, 414, 416, 410,, 413, 418, 404, 405, 406, and 407. Optional ridges 514A are the same or substantially similar to that shown in Fig.l at 14A.

Shower stall 500 is substantially similar to shower stall 400 shown in Fig. 4 with a difference that shower stall 500 occupies a larger floor area than shower stall

400. A rectangular enclosure is formed by walls 511 and 512, which may be similar to that shown in Fig. 4 at 411 and 412, and doors 501 and 502, and shower stall 500 rests on shower base 515. Shower base 515 is substantially the same as that shown in Fig. 4 at 415, but occupies a larger floor area. To compensate for larger dimensions (larger floor area occupation) in shower base 515 compared to shower base 415 in Fig. 4, first wall support 408 and second wall support 409 in the embodiment shown in Fig. 4 have been increased in size in the embodiment shown in Fig. 5. First wall support 508 and second wall support 509 may be additionally formed as a closed frame and may comprise panes 521 and 522, respectively. Panes 521 and 522 may be transparent or, optionally, translucent. Optionally, one pane may be translucent and the other pane may be transparent. Alternatively, one pane may be transparent or translucent, and the other pane may be opaque. Optionally, wall support 508 and/or 509 may be formed such that the panes are part of the closed frame.

Reference is made to Fig. 6, which shows an exemplary one door shower stall

600, in accordance with another embodiment of the invention. Shower stall 600 is assembled from a shower door 601, a partition 602, a shower base 615, a wall support

608, and hinges 604 and 605. Comprised in shower door 601 and partition 602 are closed frames 619 and 617; panes 603 and 620; handle 614; gasket 610, and push bar

613, respectively. Shower door 601, including closed frame 619, pane 603, handle

614, gasket 610, push bar 613, wall support 608 and hinges 604 and 605 are the same or substantially similar to that shown in Fig. 4 at 401, 419, 403, 414, 410, 413, 408, 404, and 405, respectively. Partition 602, including closed frame 617 and pane 620, may be the same or substantially similar to that shown in Fig. IA and IB at 10, 12 and 14, respectively.

Shower stall 600 is substantially similar to shower stall 400 shown in Fig. 4 with a difference that shower stall 600 comprises only one door and occupies a smaller floor area than shower stall 400. A rectangular enclosure is formed by walls 611 and 612, which may be similar to that shown in Fig. 4 at 411 and 412, and by door 601 and partition 602. Partition 602 is adapted to divide between an area external to shower stall 600 and an interior of the shower stall. Partition 602 may optionally be adapted to divide between adjacent shower stalls. Optionally, partition 602 may comprise a wall or a dividing panel adapted to withstand the water and humidity conditions typically encountered in a shower environment. Shower stall 600 rests on shower base 615, which is similar or substantially the same as that shown in Fig. 4 at 415, but occupies a smaller floor area. As there is only one door 601 compared to two doors 401 and 402 in Fig. 4, first second wall support 409 in the embodiment shown in Fig. 4 has been eliminated in the embodiment shown in Fig. 5. Partition 602 may be attached to wall 612 by any means of fixed attachment such as, for example, screws, bolts, and the like. Optionally, partition 602 may be attached to a wall support the same or substantially similar to wall support 608. Additionally or alternatively, partition 602 may be attached to shower base 615. Pane 620 may be transparent or, optionally, translucent. Optionally, pane 620 may be opaque. In some embodiments of the invention, partition 602 may be attached to wall 611, and wall support 608 including door 601, attached to wall 612.

Those skilled in the art to which this invention pertains will readily appreciate that numerous changes, variations and modifications can be made without departing from the scope of the invention mutatis mutandis. For example, the members 16 may be secured together by any means, such as using an adhesive, screws, clamps, and so forth. Furthermore, there are numerous configurations, in which the shower stalls can be assembled, using one or more doors, partitions, and/or walls, or any combination thereof.

Claims

CLAIMS:What we claim is:

1. A method for creating a hollow article comprising at least one elongated portion extending substantially longitudinally, the method comprising the step of:

(a) providing at least two injection-molded polymer members, each of said members being formed as a trough-like shell having two rims defining a hollow and an opening therebetween, said members being correspondingly formed such that they may be brought together so that each of said rims mates with a corresponding rim of another one of said members;

(b) bringing the members together such that each of said rims mates with a corresponding rim of another one of said members along a longitudinally extending seam; and (c) securing the members together by a secondary injecting molding of a connection material along said seams.

2. A method according to Claim 1, wherein said elongate portions constitute a closed frame.

3. A method according to any one of Claims 1 and 2, wherein four elongated portions are arranged substantially in a rectangular shape.

4. A method according to any one of Claims 1 and 2, wherein three elongated portions are arranged substantially in a C-shape.

5. A method according to any one of Claims 1 and 2, wherein at least one elongated portion extends at least partially along a curve.

6. A method according to Claim 5, wherein said article is formed in a substantially elliptical shape.

7. A method according to Claim 6, wherein said article is formed as a circle.

8. A method according to any one of the preceding claims, wherein at least two elongate portions are formed integrally with one another.

9. A method according to any one of the preceding claims, wherein the members are made of a rigid injectable plastic.

10. A method according to any one of the preceding claims, wherein the connection material is a rigid injectable plastic material.

11. A method according to any one of the preceding claims, further comprising the step of providing a pane attached to said connection material on one of said seams of each elongated portion.

12. A method according to Claim 11, wherein at least a portion of said pane is transparent.

13. A method according to Claim 11, wherein at least a portion of said pane is translucent.

14. A method according to Claim 11, wherein at least a portion of said pane is opaque.

15. A method according to Claim 11, where said pane comprises at least two regions, each being selected from the group comprising transparent, translucent, and opaque.

16. A method according to Claim 15, wherein said regions are integrally formed with one another.

17. A method according to any one of Claims 11 through 16, wherein said pane is formed integrally with said connection material.

18. A method according to Claim 11, wherein said pane is made from a material selected from the group comprising metal, wood, glass plastic, and viscoelastic materials.

19. A method according to any one of Claims 11 through 18, the article being impervious to passage therethrough of non-corrosive liquids.

20. A method according to any one of the preceding claims, said seams being formed with recesses which are larger than an external entrance thereto, and said connection material being formed with gripping ridges occupying said

23

SUBSTITUTE SHEET (RULE U) recesses.

21. A method according to Claim 20, wherein said recesses are formed in a substantially T-like formation.

22. A method according to Claim 20, wherein said recesses are formed in a substantially Y-like formation.

23. A method according to Claim 20, wherein said recesses are formed having a circular portion and a narrow neck portion, being narrower than the diameter of the circular portion, at said entrance.

24. A method according to any one of the preceding claims, further comprising the step of introducing an auxiliary member within the hollow of at least one of said polymer members.

25. A method according to Claim 24, wherein at least one of said members comprises grips projecting into the hollow, said grips being adapted to securely

hold the auxiliary member, at least when the members are secured together.

26. A method according to any one of Claims 24 and 25, wherein said auxiliary member is a rigid support member.

27. A method according to any one of Claims 24 through 26, wherein said

24

SUBSTITUTE SHEET (RULE U) auxiliary member is made of metal.

28. A method according to any one of Claims 24 through 27, wherein the auxiliary member projects beyond the hollow, at least a portion thereof being external to the members.

29. A method according to Claim 28, wherein said portion external to the members constitutes part of a hinge.

30. A method according to any one of the preceding claims, wherein said article comprises two of said members.

31. A method according to Claim 30, wherein each of said members is symmetrical with the other.

32. A method according to any one of the preceding claims, wherein said article is adapted for use as a construction element.

33. A hollow article comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members, each of said members being formed as a trough-like shell having two rims defining a hollow and an opening therebetween, each of said rims mating with a corresponding rim of another one of said members along longitudinally extending seams, said members being secured together by a secondary injecting molding of a connection material along the seams.

25

SUBSTITUTE SHE£T(IUL£l«

34. An article according to Claim 33, wherein said elongated portions constitute a closed frame.

35. An article according to any one of Claims 33 and 34, comprising four elongated portions arranged substantially in a rectangular shape.

36. An article according to any one of Claims 33 and 34, comprising three elongated portions arranged substantially in a C-shape.

37. An article according to any one of Claims 33 and 34, wherein at least one elongated portion extends at least partially along a curve.

38. An article according to Claim 37, being formed in a substantially elliptical shape.

39. An article according to Claim 38, being formed as a circle.

40. An article according to any one of Claims 33 through 39, comprising at least two elongated portions formed integrally with one another.

41. An article according to any one of Claims 33 through 40, wherein the members are made of a rigid injectable plastic material.

42. An article according to any one of Claims 33 through 41, wherein the connection material is a rigid injectable plastic material.

26

SUBSTITUTE SHEET (RULE U)

43. An article according to any one of Claims 33 through 42, further comprising a pane attached to said connection material on one of said seams of each elongate portion.

44. An article according to Claim 43, wherein at least a portion of said pane is transparent.

45. An article according to Claim 43, wherein at least a portion of said pane is translucent.

46. An article according to Claim 43, wherein at least a portion of said pane is opaque.

47. An article according to Claim 43, wherein said pane comprises at least two regions, each being selected from the group comprising transparent, translucent, and opaque.

48. An article according to Claim 47, wherein said regions are integrally formed with one another.

49. An article according to any one of Claims 43 through 48, wherein said pane is formed integrally with said connection material.

50. An article according to Claim 43, wherein said pane is made from a material selected from the group comprising metal, wood, plastic, glass and viscoelastic

27

SUBSTITUTE SHEET (RULE 26} materials.

51. An article according to any one of Claims 43 through 50, being impervious to passage therethrough of non-corrosive liquids.

52. An article according to any one of Claims 33 through 51, said seams being formed with recesses which are larger than an external entrance thereto, and said connection material being formed with gripping ridges occupying said recesses.

53. An article according to Claim 52, wherein said recesses are formed in a substantially T-like formation.

54. An article according to Claim 52, wherein said recesses are formed in a substantially Y-like formation.

55. An article according to Claim 52, wherein said recesses are formed having a circular portion and a narrow neck portion, being narrower than the diameter of the circular portion, at said entrance.

56. An article according to any one of Claims 33 through 55, further comprising an auxiliary member introduced within the hollow of at least one of said polymer members.

57. An article according to Claim 56, wherein at least one of said members comprises grips projecting into the hollow, said grips being adapted to securely hold

28

SUBSTITUTE SHEET(RϋLE26) the auxiliary member, at least when the members are secured together.

58. An article according to any one of Claims 56 and 57, wherein said auxiliary member is a rigid support member.

59. An article according to any one of Claims 56 through 58, wherein said auxiliary member is made of metal.

60. An article according to any one of Claims 56 through 59, wherein the auxiliary member projects beyond the hollow, at least a portion thereof being external to the members.

61. An article according to Claim 60, wherein said portion external to the members constitutes part of a hinge.

62. An article according to any one of Claims 33 through 61, comprising two of said members.

63. An article according to Claim 62, wherein each of said members is symmetrical with the other.

64. An article according to any one of Claims 33 through 63, adapted for use as a construction element.

65. A door comprising:

29

SUBSTITUTE SHEETIRULE26) at least one hollow article comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members, each of said members being formed as a trough-like shell having two rims defining a hollow and an opening therebetween, each of said rims mating with a corresponding rim of another one of said members along longitudinally extending seams, said members being secured together by a secondary injecting molding of a connection material along the seams.

66. The door according to claim 65, wherein said door is adapted to be used as a shower door, a partition or both.

67. A shower stall comprising: at least one hollow door comprising at least one elongated portion extending substantially longitudinally and comprising at least two injection-molded polymer members, each of said members being formed as a trough-like shell having two rims defining a hollow and an opening therebetween, each of said rims mating with a corresponding rim of another one of said members along longitudinally extending seams, said members being secured together by a secondary injecting molding of a connection material along the seams.

68. The shower stall according to claim 67, further comprising a shower base.

30

SUBSTITUTE SHEET (RULE U)