Intellex, Inc.

American Standard Inc.

Peter U Graefe

Karl T Kuszaj

A polymeric resin laminate is manufactured by bonding the molecularly-modified, adhesion-improved surface of a rigid thermoplastic resin layer to a thermoset resin layer, advantageously, in a reaction injection molding operation.

Thermoplastic resin layer chemically bonded to thermoset resin layer

An apparatus is provided for the integrated vacuum forming/reaction injection molding of a shaped polymeric laminate article, e.g., an item of sanitary ware such as a bathtub or a motor vehicle body panel, possessing a vacuum formed thermoplastic resin cosmetic layer bonded to a thermoset resin backing layer. In a preferred embodiment, the exposed surface of a vacuum formed preform is treated within the cavity of a sealed reaction injection mold, e.g., by plasma or chemically reactive gas, to modify the polymeric structure of the resin at such surface without affecting the bulk properties of the resin and thereby improve the adherent property of the preform for the subsequently formed theremoset resin layer.

Integrated vacuum forming/reaction injection molding apparatus for

In an apparatus for the reaction injection molding of a shaped article from a polymerizable flowable resin-forming composition, once such composition has attained a predetermined increased level of viscosity as measured in situ within the mold cavity, an amount of pressure is applied to the polymerizing composition which is sufficient to maintain any entrapped gas(es) dissolved therein and/or to prevent the composition from pulling away from mold cavity surfaces.

Reaction injection molding apparatus

A light weight, durable plumbing fixture, e.g., a bathtub, sink, shower receptor, etc., is fabricated from a multilayer polymer composite structure of high impact strength and delamination resistance. The composite possesses a relatively thin polymeric cosmetic, or finish, layer, e.g., of acrylic resin, chemically bonded to a relatively thick, reinforced, cross-linked, isocyanate-modified thermosetting polyester or polyether dense foam resin substrate layer.

Lightweight, durable plumbing fixture fabricated from a

A multilayer polymeric composite structure of high impact strength and delamination resistance possesses a polymeric cosmetic layer chemically bonded to a cross-linked, isocyanate-modified thermosetting polyester or polyether substrate layer. In one embodiment of the structure, a relatively thin, predominantly acrylic resin layer is chemically bonded through urethane linkages to a relatively thick, reinforced, polyester foam substrate layer. A reinforced reaction injection molding (RPIM) procedure for manufacturing the polymeric composite is also disclosed.

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Wayside, NJ, United States of America

Peter U Graefe