Fiberglass reinforced fixture with finished polymeric cap
First Claim
1. A polymeric plumbing fixture having a desired configuration, the fixture comprising:
- a continuous polymeric shell thermoformed from an extruded, calendered or cast polymeric sheet, said shell having a predetermined shape and size, and an underside;
a continuous polymeric cap thermoformed from an extruded, calendered or cast polymeric sheet, said cap substantially conforming to the shape and size of the shell;
a substantial portion of the shell being nestable inside a substantial portion of the cap;
and an intermediate layer applied to the underside of the shell while the shell is inverted, the intermediate layer comprising a cross-linkable polyester resin, a cross-linking agent and a chopped fibrous filler that bonds the shell, cap and intermediate layer into an integral structure conforming to the desired configuration of the fixture when the cap is inverted and pressed into seated, contacting engagement with the intermediate layer and cured.
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Accused Products
Abstract
Polymeric plumbing fixtures such as sinks, lavatories and tubs are disclosed that comprise a thermoformed or molded interior shell having a top side with a relatively smooth, polymeric surface; a polymeric reinforcing layer bonded to the underside of the shell; and a thermoformed or polymeric cap nestably engageable with the underside of the reinforced shell. The cap cooperates with the shell to encapsulate the reinforcing layer and the reinforcing layer bonds the cap the shell to form a unitary structure. The polymeric cap thereby provides an attractive, finished surface on the underside of the resultant fixture. The structural configuration disclosed herein is particularly preferred for use in making kitchen sinks. A method for making the subject fixtures is also disclosed.
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Citations
22 Claims
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1. A polymeric plumbing fixture having a desired configuration, the fixture comprising:
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a continuous polymeric shell thermoformed from an extruded, calendered or cast polymeric sheet, said shell having a predetermined shape and size, and an underside; a continuous polymeric cap thermoformed from an extruded, calendered or cast polymeric sheet, said cap substantially conforming to the shape and size of the shell; a substantial portion of the shell being nestable inside a substantial portion of the cap; and an intermediate layer applied to the underside of the shell while the shell is inverted, the intermediate layer comprising a cross-linkable polyester resin, a cross-linking agent and a chopped fibrous filler that bonds the shell, cap and intermediate layer into an integral structure conforming to the desired configuration of the fixture when the cap is inverted and pressed into seated, contacting engagement with the intermediate layer and cured. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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Specification