Faced aerogel article and a molding process therefor
a technology of aerogel and face, which is applied in the direction of other domestic articles, synthetic resin layered products, transportation and packaging, etc., can solve the problems of increasing environmental regulations, reducing the application efficiency of spraying operations, and reducing the cost of spraying operations, so as to reduce the spraying operation and reduce the cost. the effect of the operation and the elimination of the fiberglass spraying operation
Inactive Publication Date: 2005-09-08
MASCO CORP
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- Description
- Claims
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AI Technical Summary
Benefits of technology
"The present invention is a method of manufacturing an article by molding a surface layer onto an aerogel layer using a vacuum. This eliminates the need for fiberglass spraying, resulting in a rigid, lightweight, and cost-effective product. The aerogel layer provides the structural support, while the surface layer provides the desired shape and appearance. The technical effect is a more efficient and effective method of manufacturing a rigid structural assembly for plastic faced products."
Problems solved by technology
Although effective, the chopped fiberglass may be a relatively heavy and low rigidity backing.
Moreover, spraying operations for application of the multiple layers are being subjected to more and more inflexible environmental regulations.
Method used
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Embodiment Construction
[0013]FIG. 1 illustrates a general perspective view of a molded tub and surround 20 which is formed of three pieces of molded plastic. A tub portion 22 receives wall portions 24 and 26 to form the combined tub and surround 20.
[0014] Referring to FIG. 2, the tub portion 22 is formed according to the present invention. Although the tub portion 22 is disclosed in the illustrated embodiment, it should be understood that any number of molded articles such as shower bases, sinks, or other plastic faced components will benefit from the present invention. Preferably, such components are bathroom type articles having a generally dish-like shape. The tub portion 22 is formed of at least two layers, an aerogel layer 24 and a surface layer 26 which is vacuum formed to the aerogel layer 24.
[0015] The aerogel layer 24 provides the structural support for the article heretofore performed by chopped fiberglass. As generally known, aerogels are solids with up to 99% porosity. Such large porosities ...
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Abstract
A molded article includes an aerogel layer and a surface layer which is vacuum formed to the aerogel layer. The aerogel layer provides the structural support for the article heretofore performed by chopped fiberglass. Do to the porosity of the aerogel layer, the vacuum is drawn directly through the aerogel layer such that the aerogel layer forms the mold for the surface layer which attaches thereto.
Description
BACKGROUND OF THE INVENTION [0001] The present invention relates to components molded of an aerogel and more particularly to a molding process for tubs, shower surrounds, and other plastic faced aerogel components. [0002] 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. [0003] Tub and shower surrounds are typically molded through an open mold fiberglass reinforced plastic molding system. As the open molds transit an assembly line, spray stations perform particular spraying operations. Such spray operations include a gelcoat and resin / catalyst / chopped fiberglass fixture applicatio...
Claims
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IPC IPC(8): B65D1/00
CPCY10T428/1352A47K3/02
Inventor SELOVER, CRAIG W.
Owner MASCO CORP