Claims
- 1. A method for manufacturing a polymeric composite sanitary structure, comprising:
- forming a polymeric shell having a finish-side and non-finish side to a suitable shape;
- arranging said polymeric shell in a mold;
- introducing an uncured blended mixture of unsaturated thermosetting polymeric backing material consisting essentially of at least one component selected from the group consisting of polyester, epoxy, acrylic, vinyl ester and blends thereof, styrene, a curing promoter, a peroxide cross-linking promoter and a filler into said mold to force said backing material to directly coat the non-finish side of said shell; and
- curing said molded thermosetting polymeric backing material at a suitable temperature and sufficient time to allow hardening and cross-linking of the thermosetting polymeric material and bonding directly to said non-finish side of the polymeric shell in order to permit demolding of the composite structure without damage, said cross-linking polymeric backing material having sufficient strength, eliminating the need for additional reinforcing layers, isocyanate and a silane coupling agent.
- 2. The method for manufacturing a polymeric composite structure as recited in claim 1, wherein said thermosetting polymeric backing material thermosetting polymeric includes a mixture of rigid unsaturated polyester resin, flexible unsaturated polyester resin and said filler in a ratio from about 2:1 resin to filler up to about 1:30 resin to filler.
- 3. The method for manufacturing a polymeric composite structure as recited in claim 2, wherein said filler is selected from the group consisting of calcium carbonate, aluminum trihydrate, glass spheres, ceramic, mica, talc, silica, sand, and mixtures thereof.
- 4. The method for manufacturing a polymeric composite structure as recited in claim 2, wherein said thermosetting polymeric resin material further includes a foaming agent or reduce the density of said backing material.
- 5. The method for manufacturing a polymeric composite structure as recited in claim 1, wherein said composite structure has a configuration of a bathtub.
CROSS REFERENCE TO RELATED APPLICATIONS
This is a division of U.S. patent application Ser. No. 08/164,646 filed on Dec. 8, 1993 which is a continuation of U.S. application Ser. No. 07/881,943 filed May 12, 1992, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 07/516,284 filed on Apr. 30, 1990, now abandoned.
US Referenced Citations (7)
Foreign Referenced Citations (3)
Number |
Date |
Country |
0370918 |
May 1990 |
FRX |
2040676 |
Sep 1980 |
GBX |
0399707 |
Nov 1990 |
GBX |
Divisions (1)
|
Number |
Date |
Country |
Parent |
164646 |
Dec 1993 |
|
Continuations (1)
|
Number |
Date |
Country |
Parent |
881943 |
May 1992 |
|
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
516284 |
Apr 1990 |
|