Patent Application
20060091586
This invention relates to a method and device for fabrication of a laminated article. More particularly, this invention relates to a method and device for preparation and control of a surface finish and thickness of a laminated article.
A laminated article, for example a bathtub, is fabricated by application of several layers over a mold. A first layer is applied to the mold that forms the outer surface that is exposed and visible. Subsequent layers of material are applied onto the first layer to provide structural rigidity of the laminated article. Once the layers dry the article is removed and ready for finish processing.
Laminated articles such as a bathtub include openings for plumbing fixtures such as water faucets and drain mechanisms. The first surface that is adjacent the mold includes a smooth finish that is defined by the contours of the mold. However, subsequent layers that are not adjacent the mold do not form smooth finished surfaces. Further, it is not necessary for most portions of the back non-visible side of the laminated article to include a smooth and defined finish.
However, openings within the article for plumbing fixtures require a smooth and level surface to provide surfaces for seals. Typically, such smooth flat surfaces are fabricated in a secondary process after the article is cured and hardened. A grinder or sander is used to prepare the desired flat and smooth surface adjacent the openings for the plumbing fixtures. Disadvantageously, such grinding and sanding process create significant amounts of dust that must be evacuated and isolated from the spray areas where laminate layers are applied. Further, grinding can only be done after the laminated article has fully cured. Additionally, grinding the surface of the laminated article is inconsistent causing scrap and necessary rework of the completed laminated articles.
Accordingly, it is desirable to design and develop a method and device for providing the desired surface finish and thickness without grinding or sanding areas of a laminated article.
This invention is a method and device for creating a surface finish and thickness in a structural layer of a laminated article.
An example laminated article includes a first layer coated onto a mold to provide a smooth show surface. The first layer is preferably sprayed onto the mold and cured to form a smooth hard surface desirable on the viewable side of the bathtub. The first layer is covered with subsequent structural layers that comprise reinforcement material for providing the desired rigidity and strength required for the finished laminated article. An opening is surrounded by a surface that is treated to provide a smooth and flat finish desirable and necessary for providing a seal with subsequently installed plumbing fixtures. Further, a thickness between the surface and the show side of the first layer is defined and provided to accommodate installation of a plumbing fixture.
The surface is prepared with an application device and a plastic sheet. The plastic sheet is placed over the surface and the device is pressed against the plastic sheet and into the third layer. The device includes pointers that penetrate the third layer to seat on the cured or substantially cured second layer. The device presses the plastic sheet against the uncured third layer to define the surface. The device presses against the plastic sheet and into the third layer to both smooth and flatten the surface to a desired finish. The desired surface finish provides a flat and smooth sealing surface for application of seals corresponding to the subsequently installed drain hardware.
The device is removed after being pressed into the surface and set against the second layer. The surface is smoothed by the surface provided by the plastic sheet and flattened as desired by the plate. Removal of the device leaves the surface in the desired state. The plastic sheet is left in place to protect the surface from subsequent application of covering and materials that may be applied to the molded article.
The device and method according to this invention provide for the preparation and treatment of the surface without the need for waiting until the third layer is fully cured, as would be required by grinding operations. Further, the device provides significant control over the formation of the surface and the desired thickness to provide consistent thickness and surface preparation for the subsequently installed drain fixture.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
Referring to
The first layer 14 is covered with subsequent structural layers that comprise reinforcement material that provide the desired rigidity and strength for the finished bathtub 10. The example bathtub 10 includes a second layer 16 and a third layer 18. As appreciated, the example bathtub 10 is illustrated with three layers, however, additional layers are within the contemplation of this invention. Three layers are illustrated and discussed to simplify the explanation of the method according to this invention. Additional layers may be utilized prior to, or after formation of the desired surface of the bathtub 10.
The bathtub 10 includes an opening 20 for a drain. The opening 20 is surrounded by a surface 22. The surface 22 is treated to provide a smooth and flat finish desirable and necessary for providing a seal with subsequently installed plumbing fixtures (not shown) for the drain. Further, a thickness 54 (
Referring to
Referring to
The pointers 38 include threads received within the lateral bars 50, 51. Threading inward and outward of the pointers 38 adjust the distance 25 between the spaced apart first and second planes 24, 26. Each of the pointers 38 includes pointed tips 40 for penetrating the uncured layer and abutting the cured or substantially cured second layer 16. As appreciated, the illustrated embodiment includes three layers; however many other layers can be provided and are within the contemplation of this invention. The tips 40 minimize penetration and disruption to the third layer 18 such that upon curing no significant inconsistency is visible to disrupt desired structural features of the completed bathtub 10. The device 30 further includes handles 44 for manipulating and applying a force to displace and form the surface 22.
Referring to
A force indicated by arrows 52 is applied to the handles 44 downwardly to push the device 30 onto the bathtub 10. The pointers 38 and specifically the tips 40 penetrate the third layer 18 and abut against the substantially cured and rigid underlying second layer 16. The underlying second surface 16 provides a rigid and positive location on which the device 30 can sit.
The distance 25 between the first plane 24 and the second plane 26 corresponds with a desired thickness 54 between the show side surface of the first layer 14 and the surface 22. The thickness 54 provides for the assembly of a drain assembly and is desired to be maintained within predetermined and desired tolerances. The pointers 38 may be adjusted as desired to tailor the thickness 54 to process parameters and application specific requirements.
Referring to
Referring to
The device 30 and method according to this invention provides for the preparation and treatment of the surface 22 without the need for waiting until the third layer is fully cured, as would be required by grinding operations. Further, the device 30 provides significant control over the formation of the surface and the desired thickness to provide consistent thickness and surface preparation for the subsequently installed plumbing fixtures.
Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
