MOLD HAVING AN INSERT FOR MOLDING BATHTUBS, A METHOD OF MOLDING THE SAME AND A BATHTUB MADE BY SAID METHOD

Abstract: A method of molding and a mold for making bathtubs are disclosed. The mold includes a mold receptor and an insert attached to the mold receptor face. The mold receptor receives a shell which has a finish side and a non-finish side. The shell is placed in the mold receptor leaving a void between the non-finish side of the shell and the face of the receptor. The insert is attached to the face of the mold receptor to reduce the cross-sectional area of a portion of the space between the shell and mold receptor face. A male mold engages the finish side of the shell, sealably retaining the shell to the mold receptor. A polymeric foam material is introduced into the void between the receptor and the shell. The polymeric material fills the void and coats the shell. The molded bathtub is then removed from the mold receptor after the male mold has been removed. The insert is then removed leaving an area of reduced thickness and a periphery on the non-finish side of the molded bathtub which defines a lip.

Description: MOLD HAVING AN INSERT FOR MOLDING BATHTUBS, A METHOD OF MOLDING THE SAME AND A BATHTUB MADE BY SAID METHOD Inventors: Ron Marsilio and John C. Perantoni BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to molded articles and 10 process for molding the same involving the use of an inse attached to a mold. 2. Background of the Related Art In the development of bathtubs, porcelain-cast ir I K J fixtures have gradually been replaced by lighter and mo resilient component structures. One of the difficulties wi the porcelain-cast iron and enamelled fixtures has been the susceptibility to impact damage and their extreme weig 20 which makes movement and installation of large fixtures su as bathtubs and whirlpool tubs difficult. The porcelain-ca iron fixtures did have the advantage of having a very sol feel and high weight bearing capability. 5 Initial attempts by the industry to replace the porcelain-cast iron fixtures proved difficult. The th stainless steel fixtures were lighter than the porcelai 0 cast iron fixtures but did not have the solid feel structural strength required for large articles such bathtubs and whirlpool tubs. The early composite structur 5 have a plastic, hollow feel and would deform, crack, chip o de-laminate when subjected to impact, thermal shock or th weight of the typical bather. Additionally, their productio required the use of a large amount of polymeric materia which increased the weight of a tub and increased the cost o manufacture. Furthermore, certain polymeric materials o resins shrink upon curing. This resulted in bowing, warpag and distortion of the tubs. Reinforced grids have been used to add strength an rigidity to the surface of bathtubs. For example, U.S Patent No. 2,820,228 describes the reinforcement of a bathtu by a gridwork secured to the bottom of the tub. The gridwor may also extend to the sides of the tub in order to deade vibrations in the sides of the tub. Although the gridwor adds strength, it also adds weight and requires additiona steps in the manufacturing process. Various references have been described for creating cavity in a molded article. For example, U.S. Patent Nos 3,610,563, 3,674,394 and 3,368,239 describe methods fo forming articles, such as tanks and molded hollow articles During the molding operation, a balloon or tube expand resulting in the production of a hollow article. None o these patents however relate to the formation of composi baths or whirlpools, but rather describe the formation of cavity for the purpose of creating a hollow object, such as ^nk. German Patent DT 2951091 teaches the formation of plastic bathtub which has parallel tubes extending the lengt of the flange which tubes may be filled with foam or othe materials. The purpose of the tubes is to add rigidity t the tub and reinforce the structure, taking the place o heavy steel rods which were formerly used to reinforce th tub. The tubes are only useful in areas having a larg cross-section, and may be difficult to insert during th molding process. Commonly assigned United States Patent No. 4,664,092 t Genovese et al. and Patent Application Serial No. 07/400,28 to Kuszaj et al., both of which are incorporated by referenc herein, describe polymeric foam backed enameled-carbon stee or stainless steel plumbing fixtures that are resistant t chipping, cracking, crazing, de-lamination or deformatio when subjected to impact from either the finish or non-finis side. The use of the aforementioned composite molde structures results in fixtures which have the feel o porcelain-cast iron and enamel fixtures, high impac strength, and resistance to delamination. These composit structures possess excellent physical and mechanica properties as a result of the chemical bonding of th reinforced foamed polymeric layer to the enameled steel o stainless steel shell. A problem with such fixtures however, is that a large amount of polymeric material i used in certain portions of the tubs, resulting in increase weight and increased costs. In addition, in the portion having increased cross-sectional areas of polymeric material the fixtures still suffer problems due to distortion, bo and warpage from the shrinkage of the polymeric material a it cures. They also suffer distortion, bow and warpage i these thicker portions due to the inability of the polymeri material to release heat and gas produced during the curin process. Another approach was to replace the enamelled-stee shell with a polymeric-cosmetic surface layer and bindin that layer directly to a foamed plastic substrate to provi a high impact strength, delamination-resistant structur This approach is disclosed in commonly assigned U.S. Pate Nos. 4,844,944 and 4,844,955, both to Graefe et al., t disclosures of which are incorporated by reference herei These approaches suffer from the same problems describ above with regard to U.S. Patent No. 4,664,092 a Application Serial No. 07/400,280. Accordingly, none of the related art describes method for molding fixtures which allows for the reduction weight and/or thickness of a portion of the molded fixtu while alleviating the problems of distortion, bowing a warpage which existed in the prior molding techniques. It is therefore an object of the present invention provide a lightweight composite plumbing fixture such as bathtub which does not suffer the warpage, bowing a distortion problems associated with the shrinkage polymeric material. It is also an object of the present invention provide a mold for making a plumbing fixture such as bathtub which does not suffer the warpage, bow a distortion problems associated with the shrinkage polymeric materials in areas having a relatively large cro section. SUMMARY OF THE INVENTION These and other objects are achieved by the prese invention which provides a method for molding articles, su as bathtubs and whirlpool tubs. An apron insert is removab attached to a front mold receptor face. A bathtub she which has been suitably primed on its non-finish side placed in the mold receptor leaving a void between the mo receptor face and the non-finish side of the bathtub shel The apron of the shell is positioned parallel to the fro mold receptor face and attaches to the apron insert leaving void for introducing a hardenable polymeric foam. The she is sealably retained to the mold receptor by lowering a ma mold closing means which engages the finish side of t bathtub shell including the shell reservoir and shell dec Two side doors are closed to form sealed molding channe about a small brace and a large brace of the bathtub shell. The front apron door sealably engages the finish side of t , apron and seals to the rim of the male mold closing means an to the side doors, thus forming a sealed continuous injectio molding cavity for the introduction of the hardenabl r- polymeric foam. The polymeric foam is introduced unde pressure through an aperture in the mold receptor and fill .the molding cavity. It is preferred to maintain t temperature of the hardenable polymeric foam in the range 10 about 85" to 105°F., preferably at about 95"F. The mo receptor and insert are suitably made from a good he conducting material, preferably a metal such as aluminu The temperature of the mold receptor is preferably regulat !_; J at the preferred temperature range. The mold receptor a apron insert suitably may be coated with a non-sti material, such as Teflon which does not compromise their he conducting characteristics. After the molded polymeric fo 20 has sufficiently hardened, the apron door and the side doo are opened and the male mold closing member is retracte The molded bathtub is lifted partially out of the mo receptor by ejectors. The ejectors force the molded batht 25 and apron insert upwards, causing a chamfered surface in recess of the attachment face of the apron insert to for spring biased protrusions into an opening in the front mo 30 receptor face. After the molded bathtub and apron insert a removed from the mold receptor, an insert removal tool attached to the threaded aperture in the attachment face the apron insert. The insert removal tool has a lever a 35 - and a threaded protrusion which is rotatably inserted int the threaded aperture, and a suitable force is applied to th lever arm to pop the apron insert out of the hardene j - polymeric foam. The molded article of the present invention preferabl includes a bathtub or whirlpool tub which has a dec surrounding a reservoir. A layer of polymeric foam is molde 0 to a non-finish side of the bathtub shell. The molde bathtub also includes an apron which extends downwardly fro one side of the deck until it terminates at an inwardl curved shell lip. Suitably, the apron is supported by tw braces, a small inner brace, and a larger outer brace on bot the front and rear ends of the bathtub which exten diagonally upwards from the ends of the apron to the fron and rear of the deck. In an alternative embodiment a web o polymeric material extends between the middle of th reservoir and the middle of the apron. The polymeric foa material on the non-finish side of the apron includes rectangular area of reduced thickness covering most of th surface of apron. The area of reduced thickness i surrounded on each side of its periphery by a lip having chamfer of approximately 45°. The bathtub shell has a interior finish side and an exterior non-finish side Preferably the apron of the shell includes an inwardly bowe region near the bottom of the apron. The bathtub shell i preferably constructed from steel which has been coated wit _ an enamel on both its finish side and non-finish side. another preferred embodiment the bathtub shell may be ste which has not been coated with enamel on its non-finish sid _. or the bathtub shell may be constructed from stainle 5 steel. Alternatively the bathtub shell may be constructed a polymeric, fiberglass and/or composite materials. In alternative preferred embodiment, the molded bathtub of t 0 present invention, the area of reduced thickness is alter to follow the contour of the apron near the bowed regi forming a deeper contoured lip which is contiguous with t portion of the chamfered lip at the bottom of the area 5 reduced thickness. In another alternate embodiment, t molded bathtub includes an area of reduced thickness in t polymeric foam which extends upwardly past the apron a curves at about a 90" angle to follow the contour of t 0 deck. The area of reduced thickness which parallels t deck, is preferably about one-half (.) as thick as the ar surrounding it. The chamfered lip surrounds the periphery the area of reduced thickness which extends under the deck. 5 The bathtub of the present invention is made utilizi a mold press. The mold press includes a platform onto whi a mold receptor is mounted. The mold receptor is adapted f 0 receiving a bathtub shell, leaving a void between the no finish side of the shell and the mold receptor face. A ma mold closing member fits into the bathtub reservoir a engages the finish side of the bathtub shell deck, seali 5 the shell to the mold receptor and forming a closed cavit between the mold receptor and the non-finish side of th shell. The male mold closing member is retained against th bathtub shell and the mold receptor during the moldin process. The mold receptor includes a mold receptor face fo forming a void between the mold receptor and the non-finis side of the bathtub shell apron. The mold receptor als includes a front apron door to sealably engage and hold th apron of the bathtub shell to the mold receptor during th injection molding process. Two side doors are also include each has channels for molding of the polymeric foa surrounding the small brace and the large brace respectively. The side doors sealably engage and hold th bathtub shell to the mold receptor during the injectio molding process. An aperture in the mold recepto communicates with a mix head for introducing the hardenabl polymeric foam into the void created between the mol receptor face and the bathtub shell. A plurality of ejector are positioned in the mold receptor and serve to separate an eject the molded bathtub from the mold receptor after th molding process has been completed. An apron insert i removably attached to the front mold receptor face. Th insert is shaped to reduce the cross-sectional area of th void formed between the front mold receptor face and the non finish side of the apron of the shell. The insert i bevelled around its periphery at an angle of about 45°. Th τ_ bathtub shell is placed within the mold receptor with th apron positioned along the front mold receptor face and apro insert. In an alternative embodiment, the apron inser c - includes an aperture which communicates with a correspondin aperture in the mold receptor for molding a ' polymeric foa web. A recess in the attachment face of the apron inser receives a protrusion which extends from the front mol 0 receptor face. Protrusion is controllably biased f .extension from or retraction into the front mold recept face. In th -preferred embodiment, the protrusion is angl at an acute angle of about 45" from the front mold recept 5 face, upwards (i.e., away from the direction of gravity) The protrusion extends from an opening in the front of mo receptor face and includes a plunger face which is forc outwardly by a spring until it meets the rim of the openin 0 A recess in the attachment face has a lower chamfer surface which matches the angle of the protrusion. The apr insert, molded polymeric foam and shell lip present a smoo flat surface to the front mold receptor face allowing t 5 molded bathtub and apron insert to smoothly slide upward out of the mold receptor. There are two alterna embodiments of the apron insert. A preferred alterna 0 apron insert has a contoured region for forming a contour lip. The contoured region forms an area of reduced thickne that follows the contour of the apron and does not leave region of increased thickness near the bowed region of t 5 apron. Another alternative embodiment of the insert includ an upper portion forming an area of reduced thickness und the deck. The upper portion of this alternative insert res on top of the mold receptor which is positioned adjacent the front mold receptor face and under the deck of the shel For a better understanding of the present inventio reference is made to the following description, taken conjunction with the following figures, the scope of which pointed out in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS Figure IA is a bottom perspective view of a batht made according to the present invention showing the polymer molded non-finish side. Figure IB is a side elevational view of the batht illustrated in Figure IA. Figure IC is an enlarged vertical cross-sectional vi of the bathtub illustrated in Figure IB shown in t direction of the arrows. Figure ID is a rear elevational view of the batht illustrated in Figure IA. Figure 2A is a top perspective view of a bathtub she used with the present invention showing the finish side. Figure 2B is a bottom perspective view of the batht shell illustrated in Figure 2A having the non-finish side. Figure 2C is a rear elevation view of the bathtub shel illustrated in Figure 2A. Figure 3A is an enlarged fragmentary view of the apro portion of the bathtub made in accordance with -the presen invention illustrated in Figure IC. Figure 3B is the same view as Figure 3A illustrating bathtub which was molded without the insert of the prese invention. Figure 3C is the same view as Figure 3 illustrati an alternative preferred embodiment of the present inventio Figure 3D is the same view as Figure 3A, illustrati still another alternative embodiment of the prese invention. Figure 4A is a fragmentary cross-sectional view showi the apron portion of the bathtub illustrated in Figure 3A a mold of the present invention. Figure 4B is an enlarged fragmentary view of a spri plunger mechanism for attaching an apron insert to a mo receptor face illustrated in Figure 4A. Figure 4C is the same view as Figure 4A illustrati the alternative preferred embodiment of Figure 3C and t other alternative embodiment of Figure 3D (shown phantom) . Figure 5A is a rear elevational view of the prese invention illustrating the side which contacts the mo receptor face. Figure 5B is an enlarged vertical cross-sectional vi ■i illustrating a recess for mounting the insert, shown in th direction of the arrows. Figure 5C is a front elevational view of the apro r - insert shown in 5A, illustrating the side which faces toward the apron of the bathtub shell. Figure 5D is an enlarged vertical cross-sectional vie of a threaded aperture for removing the insert, shown in th 0 direction of the arrows. Figure 5E is the same view as Figure 5A of a alternative apron insert having a slot for forming a web. Figure 6A is a schematic front elevational view of y 5 bathtub molding apparatus in accordance with the presen invention. Figure 6B is a top perspective view of a preferred mol receptor. 0 Figure 6C shows the mold receptor of 6B with an apro insert mounted in place. Figure 6D shows the mold receptor and apron inser illustrated in Figure 6C with a shell in place. 5 Figure 7A is an assembly view of an insert remova tool and threaded aperture of the apron insert in accordanc with the present invention. 0 Figure 7B is a partial breakaway view illustrating th insert removal tool threadably engaged to the threade aperture of the apron insert illustrated in Figure 7A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A molded bathtub .10. made in accordance with the presen invention is shown in Figs. IA, IB, IC and ID. The molde - bathtub 10. has a deck 12 surrounding a reservoir 14, an polymeric foam 15 molded to a non-finish side 26 of th bathtub shell 22. illustrated in more detail in Figures 2A an 2B. The molded bathtub 1_) also includes an apron 20. Apro 0 20 extends downwardly from one side of the deck 12 until i terminates at an inwardly curved shell lip 17. In t embodiment illustrated, the shell lip 17 terminates th apron 20 at about the lowest level of the outside of t 5 reservoir 14, however, in an alternative embodiment (n shown) the apron 20 may terminate either above or below t level of the bottom of reservoir 14. The apron 20 supported by two braces, a small inner brace 18, and a larg 0 outer brace 19 on both the front and rear of the bathtub 1 which extend diagonally upwards from the ends of the apron to the front and rear of the deck 12. In an alternati _,_ embodiment a web of polymeric material 21 extends between t middle of the reservoir and the middle of the apron, (sho in phantom in Figure IC) to further support apron 20. T polymeric foam material 15 on the non finish side 26 of apr 30 20 includes a rectangular area of reduced thickness covering most of the surface of apron 20. The area reduced thickness 13 is surrounded on each side of i periphery by a lip 16 having a chamfer of approximately 45 35 -. The molded bathtub ,10 can of course be adapted to fo a whirlpool tub by the drilling of appropriately plac holes in the reservoir 14. The molded bathtub IQ. s made _. molding the polymeric foam 15 onto the non finish side 26 bathtub shell 2_2. Bathtub shell J22. is illustrated in deta in Figures 2A, 2B, and 2C. Bathtub shell 2_2 has an interi finish side 24 and an exterior non-finish side 26. The no 0 finish side 26 is not ordinarily exposed to view aft illustration, while the finish side 24 is normally seen a contacted by the user after the bathtub has been installe Preferably the apron 26 of shell 22. includes an inward bound region 28 at the bottom of apron 20 a few inches abo shell lip 17. Bathtub shell .22. is preferably constructed from ste which has been coated with an enamel on both its finish si 24 and non-finish side 26, as disclosed in commonly assign U.S. Patent No. 4,664,982 to Genovese et al., the disclosu of which is incorporated by reference herein. In anoth preferred embodiment the bathtub shell 22. may be steel whi has not been coated with enamel on its non-finish side 26 or the bathtub shell 22, may be constructed from stainle steel as disclosed in commonly assigned U.S. Pate Application Serial No. 07/400,289 to Kuszaj et al., t disclosure of which is incorporated by reference herei Alternatively bathtub shell 22. may be constructed of a , polymeric, fiberglass and/or the composite materials a disclosed in commonly assigned U.S. Patent No. 4,844,944 an 4,844,955 to Graefe et al., the disclosures of which ar incorporated by reference herein. Likewise, the respectiv polymeric foam 15 and primer suitable for each of th respective bathtub shell 22. constructions is also describe in detail in the aforementioned U.S. Patent Nos. 4,664,982 0 4,844,944 and 4,844,955, as well as in U.S. Applicatio Serial No. 07/400,289 all of which have been incorporated b reference herein. The term polymeric foam 15 and "hardenabl material" include all material suitable for making the molde ^^ articles contemplated by the present invention. Figure 3A is an enlarged fragmentary view showing th details of a vertical cross-section through the apron .2 portion of the molded bathtub JLO as illustrated in Figure 0 (the optional web 21 showing in phantom in Figure IC is n shown) . Figure 3B is shown for the sake of comparis illustrating the excess polymeric foam material 15 molded the apron 20 in the absence of the present invention. Figu 5 3D illustrates an alternative preferred embodiment of t molded bathtub .10. of the present invention, which is simil to that shown in Figure 1A-1D and figure 3A, except that t 0 area of reduced thickness 13 is altered to follow the conto of the apron 20. near the bowed region 28 forming a deep contoured lip 30 which is contiguous with the portion of t chamfered lip 16 at the bottom of the area of reduc 5 ., thickness 13. In another alternate embodiment of molde bathtubs 10, illustrated in Figure 3D the area of reduce thickness 13 in the polymeric foam 15 extends upwardly pas _. the apron 20 and curves at about a 90° angle to follow th contour of the deck 12. The area of reduced thickness whic parallels the deck 12, designated 32, is preferably abou one-half (.) or less as thick as that portion of the inser 10 which lies parallel to the apron 20. As in the embodimen illustrated in Figure 3C, the chamfered lip 16 surrounds th periphery of the area of reduced thickness 13 which extend under the deck 12. it . . . ■ ^ The bathtub of the present invention is made utilizin a mold press 100 illustrated in Figure 6A. Mold press 10 includes a platform 80 onto which a mold receptor 52 i mounted. A mix head 82 is positioned below platform 80 fo 20 injecting the polymeric foam 15 through a conduit in platfor 80 and into the mold receptor 52. Mold receptor 52 i adapted for receiving bathtub shell 22. leaving a void betwee the non-finish side 26 of the shell .22. and the mold recepto 5 face 84. A male mold closing member 54 has a rubbery elastomeri surface which snugly fits into the bathtub reservoir 14 an 0 deck 12 on the finish side 24 of the bathtub shell 22 sealing the shell .22. to mold receptor 52 and forming a close cavity between the mold receptor face 84 and the shell's non finish side 26. The male mold closing member 54 also help 5 - to minimize warp, bowing and distortion of the bathtub shel during the injection molding process. A hydraulicall operated system 85 lowers and retains the male mold closin _. member 54 against the bathtub shell 2J_ and mold receptor 5 during the molding process. A mold press 100 which i suitable for molding bathtubs including the presen invention is manufactured by Linden Industries, Inc. A 0 illustrated in Figures 6B-6D, the mold receptor 52 includes mold receptor face 86 for forming a void between it and th non-finish side 24 of the bathtub shell apron 20. The mol receptor 52 also includes a front apron door which is cover - > with an elastomeric material to sealably engage and hold t apron 20 of the bathtub shell to the mold receptor 52 duri the injection molding process. Two side doors 56 are cover with elastomeric material, as in the apron door 58, ea 0 side door includes channels 56A and 56B for molding of t polymeric foam surrounding the small brace 18 and large bra 19, respectively. As with the apron * door 58, side doors sealably engage and hold the bathtub shell to mold recept 5 52 during the injection molding process. An aperture 51 in mold receptor 52 communicates wi the mix head for introducing the hardenable polymeric fo 0 into the void created between the mold receptor face 84 a the bathtub shell £2 . . A plurality of ejectors 60 a positioned in the mold receptor 52 which serve to separa and eject the molded bathtub lj) from the mold receptor 5 - after the molding process has been completed. Preferably the ejectors are cylindrical rods which are hydraulicall activated, from a recessed position to an ejected positio _. (shown in Figure 6B) and vice versa. As shown in Figure 6C, an apron insert 34 is removabl attached to the front mold receptor face 86. The insert __ is shaped to reduce the cross-sectional area of the voi 10 formed between the front mold receptor face 86 and the non finish side 26 of the apron 20 of shell H. The insert 34 i bevelled around its periphery 16 at an angle of about 45° As illustrated in Figure 6D, the bathtub shell 22 is place it; . . . , J within the mold receptor j51 with the apron 10 positione along the front mold receptor face 86 and apron insert 3 (shown in phantom) . The preferred apron insert is illustrated in Figure 0 5A-5D. Figure 5A shows the attachment face 35 of the apro insert 34 which contacts the front mold receptor face 86 The smaller, opposite molding face which faces toward th apron 20 is shown in Figure 5C. In an alternative embodimen 5 another apron insert 3_9 includes an aperture 49 whic communicates with a corresponding aperture in the mol receptor 52 for molding a polymeric foam web 21 described 0 supra (shown in phantom in figure IC) . The periphery o apron insert 34 is bevelled at approximately a 45° angle o the side of the molding face 36. The apron insert 34 may b attached to the front mold receptor face 86 by an 5 -, convenient means, including mechanical, hydraulic, suction o magnetic attachment means. A preferred mechanical attachmen includes a recess 40 in the attachment face 35 ϊor receivin -• a protrusion, as illustrated in Figure 5A, and in th enlarged vertical cross-sectional view in Figure 5B. After the molded bathtub has been removed from the mol receptor 52, the apron insert is removed from the hardene 0 polymeric foam 15 and the apron 20 by using a removal too which attaches to a threaded aperture 38 in the attachmen face 35 of the apron insert 34, which is illustrated i Figures 5A, 7A and 7B. 5 ■ * The apron insert 34 is removably attached to the fron mold receptor face 86 of mold receptor 52. As illustrated i Figures 4A and 4B, recess 40 in attachment face 35 of th apron insert receives a protrusion 42 extending from th 0 front mold receptor face 86. Protrusion 42 is controllabl biased for extension from or retraction into the front mol receptor face 86. The controlled biasing of protrusion 4 may be by electro-mechanical, mechanical, hydraulic or oth 5 means. In the preferred embodiment illustrated in Figur 4A and 4B, the protrusion is angled at an acute angle about 45° from the front mold receptor face 86, upwar 0 (i.e., away from the direction of gravity). The protrusi 42 extends from an opening in front of mold receptor face and includes a plunger face 44 which is forced outwardly spring 45 until it meets rim 46 of opening 43. Recess 40 5 -, the attachment face 35 has a lower chamfered surface 4 which matches the angle of the protrusion 42. After th molded polymeric foam 15 has sufficiently hardened, the mal r - mold closing member 54 is lifted from the finish side 24 o the molded bathtub H), and the side doors 56 and front apro door 58 are open. The molded bathtub 3.0 is then force vertically upwards by the ejectors 60 partially out of th mold receptor 52. When the molded bathtub 10. is ejected the chamfered surface 41 of the recess 40 in the attachmen face of the apron insert 34 forces the spring biase protrusion 42 into the opening 43 in the front mold recepto face 86, thus releasing the apron insert 34 from the fron mold receptor face 86. The apron insert 34, molde polymeric foam 15 and shell lip 17 present a smooth fla surface to the front mold receptor face 86 allowing th molded bathtub _L0. and apron insert 34 to smoothly slid upwardly out of the mold receptor 52. Two alternative embodiments of the apron insert 3_1 ar illustrated in Figure 4C. The first preferred alternat apron insert 34A has a contoured region for forming th contoured lip 30 illustrated in Figure 3C. The advantage o this insert is that it forms an area of reduced thicknes that follows the contour of the apron 20 and does not leave region of increased thickness near the bowed region 28 o the apron 20. The other alternative embodiment of the inser 34B, has a lower portion which may be the same as eithe -2_- •1 insert 34 or 34A and also includes an upper portion (shown i phantom) for forming the area of reduced thickness .under th deck 12, as illustrated in Figure 3D. The upper portion o r- this alternative insert 34B rests on top of the mol receptor 52 which is positioned adjacent to the front mol receptor face 86 and under the deck 12 of shell 22. After the molded bathtub .10. and attached apron inser 0 3__ is removed from the mold receptor 52 using an inser removal tool _7 having a handle __8 through which a threade protrusion 46 is rotatably attached, as illustrated in Figur 7A. The threaded protrusion is threadably engaged into th 5-^ threaded aperture 38 in the attachment face 35 of the apro insert 34 by rotating handle 48. A force is applied to th lever arm 46 of the insert removal tool 7_7 to pop the apro insert out of the hardened polymeric foam 15 in the apro 0 20. In the process of making the molded bathtub 10 according to the present invention, apron insert 34 i removably attached to the front mold receptor face 86 b 5 inserting protrusion 42 into each recess 40 in the attachme face 35 of the apron insert 34. Prior to molding the mol receptor face 84 and apron insert are spray coated with 0 suitable mold release agent, preferably a silicone releas agent. Additionally, prior to each day of molding, t entire mold surface is waxed. A bathtub shell 22. which h been suitably primed on its non-finish side 26 preferab 5 -. with a silicone or other suitable molding primer is placed i mold receptor 52 leaving a void between the mold recepto face 84 and the non-finish side 26 of the bathtub shell 22 -. The apron 20 of shell 22. is positioned parallel to the fron mold receptor face 86 and attaches apron insert 34, leavin a void for introducing polymeric foam 15. The shell 22. i sealably retained to the mold recepto 52 by lowering a male mold closing means 54 which engage the finish side of the bathtub shell 22 including reservoi 14 and deck 12. Two side doors 56 are closed to form seale molding channels 56A and 56B about small brace 18 and larg brace 19 of bathtub shell 22- Front apron door 58 sealabl engages the finish side 24 of apron 20 and seals to the ri of male mold closing means 54 and side doors 56 thus formin a sealed continuous injection molding cavity for th introduction of polymeric foam 15. The hardened polymeric foam 15 is introduced from th mix head 82 through the aperture in the bottom of mol receptor 52 to fill the . molding cavity by the hardenabl polymeric foam 15 injected under suitable molding pressure It is preferred to maintain the temperature of th hardenable polymeric foam material 15 in the range of abou 85° F. to 105 β F., preferably, at about 95°F. The curing o the polymeric foam material 15 is exothermic, so tha initially the temperature of the mold receptor 52 must b raised, and later during the curing the mold receptor 5 -■ should be cooled. In order to accomplish this dual tas the mold receptor 5 should be made from a good he conducting material, preferably a metal such as aluminu r- Optionally, the mold receptor face 84 may be coated with layer of non-stick material, such as Teflon which does n retard its heat conducting properties. The cooling a heating of the mold receptor 52 is preferably accomplish 0 using a water jacket or other suitable heat reservo maintained at the preferred temperature range. Since t apron insert 34 contacts a large surface of the polymer foam 15, preferably, the apron insert 34 is also construct 5 of a good heat conducting material, such as aluminum. with the mold receptor face 84, the apron insert 34 may coated with a layer of non-stick material, such as Tefl which does not retard its heat conducting properties. Th 0 serves to improve the flow of the polymeric foam and hel reduce wet spots, choking and uneven flow of polymeric fo " 15 reducing distortion in the apron 20 of the molded batht 10. 5 After the molded polymeric foam 15 has sufficient hardened, the apron door 58 and the side doors 56 are open and male mold closing member 54 is retracted. The mold 0 bathtub 10. is lifted partially out of the mold receptor 52 hydraulic ejectors 60. The ejectors 60 force the mold bathtub 10 and apron insert 34 upwards, causing the chamfer surface 41 in recess 40 of the attachment face 35 of t 5 • apron insert to force spring biased protrusions 42 in opening 43 in the front mold receptor face 86. The mold bathtub IjD. and apron insert are then manually r - mechanically removed from the mold receptor 52. An insert removal tool 77 is attached to the thread aperture 38 in the attachment face 35 of the apron inse 34. The insert removal tool 7_7 has a lever arm 46 and 10 threaded protrusion 47 which is rotatably inserted into t threaded aperture 38 by means of handle 48, as illustrated Figures 7A and 7B. After attachment of the thread protrusion 47 into threaded aperture 38, a suitable force 15 applied to lever arm 46 to pop the apron insert out of t hardened polymeric foam 15. Thus, while there have been described what a presently contemplated preferred embodiments of the prese 20 invention, further changes and modifications could be made those skilled in the art without departing from the scope the invention, and it is contemplated to claim all su __. changes and modifications. 30 5

Claims: WE CLAIM: 1. A molded article comprising a shell . having a interior non-finish side and exterior finish side, the non finish side being coated with a polymeric material, said non finish side having an area of reduced thickness and periphery of said area of reduced thickness comprising lip. 2. The molded article of Claim 1 wherein said shel includes a reservoir and an apron, and wherein the peripher is formed in said polymeric material on the interior non finish side. 3. The molded article of Claim 2, wherein said lip i on a side of the periphery of said apron portion. 4. The molded article of Claim 1, wherein said molde article is a bathtub or whirlpool tub. 5. The molded article of Claim 1, wherein sai exterior finish side is coated with a ceramic material. 6. The molded article of Claim 1, wherein said shel is constructed of a metal, plastic, fiberglass or polymeri material. 7. The molded article of Claim 6, wherein said meta is steel or stainless steel. 8. The molded article of Claim 2, wherein said area o reduced thickness of polymeric material on said non-finis side follows the contour of said apron. 9. The molded article of Claim 1, further comprisin an area of reduced thickness extending from an apron portio of the molded article to a deck portion of the molde article. 10. A mold for manufacturing molded article comprising: a) a mold receptor for receiving a shell having finish side and a non-finish side, said receptor receivin said shell so as to define a void between the non-finis side of said shell and a face of said receptor; and b) an insert which is attached to said face of th mold receptor, said insert shaped to reduce the cross sectional area of a portion of a void between said shell an said mold receptor face. 11. The mold of Claim 10, further comprising a mol closing means adapted for removably engaging the finish sid of said shell and sealably retaining said shell to said mol receptor. 12. The mold of Claim 10, wherein said insert removably attached to the face of the mold receptor. 13. The mold of Claim 10, wherein said insert has attachment face communicating with said mold receptor fa and a molding face on the opposite side of said insert, sa insert having a bevelled edge on the periphery of sa molding face tapering towards said mold receptor face. 14. The mold of Claim 13, wherein said bevelled ed tapers at an angle of about 45°. 15. The mold of Claim 10, wherein said attachment mea is selected from the group consisting of mechanica hydraulic, suction and magnetic attachment means. 16. The mold of Claim 15, wherein said attachme means comprises a protrusion extending from said mo receptor face and a recess in said insert for receiving sa protrusion. 17. The mold of Claim 16, wherein said attachme means comprises a protrusion controllably biased f extension from or retraction into said mold receptor face a a recess in said insert for receiving said protrusion. 18. The mold of Claim 17, wherein said protrusio extends at an acute angle with respect to the mold recepto face, and away from the direction of gravity. 19. The mold of Claim 18, wherein said acute angle i approximately 45°. 20. The mold of Claim 10, wherein said mold recepto includes ejection means for removing the molded article fro the mold receptor after completion of the molding process. 21. The mold of Claim 10, wherein said insert include an opening for the passage of the hardenable material whic is contiguous with an opening in said mold receptor face. 22. The mold of Claim 21, wherein said opening in th insert is approximately at the center of said insert. 23. The mold of Claim 10, further comprising an apro door, said apron door having an open position and a close position, said apron door sealingly engaging the finish sid of an apron of said shell opposite said insert when sai apron door is in the closed position. 24. The mold of Claim 23, wherein said mold recept further comprises an additional face, said additional fa being positioned approximately normal to said first face. 25. The mold φf Claim 24, wherein said additional fa is adapted to receive a brace on a side of said she extending between said apron and a surface of said shell. 26. The mold of Claim 25, further comprising a doo having an open position and a closed position sealab engaging said additional face, said door having a chann for molding hardenable material about said brace when in t closed position. 27. The mold of Claim 10, wherein said mold recept and said insert are constructed of materials which all rapid thermal conductivity. 28. The mold of Claim 10, wherein said mold recept and said insert are coated with a non-stick material. 29. The mold of Claim 28, wherein said non-sti material is selected from the group consisting of releasing agent, Teflon coating, wax coating, and silic coating. 30. The mold of Claim 10, wherein said insert includ a means for removing said insert from the molded article. 31. The mold of Claim 30, wherein said means fo removal comprises an attachment means for attaching to removal tool. 32. The mold of claim 31, wherein said attachment mean comprise a threaded aperture in said insert, and sai removal tool comprises a threaded protrusion for threadabl engaging said aperture in said insert. 33. The mold of Claim 32, further comprising a leve arm into which said threaded protrusion is rotatably mounted 34. A method for molding an article, comprising: a) attaching an insert onto a face of a mol receptor; b) loading a shell for receiving a layer o hardenable material onto said mold receptor, leaving a voi between said mold receptor and a side of the shell, and void between said insert and side of said shell; c) introducing hardenable material into said void; an d) removing a molded article including the shell coated with hardened material from said mold receptor. 35. The method of Claim 34, wherein said insert i removably attached to said face of the mold receptor. 36. The method of Claim 34, further comprising removin said insert from said hardened material, leaving an area o reduced thickness of hardened material on said shell and periphery of said area of reduced thickness comprising lip. 37. The method of Claim 34, further comprisin maintaining the temperature of said mold receptor in th range of about 85° to 105°F. 38. The method of Claim 34, wherein said shel comprises a component of a plumbing fixture having an apron. 39. The method of Claim 38, wherein said shell include a reservoir and an apron extending from said edge of sai reservoir. 40. The method of Claim 34, wherein said hardenabl material is selected from the group consisting of plasti polymeric material, composite and fiberglass. 41. The method of Claim 36, further comprisi attaching a removal tool to said insert and applying a for to said removal tool sufficient to remove said insert fro said hardenable material. 42. The method of Claim 41, further comprisin rotatably inserting a threaded protrusion of said remova tool into a threaded aperture in said insert. 43. The method of Claim 39, further comprising sealabl retaining said shell to said mold receptor. 44. The method of Claim 43, wherein said shell i sealably retained to said mold receptor by engaging sai shell to said mold receptor with a mold closing means. 45. The method of Claim 44, wherein said mold closin means sealably engages said shell reservoir and apron. 46. The method of Claim 45, further comprising removin said mold closing means from said shell thereby allowin removal of the molded article from said mold receptor. 47. The method of Claim 35, wherein said insert i removably attached to said mold receptor face by placin said insert upon a protrusion extending from said mol receptor face, said protrusion fitting into a recess in sai insert. 48. The method of Claim 47, wherein said protrusio extends at an acute angle with respect to the mold recepto face, and away from the direction of gravity. 49. The method of Claim 47, further comprisin retracting said protrusion from the recess in said insert. 50. The method of Claim 34, further comprising removi said molded article from said mold receptor by ejection mea in said mold receptor. 51. The method of Claim 39, further comprising closi an apron door and a side door of said mold receptor sealab engaging said apron and reservoir of said bathtub shell. 52. The method of Claim 51, further comprising openi said apron door and said side door of said mold recept prior to removing said molded article. 53. The method of Claim 34, wherein the inse includes an opening for the passage of the hardenab material which is contiguous with an opening in said mo receptor face. 54. The method of Claim 53, wherein said insert openi is approximately in the center of said insert. 55. The method of Claim 34, further comprisin attaching said insert to an edge of said mold receptor, sai insert including a overhanging portion which attaches to a upper edge of said mold receptor for molding the non-finis side of a deck of said shell. 56. The method of Claim 39, wherein said insert has contoured surface which follows a face of said apron.

Inventors: MARSILIO RONALD M, PERANTONI JOHN C, MARSILIO, RONALD, M., PERANTONI, JOHN, C.
Applicants: AMERICAN STANDARD INC, AMERICAN STANDARD, INC.
Application year: 1990
Main classification: A47K3
IPC codes: A47K3, B29C33, B29C37, B29C70