Abstract: A polymeric composite structure having a polymeric shell layer with a finish-side and a non-finish side and a cross-linked thermosetting polymeric backing layer and method of manufacturing thereof is provided. The cross-linked thermosetting polymeric backing layer is simultaneously molded to conform to the shape of and bonded directly to essentially the entire non-finish side of the polymeric shell layer. The method includes forming the polymeric shell having a finish-side and non-finish side into a suitable shape, placing the shell into a mold, and introducing an uncured blended mixture of unsaturated thermosetting polymeric backing material and cross-linking promoter into the mold to force the backing material to directly coat the non-finish side of the shell.

Abstract: A polymeric composite structure having a polymeric shell layer with a finish-side and a non-finish side and a cross-linked thermosetting polymeric backing layer and method of manufacturing thereof is provided. The cross-linked thermosetting polymeric backing layer is simultaneously molded to conform to the shape of and bonded directly to essentially the entire non-finish side of the polymeric shell layer. The method includes forming the polymeric shell having a finish-side and non-finish side into a suitable shape, placing the shell into a mold, and introducing an uncured blended mixture of unsaturated thermosetting polymeric backing material and cross-linking promoter into the mold to force the backing material to directly coat the non-finish side of the shell.

Abstract: The present invention relates to an improved silane primer composition utilized to form multi-layer sanitaryware such as kitchen and bathroom fixtures. The silane primer composition includes N-2-(vinyl-benzylamino)-ethyl-3-aminopropyltrimethoxysilane monohydrogen chloride dissolved in a suitable carrier. Alternatively, the silane primer composition includes a silane coupling agent dissolved in a diluent-effective concentration of methoxypropanol.

Abstract: A composite structure, e.g. a plastic-backed enameled carbon steel or stainless steel finish product has high impact, delamination and thermal shock resistance. The composite structure is formed from a carbon steel or stainless steel shell having a finish side which may have a polished, ceramic, enameled, polymeric or metallic coating. On the other, non-finish side of the shell a layer of reinforced plastic is bonded directly to the steel or stainless steel shell using silane to form a laminated structure. The finish layer is resistant to deformation and delamination when subjected to relatively high impact applied directly to the finish or to the plastic layer surface, or when the composite structure is subjected to a sudden temperature change.

Abstract: A multilayer polymeric composite structure of high impact strength and delamination resistance possesses a polymeric cosmetic layer chemically bonded to a cross-linked, isocyanate-modified thermosetting polyester or polyether substrate layer. In one embodiment of the structure, a relatively thin, predominantly acrylic resin layer is chemically bonded through urethane linkages to a relatively thick, reinforced, polyester foam substrate layer. A reinforced reaction injection molding (RPIM) procedure for manufacturing the polymeric composite is also disclosed.

Abstract: A light weight, durable plumbing fixture, e.g., a bathtub, sink, shower receptor, etc., is fabricated from a multilayer polymer composite structure of high impact strength and delamination resistance. The composite possesses a relatively thin polymeric cosmetic, or finish, layer, e.g., of acrylic resin, chemically bonded to a relatively thick, reinforced, cross-linked, isocyanate-modified thermosetting polyester or polyether dense foam resin substrate layer.