Abstract: A molded tub and surround which is formed of a multiple of portions. Wall portions meet a tub portion at a joint with a retaining ledge which extends inward toward a tub bowl from a flange. A ledge interface within the bottom of the wall portions engages the ledge. An angled interface surface is located directly in front of the ledge and slopes downward toward the bowl. A shallow interface within the bottom of the wall portions engages the angled interface surface.

Abstract: The present invention is a tub and shower enclosure formed from three pieces. A wet wall, back wall, and dry wall are each formed separately. Living hinges connects the wet wall to one end of the back wall and the dry wall to the opposing end of the back wall. The hinges allow the wet wall and dry wall to be folded into positions that are generally parallel to the back wall for shipping.

Abstract: Shoulder supports extend from a shower enclosure wall and support a shower accessory. The shoulders have an attachment on the side for the shower accessories. The selected shower accessory would have a mating attachment on each of its ends to correspond to two shoulders extending from the enclosure walls. The attachment is preferably a male/female indentation on one of the shoulders and shower accessory and a corresponding attachment on the other. The indentations provide a non-permanent attachment of the shower accessory to the supports so that the chosen accessory may later be removed and replaced if desired.

Abstract: An open mold system provides various unique molds which are released from a plurality of staging queues and loaded onto a mold transportation circuit in relation to a particular customer order and transportation vehicle. A batch of molds are sequenced in an order in which a particular transportation vehicle is to be loaded. After each part is demolded, the molds are returned to their appropriate staging queues or storage areas. The parts are inspected and are sent to either a minor repair area, a major repair area, or directly to a trimming and packaging area. From the packaging area, the parts are moved to a relatively small shipping area where the batch of parts are already ordered to be effectively loaded directly onto the transportation vehicle. As the finished parts come off line in the batch particular to the transportation vehicle, a large shipping area and inventory area is avoided.

Abstract: A molded tub and surround which is formed of a multiple of portions. Wall portions meet a tub portion at a joint with a retaining ledge which extends inward toward a tub bowl from a flange. A ledge interface within the bottom of the wall portions engages the ledge. An angled interface surface is located directly in front of the ledge and slopes downward toward the bowl. A shallow interface within the bottom of the wall portions engages the angled interface surface.

Abstract: A seal for a bar mounted within a molded tub and surround. The seal includes a flexible flange and a tubular body extending therefrom. The seal provides a plurality of sealing surfaces which operate to engage the bar and aperture such that an effective redundant waterproof seal is provided. The flexible flange is generally perpendicular to the tubular body and is sized to cover any chips or cracks which may exist about the aperture and to accommodate a non-parallel, curved, and/or angled wall portion.

Abstract: A mold manufacturing system includes confining environmentally controlled applying operations to but a few area or a single area. The process airflow generated therefrom includes a substantially constant low flow with a high concentration of HAPs which maintains an auto-fired oxidizer system to provide more efficient and less expensive operation thereof.

Abstract: A packaging arrangement provides a top packaging panel and a bottom packaging panel which receives a tub portion and a first and a second wall portion of a tub and surround. The packaging arrangement provides a compact transportable unit which readily fits within a rather compact package. The packaging panels are preferably manufacture of Styrofoam or the like to absorb shock and protect the tub portion and wall portions. A tub slot is substantially U-shaped to receive a tub end. That is, tub slot receives the tub portion in a substantially vertical orientation in which the tub portion stands on end and is restrained between the panels. The first wall portion slot and the second wall portion slot are substantially L-shaped and are nested to form a larger U-shape within which the tub slot is arranged. That is, the tub slot forms an inverted U relative the orientation of the larger U-shape formed by the first and second wall portion slot.

Abstract: A multi-lap mold manufacturing system includes an overhead rail circuit upon which a multiple of molds transit a closed loop for a multiple of laps. The system is separated into Zones in which a particular mold operation is performed relative to which lap each of the plurality of molds has completed. At least one of the Zones is a spray Zone in which the mold is sprayed robotically. Robot utilization is extremely high as multiple spray operations occur in but a few spray Zones. Application of exceedingly expensive environmental emission control devices is at least partially mitigated by the reduced number of spray stations and the much smaller factory footprint. Consolidation of multiple spray operations into a few spray Zones also advantageously simplifies the control of chemical and ambient variables which improves production efficiencies and reduces operator dependency.

Abstract: A tub and shower surround assembly is initially molded as a single molded component having a waste strip which separates each individual tub and shower surround portion. The waste strip readily protects the mold and simplifies post molding operations and assures that each portion will meet final tolerances. Another waste strip is located between the tub portion and the wall portions to provide for positive draft between a tub flange which extends about the tub portion and the wall portions. Positive draft is required to assure proper removal of the mold component from the mold. The single component provides for finishing operations to be performed prior to separating the individual components. Since the majority of finishing operations are performed simultaneously prior to separating the portions, the likelihood of damage to the portions are reduced and the finish of the individual portions are of greater consistency.