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 spray gun used for manufacturing fiberglass components includes a valve body and a manifold that each contain two channels to initially separate a resin and a catalyst from each other. The channels inside the manifold converge to a vertex to allow the catalyst and resin to impinge each other. The impinged catalyst and resin are then mixed together more thoroughly in a static mixer before being sprayed out of the gun. The spray gun can be used to mix and apply any material made of two or more fluids mixed together.

Abstract: A molded tub and surround which is formed of a multiple of portions. Wall portions meet at a joint which is secured by wall clamps which bias a partially arcuate portion of a second wall portion against the visible surface of a first wall portion. The first wall portion sandwiched between the wall clamps and the partially arcuate portion. A multiple of tub clamps extend from a lower edge of the wall portions to fit upon a flange extending from a tub portion. The wall clamps and tub clamps assure an easily assembled and watertight molded tub and surround.

Abstract: A multi-panel tub/shower surround which facilitates insertion well into the construction process. The panels incorporate assembly clips along a common vertical edge which maintain the panels in sealing engagement. The assembly clip induces a watertight connection between the panels to maintain the common edge in flush engagement. As a result, a tub surround can be positioned later in the construction process while ensuring a watertight connection between the components of the surround.

Abstract: A shaped multilayer polymeric article, and a method for manufacturing said article, comprising a top layer comprised of thermoset polyester resin, a supporting layer underneath said top layer comprised of fiber reinforced, thermoset, high density polyurethane foam, said supporting layer having a density and thickness at least effective to provide support to said top layer; an intermediate layer underneath at least a portion of said supporting layer comprised of thermoset, low density polyurethane foam; and a bottom layer underneath at least said intermediate layer comprised of fiber reinforced, thermoset, high density polyurethane foam.

Abstract: A shaped multilayer polymeric article, and a method for manufacturing said article, comprising a top layer comprised of thermoset polyester resin, a supporting layer underneath said top layer comprised of high density polyurethane foam, said supporting layer having a density and thickness at least effective to provide support to said top layer; an intermediate layer underneath at least a portion of said supporting layer comprised of low density polyurethane foam; and a bottom layer underneath at least said intermediate layer comprised of high density polyurethane foam.

Abstract: Bath module includes a shell-like housing defining interiorly a tub/shower facility wherein whirlpool, steam, tanning and mist functions or modes of operation are selectable through actuation of pneumatic controls located therein. The preferred embodiment includes recessed storage and grab bar compartments, the recessed storage compartment housing the pneumatic controls as well as other items.