Reinforcement structure for a molded article

Abstract

The invention is a molded article having a reinforcement structure disposed therein. A settable mixture preferably including a catalyst, a matrix polymer, and a foaming agent introduced into a mold forms the shape of the molded article. The molded article includes a base section having a first thickness and wall sections extending upwardly about a periphery of the base section. The base section is substantially thicker than the wall sections. The reinforcement structure is disposed within the base section to reduce the amount of settable material required to form the base section and maintain the structural strength of the molded article.

What is claimed is:  
     
         1 . A molded article fabricated from at least two fluid materials which are combined to form a settable mixture, said molded article comprising; 
 a first section; and    a structure disposed within said first section to displace a quantity of the settable material.    
     
     
         2 . The assembly of  claim 1 , wherein said structure includes at least one support to position said reinforcement structure within said first section.  
     
     
         3 . The assembly of  claim 2 , wherein said supports are fabricated from the same settable matrix used to form said molded article.  
     
     
         4 . The assembly of  claim 1 , wherein said structure includes a reinforcement structure.  
     
     
         5 . The assembly of  claim 1 , wherein said reinforcement structure is positioned longitudinally within said first section.  
     
     
         6 . The assembly of  claim 1 , where said molded article is a bathtub.  
     
     
         7 . The assembly of  claim 1 , wherein said structure is fabricated from a wood material.  
     
     
         8 . The assembly of  claim 1 , wherein said structure is fabricated from particle bond.  
     
     
         9 . The assembly of  claim 1 , wherein a plurality of said structures are located within said first section.  
     
     
         10 . A bathtub fabricated from at least two fluid materials which are combined to form a settable mixture, said molded article comprising; 
 a base section having a first thickness;    a wall section extending from said base section and having a second thickness thinner than said first thickness; and    a reinforcement structure disposed within said base section to displace a quantity of the settable material required to form said base section, said reinforcement structure includes a plurality of supports to position said structure within said thickness of said base section.    
     
     
         11 . The assembly of  claim 10 , wherein said supports are fabricated from the same settable matrix used to form said bathtub.  
     
     
         12 . The assembly of  claim 11 , wherein said reinforcement structure is positioned longitudinally within said base section.  
     
     
         13 . The assembly of  claim 11 , wherein a plurality of said reinforcement structures are positioned within said base section.  
     
     
         14 . A method of forming a molded article fabricated from at least two fluid materials which are combined to form a settable mixture having a first section and a second section, said method includes the steps of: 
 a. providing a mold to form a molded article;    b. placing the reinforcement structure within the mold such that the reinforcement structure reduces the amount of settable material required to fill the mold;    c. introducing the settable mixture into the mold in a substantially liquid form;    d. curing the settable mixture such that the reinforcement structure is contained substantially within the molded article.    
     
     
         15 . The method according to  claim 14 , further including the step of supporting said reinforcement structure within the mold by a plurality of supports.  
     
     
         16 . The method according to  claim 15 , wherein said supports are pre-molded from the settable material and attached to said reinforcement structure.  
     
     
         17 . The method according to  claim 14 , wherein said reinforcement structure is arranged longitudinally in the thickness of the second section.  
     
     
         18 . The method according to  claim 14 , wherein a plurality of reinforcement structures are mounted to the reinforcement structure prior to said step b.