Polymer-based molded article with minimal flame spread and smoke properties

Abstract

A molded article includes at least three layers: a cosmetic surface layer, an intermediate layer and a backing layer. The intermediate layer is an energy absorbing layer between the surface layer and the backing layer which at least partially confines burning to the surface layer, where flame spread is controlled, and smoke is minimized by the composition of the intermediate layer.

1 . A molded article comprising: 
 a cosmetic surface layer;    a backing layer; and    an energy absorbing intermediate layer between said cosmetic surface layer and said backing layer.    
   
   
       2 . The molded article as recited in  claim 1 , wherein said intermediate layer comprises an aliphatic resin.  
   
   
       3 . The molded article as recited in  claim 2 , wherein said intermediate layer comprises a flame inhibitor.  
   
   
       4 . The molded article as recited in  claim 3 , wherein said flame inhibitor comprises aluminum trihydrate.  
   
   
       5 . The molded article as recited in  claim 1 , wherein said cosmetic surface layer comprises an acrylic.  
   
   
       6 . The molded article as recited in  claim 1 , wherein said backing layer comprises a chopped fiberglass.  
   
   
       7 . A molded bathroom fixture comprising: 
 a cosmetic surface layer;    a backing layer; and    an energy absorbing intermediate layer between said cosmetic surface layer and said backing layer.    
   
   
       8 . The molded bathroom fixture as recited in  claim 7 , wherein said intermediate layer comprises an aliphatic resin.  
   
   
       9 . The molded bathroom fixture as recited in  claim 8 , wherein said intermediate layer comprises a flame inhibitor.  
   
   
       10 . The molded bathroom fixture as recited in  claim 9 , wherein said flame inhibitor comprises aluminum trihydrate.  
   
   
       11 . The molded bathroom fixture as recited in  claim 7 , wherein said cosmetic surface layer, said backing layer, and said energy absorbing intermediate layer form a wall of a shower surround portion.  
   
   
       12 . The molded bathroom fixture as recited in  claim 7 , wherein said cosmetic surface layer, said backing layer, and said energy absorbing intermediate layer form a wall of a tub surround portion.