COMPOSITE MATERIAL
A wall panel for a bathing system includes a first layer, a second layer, and an adhesive. The first layer is thermo-formable and includes first and second sub-layers. The first sub-layer includes poly(methyl methacrylate), and the second sub-layer includes acrylonitrile butadiene styrene. The first and second sub-layers are co-extruded together. The second layer is fastened to the first layer, and includes a poly-isocyanurate foam sheet, as well as first and second metal faces fastened to the sides of the poly-isocyanurate foam sheet. The adhesive binds the second sub-layer of the first layer to either the first or the second metal face of the second layer.
1 . A composite material, comprising:
a first layer comprising a thermo-formable material; and
a second layer comprising poly-isocyanurate, the second layer coupled to the first layer.
2 . The composite material of claim 1 , wherein the first layer comprises poly(methyl methacrylate).
3 . The composite material of claim 1 , wherein the first layer comprises acrylonitrile butadiene styrene.
4 . The composite material of claim 1 , wherein the first layer is coupled to the second layer by way of an adhesive.
5 . The composite material of claim 1 , wherein the second layer includes a first face and a second face that sandwich the poly-isocyanurate.
6 . The composite material of claim 5 , wherein the first and second faces are formed from aluminum and the poly-isocyanurate includes fiberglass reinforcement.
7 . The composite material of claim 6 , wherein the first layer comprises:
a first sub-layer of poly(methyl methacrylate), and
a second sub-layer of acrylonitrile butadiene styrene,
wherein the first and second sub-layers are overlapping and coextensive.
8 . The composite material of claim 7 , wherein the first layer is coupled to the second layer by way of an adhesive.
9 . The composite material of claim 8 , wherein the second sub-layer is thicker than the first sub-layer.
10 . The composite material of claim 9 , wherein the first and second layers are substantially overlapping and coextensive.
11 . A wall panel for a bathing system, comprising:
a first layer of thermo-formable material, wherein the first layer further comprises:
a first sub-layer comprising poly(methyl methacrylate), and
a second sub-layer comprising acrylonitrile butadiene styrene,
wherein the first and second sub-layers are co-extruded together; and
a second layer coupled to the first layer, wherein the second layer comprises:
a poly-isocyanurate foam sheet;
first and second metal faces coupled to the poly-isocyanurate foam sheet;
an adhesive binding the second sub-layer of the first layer to either the first or the second metal face of the second layer.
12 . The wall panel of claim 11 , wherein the first and second layers are substantially overlapping and coextensive.
13 . The wall panel of claim 12 , wherein the first layer includes a flange on an end thereof that at least partially extends around a side of the second layer.
14 . The wall panel of claim 13 , wherein the flange forms an enclosure within which the second layer is positioned.
15 . The wall panel of claim 14 , wherein the first and second layers are substantially rectangular.
16 . A method of manufacturing a composite material, comprising:
co-extruding a first layer comprising:
a first sub-layer of poly(methyl methacrylate) and
a second sub-layer of acrylonitrile butadiene styrene; and
adhering the first layer to a second layer comprising a sheet of poly-isocyanurate foam.
17 . The method of claim 16 , wherein the adhering step further includes providing an adhesive between the second sub-layer of the first layer and a metal face of the second layer.
18 . The method of claim 17 , further comprising:
thermo-forming the first layer into a shape of a soap dish.
19 . The method of claim 17 , further comprising:
thermo-forming the first layer into a shape of a wall panel comprising a flange.
20 . The method of claim 19 , further comprising:
placing the second layer under the flange of the first layer.