Abstract: A cast, composite countertop is prepared by spraying a castable, curable organic resin composition which includes over 20% by weight of an inorganic, particulate material therein, into a mold cavity corresponding to a top surface and side wall of a countertop so as to produce a continuous coating therein. This coating is at least partially cured, and a hardenable, liquid substrate composition introduced into the mold cavity, and the resultant composite is fully cured to produce a countertop. In some instances, an additional casting step may be employed to build up the edge thickness. Also disclosed are dual spray techniques for enhancing the surface quality of the composite, and techniques for enhancing the thermal stability thereof. Also disclosed are countertops made by the disclosed methods.

Abstract: A mold assembly for creating a resin casted countertop exhibiting a built-up edge having a non-constant radius. The mold assembly includes a substantially horizontally planar and upwardly facing mold surface and a plurality of elongated member which are releasably securable upon the planar mold surface to create an outline of a countertop product to be produced. Each of the elongated members include a planar edged top, a likewise planar edged bottom, a rear face and an inwardly contoured front face. The inwardly contoured front face includes a first constant center radius throughout a first degree of angular rotation and at least one additional upper and/or lower constant center radii throughout additional degrees of angular rotation proximate the top and bottom locations of the inwardly contoured front face.

Abstract: An adjustable divider assembly for use with an open-top mold for creating a countertop with a built-up edge, the mold being rectangular in shape with a flat planar surface, first, second and third built-up and inwardly contoured edges and a fourth open edge. A U-shaped divider bar includes a central elongated member and first and second side elongated members which is pivotally attached along the four open edge of the mold using a pin and slot type arrangement and is rotated into the mold so that the elongated members of the divider bar are arranged in a desired spaced apart fashion relative to the opposing contoured mold surfaces. Suspending members extend forwardly from the central elongated member and position the bar at an elevated position above the planar mold surface. A first pour of plasticized resinous material is applied over the planar mold surface according to a predetermined depth, following which the divider bar is attached and rotated into an installed position within the mold.

Abstract: A mold and divider assembly for creating a solid surface countertop having an exterior edge according to different shapes and sizes. The mold includes a planar shaped surface which is bounded by a polygonal shaped body, at least one side of which has a raised and inwardly contoured mold defining edge. A first elongated dividing member equals a length of a first selected side of the mold and is placeable upon the planar surface so as to be movable in directions towards and away from the first selected side. A second elongated dividing member extends between the first dividing member and a second selected side of the mold so that the dividing members define in combination a subset area of the mold for receiving a resinous material pour. The second dividing member may be providing in differing lengths as a kit for producing an assortment of countertops according to differing dimensions. The mold may further be provided in a generally L-shape or rectangular shape.