Abstract: A mold assembly and method for producing a resin based countertop having an integrally formed sink bowl and a built-up edge. An elongate base is defined by a central surface area which is bounded by a plurality of interconnecting and elevated sides to establish a mold enclosure which is a negative shape of the countertop to be produced. A template is settable upon the elongate base and movable in a selected longitudinal direction so that an opening formed in the template is positioned in overlaying fashion at a desired location along the central area. A first sink bowl pattern is placeable in mating fashion within the opening in the template and upon the central area of the base prior to removal of the template. First applications of selected resinous materials are provided within the mold enclosure and around an exterior circumference of the first sink bowl pattern.

Abstract: A mold assembly for creating a countertop product displaying a built-up edge, the mold assembly having a substantially flat and rectangular planar shaped base which is bounded by first, second, third and fourth interconnected sides to define an interior cavity capable of receiving a pour of a resinous material. A selected number of the interconnected sides, up to all four sides, have inwardly facing surfaces which are configured to produce a countertop product exhibiting a built-up and preferably outwardly bowl-nosed shaped edge. A selectively removable and planar shaped top is arrayed upon the base in overhead fashion relative to the interior cavity and likewise is preferably shaped in a substantially rectangular manner.

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.