CA2228101A1 - Improved process for creating a countertop having an imitation veined or marbleized surface - Google Patents
Improved process for creating a countertop having an imitation veined or marbleized surface Download PDFInfo
- Publication number
- CA2228101A1 CA2228101A1 CA 2228101 CA2228101A CA2228101A1 CA 2228101 A1 CA2228101 A1 CA 2228101A1 CA 2228101 CA2228101 CA 2228101 CA 2228101 A CA2228101 A CA 2228101A CA 2228101 A1 CA2228101 A1 CA 2228101A1
- Authority
- CA
- Canada
- Prior art keywords
- resin material
- strips
- process according
- resin
- discrete
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
An improved process for creating a countertop having an imitation veined or marbleized surface including the steps of establishing a horizontally positioned mold which is constructed from an upwardly facing mold surface which is bounded by a plurality of sides to create a negative cavity enclosure.
A first plurality of elongated and discrete strips of a densified polyester/acrylic resin are applied onto the upwardly directed mold face either by a polypropylene squeeze bottle or through a trigger actuated air gun as an atomized mixture of fluid resin and pressurized air. The first plurality of strips of resin material are distributed across the face of the mold according to a desired pattern and are allowed to set for a period of time, following which at least one second continuous coat of a resin material is applied over the first plurality of discrete strips according to a desired thickness of up to one-half an inch. A third continuous coat of a backer resin may be applied over the second continuous coat and the first plurality of strips and second continuous coat are each selected from a desired color to arrive at an appealing veined or marbleized contrast. A recipe of the resin material may further be augmented with a percentage additional of a silacious material to increase hardness.
A first plurality of elongated and discrete strips of a densified polyester/acrylic resin are applied onto the upwardly directed mold face either by a polypropylene squeeze bottle or through a trigger actuated air gun as an atomized mixture of fluid resin and pressurized air. The first plurality of strips of resin material are distributed across the face of the mold according to a desired pattern and are allowed to set for a period of time, following which at least one second continuous coat of a resin material is applied over the first plurality of discrete strips according to a desired thickness of up to one-half an inch. A third continuous coat of a backer resin may be applied over the second continuous coat and the first plurality of strips and second continuous coat are each selected from a desired color to arrive at an appealing veined or marbleized contrast. A recipe of the resin material may further be augmented with a percentage additional of a silacious material to increase hardness.
Description
IMPROVED PROCESS FOR CREATING A COUNTERTOP
HAVING AN IMITATION VEINED OR MARBT,li'T7,~1) SURFACE
Ba~ kEround of the Invention Field of the Invention The present invention relates generally to processes and methods for forlming veined or marbleized sim~ ted countertop surfaces and, more particularly, to an improved process for creating a countertop having a veined or marbleized surface which requires fewer process steps than previously kno~;vn methods.
Desc ription of the Prior Art Various processes and methods are known in the art for creating an imitation or siml-l~ted marbleized or veined countertop surface, the desire in each in~t~nre being to fabricate a simulated marble or veined surface which as closely as possible replicates actual marble and which may be fashioned to a given application.
U.S. Patent No. 3,773,886, issued to Starr et al., teaches a process for form~ing sim--l~ted marble which includes the steps of applying a clear, protective polyester gel-coat to a mold surface which is followed by applying a colored veining composition including an unsaturated polymerizable polyester resin, a vinyl polymer or copolymer, and an organic solvent having a selected boiling point and evaporation constant. Additional steps include applying a coloI spatter composition by having the spatter composition fall through the aironto the mold surface, adding a catalyzed polyester resin matrix composition which forms a backer resin and finally curing the composition within the mold and subsequently removing it from the mold.
Starr therefore teaches a general concept of applying a clear gelcoat which is backed by a further resin of at least two different colors partially 5 mixed together to leave a veining effect of one color in a background of another color. The resin mixture is then backpoured behind the clear gelcoat to create the marble effect. While providing an effective process for creating a marbleized countertop, Starr et al. requires a fairly lengthy and involved process for creating the desired end product with. Such processes normally 10 inch:lde multiple coats of resin, higher labor and manufacturing costs, longer cure period, lower production rates and risk of pre-release of the resin material which results in disfigurement of the produced product.
U.S. Patent No. 5,055,324, issued to Stecker, teaches a method of forming a synthetic stone, marble or like sim~ tecl surface which includes the 15 step~ of combining a resin matrix with a veining pigment composition having a specific gravity which is heavier than that of the resin system and adding a blooming agent component with a pigment component having a specific gravity which is less than that of the resin system. The pigment component disperses under the influence of the blooming agent to from a pattern. The dispersement 20 of the veining pigment is further controlled by virtue of its thixotropic properties.
Finally, U.S. Patent No. 4,975,303, issued to McKinnon, teaches a process for creating a simlll~ted marble including covering a substrate with a textured sim~ tçd marble surface. Cement and sand are mixed to form a first mixture to which is added an aqueous solution of an adhesive resin such as an acry]Lic resin to create a mortar. The mortar is spread across the substrate and one or more color pigments are added to the surface at randomly spaced 5 local:ions prior to complete curing of the mortar. Air is then blown onto the surface of the mortar and serves to blend the color pigments into the mortar and to fc~rm appropliate color patterns. McKinnon does not involve the use of molcls and the creation process is substantially m~ml~lly performed.
While providing useful methods of creating veined and marbleized 10 surfaces the prior art does not teach or suggest a novel yet simplified process for c reating an imitation veined or marbleized surface which utilizes fewer method steps less time and less effort.
Summary of the Present Invention The present invention is an improved process for creating a countertop 15 having an imitation veined or marbleized surface in which a horizontally posil:ioned mold is established with an upwardly facing mold surface and bounded by a plurality of sides to create a negative cavity enclosure. A first plurality of elongated and discrete strips of a resin material are applied upon the upwardly facing mold surface according to a desired decorative pattern and 20 according to a first selected color and desired thickness. The first plurality of strips are applied either with a mech~ni~ec1 method or m~ml~lly such as by with a mi~ture with moderately pressurized air and sprayed onto the mold surface or are squeezed from one or more polypropylene bottles. The strips of resin which are spread across the mold surface from the squeeze bottles are acted upon by moderately pressurized air to distribute them in a desired spread out decorative pattern which sim~ tes veining or marbleized patterns.
Once the first plurality of strips of resin are permitted to gel for a 5 predetermined period of time, a second continuous coat of resin material is applied onto the mold according to a desired thickness which is either equal to that of the first plurality of strips or somewhat greater. In some instances, a third coating of a backer resin is applied over the second coating. The advantage of the process according to the present invention is to create a 10 simlll~t~l veined or marbleized surface in fewer steps and with less effort than that ~which is required to create a marbleized sim~ t~cl countertop according to the teachings of the prior art. The process of the present invention is also more conducive to mass production and repeatable pattern creation since it is applied directly to the mold.
Brief Des~ ,lion of the D.awi--~
Reference is now had to the attached drawings, when read in combination with the following specification, wherein like reference numerals refer to like parts throughout the several views, and in which:
Fig. 1 is a perspective view of the improved process for creating a 20 countertop having an imitation veined or marbleized surface according to a first preferred embodiment of the present invention;
Fig. 2 is a perspective view similar to that shown in Fig. 1 and illustrating yet further additional preferred embodiments for the improved process according to the present invention;
Fig. 3 is a two-dimensional side view in partial cutaway and illustrating 5 a three-layer construction for an imitation veined or marbleized countertop according to the present invention;
Fig. 4 is a view similar to that shown in Fig. 3 and illustrating a two-layer construction for an imitation veined or marbleized countertop according to the present invention;
Fig. 5 is an inverted view of a solid surface countertop consistent with the teachings of the present invention and further illustrating a built-up edge;
and Fig. 6 is a three dimensional view of an imitation veined or marbleized solid surface countertop produced according to the novel process of the present 1 5 invention.
Description of the F~ ere~ I e(l Embodiments Referring to Fig. 1, a mold assembly 10 is illustrated for producing a countertop having an imitation veined or marbleized surface according to the present invention and includes a generally horizontally positioned mold having 20 an upwardly facing mold surface 12 which is bounded by a number of sides, illustrated as first side 14, second side 16, third side 18 and fourth side 20 in order to create an overall polygonal shaped structure defining a boundary aroulld a negative shaped cavity enclosure. While a generally rectangular shaped mold is illustrated in Fig. 1, it is understood that any polygonal shapedenclosing mold structure having any number of sides between three, defining a triangle, and infinity, defining a circle, can be utilized according to the process of the present invention.
S The upwardly facing mold surface 12 and corresponding inwardly directed faces of the sides 14, 16, 18 and 20 can be of a Teflon or like known construction and it is further contemplated that a release wax coating or other release agent can be pre-applied to the exposed mold surfaces to facilitate subsequent withdrawal of the countertop product prepared according to the process of the present invention. Also, the sides 14, 16, 18 and 20 can be of any desired height sufficient for producing a countertop product having an overall thickness of between 0.50" and 0.75".
Referring again to Fig. 1, a first plurality of discrete strips 22 of a liquid resin material are applied according to a desired spaced apart pattern upon the upwardly facing mold surface 12. The resin material constituting the discrete strips is preferably polyester/acrylic material which is saturated withan a]pha tri-hydrate and, according to a preferred embodiment, is mixed from a recipe including 90 percent neopropyl glycol isophallic resin and 10 percent methyl acrylic monomer. This recipe for the resin material 22 may further be hardened by adding up to 40 to 50 percent by volume a silaceous material such as a silicate oxygen based or other like material.
According to a first embodiment, the first plurality of discrete strips 22 are applied from a polypropylene squeeze bottle 24 having a dispensing nozzle portion onto the mold surface 12 and each strip is preferably applied to a thic]~ness of up to 40 mil (0.04") and at a width of between 1/16" to 1/32".
Additional resin filled squeeze bottles 26 and 28 may also be provided, and each of the bottles 24, 26 and 28 is filled with a liquid resin mixture according 5 to a f1rst desired plurality of colors, including white, grey, black among others.
Once the mold surface has been applopliately prepared for initi~ting the resin application, the polypropylene bottles are assembled holding the desired color combination of veining materials. The squeeze bottles are inverted during the application of the discrete strips in a range extending preferably 10 between ten degrees and sixty degrees with respect to a longit~ in~l axis of the upwardly facing mold surface and the strips are laid out in either parallel or angu.lar offset fashion, or even in connPcting fashion such as substantially "Y"
shaped and "C" shaped elements which contribute to the overall authentic veining appearance.
Upon satisfactory application of one or more pluralities of strips of veining material according to a desired color scheme, it is desirable to outwardly spread or otherwise disperse the veining strips across the face of the mold according to a desired decorate pattern and to simulate a specific veined or marbleized a~ealdnce. For this purpose, a conventional air gun 30 may be 20 employed which distributes moderately pressurized through a particularly adjusted nozzle opening. Typically, the air gun 30 is activated shortly after the strips of resin material have been laid and prior to them having an opportunity to gel. The act of spreading the veining strips is performed according to a desired appearance of the veining pattern and, once the end product is removed from within the mold, will exhibit a genuine marbleized or veined appearance.
Referring again to Fig. 1, a jug or other similar container 32 is provided and is filled with a second resin material constituted of the same properties as 5 the f;rst resin material, namely a densified polyester/acrylic material saturated with an alpha tri-hydrate and possibly a silaceous or like material. The second material is poured from the container 32 is liquid form in a continuous and even fashion across the mold surface 12 once the initial strips of resin material forming the veining pattern have been allowed to begin to gel for a brief period 10 of ti]ne, preferably ten minutes or so. Specifically desired colors for the second continuous resin coat include white, grey, pink, peach, blue and any other appealing color which contrasts nicely with the colors selected for the first plurality of resin veining strips.
The overall countertop thickness which is desired to be produced is typically in the range between 0.50" and 0.75" and, in the instance of a three-layer application, the second continuous coat is applied to an equal thickness of 40 mil (.040") to form an even upper surface in combination with the first pluralities of resin strips and a third low-grade backer resin is applied over the second continuous coat to achieve the desired overall thickness. Referring to 20 Fig. 3, a mold assembly is illustrated in cut-away side profile and in which element 34 represents the second continuous coating of resin material poured to a ]level consistent with the depth of the first plurality of strips of material and which is subsequently covered with backer resin 36 constituted of some low grade resin for the purpose of providing a capable and invisible substrate.
Referring now to Fig. 2, an improved process for creating an imitation veined or marbleized countertop is shown according to a further preferred 5 embodiment 38 and likewise includes the horizontally positioned mold with upwardly facing mold surface 12 and sides 14, 16, 18 and 20. A first plurality 40 of elongated and discrete strips of resin material are applied onto the upwardly facing mold surface 12. A trigger actuated gun 42 similar to that disclosed at 30 in Fig. 1 is utilized to apply the resin by mixing it with 10 pressurized air and pnPllm~tic~lly distributing it continuously across the mold surface. The first plurality of resin strips are applied according to one or more desired color schemes as previously described and also to a preferably thickness of 0,04". The trigger actuated gun 42 may be activated in an angled fashion relative to the upwardly facing mold surface in a manner similar to that 15 disclosed in the application of the polypropylene squeeze tube in order to achieve a desired spread pattern of the veining composition.
A second continuous coat of resin material may again be applied from a vo:lume carrying jug or like container 44 and is preferably filled into the mold to either a minim~l 0.04" to equal the depth of the initial resin veining strips, 20 following which a third layer backer resin is applied as described in Fig, 3.
Alternately, the second layer of resin coating may completely fill the mold cavity to the desired 0.50" to 0.75" thickness of the countertop as illustrated by a second resin layer 46 applied over the first plurality of veining strips 40 according to the configuration set forth in Fig. 4.
Referring to Fig. S, a side profile of a solid surface countertop produced according to the parameters set forth in the veining process is shown and 5 further includes a built-up edge 50. Referring finally to Fig. 6, a sample of a finished imitation veined countertop 52 is shown and is removed from the mold subsequent to the first and second coatings of resin material having sufficient time to adequately cure and harden.
It is therefore evident that the present invention discloses a novel and 10 unique process for creating a countertop having an imitation veined or marbleized surface in fewer steps and with less time and effort than that which is required in creating similar veined surfaces according to that which is taught by the prior art. Additional embodiments will become appalelll to those skilled in the art to which it pertains without deviating from the scope of the appended 1 5 clainns.
I claim:
HAVING AN IMITATION VEINED OR MARBT,li'T7,~1) SURFACE
Ba~ kEround of the Invention Field of the Invention The present invention relates generally to processes and methods for forlming veined or marbleized sim~ ted countertop surfaces and, more particularly, to an improved process for creating a countertop having a veined or marbleized surface which requires fewer process steps than previously kno~;vn methods.
Desc ription of the Prior Art Various processes and methods are known in the art for creating an imitation or siml-l~ted marbleized or veined countertop surface, the desire in each in~t~nre being to fabricate a simulated marble or veined surface which as closely as possible replicates actual marble and which may be fashioned to a given application.
U.S. Patent No. 3,773,886, issued to Starr et al., teaches a process for form~ing sim--l~ted marble which includes the steps of applying a clear, protective polyester gel-coat to a mold surface which is followed by applying a colored veining composition including an unsaturated polymerizable polyester resin, a vinyl polymer or copolymer, and an organic solvent having a selected boiling point and evaporation constant. Additional steps include applying a coloI spatter composition by having the spatter composition fall through the aironto the mold surface, adding a catalyzed polyester resin matrix composition which forms a backer resin and finally curing the composition within the mold and subsequently removing it from the mold.
Starr therefore teaches a general concept of applying a clear gelcoat which is backed by a further resin of at least two different colors partially 5 mixed together to leave a veining effect of one color in a background of another color. The resin mixture is then backpoured behind the clear gelcoat to create the marble effect. While providing an effective process for creating a marbleized countertop, Starr et al. requires a fairly lengthy and involved process for creating the desired end product with. Such processes normally 10 inch:lde multiple coats of resin, higher labor and manufacturing costs, longer cure period, lower production rates and risk of pre-release of the resin material which results in disfigurement of the produced product.
U.S. Patent No. 5,055,324, issued to Stecker, teaches a method of forming a synthetic stone, marble or like sim~ tecl surface which includes the 15 step~ of combining a resin matrix with a veining pigment composition having a specific gravity which is heavier than that of the resin system and adding a blooming agent component with a pigment component having a specific gravity which is less than that of the resin system. The pigment component disperses under the influence of the blooming agent to from a pattern. The dispersement 20 of the veining pigment is further controlled by virtue of its thixotropic properties.
Finally, U.S. Patent No. 4,975,303, issued to McKinnon, teaches a process for creating a simlll~ted marble including covering a substrate with a textured sim~ tçd marble surface. Cement and sand are mixed to form a first mixture to which is added an aqueous solution of an adhesive resin such as an acry]Lic resin to create a mortar. The mortar is spread across the substrate and one or more color pigments are added to the surface at randomly spaced 5 local:ions prior to complete curing of the mortar. Air is then blown onto the surface of the mortar and serves to blend the color pigments into the mortar and to fc~rm appropliate color patterns. McKinnon does not involve the use of molcls and the creation process is substantially m~ml~lly performed.
While providing useful methods of creating veined and marbleized 10 surfaces the prior art does not teach or suggest a novel yet simplified process for c reating an imitation veined or marbleized surface which utilizes fewer method steps less time and less effort.
Summary of the Present Invention The present invention is an improved process for creating a countertop 15 having an imitation veined or marbleized surface in which a horizontally posil:ioned mold is established with an upwardly facing mold surface and bounded by a plurality of sides to create a negative cavity enclosure. A first plurality of elongated and discrete strips of a resin material are applied upon the upwardly facing mold surface according to a desired decorative pattern and 20 according to a first selected color and desired thickness. The first plurality of strips are applied either with a mech~ni~ec1 method or m~ml~lly such as by with a mi~ture with moderately pressurized air and sprayed onto the mold surface or are squeezed from one or more polypropylene bottles. The strips of resin which are spread across the mold surface from the squeeze bottles are acted upon by moderately pressurized air to distribute them in a desired spread out decorative pattern which sim~ tes veining or marbleized patterns.
Once the first plurality of strips of resin are permitted to gel for a 5 predetermined period of time, a second continuous coat of resin material is applied onto the mold according to a desired thickness which is either equal to that of the first plurality of strips or somewhat greater. In some instances, a third coating of a backer resin is applied over the second coating. The advantage of the process according to the present invention is to create a 10 simlll~t~l veined or marbleized surface in fewer steps and with less effort than that ~which is required to create a marbleized sim~ t~cl countertop according to the teachings of the prior art. The process of the present invention is also more conducive to mass production and repeatable pattern creation since it is applied directly to the mold.
Brief Des~ ,lion of the D.awi--~
Reference is now had to the attached drawings, when read in combination with the following specification, wherein like reference numerals refer to like parts throughout the several views, and in which:
Fig. 1 is a perspective view of the improved process for creating a 20 countertop having an imitation veined or marbleized surface according to a first preferred embodiment of the present invention;
Fig. 2 is a perspective view similar to that shown in Fig. 1 and illustrating yet further additional preferred embodiments for the improved process according to the present invention;
Fig. 3 is a two-dimensional side view in partial cutaway and illustrating 5 a three-layer construction for an imitation veined or marbleized countertop according to the present invention;
Fig. 4 is a view similar to that shown in Fig. 3 and illustrating a two-layer construction for an imitation veined or marbleized countertop according to the present invention;
Fig. 5 is an inverted view of a solid surface countertop consistent with the teachings of the present invention and further illustrating a built-up edge;
and Fig. 6 is a three dimensional view of an imitation veined or marbleized solid surface countertop produced according to the novel process of the present 1 5 invention.
Description of the F~ ere~ I e(l Embodiments Referring to Fig. 1, a mold assembly 10 is illustrated for producing a countertop having an imitation veined or marbleized surface according to the present invention and includes a generally horizontally positioned mold having 20 an upwardly facing mold surface 12 which is bounded by a number of sides, illustrated as first side 14, second side 16, third side 18 and fourth side 20 in order to create an overall polygonal shaped structure defining a boundary aroulld a negative shaped cavity enclosure. While a generally rectangular shaped mold is illustrated in Fig. 1, it is understood that any polygonal shapedenclosing mold structure having any number of sides between three, defining a triangle, and infinity, defining a circle, can be utilized according to the process of the present invention.
S The upwardly facing mold surface 12 and corresponding inwardly directed faces of the sides 14, 16, 18 and 20 can be of a Teflon or like known construction and it is further contemplated that a release wax coating or other release agent can be pre-applied to the exposed mold surfaces to facilitate subsequent withdrawal of the countertop product prepared according to the process of the present invention. Also, the sides 14, 16, 18 and 20 can be of any desired height sufficient for producing a countertop product having an overall thickness of between 0.50" and 0.75".
Referring again to Fig. 1, a first plurality of discrete strips 22 of a liquid resin material are applied according to a desired spaced apart pattern upon the upwardly facing mold surface 12. The resin material constituting the discrete strips is preferably polyester/acrylic material which is saturated withan a]pha tri-hydrate and, according to a preferred embodiment, is mixed from a recipe including 90 percent neopropyl glycol isophallic resin and 10 percent methyl acrylic monomer. This recipe for the resin material 22 may further be hardened by adding up to 40 to 50 percent by volume a silaceous material such as a silicate oxygen based or other like material.
According to a first embodiment, the first plurality of discrete strips 22 are applied from a polypropylene squeeze bottle 24 having a dispensing nozzle portion onto the mold surface 12 and each strip is preferably applied to a thic]~ness of up to 40 mil (0.04") and at a width of between 1/16" to 1/32".
Additional resin filled squeeze bottles 26 and 28 may also be provided, and each of the bottles 24, 26 and 28 is filled with a liquid resin mixture according 5 to a f1rst desired plurality of colors, including white, grey, black among others.
Once the mold surface has been applopliately prepared for initi~ting the resin application, the polypropylene bottles are assembled holding the desired color combination of veining materials. The squeeze bottles are inverted during the application of the discrete strips in a range extending preferably 10 between ten degrees and sixty degrees with respect to a longit~ in~l axis of the upwardly facing mold surface and the strips are laid out in either parallel or angu.lar offset fashion, or even in connPcting fashion such as substantially "Y"
shaped and "C" shaped elements which contribute to the overall authentic veining appearance.
Upon satisfactory application of one or more pluralities of strips of veining material according to a desired color scheme, it is desirable to outwardly spread or otherwise disperse the veining strips across the face of the mold according to a desired decorate pattern and to simulate a specific veined or marbleized a~ealdnce. For this purpose, a conventional air gun 30 may be 20 employed which distributes moderately pressurized through a particularly adjusted nozzle opening. Typically, the air gun 30 is activated shortly after the strips of resin material have been laid and prior to them having an opportunity to gel. The act of spreading the veining strips is performed according to a desired appearance of the veining pattern and, once the end product is removed from within the mold, will exhibit a genuine marbleized or veined appearance.
Referring again to Fig. 1, a jug or other similar container 32 is provided and is filled with a second resin material constituted of the same properties as 5 the f;rst resin material, namely a densified polyester/acrylic material saturated with an alpha tri-hydrate and possibly a silaceous or like material. The second material is poured from the container 32 is liquid form in a continuous and even fashion across the mold surface 12 once the initial strips of resin material forming the veining pattern have been allowed to begin to gel for a brief period 10 of ti]ne, preferably ten minutes or so. Specifically desired colors for the second continuous resin coat include white, grey, pink, peach, blue and any other appealing color which contrasts nicely with the colors selected for the first plurality of resin veining strips.
The overall countertop thickness which is desired to be produced is typically in the range between 0.50" and 0.75" and, in the instance of a three-layer application, the second continuous coat is applied to an equal thickness of 40 mil (.040") to form an even upper surface in combination with the first pluralities of resin strips and a third low-grade backer resin is applied over the second continuous coat to achieve the desired overall thickness. Referring to 20 Fig. 3, a mold assembly is illustrated in cut-away side profile and in which element 34 represents the second continuous coating of resin material poured to a ]level consistent with the depth of the first plurality of strips of material and which is subsequently covered with backer resin 36 constituted of some low grade resin for the purpose of providing a capable and invisible substrate.
Referring now to Fig. 2, an improved process for creating an imitation veined or marbleized countertop is shown according to a further preferred 5 embodiment 38 and likewise includes the horizontally positioned mold with upwardly facing mold surface 12 and sides 14, 16, 18 and 20. A first plurality 40 of elongated and discrete strips of resin material are applied onto the upwardly facing mold surface 12. A trigger actuated gun 42 similar to that disclosed at 30 in Fig. 1 is utilized to apply the resin by mixing it with 10 pressurized air and pnPllm~tic~lly distributing it continuously across the mold surface. The first plurality of resin strips are applied according to one or more desired color schemes as previously described and also to a preferably thickness of 0,04". The trigger actuated gun 42 may be activated in an angled fashion relative to the upwardly facing mold surface in a manner similar to that 15 disclosed in the application of the polypropylene squeeze tube in order to achieve a desired spread pattern of the veining composition.
A second continuous coat of resin material may again be applied from a vo:lume carrying jug or like container 44 and is preferably filled into the mold to either a minim~l 0.04" to equal the depth of the initial resin veining strips, 20 following which a third layer backer resin is applied as described in Fig, 3.
Alternately, the second layer of resin coating may completely fill the mold cavity to the desired 0.50" to 0.75" thickness of the countertop as illustrated by a second resin layer 46 applied over the first plurality of veining strips 40 according to the configuration set forth in Fig. 4.
Referring to Fig. S, a side profile of a solid surface countertop produced according to the parameters set forth in the veining process is shown and 5 further includes a built-up edge 50. Referring finally to Fig. 6, a sample of a finished imitation veined countertop 52 is shown and is removed from the mold subsequent to the first and second coatings of resin material having sufficient time to adequately cure and harden.
It is therefore evident that the present invention discloses a novel and 10 unique process for creating a countertop having an imitation veined or marbleized surface in fewer steps and with less time and effort than that which is required in creating similar veined surfaces according to that which is taught by the prior art. Additional embodiments will become appalelll to those skilled in the art to which it pertains without deviating from the scope of the appended 1 5 clainns.
I claim:
Claims (16)
1. An improved process for creating a countertop having an imitation veined or marbleized surface, comprising the steps of:
establishing a mold constructed from a planar face mold surface and bounded by a plurality of sides to create a negative cavity enclosure;
applying a first plurality of elongated and discrete strips of a resin material upon said upwardly facing mold surface in a desired decorative manner and according to at least a first selected color and a first predetermined thickness;
permitting said first plurality of resin strips to partially gel for a predetermined period of time; and applying a second continuous coat of a resin material over said first plurality of strips according to at least a second selected color and a second predetermined thickness.
establishing a mold constructed from a planar face mold surface and bounded by a plurality of sides to create a negative cavity enclosure;
applying a first plurality of elongated and discrete strips of a resin material upon said upwardly facing mold surface in a desired decorative manner and according to at least a first selected color and a first predetermined thickness;
permitting said first plurality of resin strips to partially gel for a predetermined period of time; and applying a second continuous coat of a resin material over said first plurality of strips according to at least a second selected color and a second predetermined thickness.
2. The process according to claim 1, further comprising the step of applying a third continuous coat of a backer resin material over said second continuous coat of resin material.
3. The process according to claim 1, further comprising the step of applying said first plurality of discrete and elongated strips of resin material from a polypropylene squeeze bottle with a dispensing nozzle, said nozzle being oriented at an angle in the range of ten degrees to sixty degrees with respect to a longitudinal axis of the upwardly facing mold surface.
4. The process according to claim 3, further comprising the step of applying said first plurality of discrete and elongated strips at a relatively low volume of pressure to minimize deflection, spillage and deformation as said plurality of strips impact the upwardly facing mold surface.
5. The process according to claim 3, further comprising the step of applying a stream of concentrated and pressurized air over said first plurality of discrete and elongated strips of resin material applied over the upwardly facing mold surface at a preselected angular orientation to effect outwardly spreading of said strips of material.
6. The process according to claim 1, further comprising the step of applying said first plurality of discrete and elongated strips of resin material as a mixture with pressurized air through a trigger actuated air gun having an application nozzle.
7. The process according to claim 1, further comprising the step of said second continuous coat of resin material being applied as a mixture with pressurized air through a trigger actuated air gun having an application nozzle.
8. The process according to claim 1, further comprising the step of said second continuous coat of resin material being poured from volume holding container in an evenly spaced manner across said gelling first plurality of discrete strips of resin material.
9. The process according to claim 1, further comprising the step of said first plurality of discrete and elongated strips of resin material being applied to a thickness of up to forty-thousandths (.040") of an inch.
10. The process according to claim 1, further comprising the step of said second continuous coat of resin material being applied to in a range of thickness extending between forty-thousandths (.004") of an inch and five hundred thousandths (0.50") of an inch.
11. The process according to claim 2, further comprising the step of applying said second continuous coat of resin material to a thickness up to forty-thousandths (.040") of an inch and of further applying said third continuous coat of a backer resin to a thickness of up to five hundred thousandths (.500") of an inch.
12. The process according to claim 1, further comprising the step of constructing a built-up edge around at least one edge surface of the countertop surface.
13 13. The process according to claim 1, further comprising the step of establishing a mixture of said first plurality of discrete strips of resin material and said second continuous coat of resin material from a densified resin saturated with alpha tri-hydrate.
14. The process according to claim 13, further comprising the step of mixing said first plurality of discrete strips of resin material and said second continuous coat of resin material from a recipe including ninety percent neopropyl glycol isophallic resin and ten percent methyl acrylic monomer.
15. The process according to claim 14, further comprising the step of saturating said recipe of resin material by an additional forth to fifty percent volume of a silacious material to increase a hardness factor of said recipe.
16. The process according to claim 1, further comprising the step of applying said first plurality of discrete strips of resin material at width ranging between one-sixteenth (1/16") and one-thirty secondth (1/32") of an inch.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US79619997A | 1997-02-07 | 1997-02-07 | |
| US08/796,199 | 1997-02-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2228101A1 true CA2228101A1 (en) | 1998-08-07 |
Family
ID=25167591
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2228101 Abandoned CA2228101A1 (en) | 1997-02-07 | 1998-01-29 | Improved process for creating a countertop having an imitation veined or marbleized surface |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2228101A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| USD810249S1 (en) | 2016-09-30 | 2018-02-13 | Zurn Industries, Llc | Sink |
| USD810896S1 (en) | 2016-09-30 | 2018-02-20 | Zurn Industries, Llc | Sink |
| USD810897S1 (en) | 2016-09-30 | 2018-02-20 | Zurn Industries, Llc | Sink |
-
1998
- 1998-01-29 CA CA 2228101 patent/CA2228101A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| USD810249S1 (en) | 2016-09-30 | 2018-02-13 | Zurn Industries, Llc | Sink |
| USD810896S1 (en) | 2016-09-30 | 2018-02-20 | Zurn Industries, Llc | Sink |
| USD810897S1 (en) | 2016-09-30 | 2018-02-20 | Zurn Industries, Llc | Sink |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US5372676A (en) | Method for producing replicated paving stone | |
| US5637236A (en) | Method for producing a wall, roadway, sidewalk or floor of cementitious material | |
| US5167991A (en) | Method for producing a replicated stone surface | |
| US6634617B2 (en) | Form liner | |
| US4248816A (en) | Process for forming simulated marble and resulting product | |
| CA2228101A1 (en) | Improved process for creating a countertop having an imitation veined or marbleized surface | |
| JPS5727177A (en) | Method for finishing ornamental wall representing pattern of natural stone | |
| GB2201104A (en) | Concrete units | |
| JP2877664B2 (en) | How to paint a decorative veneer | |
| JP7161417B2 (en) | Coating method | |
| JPH0356175A (en) | Surface decoration method providing gloss difference | |
| JP2698309B2 (en) | How to paint a decorative veneer | |
| JPH06235257A (en) | Inorganic wall plate | |
| JP2928969B2 (en) | Manufacturing method of decorative board | |
| JPH0250843B2 (en) | ||
| JP2004106467A (en) | Ceramic decorative laminate and its manufacturing method | |
| JP3261894B2 (en) | Surface coloring method for concrete products | |
| JP2002096020A (en) | Interior and exterior panel and method for manufacturing the same | |
| JPH01285344A (en) | Brick tile like decorative board | |
| JPH0474064B2 (en) | ||
| JPH10102723A (en) | Exterior material with sandstone split skin pattern | |
| JPS58215316A (en) | Forming method of surface pattern | |
| JPH0342943B2 (en) | ||
| JPH01189373A (en) | Production of surface decorated plate | |
| JPH06329488A (en) | Ceramic plate material having stuck sand granular material and method for decorating the same |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |