Process for fabricating countertops

Details Process for fabricating countertops Process for fabricating countertops

1999-08-02

2001-09-11

Gray, Linda (Department: 1734)

Adhesive bonding and miscellaneous chemical manufacture

Surface bonding means and/or assembly means therefor

With cutting, punching, piercing, severing, or tearing

C156S258000, C156S264000, C156S299000, C156S350000, C156S558000, C156S517000, C312S140200, C052S782220, C052S800100, C052S801100, C052S716100, C108S027000, C004S631000, C004S658000, C428S119000

Reexamination Certificate

active

06286577

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and apparatus for fabricating countertops. More particularly, the invention relates to an automated system for fabricating granite, marble, engineered stone and/or solid surface material countertops.
2. Description of the Prior Art
Granite, marble, engineered stone, and solid surface materials have become the materials of choice in the manufacture of countertops for home and commercial use. While the material composition of engineered stone and solid surface materials has improved over time, the methods employed in fabricating countertops, and other surfaces, from these materials has not changed.
Specifically, countertops made from granite, marble, engineered stone and solid surface materials are commonly fabricated in a manual, labor intensive manner. The fabricators are highly skilled artisans and rely upon a series of manual techniques to complete the fabrication of a countertop. Current techniques have been in use for many years, and few developments have been initiated to improve the process of fabricating such countertops.
While the techniques employed by skilled fabricators result in durable and aesthetically pleasing surfaces, the techniques require a substantial investment in time, equipment and space. The time consumed in the manufacturing process substantially increases the price of installing granite, marble, engineered stone and solid surface materials within a home or commercial application.
If the fabrication time for these materials were reduced, the cost of installing an engineered stone countertop, for example, would drop. As such, many consumers who would prefer an engineered stone countertop, but were previously unable to afford such countertops, would be able to purchase the countertop they desire. A need, therefore, exists for an automated system for fabricating countertops from granite, marble, engineered stone and solid surface materials, as well as other related materials. The present invention provides such a system.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an integrated system for fabricating a countertop from a slab. The system includes a saw for cutting an apron strip of a predetermined size from a slab, an adhesive station where adhesive is applied prior to bonding the apron strip to the slab, a translating device for moving the apron strip into position along an edge of the slab, and a press securely holding the apron strip and the slab while the adhesive forms a secure bond between the apron strip and the slab.
Other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a schematic of the present system.
FIG. 2
is a cross sectional view of a countertop manufactured in accordance with the present invention.
FIG. 3
is a perspective view of a slab processed in accordance with the present invention.
FIG. 4
is an exploded view of the countertop.
FIG. 5
is a cross sectional view of a countertop manufactured in accordance with an alternate embodiment of the present invention.
FIG. 6
is a perspective view of a slab in accordance with the embodiment disclosed in FIG.
5
.
FIG. 7
is an exploded view of the countertop in accordance with the embodiment disclosed in FIG.
5
.


REFERENCES:
patent: 2542860 (1951-02-01), Clements
patent: 3606508 (1971-09-01), Burnes
patent: 4814220 (1989-03-01), Brathwaite
patent: 5330262 (1994-07-01), Peters
patent: 5427159 (1995-06-01), Burgess et al.
patent: 5922157 (1999-07-01), Snider
patent: 2023025 (1971-02-01), None
patent: 29600177 (1996-08-01), None

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