This document describes systems and process for forming processed slabs having embedded optical elements.

A method of forming a laminate countertop with a curved edge profile extending around at least two adjacent sides thereof includes providing a base support having a top surface, a bottom surface, latitudinal sides, and longitudinal sides. At least one of the longitudinal sides includes the curved edge profile. The method further includes: adhering a laminate sheet to the base support to form a laminate cover over at least a portion of the top surface and a portion of the curved edge profile of the base support and mounting a preformed edge member having a curved edge profile to one of the sides of the base support to form a laminate countertop having curved edges extending around at least two sides thereof. To align the edge member and the base support, the preformed edge member is mounted to a brace to remove bowing or curvature from the preformed edge member.

A reusable countertop mold in accordance with the present invention includes a bracket member detachably secured to a rail portion of a cabinet member for a substantially horizontal substrate that receives deformable material upon a surface of the substrate. The bracket member includes vertical, horizontal and channel members integrally joined together for enabling a channel member to removably receive the rail member. The mold further includes a locking bolt for detachably securing the bracket member to the rail portion of the support member. A form member is detachably secured to the bracket member, the form member continuously extending outside the perimeter of the substrate and receives deformable material that ultimately solidifies; whereby, the substrate surface and the form member cooperate to configure a countertop that continuously extends upon and outside the perimeter of the substrate, thereby forming a countertop having an integrally joined overhang portion; whereupon, the reusable countertop mold is removed from the solidified countertop overhang portion and the rail portion.

An apparatus including a first conveyor device including a first conveyor belt; a second conveyor device including a second conveyor belt; a movement device; and a mold device including a mold; wherein the first conveyor device is connected to the second conveyor device so that when the movement device moves the first conveyor device, the second conveyor device also moves with respect to the mold device; wherein the first conveyor belt moves independent of the second conveyor belt; and wherein the first conveyor belt and the second conveyor belt move independent from the movement device. The apparatus may further include a first and second dispensing devices configured to dispense first and second materials, first and second gate devices to control height, and a computer processor to control the various components and the resulting ratio of first material to second material in a processed slab.

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

An apparatus including a first conveyor device including a first conveyor belt; a second conveyor device including a second conveyor belt; a movement device; and a mold device including a mold; wherein the first conveyor device is connected to the second conveyor device so that when the movement device moves the first conveyor device, the second conveyor device also moves with respect to the mold device; wherein the first conveyor belt moves independent of the second conveyor belt; and wherein the first conveyor belt and the second conveyor belt move independent from the movement device. The apparatus may further include a first and second dispensing devices configured to dispense first and second materials, first and second gate devices to control height, and a computer processor to control the various components and the resulting ratio of first material to second material in a processed slab.

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).