A method of forming a laminate countertop includes a step of providing a laminate countertop with at least one substantially square corner having a curved edge profile extending around the at least one square corner. The method further includes steps of: cutting a first angled slot through a portion of a longitudinal side of the countertop; cutting a second angled slot through a portion of a preformed straight edge member connected to a base support along a latitudinal side of the countertop; and cutting a connecting cut between the slots to form a cutout section of the countertop. The method also includes a step of adhering at least one preformed angled edge member including the curved edge profile into the cutout section of the countertop to form at least one angled corner, thereby forming a laminate countertop having an edge profile extending around the at least one angled corner.

A glass/quartz composite structure comprises quartz grit, quartz powder and glass grit wherein the glass grit is in an amount greater than 50% by weight of the composite structure, and a binding resin. The glass/quartz composite structure may be formed into a 1.2-1.5 cm thick slab for countertops using standard cabinet perimeter support. The slab may be made by mixing the quartz grit, the quartz powder, the glass grit, and the binding resin, pouring the mixture in a mold, and compacting the mixture in the mold. Specific natural mineral components may be added to the glass/quartz/resin composite structure to provide aesthetics of specific natural stones.

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 at least one mold sheet, but generally a plurality of mold sheets are required to extend about a predetermined portion of a periphery of a floor mounted cabinet. The mold sheet is dimensioned and configured to ultimately form a countertop having a predetermined configuration with predetermined dimensions. The mold sheet includes a relatively thin base portion and a wall portion perpendicular to the base portion. The reusable countertop mold further includes a plurality of fastener recesses in an inner side portion of the base portion, the recesses ultimately allowing fasteners to pass through a countertop substrate and into the floor mounted cabinet, after the base portion has been inserted between the countertop substrate and the cabinet. After a countertop forming material has hardened upon the countertop substrate and the mold sheet, the base portion of the mold sheet is slidably removed from between the countertop substrate and the cabinet, thereby allowing the reusable countertop mold to be reused for another countertop forming project.

What is disclosed is a method of finishing a countertop to provide for the appearance of a material, such as stone, wood, or otherwise, but utilizing a high resolution image of the actual material instead of the material itself. The image is preferably printed in high resolution on a vinyl substrate, then adhered to the countertop. Preferably a clear coat layer is then applied to protect the vinyl substrate. This clear coat can be a urethane sprayed onto the vinyl. The disclosed method provides for a less expensive mechanism to provide or change the appearance of a countertop.

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

The improved mold assembly for cultured marble molding is provided. The mold assembly can comprise a male mold portion and a female mold portion. The assembly can further comprise a molding tool. The molding tool can have a side wall having an upper curved s and a lower curved portion. The molding tool can be constructed from a flexible and/or soft material. The lower curved portion of the molding tool can be coated with a gel coat having a first color. The molding tool can facilitate molding of a countertop having a recessed bowl portion having a color different from a counter portion of the countertop.

Disclosed is an edge wrapping method for a composite board, the top board of the composite board surrounds the bottom board of the composite board, a part or all of the side of the top board is disposed with a connecting portion extending beyond the bottom board and extending outwardly; the adjacent portion of the connecting portion and the bottom board are heated, and then the connecting portion is folded toward the inner side of the composite board and the connecting portion is welded to the side of the bottom board. The connecting portion and the bottom board are heated, and the root portion of the connecting portion near one end of the bottom board and the position of the bottom board close to the connecting portion are heated to a molten state, and then, the connecting portion is folded, and the connecting portion and the bottom board are welded together, the production efficiency of the present invention is high, the automatic production is realized, and the product qualification rate is effectively improved.

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