Reusable Countertop Mold

Abstract

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.

Claims

1. A reusable countertop mold comprising: at least one relatively rigid sheet dimensioned and configured to ultimately form a countertop having a predetermined configuration with predetermined dimensions, said relatively rigid sheet having a base portion with a relatively thin edge portion that promotes a substantially horizontal insertion of said base portion of said relatively rigid sheet between a top edge portion of a cabinet and a bottom edge portion of a countertop substrate, said relatively rigid sheet including a wall portion integrally joined to an edge of said base portion such that said wall portion being perpendicular to said base portion; a plurality of fastener recesses disposed at predetermined locations in a side portion of said base portion of said relatively rigid sheet, said fastener recesses promoting the insertion of retaining screws through the countertop substrate, through said fastener recesses and into said top edge portion of the cabinet without the retaining screws engaging said relatively rigid sheet, thereby allowing said relatively rigid sheet to be slidably removed from an inserted position between the bottom edge portion of the countertop substrate and the top edge portion of the cabinet after a countertop forming material has been poured upon the countertop substrate, the countertop forming material being retained upon the countertop substrate by said wall portion joined to said relatively rigid sheet opposite said fastener recesses, the periphery of the countertop substrate ultimately receiving a plurality of said relatively rigid sheets such that a peripheral vertical wall is formed about the periphery of the countertop substrate to maintain the countertop forming material upon the countertop substrate and to extend the countertop forming material a preselected distance past the countertop substrate edges, thereby maintaining the countertop forming material in a fixed position until hardening to form a predetermined countertop configuration upon and about a vertical side wall of the countertop substrate; guide lines that identify centerlines for each fastener recess thereby identifying the insertion point for a fastener relative to said fastener recesses to secure the countertop substrate to the cabinet with said reusable countertop mold inserted between the countertop substrate and the cabinet when said fastener recesses are not visible to the user, said fastener recesses being dimensioned to allow the fasteners to avoid engagement with said relatively rigid sheet, and said fastener recesses being dimensioned to maximize an engagement portion of said relatively rigid sheet that engages the top edge portion of the cabinet and the bottom edge portion of the countertop substrate, thereby maintaining the configuration of said relatively rigid sheet when a countertop forming material is disposed upon the reusable countertop mold; at least one stopper member secured to a bottom wall of said relatively rigid sheet, said stopper member limiting the horizontal distance of insertion of said relatively rigid sheet between the bottom edge portion of the countertop substrate and the top edge portion of the cabinet, the horizontal insertion distance being determined prior to the selection of said reusable countertop mold; and pullout tabs secured to said bottom wall of said relatively rigid sheet, said pullout tabs being disposed a predetermined distance from said at least one stopper member when said at least one stopper member engages the side wall of the cabinet, said predetermined distance enabling a person to grasp said pullout tabs; whereby, said relatively rigid sheet is manually extracted from an inserted position between the bottom edge portion of the countertop substrate and the top edge portion of the cabinet via a person grasping said pullout tabs and slidably removing said relatively rigid sheet from said inserted position after the countertop forming material has hardened, thereby allowing said reusable countertop mold to be reused for another countertop forming project.

2. The reusable countertop mold of claim 1 wherein said base portion of said relatively rigid sheet includes a frictionless coating for reducing friction between said base portion and the countertop substrate and cabinet when said base portion is initially inserted between and ultimately removed from the countertop substrate and cabinet after a countertop forming material disposed in said mold has become rigid.

3. The reusable countertop mold of claim 1 wherein said base portion of said relatively rigid sheet includes a deformable film for reducing friction between said base portion includes a deformable film for reducing friction between said base portion and the countertop substrate and cabinet when said base portion is initially inserted between and ultimately removed from the countertop substrate and cabinet after a countertop forming material disposed in said mold has become rigid.

4. The reusable countertop mold of claim 1 wherein said relatively rigid sheet includes a thickness dimension that promotes flexibility and minimizes the gap between the top edge portion of the countertop substrate and the bottom edge portion of the countertop substrate.

5. The reusable countertop mold of claim 1 wherein said plurality of fastener recesses in said side portion of said relatively rigid sheet includes a substantially U shaped configuration having a lateral dimension slightly greater than the diameter of the shank of fasteners inserted through the recesses when securing the countertop substrate to the cabinet, thereby increasing the rigidity of the relatively rigid sheet and correspondingly maintaining the configuration of said reusable countertop mold when the countertop forming material is disposed upon said mold.

6. The reusable countertop mold of claim 1 wherein said at least one stopper member is disposed such that said fastener recesses are completely inserted between the countertop substrate and the cabinet, thereby enabling said reusable countertop mold to receive the countertop forming material without any of the countertop forming material seeping through said fastener recesses.

7. The relatively rigid sheet of claim 1 wherein said wall portion of said relatively rigid sheet ultimately engages an adjacent wall portion of a second adjacent relatively rigid sheet such that the two relatively rigid sheets cooperate to ultimately extend a vertical wall and a horizontal base portion about the periphery of the countertop substrate to maintain the countertop forming material upon the countertop substrate and to extend the countertop forming material a preselected distance past the countertop substrate edges, thereby maintaining the countertop forming material in a fixed position until hardening to form a predetermined countertop configuration upon a substantially horizontal wall of the countertop substrate and an extended preselected distance past the countertop substrate edges.

8. The reusable countertop mold of claim 1 wherein shims are used to replace said base portion of said relatively rigid sheet after said base portion sheet has been slidably removed from between the countertop substrate and the cabinet, thereby supporting and maintaining the position of the countertop substrate relative to the cabinet.

9. A reusable countertop mold forming device comprising: a base portion having a configuration and dimensions that promote insertion of said base portion between a top edge portion of a cabinet and a bottom edge portion of a countertop substrate such that said configuration and dimensions of said base portion prevent engagement between said horizontal portion and retaining screws extending through the countertop substrate and into the top edge portion of the cabinet; a wall portion detachably joined to pullout tabs integrally joined to an outer end of said base portion, said detachable wall portion enabling a user of the reusable countertop forming device to replace the wall portion with a wall portion having a different longitudinal dimension; and at least one stopper member secured to a bottom wall of said base portion, said stopper member limiting the insertion dimension of said base portion between the bottom edge portion of the countertop substrate and the top edge portion of the cabinet, said at least one stopper member separated a distance from said pullout tabs that promotes the manual extraction of said base portion from an inserted position between the bottom edge portion of the countertop substrate and the top edge portion of the cabinet via said pullout tabs after a countertop forming material formed by said reusable countertop mold has hardened, thereby allowing said reusable countertop mold to be reused for another countertop forming project.

10. The reusable countertop forming device of claim 9 wherein said base portion includes a frictionless coating for reducing friction between said base portion and the countertop substrate and cabinet when said base portion is initially inserted between and ultimately removed from the countertop substrate and cabinet after a countertop forming material disposed in said mold has become rigid.

11. The reusable countertop mold of claim 9 wherein said base portion includes a deformable film for reducing friction between said base portion and the countertop substrate and cabinet when said base portion is initially inserted between and ultimately removed from the countertop substrate and cabinet after a countertop forming material disposed in said mold has become rigid.

12. The reusable countertop mold of claim 9 wherein shims are used to replace said base portion as said base portion is slidably removed from between the countertop substrate and the cabinet, thereby supporting and maintaining the position of the countertop substrate relative to the cabinet.

13. The reusable countertop mold of claim 9 wherein said base portion includes fastener recesses for each fastener recess to enable sufficient insertion of said base portion between the countertop substrate and the cabinet.

14. The reusable countertop mold of claim 13 wherein said fastener recesses include guide lines that identify centerlines for each fastener recess, thereby identifying the insertion point for fasteners relative to said fastener recesses to secure the countertop substrate to the cabinet with said reusable countertop mold inserted between the countertop substrate and the cabinet, and said fastener recesses not being visible to the user.

15. A reusable countertop mold for extending an edge portion of a countertop below a top edge portion of a cabinet comprising: a cabinet portion detachably secured to a countertop portion, said cabinet portion including a horizontal portion of said cabinet portion having a configuration and dimensions that promote insertion of said horizontal portion between a countertop substrate and a cabinet such that said configuration and dimensions of said base portion prevent engagement between said horizontal base portion and retaining screws inserted through the countertop substrate and into the cabinet, said cabinet portion including a vertical portion that vertically descends from said horizontal portion a predetermined distance that cooperates with a vertical portion of a base portion of said countertop portion such that said vertical portion of said base portion is detachably secured to said vertical portion of said countertop portion by at least one fastener, said vertical portion of said cabinet portion having at least one pullout tab integrally secured to an edge portion of said vertical portion of said cabinet portion, said countertop portion including a side wall portion integrally joined to said base portion such that an inner vertical wall of said side wall portion engages a countertop forming material to ultimately form an outer wall of an edge portion of a hardened countertop; and a countertop edge forming member disposed on said base portion of said countertop portion, said countertop edge forming member including a top wall having a horizontal dimension corresponding to a predetermined distance of separation between the side wall of the cabinet and an inner wall of a countertop edge portion, said countertop edge forming member including a side wall having a vertical dimension equal to the vertical dimension of said inner wall of the countertop edge portion, the dimensions of said top and side walls of said edge forming member and the dimensions of said cabinet and countertop portions cooperating to form a recess between said edge forming member and an inner side all of side wall portion, said recess ultimately filed with countertop forming material that results in an edge portion for a hardened countertop; whereupon, said reusable countertop mold is forcibly removed from the countertop substrate and the cabinet for use on another countertop forming project.

16. The reusable countertop mold of claim 15 wherein said horizontal portion of said base portion includes a frictionless coating film for reducing friction between said horizontal portion and the countertop substrate and cabinet when said horizontal portion is initially inserted between and ultimately removed from the countertop substrate and cabinet after a countertop forming material disposed in said mold has become rigid.

17. The reusable countertop mold of claim 15 wherein said horizontal portion of said cabinet portion includes a deformable film for reducing friction between said horizontal portion and the countertop substrate and cabinet when said horizontal portion is initially inserted between and ultimately removed from the countertop substrate and cabinet after a countertop forming material disposed in said mold has become rigid.

18. The reusable countertop mold of claim 15 wherein shims are used to replace said horizontal portion of said base portion as said horizontal portion is slidably removed from between the countertop substrate and the cabinet, thereby supporting and maintaining the position of the countertop substrate relative to the cabinet.

19. The reusable countertop mold of claim 15 wherein said at least one fastener is inserted through an aperture in a vertically descending portion of said base portion of said countertop portion, said at least one fastener received by a threaded aperture in said vertical portion of said cabinet portion, thereby allowing a user to adjust the vertical dimension of the outer wall of the edge portion of the countertop forming material by replacing said countertop portion with a selected countertop portion having a vertically descending portion of said base portion with a different longitudinal dimension.

20. The reusable countertop mold of claim 15 wherein said at least one fastener is inserted through a vertically disposed slot in a vertically descending portion of said base portion of said countertop portion, said at least one fastener rotationally inserted into and received by a threaded aperture in said vertical portion of said cabinet portion, thereby allowing a user to adjust the vertical dimension of the outer wall of the edge portion of the countertop forming material by vertically repositioning said vertically descending portion of said base portion of said countertop portion upon said vertical portion of said cabinet portion; whereupon, said at least one fastener is rotationally inserted into said threaded aperture in said vertical portion of said cabinet portion, resulting in a secured and repositioned base portion relative to said cabinet portion, and a corresponding vertical dimension for the vertical outer wall of the edge portion of the hardened countertop.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The foregoing invention and its advantages may be readily appreciated from the following detailed description of the preferred embodiment, when read in conjunction with the accompanying drawings in which:

[0014] FIG. 1 is a top view of a reusable counter top mold in accordance with the present invention.

[0015] FIG. 2 is a front view of mold in FIG. 1.

[0016] FIG. 3 is a side view of the mold in FIG. 1.

[0017] FIG. 4 is a side view of the mold in FIG. 3 inserted between a top edge portion of a cabinet and a bottom edge portion of a countertop substrate.

[0018] FIGS. 5-7 depict an alternative configuration for the mold depicted in FIGS. 1-4, the alternative configuration for the mold depicting stopper members and pullout tabs with different configurations and positions when compared to the same elements of FIGS. 1-4 in accordance with the present invention; FIG. 5 is a top view of the alternative configuration.

[0019] FIG. 6 is a front view of the alternative configuration of the mold in FIG. 5.

[0020] FIG. 7 is a side view of the alternative configuration of the mold in FIG. 5.

[0021] FIGS. 8-10 depict an alternative configuration for the mold depicted in FIGS. 5-7, the alternative configuration for FIGS. 8-10 has changed the location of the pull tabs of FIGS. 5-7 from a vertical position to a horizontal position in accordance with the present invention; FIG. 8 is a top view of the alternative configuration.

[0022] FIG. 9 is a front view of the mold of FIG. 8.

[0023] FIG. 10 is a side view of the mold of FIG. 8.

[0024] FIG. 11 is a top sectional view of the mold of FIG. 1 depicting a recess in the base portion.

[0025] FIG. 12 is a top sectional view of the mold of FIG. 11, but with the recess having a V configuration in accordance with the present invention.

[0026] FIG. 13 is a cutaway side view of mold having an alternative configuration for the mold depicted in FIG. 10 in accordance with the present invention.

[0027] FIG. 13A is a front view of only the mold of FIG. 13.

[0028] FIG. 13B is the side view of FIG. 13, but with the reusable countertop mold removed and a resulting extended edge portion of a countertop depicted.

[0029] FIG. 13C is a top view of FIG. 13.

[0030] FIG. 14 is a side view of the mold depicted in FIG. 13, but with a fastener securing the cabinet portion to the countertop portion.

[0031] FIG. 15 is a side view of the mold depicted in FIG. 3, but with a wall portion detachably secured to the pullout tabs of the base portion.

[0032] FIG. 16 is a side view of the mold depicted in FIG. 3, but with the wall portion having an arcuate configuration.

[0033] FIG. 17 is a side view of the mold depicted in FIG. 3, but with the wall portion having both lineal and arcuate configurations.

[0034] FIG. 18 is a side view of the mold depicted in FIG. 3, but with the wall portion having a rough or granular side wall.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0035] Referring to FIGS. 1-4, a reusable countertop mold in accordance with the present invention is denoted as numeral 10. The reusable countertop mold 10 includes at least one relatively thin and relatively rigid mold sheet 12, but generally a plurality of mold sheets 12 are required to extend about a predetermined portion of the periphery of a floor mounted cabinet 14. The mold sheet 12 can be fabricated from a myriad a materials including but not limited to plastic, wood and metals with the preferred fabricating material being steel. The mold sheet 12 is dimensioned and configured to ultimately form a countertop 16 having a predetermined configuration with predetermined dimensions. The mold sheet 12 includes a relatively thin base portion 18 and a wall portion 20 perpendicular to the base portion 18. The base and wall portions 18 and 20 can be formed by bending the mold sheet 12 or integrally joining two mold sheets 12 at edge portions such that a ninety degree angle is formed. The reusable countertop mold 10 includes a plurality of fastener recesses 23 in an inner side portion 22 of the base portion 18. The recesses 23 are disposed at predetermined locations in the inner side portion 22. The relatively thin inner side portion 22 promotes a substantially horizontal insertion of the inner side portion 22 of the base portion 18 between a top edge portion 24 of the cabinet 14 and a bottom edge portion 26 of a countertop substrate 28.

[0036] The plurality of fastener recesses 23 disposed at predetermined locations in the inner side portion 22 of said base portion 18 of the mold sheet 12 promote the insertion of retaining screws 30 through the countertop substrate 28 and through the fastener recesses 23 in the base portion 18 of mold sheet 12, which has been inserted between the top edge portion 24 of the cabinet 14 and between the bottom edge portion 26 of the countertop substrate 28. The insertion of the retaining screws 30 continues through fastener recesses 23 and into the top edge portion 24 of the cabinet 14, without the retaining screws 30 engaging the mold sheet 12, thereby allowing the mold sheet 12 to be slidably removed from an inserted position between the bottom edge portion 26 of the countertop substrate 28 and the top edge portion 24 of the cabinet 14 after a countertop forming material 16 has been poured upon the countertop substrate 28. The countertop forming material 16 is retained upon the countertop substrate 18 by the base and wall portions 18 and 20 of the mold sheet 12 and by the fastener recesses 23 being covered by the countertop substrate 28 after the base portion 18 of the mold sheet 12 is manually inserted between the countertop substrate 28 and the cabinet 14. The periphery of the countertop substrate 28 ultimately receives a plurality of the mold sheets 28 such that a peripheral vertical wall is formed by a plurality of wall portions 20 about the periphery of the countertop substrate 28 to maintain the countertop forming material 16 upon the countertop substrate 28 and to extend the countertop forming material 16 a preselected distance past substantially vertical countertop substrate edge portions 32, thereby maintaining the countertop forming material 16 in a fixed position until hardening to form a predetermined countertop 16 configuration upon and about the edge portions 32 of the countertop substrate 28.

[0037] The reusable countertop mold 10 further includes guide lines 34 that identify centerlines 21 for each fastener recess 23, thereby identifying the insertion point for a retaining screw 30 to insert through a fastener recess 23 and through the countertop substrate 28 and into the cabinet 14 with the reusable countertop mold 10 inserted between the countertop substrate 28 and the cabinet 14, such that the fastener recesses 23 are not visible to the user. The fastener recesses 23 are dimensioned to allow the retaining screws 30 to avoid engagement with the mold sheets 12. Further, the fastener recesses 23 are dimensioned to maximize an engagement portion 36 of the mold sheet 12, the engagement portion 36 ultimately engaging the top edge portion 24 of the cabinet 14 and the bottom edge portion 26 of the countertop substrate 28, thereby maintaining the configuration of the mold sheet 12 when a countertop forming material 16 is disposed upon the reusable countertop mold 10.

[0038] The reusable countertop mold 10 further includes at least one stopper member 38 secured to a bottom wall 40 of the base portion 20. The stopper member 38 limits the horizontal distance of insertion of sheet mold between the bottom edge portion 26 of the countertop substrate 28 and the top edge portion 24 of the cabinet 14. The horizontal insertion distance is determined when the stopper members 38 engage a side wall portion 42 of the cabinet 14. The engagement portion 36 of the base portion 18 of the reusable countertop mold 10 includes a frictionless coating or a deformable film on both sides for reducing friction between the engagement portion 36 and the countertop substrate 28 and cabinet 14 when the engagement portion 36 is initially inserted between and ultimately removed from the countertop substrate 28 and cabinet 14 after a countertop forming material 16 engaging the mold 10 has become rigid.

[0039] The reusable countertop mold 10 also includes pullout tabs 44 secured to the bottom wall 40 of the mold sheet 12. The pullout tabs 44 are disposed such that sufficient space is provided between the side wall 42 of the cabinet 14 and the pullout tabs 44 after the stopper members 38 engage the side wall 42 of the cabinet 14. The provided sufficient space enables a person to grasp the pullout tabs 44, whereby, the mold sheet 12 is manually urged from an inserted position between the bottom edge portion 26 of the countertop substrate 28 and the top edge portion 24 of the cabinet 14 via a person grasping the pullout tabs 44 and slidably removing the engagement portions 36 of the base portion 18 of the mold sheet 12 from an inserted position after the countertop forming material 16 has hardened, thereby allowing the reusable countertop mold 10 to be reused for another countertop forming project. If a relatively large gap is formed via the removal of the engagement portions 36, shims can be used to replace the engagement portions 36 of the base portion 18 as the engagement portions 36 are slidably removed from between the countertop substrate 28 and the cabinet 14, thereby supporting and maintaining the position of the countertop substrate 28 relative to the cabinet 14.

[0040] The method for reusing a countertop mold includes the steps of:

[0041] determining the configuration and dimensions for a predetermined countertop 16 to be formed upon a preselected cabinet 14;

[0042] determining the configuration and dimensions for a countertop substrate 28 to be disposed upon the preselected cabinet 14, the countertop substrate 28 ultimately receives a countertop forming material 16 that ultimately sets up or otherwise hardens to form a substantially horizontal top wall 48;

[0043] providing relatively mold sheets 12 dimensioned and configured to ultimately form the predetermined countertop 16. The mold sheets have a relatively thin base portion 18 that promotes a substantially horizontal insertion of the base portion 18 of the mold sheet 12 between a top edge portion 24 of the cabinet 14 and a bottom edge portion 26 of the countertop substrate 28. The mold sheet 12 includes a wall portion 20 integrally joined to the base portion 18 such that the wall portion 20 is perpendicular to the base portion 18;

[0044] forming a plurality of fastener recesses 23 disposed at predetermined locations in an inner side portion 22 of the base portion 18 of sheet mold 12. The fastener recesses 23 promote the insertion of retaining screws 30 through the countertop substrate 28, through the fastener recesses 23 and into the top edge portion 24 of the cabinet 14 without the retaining screws 30 engaging the mold sheet 12, thereby allowing the mold sheet to be slidably removed from an inserted position between the bottom edge portion 26 of the countertop substrate 28 and the top edge portion 24 of the cabinet 14 after a countertop forming material 16 has been poured upon the countertop substrate 28. The countertop forming material 16 is retained upon the countertop substrate 28 by the base and wall portions 18 and 20. The periphery of the countertop substrate 28 ultimately receives a plurality of the mold sheets 12 such that a peripheral vertical wall is formed about the periphery of the countertop substrate 28 to maintain the countertop forming material 16 upon the countertop substrate 28 and to extend the countertop forming material 16 a preselected distance past the countertop substrate edges 32, thereby maintaining the countertop forming material 16 in a fixed position until hardening to form a predetermined countertop configuration 16 upon and about a vertical side wall or edge 32 of the countertop substrate 28;

[0045] marking guide lines 34 that identify centerlines for each fastener recess 23 thereby identifying the insertion point for a fastener retaining screw 30 relative to the fastener recesses 23 to secure the countertop substrate 28 to the cabinet 14 with the reusable countertop mold 10 inserted between the countertop substrate 28 and the cabinet 14, such that fastener recesses 23 are not visible to the user. The fastener recesses 23 are dimensioned to allow the fasteners 30 to avoid engagement with the mold sheet. Further, the fastener recesses 23 are dimensioned to maximize an engagement portion 36 of the mold sheet 12 that engages the top edge portion 24 of the cabinet 14 and the bottom edge portion 26 of the countertop substrate 28, thereby maintaining the configuration of the mold sheet 12 when a countertop forming material 16 is disposed upon the reusable countertop mold 10;

[0046] providing at least one stopper member 38 secured to a bottom wall 40 of the mold sheet 12. The stopper member 38 limits the horizontal distance of insertion of mold sheet 12 between the bottom edge portion 26 of the countertop substrate 28 and the top edge portion 24 of the cabinet 14. The horizontal insertion distance is determined when the stopper members 38 engage a side wall portion 42 of the cabinet 14; and

[0047] providing pullout tabs 44 secured to the bottom wall 40 of the mold sheet 12. The pullout tabs 44 are disposed such that sufficient space is provided between the side wall 42 of the cabinet 14 and the pullout tabs 44 after the stopper member 38 engages the side wall portion 42 of the cabinet 14. The provided sufficient space enables a person to grasp the pullout tabs 44, whereby, the mold sheet 12 is manually urged from an inserted position between the bottom edge portion 26 of the countertop substrate 28 and the top edge portion 24 of the cabinet 14 via a person grasping the pullout tabs 44 and slidably removing the mold sheet from the inserted position after the countertop forming material 16 has hardened, thereby allowing the reusable countertop mold 10 to be reused for another countertop forming project.

[0048] In the event that overlapped end portion of molds 10 positioned side-by-side leave ridges or ghost lines, hand tools well known to those of ordinary skill in the art can be used to grind down the ridges until the desired smooth surface is achieved. Alternatively, the edges of adjacent molds 10 can be engagingly positioned between the countertop substrate 28 and the cabinet 14; whereupon, duct tape or similar binding material can be used to maintain the positions of the adjacently disposed molds 10. Although the formation of ghost lines is reduced or eliminated, the time to assemble multiple molds edge to edge, secure adjacent molds 10 together, and remove the molds after the countertop forming material 16 has hardened, is more expensive to achieve then grinding down ridges formed from overlapping end portions of adjacent molds 10.

[0049] Referring now to FIGS. 5-7, an alternative configuration for the mold depicted in FIGS. 1-4 is illustrated. The alternative mold configuration is denoted as numeral 60 and includes a mold 60 having a stopper member 62 and pullout tabs 64 with different configurations and positions when compared to the same stopper members 38 and pullout tabs 44, respectively, for the reusable counter top mold 10 of FIGS. 1-4. The configuration and position of the stopper member 62 promotes more stability for the mold 60 when inserted between the top edge portion 24 of the floor mounted cabinet 14 and the countertop substrate 28. The configuration and position of the pullout tabs 64 enables a person to improve his or her grip on the mold 60 when removing the mold 60 from between the top edge portion 24 and the countertop substrate 28 after the countertop forming material 16 has solidified.

[0050] Referring now to FIGS. 8-10, an alternative configuration for the mold depicted in FIGS. 5-7 is illustrated. The alternative mold configuration is denoted as numeral 70 and includes a mold 70 having the pullout tabs 72 horizontally positioned and secured to an outer wall 74 proximate to the base portion 18 of the mold 70. Positioning the pullout tabs 72 in a horizontal position adjacent to the base portion 18 decrease the quantity of force required by a person to exert when extracting the mold 70 from an insertion position between the top edge portion 24 of the floor mounted cabinet 14 and the countertop substrate 18 after the countertop forming material 16 has hardened.

[0051] Referring now to FIGS. 11 and 12, FIG. 11 depicts a top sectional view of the mold 10 of FIG. 1 having a relatively U configured recess 23 in the base portion 18. FIG. 12 depicts a mold 10 having the same base portion 18, but with a relatively V configured fastener recess 25 in the base portion 18. The V configuration provides more stability to the base portion 18 when forcibly inserting the base portion 18 between the top edge portion 24 of the floor mounted cabinet 14 and the countertop substrate 18. The V configured recesses 25 disposed at predetermined locations in the inner side portion 22 of said base portion 18 of the mold sheet 12 promote the insertion of retaining screws 30 through the countertop substrate 28 and through the fastener recesses 25 in the base portion 18 of mold sheet 12, which has been inserted between the top edge portion 24 of the cabinet 14 and between the bottom edge portion 26 of the countertop substrate 28. The insertion of the retaining screws 30 continues through fastener recesses 25 and into the top edge portion 24 of the cabinet 14, without the retaining screws 30 engaging the mold sheet 12, thereby allowing the mold sheet 12 to be slidably removed from an inserted position between the bottom edge portion 26 of the countertop substrate 28 and the top edge portion 24 of the cabinet 14 after a countertop forming material 16 has been poured and hardened upon the countertop substrate 28

[0052] Referring now to FIGS. 13 and 13A-13C, a modified reusable countertop mold 80 having an alternative configuration for the mold depicted in FIG. 10 is depicted in accordance with the present invention. The modified mold 80 enables an edge portion 92 of a countertop 16 to extend vertically lower than a top edge portion 24 of the floor mounted cabinet 14. The mold 80 includes a cabinet portion 82 integrally secured to a countertop portion 84 such that the cabinet portion 82 replaces the stopper members 28 and inserts between the countertop substrate 28 and the cabinet 14 a distance that does not engage the retaining screws 30 (inserted through the countertop substrate 28 and into the top edge portion 24 of the floor mounted cabinet 14), thereby eliminating the need for the recesses 23 and allowing the modified reusable countertop mold 80 to be slid or otherwise pulled (via vertical cabinet portion pullout tabs 73 integrally secured to a vertical edge portion of the cabinet portion 82) in a direction parallel to a side wall 42 of the cabinet 14. The modified mold 80 further includes a countertop edge forming member 86 disposed on a base portion 88 of the countertop portion 84. In the event that the mold 80 includes a cabinet portion 82 that inserts between the countertop substrate 28 and cabinet 14 a distance that does engage the retaining screws 30, recesses 23 and guide lines 34 that identify centerlines 21 for each fastener recess 23 can be used to enable sufficient insertion of the cabinet portion 82 between the countertop substrate 28 and the cabinet 14.

[0053] The countertop edge forming member 86 is fabricated from plastic, polyurethane, Styrofoam, or similar Polystyrene materials. The edge forming member 86 includes a top wall 87 having a horizontal dimension corresponding to a predetermined distance of separation between the side wall 42 of the cabinet 14 and an inner wall 91 of a countertop edge portion 92. The countertop edge forming member 86 further includes a side wall 89 having a vertical dimension equal to the vertical dimension of the inner wall 91 of the countertop edge portion 92. The dimensions of the top and side walls 87 and 89 of the edge forming member 86 and the dimensions of the cabinet and countertop portions 82 and 84 cooperating to form a recess between the side wall 89 of the edge forming member 86 and an inner side all 95 of the side wall portion 90 of the countertop portion 84. The formed recess is ultimately filed with countertop forming material 16 that results in an edge portion 92 for the hardened countertop 16.

[0054] FIGS. 13A and 13C are front and top views of FIG. 13 separated from the edge portion 92. FIG. 13 B depicts the resulting edge portion 92 after the modified mold 80 and polyurethane countertop forming member 86 are removed from the resulting edge portion 92 of the countertop 16. The resulting countertop edge portion 92 is horizontally offset from and vertically extending below the countertop substrate 28, thereby providing a more artistic countertop. It is preferred that the edge forming member 86 be forcibly removed in a generally downward direction from the hardened countertop 16, after the modified mold 80 has been removed from between the substrate 28 and cabinet 14 by forcibly sliding the mold 80 parallel to the side wall portion 42 of the cabinet 14. Alternatively, the edge forming member 86 can be left in place to fortify the countertop edge portion 92 without the member 86 being visible.

[0055] Referring now to FIG. 14, a side view of the modified mold 80 in FIG. 13 is illustrated without the pullout tabs 72, but with pullout tabs 73 integrally joined to the vertical portion of the cabinet portion 82 of the mold 80. FIG. 14 further includes the detachable joining of the base portion 88 of the countertop portion 84 to the vertical portion of the cabinet portion 82 via fastener 96. The fastener 96 is inserted through an aperture (not depicted) in a vertically descending portion of the base portion 88 of the countertop portion 84. The fastener 96 is rotationally inserted into and received by a threaded aperture in the vertical portion of the cabinet portion 82, thereby allowing a user to adjust the vertical dimension of the vertical outer wall 94 of the edge portion 92 of the countertop forming material 16 by replacing the countertop portion 84 with a selected countertop portion having a vertically descending portion of the base portion 88 with a different longitudinal dimension.

[0056] Alternatively, the fastener 96 is inserted through a vertically disposed slot (not depicted) in a vertically descending portion of the base portion 88 of the countertop portion 84. The fastener 96 is rotationally inserted into and received by a threaded aperture in the vertical portion of the cabinet portion 82, thereby allowing a user to adjust the vertical dimension of the outer wall 94 of the edge portion 92 of the countertop forming material 16 by slightly extracting the fastener 96 from the vertical portion of the cabinet portion 82 and vertically repositioning the vertically descending portion of the base portion 88 of the countertop portion 84 upon the vertical portion of the cabinet portion 82. The fastener 96 is then re-inserted and tightened into the threaded aperture in the vertical portion of the cabinet portion 82, resulting in a secured and repositioned base portion 88 relative to the cabinet portion 82, and a corresponding vertical dimension for the vertical outer wall 94 of the edge portion 92 of the hardened countertop 16.

[0057] The modified mold 80 of FIG. 14 is adjustable such that the vertical elevation of the countertop forming material 16 above the countertop substrate 28 is adjusted by varying the vertical dimension of a side wall portion 90 of the countertop portion 84. The inclusion of the fastener 96 enables the countertop portion 84 to be removed (after the countertop forming material 16 has hardened) by removing the fastener 96; whereupon, the countertop portion 84 is separated from the cabinet portion 82 and the countertop forming member 86 is forcibly and manually lowered and removed from the hardened countertop forming material 16.

[0058] The horizontal portion of the cabinet portion 82 of the mold 80 is manually extracted from between the substrate 28 and the cabinet 14 by perpendicularly urging the vertical portion of the cabinet portion 82 from the side wall 42 of the cabinet 14 via the pullout tabs 73 until the cabinet portion 82 is separated from both the countertop substrate 28 and the cabinet 14, thereby positioning the cabinet portion 82 in a recess formed by the removal of the countertop forming member 86. The cabinet portion 82 is then lowered and removed from the edge portion 92 of the hardened countertop forming material 16. The cabinet portion 82 and countertop portion 84 are again secured together by the fastener 96 to enable the resulting mold 80 to be reused on another project. It is preferred that the edge forming member 86 be forcibly removed in a generally downward direction from the hardened countertop 16, after the modified mold 80 has been removed from between the substrate 28 and cabinet 14 by forcibly sliding the mold 80 parallel to the side wall portion 42 of the cabinet 14. Alternatively, the edge forming member 86 can be left in place to fortify the countertop edge portion 92 without the member 86 being visible.

[0059] Referring now to FIG. 15, a side view of the mold 10 in FIG. 3 is illustrated, but with a fastener 102 detachably securing a wall portion 100 to the pullout tabs 44 integrally joined to an outer end 43 the base portion 18. Detachably securing the wall portion 100 to the pullout tabs 44 enables a user of the mold 10 to vary a wall portion 100 and correspondingly vary the vertical dimension and a predetermined wall surface 104 configuration that engages the countertop forming material 16. After the material 16 hardens, the configuration of the wall surface 104 is transferred to the vertical wall 94 (see FIG. 13B) of the edge portion 92 of the material 16. This feature enables a person using the mold 10 to select one of a myriad of possible wall surfaces 104 to configure the vertical wall 94 of the countertop forming material 16 extending past the side wall portion 42 of the cabinet 14. For example, the wall surface 104 can have an arcuate configuration 106 (see FIG. 16), a combination arcuate-lineal configuration (see FIG. 17), or a rough or granular configuration (see FIG. 18).

[0060] The foregoing description is for purpose of illustration only and is not intended to limit the scope of protection accorded this invention. The scope of protection is to be measured by the following claims, which should be interpreted as broadly as the inventive contribution permits.