Laminate countertop with synthetic polymer substrate
AssigneeVangura Kitchen Tops, Inc.
InventorEdward P. Vangura
Life of this patent
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Abstract
A laminate countertop with a curved edge profile includes a base support including a synthetic polymer material. The synthetic polymer material can be a closed-cell polymer foam. The base support includes a top surface, a bottom surface, opposing longitudinal sides, at least one of which comprises the curved edge profile, and opposing latitudinal sides. The countertop also includes a laminate cover formed from a cured resin material adhered to and covering at least a portion of the top surface and at least a portion of the curved edge profile of the base support. A method for forming the laminate countertop includes steps of providing the base support and adhering the laminate cover over at least a portion of the top surface and a portion of the curved edge profile of the base support.
Claims18
A laminate countertop with a curved edge profile, comprising:
- a base support comprising a synthetic polymer material, the base support having a top surface, a bottom surface, opposing longitudinal sides, wherein the curved edge profile is carved on or molded to at least one of the opposing longitudinal sides, and opposing latitudinal sides, wherein the curved edge profile comprises an upper lip comprising an outwardly facing first convexly curved portion, a lower lip comprising an outwardly facing second convexly curved portion, and a flat vertical or angled portion extending between the first convexly curved portion and the second convexly curved portion;
- a laminate cover formed from a cured resin material adhered to and covering at least a portion of the top surface and at least a portion of the curved edge profile of the base support;
- and
- at least one preformed straight edge member having the curved edge profile connected to at least one of the latitudinal sides of the base support, such that the curved edge profile extends around a corner of the countertop,
- wherein the at least one preformed straight edge member comprises a plug comprising the synthetic polymer material having an outer surface comprising the curved edge profile, and a pre-stamped laminate cover formed from the cured resin material stamped in the curved edge profile adhered to the outer surface of the plug, and
- wherein the plug comprises a plurality of weep holes that extend from the outer surface of the plug to an inner surface of the plug, the plurality of weep holes being positioned to direct excess flowable adhesive away from a space between the pre-stamped laminate cover and the plug toward the inner surface of the plug.
A laminate countertop with a curved edge profile, comprising:
- a base support comprising a synthetic polymer material, the base support having a top surface, a bottom surface, opposing longitudinal sides, wherein the curved edge profile is carved on or molded to at least one of the opposing longitudinal sides, and opposing latitudinal sides, wherein the curved edge profile comprises an upper lip comprising an outwardly facing first convexly curved portion, a lower lip comprising an outwardly facing second convexly curved portion, and a flat vertical or angled portion extending between the first convexly curved portion and the second convexly curved portion;
- a laminate cover formed from a cured resin material adhered to and covering at least a portion of the top surface and at least a portion of the curved edge profile of the base support;
- and
- at least one preformed straight edge member having the curved edge profile connected to at least one of the latitudinal sides of the base support, such that the curved edge profile extends around a corner of the countertop,
- wherein the at least one preformed straight edge member comprises:
- a plug comprising the synthetic polymer material having an outer surface comprising the curved edge profile;
- a pre-stamped laminate cover formed from the cured resin material stamped in the curved edge profile adhered to the outer surface of the plug;
- and
- a plurality of brace holes extending through the pre-stamped laminate cover into a bottom surface of the plug, the plurality of brace holes being positioned to receive hooks of a brace for securing the at least one preformed straight edge member to the brace for adhering the pre-stamped laminate cover to the plug.
Dependencies are inferred from the claim text.