Seamless flush mounted countertop sink
AssigneeExcelstone International, Inc.
InventorsArthur J. Crigler, Hai Lecong
Life of this patent
Estimating the term…
Abstract
A process for fabricating a seamless flush mounted countertop sink, which includes the steps of constructing a sink bowl (22) that has an outwardly extending peripheral top flange (26). The sink bowl is then captivated upside-down on a flat mold (34) and uncured filled polymer (40) is poured on the mold and flattened to a level above the flange, creating an integral countertop sink (44). The polymer is vibrated and cured. In the preferred embodiment, the top surface of the countertop is sanded smooth and, in the second embodiment, a clear gelcoat is added prior to pouring, creating a glossy finish. The third embodiment spaces the sink bowl flange within the thickness of the countertop (42) and is finished by either sanding, or a previous gelcoat is added, as above.
Claims22
A process for fabricating a seamless flush mounted countertop sink which comprises the steps of:
- a) constructing a sink bowl having an outwardly extending peripheral top flange, a concave bowl, and an opening for a drain,
- b) captivating said sink bowl in an inverted attitude on a smooth flat mold having a raised perimeter rim,
- c) pouring uncured filled polymer on said flat mold and sink bowl to a level above the sink peripheral flange of from 25 percent to 50 percent of its total level to form an integral countertop sink,
- d) vibrating said flat mold to settle the polymer,
- e) curing the polymer for a time duration of from 35 minutes to 40 minutes.
- f) removing the countertop sink from the flat mold and post curing for a time duration of from 3 hours to 5 hours, and
- g) smoothing the countertop working surface with grit impregnated abrasive media.
A process for fabricating a seamless flush mounted countertop sink which comprises the steps of:
- a) constructing a sink bowl having an outwardly extending peripheral top flange, a concave bowl and an opening for a drain,
- b) captivating said sink bowl in an inverted attitude on a smooth flat mold having a raised perimeter rim,
- c) applying a transparent gelcoat to exposed sink bowl surfaces and flat mold including inner raised perimeter rim,
- d) pouring uncured filled polymer on said coated flat mold and coated sink bowl to a level above the sink peripheral flange of from 25 percent to 50 percent of its total level to form an integral countertop sink,
- e) vibrating said flat mold to settle the polymer,
- f) curing the polymer for a time duration of from 35 minutes to 40 minutes, and
- g) removing the countertop sink from the flat mold and post curing for a time duration of from 3 hours to 5 hours.
A process for fabricating a seamless flush mounted countertop sink which comprises the steps of:
- a) constructing a sink bowl having an outwardly extending peripheral top flange, a concave bowl, and an opening for a drain,
- b) attaching a plug to a smooth flat mold having a raised perimeter rim,
- c) captivating said sink bowl in an inverted attitude on the plug with the peripheral top flange spaced from 0.19 inch (0.48 cm) to 0.31 inch (0.79 cm) above the flat mold,
- d) pouring uncured filled polymer on said flat mold and sink bowl to a level above the sink peripheral flange of from 15 percent to 30 percent of its total level, to form an integral countertop sink,
- e) vibrating said flat mold to settle the polymer,
- f) curing the polymer for a time duration of from 35 minutes to 40 minutes, and
- g) removing the countertop sink from the flat mold and post curing for a time duration of from 3 hours to 5 hours.
Dependencies are inferred from the claim text.