Method for manufacturing counter tops

Abstract

An improved solid surface which, by means of an increased thickness, reduces fabrication time and cost. The solid surface is manufacture from alumina tri-hydrate, ground up granules of a previously cast solid surface and resin. A catalyst is added and the resulting mixture is poured onto a mold and cured to form a sheet of solid surface having a thickness of about 3 cm. The solid surface may be used for counter tops.

1 . A method for manufacturing a solid surface, comprising: 
 pouring alumina tri-hydrate into a vat mixer having vacuum capabilities;    pouring ground up granules of a previously cast solid surface;    adding a resin to the vat mixer to form a mixture wherein the alumina tri-hydrate and granules comprise at least thirty-five percent of the mixture;    mixing the alumina tri-hydrate, granules and resin until a homogeneous mixture is formed;    following mixing, adding a catalyst to the vat;    mixing in the catalyst to form a moldable mixture;    pouring the moldable mixture onto a mold;    curing the moldable mixture to form a sheet of solid surface; and    releasing the sheet from the mold.    
   
   
       2 . The method of  claim 1  wherein the ground granules are obtained by: 
 providing a cured sheet of solid surface manufactured from alumina tri-hydrate, granules and resin; and    grinding the cured sheet to form granules.    
   
   
       3 . The method of  claim 1  wherein the alumina tri-hydrate and granules comprise between fifty and seventy percent of the mixture.  
   
   
       4 . The method of  claim 1  wherein the alumina tri-hydrate and granules comprise fifty-five percent of the mixture and the resin comprises forty-three percent of the mixture.  
   
   
       5 . The apparatus of  claim 1  wherein the resin is selected from the group consisting of acrylic resin, polyester resin and polyester acrylic resin.  
   
   
       6 . The apparatus of  claim 1  wherein the resin is polyester acrylic resin comprised of idophthalic acid, acrylic ester, propanediol, diethylene glycol, malice anhydride, ethylene glycol, benze anhydride and adipic anhydride.  
   
   
       7 . The method of  claim 1 , further comprising the step: 
 imparting a desired color to the homogenous mixture.    
   
   
       8 . The method of  claim 7  wherein at least one polyester coloring paste imparts the desired color to the homogeneous mixture.  
   
   
       9 . The method of  claim 1  wherein the catalyst is peroxide.  
   
   
       10 . The method of  claim 1  wherein the mold is selected from the group consisting of glass, stainless steel and fiberglass.  
   
   
       11 . The method of  claim 1  wherein the mold is glass.  
   
   
       12 . The method of  claim 1  further comprising: 
 following the pouring step, the moldable mixture is agitated such that the moldable mixture settles on the mold.    
   
   
       13 . The method of  claim 12  wherein agitation of the moldable mixture is caused by vibrating the mold.  
   
   
       14 . The method of  claim 1  wherein curing step comprises: 
 applying a predetermined amount of heat to the moldable mixture for a first predetermined amount of time; and    removing the heat from the moldable mixture for a second predetermined amount of time.    
   
   
       15 . The method of  claim 1  wherein curing step comprises: 
 placing the mold into an oven and heating the moldable mixture to about 130° F. for about two hours; and    removing the mold from the oven to a temperature of about 65° F. to 85° F. for four hours.    
   
   
       16 . The method of  claim 1  further comprising: 
 following the releasing step, polishing the sheet to provide finished sheets of solid surface.    
   
   
       17 . The method of  claim 16  wherein the sheet is polish with diamond polishing pads and water.  
   
   
       18 . A sheet of solid surface consisting essentially of alumina tri-hydrate, ground up granules of a previously cast solid surface and resin mixed into a homogeneous mixture and further mixed with a catalyst wherein the homogenous mixture and resin are poured onto a mold and cured to form the sheet having a thickness of about 3 cm.  
   
   
       19 . The sheet of  claim 18  wherein the resin is selected from the group consisting of acrylic resin, polyester resin and polyester acrylic resin and the catalyst is peroxide.  
   
   
       20 . The sheet of  claim 18  wherein the alumina tri-hydrate and ground up granules of a previously cast solid surface comprise at least thirty-five percent of the homogeneous mixture.