Modular countertop and system

Abstract

A modular countertop includes a composite layer and a support layer. The composite layer includes a top surface and a bottom surface and is formed of a polymer matrix with a filler material dispersed there through. The support layer is bonded to the bottom surface of the composite layer, and the composite layer and the support layer have a combined thickness less than about 1.25 inches.

1 . A modular countertop comprising:
 a composite layer having a top surface and a bottom surface, the composite layer including a filler material dispersed within a polymer matrix; and   a support layer bonded to the bottom surface of the composite layer, the composite layer and the support layer having a combined thickness less than about 1.25 inches.   
   
   
       2 . The modular countertop as recited in  claim 1 , wherein the polymer matrix includes acrylic and the filler material includes aluminum trihydrate. 
   
   
       3 . The modular countertop as recited in  claim 1 , wherein the support layer is a wood fiber board. 
   
   
       4 . The modular countertop as recited in  claim 1 , wherein the polymer matrix includes acrylic, the filler material includes aluminum trihydrate, and the support layer is a wood fiber board. 
   
   
       5 . The modular countertop as recited in  claim 1 , further comprising an adhesive layer between the composite layer and the support layer. 
   
   
       6 . The modular countertop as recited in  claim 1 , wherein each one of the composite layer and the support layer has a thickness of one-half inch. 
   
   
       7 . The modular countertop as recited in  claim 1 , wherein the combined thickness is about one inch. 
   
   
       8 . The modular countertop as recited in  claim 1 , wherein the composite layer and the support layer extend between unfinished side edges, an unfinished back edge, and a finished front edge having a radiused corner. 
   
   
       9 . A modular countertop system comprising:
 a first modular countertop having a first size, the first modular countertop being trimmable at a first installation site based on required measurements from the first installation site to form a first finished countertop section having a first finished size that is different than the first size; and   a second modular countertop having a second size that is trimmable at a second installation site based on required measurements from the second installation site to form a second finished countertop section having a second finished size, each of the first modular countertop and the second modular countertop including a composite layer and a support layer bonded to the composite layer, the composite layer including a filler material dispersed within a polymer matrix, wherein the composite layer and the support layer have a combined thickness less than about 1.25 inches.   
   
   
       10 . The modular countertop system as recited in  claim 9 , wherein each of the first modular countertop and the second modular countertop is trimmable using portable hand-held tools. 
   
   
       11 . The modular countertop system as recited in  claim 9 , wherein the first finished size corresponds to a first building structure, and the second finished size corresponds to a second, different building structure. 
   
   
       12 . The modular countertop system as recited in  claim 9 , wherein the first size is the same as the second size. 
   
   
       13 . The modular countertop system as recited in  claim 9 , wherein the first finished size is different than the second finished size. 
   
   
       14 . A method for use with a modular countertop, comprising:
 determining a desired final size of a space at an installation site for installation of a finished modular countertop; and   trimming a modular countertop at the installation site from a first size to the desired final size to form the finished modular countertop, the modular countertop including a composite layer and a support layer bonded to the composite layer, the composite layer including a filler material dispersed within a polymer matrix, wherein the composite layer and the support layer have a combined thickness less than about 1.25 inches.   
   
   
       15 . The method as recited in  claim 14 , wherein the determining of the desired final shape and size includes measuring at the installation site. 
   
   
       16 . The method as recited in  claim 14 , including trimming the modular countertop using portable hand-held tools. 
   
   
       17 . The method as recited in  claim 14 , wherein the trimming includes cutting a piece off the modular countertop at the installation site and attaching the piece as an end cap on a cut edge of the modular countertop. 
   
   
       18 . The method as recited in  claim 14 , wherein the trimming includes cutting a final countertop piece, a back splash piece, or an end cap piece from the modular countertop. 
   
   
       19 . The method as recited in  claim 14 , wherein the trimming includes cutting an unfinished side of the modular countertop. 
   
   
       20 . The method as recited in  claim 14 , further comprising trimming a second modular countertop at the installation site to a second final size that is different than the final size of the modular countertop.