A Method for Fabricating and Installing Porcelain Enamel Kitchen Countertops

Abstract

A method for providing a countertop with a porcelain enamel surface. A metal substrate is provided with a series of cut lines. The metal substrate is formed to fit a countertop frame. A coating of porcelain enamel is applied to the surface of the metal substrate. The porcelain enamel is fused to the sheet metal through a firing process which preferably reaches between 1380 degrees Fahrenheit and 1560 degrees Fahrenheit. The metal substrate is installed over the countertop frame.

Having described my invention, I claim: 
     
         1 . A method for making a porcelain-enameled countertop comprising the steps of:
 a. providing a countertop frame having a series of measurements;   b. providing a metal substrate, having a surface;   c. cutting said metal substrate to meet said series of measurements of said countertop;   d. providing a coating of porcelain enamel applied to said surface of said metal substrate;   e. heating said sheet metal to a fusing temperature forming said porcelain-enameled countertop; and   f. installing said porcelain-enameled countertop on said countertop frame.   
     
     
         2 . The method for making a porcelain-enameled countertop as recited in  claim 1 , wherein said step of cutting said metal substrate to meet said series of measurements of said countertop further comprises a step of bending said metal substrate to form an integral backsplash. 
     
     
         3 . The method for making a porcelain-enameled countertop as recited in  claim 1 , wherein said fusing temperature is above 800 degrees Fahrenheit. 
     
     
         4 . The method of making a porcelain-enameled countertop as recited in  claim 1 , wherein said fusing temperature is between 1380° F. and 1560° F. 
     
     
         5 . The method of making a porcelain enamel countertop as recited in  claim 1 , wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises spraying said porcelain enamel in an electrostatic form on said surface of said metal substrate. 
     
     
         6 . The method of making a porcelain enamel countertop as recited in  claim 1 , wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises dipping said metal substrate into said porcelain enamel. 
     
     
         7 . A method for making a porcelain-enameled countertop comprising the steps of:
 a. providing a countertop frame;   b. providing a metal substrate, having a surface and a series of cut lines;   c. forming said metal substrate to fit said countertop frame;   d. providing a coating of porcelain enamel applied to said surface of said metal substrate;   e. fusing said porcelain enamel to said metal substrate by heating said porcelain-enamel and said metal substrate to a temperature of above 800° F. to form said porcelain-enameled countertop; and   f. installing said porcelain-enameled countertop on said countertop frame.   
     
     
         8 . The method of making a porcelain-enameled countertop as recited in  claim 7 , wherein said step of forming said metal substrate to fit said countertop frame comprises cutting said metal substrate along said series of cut lines. 
     
     
         9 . The method of making a porcelain-enameled countertop as recited in  claim 8 , wherein said step of forming said metal substrate to fit said countertop frame comprises bending said metal substrate to form an overhanging front lip. 
     
     
         10 . The method of making a porcelain-enameled countertop as recited in  claim 8 , wherein said step of forming said metal substrate to fit said countertop frame comprises bending said metal substrate to form an integral backsplash. 
     
     
         11 . The method of making a porcelain-enameled countertop as recited in  claim 8 , wherein said fusing temperature is between 1380° F. and 1560° F. 
     
     
         12 . The method of making a porcelain enamel countertop as recited in  claim 7 , wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises spraying said porcelain enamel in an electrostatic form on said surface of said metal substrate. 
     
     
         13 . The method of making a porcelain enamel countertop as recited in  claim 7 , wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises dipping said metal substrate into said porcelain enamel. 
     
     
         14 . A method for making a porcelain-enameled countertop comprising the steps of:
 a. providing a countertop having a surface;   b. providing at least two pieces of a metal substrate having a surface and a series of cut lines;   c. cutting said metal substrate into a series of pieces along said series of cut lines;   d. providing a coating of porcelain enamel applied to said surface of said series of pieces of said metal substrate;   e. fusing said porcelain enamel to said metal substrate by heating said porcelain enamel and said metal substrate to a temperature of above 800° F.;   f. fitting said series of pieces of said metal substrate together; and   g. installing said porcelain-enameled countertop on said countertop frame.   
     
     
         15 . The method of making a porcelain enamel countertop as recited in  claim 14 , wherein said step of cutting said metal substrate into a series of pieces along said series of cut lines further comprises cutting a tongue and groove joint such that said series of pieces of said metal substrate can be fitted together. 
     
     
         16 . The method of making a porcelain-enameled countertop as recited in  claim 14 , wherein said fusing temperature is between 1380° F. and 1560° F. 
     
     
         17 . The method of making a porcelain enamel countertop as recited in  claim 14 , wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises spraying said porcelain enamel in an electrostatic form on said surface of said metal substrate. 
     
     
         18 . The method of making a porcelain enamel countertop as recited in  claim 14 , wherein said step of providing a coating of porcelain enamel applied to said surface of said metal substrate further comprises dipping said metal substrate into said porcelain enamel.