Mold process for producing a finished solid surface countertop

摘要

A mold process for producing a finished solid surfaced countertop in which a mold of the product to be produced is placed in a substantially horizontal manner. A series of barriers are constructed atop a flat polished surface of the mold and creates a negative shape of the countertop product to be produced. A release wax surface is applied over the exposed edges of the mold and is followed by the spraying a predetermined layer of a high-quality resin surface coating. The coating is allowed to gel to a point at which a plasticized substrate material is poured into the mold and over the resin surface coating. A catalyst is added to the substrate material prior to pouring and elevates the temperature of the substrate and the surface coating during the hardening and curing process. The surface coating bonds to the substrate and cures without the development of pinholes or other imperfections in the surface coating. Subsequent layers of substrate material may be poured to reach any desired thickness and then one or more backing portions are attached to the countertop to permit the countertop to be attached to a cabinet. The finished countertop is allowed to harden and cure within the mold for a given period of time and is then removed from the mold to cure for an additional period of time.