Abstract:
An integrated system and method for fabricating a countertop from a slab is disclosed. The system includes a cutting station where an apron strip of a predetermined size is cut from a slab, a translating station where the apron strip is translated and positioned along the cut edge of the slab, and a press for adhesively bonding the apron to the cut edge of the slab.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a method and apparatus for fabricating countertops. More particularly, the invention relates to an automated system for fabricating granite, marble, engineered stone and/or solid surface material countertops. 
     2. Description of the Prior Art 
     Granite, marble, engineered stone, and solid surface materials have become the materials of choice in the manufacture of countertops for home and commercial use. While the material composition of engineered stone and solid surface materials has improved over time, the methods employed in fabricating countertops, and other surfaces, from these materials has not changed. 
     Specifically, countertops made from granite, marble, engineered stone and solid surface materials are commonly fabricated in a manual, labor intensive manner. The fabricators are highly skilled artisans and rely upon a series of manual techniques to complete the fabrication of a countertop. Current techniques have been in use for many years, and few developments have been initiated to improve the process of fabricating such countertops. 
     While the techniques employed by skilled fabricators result in durable and aesthetically pleasing surfaces, the techniques require a substantial investment in time, equipment and space. The time consumed in the manufacturing process substantially increases the price of installing granite, marble, engineered stone and solid surface materials within a home or commercial application. 
     If the fabrication time for these materials were reduced, the cost of installing an engineered stone countertop, for example, would drop. As such, many consumers who would prefer an engineered stone countertop, but were previously unable to afford such countertops, would be able to purchase the countertop they desire. A need, therefore, exists for an automated system for fabricating countertops from granite, marble, engineered stone and solid surface materials, as well as other related materials. The present invention provides such a system. 
     SUMMARY OF THE INVENTION 
     It is, therefore, an object of the present invention to provide an integrated system for fabricating a countertop from a slab. The system includes a saw for cutting an apron strip of a predetermined size from a slab, an adhesive station where adhesive is applied prior to bonding the apron strip to the slab, a translating device for moving the apron strip into position along an edge of the slab, and a press securely holding the apron strip and the slab while the adhesive forms a secure bond between the apron strip and the slab. 
     Other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic of the present system. 
     FIG. 2 is a cross sectional view of a countertop manufactured in accordance with the present invention. 
     FIG. 3 is a perspective view of a slab processed in accordance with the present invention. 
     FIG. 4 is an exploded view of the countertop. 
     FIG. 5 is a cross sectional view of a countertop manufactured in accordance with an alternate embodiment of the present invention. 
     FIG. 6 is a perspective view of a slab in accordance with the embodiment disclosed in FIG.  5 . 
     FIG. 7 is an exploded view of the countertop in accordance with the embodiment disclosed in FIG.  5 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The detailed embodiments of the present invention are disclosed herein. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limited, but merely as the basis for the claims and as a basis for teaching one skilled in the art how to make and/or use the invention. 
     With reference to FIG. 1, a schematic of the present system  10  is disclosed. The system  10  provides an automated method and apparatus for use in the manufacture of countertops from materials such as, for example, engineered stone, granite, marble and solid surface materials. While engineered stone, granite, marble and solid surface materials are disclosed in accordance with the preferred embodiment of the present invention, other similar materials may be used in accordance with the present invention. 
     The system  10  is composed of a series of integrated stations facilitating the manufacture of a countertop  12  from a single slab  14  of material. In accordance with a preferred embodiment of the present invention, the slab  14  is an engineered stone composed of approximately 92-93% granite and approximately 7-8% polyester resin. The slab is approximately ¾ inch (2 cm) thick, 10 feet (304.8 cm) long, and 48 inches wide (121.9 cm). As those skilled in the art will readily appreciate, various dimensions are provided throughout the body of the present application and in accordance with the preferred embodiment of the present invention. However, those skilled in the art will understand that the disclosed dimensions may be readily varied to suit specific applications without departing from the spirit of the present invention. 
     With reference to FIGS. 1-4, the slab is first placed on an in-feed conveyor  16  with its top or good side  18 , facing downwardly. The slab  14  is fed into a grinder  20  where the backside  22  of the slab  14  is wet ground and trued. 
     Once the backside  22  of the slab  14  is properly trued, the slab  14  is conveyed to a saw assembly  24  where an apron strip  26  of approximately 1½ inches (4 cm) is wet cut from the slab  14  (see FIGS.  2  and  3 ). The apron strip  26  is cut from the forward portion  28  of the slab  14  along the longitudinal axis of the slab  14 . 
     Specifically, and with reference to FIGS. 3 and 4, the apron strip  26  is formed by cutting the apron strip  26  from the front portion  28  of slab  14 . In accordance with the preferred embodiment of the present invention, the resulting apron strip  26  is approximately 1½ inches (4 cm) wide (exposed top side  44 ), ¾ inch (2 cm) thick, and 10 feet (304.8 cm) long. The resulting front edge  34  of the slab  14  is perpendicular to the top side  18  of the slab  14  and is approximately the thickness of the slab  14 , that is, ¾ inches (2 cm). 
     The slab  14  and apron strip  26  are then conveyed to an air knife  30  where the materials are thoroughly dried prior to further processing. Once the materials are thoroughly dried, they are transported to an adhesive station  32  controlled by an operator. 
     The operator applies adhesive to the backside  22  of the slab  14  at the location where the apron strip  26  is to be bonded. While the disclosed embodiment discloses an operator controlled adhesive station  32 , it is contemplated that the adhesive station may be fully automated without departing from the spirit of the present invention. In addition, and in accordance with the preferred embodiment of the present invention, the adhesive is preferably WILSONART  8206 , an epoxy adhesive, although other adhesives may be used without departing from the spirit of the present invention. The adhesive is preferably color matched with the stone, or other material, with which it is being used. 
     A rotary device  36  then translate, more particularly, rotates, the apron strip  26  180° such that its backside  38  of the apron strip faces the backside  22  of the slab adjacent the front edge  34  of the slab  14 . Similarly, the cut edge  39  of the apron strip  26  faces outwardly in alignment with the front edge  34  of the slab  14 , and the former top side  44  of the apron strip  26  faces downwardly. 
     The apron strip  26  and slab  14  are then placed within a press  40  where the backside  38  of the apron strip  26  is brought into contact with the backside  22  of the slab  14 . The components are then securely held in position for approximately six minutes. 
     A six minute press time is preferred when WILSONART  8206  adhesive is used to bond engineered stone as discussed above. However, those skilled in the art will readily appreciate that the press times may vary depending upon the materials and adhesive employed with the present system. 
     After the slab  14  is held within the press  40  for an appropriate time period, the slab  14  is released and ready for final processing. Specifically, the slab  14  is conveyed from the press  40  to a profiling machine  42  where the exposed top side  18  and front edge  34  of the slab  14 , as well as the exposed cut edge  39  and top side  44  of the apron strip  26 , are shaped as desired by the consumer. Specifically, and in accordance with the preferred embodiment of the present invention, a Bordibreton CT profiling machine is used, although other profiling machines may be used without departing from the spirit of the present invention. 
     The entire process discussed above is monitored and controlled by a control system  46  integrated with the present system  10 . 
     In accordance with a further embodiment of the present invention, and with reference to FIGS. 5,  6 , and  7 , the apron strip  126  is formed by cutting a V-groove  127  in the backside  122  of the slab  114 . In practice, it is contemplated that the backside will be facing upwardly while the V-groove is formed. The V-groove is approximately 90°, and results in an angled front edge  134  (of slab  114 ) of 45° and an angled backside  138  (of apron  126 ) of 45°, although other angular orientations may be employed without departing from the spirit of the present invention. The resulting apron strip  126  is approximately 1½ inches (4 cm) wide (exposed top side  144 ), ¾ inch (2 cm) thick, 1.06 inches (2.69 cm) along the angled backside portion  138  and 10 feet (304.8 cm) long. The resulting angled front edge  134  of the slab  114  is oriented at a 45° angle and is approximately 1.06 inches (2.69 cm). 
     By cutting the slab  114  in this manner, the angled front edge  134  of the slab  114  and the angled backside  138  of the apron strip  126  provide additional surface area which improves the bonding strength between the slab  114  and the apron strip  126  when they are assembled in the manner discussed below. In addition, the angled cut results in a seam at the forward point  139  of the resulting countertop  112 . 
     The slab  114  and apron strip  126  are then assembled in much the same manner as discussed above with regard to the embodiment disclosed in FIGS. 2,  3  and  4 . Specifically, the slab  114  and the apron strip  126  are conveyed to an air knife  30  where the materials are thoroughly dried prior to further processing. Once the materials are thoroughly dried, they are conveyed to an adhesive station  132  controlled by an operator. 
     The operator applies adhesive to the angled front edge  134  of the slab  114  at the location where the apron strip  126  is to be bonded. A rotary device  36  then rotates the apron strip  126  such that its angled backside  138  faces the front edge  134  of the slab  114  upon which adhesive has been applied. The apron strip  126  and slab  114  are then placed within a press  40  where the angled backside  138  of the apron strip  126  is brought into contact with the front edge  134  of the slab  114 , and the components are securely held in position for a predetermined period of time. 
     After the slab  114  is held within the press  40  for an appropriate time period, the slab  114  is released and conveyed from the press  40  to a profiling machine  42  where the exposed top side  144  of the apron strip  126 , top side  118  of the slab  114 , and other portions of the countertop are shaped as desired by the consumer. 
     While the preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims.