Abstract:
A system, method, and process for fabricating solid surface inserts for solid surface materials is provided. The solid surface inserts provide additional decorative and/or functional elements to a solid surface material. The solid surface inserts are designed and fabricated to capture the salient features of a desired design in order to integrate the desired design into the solid surface base to create an assembled solid surface. To create the assembled solid surface, the solid surface base has a pocket formed to accept the solid surface inserts. Then, the solid surface inserts are fabricated from other solid surface materials. The fabricated solid surface inserts are then assembled, interlocked, and secured, either with each other and/or with the solid surface base, using an adhesive to create the assembled solid surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. Nonprovisional application Ser. No. 11/329,938 filed Jan. 11, 2006. 
    
    
     TECHNICAL FIELD 
     The present invention relates to methods, devices, and processes for creating and installing inserts in solid surfaces. 
     BACKGROUND 
     Solid surface materials are used in a variety of surfacing applications in both commercial and residential settings. Examples of common types of solid surface materials include: manufactured polymer solid surfaces such as Corian®, Lexton®, Avonite®, and Swanstone®; natural solid surface materials such as marble or granite; and other manufactured solid surface materials such as concrete or glass. Solid surface materials are commonly used in a variety of different applications. Some of the more common applications of solid surface materials is for countertops or surfaces on counters, bars, reception areas, tables, windows, and ledges. Other applications include walls, facings, exterior cladding, and partitions. 
     Solid surface materials come in a wide variety of different colors. The variety of colors and finishes within a given type of solid surface material can number in the several hundreds if not thousands. Manufactured solid surface materials also may come with different highlights, including small accents and other materials molded directly into the solid surface material itself to form a textured pattern. However, these textured patterns are typically evenly dispersed throughout the entire solid surface material with a random pattern. Solid surface materials are typically supplied in sheets which are then cut to fit specific applications either at the job site or by off-site fabricators. 
     One feature of solid surface materials, and particularly manufactured polymer solid surface materials, is the ability to create a continuous surface that is relatively impervious to moisture and other substances. When multiple sheets of a solid surface material are assembled, the sheets are typically bonded together using a joint adhesive. For example, Corian® sheets may be joined using a joint adhesive, primarily methylmethacrylate, which effectively bonds the sheets together such that the multiple sheets remain relatively impervious to moisture and other substances. 
     Although solid surface materials, and manufactured polymer solid surfaces in particular have a wide variety of decorative and functional attributes, there are some limitations to their use. Purchasers commonly desire a customized look and feel for a solid surface being installed. One common way to customize the look and feel of a particular installation is to select the color, texture, and finish of the installation. However, the solid surface cannot be manufactured so that specific colors and textures are arranged into specific distinct patterns; rather they are diffused throughout the material. Therefore, there is a practical limit to the ability of a customer to customize a solid surface or to replicate a desired design in the solid surface material. 
     Therefore, there is a need for a method, device, and process for creating inserts for solid surface materials that enables a customer to recreate a desired design in a solid surface by the inclusion of a patterned insert into the solid surface. Specifically, the customized insert can replicate a number of different decorative or functional shapes, patterns, logos, or other designs as desired by the customer without substantially interfering with the performance of the solid surface. 
     SUMMARY 
     The following presents a simplified summary of the invention in order to provide a basic understanding of some of its aspects. This summary is not an exhaustive overview of the invention and is intended to neither identify key or critical elements of the invention nor delineate its scope. The primary purpose of this summary is to present some concepts of the invention in a simplified form as a prelude to a more detailed description that is presented later. 
     A system, method, and process for fabricating solid surface inserts for solid surface materials is provided. The solid surface inserts provide additional decorative and/or functional elements to a solid surface material. The solid surface inserts are designed and fabricated to capture the salient features of a desired design, which may be presented by a customer. The solid surface inserts may be fabricated from the same type of material as the solid surface they are being integrated into, or from different types of materials in order to achieve other effects. The solid surface inserts are fabricated from multiple pieces which can either be integrated directly with the surface as part of the solid surface fabrication or alternatively assembled into a separate assembly and integrated with the solid surface once the solid surface is installed in its desired location. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures depict multiple embodiments of the solid surface insert design, fabrication and use. A brief description of each figure is provided below. Elements with the same reference numbers in each figure indicate identical or functionally similar elements. Additionally, the left-most digit(s) of a reference number identifies the drawings in which the reference number first appears. 
         FIG. 1  is a perspective view of a solid surface base prepared to accept one embodiment of a solid surface insert. 
         FIG. 2  is a perspective view of one embodiment of a first solid surface insert piece. 
         FIG. 3  is a perspective view of one embodiment of a second solid surface insert piece. 
         FIG. 4  is an illustration of how one embodiment of a solid surface insert is assembled. 
         FIG. 5  is an perspective view of one embodiment of an assembled solid surface insert in a solid surface material. 
         FIG. 6  shows an original desired design prior to conversion into a solid surface insert. 
         FIG. 7  is a cross sectional view of another embodiment of a solid surface insert using protrusions to locate the solid surface insert in the completed assembly. 
     
    
    
     DETAILED DESCRIPTION 
     Solid Surface Base Fabrication 
       FIG. 1  shows a perspective view of a solid surface base  100  prepared to accept one embodiment of a solid surface insert. The solid surface base  100  is a sheet of either a manufactured polymer solid surface material, natural solid surface material, or other manufactured solid surface material. Preferably the solid surface base  100  is a polymer solid surface material such as Corian®. 
     Material is removed from the solid surface base  100  to form a base pocket  102 . The solid surface material is removed from the solid surface base  100  using common processes known to those of ordinary skill in the art such as routing or milling. The base pocket walls  104  are cut to a depth such that when an assembled interlock insert  500  (described in detail below) is placed in the base pocket  102 , the upper most surface  502  of the assembled interlock insert  500  is substantially level with the upper surface  106  of the solid surface base  100 . Although only one base pocket  102  is depicted for simplicity, the practical limit to the number of inserts placed on a solid surface base  100  is only limited by the available surface area needed for the desired inserts and the need for the solid surface base  100  to retain enough material to maintain the strength of the assembled product necessary for the desired application. The depth of the base pocket is selected such that it is sufficient to accommodate the thickness of the desired design  600  while still remaining less than the thickness of the solid surface base  100 . In an alternative embodiment the base pocket may emerge from the bottom of the solid surface base  100  and protrude into a third material under the solid surface base to accommodate larger patterns. 
     The base pocket floor  108  as shown in this embodiment is substantially at one level. In this embodiment, the assembled interlock insert  500  has a substantially flat bottom face that rests against the base pocket floor  108  when inserted in the base pocket  102 . Further the assembled interlock insert  500  fits within the base pocket  102  such that the upper most surface  502  of the assembled interlock insert  500  is substantially flush with or higher than the upper surface  106 . Movement of assembled interlock insert  500  within the base pocket  102  is restrained by both solid surface adhesive  404  and the base pocket wall  104  and the base floor  102 . In other embodiments of the present invention, the base pocket floor  108  has multiple levels, thereby forming additional base pocket wall  104  areas at a variety of depths that provide additional surfaces for locating interlock insert pieces inside the base pocket  102 . 
     The depth of the base pocket floor  108  and the corresponding height of the base pocket walls  104  are principally determined by multiple factors including the number of inserts necessary for a desired design  600 , the thickness of the solid surface base  100 , and the strength of the solid surface inserts such as the first solid surface insert  200  and second solid surface insert  300 , the assembled interlock insert  500 , and the solid surface base  100 . In the embodiment depicted in  FIG. 1 , the base pocket  102  is sized to accommodate a first solid surface insert  200  and a second solid surface insert  300  wherein the second solid surface insert  300  at least partially overlays the first solid surface insert  200 . In one embodiment, a solid surface base  100  and inserts  200 ,  300  comprised of a manufactured polymer solid surface material, the depth of the base pocket  102  is preferably 0.2 and 0.3″ and most preferably about 0.25″. 
     Solid Surface Insert Fabrication 
     Referring now to the first solid surface insert  200  depicted in  FIG. 2 . The first solid surface insert  200  is fabricated from another piece of solid surface material. Alternative materials for the first solid surface insert  200  include manufactured polymer solid surfaces, natural solid surface materials, other manufactured solid surface materials, metals, ceramics, and glasses. Preferably the materials of the first solid surface insert  200  and the solid surface base  100  are matched. More preferably, the first solid surface insert  200  is a manufactured polymer solid surface material and the solid surface base  100  also comprised of a manufactured polymer solid surface material. Most preferably, the first solid surface insert  200  and the solid surface base  100  are the same brand of manufactured polymer solid surface material. 
     The initial step in the fabrication of the first solid surface insert  200  is to plane, mill or otherwise machine, using techniques known to those of ordinary skill in the art, the solid surface material blank to the desired thickness if the material is not supplied at the appropriate thickness by the manufacturer. The thickness of the first solid surface insert  200  is dictated by multiple factors including the number of inserts necessary for a desired design  600 , the thickness of the solid surface base  100  and the depth of the corresponding base pocket  102 , and the as fabricated strength of the respective inserts and base such as the first solid surface insert  200  and second solid surface insert  300 , the assembled interlock insert  500 , and the solid surface base  100 . In the case of the embodiment detailed in the figure, the nominal thickness of the first solid surface insert  200  is preferably between 0.21″ to 0.36″ and most preferably about 0.31″. 
     The next step in the fabrication process for the first solid surface insert  200  is to remove material inside the overlap zone  204  where the second solid surface insert  300  will overlap the first solid surface insert  200 . The shape of the overlap zone  204  is primarily dictated by the shape and orientation of the second solid surface insert  300  relative to first solid surface insert  200 . In the embodiment depicted, the second solid surface insert  300  substantially covers entire overlap zone  204  without covering any area of the upper surface  206  outside of the overlap zone  204  and is substantially supported by the first solid surface insert  200 . An alternative embodiment has the second solid surface insert  300  substantially covering the entire overlap zone  204 , but extending beyond the overlap zone and being substantially supported by other elements of the design including the base pocket floor  108 . In the embodiment shown, the nominal thickness of the first solid surface insert  200  in the area of the overlap zone is preferably between 0.08 and 0.25″ and most preferably about 0.19″. The thickness under the upper surface  206  remains at the nominal thickness of the first solid surface insert  200 . 
     After the first solid surface insert  200  is fabricated with an overlap zone  204  to support the second solid surface insert  300 , the next step is to remove the remainder of the material using either milling or cutting operations known to those of ordinary skill in the art. The material is removed from the first solid surface insert  200  to form the desired shape of the first solid surface insert  200  as dictated by the shape of the base pocket  102  and the desired shape  600 . 
     Referring now to the second solid surface insert  300  depicted in  FIG. 3 . The second solid surface insert  300  is fabricated from another piece of solid surface material. The second solid surface insert  300  has an upper surface  300 , but no overlap zone  204 . Alternative materials for the second solid surface insert  300  include manufactured polymer solid surfaces, natural solid surface materials, other manufactured solid surface materials, metals, ceramics, and glasses. Preferably the materials of the first solid surface insert  200 , the second solid surface insert  300 , and the solid surface base  100  are matched. More preferably, the second solid surface insert  300  is a manufactured polymer solid surface material and the first solid surface insert  200  and the solid surface base  100  are also comprised of a manufactured polymer solid surface material. Most preferably, the second solid surface insert  300 , the first solid surface insert  200 , and the solid surface base  100  are the same brand of manufactured polymer solid surface material. 
     The first step in the fabrication of the second solid surface insert  300  is to plane, mill or otherwise machine, using techniques known to those of ordinary skill in the art, the solid surface material blank to the desired thickness if the material is not supplied at the appropriate thickness by the material manufacturer. The thickness of the second solid surface insert  300  is dictated by multiple factors including the number of inserts necessary for a desired design  600 , the thickness of the solid surface base  100 , the depth of the corresponding base pocket  102 , the depth of the overlap zone  204 , and the fabricated strength of the respective inserts and base such as the first solid surface insert  200  and second solid surface insert  300 , the assembled interlock insert  500 , and the solid surface base  100 . In the case of the embodiment detailed in the figure the nominal thickness of the second solid surface insert  300  is preferably between 0.06″ to 0.28″ and most preferably about 0.19″. 
     After the second solid surface insert  300  has the desired thickness, the next step is to remove the remainder of the material using either milling or cutting operations known to those of ordinary skill in the art. The material is removed from the second solid surface insert  300  to form the desired shape of the second solid surface insert  300  as dictated by the shape and space defined by the extents of the base pocket  102 , the first solid surface insert  200 , and the desired shape  600 . 
     Although in the embodiment depicted in the figures and described in detail herein has a first solid surface insert  200  and a second solid surface insert  300 , it is obvious to one of ordinary skill in the art the same fabrication and design procedure may be repeated so long as sufficient material remains to maintain the strength of the inserts and solid surface base  100  during the fabrication and assembly process in order to form more complex designs and produce a greater array of different color patterns. 
     Assembly and Finishing Process 
     After completing the fabrication of base pocket  102  in the solid surface base  100 , and the fabrication of the first solid surface insert  200  and the second solid surface insert  300  (collectively solid surface inserts  200 ,  300 ) it is necessary to assemble the elements. Each of the solid surface inserts  200 ,  300  must be assembled with each other and integrated into the base pocket  102  to form solid surface assembly  510 .  FIG. 4  highlights the relative stacking between the second solid surface insert  300  into the first solid surface insert  200  and into the solid surface base  100  in the direction of the arrows A, B. 
     The first step in the assembly process is to clean of all elements of the design in order to remove dust, debris, oils, and other substances that may have accumulated on the elements during the manufacturing, transport, and fabrication processes. The cleaning solution used must be free of chemicals that would adversely effect either the solid surface material or the adhesive used to affix the solid surface pieces together. For manufactured polymer solid surface elements denatured alcohol is used as a cleaning solution. Alternative cleaning solutions may be selected by those of ordinary skill in the art. 
     After the elements are cleaned, a layer of solid surface adhesive  404  is applied to the areas of the solid surface inserts  200 , 300  that will be in contact with each other when assembled. A typical assembly process applies the solid surface adhesive  404  to the areas where the base pocket  102  and the first solid surface insert  200  are in contact. After the solid surface adhesive  404  is applied, the first solid surface insert  200  is oriented with and placed into the base pocket  102 . Once the first solid surface insert  200  is placed inside the base pocket  102 , a solid surface adhesive  404  is applied to the areas of the first solid surface insert  200  and the second solid surface insert  300  that are in contact with each other and the areas of the second solid surface insert  300  that is in contact with the base pocket  102 . After the solid surface adhesive  404  is applied, the second solid surface insert  300  is oriented with and placed into the areas formed by the first solid surface insert  200  and the base pocket  102 . 
     Another embodiment of the installation process uses the solid surface adhesive  404  to attach inserts together separate from the solid surface base  100  to create an assembled interlock insert  500 . The assembled interlock insert  500  can then be stored and moved separately from the solid surface base  100  in order to protect the assembled interlock insert  500  until it is time to affix the assembled interlock insert  500  into the solid surface base  102  and finish the fabrication process. The solid surface base  100  can have the base pocket  102  fabricated either on-site or off-site. Once the solid surface base  100  is installed at the job site, the assembled interlock insert  500  is then joined with the solid surface base  100  using the cleaning and adhesive procedures described above in order to create the solid surface assembly  510 . 
     Once the elements are assembled with the solid surface adhesive  404 , a thin membrane  400  is installed overtop the solid surface assembly  510 . The membrane  400  substantially covers the assembled interlock insert  500  and may also cover a substantial portion of the solid surface base  100  as well. The membrane  400  protects the solid surface assembly  510  while the solid surface adhesive  404  cures. The membrane  400  also provides a protective covering whereby a weight  402  is placed on the membrane  400 , on top of the assembled interlock insert  500  to ensure the elements are bonded together levelly and fully. The membrane  400  also protects the solid surface assembly  510  from being marred by the weight  402  and for the weight from adhering to the solid surface adhesive  404 . The membrane  400  can be made from a number of different materials known to those of ordinary skill in the art including wax paper, plastic sheets, and paper. The weight  402  maybe selected from a number of different materials, including bags filled with different materials including sand or lead shot or large physical objects. The weight  402  is removed from the membrane  400  after the solid surface adhesive  404  sets and cures. The time for the solid surface adhesive  404  to set and cure varies according to a number of factors including the relative humidity and temperature of the environment as well as the characteristics of the solid surface adhesive  404  and the amount used. In a nominal scenario with methymethacralte, a solid surface adhesive  404  commonly used with solid surface materials such as Corian®, the cure time is between 20 to 40 minutes. 
     Once the solid surface adhesive  404  is set and cured, the solid surface assembly  510  is ready for finishing. The finishing process is primarily comprised of sanding and polishing steps. Typically a random orbital sander with micron sanding discs are used for solid surface materials. Prior to sanding, non-adhering portions of the membrane  400  are removed from the surface. Any remaining portions of the membrane  400  are then sanded away as part of the final surface preparation process. Alternatively, the membrane  400  may be removed in its entirety by the sanding discs as part of the final surface preparation process. Commonly, for a matte surfaced manufactured polymer solid surfaces the sanding starts with a 180 to 220 grit sand paper. For semi-gloss surfaces the sanding starts with 400 grit sand paper. As the surface of the solid surface assembly  510  is smoothed, the grit level is increased until ultimately the final polishing is completed with a wool or other fine polishing pad and potentially a fine polishing compound. Persons of ordinary skill in the art easily identify and use alternative sanding and polishing steps in order to smooth discontinuities in the solid surface assembly  510  and provide a consistent finish. 
     Desired Design Adjustment 
     The design for the base pocket  102  is based on and representative of a desired design  600  shown in  FIG. 6 . In this particular exemplary embodiment, the desired design  600  has a first color  602  and a second color  604 . The design process to adjust the desired design  600  from typically, but not always, a two-dimensional image, into a solid surface interlock design may take multiple steps. First, the size of the desired design  600  is scaled to a size that is appropriate for the type of installation. Next, the features of the desired design  600  are analyzed to determine if specific features are too small for fabrication due primarily to the inability to fabricate those features with enough material to maintain sufficient strength to support themselves during fabrication. Those features that are too small for fabrication are eliminated from the design, scaled up, or combined with other nearby features to preserve the overall integrity of the desired design  600  based on aesthetics and desired customer outcomes. 
     After scaling, the desired design  600  is analyzed to determine common colors that are effectively contiguous with each other and are thus able to be formed from a single piece of solid surface material. In the depicted embodiment, there is a first color  602  and a second color  604 . The second color  604  is contiguous along the entire surface of a second solid surface insert  300 , while the first color  602  can be formed as part of a single contiguous first solid surface insert  200 . The proper colors, shapes, and orientations matching the scaled desired design  600  are then placed in proper relationship to each other in this manner. In the embodiment depicted, the desired design  600  can be replicated using only a first solid surface insert  200  and a second solid surface insert  300 . However, multiple layers of inserts may be stacked at different depths without substantially modifying the procedure used. In alternative embodiments it is possible for solid surface inserts to be fabricated as singular elements which are then fitted together in the same procedure outlined above. 
     After scaling and estimating the number of solid surface inserts necessary to replicate a given desired design  600 , the next step in the design adjustment process is to ready the desired design  600  for fabrication. Depending on the desired design  600  there are several adjustments that may be necessary. One adjustment is to compensate for features such as a square open corner  606  in the desired design  600 . A square open corner  606  requires a matching square corner to be machined in the base pocket  102 . A square open corner  606  in a blind pocket such as the base pocket  102  is both expensive and time consuming to fabricate. Therefore, the desired design  600  maybe adjusted such that the square open corner  606  can be chamfered or radiused. The modification of the desired design  600  for a square open corner  606  is shown in the radius open corner base pocket  110  and the radius open corner  210  of the first solid surface insert  200 . Typically if the depth of the pocket is greater than 3 times the diameter of the radius then a chamfer is preferred to ensure smooth machining of the base pocket  102 . In cases where the desired design  600  is not suitable for chamfering or radiusing an alternative processes is to create a relief hole in the solid surface base  100 . The relief hole would be substantially centered on the point where the base pocket walls  104  come together. After the parts are assembled, the relief hole is filled with an adhesive fill material color matched to the solid surface base  100 . The adjustment for a square open corner  606  can be performed on any or all of the solid surface inserts used on a given desired design  600  and their mating base pockets  102  as necessary for fabrication. 
     A second type of corner adjustment compensates for features such as a square closed corner  608  in the desired design  600  in a similar manner to the compensation used for a square open corner  606  discussed above. However, a square closed corner  608  poses a similar fabrication challenge whereby fabricating the desired design  600  is both expensive and time consuming. Therefore, the desired design  600  is adjusted such that the square closed corner  608  is chamfered or radiused. The modification of the desired design  600  for a square closed corner  608  is shown in the radius closed corner  312  on the second solid surface insert  300 , and the mating radius closed corner base pocket  112 . The adjustment for a square closed corner  608  can be performed on any or all of the solid surface inserts used on a given desired design  600  and their mating base pockets  102  as necessary for fabrication. 
     Another type of adjustment compensates for floating or non-contiguous pieces. In the case of designs not amenable to fabrication of each solid surface insert part as a single contiguous piece, multiple parts are assembled as non-contiguous components. These non-contiguous elements are locked into the solid surface base  100  to form the assembled interlock insert  500  using alternative design approaches. One approach is to provide an additional locking mechanism for the solid surface inserts by including a protrusion on the parts thereby reducing the reliance on the sides of the solid surface inserts for locating or locking the parts together. In one embodiment, shown in  FIG. 7 , a first solid surface insert  200  and a second solid surface insert  300  are shown with a first protrusion  704  and a second protrusion  702  respectively. The second protrusion  702  is sized to fit within a second receptacle  706  milled into the first solid surface insert  200 . The interface between the second protrusion  702  and the second receptacle  706  effectively locates the second solid surface insert  300  relative to the first solid surface insert  200 . Similarly, the first protrusion  704  is sized to fit within a first receptacle  708  formed within the base pocket  102 . The interface between the first protrusion  704  and the first receptacle  708  effectively locates the first solid surface insert  200  relative to the solid surface base  100 . The use of protrusions  702 ,  704  rather than interfaces between walls reduces reliance on the interface between the edges and walls of the solid surface inserts  200 ,  300  relative to each other and the solid surface base  100  to locate the parts and enable accommodation of designs with non-contiguous components. 
     Another desired design  600  adjustment compensates for tolerance stack-up between the parts necessary to enable integration of the assembled interlock insert  500  and insertion of the assembled interlock insert  500  into the solid surface base  100 . For example, the base pocket walls  104  nominally form a perpendicular or obtuse angle with the base pocket floor  108 . The dimensions of the base pocket wall  104  are sized using design criteria well known to those or ordinary skill in the art to provide sufficient tolerance for an assembled interlock insert  500  to fit into the base pocket  102 . The fit between the edges of an assembled interlock insert  500  and the base pocket wall  104  may comprise either a clearance, transition, or interference fit as known to those or ordinary skill in the art. The fit as shown in the embodiment depicted in  FIG. 5  is a clearance fit whereby there is clearance between the base pocket wall  104  and the corresponding edges of the assembled interlock insert  500 . Similarly the fit between the first solid surface insert  200  and the second solid surface insert  300  are toleranced for the desired fit as well. The depicted clearance fit shown in  FIG. 5  provides nominally between 0.015″ and 0.020″ gap between individual insert pieces  200 ,  300  and the base pocket  102 . In different embodiments, tighter or wider tolerances are selected based on the performance of equipment used to fabricate the insert pieces and the base pocket  102 , the desired design  600 , and other factors known to person of ordinary skill in the art. 
     Another adjustment to the desired design  600  is the inclusion of a fill material gap  710  between the edges of the assembled interlock insert  500  and the base pocket wall  104 . The size of the assembled interlock insert  500  is smaller in comparison to the typical fit into the base pocket  102  thereby creating a fill material gap  710 . The fill material gap  710  is then filled, during the final fabrication process with an adhesive fill that includes an alternative color or highlighting material to setoff the assembled interlock insert  500  from the solid surface base  100 . The alternative color or highlighting material maybe blended together such that it varies continuously over length of the fill material gap  710  around the assembled interlock insert  500 . A second fill material gap  712  may also be formed between individual solid surface inserts  200 ,  300  such as between the first solid surface insert  200  and the second solid surface insert  300 . 
     The adjustment of the desired design  600  can be integrated into a series of automated or semi-automated steps as part of manual or computer-aided manufacturing system. For example, in the case of an expert system based computer-aided manufacturing (CAM) system the adjustments are conceptualized as a series of design rules necessary to adjust a desired design  600  into a design suitable for the solid surface assembly  510 . The design rules are then sequenced and arrayed into a logical hierarchy of decisions, thereby forming a logic tree, using understood expert system design approaches. The expert system can then automatically perform the adjustment to the desired design  600  using the logic tree to create a design suitable for the solid surface interlock process to create the solid surface assembly  510 . The process can operate in either a completely automated fashion or enable a user to interact with the expert system to tailor the design adjustments to best reflect their perception of critical elements of the desired design  600  to be reflected in the solid surface assembly  510 . Finally, as part of the expert system design process, cost estimating tools can be integrated with the system to provide estimated costs and fabrication estimates for a desired design  600 . 
     The expert system adjustment process can be accessed in a number of ways. In one embodiment, the expert system is integrated into an online process whereby a user can access the system over a wide area network such as the Internet to submit an electronic version of a desired design  600 . The user can then interact with the expert system through an internet browser such Explorer® or Firefox, or browser plug-in, to control the look and feel of the solid surface assembly  510 . The expert system, when accessed online, may be integrated with an online payment and ordering system and/or data links to an enterprise resource management system(s) to enable a customer to place an order online and initialize the manufacturing process electronically. In another embodiment, the expert system is integrated into a design tool ‘plug-in’ module that can be integrated with common architectural and interior design programs such as Vellum® or AutoCAD®. Then, a user can interact with the expert system while they are designing a specific solid surface material application. In yet another embodiment, the expert system is integrated into a store kiosk located inside a solid surface material retailer that enables a customer to select pre-defined designs  600  or submit their own desired design  600  for a solid surface installation they are purchasing using similar methods used in the wide area access system. In still another embodiment, the expert system is integrated into a package of tools, equipment, training, and other intellectual property licenses provided to a third-party thereby enabling a consistent quality product to be delivered by multiple third-parties. 
     The embodiments of the invention shown in the drawings and described above are exemplary of numerous embodiments that may be made within the scope of the appended claims. It is contemplated that numerous other configurations of and processes for making solid surface interlock inserts may be created by those of ordinary skill in the art taking advantage of the disclosed approach. It is the applicant&#39;s intention that the scope of the patent issuing herefrom will be limited only by the scope of the appended claims.