Patent Publication Number: US-2005132559-A1

Title: Method of manufacturing solid surface counter top

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to a method of manufacturing solid surface counter top, and more particularly, to a method of manufacturing solid surface counter top making the manufacturing process remarkably fast, and reducing labor dramatically.  
      2. Description of the Related Art  
      In general, solid surfacing is manufactured for interior applications where a decorative, durable, wear and stain resistant surface is required. Horizontal applications include vanity tops, countertops, residential and commercial furniture, window sills and thresholds. Vertical applications include wall panels, wainscoting, backsplashes, baseboards, and bath and shower enclosures.  
      For example, as shown in  FIG. 1 , a sink consists of a cabinet  15  for storing items, a solid surface counter top  10  installed on the top of the cabinet  15  to carry out cooking thereon, and a basin  30  inserted in an opening formed in part of the top plate  10 .  
      The finished solid surface top  10  is divided into three parts: a flat panel portion  11 , edge portion  12  and backsplash portion  13 , respectively. A conventional method, as shown in  FIGS. 2A through 2D , has been used to manufacture the solid surface counter top. Generally, a row-material sheet  1  having one surface that is polished is used as the solid surface counter top. The row-material sheet  1  having a protection film  1   a  for preventing scratches attached to the glossy surface is supplied to a manufacturing line. Then, the protection film  1   a  is ripped off from the raw-material sheet  1  and the raw-material sheet  1  is cut into three parts of the flat panel portion  11 , the edge portion  12 , and the backsplash portion  13 , as shown in  FIG. 2B . The cut three parts are attached together by using an adhesive, fitting to the shape of the solid surface counter top plate  10 , and clamped until the adhesive is hardened as shown in  FIG. 2C . Reference numeral  14  indicates an auxiliary member that is attached to make a portion where the flat panel  11  and the backsplash  13  meet, smoothly curved. When the adhesive is completely hardened, edge portions exposed to a user are made smooth as shown in  FIG. 2D , through a process such as round cutting and sanding. Lastly, the glossy surface that is damaged during the attachment and processing steps is polished again to give luster.  
      However, the above method requires quite a number of steps such as detaching the protection film in advance, cutting, attaching, round cutting, and sanding and polishing, manufacturing there for is inconvenient and it takes a long time to complete a product.  
      Unlike the above general attachment method, the top plate  10  can be manufactured in a V-grooving method as shown in  FIGS. 3A through 3E . Referring to  FIG. 3A , a protection film  1   a  attached to a glossy surface of the solid surface raw-material sheet  1  is ripped off. An adhesive tape  1   b  is attached to a surface opposite to a portion to be V-grooving process, so that the respective portion are not completely separated as shown in  FIG. 3B . Next, as shown in  FIG. 3C , the V-grooving process is performed with respect to a boundary portion between the flat panel portion  11  and each of the edge  12  and backsplash  13 . After the V-grooving process, the processed surfaces are coated with an adhesive and bent to have the shape of the top plate  10  and the adhesive is hardened, as shown in  FIG. 3D . When the adhesive is completely hardened, the adhesive tape  1   b  is detached and edge portions exposed to a user and portions where the adhesive squeezes out are processed in a method such as round cutting and sanding, so that a product is manufactured as shown in  FIG. 3E . Lastly, the glossy surface that is damaged during the attachment and processing steps is polished again to give luster.  
      However, in the above method, since quite a number of steps from the step of detaching the protection film  1   a  from the raw-material sheet  1  in advance, to the final polishing step are required, manufacturing is inconvenient and productivity is lowered. Thus, an improved method of manufacturing solid surface counter top is needed.  
     SUMMARY OF THE INVENTION  
      To solve the above and/or other problems, the present invention provides a method of manufacturing a solid surface counter top having a simplified manufacturing process so that rapid product manufacturing is possible.  
      According to an aspect of the present invention, a method of manufacturing a solid surface counter top comprising preparing a solid surface raw-material sheet having a glossy surface to which a protection film is attached, processing a groove on an opposite surface of the glossy surface, leaving a connection portion having a fine thickness, to fold the raw-material sheet to fit to a shape of the top plate having at least one bent portion, heating the connection portion, and folding the raw-material sheet to fit to the shape of the top plate by bending the heated connection portion. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The above and other features and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:  
       FIG. 1  is a perspective view illustrating the structure of a typical sink adopting a solid surface counter top;  
       FIGS. 2A through 2D  are views illustrating the process of manufacturing a solid surface counter top in a conventional attachment method;  
       FIGS. 3A through 3E  are views illustrating the process of manufacturing a solid surface counter top in a conventional V-grooving method;  
       FIGS. 4A through 4E  are views illustrating the process of manufacturing a solid surface counter top according to a first preferred embodiment of the present invention;  
       FIG. 5  is a view illustrating a modification of the shape of a edge portion in manufacturing the solid surface counter top shown in  FIG. 4E ;  
       FIGS. 6A through 6E  are views illustrating the process of manufacturing a solid surface counter top according to a second preferred embodiment of the present invention; and  
       FIGS. 7A through 9E  are views illustrating modifications of the shape of a edge portion in manufacturing the solid surface counter top according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring to  FIGS. 4A through 4E , in a method of manufacturing a solid surface counter top according to a first preferred embodiment of the present invention, first, an raw-material sheet  100  is prepared for manufacturing a solid surface counter top. A protection film  100   a  for preventing a glossy surface from scratches is attached to the raw-material sheet  100 , as shown in  FIG. 4A . In the present invention, the raw-material sheet  100  is processed without detaching the protection film  100   a.    
      The processing is performed at a surface opposite to the glossy surface where the protection film  100   a  is attached. As shown in  FIG. 4B , a groove  130   a  having a “T” shape is formed between the flat panel portion  110  and the backsplash  130  while a groove  120   a  having an angled “T” shape is formed between the flat panel portion  110  and the edge  120 . Connection portions  120   b  and  130   b  having a fine thickness are left on the grooves  120   a  and  130   a , respectively, so that the respective portions are not completely separated. The thickness of the connection portions  120   b  and  130   b  is preferably about 1.5-2.0 mm.  
      When the processing of the grooves  120   a  and  130   a  is completed, as shown in  FIG. 4C , the connection portions  120   b  and  130   b  are heated by a heating/cooling apparatus  20  so that plastic deformation is possible. The heating/cooling apparatus  20  includes a heating portion  21  and a cooling portion  22 . While the heating portion  21  of the heating/cooling apparatus  20  heats the connection portions  120   b  and  130   b , the cooling portion  22  cools a portion near the connection portions  120   b  and  130   b  the so that the heat is not transmitted to the nearby portion. A typical heater and a container storing water may be used as the heating portion  21  and the cooling portion  22 , respectively.  
      The raw-material sheet  100  is folded to fit to the shape of the solid surface counter top, as shown in  FIG. 4D , by bending the heated connection portions  120   b  and  130   b . Then, the sufficiently heated connection portions  120   b  and  130   b  are smoothly bent so as to be folded to fit to the shape of the solid surface counter top. Preferably, spaces formed as the grooves  120   a  and  130   a  are folded are filled with an adhesive so as to firmly fix the shape.  
      Then, the protection film  100   a  adhering to the glossy surface is detached so that the solid surface counter top as shown in  FIG. 4E  is obtained. That is, since smooth curves are formed as the connection portions  120   b  and  130   b  are bent at the boundary portions between the flat panel portion  110  and each of the edge  120  and backsplash  130 , the additional round cutting and sanding steps are not needed. Accordingly, since the polishing step to give luster is not needed as well, the entire manufacturing process is completed by simply detaching the protection film  100   a . In this regard, the protection film detaching step is preferably performed after the completed top plate is delivered to a customer because detaching the protection film  100   a , on which a trademark of the raw-material sheet  100  is marked, in front of the customer, may give reliability of the product to the customer. Reference numeral  140  indicates a reinforcement member which is attached to the rear side of the backsplash  130  to balance against the edge  130 . A typical rectangular shaped plate is used as the reinforcement member  140 .  
      Thus, compared to the conventional method in which the additional steps such as detaching the protection film in advance, round cutting, sanding, and polishing are needed, the manufacturing method according to the present invention is simplified by far so that rapid manufacturing is possible.  
      In addition to the “L” shape described above, the edge  120  may have a “ ” shape as shown in  FIG. 5 . In this case, two grooves  120   a  and  120   a ′ having the angle “T” shape are formed and bent by heating connection portions  120   b  and  120   b ′, so that the “ ” shape can be formed as shown in the drawing. Also, space formed as the grooves  120   a ,  120   a ′, and  130   a  are folded are filled with an adhesive so as to firmly fix the shape.  
      Next,  FIGS. 6A through 6E  show a method of manufacturing a solid surface counter top according to a second preferred embodiment of the present invention. Referring to  FIG. 6A , a raw-material sheet  200  on which a protection film  200   a  for protecting a glossy surface is prepared as a material. A surface opposite to the glossy surface where the protection film  200   a  adheres is processed. As shown in  FIG. 6B , a rectangular groove  230   a  is formed between a flat panel portion  210  and a backsplash  230  and a “Y” shaped groove  220   a  open at an angle of 90° is formed between the flat panel portion  210  and a edge  220 . In the present preferred embodiment, unlike the first preferred embodiment, the edge  220  is shaped as “ ” Thus, two “Y” shaped grooves  220   a  are formed. If the “L” shape is needed, it is necessary to form a single “Y” shaped groove  220   a.    
      Connection portions  220   b  and  230   b  having a thickness of about 1.5-2 mm are left on the grooves  220   a  and  230   a  so that the respective portions are not completely separated.  
      After the grooves  220   a  and  230   a  are completely processed, as shown in  FIG. 6C , the connection portions  220   b  and  230   b  are heated by the heating/cooling apparatus  20  (refer to  FIG. 4C ) so that plastic deformation is possible. While the heating portion  21  of the heating/cooling apparatus  20  heats the connection portions  220   b  and  230   b , the cooling portion  22  cools a portion near the connection portions  220   b  and  230   b  so that the heat is not transmitted to the nearby portion.  
      The raw-material sheet  200  is folded to fit to the solid surface counter top, as shown in  FIG. 6D , by bending the heated connection portions  220   b  and  230   b.    
      Then, the sufficiently heated connection portions  220   b  and  230   b  are smoothly bent so as to be folded to fit to the shape of the solid surface counter top. Preferably, spaces formed as the grooves  220   a  and  230   a  are folded are filled with an adhesive so as to firmly fix the shape.  
      Then, the protection film  200   a  adhering to the glossy surface is detached so that the solid surface counter top as shown in  FIG. 6E  is obtained. As described above, to give reliability of the product to the customer, the protection film detaching step is preferably performed after the completed top plate is delivered to the customer.  
      In the present preferred embodiment, since the shapes of the grooves  220   a  and  230   a  are simpler than those of the first preferred embodiment, processing the grooves  220   a  and  230   a  is easier than the first preferred embodiment. In contrast, in the present preferred embodiment, since a reinforcement member  240  to be installed at the rear of the backsplash  230  needs to be processed to fit to curvature of the connection portion  230   b  which is curved, as shown in  FIG. 6E , the preparation of the reinforcement member  240  may be relatively difficult. Thus, considering the convenience in processing and stability in bending, appropriate groove shapes are selected among the above-described grooves and then combined.  
      In some cases, a unique shape different from the above-described shapes, for example, the “L” shape or “ ” shape, is requested for the edge of the solid surface counter top. For example,  FIG. 7B  shows an edge  320  having a round shape. In this case, a groove  320   a  in which a circular rod type molding member J is inserted and rolled is processed. Then, the above-described heating and bending steps are performed by inserting the molding member J in the groove  320   a . Thus, the inner surface of the edge  320  is formed circular along the outer circumferential shape of the molding member J. Preferably, an adhesive is coated between the groove  320   a  and the molding member J.  
      Also, as shown in  FIGS. 8A through 8D , in order to make the inner space of the edge  420  have a bowl shape, a molding member J corresponding to the shape is inserted in the inner space and the edge  420  is bent. That is, a portion in which the molding member J is to be inserted is heated by using the heating portion  21  of the heating/cooling apparatus  20 , as shown in  FIG. 8A . Then, the end portion of the edge  420  is lifted, as shown in  FIG. 8B , and the molding member J is inserted, as shown in  FIG. 8C . In this state, by bending an end portion of the edge  420 , the shape as shown in  FIG. 8D  is obtained. Reference numeral  420 ′ indicates a protruding portion to prevent water drops or pencils falling from the edge  420 . The protruding portion  420 ′ can be made in a method shown in  FIGS. 9A through 9E . That is, as shown in  FIG. 9A , a rectangular groove  621  and an angled “T” shaped groove  622  are formed in the edge  620 . The angled “T” shaped groove  120   a  in the previous preferred embodiment is open at an angle of 90° to make a right angle when folded. However, in the present preferred embodiment, the angled “T” shaped groove  622  is formed to have an angle of about 100°. After the heating step of  FIG. 9B , the angle “T” shaped groove  120   a  is bent to be less than 90°, as shown in  FIG. 9C . Then, as shown in  FIG. 9D , the rectangular groove  621  is bent to form a protruding portion  620 ′. In the state, as shown in  FIG. 9E , the grooves  621  and  622  are filled with an adhesive B which is hardened and functions as a caulking member to firmly fix the shape.  
      Thus, in the manufacturing method according to the present invention, as shown in the first and second preferred embodiments, grooves are formed, leaving the connection portions, on the opposite surface of the glossy surface where the protection film adheres and the connection portions are heated and bent. Consequently, the steps of detaching the protection film in advance, round cutting, sanding, and polishing can be omitted. The grooves processed in the flat panel portion and the edge and backsplash are formed by combining the above-described shapes. The solid surface counter top plate manufactured as above can be used as top plates for kitchen sinks, bathroom washbasins, tables, counter desks, window sills, bathroom door sills, reception desks, and furniture.  
      As described above, the method of manufacturing the solid surface counter top plate according to the present invention has the following effects.  
      First, since the steps of detaching the protection film in advance, round cutting, sanding, and polishing, which are required in the conventional method, are not needed, the manufacturing process is simplified so that products can be rapidly manufactured.  
      Second, since the process is simplified, the product cost is reduced and price competitiveness is improved.  
      Third, since the steps such as round cutting, sanding, and polishing generating dusts are not needed, the working environment is improved.  
      Fourth, since the protection film on which the trademark of the raw-material sheet is marked is detached after the product is delivered to the customer, it is possible to give reliability of the product to the customers.