Mold
The improved mold assembly for cultured marble molding is provided. The mold assembly can comprise a male mold portion and a female mold portion. The assembly can further comprise a molding tool. The molding tool can have a side wall having an upper curved portion and a lower curved portion. The molding tool can have a bowl portion and an apron portion spaced from the bowl portion by a gap. The molding tool can be constructed from a flexible and/or soft material. The molding tool can facilitate molding of a countertop having at least one seamless curved edge and/or an at least partially seamless sink portion.
1. An insert configured for use with male and female mold portions of a mold assembly for producing a countertop, the insert comprising a flexible material and further comprising:
a main body extending along a first plane;
a bowl portion projecting outward from the main body, the bowl portion comprising a first surface and a second surface opposite the first surface, wherein the first surface is convex and the second surface is concave, wherein the bowl portion is at least partially curved in a first direction and in a second direction that is perpendicular to the first direction; and
an apron portion projecting outward from the main body and spaced from the bowl portion, the apron portion comprising a first surface and a second surface opposite the first surface of the apron portion, wherein the first surface of the apron portion is convex and the second surface of the apron portion is concave, wherein the apron portion is at least partially curved in the first and second directions;
wherein the first surface of the bowl portion is separated from the second surface of the apron portion by a gap; and
wherein the main body, the bowl portion, and the apron portion are integral.
2. The insert of claim 1 , wherein the flexible material comprises rubber.
3. The insert of claim 1 , further comprising a first sidewall extending outward from a first edge of a perimeter of the main body.
4. The insert of claim 3 , wherein the first sidewall is at least partially curved.
5. The insert of claim 3 , further comprising a second sidewall extending outward from a second edge of the perimeter of the main body, the second edge being opposite and parallel to the first edge.
6. The insert of claim 3 , further comprising a back wall extending outward from a second edge of the perimeter of the main body, the second edge being perpendicular to the first edge.
7. The insert of claim 1 , wherein the gap between the first surface of the bowl portion and the second surface of the apron portion can be increased by deflecting at least a portion of the apron portion away from the bowl portion.
8. The insert of claim 1 , wherein the apron portion surrounds a portion of the bowl portion.
9. An insert configured for use with male and female mold portions of a mold assembly for producing a countertop, the insert comprising:
a main body;
a bowl portion projecting outward from the main body, wherein the bowl portion is at least partially curved in a first direction and in a second direction that is perpendicular to the first direction; and
an apron portion projecting outward from the main body and spaced from the bowl portion by a gap, wherein the apron portion is at least partially curved in the first and second directions, and wherein the gap can be increased by deflecting at least a portion of the apron portion away from the bowl portion;
wherein the main body, the bowl portion, and the apron portion are integral.
10. The insert of claim 9 , wherein:
the bowl portion comprises a first surface and a second surface opposite the first surface, wherein the first surface is convex and the second surface is concave; and
the apron portion comprises a first surface and a second surface opposite the first surface of the apron portion, wherein the first surface of the apron portion is convex and the second surface of the apron portion is concave.
11. The insert of claim 10 , wherein the first surface of the bowl portion is separated from the second surface of the apron portion by the gap.
12. The insert of claim 9 , wherein the insert comprises rubber.
13. The insert of claim 9 , further comprising a first sidewall extending outward from a first edge of a perimeter of the main body, wherein the first sidewall is at least partially curved.
14. The insert of claim 13 , further comprising a back wall extending outward from a second edge of the perimeter of the main body, the second edge being perpendicular to the first edge.
15. The insert of claim 9 , wherein the apron portion surrounds a portion of the bowl portion.
16. An insert configured for use with male and female mold portions of a mold assembly for producing a countertop, the insert comprising a flexible material and further comprising:
a main body;
a bowl portion projecting outward from the main body; and
an apron portion projecting outward from the main body and spaced from the bowl portion by a gap;
wherein the main body, the bowl portion, and the apron portion are integral; and
wherein the apron portion is at least partially curved in a first direction and in a second direction that is perpendicular to the first direction.
17. The insert of claim 16 , wherein:
the bowl portion comprises a first surface and a second surface opposite the first surface, wherein the first surface is convex and the second surface is concave;
the apron portion comprises a first surface and a second surface opposite the first surface of the apron portion, wherein the first surface of the apron portion is convex and the second surface of the apron portion is concave; and
the first surface of the bowl portion is separated from the second surface of the apron portion by the gap.
18. The insert of claim 16 , wherein the insert comprises rubber.