IP Library Granted Patent US 12,466,111
Granted Patent B2
US 12,466,111 · App. 17/661,628 · Granted Nov 11, 2025

Countertop

Inventors: Damian J. Le Duff (Chula Vista, CA); Manuel Alvarez (Ontario, CA)
Assignee: American Woodmark Management Company
B29C33/44B29C33/50B29C37/0025B29C70/44B29C33/405B29C33/58B29K2103/08B29K2995/0046B29L2031/7698
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Quick Facts
Patent No.
US 12,466,111
App. No.
17/661,628
Granted
Nov 11, 2025
Kind
B2
Abstract

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.

Claims (47)

1 . A countertop comprising:

a counter portion including:

a main body extending along a plane, the main body comprising a top surface, a bottom surface opposite the top surface, a first side, a second side opposite the first side, a front end, and a back end opposite the front end;

a first curved portion extending from the first side of the main body in a first direction and curving at least partially toward the bottom surface of the main body, the first curved portion comprising an overhanging edge that is spaced from the bottom surface of the main body, wherein the first curved portion is integral with the main body and extends along an entire length of the first side of the main body, and wherein the first curved portion further comprises an upper curved portion connected to and extending away from the top surface of the main body and a lower curved portion connected to and extending between the upper curved portion and the overhanging edge;

a second curved portion extending from the second side of the main body in the first direction and curving at least partially toward the bottom surface of the main body, the second curved portion comprising an overhanging edge that is spaced from the bottom surface of the main body, wherein the second curved portion is integral with the main body and extends along an entire length of the second side of the main body, and wherein the second curved portion further comprises an upper curved portion connected to and extending away from the top surface of the main body and a lower curved portion connected to and extending between the upper curved portion of the second curved portion and the overhanging edge of the second curved portion;

a back portion extending from the back end of the main body substantially perpendicular relative to said plane in a second direction that is opposite the first direction, wherein the back portion is integral with the main body and extends along an entire length of the back end of the main body;

a third curved portion extending from the front end of the main body in the first direction, wherein the third curved portion is integral with the main body and extends along a first portion of a length of the front end of the main body; and

a fourth curved portion extending from the front end of the main body in the first direction, wherein the fourth curved portion is integral with the main body and extends along a second portion of the length of the front end of the main body, wherein the first and second portions of the length of the front end of the main body are substantially equal;

a sink portion recessed from the top surface of the main body of the counter portion, the sink portion comprising an inner surface, an outer surface, and a drain opening extending through the sink portion from the inner surface to the outer surface;

a drain portion extending from the outer surface of the sink portion around the drain opening of the sink portion; and

an apron portion arranged at the front end of the main body of the counter portion and between said third and fourth curved portions of the main body of the counter portion, the apron portion positioned adjacent and in front of the sink portion, the apron portion extending from the front end of the main body of the counter portion in the first direction and comprising an overhanging edge, a height extending between the front end of the main body of the counter portion and the overhanging edge of the apron portion, and a front surface that faces away from the sink portion and extends along said height, wherein the overhanging edge of the apron portion is arranged below a bottom portion of the outer surface of the sink portion and said front surface comprises a continuous curvature along said height;

wherein the counter portion, the sink portion, the drain portion, and the apron portion are integral with one another.

2 . The countertop of claim 1 , wherein the sink portion is spaced from the back portion of the counter portion by a gap.

3 . The countertop of claim 1 , wherein the sink portion is spaced from each of the first and second curved portions of the counter portion by a gap.

4 . The countertop of claim 1 , wherein a front edge of the sink portion is spaced from a front edge of the main body of the counter portion by a gap.

5 . The countertop of claim 1 , wherein the sink portion comprises a substantially straight back portion and a remainder portion that is curved, and wherein said substantially straight back portion is positioned closer to the back end of the counter portion than said remainder portion.

6 . A countertop comprising:

a counter portion including:

a main body extending along a plane, the main body comprising a top surface, a bottom surface opposite the top surface, a first side, a second side opposite the first side, a front end, and a back end opposite the front end;

a first curved portion extending from the first side of the main body in a first direction, wherein the first curved portion is integral with the main body; and

a second curved portion extending from the second side of the main body in the first direction, wherein the second curved portion is integral with the main body;

a sink portion recessed from the top surface of the main body of the counter portion, the sink portion comprising an inner surface, an outer surface, and a drain opening extending through the sink portion from the inner surface to the outer surface; and

an apron portion arranged at the front end of the main body of the counter portion, the apron portion positioned adjacent and in front of the sink portion, the apron portion extending from the front end of the main body of the counter portion in the first direction and comprising an overhanging edge, a height extending between the front end of the main body of the counter portion and the overhanging edge, and a front surface that faces away from the sink portion and extends along said height, wherein the overhanging edge is arranged below a bottom portion of the outer surface of the sink portion and said front surface comprises a continuous curvature along said height;

wherein the counter portion, the sink portion, and the apron portion are integral with one another.

7 . The countertop of claim 6 , wherein the counter portion further comprises a back portion extending from the back end of the main body substantially perpendicular relative to said plane in a second direction that is opposite the first direction, wherein the back portion is integral with the main body.

8 . The countertop of claim 7 , wherein the sink portion is spaced from the back portion of the counter portion by a gap.

9 . The countertop of claim 6 , wherein the counter portion further comprises:

a third curved portion extending from the front end of the main body in the first direction, wherein the third curved portion is integral with the main body and extends along a first portion of a length of the front end of the main body; and

a fourth curved portion extending from the front end of the main body in the first direction, wherein the fourth curved portion is integral with the main body and extends along a second portion of the length of the front end of the main body, wherein the apron portion extends between the third and fourth curved portions.

10 . The countertop of claim 6 , wherein the sink portion is spaced from each of the first and second curved portions of the counter portion by a gap.

11 . The countertop of claim 6 , wherein a front edge of the sink portion is spaced from a front edge of the main body of the counter portion by a gap.

12 . The countertop of claim 6 , wherein the sink portion comprises a substantially straight back portion and a remainder portion that is curved, and wherein said substantially straight back portion is positioned closer to the back end of the counter portion than said remainder portion.

13 . A countertop comprising:

a counter portion including:

a main body comprising a top surface, a bottom surface opposite the top surface, a first side, a second side opposite the first side, a front end, and a back end opposite the front end;

a first curved portion extending from the first side of the main body in a first direction, the first curved portion comprising an overhanging edge that is spaced from the bottom surface of the main body, wherein the first curved portion is integral with the main body, and wherein the first curved portion further comprises an upper curved portion connected to and extending away from the top surface of the main body and a lower curved portion connected to and extending between the upper curved portion and the overhanging edge; and

a second curved portion extending from the second side of the main body in the first direction, the second curved portion comprising an overhanging edge that is spaced from the bottom surface of the main body, wherein the second curved portion is integral with the main body, and wherein the second curved portion further comprises an upper curved portion connected to and extending away from the top surface of the main body and a lower curved portion connected to and extending between the upper curved portion of the second curved portion and the overhanging edge of the second curved portion;

a sink portion recessed from the top surface of the main body of the counter portion, the sink portion comprising an inner surface, an outer surface, and a drain opening extending through the sink portion from the inner surface to the outer surface; and

an apron portion extending from a portion of the main body of the counter portion adjacent to the sink portion, wherein the apron portion extends from the top surface of the main body in the first direction and comprises an overhanging edge, a height extending between the top surface of the main body and the overhanging edge of the apron portion, and wherein the overhanging edge of the apron portion is arranged below a bottom portion of the outer surface of the sink portion;

wherein the counter portion, the sink portion, and the apron portion are integral with one another.

14 . The countertop of claim 13 , wherein the counter portion further comprises a back portion extending from the back end of the main body, wherein the back portion is integral with the main body.

15 . The countertop of claim 14 , wherein the sink portion is spaced from the back portion of the counter portion by a gap.

16 . The countertop of claim 13 , wherein the counter portion further comprises:

a third curved portion extending from the front end of the main body, wherein the third curved portion is integral with the main body and extends along a first portion of a length of the front end of the main body; and

a fourth curved portion extending from the front end of the main body, wherein the fourth curved portion is integral with the main body and extends along a second portion of the length of the front end of the main body.

17 . The countertop of claim 13 , wherein the sink portion comprises a substantially straight back portion and a remainder portion that is curved, and wherein said substantially straight back portion is positioned closer to the back end of the counter portion than said remainder portion.

18 . The countertop of claim 13 , wherein the apron portion further comprises a front surface that faces away from the sink portion and comprises a continuous radius of curvature along the height of the apron portion.

Assignments (3)
RELEASE OF SECURITY INTEREST (REEL/FRAME NO. 068877/0300) Recorded May 28, 2026
From: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS ADMINISTRATIVE AGENT
To: AMERICAN WOODMARK MANAGEMENT CORPORATION
Reel/Frame 075643/0670 →
CHANGE OF NAME Recorded Jun 27, 2024
From: RSI HOME PRODUCTS MANAGEMENT, INC.
To: AMERICAN WOODMARK MANAGEMENT COMPANY
Reel/Frame 067965/0963 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 26, 2024
From: LE DUFF, DAMIAN J.; ALVAREZ, MANUEL
To: RSI HOME PRODUCTS MANAGEMENT, INC.
Reel/Frame 067848/0755 →
Continuity (6)
Continuation 16910634 · Jun 24, 2020
Continuation 15852877 · Dec 22, 2017
Division 14444835 · Jul 28, 2014
Provisional Application 61876198 · Sep 10, 2013
Provisional Application 61875689 · Sep 10, 2013
Related Publication 20220396010A1 · Dec 15, 2022
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