Molded solid surfaces including ferrous material

Patent metadata

Field	Value
Publication number	US-12472665-B2
Application number	US-202318107351-A
Country	US
Kind code	B2
Filing date	Feb 8, 2023
Priority date	Feb 18, 2022
Publication date	Nov 18, 2025
Grant date	Nov 18, 2025

Abstract

A method of manufacturing a molded solid surface includes mixing ferrous particles into a resinous material, injecting the resinous material including the ferrous particles into a mold, the mold including an upper mold half and a lower mold half, creating a predetermined pattern in the resinous material by applying a force to the ferrous particles in the resinous material toward a surface of the upper mold half or the lower mold half using one or more magnets, and curing the resinous material in the mold into the molded solid surface.

First claim

What is claimed is:

1 . A method of manufacturing a molded solid surface, the method comprising:
mixing ferrous particles into a resinous material; injecting the resinous material including the ferrous particles into a mold, the mold including an upper mold half and a lower mold half; creating a predetermined pattern in the resinous material by applying a force to the ferrous particles in the resinous material toward a surface of the upper mold half or the lower mold half using one or more magnets, such that visible concentrations of the ferrous particles accumulate near a surface of the mold creating the predetermined pattern; and curing the resinous material in the mold into the molded solid surface.

2 . The method of claim 1 , wherein the creating a predetermined pattern in the resinous material comprises:
applying a force to the ferrous particles in the resinous material toward a surface of both the upper mold half and the lower mold half using the one or more magnets.

3 . The method of claim 1 , wherein after curing the molded solid surface is a transparent surface or a semitransparent surface.

4 . The method of claim 1 , wherein creating the predetermined pattern further comprises:
moving the one or more magnets towards a surface of one of the upper mold half or the lower mold half; or moving the one or more magnets along a surface of the upper mold half or the lower mold half.

5 . The method of claim 1 , wherein the one or more magnets are disposed in one of the upper mold half and the lower mold half.

6 . The method of claim 1 , wherein one of the upper mold half and the lower mold half includes two or more electromagnetic circuits configured to create predetermined patterns in the resinous material.

7 . The method of claim 1 , further comprising:
withdrawing the upper mold half from the lower mold half; and removing the molded solid surface from the lower mold half.

8 . The method of claim 1 , wherein the molded solid surface is a countertop, tile, wall, floor, sink, toilet, or faucet and the resinous material is one of an acrylic, polystyrene, urethane, polyester, epoxy, or hybrid composite.

9 . The method of claim 1 , wherein the molded solid surface is adapted for absorbing heat via induction.

10 . A method of manufacturing a molded solid surface, the method comprising:
mixing ferrous particles into a resinous material; injecting the resinous material including the ferrous particles into a mold, the mold including an upper mold half and a lower mold half; creating a docking location in the resinous material by pulling the ferrous particles in the injection material toward a surface of one of the upper mold half and the lower mold half using one or more magnets, the one or more magnets applying a force to the ferrous particles, such that the ferrous particles accumulate near a surface of one of the upper mold half or the lower mold half, forming the docking location, and remain at least a predetermined distance away from the surface of the upper mold half or the lower mold half; and curing the resinous material in the mold into the molded solid surface, wherein the docking location is configured to secure an accessory including a magnet to the molded solid surface.

11 . The method of claim 10 , wherein the accessory is a soap dispenser or a container configured to store a kitchen or bathroom implement.

12 . The method of claim 10 , wherein the accessory is a vanity, and the molded solid surface is a countertop is configured to secure itself to a top of the vanity.

13 . A method of manufacturing a molded solid surface, the method comprising:
mixing ferrous particles into a resinous material; providing the resinous material including the ferrous particles into a mold; and creating a predetermined pattern in the resinous material by applying a force to the ferrous particles toward a surface of the mold using one or more magnets, such that visible concentrations of the ferrous particles accumulate near a surface of the mold creating the predetermined pattern.

14 . The method of claim 13 , further comprising:
curing the resinous material forming the molded solid surface, wherein the molded solid surface is transparent or semitransparent.

15 . The method of claim 13 , wherein the one or more magnets are coupled to the mold.

16 . The method of claim 13 , wherein the one or more magnets are electromagnets.

17 . The method of claim 13 , wherein the resinous material including the ferrous particles is injection molded into the mold.

18 . The method of claim 10 , wherein the docking location is visible within the molded solid surface.

19 . The method of claim 1 , wherein:
one of the upper mold half and the lower mold half include one or more dimples; and the one or more magnets apply a force to the ferrous particles causing the ferrous particles to move into the one or more dimples.

20 . The method of claim 13 , wherein:
one of the upper mold half and the lower mold half include one or more dimples; and the one or more magnets apply a force to the ferrous particles causing the ferrous particles to move into the one or more dimples.

Assignees

• Kohler Co

Inventors

• Clouse Kathryn L
• Schibur Mark
• Lipinski John O

Classifications

• B29K2995/0026

  Transparent · CPC title

• B29K2995/0008

  Magnetic or paramagnetic · CPC title

• B29K2903/06

  Metal powders, metal carbides or the like · CPC title

• B29C2791/004

  Shaping under special conditions · CPC title

• B29C45/14778

  the article consisting of a material with particular properties, e.g. porous, brittle · CPC title