Molded solid surface comprising a ferrous material

Abstract

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

Description

[0001] Cross-reference to Related Patent Applications

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 311,633, filed February 18, 2022 (Docket No. 010222-21039A-US), and U.S. Non-Provisional Patent Application No. 18 / 107,351, filed February 8, 2023, which are incorporated by reference herein. TECHNICAL FIELD

[0003] The present application relates to magnetic devices for use in a bathroom or kitchen environment. BACKGROUND

[0004] A magnet is a material or object that produces a magnetic field. A permanent magnet is an object or material that is magnetized and produces its own magnetic field. A temporary magnet only retains its magnetic field for a certain time, such as when there is a permanent magnetic field or an electric current. An electromagnet only produces a magnetic field when, for example, connected to an electric current. Although ferromagnetic materials (such as iron, nickel, and cobalt) are the only materials that are strongly attracted by magnets and are considered to have magnetism, other substances can react weakly to a magnetic field. These other substances can include objects that are not traditionally considered to have magnetism, such as wood, water, and particles suspended in water. Generally, a magnetic field has no effect on non-ferromagnetic materials; however, small forces applied in specific situations can provide useful functionality in the following embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0005] According to example embodiments, example embodiments are described herein with reference to the following drawings.

[0006] Figure 1 A device including a molded solid surface and a ferrous material according to example embodiments of the present disclosure is shown.

[0007] Figure 2 A device including a molded solid surface and a ferrous material according to example embodiments of the present disclosure is shown.

[0008] Figure 3 A flowchart for manufacturing a molded solid surface according to example embodiments of the present disclosure is shown.

[0009] Figure 4 A flowchart for manufacturing a molded solid surface according to example embodiments of the present disclosure is shown.

[0010] Figure 5 A method for manufacturing a molded solid surface according to example embodiments of the present disclosure is shown.

[0011] Figure 6A system for manufacturing a molded solid surface is shown in accordance with example embodiments of the present disclosure.

[0012] Figure 7 A system for manufacturing a molded solid surface is shown in accordance with example embodiments of the present disclosure.

[0013] Figure 8 A system for manufacturing a molded solid surface is shown in accordance with example embodiments of the present disclosure.

[0014] Figure 9 A cross-section of a system for manufacturing a molded solid surface is shown in accordance with example embodiments of the present disclosure.

[0015] Figure 10 A cross-section of a system for manufacturing a molded solid surface is shown in accordance with example embodiments of the present disclosure. Figure 9

[0016] Figure 11 A predetermined pattern on a molded solid surface and a corresponding magnet configuration are shown.

[0017] Figure 12 A predetermined pattern on a molded solid surface and a corresponding magnet configuration are shown.

[0018] Figure 13 An example of a controller for any one of the electronic examples herein is shown. DETAILED DESCRIPTION

[0019] The following embodiments include magnetic-based devices, systems, and techniques suitable for use in a bathroom environment or a kitchen environment. Various embodiments are described and illustrated separately. However, each of these embodiments can be used together in a single implementation, device, or system. It should be understood that the present disclosure is not limited to the details and methods set forth in the specific implementation or shown in the drawings. It should be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0020] When components, elements, devices, etc. of the present disclosure are described as having certain purposes or performing certain operations, functions, etc., the components, devices, or elements should be understood to be "configured" to serve the purposes or perform the operations or functions.

[0021] Natural and man-made stone surfaces have desirable aesthetics, including natural veins and apparent geometric patterns. However, natural and man-made stone surfaces are expensive. Producing natural stone surfaces requires access to a stone quarry, and the stone surfaces are limited to flat surfaces that must be closed. Further, producing natural and man-made stone surfaces requires the use of expensive specialized equipment. Thus, there is a need for an inexpensive solid surface product that has desirable aesthetics.

[0022] ​Described herein are devices comprising a molded solid surface and ferrous particles and methods of manufacturing a molded solid surface comprising ferrous particles. More specifically, the present disclosure describes methods of manufacturing a molded solid surface comprising ferrous particles, wherein a predetermined pattern and / or docking location is created on the molded solid surface by applying a force to the ferrous particles using a localized magnetic field (i.e., one or more permanent magnets, temporary magnets, electromagnets, etc.). Any of the magnets described in the present disclosure can be neodymium, electromagnets, or other types of magnets. The devices comprising a molded solid surface and ferrous particles can provide a solid surface with an ideal aesthetic. The devices can provide a more affordable alternative for natural and man-made stone surfaces.

[0023] Figure 1 A device comprising a molded solid surface and ferrous particles is shown in accordance with example embodiments of the present disclosure. Figure 1 A front view of the device 105 is shown, which comprises a molded solid surface 119 and ferrous particles 130 that are injection molded within a portion of the molded solid surface 119 formed from a resin material. In other embodiments, the molded solid surface 119 comprising the ferrous particles 130 can be manufactured using compression molding, resin transfer molding (RTM), gravity casting, extrusion, pultrusion, etc. In embodiments where the ferrous particles 130 are injection molded within the molded solid surface 119, the ferrous particles 130 can be mixed with the resin material and injected into a mold. The ferrous particles 130 can be attracted to the surface of the mold with a magnet before the resin material solidifies into the molded solid surface 119. In embodiments where the molded solid surface is manufactured using extrusion or pultrusion, the ferrous particles can be attracted to the surface of the extruded or molded material (e.g., the solid surface of the extruded or molded material). In some embodiments, as shown, the ferrous particles 130 can create a predetermined pattern 109 in the molded solid surface 119. In other embodiments, the ferrous particles 130 can create a docking location in the molded solid surface 119. The docking location can be configured to secure a fitting comprising a magnet on the molded solid surface 119. Figure 1

[0024] As shown, the molded solid surface 119 is a planar surface. As shown, the molded solid surface can be one of a countertop, a tile, a wall (e.g., a shower wall), and a floor. In other embodiments, the molded solid surface 119 is not a planar surface. For example, the molded solid surface 119 can be one of a sink, a toilet, and a faucet. The molded solid surface 119 can be any solid surface manufactured by molding a resin material. Figure 1 Figure 1

[0025] ​​​A portion of the molded solid surface 119 that receives the injection molded ferrous particles 130 includes a resin material. The resin material can be an acrylic, a polyester, a urethane, an epoxy, or a hybrid composite material, or other suitable resin. The device 105 illustrates a portion of the molded solid surface 119 that includes a resin material in a state where the resin material has solidified into a solid surface. In some embodiments, the resin material can be a transparent or translucent material when solidified. In other embodiments, the resin material can be opaque when solidified. In some embodiments, the resin material can include a colorant such that the resin material has a colored appearance when solidified. The resin material can be configured to provide a desired exterior finish when solidified.

[0026] The ferrous particles 130 in the portion of the molded solid surface 119 that is composed of the resin material can be ferromagnetic particles. The ferrous particles can be one of iron, nickel, cobalt, and alloys thereof. In some embodiments, the ferrous particles 130 can be iron powder. In some embodiments, the ferrous particles 130 can be recycled from a manufacturing scrap stream of another product. For example, the ferrous particles 130 can be recycled from a foundry scrap stream.

[0027] The predetermined pattern 109 formed by the ferrous particles 130 in the portion of the molded solid surface 119 formed from the resin material is an intentional manipulation of the position of the ferrous particles 130 in the resin material. The predetermined pattern 109 can create an aesthetic design on the molded solid surface. In some embodiments, the predetermined pattern 109 can be a repeating pattern on the molded solid surface. However, the predetermined pattern 109 need not be a repeating pattern.

[0028] A cross-section of the device 105 taken along line 140 is illustrated. The ferrous material 130 is located near the surface of the molded solid surface 119. The ferrous material 130 located near the molded solid surface can create the predetermined pattern 109 on the molded solid surface. The ferrous particles 130 can be visible through the transparent or translucent solidified resin material, allowing a user to see the predetermined pattern 109.

[0029] A cross-section of the device 105 taken along line 160 is illustrated. The ferrous particles 130 are located near the surface of the molded solid surface 119. The cross-section 160 is taken at a different location along the device 105 than the cross-section 140, where the ferrous particles 130 forming the predetermined pattern 109 are present in a different location than illustrated with respect to the cross-section 140.

[0030] Figure 2 A device 363 is shown in accordance with example embodiments of the present disclosure, including a molded solid surface 320 and ferrous particles 330. Figure 2A front view of a device 363 is shown that includes a molded solid surface 320 and a ferrous particle 330 that is injection molded within a portion of the molded solid surface formed from a resin material. The molded solid surface 320 and the ferrous particle 330 can be the same as those discussed above with respect to the device 105 and Figure 1 the device 205. The resin material can be the same as the resin material discussed above with respect to the device 105 and Figure 1 the device 205. As shown, the ferrous particle 330 creates a docking location 310 in the molded solid surface 320. Figure 2

[0031] The docking location 310 formed by the ferrous particle 130 in the portion of the molded solid surface 320 formed from a resin material is configured to secure (e.g., mount) an accessory that includes a magnet to the molded solid surface 320. In some embodiments, the accessory can be a soap dispenser or a container configured to store a kitchen or bathroom utensil. In some embodiments, the accessory can be a kitchen utensil, such as a coffee maker, a toaster, an oven, etc. In some embodiments, the accessory can be a kitchen accessory, such as a cutting board, a knife block, a tripod, etc. The kitchen utensil can be one of a knife, a fork, a spoon, a cookware (such as a spatula, a whisk, etc.), etc. In some embodiments, the accessory can be a bathroom utensil, such as a toothbrush (or a toothbrush holder), a hair dryer, an electric shaver, etc. The bathroom utensil can be one of a toothbrush, a brush, a comb, a tweezer, a cotton swab, etc. In some embodiments, the accessory can be a vanity, and the device can be configured to secure itself to a top of the vanity. For example, the device can be a countertop, and the countertop can be configured to secure itself to the vanity (e.g., during installation of the countertop). In some embodiments, the docking location 310 can be visible within the molded solid surface 320.

[0032] In some embodiments, the docking location 310 can not be visible within the molded solid surface 320. A cross-section of the device 363 taken along the line 340 illustrates that the ferrous material 330 is located near the surface 325 of the molded solid surface 320. The ferrous material 330 located near the surface 325 of the molded solid surface 320 can form the docking location 310. The device 363 can be configured to secure an accessory that includes a magnet to the molded solid surface 320. The magnet in the accessory can be attracted to the ferrous material 330 in the device 363, thereby securing the accessory to the molded solid surface 320. In some embodiments, a magnet can be included in the device 363, and the accessory can include a ferromagnetic material.

[0033] ​In some embodiments, a magnet component (e.g., a permanent magnet) can be embedded in the molded solid surface. The magnet component can be embedded in the molded solid surface to secure (e.g., mount) an accessory comprising a ferrous component to the molded solid surface. Thus, a molded solid surface containing a magnet embedded therein can be configured to secure (e.g., mount) any of the accessories described above or below comprising a magnet, the accessory comprising the magnet by including a ferrous material in the accessory described as comprising a magnet. For example, a soap dispenser comprising a ferrous component, or a container configured to store a kitchen or bathroom appliance comprising a ferrous component, can be secured or mounted on a molded solid surface containing a magnet embedded therein. In some embodiments, an object comprising a ferrous component can be secured on a molded solid surface containing a magnet embedded therein. For example, a pen, a paperclip, and the like can be secured on the molded solid surface. In some embodiments, the molded solid surface can comprise both the ferrous particles 330 and the magnet component.

[0034] In some embodiments, the molded solid surface can be one of the tiles. In embodiments where the molded solid surface is one of the tiles, the docking locations formed in the tile can be configured to secure an accessory comprising a magnet to the tile. For example, a shelf, a dispenser (e.g., a soap dispenser, a shampoo dispenser, a conditioner dispenser, and the like), or a container configured to store a kitchen and / or bathroom appliance can be secured on the tile. In other embodiments, the docking locations formed in the tile can be configured to secure a mat, a rug, a trash can, or a toilet brush holder.

[0035] In some embodiments where the molded solid surface is one of the sinks, the molded solid surface can form a basin of the sink. In embodiments where the basin of the sink has a rectangular or substantially rectangular shape, the molded solid surface can form a bottom and / or a wall of the basin. In some embodiments, the molded solid surface can be a strainer, a strainer basket, or a drain plug of the sink. Thus, the predetermined pattern can be formed in any of the basin, the wall, the bottom, the strainer, the strainer basket, and / or the plug. Likewise, the docking locations can be formed in any of the basin, the wall, the bottom, the strainer, the strainer basket, and / or the plug of the sink. For example, the docking locations on the basin and / or the wall of the sink can be configured to secure an accessory such as a basket for placing a sponge, a soap, or a similar item. In another example, the strainer can be configured to secure the strainer basket and / or the plug.

[0036] In some embodiments where the molded solid surface is one of a toilet, the molded solid surface can form one or more portions of a flush engine of the toilet, such as an interior of a bowl, a rim, a sump, and / or a trapway, among others. In other embodiments, the molded solid surface can be one or more portions of a surrounding housing of the toilet, such as a shroud, a base, a cover, among others. The cover can be configured to cover an exterior surface of the bowl, the sump, the trapway, among others. In some embodiments, the molded solid surface can form one or more components of the surrounding housing and can be overmolded on an exterior surface of the flush engine. In some embodiments, the molded solid surface can form a tank or a cover of a toilet tank. Accordingly, a predetermined pattern can be formed on an interior of the bowl, the rim, the sump, the trapway, the shroud, the base, the cover, the tank, or the tank cover. Likewise, a docking location can be formed on an interior of the bowl, the rim, the sump, the trapway, the shroud, the base, the cover, the tank, or the tank cover. For example, a docking location can be formed on an interior of a toilet bowl to dispense a cleaning agent into the bowl. In another example, a docking location can be formed in a tank cover to secure an air freshener or similar item on the tank cover.

[0037] In some embodiments where the molded solid surface is one of a faucet, the molded solid surface can be one or more surfaces of a faucet body and / or a faucet handle. In some embodiments, the faucet body can be configured to receive the faucet handle and / or a plumbing network (e.g., internal waterways, aerator, valve system, valve core). For example, the faucet body can extend vertically to conceal a portion of the plumbing network (e.g., internal waterways and / or valve system) and can extend horizontally and / or vertically to conceal another portion of the plumbing network (e.g., faucet spout). In other embodiments, the faucet body can be formed around the valve core and the plumbing network, such as by injection molding, compression molding, resin transfer molding (RTM), gravity casting, among others. The faucet body can be configured to cause the faucet to have a desired surface finish and / or aesthetic (e.g., shape, texture, color, among others). Accordingly, a predetermined pattern can be formed in the faucet body and / or the faucet handle. Likewise, a docking location can be formed in the faucet body and / or the faucet handle. For example, a docking location can be formed in the faucet body to secure a water filter or similar item on an end of the faucet.

[0038] Figure 3 A flow diagram for manufacturing a molded solid surface according to example embodiments of the present disclosure is shown. Various systems and apparatuses disclosed herein can employ the method of Figure 3 Other, different, or fewer acts can be provided.

[0039] At act S101, ferrous particles are mixed into a resin material. The ferrous particles and the resin material can be as described above with respect to Figure 1 andFigure 2 The same as discussed. At act S101, the resin material can be in a liquid phase, including a mixture of two or more liquids. For example, one of the liquids can include a used epoxy resin composition, and the other liquid can be a curing agent (e.g., an epoxy curing agent). While the resin material is in the liquid phase, the ferrous particles can be mixed into the resin material. The ferrous particles can be mixed into the resin material so that they are distributed throughout the resin material. In some embodiments, a filler material and / or a colorant can be further mixed into the resin material.

[0040] At act S103, the resin material including the ferrous particles is injected into a mold. The mold can include a top half mold and a bottom half mold. At act S103, the mold can be closed so that the top half mold and the bottom half mold form a sealed, enclosed space having a shape of a desired molded solid surface. For example, the desired shape can be one of a countertop, a tile, a wall, a floor, a toilet, a faucet, etc. The resin material including the ferrous particles can be injected into the mold through an injection channel. The injection channel can be fluidly connected to the top half and / or the bottom half of the mold so as to fill the interior of the mold with the resin material including the ferrous particles during the injection process. The resin material including the ferrous particles can be injected into the mold under pressure so that the entire interior of the mold is filled.

[0041] At act S105, a predetermined pattern is created in the resin material by using one or more magnets to apply a force to the ferrous particles toward the surface of the mold. The one or more magnets can be disposed in or near the mold so that, after the resin material is injected into the mold, the magnets apply a magnetic force to the ferrous particles in the resin material. The one or more magnets can be configured to apply a magnetic force to the ferrous particles so that the ferrous particles are gathered at specific locations near the surface of the mold. The one or more magnets can be one of a permanent magnet and an electromagnet. The one or more magnets can have a particular strength (e.g., produce a magnetic field of a certain strength) and be placed at a particular location relative to the mold so that a predetermined pattern is created in the resin material (and subsequently the molded solid surface) by using the applied magnetic force to move (e.g., pull, push, attract) the ferrous particles toward the surface of the mold. In some embodiments, the ferrous particles can be moved toward the surface of the mold so that they are visible (i.e., a visible concentration of the ferrous particles can be formed) in the molded solid surface near the surface of the mold toward which the ferrous particles are moved. The area of the molded solid surface corresponding to the area of the mold in which the ferrous particles are moved toward the surface of the mold can have a relatively dark shade due to the relatively high concentration of ferrous particles. In some embodiments, the ferrous particles can be moved away from the surface of the mold so that they are not visible (i.e., all visible particles can be removed from the area) in the molded solid surface near the surface of the mold away from which the ferrous particles are moved. The area of the molded solid surface corresponding to the area of the mold in which the ferrous particles are moved away from the surface of the mold can have a relatively light shade due to the relatively low concentration of ferrous particles. In certain areas of the mold, the particles can not be moved toward or away from the surface of the mold. The area of the molded solid surface corresponding to the area of the mold in which the ferrous particles are neither moved toward nor away from the surface of the mold can have a medium shade due to the medium concentration of ferrous particles. In some embodiments, the ferrous particles can be moved toward the surface of the mold in certain areas, away from the same surface in other areas, and not toward or away from the same surface in different areas. Thus, a predetermined pattern including three different shades can be formed in the molded solid surface. The one or more magnets can be configured to apply a force to the ferrous particles so that the ferrous particles are held at a particular distance from the surface of the mold. The resin material can be transparent or translucent when cured, and the ferrous particles can have a different color than the resin material when cured, so that the user can see the predetermined pattern created in the resin material after the solid surface of the mold is cured.

[0042] In some embodiments, one or more magnets can be moved toward and / or away from one of the upper half mold and the lower half mold to create the predetermined pattern. In some embodiments, one or more magnets can be moved along a surface of one of the upper half mold and the lower half mold to create the predetermined pattern. In some embodiments, one or more magnets can be moved along a plane that is perpendicular to a surface of one of the upper half mold and the lower half mold to create the docking position.

[0043] At act S107, the resin material including the ferrous particles is cured into a molded solid surface including the predetermined pattern. The resin material can be cured into a device including a molded solid surface having the ferrous particles forming the predetermined pattern injection molded within a portion of the molded solid surface formed by the resin material. In some embodiments, the resin material can begin to cure during the creation of the predetermined pattern (act S105). In some embodiments, the resin material can be cured at an elevated temperature. For example, one of the upper half mold and the lower half mold can be in an elevated temperature state during the injection molding (act S103), the creation of the predetermined pattern (act S105), and the curing of the resin material (act S107).

[0044] The resin material can be cured into a transparent or translucent molded solid surface such that the predetermined pattern including the ferrous particles is visible within the molded solid surface. The resin material can be configured such that the molded solid surface has a particular color after curing. The resin material can be configured to cause the molded solid surface to have desirable surface properties (e.g., stain resistance, heat resistance, wear resistance, etc.) after curing.

[0045] In some embodiments, the method of manufacturing a molded solid surface further includes separating the upper half mold and the lower half mold and removing the molded solid surface from one of the upper half mold and the lower half mold.

[0046] Figure 4 A flowchart for manufacturing a molded solid surface according to example embodiments of the present disclosure is shown. Various systems and devices disclosed herein can employ the method of Figure 4 Other different or fewer acts can be provided.

[0047] At act S201, ferrous particles are mixed into a resin material. The ferrous particles and the resin material can be the same as those discussed above with respect to Figures 1 to 3 act S101. In some embodiments, act S201 can be the same as act S101 discussed above with respect to Figure 3

[0048] At act S203, the resin material including the ferrous particles is injected into a mold. The mold can be the same as that discussed above with respect to Figure 3 ​The mold discussed is the same. In some embodiments, the action S203 can be the same as the action S103 discussed above with respect to Figure 3

[0049] In action S205, the docking locations are created in the resin material by using one or more magnets to apply a force to the ferrous particles towards the surface of the mold. The one or more magnets can be disposed in or proximate to one of the upper half mold and the lower half mold. The one or more magnets can be one of a permanent magnet and an electromagnet. In some embodiments, the one or more magnets can be moved towards and / or away from one of the upper mold surface and the lower mold surface to create the docking locations. In some embodiments, the one or more magnets can be moved along a surface of one of the upper mold surface and the lower mold surface or along a plane perpendicular to the surface of one of the upper half mold and the lower half mold to establish the docking locations.

[0050] The one or more magnets can be configured to apply a magnetic force to the ferrous particles in the resin material towards the surface of one of the upper half mold and the lower half mold. The one or more magnets can be configured to apply a magnetic force to the ferrous particles such that the ferrous particles are gathered at one or more locations where the docking locations are formed. The one or more magnets can have a particular strength (e.g., produce a magnetic field of a certain strength) and be placed at a particular location relative to the mold so as to create the docking locations in the resin material (and subsequently the molded solid surface) by using the applied magnetic force to move (e.g., pull, push, attract) the ferrous particles towards the surface of the mold. The one or more magnets can be configured to apply a force to the ferrous particles such that the ferrous particles are held at a particular distance from the surface of the mold. The magnets can be configured to apply a force to the ferrous particles such that the magnets included in the accessory can secure the accessory to the ferrous particles of the solidified molded solid surface. In some embodiments, the resin material can be transparent or translucent when solidified.

[0051] In action S207, the resin material including the ferrous particles is solidified into a molded solid surface including the docking locations. In some embodiments, the action S207 can be the same as the action S107 discussed above with respect to Figure 3 The resin material can be solidified into the molded solid surface such that the magnets included in the accessory are attracted to the ferrous particles in the molded solid surface such that the accessory is secured to the molded solid surface. The resin material can be configured such that the solidified molded solid surface has desirable surface properties (e.g., stain resistance, heat resistance, wear resistance, etc.). In some embodiments, the docking locations can be visible within the molded solid surface.

[0052] ​In some embodiments, the method of manufacturing a molded solid surface further includes separating the upper half-mold and the lower half-mold and removing the molded solid surface from one of the upper half-mold and the lower half-mold.

[0053] Figure 5 A non-exclusive example method of manufacturing a molded solid surface according to example embodiments of the present disclosure is shown. As shown, Figure 5 The system 200 for manufacturing a molded solid surface includes an injection channel 210, a lower half-mold 230, an upper half-mold 240, a magnet 260, and a molded solid surface 270. The injection channel 210 can be fluidly coupled with one of the lower half-mold 230 and the upper half-mold 240. The injection channel can be configured to provide a resin material flow including ferrous particles to one of the lower half-mold 230 and the upper half-mold 240. The lower half-mold 230 and the upper half-mold 240 can be detachably coupled with each other. When coupled with each other, the lower half-mold 230 and the upper half-mold 240 can create a sealed, enclosed interior. The sealed, enclosed interior of the lower half-mold 230 and the upper half-mold 240 can create a desired shape of the molded solid surface. The desired shape of the molded solid surface can be one of a countertop, a tile, a wall, a floor, a toilet, and the like. The magnet 260 can be configured to exert a force on the ferrous particles toward a surface of one of the lower half-mold 230 and the upper half-mold 240. The magnet 260 can be configured to create a predetermined pattern and / or a docking location in the resin material (and subsequently the molded solid surface after the resin material is cured).

[0054] Figure 5 A system 200 for manufacturing a molded solid surface including ferrous particles in a first state is shown. In the first state, the lower half-mold 230 and the upper half-mold 240 are coupled with each other forming a sealed, enclosed interior having a desired shape of the molded solid surface. As shown, Figure 1 The injection channel is fluidly coupled with the lower half-mold 230. In other embodiments, the injection channel can be fluidly coupled with the upper half-mold 240 or fluidly coupled with both the lower half-mold 230 and the upper half-mold 240. In the first state, a mixture of resin material and ferrous particles is supplied (e.g., injected) to the mold (i.e., the lower half-mold 230 and the upper half-mold 240) through the injection channel. The mixture of resin material and ferrous particles can be supplied to the mold under pressure, filling the entire interior of the coupled lower half-mold 230 and the upper half-mold 240.

[0055] Further, in the first state, after the interior of the mold is filled with the mixture of the resin material and the ferrous particles, a predetermined pattern and / or docking location comprising the ferrous particles can be formed in the resin material. The magnet 260 can exert a magnetic force on the ferrous particles causing the ferrous particles to move (e.g., push, pull) toward the surface of the mold. As described above with respect to Figure 3 and Figure 4 During the first state, the magnet can exert a magnetic force creating the predetermined pattern and / or docking location in the resin material, as described with respect to acts S105 and S205 of

[0056] Finally, in the first state, after the predetermined pattern and / or docking location is formed in the resin material, the resin material can solidify into a molded solid surface comprising the predetermined pattern and / or docking location. As described with respect to acts S107 and S207 of Figure 3 and Figure 4 The resin material can solidify into a molded solid surface, as described with respect to acts S107 and S207. In some embodiments, one of the lower half mold and the upper half mold can further comprise a heating element configured to heat the lower half mold 230 and / or the upper half mold 240. In some embodiments, the lower half mold 230 and / or the upper half mold 240 can be heated to increase the speed of solidification of the resin material. In other embodiments, one of the lower half mold 230 and / or the upper half mold 240 can be heated to increase the ductility of the resin material entering the mold. In other embodiments, the resin material can be solidified at room temperature. In some embodiments, ultraviolet light can be applied to the resin material to facilitate the solidification of the resin material.

[0057] Figure 5 A system 200 for manufacturing a molded solid surface comprising ferrous particles in a second state is shown. In the second state, the lower half mold 230 and the upper half mold 240 are no longer coupled to each other. In the second state, the molded solid surface 270 comprising the predetermined pattern and / or docking location formed (e.g., manufactured) in the first state is visible. In the second state, a portion of the molded solid surface 270 is in the mold lower half 230. The resin material can be configured such that the molded solid surface 270 can have desirable surface properties (e.g., visible predetermined pattern, stain resistance, heat resistance, wear resistance, etc.).

[0058] Figure 5 A system 200 for manufacturing a molded solid surface comprising ferrous particles in a third state is shown. In the third state, the molded solid surface 270 has been removed from the mold lower half 230. As shown by the system 200, the molded solid surface 270 is planar. As described above with respect to Figure 5As shown in the embodiment of FIG. 2, the molded solid surface 270 can be one of a countertop, a tile, a wall, a floor, etc. In other embodiments, the molded solid surface can be one of a toilet and a faucet. In other embodiments, the molded solid surface can be any surface that can be molded using a resin material.

[0059] Figure 6 A system 201 for manufacturing a molded solid surface including ferrous particles according to embodiments of the present disclosure is shown. The system 201 includes an injection channel 210, a lower mold half 231, an upper mold half 241, a magnet 261, and a molded solid surface 270. Figure 6 The injection channel 210, the upper mold half 241, and the molded solid surface 270 in FIG. 2 can be the same as those discussed above with respect to Figure 5 FIG. 1. Figure 6 The lower mold half 231 shown in the embodiment of FIG. 2 includes the magnet 261. Figure 6 The magnet 261 in the embodiment of FIG. 2 can be a permanent magnet. The lower mold half 231 can include a grid structure into which the magnet 261 is inserted. The grid structure can include different locations into which the magnet can be inserted in order to create different predetermined patterns and / or docking locations in the molded solid surface.

[0060] Figure 7 A system 202 for manufacturing a molded solid surface including ferrous particles according to embodiments of the present disclosure is shown. The system 202 includes an injection channel 210, a lower mold half 232, an upper mold half 242, a magnet 223, a power source 280, electrical wires 285, and a molded solid surface 270. Figure 7 The injection channel 210, the upper mold half 242, and the molded solid surface 270 in FIG. 2 can be the same as those discussed above with respect to Figure 5 FIG. 1. Figure 7 Further including the lower mold half 232, the lower mold half 232 includes the magnet 262, the power source 280, and the electrical wires 285. In other embodiments, the magnet 261 can be located in the upper mold half 241.

[0061] In an embodiment of system 202, the lower mold 322 includes a magnet 262. The magnet 262 in the embodiment of system 202 may be an electromagnet. The electromagnet 262 may be connected to another electromagnet and a power source 280 via wires 285. The power source 280 may be configured to provide a specific current or current range to the electromagnet so that the electromagnet has a desired strength (e.g., creating a magnetic field of desired strength). In some embodiments, the power source may be a power supply that provides direct current or alternating current. In some embodiments, the power source may be a battery. In other embodiments, the wires 285 may be plugged into a power source, such as a wall socket. In some embodiments, the lower mold may include two or more electromagnetic circuits configured to create different predetermined patterns and / or mating positions in the molded solid surface 270. In some embodiments, the magnet 262, connected to the power source 280 via wires 285, may be on the upper surface 252 of the mold.

[0062] Figure 8 A system 203 for manufacturing a molded solid surface comprising ferrous particles, according to an embodiment of the present disclosure, is shown. The system 203 includes an injection channel 210, a lower mold half 233, an upper mold half 243, a magnet 263, an arm 290, and an actuator 295. The injection channel 210, the lower mold half 233, the upper mold half 243, and the molded solid surface 270 can be connected to the above-described components. Figure 5 The same applies to those discussed. System 203 further includes an arm 290 connecting magnet 263 and actuator 295. In embodiments of system 203, magnet 263 may be a permanent magnet or an electromagnet. Actuator 295 may be a motor or a solenoid. Actuator 295 is configured to move arm 290, thereby moving magnet 263 relative to the lower half 233 and upper half 233 of the mold. For example, actuator 295 may move arm 290 and thus magnet 263 along a predetermined path to create a predetermined pattern and / or mating position by applying a force toward the surface of the mold to the ferrous particles as magnet 263 moves along the predetermined path. In some embodiments, magnet 263, arm 290, and actuator 295 may be located on the opposite side of the mold, near upper half 243. In some embodiments, actuator 295 may be configured to move arm 290 and magnet 263 toward and / or away from lower half 233 of the mold. In some embodiments, actuator 295 may be configured to move magnet 263 along a plane parallel to the surface of lower mold 233. As actuator moves magnet relative to mold, system 203 may create predetermined patterns and / or mating positions in resin material (and subsequently molded solid surfaces).

[0063] Figure 9A cross-section of a system for manufacturing a molded solid surface including ferrous particles is shown in accordance with example embodiments of the present disclosure. The system 204 includes an injection channel 210, a lower mold half 234, an upper mold half 244, and a magnet 264. The injection channel 210 and the magnet 264 can be the same as those discussed above with respect to Figure 5 FIG. 1. As shown, the lower mold half includes a recess 298 formed therein. In some embodiments, the recess 298 can be formed in the upper mold half 244. In other embodiments, the recess 298 can be formed in the lower mold half 234 and the upper mold half 244. The recess 298 can correspond to a protrusion 299 formed in the molded solid surface 270. Figure 9

[0064] In the system 204, the magnet can move ferrous particles into the recess formed in the lower mold half 234 and / or the upper mold half 244. In some embodiments, the magnet 264 can push ferrous particles into the recess 298. Thus, after the resin material solidifies, a relatively high concentration of ferrous particles can be located in the protrusion 299 formed in the molded solid surface 270. Due to the high concentration of ferrous particles in the protrusion 299, the protrusion 299 can have a relatively deep shadow. In other embodiments, the magnet 264 can pull ferrous particles into the recess 298. In some embodiments, the magnet 264 can be located within the lower mold half 234 and / or the upper mold half 244. In other embodiments, the magnet 264 can be located in the vicinity of the lower mold half 234 and / or the upper mold half 244.

[0065] Figure 10 A cross-sectional view of the system 204 taken along line 239 is shown. The recess 298 formed in the lower mold half 234 and / or the upper mold half 244 can be configured to create a preconfigured texture and / or geometric pattern in the molded solid surface 270. As shown, Figure 9 Figure 10 the location of the recess 298 formed in the lower mold half 234 and / or the upper mold half 244 can correspond to the preconfigured texture and / or geometric pattern in the molded solid surface. Thus, after the resin material solidifies, the ferrous particles in the protrusion 299 can form the preconfigured texture and / or geometric pattern.

[0066] Figure 11 A predetermined pattern 301 in a molded solid surface 302 is shown in accordance with example embodiments of the present disclosure. Figure 11 A magnet configuration 303 for creating the predetermined pattern 301 shown in Figure 11 is further shown.

[0067] Figure 12 ​​A predetermined pattern 401 on a molded solid surface 402 according to example embodiments of the present disclosure is shown. Figure 12 A magnet configuration 403 for creating the predetermined pattern 401 is shown.

[0068] Example molded solid surfaces including ferrous particles according to any disclosed embodiments can be adapted for induction heating. Cast sand with ferrous or magnetic material can be added to ceramic tiles that form a countertop or another device or surface for heating. The ceramic tiles can be configured to operate as induction heaters. Molded solid surfaces including ferrous particles can be adapted for other heatable surfaces, such as a bathtub surface, a shower surface, a toilet seat, a bidet, and a shower seat.

[0069] The electrical coil underneath the tile (e.g., within the countertop) generates an electromagnetic field that travels through the ferrous particles in the tile. The ferrous material can be heated by eddy currents, Joule heating, and / or hysteresis losses. The ceramic tile can heat a pot or pan as a stove or other heated surface. That is, the ceramic tile is heated by induction heating, and heat is applied to one or more objects in contact with the ceramic tile. The ceramic tile can operate as a warming tray, keeping items warm. The ceramic tile can be used to dry surfaces or other objects, such as towels or clothing. The ceramic tile can be used to heat wax, scents, or other fragrance materials.

[0070] In another example, the at least one magnet underneath the molded solid surface including ferrous particles (e.g., within the ceramic tile) includes an electromagnet. The electromagnet, when energized, generates induction heat by an electromagnetic field. The electromagnetic field is applied to an object placed on the molded solid surface to heat the object. The object can be a pot or pan suitable for induction heating.

[0071] When a component, device, element, or the like of the present disclosure is described as having a certain purpose or performing a certain operation, function, or the like, that component, device, or element should be interpreted here as being "configured to" serve the purpose or perform the operation or function.

[0072] The electromagnet can be connected to a power source configured to supply a particular current or range of currents to the electromagnet so that the electromagnet has a desired strength (e.g., generates a magnetic field of a desired strength) under the direction, signal, or command from the controller 222. In some embodiments, the power source can be a power source that provides direct current or alternating current. In some embodiments, the power source can be a battery. In other embodiments, the electromagnet can be electrically connected to a power source, such as a wall outlet.

[0073] Figure 13An example of a control system or controller 222 for any of the embodiments described herein is shown. The controller 222 can include a processor 300, a memory 352, and a communication interface 353 for interfacing with a device or with the Internet and / or other networks 346. In addition to the communication interface 353, a sensor interface can be configured to receive data from sensors described herein or from any source. The components of the control system can communicate using a bus 348. The control system can be connected with a workstation or another external device, such as a control panel, and / or a database to receive user input, system characteristics, and any of the values described herein.

[0074] The controller 222 can generate commands for the electromagnets in response to sensors, such as temperature sensors, to control a target temperature by duty cycle or current provided to the electromagnets. The controller 222 can generate commands for the electromagnets in response to a predetermined pattern of the pattern 109 stored in the memory 352. The electromagnets can include an array of electromagnets having a plurality of pattern components. The controller 222 selects a stored pattern from the memory 352 and determines a subset of the plurality of electromagnet pattern components to energize to provide the pattern 109.

[0075] Optionally, the control system can include an input device 355 and / or sensing circuitry 356 in communication with any sensors. The sensing circuitry receives sensor measurements from sensors as described above. The input device can include any user input, such as buttons, a touchscreen, a keyboard, a microphone for voice input, a camera for gesture input, and / or another mechanism.

[0076] Optionally, the control system can include a drive unit 340 for receiving and reading a non-transitory computer medium 341 having instructions 342. Additional, different, or fewer components can be included. The processor 300 is configured to execute the instructions 342 stored in the memory 352 for performing the algorithms described herein. The display 350 can be an indicator or other screen output device. The display 350 can be combined with the user input device 355.

[0077] The processor 300 can be a general or special purpose processor, an application specific integrated circuit (ASIC), one or more programmable logic controllers (PLCs), one or more field programmable gate arrays (FPGAs), a set of processing components, or other suitable processing components. The processor 300 is configured to execute computer code or instructions stored in the memory 352 or received from other computer-readable media (e.g., embedded flash, local hard storage, local ROM, network storage, remote servers, etc.). The processor 300 can be a single device or a combination of devices, such as associated with a network, distributed processing, or cloud computing.

[0078] Memory 352 can include one or more devices (e.g., storage units, memory devices, storage devices, etc.) for storing data and / or computer code for completing and / or facilitating the various processes described in the present disclosure. Memory 352 can include random access memory (RAM), read-only memory (ROM), hard disk storage, temporary storage, non-volatile storage, flash memory, optical storage, or any other suitable type of memory for storing software objects and / or computer instructions. Memory 352 can include database components, object code components, script components, or any other types of information structures for supporting various activities and information structures described in the present disclosure. Memory 352 can be communicably connected to processor 300 via processing circuitry and can include computer code for implementing one or more processes described herein (e.g., by processor 300). For example, memory 352 can include graphics, webpages, HTML files, XML files, script code, spray configuration files, or other resources for generating a graphical user interface for display and / or for interpreting user interface input to make command, control, or communication decisions.

[0079] In addition to the ingress port and the egress port, communication interface 353 can include any operable connection. An operable connection can be a connection by which signals, physical communications, and / or logical communications can be sent and / or received. An operable connection can include a physical interface, an electrical interface, and / or a data interface. Communication interface 353 can connect to a network. The network can include a wired network (e.g., Ethernet network), a wireless network, or a combination thereof. The wireless network can be a cellular telephone network, an 802.11, 802.16, 802.20, or WiMax (Worldwide Interoperability for Microwave Access) network, a Bluetooth pairing of devices, or a Bluetooth mesh network. Further, the network can be a public network, such as the Internet, a private network, such as an intranet, or a combination thereof, and can utilize various

[0080] Although the computer readable medium (e.g., memory 352) is shown as a single medium, the term "computer readable medium" includes a single medium or multiple media, such as a centralized or distributed database, and / or associated caches and servers that store one or more sets of instructions. The term "computer readable medium" shall also include any medium that is capable of storing or encoding a set of instructions for execution by a processor or that is capable of storing or encoding data that can be read by a computer system to perform any one or more of the methods or operations described herein.

[0081] In particular non-limiting, exemplary embodiments, the computer readable medium can include a solid-state memory such as a memory card or other package that houses one or more non-volatile read-only memories. Further, the computer readable medium can be a random access memory or other volatile re-writable memory. Additionally, the computer readable medium can include a magneto-optical or optical medium, such as a disk or tapes or other storage device that captures carrier wave signals such as a signal communicated over an electrical, optical, and / or physical interface. A digital file attachment to an e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. Accordingly, the disclosure is considered to include a computer readable medium or distribution medium, as well as other equivalents and successor media, in which data or instructions can be stored.

[0082] In another embodiment, dedicated hardware implementations, such as application specific integrated circuits, programmable logic arrays and other hardware devices, can be constructed to implement one or more of the methods described herein. Applications that can include the apparatus and systems of various embodiments can broadly include a variety of electronic and computer systems. One or more embodiments described herein can implement functions using two or more specific interconnected hardware modules or devices with related control and data signals that can be communicated between and through the modules, or as portions of an application-specific integrated circuit. Accordingly, the present system encompasses software, firmware, and hardware implementations.

[0083] The drawings described herein are intended to provide a general understanding of the structure of various embodiments. The drawings are not intended to provide an exhaustive explanation of all aspects of the devices and systems utilizing the structures or methods described herein. Many other embodiments will be apparent to those of ordinary skill in the art upon reviewing the present disclosure. Other embodiments can be utilized and derived from the disclosure, such that structural and logical substitutions and changes can be made without departing from the scope of the disclosure. Furthermore, unless indicated to the contrary, the drawings disclosed herein are not necessarily to scale. The proportions of certain parts have been exaggerated or minimized for the sake of clarity. Thus, the disclosure and the drawings are to be regarded as illustrative in nature rather than a restrictive. The Figures can not be drawn to scale.

[0084] While this specification contains many specifics, these should not be construed as limitations on the scope of the application or of what may be claimed, but rather as descriptions of particular embodiments of the application. Certain features that are, for clarity, described above and below in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any suitable subcombination. In addition, while the above description has been made with respect to specific embodiments, it will be appreciated that many alternatives, modifications and variations will be apparent to those skilled in the art from the foregoing detailed description. It will be understood that this application is to be broad in scope, and that the described details are to be considered as merely illustrative and not restrictive.

[0085] One or more embodiments of the disclosure can be referred to herein, individually and / or collectively, by the term "application" merely for convenience and without intending to voluntarily limit the application to any particular application or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose will not be considered outside the scope of the application. This disclosure is intended to cover any and all subsequent adaptations or variations. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of reasonable skill in the art upon reading the above description.

[0086] The above detailed description is to be considered as illustrative and not restrictive, and the scope of the application is to be determined by the following claims, which are to be construed in accordance with the principles of patent law. The claims should not be understood to be limited to the described sequences or elements unless so specified. Thus, all embodiments falling within the scope of the following claims and their equivalents are intended to be embraced by the application.

Claims

1. A method of manufacturing a molded solid surface, the method comprising: mixing ferrous particles into a resin material; injecting the resin material including the ferrous particles into a mold, the mold including an upper half mold and a lower half mold; applying a force to the ferrous particles in the resin material toward a surface of the upper half mold or the lower half mold using one or more magnets such that a visible concentration of the ferrous particles gathers near the surface, thereby creating a predetermined pattern in the resin material; and curing the resin material in the mold as the molded solid surface; the method further comprising arranging an electrical coil or electromagnet within the molded solid surface, when the electrical coil or electromagnet produces an electromagnetic field, the electromagnetic field passing through the ferrous particles to heat the ferrous particles.

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

3. The method of claim 1, wherein during the curing of the resin material, one of the upper half mold and the lower half mold is heated to accelerate the curing of the resin material.

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

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

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

7. The method of claim 1, wherein the one or more magnets are electromagnets.

8. The method of claim 7, wherein one of the upper half mold and the lower half mold includes two or more electromagnetic circuits configured to create a predetermined pattern in the resin material.

9. The method of claim 7, wherein creating the predetermined pattern further comprises: providing an electrical current to the one or more magnets.

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

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

12. A method of manufacturing a molded solid surface, the method comprising: mixing ferrous particles into a resin material; injecting the resin material including the ferrous particles into a mold, the mold including an upper half mold and a lower half mold; creating a docking location in the resin material by using one or more magnets to pull the ferrous particles in the injection material towards a surface of one of the upper mold half and the lower mold half, the one or more magnets applying a force to the ferrous particles such that the ferrous particles gather near the surface to form a docking location and maintain a certain distance from the surface; and solidifying the resin material in the mold as the molded solid surface, wherein the docking location is configured to secure a fitting including a magnet to the molded solid surface, the method further comprising arranging an electrical coil or electromagnet within the molded solid surface, when the electrical coil or electromagnet generates an electromagnetic field, the electromagnetic field passing through the ferrous particles to heat the ferrous particles.

13. The method of claim 12, wherein the fitting is a soap dispenser or a container, the container configured to store a kitchen or bathroom appliance.

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

15. An apparatus comprising a molded solid surface; and ferrous particles injection molded within a portion of the molded solid surface, the portion formed of a resin material, wherein the ferrous particles mixed with the resin material and injected into a mold with the resin material, a visible concentration of the ferrous particles attracted by a magnet to gather near a surface of the mold to create a predetermined pattern before the resin material solidifies as the molded solid surface, the apparatus further comprising an electrical coil or electromagnet arranged within the molded solid surface, when the electrical coil or electromagnet generates an electromagnetic field, the electromagnetic field passing through the ferrous particles to heat the ferrous particles.

16. The apparatus of claim 15, wherein the ferrous particles injection molded in the molded solid surface create a docking location in the molded solid surface, the docking location configured to secure an accessory including a magnet to the molded solid surface.

17. The apparatus of claim 15, wherein the resin material is one of an acrylic, a polystyrene, a urethane, a polyester, an epoxy, or a hybrid composite material, and the molded solid surface is a countertop, a tile, a wall, a floor, a sink, a toilet, or a faucet.

18. The apparatus of claim 15, wherein the molded solid surface is a sink including a magnetic plug.

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