AU2012203909A1

AU2012203909A1 - A composite stone board, a method of manufacturing a composite stone board and a stone worktop system

Info

Publication number: AU2012203909A1
Application number: AU2012203909A
Authority: AU
Inventors: Atis Eriks LODE
Original assignee: LODE ATIS
Current assignee: Lode Atis Eriks Mr
Priority date: 2012-07-04
Filing date: 2012-07-04
Publication date: 2014-01-30
Anticipated expiration: 2032-07-04
Also published as: AU2012203909B2

Abstract

A stone worktop system is disclosed and particularly, but not exclusively, a composite stone worktop system for use by an end user to assemble. In addition, a method of manufacturing a composite stone worktop and a clipping system for stone s worktops is disclosed. Fig. 3(a) Fig. 3(b) Fig. 3(c) F 3(d37 Fig.3(d)

Description

A COMPOSITE STONE BOARD, A METHOD OF MANUFACTURING A COMPOSITE STONE BOARD AND A COMPOSITE STONE WORKTOP SYSTEM FIELD OF THE INVENTION The present invention relates to a stone worktop system and particularly, but not 5 exclusively, a composite stone worktop system for use by an end user to assemble. BACKGROUND TO THE INVENTION Composite stone worktops are an increasingly popular solution for residential kitchens and other situations in which a hard wearing yet aesthetic surface is required. Composite stone worktops are currently available, mostly, in a bespoke .0 form, where dimensions for the particular installation are provided to a stone mason to manufacture the worktop. This means that, despite the cost of composite stone being relatively inexpensive, the labour required to manufacture the worktops to a satisfactory standard in a bespoke manner means that the overall cost is relatively high. Some retailers have provided "do-it-yourself" composite stone worktops .5 previously but the product was not user friendly, as significant modification was required, which resulted in a poor finish and, ultimately, no market desire for the product. SUMMARY OF THE INVENTION According to a first aspect of the present invention, there is provided a method of 20 manufacturing a composite stone board including: providing a mixture of stone particles and a binder providing a mould wherein the mixture is deposited on the mould and subsequently hardened to provide the composite stone board. 25 Preferably, the mould is a backing board, the backing board providing support for the composite stone board. 1 Alternatively, the method further comprises removing the composite stone board from the mould and placing the composite stone board on a backing board. According to a second aspect of the present invention there is provided a composite stone worktop including a composite stone board having a backing board formed 5 therein. Preferably, the backing board is integrally formed with the composite stone worktop. Preferably, the backing board is made of plastic, wood, metal, carbon fibre, or a combination of these materials. Preferably, the backing board has a plurality of recesses and the stone board has corresponding protrusions. Alternatively, the recesses in the backing board are filled with alternative strengthening materials, .0 such as wood, metal, carbon fibre or plastic. Preferably, the composite stone worktop is manufactured according to the first aspect of the present invention. According to a third aspect of the present invention there is provided a clamping means for two worktop boards including: a first anchoring means attachable to a first worktop board and a second .5 anchoring means attachable to a second worktop board, an inner screw and an outer screw barrel, the inner screw attachable to the first anchoring means and the outer screw barrel attachable to the second anchoring means, wherein, the inner screw and outer screw barrel are capable of being screwed 20 together whilst remaining attached to the respective anchoring means. Preferably, one of the inner screw or outer screw barrel are prevented from rotation by the first or second anchoring means. That is, if the inner screw is prevented from rotation by the first anchoring means, then the outer screw barrel is capable of rotation and, if the outer screw barrel is prevented from rotation by the second 25 anchoring means, the first inner screw is capable of rotation. Preferably, the first anchoring means includes a first anchor barrel having a first passage for a first anchor attachment means, and a second passage for the inner screw. Preferably, the second anchoring means includes a first anchor barrel having a first passage for a second anchor attachment means, and a second passage for 2 the inner screw. Preferably, the first and second anchor attachment means are screws. Preferably, the inner screw has an end stop which is capable of engaging with the first anchoring means such that the inner screw is prevented from rotating. 5 Alternatively, the outer screw barrel has an end stop capable of engaging with the second anchoring means such that the outer screw barrel is prevented from rotating. In an alternative embodiment of the clamping means, the first anchoring means is insertable into a recess in the first worktop board and the inner screw is insertable into a passage in the first worktop board which connects with the recess, and the .0 second anchoring means is insertable into a recess of the second worktop board and the outer screw barrel is insertable into a passage in the second worktop board which connects with the recess. According to a fourth aspect of the present invention there is provided a worktop accessory clipping system for attaching accessories to worktops including a clip .5 having an accessory attachment means and a resiliently deformable portion, the resiliently deformable portion extending from the accessory attachment means and capable of being deformed when attached to an accessory and being inserted through a worktop and, at a pre-determined thickness, or range of thicknesses, corresponding to the thickness, or range of thicknesses of the worktop, resiliently .0 extending beyond the further surface of the worktop to grip the accessory to the worktop. Preferably, the clip is made of spring steel. According to a fifth aspect of the present invention there is provided a composite worktop system including a composite worktop board as described in relation to the second aspect of the present invention. 25 Preferably, the system includes clamping means as describe in relation to the third aspect of the present invention. Preferably, the system includes clipping means as described in relation to the fourth aspect of the present invention 3 BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will now be described, by way on non limiting example only, with reference to the accompanying drawings, in which: Fig. 1 shows a composite stone worktop; 5 Fig. 2 shows a composite stone worktop with a sink; Fig. 3(a) shows a cross section of a composite stone board having a supporting backing board, Fig 3(b) shows the backing board of Fig. 3(a) and Fig. 3(c) and Fig. 3(d) show alternative backing boards; Fig. 4(a), (b), (c) and (d) shows cross sections of alternative composite stone boards .0 and backing boards; Fig. 5(a), (b), (c) and (d) shows different configurations of backing boards; Fig. 6(a) and (b) show an arrangement of the composite stone board and backing board for use as sidepanels or "waterfalls"; Fig. 7(a) and (b) show a fixing arrangement for fixing the backing board to a .5 structure, such as a cabinet; Fig. 8(a), (b) and (c) shows a fixing arrangement of one composite stone board having a supporting backing board to another composite stone board having a supporting backing board at a corner; Fig. 9(a) and (b) shows an alternative fixing arrangement of one composite stone 20 board having a supporting backing board to another composite stone board having a supporting backing board at a corner; and Fig. 10 shows a fixing arrangement of a device, such as a sink, to the centre of a composite stone board having a supporting backing board. DETAILED DESCRIPTION 4 Composite stone worktops, as mentioned above, are currently a popular solution for the work surfaces of residential kitchens, as well as other situations in which a hard wearing yet aesthetic surface is required. Composite stone is particularly desirable because it is lower cost and because it can be cut or prepared as a relatively thin 5 layer, for example, between 2mm and 20mm, and then adhered or veneered to a backing board. Preferably, due to the strength provided by the backing board, the composite stone thickness is minimised, and preferably, the thickness of the board is between 2mm and 9mm. Standard kitchen worktops are 30mm deep; however, there is a trend to use thicker worktops, such as 40mm. By reducing the thickness of the .0 composite stone used, a lighter and more cost effective product produced. Where appropriate, it is also possible to veneer natural stone to a backing board which, whilst more expensive than composite stone, has similar weight and cost advantages over a full stone thickness worktop. Composite stone is a man-made product which is produced by making a slurry of .5 crushed stones and adhesives and/or acrylic. The slurry is poured and pressed into slabs to create a product for use in worktops. Currently, if a new kitchen worktop surface of composite stone is required, such as worktop 10 shown in Figure 1, a kitchen installer will visit the intended install location and measure where the worktop is to be situated. The kitchen installer will then .0 construct a template board that fits the desired area. In the case of Figure 1, two portions 12 and 14 are required to fit an 'L' shaped kitchen area. A stone mason will then take the kitchen installers measurements and template board and construct a backing board and cut the composite stone to fit the measurements and template board and then adhere the composite stone to the 25 backing board. During this process, the stone mason will construct an edge to the composite stone, which hides the fact that the worktop is not completely stone. Figure 2 shows one known method to hide the actual thickness of composite stone used to construct the worktop. An upper stone board 22 is adhered to a backing board 24. A side stone board 26 is also adhered to the backing board 24 30 perpendicular to the upper board 22. The upper board 22 and side board 26 have a 450 chamfer such that each board meets the other at an edge 28. To hide the join 5 between the two boards further a chamfer 29 is applied to the outer edge of the join 28. This is simply one known way of providing a veneered stone worktop, and others are known and are also applicable to the, or each, invention disclosed herein. Whilst the above known method of constructing a kitchen composite stone worktop, 5 or any other composite stone worktop, provides a useful end product, a large amount of time is required by the kitchen installer and stone mason to produce the required worktops. In particular, a template board, a backing board and the stone requires to be constructed and finished. This results in a very expensive finish, when compared with polyester/acrylic products, such as Laminex*, or wood based products, such as .0 fibreboard/chipboard laminates. Moreover, it is relatively straight forward for a kitchen installer, whether professional or a do-it-yourself enthusiast, to install a worktop made from polyester/acrylic or fibreboard/chipboard, as the products do not need to be specially manufactured and are easy to join together. .5 Referring now to Figures 3(a), (b) and (c), a composite stone worktop 30 is shown in cross-section. Composite stone 32 is adhered to a backing board 34. The backing board 34 contains recesses 36 and the composite stone 32 has corresponding projections which fill the recesses 36. These recesses, in this example, are channels which run along the length of the backing board and the projections of the composite .0 stone are corresponding ribs or "stringers". The composite stone 32 also has edges 38, which project down over the backing board 34 so that it is not easily visible. The edges 38, although not shown here, can extend beyond the backing board 34. Figure 3(b) shows the backing board 34 of Figure 3(a) without the stone 32, showing the recesses 36 clearly. Figure 3(c) shows an alternative backing board 39 with no 25 recesses. The backing board 39 would be surrounded by composite stone in a similar manner to Figure 3(a). In an alternative embodiment, as shown in Fig. 3(d), recesses of a backing board 35 are not filled with composite stone but contain an alternative strengthening material 37. For example, the alternative strengthening material 37 can be wood, steel or 6 carbon fibre elements, used to provide greater strength than the backing board provides whilst minimising weight. The stone worktop described in relation to of Figure 3(a), (b) and (c) has a number of advantages over previously known composite stone worktops. Firstly, the recesses 5 36 on the backing board 34 and corresponding projections of the composite stone allow the composite stone 32 to be thinner, as additional support is provided by the ribs. Secondly, the composite stone 32 is constructed with integral edges 38, that is, the edges 38 are not separate pieces of composite stone. The backing board 34, and any other backing board discussed herein is, preferably, .0 made out of plastics, making it more resistant to breaking down, especially due to water ingress, and giving longevity to the product. However, it can also be made of other appropriate materials, including wood or metal based products, or a combination of these. To enable construction of the worktop 30, the composite stone slurry, which is a mix .5 of crushed stones and adhesives and/or acrylic, is poured onto a mould which matches the shape of the backing board, or is poured onto the backing board itself before being finished in a known manner of composite stone boards. Therefore, a composite stone board is produced with an integral backing board. Having the backing board and the stone integrally produced, combined at this stage 20 also means less composite material is used to create composite stone worktop, thus further reducing the cost of making the bench tops. This is particularly due to the waste stone produced when a stone mason is required to produce a custom worktop. Figures 4(a), (b) and (c) show cross-sections of composite stone worktops 40, 42 25 and 44, which are similar to the worktop 30 of Figure 3(a) but with alternative arrangements of recesses and projections of the backing board and composite stone. In this manner it is demonstrated that alternative arrangements of the backing board can be produced. 7 Referring now to Figures 5(a), (b), (c) and (d), sectional plan views of composite stone boards are shown. The sectional view allows the patterns of the projections from the composite board in the backing board. For example, a worktop 50 in Figure 5(a) has parallel ribs of composite stone. In fact, the worktop 50 is the type of ribbed 5 composite stone board described in relation to Figure 3(a). Figure 5(b) shows a worktop 52 in which the projections of the composite stone board have ribs on two axes, creating a ladder type pattern. Figure 5(c) shows a worktop with the same projections as Figure 5(b) but with additional diagonal ribs. Figure 5(d) shows a worktop in which the ribs are in the form of concentric ovals. .0 Referring now to Figure 6(a), a side panel 60 is shown having a backing board 62 and composite stone board 64. The backing board 62 has recesses 66, as has been described earlier. Side panels are used where a large area of vertical composite stone is desired. The side panel 60 has a 450 cut 68 which can be joined to a corresponding cut on a horizontal worktop. Alternatively, a side panel 61, which is .5 otherwise identical to side panel 60, has an end piece 69 which is similar to that of a horizontal worktop. A method of joining the side panels 60 and 61 is discussed below. However, these panel enable a number of designer features in kitchen installations including, for example, "waterfall" joins, where the worktop continues from horizontal to vertical, .0 usually all the way down to the ground and with a seamless join. Now referring to Figures 7(a) and (b), a backing board 70 and 71 is shown. Although not shown, a composite stone board would already in place in these Figures, but has been left out for simplicity. Backing board 70 requires to be affixed to a vertical supporting structure 72. In 25 practice, the structure 72 can be a kitchen cabinet, wall or other suitable structure. To enable the backing board 70, and, therefore, the corresponding worktop, to be easily affixed, a recess 74 is provided in the backing board 70 into which a clip 76 can be temporarily or permanently seated. The clip 76 has an extending portion 78 which can receive a screw, or other attachment means, for fixing to the structure 72. 30 The clip 76 has a lip 79 which prevent lateral movement and, therefore, prevents the worktop from separating from the structure 72. 8 Backing board 71 is also affixed to the structure 72 and has a recess 74. An alternative clip 75 is shown, which still has an extending portion 78 for securing the clip to the structure 72. The clip 75 does not, however, have a lip preventing lateral movement. In this case, clip 75 can either allow lateral movement, or be permanently 5 fixed into the backing board 71, and, therefore, prevent lateral movement. Referring now to Figure 8(a), (b) and (c), a corner joint 800 is shown in which a horizontal composite stone worktop 802, such as that described in relation to Figure 3(a) but having a 450 end, and a vertical composite stone side panel 804, such as that described in relation to Figure 6(a), is shown. .0 Horizontal worktop 802 has a 450 face 804 at one end, a recess 806 a pre determined distance from the face 804 and a passage 808 between the recess 806 and face 804. Similarly, the vertical side panel has a 450 face 810, recess 812 and passage 814 between the face 810 and passage 814. The passages 808 and 814 are arranged such that, if they meet substantially .5 exactly, the face 810 and face 804 also meet substantially exactly, creating a smooth join between the horizontal worktop 802 and the vertical worktop 804. To enable the passages to meet exactly a fixing means 816 is provided. For clarity, fixing means 816 is only fully labelled in Figure 8(b) but it should be appreciated that Figures 8(a), (b) and (c) all show exactly the same features at 20 progressive steps in the process of fixing the worktops 802, 804 together. Fixing means 816 includes a first end stop 818, inner screw 820, outer screw barrel 822, second end stop 824, universal joint 826 and actuating bar 828. In use, inner screw 820 is inserted into passage 814 from the face 810 and first end stop 818 is inserted into recess 812. Inner screw 820 is then engaged onto first end 25 stop 818. The engagement between the inner screw 820 and the first end stop 818 is such that inner screw 820 is not free to rotate relative to the end stop 818. Moreover, the end stop 818 is, at least, prevented from exiting from the end of the inner screw 820. Furthermore, the end stop 818 is also prevented from rotating, preferably due to a combination of the shape of the end stop 818 and the shape of the recess 812. 9 Outer screw barrel is inserted into passage 808 from recess 806 with the second end stop 824 already in place. The inner screw 820 is inserted into the outer screw barrel 822 and the actuating bar 828 is rotated, which, due to universal joint 826, rotates the outer screw barrel 822. As such, the outer screw barrel 822 is screwed onto the 5 inner screw 820. The two passages 814 and 808 are sized to match the outer screw barrel 822 such that, when screwed together, the two passages 814 and 808 meet up substantially exactly, as shown in Figure 8(c). The fixing means 816, especially due to the universal joint 826, may be quickly screwed together using a power tool. Whether a power tool is used or not, the fixing .0 means 816 is accessible vertically, so that access is easy and to increase the speed to tightening. In this case the actuating bar 828 has an end capable of being rotated by a suitable matching head on the power tool. For example, the actuating bar 828 can have a recess slot for accepting a corresponding flat screwdriver end or the actuating bar 828 can have a hexagonal end over which a standard socket. Having a .5 fixing mechanism operable by a power tool is particularly advantageous in the field of stone worktops, as the stone worktops are heavier than standard worktops and, therefore, if manual fixings are used, additional persons are required to install. A fixing mechanism operated by a power tool allows for a quick install and allows for a person to operate the fixing mechanism with one hand allowing them to hold or .0 manoeuvre the composite stone worktops being fixed together. Fixing means, such as described above reduces the amount of labour required to join the worktops together. In addition, using a fixing means, such as that described in relation to Figures 8(a), (b) and (c), allows the fixing together of composite stone boards with backing boards 25 without specialist equipment. That is, a stone mason typically requires to use a quick setting adhesive and a jig to adhere a worktop and side panel (or any other combination of stone worktop boards) together, which then requires to be transported as a whole to the location for installation. Fixing means have been utilised between standard non-stone worktops have been known to use an all thread 30 bolt (that is a bolt having no head and threaded fully along its length) with a nut at either end. These fixing means have disadvantages including: that the all thread bolt does not provide a smooth surface for accurate mating of the board; it requires 10 holding or tightening from both ends of the bolt; there is no easy way to use a power tool to speed up the installation; and a spanner,or other like tool, requires room for it to be physically turned around. This can be quite difficult when working with worktops due to the limited space. 5 Although a universal joint 826 is shown for turning the outer screw barrel 822, it is possible to use alternative means of driving the outer screw barrel. For example, the screw barrel may have a hexagonal nut end and the recess may be large enough to allow a spanner or socket to be inserted to turn the barrel. Or, it may be possible to connect a flexible drive means, such as a spring steel gear. .0 An alternative means of fixing a worktop and side panel together is shown in Figures 9(a) and 9(b). Again, a corner joint 900 is shown having a horizontal composite stone worktop 902 and a vertical composite stone side panel 904. Worktop 902 has a protrusion 906 and side panel 904 has a recess 908. The protrusion 906 and recess 908 are manufactured and positioned such that protrusion 906 fits into recess 908 .5 such that the worktop 902 and side panel 904 are joined together with substantially no overlap. A further alternative means of means of fixing a worktop and side panel together is shown in Figures 1 0(a) and (b). Fixing means 1000 has an inner screw 1002, first end stop 1004, outer screw barrel 1006, second end stop 1008, universal joint 1010 .0 and an actuating means 1012, which are similar features to those described in relation to Figure 8. However, fixing means 1000 also has a first anchor barrel 1014 and first anchor screw 1016 as well as a second anchor barrel 1018 and second anchor screw 1020. The inner screw 1002 passes through the first anchor barrel 1014 and first end stop 25 1004 engages with first anchor barrel 1014. Similarly, the outer screw barrel 1006 passes through the second anchor barrel 1018 and second end stop 1008 engages with the second anchor barrel (although it allows the barrel to rotate). In use, the first anchor screw 1016 is screwed into a predetermined point in the backing board of a composite stone worktop as described above, and the second 30 anchor screw is screwed into a predetermined point on another composite stone 11 worktop. When the outer screw barrel 1006 and inner screw 1002 are engaged and screwed together, the two composite stone worktops are drawn together. Preferably, the predetermined points for the first and second anchor screws 1016 and 1020 are pre-formed in the respective backing boards of the worktops, so that 5 accuracy is ensured. Referring now to Figure 11, a composite stone worktop board 1100 is shown with a sink 1102 inserted into a corresponding hole in the board 1100. Although a sink is shown, any item that requires to be inserted into a composite stone worktop board is also applicable to this description. .0 A plurality of clips 1104 extend from the sink 1102. The clips 1104 include a sprung steel portion 1106. When the sink 1102 is inserted into the board 1100, the clips 1104 deform as they pass through hole and, when they reach the far side of the board 1100, spring out to grip onto the bottom side of the board 1100. In this manner, sinks, stove tops and other features which require to be installed into .5 a composite stone worktop can be installed quickly and efficiently. Modifications and improvements may be made without departing from the scope of the present invention. 12

Claims

1. A method of manufacturing a composite stone board including: providing a mixture of stone particles and a binder providing a mould 5 wherein the mixture is deposited on the mould and subsequently hardened to provide the composite stone board.

2. A method as claimed in claim 1, wherein the mould is a backing board, the backing board providing support for the composite stone board. .0

3. A method as claimed in claim 1, wherein the method further comprises removing the composite stone board from the mould and placing the composite stone board on a backing board.

4. A composite stone worktop including a composite stone board having a .5 backing board formed therein.

5. A composite stone worktop as claimed in claim 4, wherein the backing board is integrally formed with the composite stone worktop.

6. A composite stone worktop as claimed in claim 4 or claim 5, wherein the backing board is made of plastic, wood, metal, carbon fibre, or a combination .0 of these materials.

7. A composite stone worktop as claimed in any of claims 4 to 6, wherein the backing board has a plurality of recesses and the stone board has corresponding protrusions.

8. A composite stone worktop as claimed in any of claims 4 to 6, wherein the 25 recesses in the backing board are filled with alternative strengthening materials, such as wood, metal, carbon fibre or plastic.

9. A composite stone worktop as claimed in any of claims 4 to 6, wherein the composite stone worktop is manufactured according to any of claims 1 to 3.

10. A clamping means for two worktop boards including: 30 a first anchoring means attachable to a first worktop board and a second anchoring means attachable to a second worktop board, 13 an inner screw and an outer screw barrel, the inner screw attachable to the first anchoring means and the outer screw barrel attachable to the second anchoring means, wherein, the inner screw and outer screw barrel are capable of being 5 screwed together whilst remaining attached to the respective anchoring means.

11. A clamping means as claimed in claim 10, wherein one of the inner screw or outer screw barrel are prevented from rotation by the first or second anchoring means .0

12. A clamping means as claimed in claim 11, wherein the first anchoring means includes a first anchor barrel having a first passage for a first anchor attachment means, and a second passage for the inner screw.

13. A clamping means as claimed in claim 11 or claim 12, wherein the second anchoring means includes a first anchor barrel having a first passage for a .5 second anchor attachment means, and a second passage for the inner screw.

14. A clamping means as claimed in any of claims 10 to 13, wherein the first and second anchor attachment means are screws.

15. A clamping means as claimed in any of claims 10 to 14, wherein the inner screw has an end stop which is capable of engaging with the first anchoring .0 means such that the inner screw is prevented from rotating.

16. A clamping means as claimed in any of claims 10 to 14, wherein the outer screw barrel has an end stop capable of engaging with the second anchoring means such that the outer screw barrel is prevented from rotating.

17. A clamping means as claimed in any of claims 10 to 14, wherein the first 25 anchoring means is insertable into a recess in the first worktop board and the inner screw is insertable into a passage in the first worktop board which connects with the recess, and the second anchoring means is insertable into a recess of the second worktop board and the outer screw barrel is insertable into a passage in the second worktop board which connects with the recess. 30

18. A worktop accessory clipping system for attaching accessories to worktops including a clip having an accessory attachment means and a resiliently deformable portion, the resiliently deformable portion extending from the accessory attachment means and capable of being deformed when attached to an accessory and being inserted through a worktop and, at a pre 14 determined thickness, or range of thicknesses, corresponding to the thickness, or range of thicknesses of the worktop, resiliently extending beyond the further surface of the worktop to grip the accessory to the worktop.

19. A system means as claimed in claim 18, wherein the clip is made of spring 5 steel.

20. A composite worktop system including a composite worktop board as described in any of claims 4 to 9.

21. A composite worktop system as claimed in claim 20, wherein the system includes clamping means as describe in relation to the third aspect of the .0 present invention.

22. A composite worktop system as claimed in claim 20 or 21, wherein the system includes clipping means as described in relation to claims 18 or 19. 15