GB2468640A

GB2468640A - Levelling and installation of work surfaces

Info

Publication number: GB2468640A
Application number: GB0904000A
Authority: GB
Inventors: Richard William Cogger
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-03-09
Filing date: 2009-03-09
Publication date: 2010-09-22
Also published as: GB0904000D0

Abstract

A method for levelling first and second worktop components (10, 12) prior to joining them is disclosed. In the method, each worktop component (10, 12) has a generally flat working surface and a jointing surface normal to the working surface - the jointing surfaces face one another and are to be parallel and closely spaced from one another once installed. The method comprises forming a slot (24) in each jointing surface, the slots extending at an angle to the working surface, the slots being arranged so as to face one another in a final installation. Then, a jointing element (34) is placed in each slot of a worktop component, whereby each jointing element is substantially enclosed within its slot (24). The first and second worktop components are placed on a support structure. Each jointing element (34) is manipulated such that it extends from the slot (24) in the first worktop component (10) into a corresponding slot in the second worktop component (12) The jointing element (34) is moved along the slots (24) to thereby adjust the relative positions of the two worktop components (10, 12) in a direction normal to the working surface until the work surfaces are levelled.

Description

Installation of work surfaces This invention relates to installation of work surfaces. It has particular, but not exclusive, application to installation of granite work surfaces in a fitted kitchen.

A fitted kitchen typically is constructed from units that include several carcasses upon which a work surface is supported. The aim of the installer is to provide a work surface that gives the impression of a single, flat planar surface, while, in practice, the work surface is typically constructed from several components, each of which must be levelled, and arranged such that there is an absolute minimum step change in height between adjacent components. This is particularly important and difficult to achieve when the work surface is formed from granite.

The nature of granite draws attention to any difference in height between adjacent components. Since it is a natural material, there is a significant variation in its thickness between and within components. Moreover, the weight of granite makes it difficult to handle and difficult to move the very small distances necessary to achieve a high-quality installation.

The conventional approach to levelling of granite work surfaces is to drive a plurality of wedges between a support member of the carcass and the granite worktop component. The worktop component can be raised by driving the wedge in further and lowered by withdrawing it. Once the components have been levelled, filler is introduced to fill the gap between them. The filler then sets hard to form a continuous surface. With skill, it is possible to achieve a complete work surface that is levelled to a very high standard. However, if the installer is lacking skill, the outcome can be poor. Levelling in this way is typically time-consuming and is therefore costly.

An aim of this invention is to provide a method and apparatus that can assist an installer in achieving a high standard of levelling when installing a work surface with greater reliability and speed of installation than is possible with existing techniques.

To this end, form a first aspect, the invention provides a method for levelling first and second worktop components prior to joining them, each worktop component having a generally flat working surface and a jointing surface normal to the working surface, in which the jointing surfaces face one another and are to be parallel and closely spaced from one another once installed; the method comprising: a. forming a slot in each jointing surface, the slots extending at an angle to the working surface, the slots being arranged so as to face one another in a final installation; b. placing a jointing element in each slot of a worktop component, whereby each jointing element is substantially enclosed within its slot; c. placing the first and second worktop components on a support structure; d. manipulating each jointing element such that it extends from the slot in the first worktop component into a corresponding slot in the second worktop component; and e. moving the jointing element along the slots to thereby adjust the relative positions of the two worktop components in a direction normal to the working surface until the work surfaces are levelled.

The jointing elements allow an installer to adjust the levelling of the worktop components in a controlled and predictable manner, and thereby allow the worktop to be installed in a quicker and more straightforward manner than conventional, ad hoc methods.

All of these steps may be performed at an installation site. Alternatively, step a and/or step b may be performed in a factory prior to moving the worktop components to an installation site.

Note that steps b and c may be performed in either order.

A method embodying the invention may further include a step of introducing a hardening filler material into the space between the jointing faces. This can form a continuous, hard, flat surface between the worktop components.

The jointing element may be connected to a stem portion whereby it can be manipulated in steps d and e. In such cases, the stem portion may be separated from the jointing element after completion of step e. Preferably, the stem portion is of polygonal cross-section to enable it to be gripped by a tool.

Alternatively, the jointing element may include connection means to which a tool can be connected to manipulate the jointing element in steps d and e, and subsequently removed. For example, the tool may be an elongate shaft.

Subsequent to step e, spacing elements are typically introduced between the worktop components and the support structure to maintain the relative positions of the worktop components achieved in step e.

The angle of the slots formed in step a may be in the range of 10 to 50 to the work surface.

From a second aspect, the invention provides a jointing element for use in a method according to the first aspect of the invention.

Such a jointing element may include a planar head portion and a stem portion that projects normally form the head portion. Preferably, the stem portion and the head portion are interconnected at a region of weakness. The stem portion can thus be removed by fracture of the region of weakness subsequent to completion of steps d and e. Alternatively, the jointing element may includes a planar head portion that has a formation by which it can be releasably connected to a tool to perform steps d and e.

From a third aspect, the invention provides an installation kit comprising a plurality of jointing elements according to the second aspect of the invention together with a set of instructions directing a user to perform a method according to the first aspect of the invention.

An embodiment of the invention will now be described in detail, by way of example, and with reference to the accompanying drawings, in which: Figure 1 is a general view of two work surface components in place on kitchen unit carcasses; Figure 2 shows a jointing element for use in an embodiment of the invention; Figures 3 and 4 are, respectively, a side view and a plan view of part of a worktop component prepared for use in a method of the present invention; Figures 5 and 6 are plan views of components of a worktop during installation using a method embodying the invention; Figure 7 shows an alternative jointing element for use in an embodiment of the invention; and Figures 8 and 9 are front and underneath views of a disc cutter suitable for use in a method embodying the invention.

With reference to the drawings, the invention will be described with reference to forming a *joint between first and second closely-spaced rectangular components 10, 12 of granite worktop that are to be supported on kitchen unit carcasses 20. Each component 10, 12 has an upper, working surface 14 that is finished to be flat and well polished and edge surfaces that are generally normal to the working surface 14. The aim of the installer is to ensure that the working surfaces 14 are as near as possible horizontal and coplanar in the final installation. A respective edge surface 16 of the two components are positioned close to and parallel to one another in the final installation. These will be referred to as the jointing surfaces. Each component has a lower surface 22 opposite to the working surfaces 14. (Note that any one worktop component may have more than one jointing surface if it is to abut more than one other component.) The lower surfaces 22 are generally flat, but are not finished to a high degree of accuracy, which means that the components have some variation in their thicknesses and flatnesses: this means that simply laying them on flat, level supports will not achieve the required accuracy in the joint between the components 10, 12. In this example, the first component 10 is shown as being slightly thinner than the second component 12.

A joining element 30 for use with this embodiment will now be described with reference to Figure 2.

The jointing element 30 is formed of a tough material, such as a hard plastic or metal such as mild steel, galvanised steel or stainless steel. It has a head portion 32 and a stem portion 34.

The head portion 32, in this embodiment, is shaped in plan as a rectangle with rounded ends, and therefore has two straight sides and two convex sides. The stem portion 34 extends normally from the head portion 32 from mid-way along one of its straight sides. In cross-section, the stem portion 34 is polygonal, meaning that it has a plurality of peripheral flats extending along its length. A region of weakness 36 is formed in the stem portion 34 close to the head portion 32. The largest dimension of the head portion 32 is somewhat less than the length of the slots 24, and the thickness of the heat portion is less than the width of the slots.

With reference now to FIgures 3 and 4, a worktop component lOis shown that Is prepared for use In a method embodying the present Invention. Both components to be Joined are simllsrly prepared. To prepare the worktop component 10, several slots 24 are formed Into It through Its Jointing surface 16. Each slot 24 extends Into the component normal to the Jointing surface 16, wIth the centre of the slot being coincident with a plane A-A that Is equidistant between the worldng surface 14 and the lower surface 22. A respective slot Is formed In each Jointing surface 16 & two components to be Joined, such that they face one another when the components are properly positioned.

Each slot 24 Is angled to slope by a small amount with respect to the plane A-A, and therefore with respect to the working surface 14. In thIs example the slope Is about 2°. The slope formed In each component Is of the same Thand". That Is, when It Is observed by looking at the Jointing surface 16, each slot 24 slopes up towards the worldng surface 14 from left to right The slots could all slope the other way It Is consistency that Is Important, not the absolute direction of slope. Each slot 24 Is of thickness (that Is, depth when Installed) that Is a small fraction of the thickness of the worktop component 10 to ensure that It does not substantially weaken Its structure. The length of each slot 24 in the plane A-A Is chosen to be greater than the longest dimension of the head portion 32 of the Jointing element 30.

A method of installation in accordance with an embodiment of the invention will now be described.

Flrst, aflrstoftheworktopcomponentslotobejoinedIsplacedinposltlononacarcassofa unit Ajointlngelement3oIsthenplacedlntoeachslot24oftheflrstworktopcomponent 10 such much of Its head portion 32 extends into the slot 24 and the stem portIon 34 dosely abuts the jointing surface 16 and extends to project past the working surface 14 -that Is, in a direction that Is approximately upward.

The second worktop component 12 Is then placed on the carcass and It Is moved into positIon, such that the jointing surfaces 16 of the first and second worktop components 10,12 are dosely spaced from one another and parallel, to the position shown in FIgure 6. It will be noted that the stem portIons 32 are between the Jointing surfaces 16, and can therefore act as a guide to ensure that the gap between the jointing surfaces 16 Is constant The next stage is to level the worktop components 10, 12. If it is discovered that there is a substantial difference in level, this may first be accommodated, for example, by driving wedges under lower parts of one or other component 10, 12 until is they are appropriately level. The shaft portion 32 is then grasped in a suitable tool, and rotated about its axis. This causes the head portion 34 to rotate in its own plane. One convex side of the head portion 34 emerges from the slot 24 in the first worktop component 10 and is guided into the opposite slot in the second worktop component 12, as shown in Figure 6.

It is important to remember that the two slots 24 within which the head portion 34 is located slope in opposite directions. This means that the relative heights of the two worktop components 10, 12 in the region of the slots 24 can be moved by moving the longitudinal position of the head portion 34 within the slots 24: this can be achieved using the shaft portion 32. Looking at Figure 6, if the jointing element 30 is moved to the left, the first worktop component 10 will be moved up with respect to the second worktop component 12, and vice versa. This process is repeated at each jointing element 30 until the desired degree of levelling is achieved.

Once the worktop components 10, 12 are levelled, their position is fixed by introducing packing pieces between the components 10, 12 and the support members of the carcass. For example, wedges can be used. In contrast to conventional levelling methods, insertion of the wedges is not intended to adjust the position of the worktop components 10, 12. Instead, it is intended to fix the position that is achieved using the jointing elements 30.

To complete the joint, the shaft portion 32 of each jointing element must be removed. This is done by bending the shaft portion 32 in a direction along the length of the gap between the first and second worktop components 10, 12. This causes the shaft portion 32 to fracture at the region of weakness 36, so allowing the shaft portion 32 to be removed and discarded. This leaves the gap between the first and second worktop components 10, 12 clear. If required, the worktop components 10, 12 can be slid together closing the gap between them. The joint is then completed by introducing a hardening filler into the gap, as is conventional.

Various alternative jointing elements may be provided in alternative embodiments.

As shown in Figure 7, an alternative jointing element is formed from a plate of metal 40 of similar size and shape to the head portion 34 of the jointing element 30 of the first embodiment. A boss 42 projects from a mid section of one of the straight sides and a polygonal aperture 44 extends through the boss normal to the plane of the plate 40. Instead of a stein portion, the jointing element 30 is used with a shaft 48 of polygonal cross-section that can be engaged within the aperture 44, such that rotation of the shaft 48 causes the plate 40 to rotate. Therefore, when the joint is formed using a method generally as described above, a plate is positioned within each slot 24 in the first worktop component 10 with the boss 42 projecting from the slot 24. Once the second worktop component 12 is placed on the carcass, the shaft 48 can be introduced into the gap between the worktop components 10, 12 to rotate and then move the plate 40. The shaft 48 may optionally carry a retention component to hold the plate 40 onto the shaft 48. For example, in cases where the plates 40 are formed from a ferrous metal, the retention component might be a magnetic collar 50. Alternatively, the retention component couki be a s'eeve or resilienfly deflectabe p'astic materia' that can grip the aperture 44 with a friction fit.

The optimum spacing for the slots 24 must be determined by experiment. There must be sufficient slots that the jointing pieces 30, 40 can satisfactorily locate the worktop components, yet there must not be an excess of slots 24 since this could weaken the worktop components 10, 12. The spacing selected may be dependent upon, amongst other things, the nature of the material of the worktop and the thickness of the worktop components 10, 12.

The slots 24 can conveniently be formed by an adaptation to a conventional disc cutter. Such a cutter has a cutting disc 60 of hard material driven to rotate by a motor 62. It is known to provide such a cutter with a guide 64 that can be placed on an edge part of a surface of a solid such that the cutter can be used to make a slot in a side wall of the solid at a fixed distance from the surface. Conventionally, the guide 64 is formed parallel to the plane of the cutting disc 60 so that the slot is formed parallel to the surface upon which the guide 64 is placed.

This invention modifies such a cutter by ensuring that there is effectively a slope between the guide 64 and the plane of the cutting disc 60, for example by applying a wedge-shaped spacer 66 on the guide, as shown in Figures 8 and 9.

The method could equally be used to install worktops formed of other materials such as wood, composites or other stone materials such as marble.

Claims

Claims 1. A method for levelling first and second worktop components prior to joining them, each worktop component having a generally flat working surface and a jointing surface normal to the working surface, in which the jointing surfaces face one another and are to be parallel and closely spaced from one another once installed; the method comprising: a. forming a slot in each jointing surface, the slots extending at an angle to the working surface, the slots being arranged so as to face one another in a final installation; b. placing a jointing element in each slot of a worktop component, whereby each jointing element is substantially enclosed within its slot; c. placing the first and second worktop components on a support structure; d. manipulating each jointing element such that it extends from the slot in the first worktop component into a corresponding slot in the second worktop component; and e. moving the jointing element along the slots to thereby adjust the relative positions of the two worktop components in a direction normal to the working surface until tile work surfaces are levelled.
2. A method according to claim 1 in which all of these steps are performed at an installation site.
3. A method according to claim 1 in which step a and/or step b are performed in a factory prior to moving the worktop components to an installation site.
4. A method according to any preceding claim further including a step of introducing a hardening filler material into the space between the jointing faces.
5. A method according to any preceding claim in which the jointing element is connected to a stem portion whereby it can be manipulated in steps d and e.
6. A method according to claim 5 in which the stem portion is separated from the jointing element after completion of step e.
7. A method according to claim 5 or claim 6 in which the stem portion is of polygonal cross-section to enable it to be gripped by a tool.
8. A method according to any one of claims 1 to 4 in which the jointing element includes connection means to which a tool can be connected to manipulate the jointing element in steps d and e, and subsequently removed.
9. A method according to claim 5 in which the tool is an elongate shaft.
10. A method according to any preceding claim in which, subsequent to step e, spacing elements are introduced between the worktop components and the support structure to maintain the relative positions of the worktop components achieved in step e.
11. A method according to any preceding claim in which the angle of the slots formed in step a is in the range of 10 to 50 to the work surface.
12. A method for levelling first and second worktop components substantially as herein described with reference to the accompanying drawings.
13. A jointing element for use in a method according to any preceding claim.
14. A jointing element according to claim 13 that includes a planar head portion and a stem portion that projects normally form the head portion.
15. A jointing element according to claim 14 in which the stem portion and the head portion are interconnected at a region of weakness.
16. A jointing element according to claim 13 that includes a planar head portion that has a formation by which it can be releasably connected to a tool to perform steps d and e.
17. A jointing element substantially as described herein with reference to Figure 2 or to Figure 7 of the accompanying drawings.
18. An installation kit comprising a plurality of jointing elements according to any one of claims 13 to 17 together with a set of instructions directing a user to perform a method according to any one of claims 1 to 12.