SE2050228A1

SE2050228A1 - Countertop for undermounted sink and method for preparation thereof

Info

Publication number: SE2050228A1
Application number: SE2050228A
Authority: SE
Inventors: Mathias Olofsson
Original assignee: Ikea Supply Ag
Priority date: 2020-02-28
Filing date: 2020-02-28
Publication date: 2021-08-29
Also published as: EP4110137A4; SE544244C2; WO2021173059A1; EP4110137A1

Abstract

A method of preparing a countertop (1) for an undermounted sink (2), comprises milling the countertop (1) to form an orifice wall (16) and a flange precursor around an orifice for receiving the sink (2). The flange precursor is stabilised with a resin (10), which is cured, to form an edge flange (9).A countertop (1) comprises an orifice with an orifice wall (16) for receiving an undermounted sink (2). An upper edge of the orifice wall (16) is provided with a circumferential edge flange (9).A set comprises a countertop (1), a sink (2), and fittings (11). The countertop (1) is provided with an opening for receiving the sink (2) and clamping grooves (15) for receiving the fittings (11), which are arranged to clamp the sink (2) against the countertop (1).A method of mounting an undermounted sink (2) in a countertop (1) comprises applying an adhesive to a lower side of a circumferential edge flange (9), pressing and clamping an upper flange (8) of the sink (2) against the circumferential edge flange (9).

Description

COUNTERTOP FOR UNDERMOUNTED SINK AND METHOD FORPREPARATION THEREOF Field of the inventionThe present invention relates to a method of preparing a countertop for anundermounted sink, prior to attaching the sink.

The invention also relates to a countertop comprising an orifice with an orifice wall for receiving an undermounted sink.

The invention further relates to a set comprising a countertop, a sink, andfittings, wherein the countertop is provided with an opening for receiving the sink.

Finally, the invention relates to a method of mounting an undermounted sink ina countertop with an orifice with an orifice wall and a circumferential edge flangeextending transversally from the orifice wall.

BackgroundUS8245380 discloses a method for undermounting a sink in a countertop. A channel is routed from the back of a countertop including a laminate. After theunderside of a decorative laminate on the top of the countertop has been exposed ina deeper section of the channel, an adhesive is applied directly thereon. An adhesiveis applied on the bottom of a shallower section of the channel, and then the sink isarranged with its flange in the channel. Support plates are arranged around the sink,to hold the flange in its place. When the sink is fully secured, the portion of thecountertop surrounded by the channel, and covering the sink, may be removed andthe edges softened. Thereafter installation on a cabinet may take place.

Since the exposed laminate is thin, extreme care must be taken not to damageit, before the sink has been mounted thereon. Typically, the undermounting of thesink may take place in a production plant in order to avoid transportation of thecountertop in a state wherein parts of it may be easily damaged. The resultingproduct is a countertop with a sink mounted therein, and this combination is generallybulky and difficult to transport without damages. The transports may also beexpensive, since the space in the transportation vehicles is not used efficiently.

Often it is difficult to repair a combined product wherein one part, e. g. thesink, has been damaged. lnstead, both the countertop and the sink may have to bediscarded.

Summarylt is an object of the present invention to solve, or at least mitigate, parts or all of the above-mentioned problems. To this end, there is provided a method ofpreparing a countertop for an undermounted sink, prior to attaching the sink,comprising milling the countertop to form an orifice wall and a flange precursoraround an orifice for receiving the sink, stabilising the flange precursor with a resin,and curing the resin, to form an edge flange.

Hereby the resulting edge flange will have both a high stability and resistanceto water. An edge flange with a high stability will allow for a mounting of the sink inthe countertop at the building site, i. e. in the house of the end customer, as analternative to mounting in a factory. An advantage is that transportation of thecountertops and the sinks will be easier and less bulky, which is also more costefficient. ln an embodiment the stabilising of the flange precursor comprises adding tothe thickness of the flange precursor.

The flange precursor may hence be milled to a very low thickness, and someof the goods that has been milled off is replaced by resin, which is both hard andwater resistant when it is cured. ln many cases the milled off material consists ofparticleboard, the strength, smoothness and water resistance of which are typicallylimited. ln another embodiment of the method, the countertop has a countertop faceand a bottom face, wherein forming the edge flange comprises milling a primary trackin the bottom face of the countertop, and a secondary, deeper track next to theprimary track, applying a resin in the primary and the secondary tracks, cutting awaya central piece surrounded by the tracks.

Hereby a useful method of obtaining the reinforced edge flange is disclosed.The depth and width of the tracks may be milled with a high precision. ln a further embodiment, the method comprises milling the resin to form asupport area for the undermounted sink on the edge flange.

The flange resulting after the milling may also have exact dimensions and besuitable for mounting an undermounted sink thereon with a high precision. The visualappearance will be attractive, and the risk of leaks is essentially eliminated. ln a still further embodiment, the method comprises securing the central piece,surrounded by the tracks, in its position, and removing the central piece after theresin is cured to form the edge ﬂange.

Keeping the central piece in place until the resin has cured provides a solidsupport for the resin while it is curing. ln an even further embodiment, the method comprises applying a layer of resin on the orifice wall.

Hereby the interior material of the countertop, exposed when the tracks aremilled, may be more or less protected from moisture that may accidentally leakbetween the orifice wall and the sink. ln an embodiment the method further comprises milling the resin to a flatsupport surface for the undermounted sink on the edge flange, extendingtransversally from the orifice wall. ln an embodiment the method further comprises milling the resin to form theedge ﬂange which has a thickness of 1-5 mm. ln an embodiment the method further comprises milling a clamping groove inan outer side wall of the tracks.

Hereby means for further securing the undermounted sink to the countertopmay be obtained. ln a second aspect of the invention, a countertop comprises an orifice with anorifice wall for receiving an undermounted sink, wherein the upper edge of the orificewall is provided with a circumferential edge ﬂange, extending transversally from theorifice wall towards the center of the orifice.

The edge flange has the advantage of providing a suitable support for an undermounted sink in the orifice. ln an embodiment of the countertop, the circumferential edge flangecomprises a support layer of resin.

A layer of resin is advantageous since it may have a strengthening andwaterproofing effect. ln a further embodiment of the countertop, the resin is arranged on a lowersurface of the edge flange.

Hereby a support surface, which may be milled to a high degree ofsmoothness, may be provided. ln other embodiments of the countertop, the resin is arranged on a free edgeof the edge ﬂange.

A free edge of the ﬂange will typically be exposed next to the undermountedsink. Strength and resistance to water are useful properties for the free edge. ln further embodiments of the countertop the resin is a two-component resin.ln an embodiment of the countertop the thickness of the flange is 1-5 mm. ln still further embodiments the countertop comprises a circumferentialclamping groove in the orifice wall.

Hereby the countertop is prepared for the attachment of fittings which mayclamp the undermounted sink onto the edge flange. ln even further embodiments of the countertop, the clamping groove extendsinto the orifice wall transversally thereto. ln some embodiments of the countertop, the orifice wall is at least partlycoated with resin. ln some embodiments the comprises a laminated board with a sealing toplayer and a supporting main layer. ln some embodiments the countertop comprises a polymer film as the toplayen ln other embodiments the countertop further comprises a veneer as the toplayen ln some embodiments the countertop comprises a particle board as thesupporting main layer. ln a third aspect of the invention, there is provided a set comprising acountertop, a sink, and fittings, wherein the countertop is provided with an openingfor receiving the sink, and clamping grooves for receiving the fittings; the sink isadapted for undermounting in the countertop; and the fittings are arranged to clampthe sink against the countertop.

Although the countertop, the sink, and the fittings are not mounted at the timeof sale, they may still be sold as a set wherein the parts are adapted for mounting ata later stage. The advantage of a set of parts is that some parts may be selectedamong several varieties, in order to provide a customized product, i. e. a countertopwith a sink according to the wishes of the end customer. Also, it may be easier totransport a non-assembled set of parts than the finished product. ln an embodiment a set comprises a countertop as described above. ln a fourth aspect of the invention there is provided a method of mounting anundermounted sink in a countertop with an orifice with an orifice wall and acircumferential edge ﬂange extending transversally from the orifice wall, comprisingapplying an adhesive to a lower side of the circumferential edge flange, pressing anupper flange of the sink against the circumferential edge flange, and clamping theupper flange of the sink against the circumferential edge flange.

Hereby it is possible to mount the sink at the end customer, and avoiding risksof damages during transport, as well as costly transports of bulky items. The endproduct will be adapted to the place of use, without mistakes. ln an embodiment of the method, the clamping of the sink against thecircumferential edge ﬂange comprises arranging fittings in a clamping groove in the orifice wall and tensioning the fittings to press the sink in a direction towards thecircumferential edge flange.

This provides an increased security and durability of the mounting. ln an embodiment of the method, the mounting is performed on a set asdescribed above. lt is noted that embodiments of the invention may be embodied by all possiblecombinations of features recited in the claims. Further, it will be appreciated that thevarious embodiments described for the device are all combinable with the method asdefined in accordance with the second aspect of the present invention, and viceversa.

Brief description of the drawingsThe above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, withreference to the appended drawings, where the same reference numerals will beused for similar elements, wherein: Fig. 1 is a diagrammatic view in perspective of a countertop with an undermounted sink;Fig. 2 is a partially sectional view in perspective of the undermounted sink; Fig. 3A is a partially sectional view, with an enlargement, in perspective of amanufacturing step of the countertop; Fig. 3B is an enlarged, partially sectional view of another manufacturing stepof the countertop; Fig. 3C is a sectional view of a third manufacturing step of the countertop; Fig. 3D is a view corresponding to that of Fig. 3C of a fourth manufacturingstep of the countertop; and Fig. 4 is an exploded view in perspective with a partial section of thecountertop and the sink.

All the figures are schematic, not necessarily to scale, and generally only showparts which are necessary in order to elucidate the embodiments, wherein other partsmay be omitted.

Detailed description of the exemplarv embodiments Fig. 1 illustrates a countertop 1, with a sink 2, typically for a kitchen. There is afaucet 3 for providing water to the sink 2, as well as a drain 4 at the bottom of thesink 2, for draining water from the sink 2. One or more cabinets 5 may be providedunder the countertop 1, as seen in Fig. 1.

The sink 2 is mounted in an orifice in the countertop 1 by undermounting,which means that a circumferential flange on the sink 2 is arranged underneath atleast a top layer of the countertop 1 and glued thereto.

Details of the undermounting of the disclosed sink 2 to the countertop 1 areshown in Fig. 2. The countertop 1 disclosed in Fig. 2 is a laminate comprising asupporting particle board 6 and a decorative and sealing top layer 7.

The sink 2 has a circumferential mounting flange 8 which is partly visible andpartly covered by the countertop 1 when the sink 2 is mounted therein. ln thedisclosed embodiment, an upper side of the mounting flange 8 on the sink 2 is gluedagainst a bottom side of a corresponding edge flange 9 of the orifice in thecountertop 1.

The edge flange 9 of the orifice comprises a layer of resin 10, which extendsalong the bottom side of the edge flange 9 and thereby provides a contact surface forgluing the mounting flange 8 thereto. The resin 10 has a stabilizing effect on the edgeﬂange 9. The resin 10 also extends along an outer edge portion of the edge flange 9.This has the additional effect of waterproofing the edge flange 9, thereby protectingthe particle board 6 comprised in the countertop 1. Also, the exposed resin 10 willpresent a visually appealing transition from the top layer 7 of the countertop 1 to thesink 2.

Although the gluing between the mounting flange 8 and the edge flange 9 maybe sufficiently strong and durable to keep the sink 2 in its position, the disclosedembodiment comprises a number of fittings 11 to secure the sink 2 mechanically inits position. Each of the fittings 11 comprises a screw 12 and a plate 13. The screw 12 is arranged in a threaded hole 14 in the plate 13. Thereby the screw 12 will bedisposed transversally to the extension plane of the plate 13. The plate 13 maycomprise metal, plastic or any other suitable material, which will allow for a durablefitting 11 and an easy and cost-efficient manufacture. The plate 13 is arranged to beinserted into a groove 15, which has been milled in the orifice wall 16 in thecountertop. When the screw 12 is tensioned, it will bear against the bottom side ofthe mounting flange 8 and press it upwards against the edge flange 9.

The disclosed countertop 1 may allow for a mounting of the sink 2 in thecountertop 1 at the building site, i. e. in the home of the consumer. Hence thecountertop 1, which has been provided with an orifice and an edge flange 9 aroundthe orifice, and the sink 2 may be transported as separate units. This allows for amore cost-efficient transportation, and the risk of damages to the sink 2 and/or thecountertop 1 are reduced. ln Figs. 3A to 3D, a method of preparing the countertop 1 for anundermounted sink 2 is disclosed.

Fig. 3A shows a bottom side of the countertop 1, wherein two tracks 17, 18have been milled. The two tracks 17, 18 extend around a center portion 19 of thecountertop 1. The two tracks 17, 18 do not extend all the way through the countertop1. A primary track 17 is milled so that its bottom may comprise a layer of the particleboard 6 as well as the top layer 7. A secondary track 18 is milled deeper, so that itsbottom may comprise only the top layer 7. The secondary track 18 is arranged closerto the center portion 19 of the countertop 1.

The center portion 19 is still integral with the rest of the countertop 1, althoughit is connected therewith only by way of the top layer 7 at the bottom of the secondarytrack 18. ln order to stabilize the center portion 19, and keep it in its original positionrelative to the surrounding part of the countertop 1, a board 20 is placed thereon andis temporarily secured to the center portion 19 as well as to the surrounding part ofthe countertop 1. Hereby the center portion 19 may be held in place and the width ofthe bottom of the secondary track 18 may be kept constant, which may be useful forforming the edge flange 9.

The respective bottoms of the primary 17 and secondary 18 tracks form aﬂange precursor for the edge flange 9. However, the flange precursor may need8 further reinforcement before an edge flange 9 may be formed and used forattachment of a sink 2.

Fig. 3B discloses that a liquid resin 21 is poured into the primary 17 andsecondary 18 tracks. Although not explicitly shown in the figure, the liquid resin 21may also be arranged to form a thin coat on the orifice wall 16 and in someembodiments even in the groove 15. Hereby the particle board 6 is at least partlyprotected from moisture. The main portion of the liquid resin 21 will, however, flowinto the primary 17 and secondary 18 tracks and form a layer of resin 21, which willcure therein. The orifice wall 16 as well as the side of the center portion 19 form sidewalls of the tracks and may serve as side walls of a mould for the liquid resin 21 Fig. 3C discloses the cured resin 10 in the bottom of the primary 17 andsecondary 18 tracks. lts top surface may be milled to smoothness. The cured resin10 may provide stability to the respective bottoms of the tracks 17, 18, which form theﬂange precursor. The edge flange 9 may now have sufficient stability to serve as amounting surface for the mounting flange 8 of the sink 2.

Fig. 3D discloses a final step in the preparation of the countertop 1 for theundermounting of a sink 2. The center portion 19 of the countertop 1 has beenremoved to form an orifice for the sink 2. The edge flange 9, which extendscircumferentially around the orifice in the countertop, is cantilevered and self-supporting, due to the layer of cured resin 10 arranged on the flange precursor,which included only a thin layer of particle board 6 and the top layer 7, which may beas thin as 0,4-0,5 mm. ln addition to the stability provided by the cured resin 10, theouter edge of the edge ﬂange 9 comprises the resin 10 covered by the top layer 7,which, as mentioned above, will provide a waterproof outer edge of the edge flange9.

The stabilized edge ﬂange 9 will allow for the mounting of the sink 2 in theorifice outside of a factory environment, i. e. at the building site. The risks of adefective mounting, which is not adapted to the environment at the building site ispractically eliminated.

Fig. 4 is an exploded view of the sink 2 and the countertop 1, illustrating themounting of the sink 2 in the orifice in the countertop 1. After an adhesive, which maybe silicone containing, has been applied on the edge flange 9, in particular on the side thereof closest to the orifice wall 16, the mounting ﬂange 8 of the sink 2 ispressed against the edge ﬂange 9. Any excess adhesive seeping out onto theexposed part of the mounting flange 8 of the sink 2 may be wiped off, before it hasdried.

At least one of the fittings 11, which are shown in fig 2, may be arranged oneither side of the sink 2, by inserting the respective plates 13 into the groove 15 andtensioning the respective screws 12, so that their ends will press each section of themounting flange 8 of the sink 2 against the edge flange 9.

The invention has mainly been described above with reference to a fewembodiments. However, as is readily appreciated by a person ski||ed in the art, otherembodiments than the ones disclosed above are equally possible within the scope ofthe invention, as defined by the appended patent claims. ln the claims, the word "comprising" does not exclude other elements or steps,and the indefinite article "a" or "an" does not exclude a plurality.

Claims

1.Method attaching the sink (2), comprising milling the countertop (1) to form an orificewall (16) and a flange precursor around an orifice for receiving the sink (2),stabilising the flange precursor with a resin (10), and curing the resin (10), toform an edge flange (9).

2. Method according to c|aim 1, wherein stabilising the flange precursor comprises adding to the thickness of the flange precursor.

3. Method according to c|aim 1 or c|aim 2, the countertop (1) having a countertop face and a bottom face, wherein forming the edge flange (9) comprises millinga primary track (17) in the bottom face of the countertop (1), and a secondary,deeper track (18) next to the primary track (17), applying a resin in the primaryand the secondary tracks (17, 18), cutting away a central piece (19)surrounded by the tracks (17, 18).

4. Method according to c|aim 3, further comprising milling the resin (10) to form a support area for the undermounted sink (2) on the edge ﬂange (9).

5. Method according to c|aim 3 or 4, further comprising securing the central piece (19), surrounded by the tracks 17, 18), in its position, and removing the centralpiece (19) after the resin (10) is cured to form the edge flange (9).

6. Method according to any of claims 1 to 5, further comprising applying a layer of resin (10) on the orifice wall (16).

7. Method according to any of claims 1 to 6, further comprising milling the resin (10) to a flat support surface for the undermounted sink (2) on the edge flange(9), extending transversally from the orifice wall (16).

8. Method according to any of claims 1 to 7, further comprising milling the resin (10) to form the edge flange (9) which has a thickness of 1-5 mm.

9. Method according to any of claims 1 to 8, further comprising milling a clamping groove (15) in the orifice wall (16).

10.Countertop (1) comprising an orifice with an orifice wall (16) for receiving anundermounted sink (2), wherein the upper edge of the orifice wall (16) isprovided with a circumferential edge f|ange (9), extending transversally fromthe orifice wall (16) towards the center of the orifice.

11.Countertop (1) according to claim 10, wherein the circumferential edge f|ange(9) comprises a support layer of resin (1 O).

12.Countertop (1) according to claim 11, wherein the resin (10) is arranged on alower surface of the edge f|ange (9).

13.Countertop (1) according to claim 11 or claim 12, wherein the resin (10) isarranged on a free edge of the edge f|ange (9).

14.Countertop (1) according to any of claims 11 to 13, wherein the resin (10) is a two-component resin.

15.Countertop (1) according to any of claims 10 to 14, wherein the thickness ofthe edge f|ange (9) is 1-5 mm.

16.Countertop (1) according to any of claims 10 to 15, further comprising acircumferential c|amping groove (15) in the orifice wall (16).

17.Countertop (1) according to claim 16, wherein the c|amping groove (15)extends into the orifice wall (16) transversally thereto.

18.Countertop (1) according to any of claims 10 to 17, wherein the orifice wall(16) is at least partly coated with resin (10).

19.Countertop (1) according to any of claims 10 to 18, comprising a laminatedboard with a sealing top layer (7) and a supporting main layer (6).

20.Countertop (1) according to claim 19, further comprising a polymer film as thetop layer (7).

21. .Countertop (1) according to claim 20, further comprising a veneer as the toplayer (7).

22.Countertop (1) according to any of claims 19 to 21, comprising a particle boardas the supporting main layer (6).

23.Set comprising a countertop (1), a sink (2), and fittings (11), wherein thecountertop (1) is provided with an opening for receiving the sink (2), andclamping grooves (15) for receiving the fittings (11); the sink (2) is adapted forundermounting in the countertop (1 ); and the fittings (11) are arranged toclamp the sink (2) against the countertop (1 ).

24.Set according to claim 23, wherein the countertop (1) is a countertopaccording to any of claims 10 to 22.

25.Method of mounting an undermounted sink (2) in a countertop (1)with anorifice with an orifice wall (16) and a circumferential edge f|ange (9) extendingtransversally from the orifice wall (16), comprising applying an adhesive to alower side of the circumferential edge f|ange (9), pressing an upper f|ange (8)of the sink (2) against the circumferential edge ﬂange (9), and clamping theupper f|ange (8) of the sink (2) against the circumferential edge f|ange (9).

26.Method according to claim 25, wherein the clamping of the sink (2) against thecircumferential edge f|ange (9) comprises arranging fittings (11) in a clampinggroove (15) in the orifice wall (16) and tensioning the fittings (11) to press thesink (2) in a direction towards the circumferential edge f|ange (9).

27.Method according to claim 25 or claim 26, wherein the mounting is performedon a set according to claim 23 or claim 24.