US20160095438A1

US20160095438A1 - End-cap system and device for use with countertops

Info

Publication number: US20160095438A1
Application number: US14/867,534
Authority: US
Inventors: Thomas Joseph Costello; David Oliver Boone
Original assignee: Ez Countertop LLC
Current assignee: Ez Countertop LLC
Priority date: 2014-10-03
Filing date: 2015-09-28
Publication date: 2016-04-07
Also published as: WO2016054113A1

Abstract

An end-cap component for installation on an open end of a countertop includes an end-cap front element, and an end-cap stabilizer, which can be solid rectangular pieces or laminated components. The end-cap component can be made in a right-side, left-side or center-mount configuration, and can be glued together with an adhesive and configured with a polished face of the end-cap front element. Also disclosed is a stabilized end-cap countertop system, including a countertop, with an upper surface element and a front edge; and an end-cap component. The system is suitable for manufacturing in stone materials, including engineered quartz, using lighter-weight parts, resulting in improved precision and efficiency of manufacturing and installation.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/059,270, filed Oct. 3, 2014.

FIELD OF THE INVENTION

The present invention relates generally to the field of countertop construction and installation, and more particularly to methods and systems for applying an end-cap to countertops made of stone materials.

BACKGROUND OF THE INVENTION

A countertop is a horizontal work surface commonly used in kitchens, bathrooms, and workrooms. Countertops are made in a number of natural and engineered materials. While modern lightweight laminated materials have become popular for low-cost and DIY installations, countertops made from natural or engineered stone materials remain popular for higher-end installations.
Some common materials used for prefabricated countertops are granite, marble, engineered marble, porcelain & ceramic tile, engineered quartz, such as Silestone™, glass, and other homogeneous materials, or combinations thereof. These pre-manufactured countertops are often referred to as countertop blanks.
Most often countertop blanks must be cut down in length and/or depth to precisely fit each unique end-use application. This modification from the standard size can be performed either at a local fabrication facility or on the jobsite.
In related aspects, use of a thinner deck material and a thicker edge of the countertop can be achieved at the factory by either a sandwich construction, also referred to as a lamination construction, or with a mitered edge.
This cutting of the countertop blank and application of a front facing edge leaves an L or U shaped unfinished end cavity that must then be finished off to match the look of the factory finished front edge. Conventional and well-known systems and methods for filling in the L or U shaped cavity are achieved by a sandwich or lamination construction.
Once laminated, the end cap is flush trimmed and polished by hand. Cutting and polishing this unfinished sandwich/lamination end is labor intensive, expensive, requires a highly skilled worker, and the finished product may be aesthetically unpleasing, often leaving an undesirable visible seam in the face of the end of the countertop.
As such, considering the foregoing, it may be appreciated that there continues to be a need for novel and improved devices and methods for attaching an end-cap to a countertop surface.

SUMMARY OF THE INVENTION

The foregoing needs are met, to a great extent, by the present invention, wherein in aspects of this invention, enhancements are provided to the existing models for finishing of an unfinished end of a countertop, providing a more efficient workflow with significantly improved aesthetic results.
In an aspect, an end-cap component for installation on an open end of a countertop, includes an end-cap front element; and an end-cap stabilizer, which is connected to a rear side of the end-cap front element; such that the end-cap stabilizer is recessed from an upper edge and at least one side of the end-cap component.
In a related aspect, the end-cap front element and the end-cap stabilizer can be rectangular solid pieces.
In other related aspects, the end-cap component can be a right-side, left-side or center-mount component.
In another related aspect, a face of the end-cap front element can be polished.
In yet another related aspect, the end-cap stabilizer can be connected to the end-cap front element with an adhesive, which for example can be an acrylic adhesive.
In a further related aspect, the end-cap stabilizer and the end-cap front element can be made from a stone material, which for example can be engineered quartz.
In another aspect, a stabilized end-cap countertop system, can include:

- a) a countertop that includes an upper surface element and a front edge, which is perpendicularly connected to a front side of the upper surface element, such that the countertop includes an open end; and
- b) an end-cap component for installation on an open end of a countertop, includes an end-cap front element; and an end-cap stabilizer, which is connected to a rear side of the end-cap front element; such that the end-cap stabilizer element is recessed from an upper edge and at least one side of the end-cap component;
- such that the end-cap component is connected to the open end of the countertop.

There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a rear perspective view of an end-cap component, according to an embodiment of the invention.

FIG. 2 is a rear perspective view of an end-cap component, according to an embodiment of the invention.

FIG. 3 is a front perspective view of an end-cap component, according to an embodiment of the invention.

FIG. 4 is a perspective view of an end-cap component and a countertop with an open end, prior to assembly, according to an embodiment of the invention.

FIG. 5 is a perspective view of an end-cap component and a countertop with an open end, prior to assembly, according to an embodiment of the invention.

FIG. 6 is a rear elevation view of a left-side end-cap component, according to an embodiment of the invention.

FIG. 7 is a rear elevation view of a right-side end-cap component, according to an embodiment of the invention.

FIG. 8 is a rear perspective view of a center-mount end-cap component, according to an embodiment of the invention.

FIG. 9 is a rear elevation view of a center-mount end-cap component, according to an embodiment of the invention.

FIG. 10 is a perspective view of an end-cap component and a countertop with an open end, after assembly, prior to finishing, according to an embodiment of the invention.

FIG. 11 is a perspective view of an end-cap component and a countertop with an open end, after assembly and finishing, according to an embodiment of the invention.

DETAILED DESCRIPTION

Before describing the invention in detail, it should be observed that the present invention resides primarily in a novel and non-obvious combination of elements and process steps. So as not to obscure the disclosure with details that will readily be apparent to those skilled in the art, certain conventional elements and steps have been presented with lesser detail, while the drawings and specification describe in greater detail other elements and steps pertinent to understanding the invention.
The following embodiments are not intended to define limits as to the structure or method of the invention, but only to provide exemplary constructions. The embodiments are permissive rather than mandatory and illustrative rather than exhaustive.
In the following, we describe the structure of an embodiment of an end-cap component 100 with reference to FIG. 1, in such manner that like reference numerals refer to like components throughout; a convention that we shall employ for the remainder of this specification.
In an embodiment, as shown in FIG. 1, an end-cap component 100 can comprise:

- a) An end-cap front element 110; and
- b) An end-cap stabilizer 120;
- wherein the end-cap stabilizer 120 is connected to a rear side of the end-cap front element 110;
- such that the end-cap stabilizer 120 is recessed from an upper edge of the end-cap front element 110; and
- such that the end-cap stabilizer 120 is recessed from at least one side edge of the end-cap front element 110.

In a related embodiment, the end-cap component 100 can be manufactured in one piece, such that it can for example be cut from one piece of a stone material, or alternatively it can be assembled from stone material pieces that are glued together, for example such that the end-cap front element 110 and the end-cap stabilizer 120 are separate pieces, which are glued together.
Cutting a stone material, such as engineered quartz, produces a significant back pressure and vibration, such that the part must be precisely and securely held at all times to keep the part from “wandering” or “shattering”. In related embodiments, wherein the end-cap component 100 is manufactured in one piece that is cut from a stone material, existing well-known cutting tools and equipment are generally not well suited for manufacturing, which may instead have to rely on custom designed equipment.
In a further related embodiment, the end-cap component 100 can be configured to connect with an open end 150 of countertop 180, wherein the counter top 180 is comprised of an upper surface element 182 and a perpendicularly connected front edge 184, which for example can be connected by a mitered edge 185.
In a further related embodiment, as shown in FIG. 1, the end-cap front element 110, the end-cap stabilizer 120, the upper surface element 182, and the front edge 184 can be rectangular pieces made from a solid material.
As shown in FIG. 1, the end-cap component can be configured as a left-side end-cap component 100, as viewed from a rear side of the end-cap component 100; such that the end-cap stabilizer 120 is recessed from a left-side edge of the end-cap front element 110, as viewed from a rear of the end-cap component 100; whereby the left-side end-cap component 100 can be connected on a left open end 150 of a countertop 180, as viewed from a front of the counter top 180;
In a related embodiment, as shown in FIG. 2, an end-cap component can be configured as a right-side end-cap component 200; such that the end-cap stabilizer 120 is recessed from a right-side edge of the end-cap front element 110, as viewed from a rear of the end-cap component 100; whereby the right-side end-cap component 200 can be connected on a right open end of a countertop 180, as viewed from a front of the counter top 180.
FIG. 3 shows a front perspective view of the right-side end-cap component 200, showing the front side 312, also referred to as the face 312 of the front element 110. The face 312 can be pre-fabricated in a polished configuration.
In a related embodiment, FIG. 4 shows a rear perspective view of a left-side end-cap component 100.
In a related embodiment, as shown in FIG. 5, an end-cap component 100 can be connected with an open end 150, such that

- a. an exposed inner surface 514 of the end-cap front element 110 is connected with an outer edge surface 544 of the countertop 180, such that an upper recession 502 of the end-cap stabilizer 120 is equal to a surface thickness 558 of the upper surface element 182, and such that a side recession 506 from a side of the end-cap stabilizer 120 is equal to an edge thickness 556 of the countertop edge 184;
- b. An outer edge surface 526 of the end-cap stabilizer 120 is configured to connect with an inner edge surface 546 of the front edge 184 of the countertop 180; and
- c. An upper edge surface 528 of the end-cap stabilizer 120 is configured to connect with an inner upper surface 548 of the upper surface element 182 of the countertop 180.

In a related embodiment, FIG. 6 shows a rear side elevation view of a left-side end-cap component 100, showing the L-shape configuration of the exposed inner surface 514 of the of the end-cap front element 110.
In a related embodiment, FIG. 7 shows a rear side elevation view of a right-side end-cap component 200, showing the L-shape configuration of the exposed inner surface 714 of the end-cap front element 110.
In an embodiment, as shown in FIG. 8, an end-cap component can be configured as a center-mount end-cap component 800; such that the end-cap stabilizer 820 is recessed from both right-side and left-side edges of the end-cap front element 810, as viewed from a rear of the center-mount end-cap component 800, thereby forming an exposed inner surface 814 of the end-cap front element 810 with an inverted u-shape. whereby the center-mount end-cap component 800 can be connected on a right or left open end of a countertop 180, as viewed from a front of the counter top 180.
In a related embodiment, FIG. 9 shows a rear side elevation view of a center-mount end-cap component 800, showing the inverted-u-shaped configuration of the exposed inner surface 814 of the end-cap front element 810.
In a related embodiment, an end-cap component 800 can be configured with:

- a. an upper recession 902 from an upper side of the end-cap stabilizer 820 to the upper edge of the end-cap front element 810;
- b. a right recession 904 from a right side of the end-cap stabilizer 820 to a right edge of the end-cap front element 810; and
- c. a left recession 906 from a left side of the end-cap stabilizer 820 to the left edges of the end-cap front element 810.

In a related embodiment, if the right recession 904 is zero, whereby the right side of the end-cap stabilizer 820 is flush with the right edge of the end-cap front element 810, and the left recession 906 is greater than zero, the end-cap component 800 is a left-side end-cap component.
In a related embodiment, if the left recession 906 is zero, whereby the left side of the end-cap stabilizer 820 is flush with the left edge of the end-cap front element 810, and the right recession 904 is greater than zero, the end-cap component is a right-side end-cap component.
In a related embodiment, as shown in FIG. 9, if both the left and right recessions 904 906 are greater than zero, the end-cap component is a center-mount end-cap component 800. Typically, in such configurations, the right recession 904 will be the same as the left recession 906, in order to match a given thickness of front and rear edges on a countertop.
In related embodiments, the end-cap front element 110 and the end-cap stabilizer 120 can be made from

- a. stone materials, including
  - i. granite;
  - ii. marble;
  - iii. engineered marble;
  - iv. porcelain;
  - v. ceramic tile;
  - vi. engineered quartz, such as Silestone™;
  - vii. glass;
  - viii. other natural stone materials; and
  - ix. other engineered stone materials;
  - x. agglomerated materials; and
  - xi. combinations thereof;
- b. Other well-known countertop materials, including:
  - i. Countertop laminate materials.

In an example embodiment, which can be manufactured in engineered quartz, an end-cap component 800 can be configured with:

- a. A front element height 812 of 3 cm;
- b. A front element width 112 of 4 mm;
- c. An upper recession 902 of 1.25 cm;
- d. A right recession 904 of 3 cm;
- e. A left recession 906 of 3 cm;
  which can be connected to an open end of a countertop 180 with a surface thickness 558 of 1.25 cm and a front edge thickness 556 of 3 cm.

In a related embodiment, the end-cap component 800 can be configured with a front element width 112 in a range of 2-12 mm.
In a related embodiment, the end-cap component 800 can be configured with a front element height 812 in a range of 2-15 cm.
In a related embodiment, the end-cap component 800 can be configured with an upper recession 902 in a range of 0.75-3 cm.
In a related embodiment, as shown in FIG. 10, which shows an assembled version of the components shown in FIGS. 1 and 4, in the form of a stabilized end-cap countertop system 1000, wherein the end-cap component 100 can be glued to the open end 150 (not visible in FIG. 10) of the countertop 180 using an adhesive, such as an epoxy, polyester, silicone, or acrylic adhesive, of a type normally used for gluing natural and engineered stone materials.
In a further related embodiment, as shown in FIG. 11, edges of the end-cap countertop system 1000 can be smoothed and surfaces polished for a finished configuration of the end-cap countertop system 1000. Normally, only the edge of the end-cap front element 110 will need to be finished, as the front face 312 can be pre-fabricated in a polished configuration.
In a related embodiment, the end-cap component 100 provides a novel end cap solution for prefabricated, i.e. factory prepared, countertops 180, cabinet tops, worktops, desktops, casework, and fixture applications, wherein the factory front edge can typically be thicker than the countertop deck material itself, such that the countertop deck material for example can be 2 cm, but the edge can be 4 cm.
In related embodiments, the end-cap stabilizer 120 of the end-cap component 100 provides structure to attach the end cap 100 to an end of a counter top 180, including providing a locating and locking function for both vertical and horizontal positioning, whereas previous methods and systems requires positioning of blocks and/or other devices to position a laminated end-cap.
In a further related embodiment, if attaching the end-cap component 100 with adhesive, the device allows the adhesive to be applied with maximum ease and minimum waste.
In a further related embodiment, since a joint seam is not located in the flat plane of the face 312 of the end-cap front element 110, the finished product has the appearance of a solid, thicker, and more expensive product.
In a further related embodiment, use of the end-cap component 100 minimizes color and pattern variation issues that occur with previous methods, thereby minimizing repair and rework of esthetically inferior seams. Additionally, use of the end-cap component 100 significantly reduces the skill level and tooling required for installation projects, and thereby allows this type of product to be sold at Home centers and other markets for the DIY consumer.
Here has thus been described a multitude of embodiments of an end-cap component 100 and an end-cap countertop system 1000, and methods related thereto, which can be employed in numerous modes of usage.
The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention, which fall within the true spirit and scope of the invention.
Many such alternative configurations are readily apparent, and should be considered fully included in this specification and the claims appended hereto. Accordingly, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and thus, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

What is claimed is:

1. An end-cap component for installation on an open end of a countertop, comprising:

a) an end-cap front element; and

b) an end-cap stabilizer;

wherein the end-cap stabilizer is connected to a rear side of the end-cap front element;

such that the end-cap stabilizer is recessed from an upper edge of the end-cap front element; and

such that the end-cap stabilizer is recessed from at least one side edge of the end-cap front element.

2. The end-cap component of claim 1, wherein the end-cap front element and the end-cap stabilizer are rectangular solid pieces.

3. The end-cap component of claim 1, wherein the end-cap component is configured as a left-side end-cap component, such that the end-cap stabilizer is recessed from a left-side edge of the end-cap front element.

4. The end-cap component of claim 1, wherein the end-cap component is configured as a right-side end-cap component, such that the end-cap stabilizer is recessed from a right-side edge of the end-cap front element.

5. The end-cap component of claim 1, wherein the end-cap component is configured as a center-mount end-cap component, such that the end-cap stabilizer is recessed from a right-side edge and from a left-side edge of the end-cap front element.

6. The end-cap component of claim 1, wherein a face of the end-cap front element is polished.

7. The end-cap component of claim 1, wherein the end-cap stabilizer and the end-cap front element are separate pieces, which are connected with an adhesive.

8. The end-cap component of claim 1, wherein the end-cap component is manufactured in one piece, which comprises the end-cap stabilizer and the end-cap front element.

9. The end-cap component of claim 1, wherein the end-cap stabilizer and the end-cap front element are made from a stone material.

10. The end-cap component of claim 9, wherein the stone material is engineered quartz.

11. The end-cap component of claim 1, wherein the end-cap component is configured with a front element width in a range of 2-12 mm, a front element height in a range of 2-15 cm, and an upper recession in a range of 0.75-3 cm.

12. A stabilized end-cap countertop system, comprising:

a) a countertop, comprising:

an upper surface element; and

a front edge, which is perpendicularly connected to a front side of the upper surface element;

such that the countertop includes an open end; and

b) an end-cap component, comprising:

an end-cap front element; and

an end-cap stabilizer;

such that the end-cap stabilizer is recessed from at least one side edge of the end-cap front element;

such that the end-cap component is configured to connect with the open end of the countertop;

wherein an exposed inner surface of the end-cap front element is configured to connect with an outer edge surface of the countertop, such that an upper recession of the end-cap stabilizer is equal to a surface thickness of the upper surface element, and such that a side recession from a side of the end-cap stabilizer is equal to an edge thickness of the front edge;

wherein an outer edge surface of the end-cap stabilizer is configured to connect with an inner edge surface of the front edge of the countertop; and

wherein an upper edge surface of the end-cap stabilizer is configured to connect with an inner upper surface of the upper surface element of the countertop.

13. The stabilized end-cap countertop system of claim 12, wherein the end-cap front element and the end-cap stabilizer are rectangular solid pieces.

14. The stabilized end-cap countertop system of claim 12, wherein the end-cap component is configured as a left-side end-cap component and wherein the open end is in a left side of the countertop, such that the end-cap stabilizer is recessed from a left-side edge of the end-cap front element.

15. The stabilized end-cap countertop system of claim 12, wherein the end-cap component is configured as a right-side end-cap component and wherein the open end is in a right side of the countertop, such that the end-cap stabilizer is recessed from a right-side edge of the end-cap front element.

16. The stabilized end-cap countertop system of claim 12, wherein the end-cap component is configured as a center-mount end-cap component, such that the end-cap stabilizer is recessed from a right-side edge and from a left-side edge of the end-cap front element.

17. The stabilized end-cap countertop system of claim 12, wherein a face of the end-cap front element is polished.

18. The stabilized end-cap countertop system of claim 12, wherein the end-cap stabilizer and the end-cap front element are separate pieces, such that the end-cap stabilizer is connected to the end-cap front element with an adhesive; and wherein the end-cap component is connected to the open end of the countertop with the adhesive.

19. The stabilized end-cap countertop system of claim 18, wherein the adhesive is an acrylic adhesive.

20. The stabilized end-cap countertop system of claim 12, wherein the upper surface element, the front edge, the end-cap stabilizer and the end-cap front element are made from a stone material.

21. The stabilized end-cap countertop system of claim 20, wherein the stone material is engineered quartz.

22. The stabilized end-cap countertop system of claim 21, wherein the end-cap component is configured with a front element width in a range of 2-12 mm; a front element height in a range of 2-15 cm; and an upper recession in a range of 0.75-3 cm.