US2981580A - Counter construction - Google Patents

Description

2 Sheets-Sheet 1 Original Filed March 15, 1956 INVENTOR HERMAN E. HANSEN ATTORNEYS April 1961 H. E. HANSEN 2,981,580

COUNTER CONSTRUCTION Original Filed March 15, 1956 2 Sheets-Sheet 2 /04 his ATTORNEYS United rates 1. atent COUNTER 'CONSTRUC'IION Herman E. Hansen, Winterton, N.Y., assignor to Conggileltgm-Nairn, Inc., Kearny, NJ a corporation of New Original application Mar. 15, 1956, Ser. No. 571,689,

now Patent No. 2,890,919, dated June 16, 1959. Divided and this application Dec. 8, 1958, Ser. No.

2 Claims. Cl. 311-406 This invention relates to counters and to component parts useful in the construction thereof. This application isia division of co-pending application S.N. 571,689 filed March 15, 1956 for Counter Construction, now Patent No. 2,890,919, issued June 16, 1959.

The demand for counters having surfaces which are durable, attractive, and easily maintained, has resulted in Widely increasing use of permanently mounted surfacing sheets formed of such materials as hardened resin compositions, vinyl plastic coated felt base or the like.

In practice the surfacing sheets are adhesively laminated of leakagewhich can loosen the adhesive bond securing the surfacing sheet and can rot the wooden substructure I of a counter. Also, they tend to collect dirt at the line of-junction with the surfacing sheet and, in many applications, form an undesirably conspicuous margin around the entire counter assembly. It has, of course, been recognized that metal edge moulding can be eliminated by utilizing some of the surfacing sheet materialto cover the raw edge in what is commonly called a self edge. A

liquid-tight, durable self edge has not, however, been attainable heretofore except by the most costly techniques,

and in site+fabricated units they are. all but unattainable asa practical matter. Y 1

Accordingly, it is one object of the present invention to. provide improved counter constructions havingself edges. of pleasingly rounded contour which are both liquid-tightand durable whileat the same time capable of simplified fabrication. I i

Another object of the invention is to provide an improved counter construction, the sub-structure of which can comprise conventional, easily Worked, wood panels,

and the surfacing of which comprises durable, waterimpervious sheet material uniquely integrated with the; sub-structuretto form acompieted assembly in which; unbroken extensions of the surfacing material definethe edges. a t Another object of the invention is to provide novel sub .structure form pieces for contouring a counter framework" to receive surface sheeting.

.In accordance with the presentinvention, a series of form pieces for defininggresfpectively the front iorleading edge. of the 'counter, the cove; between the flattworking.

surface of the countenand the'upright back splash, and. the top edge of the back splash, are provided for attach mentto flat panels to become,,together withthe; panels,

I part of a counter substructure defining; a smooth, con i tinuous surface to which a single piece of surfacing sheet material is adhesively attached to integrate the assembly and to provide, if desired, a water-impervious, attractive wear surface altogether free of breaks, cracks, or externally applied marginal mouldings.

The form piece which defines the front edge of the counter can be arranged for application to the horizontal panel in a simple snap fit, with the design being such that once in position and with the surfacing sheet applied, it defines an enlarged,- gently rounded edge which is not susceptible of displacement either angularly or in translation. The cove forming piece is designed in accordance with the invention to form a junction between the horizontal and vertical panels and includes surfaces complementary to both panels. In one embodiment, the cove forming piece comprises not only a sub-structurefor backing up the surfacing sheet but a bridging link by means of which the vertical back splash panel is attached to and carried by the horizontal panel. The form piece for defining the top of the back splash is provided in accordance with the invention with a rearwardly extending flange by means of which the counter assembly can be scribed into the wall in an abutting relationship which eliminates the usual gaps and prevents, it follows, the ingress of liquid, food particles, or the like, down the wall behind the counter to points forever inaccessible for washing.

Representative embodiments of the invention are described below having reference to the accompanying drawings in which: 5

Figure 1 is a view in perspective of a counter assembly embodying the present invention;

Figure 2 is a view in vertical section of the counter assembly shown in Figure 1;

Figure 3A is a view in perspective with its left hand end in vertical section of a short length of a form or contouring piece for main fabricating the front edge of the counter;

Figure 3B is a view similar to 'Figure 3A showing a modified form piece forthe front edge of the counter;

Figure 4 is a view similar toFigure 3A showing one design of form piece for defining the cove of the counter assembly at the intersection of the counter and the back splash;

FigureSA is a view similar to Figure 3A showing the form piece for completing the back splash of the counter and for definiuga Wall junction;

Figure 5B is a view similar to Figure 5A showing av :modified form piece for completing the, back splash of i the counter surface is provided withqan uprighta back. 3 splash, in which form it is illustrateclfin the-accompany, ing-drawings; i i

Referring to Figuresl and 2 counter of tlie present back panel;

,the counter and for defining a wall junction, the form piece being illustrated asrnounted on'a' fragment of a w Figure 6 is a fragmentary view in vertical section illustrating an alternative technique for forming the counter construction; and

Figure '7"is a fragmentary view in vertical section 1 showing a modified form of, the cove portion of the counter construction which is particularly useful in the practice of the counter fabricating technique partially illustrated by Figure 6.

As will beapparent from the following description, the present invention is generally applicable to counters such.- as kitchen "counters, bar topsQtable tops, or the like, 'and certain parts-. thereof arfe applicable to surfaced stair treads, KIt has particularutility; in the construction ofsink area and fioor cabinet tops forwkitchens wherein.

- invention; generally indicated by thelnutneralj 10 and shown for purposes of illustration as formed with a cutout to receive a conventional sink 11, includes a main horizontal panel 12 which can be constructed of plywood or another suitable sub-structure material. Secured to the forward edge of the panel 12 is a contoured front edge form piece 14 described more fully below. This form piece, as well as the other form pieces hereinafter referred to, are preferably made of a strong, rigid material such as metal, and the metal is preferably of the extrudable type such as aluminum having inv its finished form surfaces which are slightly dull, e.g., a satin finish capable of establishing a strong adhesive bond to the overlying surfacing sheet material of the finished counter.

As shown in Figures 2 and 3A, the front edge form piece 14 includes a continuously curving convex outer wall 15, the central inner portion of which is formed with a pair of ribs 16 and 17 adapted to abut the leading edge of the panel 12 along vertically spaced apart lines. The upper portion of the wall 15, which overlies the panel 12, is formed with a slight reverse curvature 18 to define a feather edge 19 at the line of junction with the panel. The underside of the feather edge 19 is formed with a flat 20 adapted to rest on the panel 12 and rearward of the flat 20 is a depending rib 21 adapted to rest on the panel 12 close to its edge. The lower end of the contoured outer wall terminates in an upwardly extending vertical flange 22 inturned at 23 to form an abutment to engage the underside of the panel 12. As best shown in Figure 2, the form piece 14 surrounds the forward end of the panel 12 so that the feather edge 19 smoothly merges into the upper surface of the panel 12 along a line spaced inwardly from the for ward edge thereof with the flat and rib 21 engaging the upper surface. In addition, the ribs 16 and 17 engage the forward edge of the panel and the inturned edge 23 of the flange 22 engages the lower surface of the panel along a marginal line spaced inwardly from the forward edge. Preferably the form piece 15 is so constructed that it must be slightly expanded to fit over the panel edge, the expansion being accommodated by slight flexing of the resilient wall 15. In this fashion, a tight, snap-on fit is assured. The design of the form piece 14 is such that most externally applied forces tend to increase the frictional binding or clamping forces which help to hold it inposition on the panel 12. Together with the adhesively applied sheet overlay, as described below, the leading edge construction becomes fully secured against angular and translational displacement.

7 The modified design for the form piece 14' shown by:

cove forming piece 28 is an upright back splash panel 40 which can be formed of any suitable material such as plywood or the like. Fastening'means such as nails 44 can be driven through the lower end portion of the back splash panel and into the rear edge of the panel 12 through the flange 38. If necessary, the flange 38 of the cove piece can be apertured, as at 42 to receive the fastening means.

The upper edge of the back splash panel 40 has secured thereto a top edge form piece, different designs of which are illustrated by Figures 5A and 5B. Referring first to Figures 2 and 5A, there is shown a top edge form piece 50 including a convexly curved exterior surface 52 terminating at its upper end in a horizontal, slightly sharpened flange 54 extending rearwardly therefrom which provides a continuation of the convex exterior surface. At its lower end the piece is formed with an inturned flange or shoulder 56 which rests on the top edge corner of the back panel 40. The piece 50 is completed by a panel flush therewith. As shown in Figure 2, the back Figure 33 includes a supplemental securing means in V V the form of a'central barbed flange 24 adapted to'be driven into a suitable groove (not shown) which is preferably pre-formed in the leading edge o'f the panel 12.

Parts generally similar to those of Figure 3A are identia cove forming piece 28. As shown in Figure 4, the

cove piece 28 can include a body portion 38 preferably 7 hollow and having a concavely curved exterior surface S'Zandflat under surfaces 34and 36 which form feather edges at either extreme of the concave surface. Extending perpendicularlydownward fr'om'the surface 36 isa'flange 38. As shownin Figure 2, the cove piece 28 engages'the rear endportion of the panel '12 with the flange 38 flush with the rear edge thereof and the surface 36 abutting the upper surface thereof so' that the adjacent feather edge merges smoothly with the upper I surface of. the panel along a line spaced inwardly from therear edge.. i-.: v

;Secured iin. abutting relation to the surface .34 of the splash top forming piece 50 is secured in position by securing means such as nails 59 passing through the flange 57 to enter the panel 40. The convex exterior surface 52 of the form piece forms a continuation of the forward surface of the panel with the horizontal flange 54 extending beyond the rearward surface thereof to be received, after the sheet surfacing material is applied, in a suitable groove scored in the wall W against which the counter assembly abuts. In this fashion, a gap-free junction results.

As shown by Figure 5B, the top edge form piece 60' can be modified by the addition of a barbed inner flange 62 depending from a shoulder 64 and adapted to be re ceived in a groove 66 formed in the upper edge of the back splash panel, a fragment of which is identified by the numeral 40'. The form piece 60 also includes a convexly curved wall 70 terminating at its lower, forward end in a surface to rest on the forward corner edge of the back splash panel 40' and terminating at its rearward,

upper end in a horizontal wall engaging flange 72. Extending downward from the underside of the wall 70 is al flange 74, the free end of which rests on the back corner 1 edge of the back splash panel 40.

It can thus be seen that the assembled panels 12 and 48 or 40 with the three form pieces 14, 28 andSl] or60 attached thereto provide a smooth, continuous exterior surface which extends from the front edge of the counter a to the top of the, back splash. As stated, preferably 1 each of the form pieces is formed with non-polished, i.e.,

satin finish surfaces for purposes now to be described.

intimately bonded with the exterior surfaces of eachof the pieces 14, 28 and 50 and the mutuallyperpendicular flat surfaces of the two panels 12 and '40 is a'sin'gleii thin, e.g., 5& thick, sheet of water impervious material.- 76, such as plastic or the like. erably flexible under normal conditions and can take the: 7 form, for example, of a felt bajse product coated with a vinyl plastic or it can take the form of a solid plastic". Adhesive is spread uniformly overall of the surfaces. The sheet material is preferably pressed into position so that voids do not occur between it and its supporting surfaces. In position, it will 'be understood that the; sheet 76 imparts additional strength to the counter asse1i1- bly. Inpartiuclar, the sheet assists in-securing the fronts; edge form piece 14 against translational movement off of The sheet material is pref sheet.

the panel 12 in the direction of the plane of the panel.

be ofthe conventional'snap-on type.

A method and an apparatus'or toolforapplying the Y surfacing sheet material 76 to' the'sub-structureassembly' Y described above are disclosed in the copending application, Serial No. 571,653, filed March 15, 1956. In accordance with the disclosure of that application, the sheet of surfacing material is cut and fitted in a single piece to the counter surface. Next a suitable adhesive is applied between the exterior counter surface and the underside of the sheet, preferably by applying the adhesive separately to both surfaces. After the adhesive has been applied the sheet is brought into registry with the sub-structure and pressed into position, using, for example, the matrix or tool of said copending application to bring the sheet and sub-structure into intimate relationship throughout,

the single sheet thereby bing bonded to the exposed surfaces of the several panel and form pieces alike.

Another example of a material which can be utilized in conjunction with the present invention, is the socalled C-stage plastic materials of the type comprising laminated sheets, such as, for example, paper woven fabric and matter or woven glass fibers impregnated with any suitable thermosetting resin such as phenol urea melamine formaldehyde resins and their derivates including the group of unsaturated polyester resins, e.g., ethylene glycolmaleate acid, polymer modified with monomeric styrene. Such plastics are commercially available as Formica which is the trade mark of a product of the Formica Company of Cincinnati, Ohio, Micarta" which is the trade mark of a product of the Westinghouse Electric and Manufacturing Company of Pittsburgh, Pennsylvania, or Farlite which is the trade mark of a product of Farley and Loetscher of Dubuque, Iowa.

In general, the C-stage plastic laminates cannot be bent to conform with a counter surface such as presently disclosed without the application of heat. Accordingly, where such plastics are utilized it is desirable to preform the sheet into the shape of the exterior surface of the counter. After the C-stage plastic sheet has been preformed, suitable adhesives of the type mentioned above are then applied in the same manner as previously indicated. The sheet is then engaged to the counter surface and the matrix applied and clamped in the manner indicated before.

Referring now to Figures 6 and 7, an alternative fabricating technique and a modified cove forming piece are illustrated. A back splash panel 88 can, as a preliminary step in the fabrication of the counter, first be disposed in the plane of the horizontal panel 90 and spaced edgewise therefrom for a predetermined distance to receive a flat, unbent sheet 92 of surfacing material, adhesive being applied between the opposed surfaces. After the adhesive has set, the back splash panel 88 is swung into a plane normal to that of the panel 90 by flexing the bridging strip of the sheet material into a generally rounded curvature to define the cove. Next, a reinforced form piece 94 is inserted behind the sheet material at the cove and is secured to both the horizontal and vertical panels. The form piece 94 includes a concavely rounded center wall 96 terminating at its respective ends in reinforced mutually perpendicular shoulders 98 and 100 which abut the edges of the panels 88 and 90, respectively. Marginal flanges 102 and 104 can be formed at the ends of the shoulders 98 and 100 respectively to overlie the panels 88 and 90 and to set the position of the form piece 94 so its curved surface 96 precisely backs up the sheet material 92 at the cove. A barbed flange 106 can be formed on the shoulder 100 to be driven into a suitable channel or groove 108 formed in the horizontal panel 90, after which suitable securing means 110 such as nails, screws, or the like, can be driven into the edge or side, as the case may be, of the back panel 88. It will be seen, therefore, that the form piece 94 serves as both a cove defining member and as a structural link between the two panels.

It can thus be seen that there has been provided a counter which may be easily constructed without the need of expensive tools or machines. Of particular significance is the fact that the counter presents a smooth, continuous, water impervious surface, thereby eliminating the need for exposed moulding strips. As noted above, the use of such exposed moulding strips presents the disadvantage of dirt collection and leakage so that wi h the counter of the present invention, these disad-- vantages are effectively overcome. It should also be: noted that the rearwardly extending horizontal flange 54- of the back splash form piece provides an effective means. whereby the counter may be installed against a wall so as to insure a leakproof fit. It is well known that most walls are not precisely fiat and include undulations, dips and the like. Heretofore, it has been found necessary to either shape the back splash panel of the counter to the wall or provide caulking between the space between the wall and the back splash panel, which procedures have obvious disadvantages. With the present invention, the counter is initially placed against the wall so that the end of the flange 54 engages the same. The wall is then scored or grooved along the flange and this scoring is repeated until a horizontal groove is formed in the wall which is suitable to receive the flange with the rear surface of the back splash panel abutting the wall. In this manner, there is provided a horizontal surface which intersects the wall, the horizontal surface being impervious to water and shaped to direct the water downwardly away from the wall.

It will be appreciated that various modifications can be made in the invention as described above without in any way deviating from the scope thereof as defined in the appended claims.

I claim:

1. In a counter construction, a horizontal panel, a back splash panel extending upwardly from the rear end thereof, the rear end of said horizontal panel and the lower end of said back splash panel including closely spaced parallel surfaces, a form piece to define a cove secured between said panels, said piece having a straight, fiat flange extending within the space between said parallel surfaces and presenting a concave exterior surface which merges smoothly with the forward surface of said back splash panel along a line spaced upwardly from its lower end and with the upper surface of said horizontal panel along a line spaced forwardly from its rear end, and a thin sheet of material intimately bonded to the upper surface of said horizontal panel, the exterior surface of said form piece, and the forward surface of said back splash panel. 1

2. A counter construction according to claim 1, said horizontal and back splash panels being joined at their said closely spaced parallel surfaces by securing means passing through one panel, through said flange of the form piece and into the other panel.

References Cited in the file of this patent UNITED STATES PATENTS 2,038,638 Bray Apr. 28, 1936 2,134,999 Crouch Nov. 1, 1938 2,532,769 Houpt Dec. 5, 1950 2,570,850 Pearson Oct. 9, 1951 2,582,816 Bonnell Jan. 15, 1952 2,626,846 Morris Jan. 27, 1953 2,635,308 Crook Apr. 21, 1953 2,646,326 Stanitz July 21, 1953 2,648,370 Beach Aug. 11, 1953 2,721,333 Stanitz Oct. 25, 1955 2,821,754 I-Iillson Feb. 4, 1958

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