WO2021173059A1

WO2021173059A1 - Countertop for undermounted sink and method for preparation thereof

Info

Publication number: WO2021173059A1
Application number: PCT/SE2021/050139
Authority: WO
Inventors: Mathias OLOFSSON
Original assignee: Ikea Supply Ag
Priority date: 2020-02-28
Filing date: 2021-02-19
Publication date: 2021-09-02
Also published as: EP4110137A4; EP4110137A1; SE2050228A1; SE544244C2

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 FOR PREPARATION THEREOF

Field of the invention

The present invention relates to a method of preparing a countertop for an undermounted 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, and fittings, wherein the countertop is provided with an opening for receiving the sink.

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

Background

US8245380 discloses a method for undermounting a sink in a countertop. A channel is routed from the back of a countertop including a laminate. After the underside of a decorative laminate on the top of the countertop has been exposed in a deeper section of the channel, an adhesive is applied directly thereon. An adhesive is applied on the bottom of a shallower section of the channel, and then the sink is arranged 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 the countertop surrounded by the channel, and covering the sink, may be removed and the edges softened. Thereafter installation on a cabinet may take place.

Since the exposed laminate is thin, extreme care must be taken not to damage it, before the sink has been mounted thereon. Typically, the undermounting of the sink may take place in a production plant in order to avoid transportation of the countertop in a state wherein parts of it may be easily damaged. The resulting product is a countertop with a sink mounted therein, and this combination is generally bulky and difficult to transport without damages. The transports may also be expensive, 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. the sink, has been damaged. Instead, both the countertop and the sink may have to be discarded.

Summary

It 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 of preparing a countertop for an undermounted sink, prior to attaching the sink, comprising milling the countertop to form an orifice wall and a flange precursor around 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 resistance to water. An edge flange with a high stability will allow for a mounting of the sink in the countertop at the building site, i. e. in the house of the end customer, as an alternative to mounting in a factory. An advantage is that transportation of the countertops and the sinks will be easier and less bulky, which is also more cost efficient.

In an embodiment the stabilising of the flange precursor comprises adding to the thickness of the flange precursor.

The flange precursor may hence be milled to a very low thickness, and some of the goods that has been milled off is replaced by resin, which is both hard and water resistant when it is cured. In many cases the milled off material consists of particleboard, the strength, smoothness and water resistance of which are typically limited.

In another embodiment of the method, the countertop has a countertop face and a bottom face, wherein forming the edge flange comprises milling a primary track in the bottom face of the countertop, and a secondary, deeper track next to the primary track, applying a resin in the primary and the secondary tracks, cutting away a 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. In a further embodiment, the method comprises milling the resin to form a support area for the undermounted sink on the edge flange.

The flange resulting after the milling may also have exact dimensions and be suitable for mounting an undermounted sink thereon with a high precision. The visual appearance will be attractive, and the risk of leaks is essentially eliminated.

In a still further embodiment, the method comprises securing the central piece, surrounded by the tracks, in its position, and removing the central piece after the resin is cured to form the edge flange.

Keeping the central piece in place until the resin has cured provides a solid support for the resin while it is curing.

In 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 are milled, may be more or less protected from moisture that may accidentally leak between the orifice wall and the sink.

In an embodiment the method further comprises milling the resin to a flat support surface for the undermounted sink on the edge flange, extending transversally from the orifice wall.

In an embodiment the method further comprises milling the resin to form the edge flange which has a thickness of 1-5 mm.

In an embodiment the method further comprises milling a clamping groove in an outer side wall of the tracks.

Hereby means for further securing the undermounted sink to the countertop may be obtained.

In a second aspect of the invention, a countertop comprises an orifice with an orifice wall for receiving an undermounted sink, wherein the upper edge of the orifice wall is provided with a circumferential edge flange, extending transversally from the orifice wall towards the center of the orifice, and comprising a support layer of resin. The edge flange has the advantage of providing a suitable support for an undermounted sink in the orifice. A layer of resin is advantageous since it may have a strengthening and waterproofing effect.

In a further embodiment of the countertop, the resin is arranged on a lower surface of the edge flange.

Hereby a support surface, which may be milled to a high degree of smoothness, may be provided.

In other embodiments of the countertop, the resin is arranged on a free edge of the edge flange.

A free edge of the flange will typically be exposed next to the undermounted sink. Strength and resistance to water are useful properties for the free edge.

In further embodiments of the countertop the resin is a two-component resin.

In an embodiment of the countertop the thickness of the flange is 1-5 mm.

In still further embodiments the countertop comprises a circumferential clamping groove in the orifice wall.

Hereby the countertop is prepared for the attachment of fittings which may clamp the undermounted sink onto the edge flange.

In even further embodiments of the countertop, the clamping groove extends into the orifice wall transversally thereto.

In some embodiments of the countertop, the orifice wall is at least partly coated with resin.

In some embodiments the comprises a laminated board with a sealing top layer and a supporting main layer.

In some embodiments the countertop comprises a polymer film as the top layer.

In other embodiments the countertop further comprises a veneer as the top layer. In some embodiments the countertop comprises a particle board as the supporting main layer.

In a third aspect of the invention, there is provided a set comprising a countertop according to the previously described countertop, a sink, and fittings, wherein the countertop is provided with an opening for receiving the sink, and clamping grooves for receiving the fittings; the sink is adapted for undermounting in the countertop; and the fittings are arranged to clamp the sink against the countertop.

Although the countertop, the sink, and the fittings are not mounted at the time of sale, they may still be sold as a set wherein the parts are adapted for mounting at a later stage. The advantage of a set of parts is that some parts may be selected among several varieties, in order to provide a customized product, i. e. a countertop with a sink according to the wishes of the end customer. Also, it may be easier to transport a non-assembled set of parts than the finished product.

In an embodiment a set comprises a countertop as described above.

In a fourth aspect of the invention there is provided a method of mounting an undermounted sink in a countertop with an orifice with an orifice wall and a circumferential edge flange extending transversally from the orifice wall, comprising applying an adhesive to a lower side of the circumferential edge flange, pressing an upper flange of the sink against the circumferential edge flange, and clamping the upper flange of the sink against the circumferential edge flange by arranging fittings in a clamping groove in the orifice wall and tensioning the fittings to press the sink in a direction towards the circumferential edge flange.

Hereby it is possible to mount the sink at the end customer, and avoiding risks of damages during transport, as well as costly transports of bulky items. The end product will be adapted to the place of use, without mistakes. The clamping provides an increased security and durability of the mounting.

In an embodiment of the method, the mounting is performed on a set as described above.

It is noted that embodiments of the invention may be embodied by all possible combinations of features recited in the claims. Further, it will be appreciated that the various embodiments described for the device are all combinable with the method as defined in accordance with the second aspect of the present invention, and vice versa.

Brief description of the drawings

The 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, with reference to the appended drawings, where the same reference numerals will be used 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 a manufacturing step of the countertop;

Fig. 3B is an enlarged, partially sectional view of another manufacturing step of 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 manufacturing step of the countertop; and

Fig. 4 is an exploded view in perspective with a partial section of the countertop and the sink.

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

Detailed description of the exemplary embodiments

Fig. 1 illustrates a countertop 1 , with a sink 2, typically for a kitchen. There is a faucet 3 for providing water to the sink 2, as well as a drain 4 at the bottom of the sink 2, for draining water from the sink 2. One or more cabinets 5 may be provided under 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 at least a top layer of the countertop 1 and glued thereto.

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

The sink 2 has a circumferential mounting flange 8 which is partly visible and partly covered by the countertop 1 when the sink 2 is mounted therein. In the disclosed embodiment, an upper side of the mounting flange 8 on the sink 2 is glued against a bottom side of a corresponding edge flange 9 of the orifice in the countertop 1.

The edge flange 9 of the orifice comprises a layer of resin 10, which extends along the bottom side of the edge flange 9 and thereby provides a contact surface for gluing the mounting flange 8 thereto. The resin 10 has a stabilizing effect on the edge flange 9. The edge flange 9 may hereby be free and self-supporting. A center portion 19 (see Fig. 3D) of the countertop 1 may hereby be removed without the risking the integrity of the edge flange 9 during transport of the countertop 1 before the sink 2 has been mounted thereon. 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 protecting the particle board 6 comprised in the countertop 1. Also, the exposed resin 10 will present a visually appealing transition from the top layer 7 of the countertop 1 to the sink 2.

Although the gluing between the mounting flange 8 and the edge flange 9 may be sufficiently strong and durable to keep the sink 2 in its position, the disclosed embodiment comprises a number of fittings 11 to secure the sink 2 mechanically in its 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 be disposed transversally to the extension plane of the plate 13. The plate 13 may comprise metal, plastic or any other suitable material, which will allow for a durable fitting 11 and an easy and cost-efficient manufacture. The plate 13 is arranged to be inserted into a groove 15, which has been milled in the orifice wall 16 in the countertop. When the screw 12 is tensioned, it will bear against the bottom side of the 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 the countertop 1 at the building site, i. e. in the home of the consumer. Hence the countertop 1, which has been provided with an orifice and an edge flange 9 around the orifice, and the sink 2 may be transported as separate units. This allows for a more cost-efficient transportation, and the risk of damages to the sink 2 and/or the countertop 1 are reduced.

In Figs. 3A to 3D, a method of preparing the countertop 1 for an undermounted sink 2 is disclosed.

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

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

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

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

Fig. 3D discloses a final step in the preparation of the countertop 1 for the undermounting of a sink 2. The center portion 19 of the countertop 1 has been removed to form an orifice for the sink 2. The edge flange 9, which extends circumferentially 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 be as thin as 0,4-0, 5 mm. In addition to the stability provided by the cured resin 10, the outer 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 flange 9.

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

Fig. 4 is an exploded view of the sink 2 and the countertop 1 , illustrating the mounting of the sink 2 in the orifice in the countertop 1. After an adhesive, which may be 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 is pressed against the edge flange 9. Any excess adhesive seeping out onto the exposed part of the mounting flange 8 of the sink 2 may be wiped off, before it has dried. At least one of the fittings 11 , which are shown in fig 2, may be arranged on either side of the sink 2, by inserting the respective plates 13 into the groove 15 and tensioning the respective screws 12, so that their ends will press each section of the mounting flange 8 of the sink 2 against the edge flange 9. The invention has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended patent claims.

In 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 of preparing a countertop (1 ) for an undermounted sink (2), prior to attaching the sink (2), comprising milling the countertop (1) to form an orifice wall (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), to form an edge flange (9).

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

3. Method according to claim 1 or claim 2, the countertop (1) having a countertop face and a bottom face, wherein forming the edge flange (9) comprises milling a 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 primary and the secondary tracks (17, 18), cutting away a central piece (19) surrounded by the tracks (17, 18).

4. Method according to claim 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 claim 3 or 4, further comprising securing the central piece (19), surrounded by the tracks 17, 18), in its position, and removing the central piece (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 an undermounted sink (2), wherein the upper edge of the orifice wall (16) is provided with a circumferential edge flange (9), extending transversally from the orifice wall (16) towards the center of the orifice, and comprising a support layer of resin (10).

11. Countertop (1) according to claim 10, wherein the resin (10) is arranged on a lower surface of the edge flange (9).

12. Countertop (1) according to claim 10 or claim 11, wherein the resin (10) is arranged on a free edge of the edge flange (9).

13. Countertop (1 ) according to any of claims 10 to 12, wherein the resin (10) is a two-component resin.

14. Countertop (1 ) according to any of claims 10 to 13, wherein the thickness of the edge flange (9) is 1-5 mm.

15. Countertop (1) according to any of claims 10 to 14, further comprising a circumferential clamping groove (15) in the orifice wall (16).

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

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

18. Countertop (1) according to any of claims 10 to 17, comprising a laminated board with a sealing top layer (7) and a supporting main layer (6).

19. Countertop (1) according to claim 18, further comprising a polymer film as the top layer (7).

20. Countertop (1 ) according to claim 18, further comprising a veneer as the top layer (7).

21. Countertop (1 ) according to any of claims 18 to 20, comprising a particle board as the supporting main layer (6).

22. Set comprising a countertop (1 ) according to any of claims 10 to 21 , a sink (2), and fittings (11), wherein the countertop (1) is provided with an opening for receiving the sink (2), and clamping grooves (15) for receiving the fittings (11); the sink (2) is adapted for undermounting in the countertop (1); and the fittings (11 ) are arranged to clamp the sink (2) against the countertop (1 ).

23. Method of mounting an undermounted sink (2) in a countertop (1 ) with an orifice with an orifice wall (16) and a circumferential edge flange (9) extending transversally from the orifice wall (16), comprising applying an adhesive to a lower side of the circumferential edge flange (9), pressing an upper flange (8) of the sink (2) against the circumferential edge flange (9), and clamping the upper flange (8) of the sink (2) against the circumferential edge flange (9) by arranging fittings (11 ) in a clamping groove (15) in the orifice wall (16) and tensioning the fittings (11 ) to press the sink (2) in a direction towards the circumferential edge flange (9).

24. Method according to claim 23, wherein the mounting is performed on a set according to claim 22.