Baths – closets – sinks – and spittoons – Miscellaneous
Reexamination Certificate
2000-04-07
2002-02-26
Phillips, Charles E. (Department: 3751)
Baths, closets, sinks, and spittoons
Miscellaneous
C004S631000
Reexamination Certificate
active
06349429
ABSTRACT:
FIELD OF THE INVENTION
The invention is in the field of countertop mounting units, such as sink mounts. More particularly, the invention relates to sealing means associated with sink mounts and the like.
BACKGROUND OF THE INVENTION
Laminated countertops are typically constructed with a thin surface layer of plastic laminate (such as FORMICA™ brand laminate from the Formica Corporation, Cincinnati, Ohio). The laminate is generally made up of layers of colored paper impregnated with polymeric resin and pressed into sheet stock. The surface laminate is typically bonded to a wood fibre core, such as plywood, particle board or flake board. The laminate serves, among other things, to seal the surface of the countertop against liquids. Similarly, porous countertops may be covered with tiles, typically made from ceramic materials, to form a surface seal.
To mount a sink in a laminated or tile countertop, a cross-sectional hole is typically cut through the porous core. The core, such as wood fibre, exposed by the cross-sectional cut in the countertop is generally porous. A seal must be used to exclude water from the unlaminated, cut edge of the countertop. Typically, this is achieved by dropping a sink with an upper circumferential flange into the mounting aperture from above. In some cases, steps may be taken to seal the flange against the laminated or tiled countertop. In the case of a tile countertop, the top of which may be uneven, it may be particularly difficult to form such a seal.
The traditional method of mounting flanged drop-in sinks gives rise to a number of problems. For example, it is not convenient to run cleaning solution over the flange, since the cleaner would not run back into the sink but out over the countertop. Wiping the countertop next to the flange tends to have the effect of forcing water, dirt and debris under the flange.
If the seal between the sink flange of a drop-in sink and the countertop laminate or tile deteriorates, water can leak down into the exposed porous wood fibre edge of the countertop core. The positioning of the flange above the wood fibre edge facilitates this undesirable downward flow into the core. Eventually, the countertop may suffer structural failure as the wetted core first swells, then looses its structural integrity altogether. Even before the fibre core fails, however, the area beneath a leaking sink flange may become an unsanitary habitat for the proliferation of microorganisms.
Solid countertops, made of natural materials such as stone, are a generally a more expensive alternative to laminated countertops. Synthetic polymer based ‘solid surface’ materials have been developed as an alternative to natural solid surface countertop materials. For example, E.I. du Pant de Nemours and Company sell an alumina trihydrate filled methylmethacrylate polymer solid surface countertop material, marketed under the trade-mark CORIAN™. Similar polymer based synthetic products are also available from others, such as AVONITE™ (by Avonite, Inc., Belen, N. Mex.), FOUNTAINHEAD™ (by the Nevamar Division of International Paper, Odenton, Md. a homogeneous, thermoses polymer alloy, comprised of polyester and acrylic components and filled with aluminum trihydrate), SURELL™ (by Wilden Industries, Inc.) and GIBRALTAR™ (an acrylic resin with fire-retardant mineral fillers, by Wilsonart International, Temple, Tex.). These solid surface materials generally have high temperature resistance, low thermal expansion, low water absorption (they are non-porous) and are hard and impact resistant.
Polymer based solid surface materials are generally available as sheet stock in an appropriate thickness for use as countertop material, such as ¼ inch ½ inch or ¾ inch thicknesses. Alternatively, thinner solid surface materials may be available as a laminated layer on a substrate such as plywood or particleboard (such as ⅛ inch Solid Surfacing Veneer ‘SSV’ product available from Wilsonart International, Temple, Tex.).
The widespread market acceptance of novel solid surface materials has led in turn to new developments in kitchen and bathroom fixtures. Unlike laminated countertops, solid surface countertops lack a porous wettable core. As a result, a sink may be mounted to the underside of an aperture cut in a solid surface countertop, and the non-porous crosssectional edge of the countertop left exposed without risk of damage to the countertop. To take advantage of this feature, a wide range of sinks are available that have been adapted for installation below countertop surfaces. These ‘undermount’ sinks generally include an upper peripheral flange adapted to seal against the underside of a solid surface countertop. Undermount sinks may be made out of a wide variety of materials, including natural stone, polymer based solid surface materials and stainless steel (which may be available for example from Kindred Industries of Midland Ontario, Canada).
At least in part because of the problems inherent in the typical method of top-mounting drop-in sinks, undermount sinks have gained widespread acceptance for use with solid surface countertops. However, solid surface countertops remain significantly more expensive than laminated countertops. It is therefore an object of the present invention to facilitate the use of undermount sinks with laminated countertops, including countertops laminated with polymeric solid surface materials, as well as tiled countertops.
SUMMARY OF THE INVENTION
In one aspect, the invention provides an apertured mounting unit comprising a deck sheet with a top surface and a bottom surface. The deck sheet may have a porous cross-sectional edge defining an aperture. Such an aperture may be of any shape and may be completely defined by surrounding deck sheet, or may be a partial cut-out in the deck sheet, such as a semi-circular cut-out in one side of the deck sheet.
A non-porous seal member is provided to facilitate sealing of the cross-sectional edge. As used herein, a nonporous material is defined as a material that is generally resistant to the passage of fluids, especially water, while porous materials do not form an adequate fluid barrier. It will be appreciated that these are relative terms, reflecting a difference in the porosity of the seal member and the deck sheet.
The outer peripheral surface of the seal member may be positioned to abut the cross-sectional edge. The inner peripheral surface of the seal member accordingly defines an opening.
A utility member, such as a sink, may be provided for mounting to the apertured mounting unit. The utility member may have a circumferential outwardly extending flange. This flange need not extend from the whole circumference of the utility member. The utility member is adapted for sealing engagement with the bottom surface of the seal member and adapted to abut a stopping surface fixed with respect to the bottom surface of the deck sheet. The utility member may be supported, or depend, from a bottom surface of the deck sheet.
A fastener or other means are provided for removably supporting the utility member from the bottom surface of the deck sheet. The removability of the utility member may be desirable, for example, to facilitate replacement of a damaged sink. Such removal of the utility member may necessitate careful removal of any adhesive, such as cured silicone, holding the utility member to the ring. The means for removably holding the utility member includes adhesives, clamps or other biasing means, as well as combinations and equivalents thereof. A wide variety of fasteners and means for holding may be utilized, such as those that are known in the art of sink undermounting, including nails, screws, nuts with bolts and specialized sink-mounting clamps, all of which may be used for the present invention provided they are capable of removably supporting the utility member on the bottom of the deck sheet.
The fasteners or means for holding the utility member may be used to apply a biasing force to bias the circumferential outwardly extending flange of the utility member towards t
Drozdowich Bryan Gordon
Zurba Peter
Counter-Mate, Inc.
Phillips Charles E.
TraskBritt
LandOfFree
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