US20050088063A1

US20050088063A1 - Modular kitchen component system

Info

Publication number: US20050088063A1
Application number: US10/944,792
Authority: US
Inventors: Preston Cox
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-09-22
Filing date: 2004-09-21
Publication date: 2005-04-28
Also published as: GB0419770D0; GB2406046A; GB2406046B; GB0322072D0

Abstract

A kitchen sink top is produced to a standard size selected from one or more predetermined standard sizes. The kitchen sink top is formed from natural stone or other homologous stone-effect material and, during production, is formed with an aperture suitable for an undermount-type sink bowl, at least one aperture for mounting a tap or faucet, and a recessed drainage area adjacent the sink bowl aperture. A modular kitchen component system, a method of producing the sink top, and an extension or backsplash element are also provided.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a modular kitchen component system, a kitchen sink top, an extension or backsplash element, and to a method of production.
Modular kitchen component systems are already well known and widely available from home improvement centres and such like. These are provided with tops, such as sink tops and counter tops, which are generally wood, for example chipboard, and a laminate surface adhered thereto. To date, only wood-based tops have been able to be provided as part of a modular kitchen component system.
Tops formed from other materials, such as natural stone, have to be pre-ordered and individually custom designed. This is expensive and thus often prohibitive to a person installing a new kitchen.
It should be understood that, although reference is made throughout to ‘kitchen’ this is intended to include any preparation area requiring sink access. For example, the ‘kitchen’ could be a bar area, restaurant, laboratory, galley of a ship or indeed any food preparation area.
U.S. Pat. No. 6,594,973 has gone some way to addressing the above problem. This document suggests pre-cut stone tops being supplied to high volume home improvement centres. However, problems arise due to the ‘one size fits all’ approach taken, and no solution is provided to enable such a worktop to be incorporated as part of a modular kitchen component system. Furthermore, multiple orientation of the worktop is not provided for, nor are drainage requirements for washed articles taken into account.
The present invention seeks to provide a solution to all of the above-mentioned problems.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided a kitchen sink top which is produced to a standard size selected from one or more predetermined standard sizes, the kitchen sink top being formed from natural stone or other homologous stone-effect material and, during production, being formed with an aperture suitable for an undermount-type sink bowl, at least one aperture for mounting a tap or faucet, and a recessed drainage area adjacent the sink bowl aperture.
Preferably, the sink top is produced as part of a batch of identical or substantially identical sink tops.
The term ‘batch’ is defined as being two or more, and includes bulk- and mass-production. Batch production of the tops is advantageous in that expensive unique templates produced from a site survey by a skilled tradesman can be dispensed with.
According to a second aspect of the invention, there is provided a kitchen sink top which is produced to a standard size selected from one or more predetermined standard sizes, the kitchen sink top being formed from natural stone or other homologous stone-effect material and which, during production, is formed with an aperture suitable for an undermount-type sink bowl, and two apertures for mounting a tap or faucet, one of the two tap or faucet apertures being provided adjacent a first edge of the sink top and the other of the two tap or faucet apertures being provided adjacent a second different edge of the sink top, so that the sink top can be installed in two different orientations.
According to a third aspect of the invention, there is provided a method of batch-producing kitchen sink tops, the method comprising the steps of:

- a. supplying a first location with slabs of quarried natural stone and/or sheets of homologous stone-effect material;
- b. sizing one said slab or sheet to a standard size selected from one or more predetermined standard sizes at the first location;
- c. forming in the one slab or sheet an aperture suitable for an undermount-type sink bowl at the first location;
- d. forming in the one slab or sheet at least one aperture for mounting a tap or faucet at the first location;
- e. forming in the one slab or sheet a recessed drainage area adjacent the sink bowl aperture at the first location;
- f. finishing the sink top at the first location;
- g. repeating steps (a) to (f) to form at least one further identical or substantially identical kitchen sink top; and
- h. supplying at least one of the finished kitchen sink tops to a second location ready for installation.

According to a fourth aspect of the invention, there is provided an extension or backsplash element which is formed from natural stone or other homologous stone-effect material and which is for use with a kitchen countertop or worktop, the extension or backsplash element having two rear surfaces which extend transversely to each other, and a front face, the two rear surfaces having different dimensions so that the extension or backsplash element can be installed in either of two orientations to cover a gap between a wall and an edge of an installed kitchen countertop or worktop.
According to a fifth aspect of the invention, there is provided a method of producing an extension or backsplash element for use with a kitchen countertop or worktop, the method comprising the steps of

- a. supplying a first location with quarried natural stone or homologous stone-effect material;
- b. sizing the stone or stone-effect material to a standard size selected from one or more predetermined standard sizes at the first location;
- c. forming the extension or backsplash element from the sized material at the first location;
- d. supplying the extension or backsplash element to a second location.

According to a sixth aspect of the invention, there is provided a modular kitchen component system comprising a sink unit having a sink top in which is provided one or more pre-formed apertures for an undermount-type sink and which is reversible to allow installation in either of two different orientations; a corner unit having a corner top; a standard unit having a standard top; an extension or backsplash unit having internal and/or external corners; end profile units having end profile tops; and hob slip units having hob slip tops, each said top being produced to a standard size selected from one or more predetermined standard sizes and formed from natural stone or other homologous stone-effect material at a production location remote from an installation location at which the modular kitchen component system is to be installed.
The present invention will now be more particularly described, by way of example only, with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective schematic view of part of one embodiment of a modular kitchen component system, in accordance with the seventh aspect of the invention;
FIG. 2 shows a perspective view of a top of a corner unit suitable for use with the modular component system shown in FIG. 1;
FIG. 3 shows a perspective view of a marketing badge for use with a kitchen sink top, in accordance with the second aspect of the invention;
FIG. 4 shows a plan view of a standard top for use with the modular kitchen component system shown in FIG. 1;
FIG. 5 shows a transverse sectional end view of an extension or backsplash element, in accordance with the fifth aspect of the invention and which is suitable for use with the modular kitchen component system shown in FIG. 1;
FIG. 6 is a transverse sectional end view showing the extension or backsplash element shown in FIG. 5 arranged in a first condition on the standard top shown in FIG. 4;
FIG. 7 is a transverse sectional end view showing the extension or backsplash element shown in FIG. 5 arranged in a second condition on the standard top shown in FIG. 4;
FIG. 8 is a scrap perspective view of an end profile top shown in FIG. 1;
FIG. 9 shows an end view of the standard top shown in FIG. 4;
FIG. 10 shows an end view of the hob slip top shown in FIG. 1; and
FIG. 11 shows an enlarged perspective view of the hob slip top shown in FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1, there is shown a modular kitchen component system which comprises a sink unit having a sink top 1, a corner unit having a corner top 2, a standard unit having a standard top 3, extension or backsplash elements 4, which at a corner have an internal corner 5 or an external corner (not shown), an end profile unit having an end profile top 6, and front and rear hob slip tops 7 & 8.
The sink top 1 is produced from a rectangular slab of natural stone or other homologous stone-effect material. The sink top 1 has profiled edges 9 on two parallel sides whose distance apart is equal to the width of the standard top 3 plus the additional length of a profiled edge 9 when viewed on plan. The length which will be dependant on the numbers of sinks and any design features such as a drainage area 10 and drainage grooves 11. The thickness of the sink top 1 will be a standard thickness of slab or sheet, typically in the range of 20 millimetres (mm) to 60 mm.
The front-to-back width of the sink top 1 will be greater than that of the other modular tops, but is likely to be no more than 15 millimetres (mm) greater. This small addition in width can be accommodated within the structure of the building and is normally contained within the plaster or plasterboard thickness of the mounting wall. Alternatively, this small addition can be removed on-site. This extra width allows the face edges of adjacent tops to run through in the same plane when viewed on plan.
The sink top 1 in addition to one or more off-centre sink bowl apertures 1 a has design features such as the sunken or recessed drainage area 10 and drainage grooves 11. The or each sink bowl aperture 1 a is suitable for an undermount-type sink bowl only.
By providing two tap or faucet apertures 12, one adjacent an edge 9 a of the sink top 1 and the other adjacent a parallel edge 9 b, the sink top 1 can be installed in two different orientations with the drainage area 10 extending to the left or right of the or each sink bowl aperture 1 a. The orientation of the sink top 1 determines which of the two tap or faucet apertures 12 is redundant after installation of a mono block tap or faucet (not shown). The aperture 12 which does not contain the mono block tap can be used for a pop up waste control, a soap dispenser or a marketing badge 14, shown in FIG. 3.
The edges 9 a and 9 b of the sink top 1 have profiled faces. However, only one of the edges 9 a and 9 b need be profiled.
FIG. 2, shows a corner top 2 a having a different shape. This top 2 a is formed from a rectangular piece of stone or stone-effect material having sides greater in length than the width of the top. The thickness is a standard thickness of slab or sheet material. As with the sink top 1, the corner tops 2 and 2 a have at least one profiled edge 9. Two butt joints 13, which are perpendicular to the profiled edge 9, allows for the adjacent top to have the same perpendicular edge.
Although not shown, the corner top 2 a could contain a sink bowl aperture.
FIG. 3 shows the marketing badge 14, which is of a diameter greater than the tap or faucet aperture 12. The badge 14 is approximately 2-3 mm thick and formed of stainless steel to match the tap and/or the undermount sink when attached. A plug 15 is attached to the underside of the badge 14. The plug 15 fits the tap or faucet aperture 12, and is held in position by friction or adhesive.
FIG. 4 shows the standard top 3 for the standard unit. The standard top 3 is rectangular in shape, and has a width equal to that of a standard unit. The length of the standard top 3 is pre-selectable and limited only by the variety of chosen stone. The thickness of the standard top 3 is a standard thickness of slab sold within the Industry.
The standard top 3 has at least one profiled edge 9 and two butt joints 13, which are perpendicular to the profiled edge 9. It is the standard top 3 which accommodates the variables of the widths and lengths of the other tops. The standard top 3 is cut to length on-site to interface between the other units and tops.
It is the intention of this invention to limit any on-site cutting to that which can be performed to a satisfactory standard on-site using hand held machinery.
Furthermore, it is intended that the length of any on-site cut be limited to the width of the standard top 3.
A company that provides such machinery for this task is Alpha Professional Tools of 250, Braen Avenue, Wyckoof, N.J. 078481 USA which have world wide distributors. The machine, the AWS-110, comes with a guide carriage and guide rail as optional extras. These extras would be needed to ensure that the new cut edge is perpendicular to the face profiled edge.
FIG. 5 shows the extension or back splash element 4 which is produced from a rectangular section of natural stone or other homologous stone-effect material. having unequal sides, approximately in the ratio of 3:1 to 4:1.
The extension or backsplash element 4 has a contoured, sculpted or profiled front face 16. The front face 16 may be concave as shown in FIG. 5, or convex. The extension or backsplash element 4 has two rear surfaces 4 a which extend transversely, preferably perpendicularly, to each other. The two rear surfaces 4 a have different dimensions.
The return sides 17 of the extension or backsplash element 4 have a dimension which exceeds the combined thickness of a standard ceramic wall tile and the thin bed adhesive used to fix the tiles to the wall.
FIG. 6 shows a section through the extension or backsplash element 4 and a standard top 3 having a profiled edge 9 shown here as a semi bulnose, and wall tiling 18. The extension or backsplash element 4 is shown here as a vertical back splash used to cover a small gap between the mounting wall and the adjacent edge of the standard top 3.
FIG. 7 shows a similar section through an extension or backsplash element 4 and a standard top 3 having profiled edge 9 shown here as a full bulnose, and wall tiling 18 The extension or backsplash element 4 is shown here as an extender to extend the width of the standard top 3 to cover a larger gap between the mounting wall and the adjacent edge of the standard top 3.
The extension or backsplash element 4 can be provided in straight lengths or with an internal corner 5 (see FIG. 1), or with an external corner (not shown). This prevents the need for on-site mitring to allow the extension or backsplash element 4 to extend around corners of the supporting wall surface.
FIG. 8 shows the end profile top 6 of the end profile unit. This top 6 is provided adjacent the standard top 3 and an extension or backsplash element 4. A timber batten 19 is optionally used for support of the extension or backsplash element 4.
The end profile top 6 has two profiled edges 9 at 90 degrees to one another.
The end profile top 6 is produced from a rectangular piece of stone or homologous stone-effect material, the minimum width of which allows for the profile size plus the dimension equal to the radius of supporting discs 21 held in slots 20.
The thickness of the end profile top 6 is a standard thickness of slab or sheet of material
The length of the slots 20 is less than the width of the hob slip tops 7 and 8. The height of the slots 20 is marginally greater than the thickness of the supporting discs 21 to allow an adhesive to fill and set. The depth of the slots 20 is not less than the radius of the supporting discs 21, as it intended that 50% of each disc 21 lies within the end profile top 6 and the adjacent top when fixed.
The vertical & horizontal centre lines of the slots 20 are standardise for all tops as shown in FIGS. 9 and 10. The end profile top 6 is used to finish an open end of a sink top 1, corner top 2, standard top 3, or hob slip tops 7 and 8.
The end profile top 6 can be cut to length if need be, as described above. It can be adhered to the adjacent top by means of a polyester resin or an epoxy resin two part adhesive. Adhesives are widely available through the international stone industry. Akemi and Fidal are two well established trade names of these adhesives with world wide distribution.
A standard top 3 is shown in FIG. 9, and this arrangement is also typical for corner tops 2, sink tops 1 and end profile tops 6. Two slots 20 are provided on or substantially on the centreline X.
FIG. 10 shows an end view of the front and rear hob slip tops 7 and 8. The term ‘slip top’ means a top in or on which a hob, cooker or burner unit is mounted, and is also commonly referred to as a ‘cooker top’. Two slots 20 are again provided on the centreline X.
Both front hob slip top 7 and rear slip top 8 are produced from a rectangular area of stone, or stone-effect material as mentioned above, having similar or identical widths, as most hob or drop-in-cooker units are produced to be incorporated into standard size countertops with good tolerances, so it is envisaged that the widths of the hob slips can be standardised.
The thickness of the hob slip tops 7 and 8 are a standard thickness of slab or sheet. The front hob slip 7 has the profiled edge 9. The length of both the front and rear slip tops 7 and 8 is a variable dependant upon the length of the hob (cooker drop in units) but it is envisaged that it will be standardised into two or three lengths equating to 4, 6, or 8 ring hobs.
Each of the tops 1, 2, 3, 6, 7 and 8 described above is produced by supplying a first location with quarried natural stone or homologous stone-effect material. The natural stone is, by way of example, granite, marble, limestone, sandstone, slate or serpentine. The stone-effect material is, by way of example, micro-grain marble or other polymer based material such as Corian RTM or Surell RTM.
Preferably, the stone or stone-effect material supplied to the first location is already in slab or sheet form. However, it may be supplied in a form requiring slabbing.
The stone or stone-effect material is sized at the first location to a standard size selected from one or more predetermined standard sizes. In the case of the sink top 1, the sink bowl aperture or apertures 1 a and at least one tap or faucet aperture 12 are then formed in the sink top 1, still at the first location. The recessed drainage area 10 adjacent the sink bowl aperture(s) 1 a is also formed at the first location.
The top is then finished at the first location before it is supplied to a second location ready for installation. The second location may be, for example, a distributor, a customer's premises, or a wholesaler.
The tops 1, 2, 3, 6, 7, 8 are batch produced at the first location for supply to second installation locations. Different batches will be produced to pre-selected standard sizes, allowing a degree of mixing and matching to suit most, if not all, installation environments.
It is envisaged that the consumer will select the required units including tops, and sizes from the given standard sizes, in addition to taps or faucets and one or more undermount-type sinks suitable for the aperture or apertures 1 a in the sink top 1. This allows the consumer to have a degree of flexibility, while still allowing batch production. At least the tops 1, 2, 3, 6, 7, 8 will then be supplied from the first location from amongst a pre-produced batch of standard tops.
The batch production of tops 1, 2, 3, 6, 7 and 8, including sizing, aperture forming, recessing and finishing, can conveniently be performed by CNC machinery. These processes can thus be automated, and a standard size for a batch of identical or substantially identical tops can be selected from one or more predetermined standard sizes.
Similarly, the extension or backsplash element 4 can be batch produced. As described above, the extension or backsplash element 4 is produced by supplying a first location with quarried natural stone or homologous stone-effect material. The natural stone is, by way of example, granite, marble, limestone, sandstone, slate or serpentine. The stone-effect material is, by way of example, micro-grain marble or other polymer based material such as Corian RTM or Surell RTM.
Preferably, the stone or stone-effect material supplied to the first location is already in slab or sheet form. However, it may be supplied in a form requiring slabbing.
The stone or stone-effect material is sized at the first location to a standard size selected from one or more predetermined standard sizes. If internal corners 5 or external corners are required, these are formed at the first location.
The extension or backsplash element 4 is then finished at the first location before it is supplied to a second location as above.
The extension or backsplash elements 4 are batch produced at the first location for supply to second installation locations. Different batches will be produced to one or more pre-selected standard sizes, allowing a degree of mixing and matching to suit most, if not all, installation environments.
The batch production of the extension or backsplash elements 4, including sizing, corner forming, and finishing, can conveniently be performed by CNC machinery. These processes can thus be automated, and a standard size for a batch of identical or substantially identical extension or backsplash elements 4 can be selected from one or more predetermined standard sizes.
Of course, the batch processes performed by the CNC machinery could be batch performed by hand.
It is preferable, although not essential, that the taps or faucets and undermount sink bowl or bowls selected by the consumer, along with the base carcasses of the units for the tops all be supplied to the consumer from the first location.
Finishing can also be performed at a different location, for example at the installation location.
By the method described above, it is possible to have a run producing only a single unique top or tops. It is also possible to produce a sink top having the undermount sink bowl aperture, the recessed drainage area and only one tap or faucet aperture. In this case, the sink top will not be reversible.
Alternatively, a sink top having an undermount sink bowl aperture and two tap or faucet apertures, without the recessed drainage area is possible.
Additionally, the above-described tops can be produced independently of each other, for example, the sink top does not have to be produced solely for the inclusion as part of a modular kitchen component system. Similarly, the extension or backsplash element can be produced separately of the tops and does not have to be included and used as part of a modular kitchen component system.
The embodiments described above are given by way of examples only, and modifications will be apparent to persons skilled in the art without departing from the scope of the invention as defined by the appended claims.

Claims

1. A kitchen sink top which is produced to a standard size selected from one or more predetermined standard sizes, the kitchen sink top being formed from natural stone or other homologous stone-effect material and, during production, being formed with an aperture suitable for an undermount-type sink bowl, at least one aperture for mounting a tap or faucet, and a recessed drainage area adjacent the sink bowl aperture.

2. A kitchen sink top as claimed in claim 1, wherein two tap or faucet apertures are provided, one of the said tap or faucet apertures being positioned adjacent a first edge of the sink top and the second said tap or faucet aperture being positioned adjacent a second different edge of the sink top, the citing of the tap or faucet apertures allowing the sink top to be installed in two different orientations.

3. A kitchen sink top as claimed in claim 1, wherein at least one edge of the sink top is profiled.

4. A kitchen sink top as claimed in claim 1, wherein the sink top is produced as part of a batch of identical or substantially identical sink tops.

5. A kitchen sink top as claimed in claim 1, further comprising an undermount-type sink bowl.

6. A kitchen sink top which is produced to a standard size selected from one or more predetermined standard sizes, the kitchen sink top being formed from natural stone or other homologous stone-effect material and which, during production, is formed with an aperture suitable for an undermount-type sink bowl, and two apertures for mounting a tap or faucet, one of the two tap or faucet apertures being provided adjacent a first edge of the sink top and the other of the two tap or faucet apertures being provided adjacent a second different edge of the sink top, so that the sink top can be installed in two different orientations.

7. A kitchen sink top as claimed in claim 6, further comprising a recessed drainage area adjacent the sink bowl aperture, the recessed drainage area being formed in the natural stone or other homologous stone-effect material.

8. A kitchen sink top as claimed in claim 6, wherein at least one edge of the sink top is profiled.

9. A kitchen sink top as claimed in claim 6, wherein the sink top is produced as part of a batch of identical or substantially identical sink tops.

10. A kitchen sink top as claimed in claim 6, further comprising an undermount-type sink bowl.

11. A method of batch-producing kitchen sink tops, the method comprising the steps of:

a. supplying a first location with slabs of quarried natural stone and/or sheets of homologous stone-effect material;

b. sizing one said slab or sheet to a standard size selected from one or more predetermined standard sizes at the first location;

c. forming in the one slab or sheet an aperture suitable for an undermount-type sink bowl at the first location;

d. forming in the one slab or sheet at least one aperture for mounting a tap or faucet at the first location;

e. forming in the one slab or sheet a recessed drainage area adjacent the sink bowl aperture at the first location;

f. finishing the sink top at the first location;

g. repeating steps (a) to (f) to form at least one further identical or substantially identical kitchen sink top; and

h. supplying at least one of the finished kitchen sink tops to a second location ready for installation.

12. A method as claimed in claim 11, wherein step (b), step (c), step (d), step (e), and/or step (f) are performed utilising a machining process.

13. A method as claimed in claim 12, wherein the machining process is automated.

14. A method as claimed in claim 11, wherein, in step (h), the finished kitchen sink top and an undermount-type sink bowl are supplied to the second location.

15. An extension or backsplash element which is formed from natural stone or other homologous stone-effect material and which is for use with a kitchen countertop or worktop, the extension or backsplash element having two rear surfaces which extend transversely to each other, and a front face, the two rear surfaces having different dimensions so that the extension or backsplash element can be installed in either of two orientations to cover a gap between a wall and an edge of an installed kitchen countertop or worktop.

16. An extension or backsplash element as claimed in claim 15, wherein the front face is at least one of sculpted, profiled, convex and concave.

17. An extension or backsplash element as claimed in claim 15, further comprising an internal and an external corner to allow extension around a corner of a supporting surface.

18. A method of producing an extension or backsplash element for use with a kitchen countertop or worktop, the method comprising the steps of

a. supplying a first location with quarried natural stone or homologous stone-effect material;

b. sizing the stone or stone-effect material to a standard size selected from one or more predetermined standard sizes at the first location;

c. forming the extension or backsplash element from the sized material at the first location;

d. supplying the extension or backsplash element to a second location.

19. A method as claimed in claim 18, further comprising a step (e) between step (c) and step (d) of finishing the extension or backsplash element at the first location.

20. A method as claimed in claim 18, wherein steps (a) to (d) are repeated to produce a batch of extension or backsplash elements to a single pre-selected standard size.

21. A method as claimed in claim 18, wherein step (b), step (c) and/or step (e) are performed utilising a machining process.

22. A method as claimed in claim 21, wherein the machining process is automated.

23. A modular kitchen component system comprising a sink unit having a sink top in which is provided one or more pre-formed apertures for an undermount-type sink and which is reversible to allow installation in either of two different orientations; a corner unit having a corner top; a standard unit having a standard top; an extension or backsplash unit having internal and/or external corners; end profile units having end profile tops; and hob slip units having hob slip tops, each said top being produced to a standard size selected from one or more predetermined standard sizes and formed from natural stone or other homologous stone-effect material at a production location remote from an installation location at which the modular kitchen component system is to be installed.

24. A system as claimed in claim 23, further comprising an undermount-type sink for attachment to the sink top of the sink unit.

25. A system as claimed in claim 23, wherein the said tops have at least one profiled edge.

26. A system as claimed in claim 23, wherein the said tops are finished at the production location.

27. A system as claimed in claim 23, wherein the said tops are batch-produced to the said selected standard size.

28. A system as claimed in claim 23, wherein the sink top includes a recessed drainage area formed in the natural stone or other homologous stone-effect material.