Countertop installation

Abstract

Aspects of the present invention provide devices and methods for countertop installation. The countertop installation device may include a housing, a rim extending outward from the housing, the rim connectable to a frame, a movable tongue disposed to move along a first axis of a shaft and extend from the housing, and an adjustment screw configured to adjust the location of the movable tongue along a second axis. During installation of the device, the first axis may be a horizontal axis and the second axis may be a vertical axis.

Description

[Technical field]

[0001] The present invention relates generally to devices and methods for countertop installation, and more specifically, the present invention relates to countertop installation devices and methods for easy installation, removal, and adjustment thereof. [Background technology]

[0002] Countertops usually refer to the horizontal surface of a kitchen, furniture, bathroom, or other table. It is frequently installed on and supported by a cabinet framework. The countertop surface is typically positioned at the optimum height for which the countertop is designed. Countertop surfaces can be composed of a variety of materials with different attributes and aesthetics. For example, countertop surfaces can be natural or artificial stone or other materials. Traditional countertops, both natural and manmade, are often heavy and require professional installers to install. For example, for natural materials, specialized equipment is required to cut, measure, and polish materials such as granite. Additionally, granite slabs are very heavy and require upright vertical positioning if not supported horizontally to prevent the slab from cracking or breaking. Also, typically, at least two people are required to transport and install the slab as a countertop. Laminate and similar countertops are heavy and cumbersome to handle. Additionally, these countertops have other drawbacks. For example, special tools, and adhesives or other bonding agents are required to fit and install these countertops. The bonding agents can release harmful fumes, thereby necessitating adequate ventilation during the curing process. The overall process of installing laminate countertops is time and labor intensive.

[0003] Another drawback is the difficulty of removing the countertop to install a new one, which usually involves breaking the countertop and can cause damage to the framework, walls or other kitchen items.

[0004] Another major problem in countertop installation is joining adjacent stone slabs together so that the seam is invisible. The two slabs should ideally be perfectly abutted along the entire seam and exactly the same height, allowing the user to feel and see the slabs as one continuous piece of stone. However, in reality, nothing is perfect. Prior art techniques require significant effort to align and abut the joining slabs, and the slabs are heavy and cumbersome, making aligning and abutting them a major challenge. Summary of the Invention

[0005] Aspects of the invention provide devices and methods for the installation of countertops, such as stone countertops, that, among other things, allow for easy removal of the countertop and installation of a new one in place of the previous one. In all embodiments, the countertop may not be coupled to any framework or wall. In some embodiments, the countertop may be attached to brackets, such as with mechanical fasteners, but not to a framework, allowing for easy removal and replacement.

[0006] Some embodiments provide a countertop leveling and joining device that can be attached to a framework and provides an easy and convenient device for joining and leveling adjacent stone slabs, a major challenge in the prior art.

[0007] Thus, in accordance with certain non-limiting embodiments of the present invention, there is provided a method for installing a countertop, comprising attaching a mechanical interface to at least one of a cabinet framework and a wall, and fastening the countertop directly to the mechanical interface without being directly attached to the cabinet framework or the wall.

[0008] The method may further include removing the countertop from the mechanical interface and installing a different countertop in its place.

[0009] Some aspects of the invention may be directed to a countertop installation device comprising a housing, a rim extending outwardly from the housing, the rim being connectable to a frame, a movable tongue disposed to move along a first axis of the shaft and extend from the housing, and an adjustment screw configured to adjust a location of the movable tongue along a second axis. In some embodiments, during installation of the device, the first axis may be a horizontal axis and the second axis may be a vertical axis.

[0010] In some embodiments, the countertop installation device may further include an adjustment unit for adjusting a location of the movable tongue along the first axis. In some embodiments, the adjustment unit may include a threaded shaft. In some embodiments, the adjustment unit may include a shaft, a gear, and a gear screw configured to rotate the gear and the shaft.

[0011] In some embodiments, the countertop installation device may further include a slotted plate configured to be attached to the countertop, the slotted plate may include a slot configured to receive the movable tongue.

[0012] In some embodiments, the countertop installation device may further include a telescoping frame configured to mount the countertop installation device. In some embodiments, the telescoping frame may be configured to mount two or more countertop installation devices.

[0013] Some other aspects of the invention may be directed to a lateral countertop installation device comprising a framework bracket and a countertop interface member coupled to the framework bracket by a flexible member. In some embodiments, the countertop interface member may be configured to be received by one of a slot in the slotted plate and a groove in the countertop.

[0014] In some embodiments, the horizontal countertop installation device may further include a slotted plate configured to be attached to a countertop, the slotted plate including a slot configured to receive the countertop interface member.

[0015] Some additional aspects of the present invention may be directed to a bracket member comprising a wall interface member and a wall piece support member extending perpendicularly from the wall interface member and configured to provide spacing between the countertop and a wall piece thereover.

[0016] In some embodiments, the bracket member may further include a countertop support member extending perpendicularly from the wall interface member and configured to support a countertop, hi some embodiments, the bracket member may further include a smoothing element located between the wall interface member and the wall.

[0017] Some additional aspects of the invention may be directed to a sink installation device comprising a sink wall mount member configured to be attached to a wall of a sink and a pusher element disposed for linear movement within a threaded housing. In some embodiments, the threaded housing may include a mating element that mates with a receiving element on the sink wall mount member.

[0018] Some additional aspects of the invention may be directed to a method for installing a countertop including attaching a bracket member to at least one of a cabinet framework and a wall, and fastening the countertop directly to the bracket member without directly attaching the countertop to the cabinet framework or the wall.

[0019] In some embodiments, the method may further include removing the countertop from the bracket member and installing a different countertop in its place.

[0020] Some additional aspects of the invention may be directed to a method for adjusting a position of a countertop slab relative to another countertop slab, comprising mounting a countertop installation device to a cabinet framework. In some embodiments, the countertop installation device may include a movable tongue arranged to move along a first axis, the tongue being received in a slot. In some embodiments, moving the tongue along the first axis may adjust the position of the countertop slab along the first axis. In some embodiments, the countertop installation device may include an adjustment screw arranged to move the countertop slab along a second axis perpendicular to the first axis, and adjusting the position of the countertop slab relative to another countertop slab is performed by moving the tongue and the adjustment screw to adjust the position of the countertop slab along the first axis and the second axis, respectively. In some embodiments, the countertop installation device includes a telescoping frame mounted to the cabinet framework. [Brief description of the drawings]

[0021] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of this specification, however, the invention, both as to organization and method of operation, together with its objects, features, and advantages, may best be understood by reference to the following detailed description when read in connection with the accompanying drawings, in which:

[0022] [Figure 1A-1C] 1 is a diagram of a countertop installation device according to a non-limiting embodiment of the present invention. [Figures 2A-2E] FIG. 13 is a diagram of a countertop installation device according to another non-limiting embodiment of the present invention. [Figure 3A-3B] 2A-2E depict an installation of a countertop comprising the embodiment of FIGS. 2A-2E. FIG. [Figure 4A-4C] FIG. 13 is a diagram of a countertop installation device according to another non-limiting embodiment of the present invention. [Figure 5A-5C] 2A-2E are diagrams of a telescoping frame onto which the mechanical fasteners of FIGS. 2A-2E can be mounted, according to some non-limiting embodiments. [Figures 6A-6D] 1A-1C are diagrams of a tool for placing a slotted plate for a countertop installation device, according to some non-limiting embodiments of the present invention. [Figure 7A-7D] FIG. 13 is a diagram of a countertop installation device according to another non-limiting embodiment of the present invention.

[0023] It will be understood that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.

[0025] It should be noted that terms such as horizontal, vertical, top, bottom, etc., refer to the drawings and are not limiting. It should be understood that these terms refer to the orientation of an element during installation or operation and may refer to absolute directions such as gravity, such that the vertical direction is parallel to the direction of gravity and the horizontal direction is perpendicular to gravity.

[0026] Some aspects of the present invention are directed to installation devices, tools, and methods for countertop installation. For example, countertop installation in a kitchen requires precise placement of the countertop. In some embodiments, using an installation device according to an embodiment of the present invention may allow simple assembly and disassembly of the countertop to both the cabinet and the wall. Using such insulation devices and methods may further allow precise height alignment and adjustment of the countertop plates to the cabinet and each other.

[0027] Reference is now made to Figures 1A, 1B, and 1C, which show a countertop installation device 10, according to a non-limiting embodiment of the present invention.

[0028] The system 10 may include a countertop 20 and a bracket member 12 including a wall interface member 13 and a wall piece support member 15 extending perpendicularly from the wall interface member 13. In some embodiments, when the bracket member 12 is assembled, the wall piece support member 15 may be located above the countertop 20. In some embodiments, the bracket member 12 may further include a countertop support member 14. A non-limiting example of a bracket member having only a wall interface member and a wall piece support member is shown in FIG. 1C. The countertop support member 14 may support the countertop 20 and may be spaced further away from the wall piece support member 15 to allow insertion of the countertop 20 between the wall piece support member 15 and the countertop support member 14. According to some embodiments, the countertop support member 14 may protrude further from the wall interface member 13 than the wall piece support member 15. The countertop support member 14 does not have to protrude beyond the end of the wall interface member 13 ; instead, a portion of the wall interface member 13 may extend beyond (below) the countertop support member 14 .

[0029] In FIG. 1A, the bracket member 12 may be secured (e.g., with fasteners such as screws) to the cabinet framework 16 and / or the wall 18. In FIG. 1B, a countertop 20 is installed on the bracket member 12. The countertop 20 may be natural, such as granite, quartz, onyx, marble, sandstone, bluestone, limestone, and other natural materials, or manmade, such as concrete, laminate, acrylic, or other manmade materials in a variety of colors and patterns. The countertop 20 may be formed with an undercut surface 22 along its edge for the length of the countertop support member 14. Thus, the undercut surface 22 rests on the countertop support member 14. The space between the countertop support member 14 and the wall piece support member 15 is designed to accommodate the thickness of the countertop 20. A non-adhesive sealant, such as RTV or other suitable material, may be used to seal the countertop 20 to the bracket member 12.

[0030] FIG. 1C is a diagram of bracket member 12a according to some embodiments. Bracket member 12a may include a wall interface member 13 and a wall piece support member 15 extending perpendicularly from wall interface member 13. Bracket member 12a may not include a countertop support member, such as countertop support member 14 of FIG. 1A, and thus, use of bracket member 12a may not require forming an undercut (such as undercut 22) in countertop 20. In some embodiments, wall piece 24 may be installed on wall 18 above countertop 20, such as with RTV or other suitable base material, as before. Wall piece 24 may rest on wall piece support member 15. In some embodiments, wall interface member 13 may further include a smooth member 19 on a face of interface member 13 opposite the face from which wall piece support member 15 protrudes, such that when bracket member 12 is installed, smooth member 19 may be positioned between wall interface member 13 and wall 18. The spacers 19 may be made from any suitable material for providing a smooth or even surface to the wall 18 .

[0031] Reference is now made to Figures 2A, 2B, 2C, 2D and 2E, which show countertop installation devices 30 and 30a, according to another non-limiting embodiment of the present invention. Devices 30 and 30a can be useful for leveling and abutting adjacent countertop sections.

[0032] 2A and 2B are top and bottom views of a countertop installation device 30 that may include a movable tongue 32 that may be arranged to move along a first axis 33. The countertop installation device 30 may include an adjustment unit 31 for adjusting the location of the movable tongue 32 along the first axis 33. For example, as can be seen in FIG. 2B, the tongue 32 may be mounted on a threaded shaft 34 included in the adjustment unit 31, which may be secured to an underside of a housing 36. The tongue 32 may protrude through a notch 38 formed in the housing 36. A rim 37 may extend outwardly from the housing 36. In some embodiments, the first axis 33 may be parallel to the axis of rotation of the shaft 34. An adjustment screw 40 (FIG. 2B) may be provided on the underside of the housing 36, or the like. The adjustment screw 40 may be configured to adjust the location of the movable tongue 32 along a second axis 43. In some embodiments, during installation of the device, the first axis 33v may be a horizontal axis and the second axis 34 may be a vertical axis.

[0033] 2C and 2D are bottom and top plan views of a countertop installation device 30a that may include a movable tongue 32a that may be arranged to move along a first axis 33 parallel to the axis of rotation of a shaft 34a. For example, the tongue 32 may be attached to an adjustment unit 31a arranged to move the movable tongue 32a. The adjustment unit 31a may include a shaft 34a, a gear 304, and a gear screw 46 configured to rotate the gear 304 and the shaft 34a. Turning the gear screw 46 may rotate the gear 304, and thus the shaft 34a, to move the movable tongue 32a along the axis 33.

[0034] In some embodiments, to avoid the need to form slots 44 in the countertop 20 for receiving the movable tongue 32a (or the movable tongue 32), the device 30a (or the device 30) may further include at least one slotted plate 100. During installation, the slotted plate 100 may be attached (e.g., screwed, glued, pasted) to the underside of the countertop 20. The slotted plate 100 may include a slot 107 for receiving the movable tongue 32a (or the movable tongue 32). Thus, during installation of the countertop 20, the location of both the movable tongue 32a and the slotted plate 100 may be adjusted to achieve optimal joining of adjacent countertop portions. A detailed disclosure discussing the structure and installation of the slotted plate 100 is provided below with respect to Figures 4C and 6A-6D.

[0035] As can be seen in FIG. 2E, the countertop installation device 30 can be installed in a groove 42 formed on the underside of the framework 16. In some embodiments, the countertop installation device 30a (not shown) can be installed in a groove 42 formed on the underside of the framework 16. The housing 36 or 36a (not shown) can fit into the groove 42, and the rim 37 or 37a (not shown) can be fastened to the underside of the framework 16. The countertop 20 can be formed with a slot 44 configured to receive the tongue 32. Alternatively, a slotted plate 100 can be attached to the underside of the countertop 20. For example, turning the threaded shaft 34 can adjust the horizontal position of the tongue 32 within the slot 44, thereby adjusting the joining of adjacent countertop portions. In other words, when the tongue 32 is placed within the slot 44 of the countertop 20 (or the slot of the plate 100, not shown), adjusting the horizontal position of the tongue 32 can move the countertop 20 in the same direction to allow the joining of adjacent countertop portions.

[0036] Turning the adjustment screws 40 or 48 (shown in Figures 2B and 2C, respectively) can be used to press the ends of the screws against the undersides of the countertop portions to adjust the vertical position of the countertop portions. In this manner, adjacent countertop portions can be easily aligned by adjusting the height of the screws 40 or 48 relative to the countertop portions, and joined to adjust the horizontal position of the tongues 32 to achieve a seamless joint.

[0037] Further, reference is made to Figures 3A and 3B, which are illustrations of the installation of the undertop 20 using the countertop installation device 30 or 30a. In Figure 3A, a groove 42 is prepared in the framework 16 to receive the mechanical fastener (countertop installation device 30 or 30a). In Figure 3B, the countertop 20 can be placed on the framework 16. As seen from below the framework 16, the countertop installation device 30 or 30a can be placed in the hole 42. Thus, in some embodiments, each installation device 30 or 30a can be attached to the framework 16 and is easily accessible to achieve a seamless joint. In some embodiments, the countertop 20 can include a slot 44 for receiving the movable tongue 32 or 32a. In some embodiments, a slotted plate 100 can be attached to the underside of the countertop 20, which can thus replace the need to form the slot 44 before assembling the countertop 20.

[0038] Reference is now made to Figures 4A, 4B and 4C, which show horizontal countertop installation devices 50 and 50a, according to another non-limiting embodiment of the present invention.

[0039] 4A, countertop 20 may be formed with a groove 57 into which countertop interface member 54 is received. Adjustment screws 58 may be tightened against framework bracket 52 to press countertop interface member 54 against groove 57 and secure countertop 20 in place. Fasteners may be used with cabinets with or without horizontal support.

[0040] As can be seen in FIG. 4B, the horizontal countertop installation device 50 may include a framework bracket 52 and a countertop interface member 54 coupled to the framework bracket 52 by a flexible member 56, such as a U-shaped resilient member. An adjustment screw 58 may be coupled to the countertop interface member 54, such as by threaded engagement with a threaded hole 59. The adjustment screw 58 may abut a portion of the framework bracket 52. Movement of the adjustment screw 58 relative to the framework bracket 52 may cause the countertop interface member 54 to move further away from the framework bracket 52, and vice versa, as can be seen in FIG. 4B.

[0041] In some embodiments, to avoid the need to form a groove 57 on the underside of the countertop 20, a slotted plate 100 may be added to the lateral countertop installation device 50 or 50a, as shown in FIG. 4C. The slotted plate 100 may include a slotted base 102 with a slot 107 for receiving the countertop interface member 54 or countertop interface member 54a (or a movable tongue as discussed herein above) of the device 50a. The slotted plate 100 may further include attachment means for attaching (e.g., screwing, gluing, sticking, etc.) the slotted plate 100 to the underlying countertop 20, for example, into the hole 103 shown.

[0042] As should be understood by one of ordinary skill in the art, the rounded base 102 of the plate 100 shown in Figures 2D and 4C is given by way of example only, and the base 102 may have any geometric shape, such as a rectangle, a triangle, an arrow, etc.

[0043] 4C, device 50a may include countertop interface member 54a coupled to framework bracket 52a by flexible member 56a. In such an arrangement, no other elements are required and framework bracket 52a may be secured to a framework (e.g., framework 16) by, for example, screws, such that countertop interface member 54a may be received in slot 107 or groove 57.

[0044] In some embodiments, slotted plate 100 may also be included in device 50 (not shown). In such case, slotted plate 100 may be attached to the underside of countertop 20 and countertop interface member 54 may be inserted into slot 107. Tightening adjustment screws 58 against framework brackets 52 may compress countertop interface member 54 against slot 107 to attach countertop 20 in place. Fasteners may be used with cabinets with or without horizontal support.

[0045] Reference is now made to Figures 5A, 5B and 5C. In some cases, a horizontal cabinet framework for mounting or mounting the countertop installation device is not available. In some embodiments, the countertop installation device 30 or 30a may include a telescoping frame 60a, 60b and / or 60c for mounting the countertop installation device 30 or 30a of Figures 2A-2D (or any other countertop installation device of the present invention) thereon. As can be seen in Figure 6A, the telescoping frame 60a may include a telescoping bar 62 that can be adjusted (i.e., lengthen or shorten the overall length of the bar) to fit any installation requirement. The telescoping frame 60a may further include one or more housings 64 mounted on the telescoping bar 62 and configured to move along the longitudinal axis of the telescoping frame 60a. Each housing 64 may include an opening 66 for receiving and holding the countertop installation device 30 or 30a. Thus, the position of the installation device 30 or 30a may be adjusted when joining adjacent countertop slabs.

[0046] A similar arrangement can be achieved using the slidable firm 63 and 69 of the telescoping frames 60b and 60c shown in Figures 6B and 6C, respectively. The telescoping frame 60b may further include two or more housings 65 mounted on the slidable firm 63, each having an opening 67 for receiving and holding the countertop installation device 30 or 30a. The telescoping frame 60c may include a single housing 68 mounted on a slidable firm 69 having an opening 67, as in the telescoping frame 60b. The housings 65 and 68 may be configured to move along the longitudinal axis of the telescoping frames 60d and 60c, respectively.

[0047] 6A, 6B, 6C, and 6D, which are illustrations of tools for mounting the slotted plate 100 within a framework according to some embodiments of the present invention. Tools 600 and 610 can allow for precise installation of the slotted plate 100 onto the underside of the countertop 20.

[0048] 6A and 6B, a tool 610 may be used to mount the slotted plate 100 to the telescoping frames 60a, 60b, or 60c. The tool 610 may include a holder 614 for holding the slotted plate 100 and a handle 612 that is held by a user to mount the slotted plate 100.

[0049] 6C and 6D , a tool 600 may be used to place the slotted plate 100 against a wall of the cabinet framework 16 so as to maintain a substantially right angle between the base 102 of the plate 100 and the wall. The tool 600 may include a holder 602 for holding the plate 100 and a placer 604 for ensuring a right angle between the base 102 of the plate 100 and the wall of the framework 16.

[0050] Reference is now made to Figures 7A, 7B and 7C, which show a sink mounting device 70.

[0051] 7A and 7B, sink installation device 70 may include a sink wall mounting member 72 that may be attached to the wall of sink 82, such as by an adhesive backing 73. Sink installation device 70 may include a pusher element 74, such as a threaded rod that is disposed for linear movement within a threaded housing 76. Housing 76 may include a mating element 77 that mates with a receiving element 78 on wall mounting member 72.

[0052] 7C shows sink installation device 70 mounted to the wall of sink 82 below countertop 80. Sink wall mounting member 72 may be mounted to the wall of sink 82. A mating element of housing 76 may be received in receiving element 78 of sink wall mounting member 72. Pusher element 74 may be moved so that it abuts the underside of countertop 80. As can be seen in FIG. 7D, a rim of sink 82 may rest on countertop 80. Pusher element 74 may press the underside of countertop 80 against the rim to secure sink 82 in place.

[0053] While certain features of the invention have been described herein, many modifications, substitutions, changes, and equivalents will occur to those skilled in the art, and it is therefore to be understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit of the invention.

Claims

1. 1. A countertop mounted device comprising: Housing and a rim extending outwardly from the housing, the rim being connectable to a frame; and a movable tongue disposed to move along a first axis of the shaft and to extend from the housing; an adjustment screw configured to adjust the location of the movable tongue along a second axis; Equipped with During installation of the device, the first axis of the shaft is a horizontal axis and the second axis is a vertical axis. Countertop installation device.

2. The countertop installation device of claim 1 , further comprising an adjustment unit for adjusting a location of the movable tongue along a first axis of the shaft.

3. The countertop installation device of claim 2 , wherein the adjustment unit comprises a threaded shaft.

4. The countertop installation device of claim 2 , wherein the adjustment unit comprises a shaft, a gear, and a gear screw configured to rotate the gear and the shaft.

5. The countertop installation device of any one of claims 1 to 4, further comprising a slotted plate configured to be attached to a countertop, the slotted plate comprising a slot configured to receive the movable tongue.

6. The countertop installation device of any one of claims 1 to 5, further comprising a telescoping frame configured to mount the countertop installation device.

7. The countertop installation device of claim 6 , wherein the telescoping frame is configured to mount two or more countertop installation devices.

8. 1. A method for adjusting the position of a countertop slab relative to another countertop slab, comprising: Attaching the countertop mounting device to a cabinet framework; the countertop installation device includes a movable tongue disposed for movement along a first axis of the shaft, the tongue being received in the slot; moving the tongue along the first axis adjusts a position of the countertop slab along the first axis; the countertop installation device includes an adjustment screw arranged to move the countertop slab along a second axis perpendicular to the first axis, and adjusting the position of the countertop slab relative to another countertop slab is performed by moving the tongue and the adjustment screw to adjust the position of the countertop slab along the first axis and the second axis, respectively; method.

9. The method of claim 8 , wherein the countertop installation device comprises a telescoping frame attached to the cabinet framework.

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