Stabilized miter edge system and device

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This International PCT application claims the benefit of United States

Non-Provisional Application No. 14/867,385 filed September 28, 2015, and United States Provisional Application No. 62/080,539, filed November 17, 2014.

FIELD OF THE INVENTION

[0002] The present invention relates generally to the field of countertop construction and installation, and more particularly to methods and systems for applying a thicker edge on countertops with a thinner upper surface.

BACKGROUND OF THE INVENTION

[0003] A countertop is a horizontal work surface commonly used in kitchens, bathrooms, and workrooms. Countertops are made in a number of natural and engineered materials. While modern lightweight laminated materials have become popular for low-cost and DIY installations, countertops made from natural or engineered stone materials remain popular for higher-end installations.

[0004] Countertops made from stone materials can be made with an upper surface and attached edges that provide a thicker edge than the upper surface.

Current methods for applying an edge include building up a sandwich construction of layers of stone sheets.

[0005] Build-up of a sandwich construction is time consuming and may expose edges between the layers of sandwiching, which can be hard to hide even after extensive polishing.

[0006] A conventional mitered edge produces better esthetic results, but due to the instability of a miter construction it is difficult and time consuming to install, normally requiring specialized heavy duty clamping devices to hold, align, and apply necessary pressure to the mitered edge against the mitered countertop surface element during gluing. Due to the inherent instability of a conventional miter assembly, there is a limit to how thin the surface and edge components can be made, as otherwise the edge is susceptible to breaking of during normal use, particularly when a lateral force is applied to the edge.

[0007] As such, considering the foregoing, it may be appreciated that there continues to be a need for novel and improved devices and methods for attaching a front edge to a countertop surface.

SUMMARY OF THE INVENTION

[0008] The foregoing needs are met, to a great extent, by the present invention, wherein in aspects of this invention, enhancements are provided to the existing model of countertop edge installation, providing a more stable and flexible edge connection, which can be based on use of a thinner surface element.

[0009] I n an aspect, a stabilized miter edge system can include a top element and an edge element, such that the edge element includes a stabilized miter surface, which connects along a miter surface of the top element and along an elongated rectangular edge portion of the underside of the top element.

[00010] I n a related aspect, the stabilized miter surface provides a connection with enhanced stability, which is configured to lock the edge element in place on the top element, without sliding either vertically or horizontally, thereby serving as a precise locating device.

[00011] I n another related aspect, the stabilized miter surface provides an increased area of connection, which can be stable even when used with thinner materials, than would normally be acceptable with a conventional mitered edge.

[00012] I n another related aspect, the stabilized miter surface can be installed and glued together using only spring clamps, without any need for specialized clamping mechanisms.

[00013] I n various related aspects, the stabilized miter surface can be manufactured from stone materials, including engineered quartz, engineered marble, porcelain, etc.

[00014] There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

[00015] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

[00016] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[00017] FIG. 1 is a perspective view of a stabilized miter edge system in a disassembled configuration, according to an embodiment of the invention.

[00018] FIG. 2 is a perspective view of a stabilized miter edge system in a disassembled configuration, according to an embodiment of the invention.

[00019] FIG. 3 is a perspective view of a stabilized miter edge system in an assembled configuration, according to an embodiment of the invention.

[00020] FIG. 4 is a cross-sectional view of an edge element, according to an embodiment of the invention.

[00021] FIG. 5 is a cross-sectional view of an edge element, according to an embodiment of the invention.

[00022] FIG. 6 is a rear perspective view of an edge element, according to an embodiment of the invention.

[00023] FIG. 7 is a front perspective view of an edge element, according to an embodiment of the invention.

[00024] FIG. 8 is a perspective view of a stabilized miter edge system during installation with clamps applied, according to an embodiment of the invention.

[00025] FIG. 9 is a perspective view of a stabilized miter edge system in a disassembled configuration, according to an embodiment of the invention.

[00026] FIG. 10 is a top view of a stabilized miter edge system in a disassembled configuration, according to an embodiment of the invention.

[00027] FIG. 11 is a perspective view of a stabilized miter edge system in a disassembled configuration, according to an embodiment of the invention. [00028] FIG. 12 is a top view of a stabilized miter edge system in a disassembled configuration, according to an embodiment of the invention.

[00029] FIG. 13 is a perspective view of a stabilized miter edge system during installation with spring clamps applied, according to an embodiment of the invention.

[00030] FIG. 14 is a perspective view of a stabilized miter edge system in a disassembled configuration, according to an embodiment of the invention.

DETAILED DESCRIPTION

[00031] Before describing the invention in detail, it should be observed that the present invention resides primarily in a novel and non-obvious combination of elements and process steps. So as not to obscure the disclosure with details that will readily be apparent to those skilled in the art, certain conventional elements and steps have been presented with lesser detail, while the drawings and specification describe in greater detail other elements and steps pertinent to understanding the invention.

[00032] The following embodiments are not intended to define limits as to the structure or method of the invention, but only to provide exemplary constructions. The embodiments are permissive rather than mandatory and illustrative rather than exhaustive.

[00033] I n the following, we describe the structure of an embodiment of a stabilized miter edge system 100 with reference to FIG. 1, in such manner that like reference numerals refer to like components throughout; a convention that we shall employ for the remainder of this specification.

[00034] I n an embodiment, a stabilized miter edge system 100, for attaching a front edge to a countertop surface, can include: a) a top element 110, shown in an upper perspective view in FIG. 1,

wherein the top element 110, is configured with a top miter surface 215, as shown in FIG. 2, along a front edge of the top element 110, such that the top miter surface is configured with a miter angle 113 in a range of 5 to 85 degrees, between the top miter surface and the upper surface 111 of the top element 110; and b) an edge element 120; wherein the edge element 120 is configured with a stabilized miter surface 122; wherein the stabilized miter surface 122 is configured to connect to the top miter surface 215 and an elongated rectangular edge portion 217 of the underside of the top surface 110, configured such that a miter angle 123 of the edge element 120 is equal to the miter angle 113 of the top element 110, such that a receiving angle 125 of the stabilized miter surface 122 is 180 degrees minus the miter angle 113.

[00035] In a related embodiment, the miter angle 113 can be 45 degrees.

[00036] FIGS. 1 and 2 shows the stabilized miter edge system 100 in a non- assembled configuration, such that the top element 110 and edge element 120 are separate.

[00037] FIG. 2 shows the stabilized miter edge system 100, such that the top element 110 is shown in a lower perspective view, to show the top miter surface 212, and the underside 214 of the top element 110.

[00038] In a related embodiment, as illustrated in FIG. 2,

the edge element 120 can further include: a. a front miter part 224, which comprises a front miter surface 225 on an upper surface of the front miter part 224; and b. a rear stabilizer part 226, which comprises a rear stabilizer surface 227 on an upper surface of the rear stabilizer part 226; and the top element 110 can further include: a. a top miter surface 215, along a front edge of the top element 110; and b. an elongated rectangular edge portion 217 of the bottom side of the top element 110; wherein the top element 110 connects with the edge element 120, such that the front miter surface 225 is configured to connect with the top miter surface 215; such that a vertical miter height 402, as shown in FIG. 4, of the edge element 120 is equal to a thickness 112 of the top element 110; and the rear stabilizer surface 227 is configured to connect with the elongated rectangular edge portion 217.

[00039] In further related embodiments, as shown in FIGS. 1 and 2, the top element 110 can be a substantially rectangular flat piece, which can be solid, and configured with a top miter surface 215 that is configured with a miter angle 113, such that the top element 110 can be an integral piece that can be described as comprised of a rectangular flat piece 252 with a side mounted elongated triangular piece 254.

[00040] In further related embodiments, as shown in FIGS. 1 and 2, the front miter part 224 of the edge element 120 can be a substantially rectangular elongated piece, which can be solid, and configured with a front miter surface 225 that is configured with a miter angle 113, such that the front miter part 224 can be an integral piece that can be described as comprised of a rectangular elongated piece 262 with a top mounted elongated triangular piece 264.

[00041] In further related embodiments, as shown in FIGS. 1 and 2, the rear stabilizer part 226 of the edge element 120 can be a substantially rectangular elongated piece, which can be solid.

[00042] In a related embodiment, as shown in FIG. 3, the edge element 120 can be connected to the top element 110 with an adhesive, such as an epoxy, polyester, silicone, or acrylic adhesive, of a type normally used for gluing natural and engineered stone materials.

[00043] In a related embodiment, the edge element 120 can be manufactured in one piece, such as shown in FIG. 1, such that it can for example be cut from one piece of a stone material, or alternatively, such as shown in FIGS. 2 and 3, it can be assembled from multiple pieces that are glued together. Further, the edge element can consist of a single or multiple laminated parts. A laminated edge element can include a surface material that can be different from a substrate or inner core material, such as for example of a lower grade or less expensive.

[00044] Cutting a stone material, such as engineered quartz, produces significant back pressure and vibration, such that a part must be precisely and securely held at all times to keep the part from "wandering" or "shattering". In related embodiments, wherein the edge element 120 is manufactured in one piece that is cut from a stone material, existing well-known cutting tools and equipment are generally not well suited for manufacturing, which may instead have to rely on custom designed equipment.

[00045] In a related embodiment, FIG. 4 shows a cross-sectional view of the edge element 120, showing a: a. A vertical miter height 402; b. A front face height 404; c. A depth 406;

[00046] In a related embodiment, FIG. 1 shows a length 108 of the edge element 120.

[00047] In a related embodiment, FIG. 1 shows a thickness 112 of the top element 110.

[00048] In a first further related example embodiment, as shown in FIGS. 1 and

4, an edge element 120 can be configured with: a. a length 108 of 307 cm; b. a vertical miter height 402 of 1.25 cm; c. A front face height 404 of 6.05 cm; d. A depth 406 of 3 cm; which fits to a top element 110 with a thickness 112 of 1.25 cm and a length of the top miter surface 215 of 307 cm, with a matching miter angle 113 of 45 degrees.

[00049] In a first further related example embodiment, an edge element 120 can be configured with: a. a length 108 of 307 cm; b. a vertical miter height 402 of 1.25 cm; c. A front face height 404 of 3.05 cm; d. A depth 406 of 3 cm. which fits to a top element 110 with a thickness 112 of 1.25 cm and a length of the top miter surface 215 of 307 cm, with a matching miter angle 113 of 45 degrees.

[00050] In a related embodiment, the top element 110 can be configured with a thickness 112 in a range of 0.75 - 3 cm.

[00051] In a related embodiment, the top element 110 can be configured with a front face height 404 in a range of 2 - 15 cm.

[00052] In various related embodiments, the stabilized miter edge system 100 can be manufactured in a large plurality of dimensions, as suited for particular applications. For example for some commercial use countertop installations, the front face height 404 can be up to 250 mm or higher. [00053] Similarly, in embodiments for use of the stabilized miter edge system 100 in prefabricated building construction, the top element 110 thickness 112 can be configured in a range of 3 - 20 inches, to form a floor element and the front face height 404 can be up to 8-12 feet, to form a wall element. Such a stabilized miter edge system 100 can for example be made with a sandwich/composite construction with rigid foam between high-strength sheets of polymer, glass fiber, and/or carbon fiber, or other lightweight and high-strength construction components.

[00054] In a related embodiment, FIG. 5 shows that a cut of the front miter surface 225 can be slightly deeper than the level of the rear stabilizer surface 227, such that the cut of the front miter surface 225 for example can be about 1 mm deeper than a level of the rear stabilizer surface 227.

[00055] In a related embodiment, FIG. 6 shows a rear perspective view of the edge element 120, further showing the back surface 602 of the edge element 120, also referred to as the back 602.

[00056] In a related embodiment, FIG. 7 shows a front perspective view of the edge element 120, further showing the front face surface 704 of the edge element 120, also referred to as the face 704. In typical applications, the face 704 can be clean polished.

[00057] In a related embodiment, the stabilized miter edge system 100 decreases the degree of difficulty in attaching a mitered type edge to countertops, cabinet tops, worktops, desktops, casework, and fixture applications.

[00058] In a related embodiment, as shown in FIG. 8, the stabilized miter edge system 100 eliminates the need for complex bi-directional clamping during the gluing and installation process, requiring only simple uni-directional spring clamps 802. As shown, the stabilized miter edge system 100 can be clamped together by application of spring clamps or similar uni-directional between the top surface of the top element 110 and the bottom surface of the edge element 120, whereas in earlier methods and systems complex and expensive clamping devices are attached to a front and top of a countertop with a conventional miter construction, to provide both vertical and horizontal clamping action.

[00059] In an embodiment, as shown in FIG. 2, the edge element 120 can be manufactured with ends that have a straight cut-off angle 240.

[00060] In a related embodiment, as shown in FIGS. 3 and 8, which both show an edge element 120 with a straight cut-off angle, the straight cut-off angle creates a flush surface of the end of the edge element 120 flush with the end of the top element 110. The resulting combined end can be capped with an end-cap, which can be applied according to conventional methods for applying end-caps to a countertop.

[00061] In related embodiments, use of edge elements 120 with a straight cutoff angle is particularly useful for do-it-yourself home projects and other projects that are not custom designed, but rely on in-place fitting of parts to the particular dimensions needed. An installer can purchase edge elements 120 with straight cut-off angles in both ends of each edge element, and then make a straight cut to a selected end to a measured length, such that the new end has a straight cut-off angle.

[00062] In another related embodiment, the stabilized miter edge system 100 allows for the countertop surface to be a thinner, lighter and less expensive material than in a traditional miter construction, due to the increased stability of the stabilized miter edge system 100

[00063] In a further related embodiment, the edge element 120 can be thicker and stronger than in a conventional miter construction, creating the look of a more expensive countertop material when viewed in the direction of the face 704 of the edge element 120. [00064] In related embodiments, the top element 110 and the edge element 120 can be made from

a. stone materials, including

i. granite;

ii. marble;

iii. engineered marble;

iv. porcelain;

v. ceramic tile;

vi. engineered quartz, such as Silestone™;

vii. glass; agglomerated materials

viii. other natural stone materials;

ix. other engineered stone materials;

x. agglomerated materials; and

xi. combinations thereof;

b. other well-known countertop materials, including:

i. countertop laminate materials.

[00065] In a related embodiment, the top element 110 and the edge element 120 in a configuration using stone materials can be cut and shaped with custom designed diamond cutter based tooling.

[00066] In a related embodiment, the stabilized miter edge system 100 has a number of unique characteristics and advantages, which include that the stabilized miter edge system 100:

a. Facilitates locating, locking and aligning the face of the edge at the desired angle relative to the face of the deck and allows for easy edge positioning and a tight miter joint; b. Allows adhesive to be applied with maximum ease and minimum

waste; c. I ncreases the area of seam for adhesion and consequently increases the strength of the joint; d. Has a geometry which increases front edge resistance to direct face pressure; e. Allows edge profiles to be thicker and/or higher, while increasing

structural integrity without requiring the use of a thicker deck material.

[00067] I n an embodiment, as shown in FIG. 9, a stabilized miter edge system 900 can include edge elements 120 manufactured with mitered cut-off angles, such that a first edge element 920, which includes a mitered cut-off angle, matches with the mitered cut-off angle of a second edge element 930, when mounted on first and second sides of a top element 910, such that the first and second sides respectively com prise adjoining first and second top miter surfaces 1015 1016.

[00068] I n a related embodiment, FIG. 10 shows a top view of the top element 910, the first edge element 920, and the second edge element 930, with a mitered cut-off angle of 45 degrees, which matches the adjoining angle of the first and second top miter surfaces 1015 1016; a. wherein the top element 910 connects with the first and second edge elements 920 930, b. such that the first and second front miter surfaces 1025 1035 are

configured to connect with respectively the first and second top miter surface 1015 1016; and c. such that the first and second rear stabilizer surfaces 1027 1037 are configured to connect with respectively the first and second elongated rectangular edge portion 1017 1018.

[00069] I n a related embodiment, FIG. 11 shows a perspective view of the top element 910, the first edge element 920, the second edge element 930, a third edge element 1140, and a fourth edge element 1150, such that all edge elements have mitered cut-off angles of 45 degrees in both ends, which match the adjoining angles top miter surfaces of the top element 910. FIG. 11 shows all edge elements separate from the top element 910, prior to installation on the edges of the top element 910.

[00070] FIG. 12 shows a top view of the embodiment shown in FIG. 11.

[00071] I n further related embodiments, such as illustrated in FIGS. 11 and 12, edge elements 920 930 1140 1150 can be pre-manufactured with custom lengths, such that each edge elements have first and second ends manufactured with a mitered cut-off angle, such that the edge elements fit to a custom size pre- manufactured top element 910, without the need for any end-cap.

[00072] I n a related embodiment, FIG. 13 shows a perspective view of the stabilized miter edge system 900 wherein the first and second edge elements 920 930 have been glued and clamped together with light-duty conventional clamping devices 802, here shown as spring clamps 802, such that a second end of the first edge element 920 with a mitered cut-off angle, has been connected in a corner to a first end of the second edge element 930 with a matching mitered cut-off angle. As shown, the stabilized miter edge system 900 can be clamped together by application of light- duty uni-directional clamps between the top surface of the top element 910 and the bottom surfaces of the edge elements 920 930, whereas in earlier methods and systems complex and expensive clamping devices are typically attached to a front and top of a countertop with a conventional miter construction.

[00073] FIGS 1-13 illustrate embodiments wherein, as shown in FIG. 2, a lower end 235 of the front miter part 224 is flush with a lower end 237 of the rear stabilizer part 226. Such embodiments are convenient to manufacture in one-piece, and have a high-degree of strength and stability.

[00074] In a related alternative embodiment, as shown in FIG. 14, a lower end 1435 of a front miter part 1425 can protrude below a lower end 237 of the rear stabilizer part 226. Such embodiments are practical to manufacture mainly when the front miter part 1425 is connected to the rear stabilizer part 226 with an adhesive.

[00075] Here has thus been described a multitude of embodiments of the stabilized miter edge system and methods related thereto, which can be employed in numerous modes of usage.

[00076] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention, which fall within the true spirit and scope of the invention.

[00077] Many such alternative configurations are readily apparent, and should be considered fully included in this specification and the claims appended hereto. Accordingly, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and thus, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.