AND FRAME ASSEMBLY

Field of the Invention

The present invention relates to a technique which enables an accessory and frame assembly to be mounted in a countertop. The accessory may for example be a sink, a stovetop or a kitchen fan and to a countertop comprising such an accessory and frame assembly.

Background of the Invention

Every year, around 3 million kitchens are produced in Europe, and most kitchens include a countertop comprising at least one sink, a stovetop and occasionally an overmounted kitchen fan. Countertops may be provided in a wide range of materials such as wood, stone, laminate materials, ceramics etc., and there are also a vast number of different sinks, stovetops and kitchen fans available. As regard sinks, they can be mounted in a countertop in different ways, such as undermounting and overmounting. Given the wide range of options, it is not possible to manufacture and store countertops satisfying the needs and requirement of the customers.

Moreover, the need to manufacture a countertop on-demand based on customer wishes increases both the cost and waiting times.

Some sink and countertop combinations are assembled in place in the kitchen while other combinations are premade and shipped to the customer.

A countertop with an attached sink is both bulky and sensitive to impact, thereby making it difficult and costly to ship, even if a number of identical countertops and sinks can be shipped together on e.g. a pallet. Furthermore, the bulky packaging methods which are required to ensure that the sink is not damaged leads to an increased environmental impact as a result of the high shipping volume. Accordingly, even though much effort is put into proper packaging, which in itself is costly and time consuming, there is a high risk for damage during transportation. Summary

In view of above-mentioned and other drawbacks of the prior art, it is an object of the present invention to provide an improved countertop and sink assembly which among other things simplifies shipping and handling.

According to a first aspect of the invention, there is provided a modular accessory and frame assembly for mounting in an opening of a countertop. The accessory and frame assembly comprising: a frame consisting of a vertical portion, a first horizontal portion extending in a first direction from a first end of the vertical portion and a second horizontal portion extending in a second direction from a second end of the vertical portion, the second direction being opposite the first direction, the first horizontal portion being configured to be attached to a countertop; an accessory comprising a flange located at an upper portion of the accessory, the flange being configured to rest on an upper side of the second horizontal portion of the frame, and wherein the accessory further comprises flexible self-engaging fastening means for securing the accessory to the frame, wherein the fastening means are configured to engage with the second horizontal portion when accessory is lowered into the frame.

The accessory will in the following be represented by a sink and to a corresponding sink and frame assembly, but the accessory may also be a stovetop or a kitchen fan.

The modularity of the sink and frame assembly is provided in that the configuration of the frame and the sink makes it possible to mount the sink in a countertop in any desirable way, i.e. either overmounting, undermounting or in-plane mounting without any modifications or adaptations to the frame and sink.

The self-engaging fastening means of the sink are operable to secure the sink to the frame, and thereby to the countertop when the frame is attached to a countertop, without the use of any tools and without the need for specific installation be the user. In other words, once the sink has been lowered into the frame, the self-engaging fastening means engage the frame to secure the sink. A certain downward force may have to be applied to properly mount the sink in the frame.

The present invention is based on the realization that manufacturing, packaging and distribution of countertops with sinks can be significantly simplified by a modular assembly where a countertop can be shipped with an attached frame, and where the sink can be attached once the countertop is installed and in place in e.g. a kitchen. Accordingly, the countertop can be sold, manufactured, packaged, shipped and delivered to the customer separately from the sink. Moreover, by means of the described design of the frame, there is no need for different mounting arrangements for different types on installations, meaning that only one frame design is needed for accommodating all installation options.

The size of the frame is preferably adapted to the size of the cabinet, in particular to standard sizes of kitchen cabinet, such as a 40 cm or 60 cm wide cupboard. Moreover, the described frame may also be used for stovetops and kitchen fans. Preferably, the same frame can be used either for a sink or for a stovetop so that one and the same countertop with a fitted frame can be manufactured and sold for either use.

According to one embodiment of the invention the self-engaging fastening means comprises a leaf spring attached to a side surface of the sink. However, other self-engaging spring-loaded mechanisms are also feasible and within the scope of the present invention.

According to one embodiment of the invention, the second horizontal portion is arranged and configured to press against the leaf spring when the sink is lowered into the frame, and wherein the leaf spring is arranged so that when an upper portion of the leaf spring passes the second horizontal portion of the frame, the leaf spring snaps into position to lock the sink to the frame by engaging with the lower surface of the second horizontal portion.

According to one embodiment of the invention, an upper side of the second horizontal portion comprises sealing means such that a watertight, or at least water resistant, seal is formed between the flange of the sink and the frame. The sealing means may for example comprise a rubber liner, silicone, glue or the like.

According to one embodiment of the invention there is provided a countertop having an opening comprising a frame and sink assembly according to any one of the preceding claims arranged in the opening, wherein a top surface of the first horizontal portion is attached underneath a protruding ledge of the countertop. Undermounting of the sink using a protruding ledge of the countertop may for example be suitable four countertops made from laminate materials or solid wood.

According to one embodiment of the invention, there is provided a countertop having an opening comprising a frame and sink assembly according to any one of the preceding claims arranged in the opening, wherein a lower surface of the first horizontal portion is attached to a recessed portion of the countertop. Countertops made from wood, stone or other solid materials may advantageously comprise a recess such that the sink can be arranged aligned with the surface of the countertop. A recessed countertop may be less suitable for countertops made from laminate materials.

According to one embodiment of the invention there is provided a countertop having an opening comprising a frame and sink assembly according to any one of the preceding claims arranged in the opening, wherein a top surface of the first horizontal portion is attached to an underside of the countertop.

According to one embodiment of the invention an overall height of the frame preferably is lower than a total thickness of the countertop. Thereby, a countertop with a frame can be stacked with other similar countertops without the frame protruding either above or below the surfaces off the countertop.

According to one embodiment of the invention the frame is configured to not extend beneath a lower surface of the countertop.

According to one embodiment of the invention the frame is continuous and runs along the entire circumference of the opening. Thereby, the stability and torsional rigidity of the countertop is improved, reducing the risk of damage to the countertop during handling. It should however be noted that the frame may be sectioned and arranged in the form of separate portion while still being fully capable of performing the desired functionality of attaching the sink to the countertop.

According to one embodiment of the invention, there is provided a modular sink and frame assembly for mounting in an opening of a countertop. The sink and frame assembly comprises: a frame consisting of a vertical portion, a first horizontal portion extending in a first direction from a first end of the vertical portion and a second horizontal portion extending in a second direction from a second end of the vertical portion, the second direction being opposite the first direction, the first horizontal portion being configured to be attached to a countertop; a sink comprising a flange located at an upper portion of the sink, the flange being configured to rest on an upper side of the second horizontal portion of the frame. The sink further comprises flexible self-engaging fastening means for securing the accessory to the frame, wherein the fastening means are configured to engage with the second horizontal portion and to snap into place underneath the second horizontal portion to restrict movement of the sink in a vertical direction when the accessory is lowered into the frame.

Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following description. The skilled person realize that different features of the present invention may be combined to create embodiments other than those described in the following, without departing from the scope of the present invention.

Brief Description of the Drawings

These and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing an example embodiment of the invention, wherein:

Fig. 1 schematically illustrates a countertop and a sink and frame assembly according to an embodiment of the invention; Figs. 2A-B are schematic profile views of a sink and frame assembly in a countertop according to an embodiment of the invention;

Fig. 3 is a schematic profile view of a sink and frame assembly in a countertop according to an embodiment of the invention;

Fig. 4 is a schematic profile view of a sink and frame assembly in a countertop according to an embodiment of the invention;

Fig. 5 is a schematic profile view of a sink and frame assembly in a countertop according to an embodiment of the invention;

Fig. 6A schematically illustrates a frame of a modular accessory and frame assembly according to an embodiment of the invention;

Fig. 6B schematically illustrates a sink and frame assembly according to an embodiment of the invention; and

Fig. 7 schematically illustrates a countertop and a stovetop and frame assembly according to an embodiment of the invention.

Detailed Description of Example Embodiments

In the present detailed description, various embodiments of the system and method according to the present invention are mainly described with reference to a countertop and sink assembly. It should however be noted that the described invention equally well could be used for mounting other modules in an opening of a countertop, such as a stovetop and kitchen fans.

Fig. 1 schematically illustrates a modular accessory and frame assembly 100 for mounting in an opening 104 of a countertop 102. In the present description, the accessory is illustrated in the form of a sink 115 which may be the most common accessory to mount in a countertop in the described manner. Flowever, as outlined above, the accessory may equally well be a stovetop of a kitchen fan mounted in a cupboard as long as the accessory comprises the described features required for mounting the accessory in the frame. The sink 115 and frame 106 is illustrated in further detail in Figs. 2A-B where it is shown that the assembly 100 comprises a frame 106 consisting of a vertical portion 108, a first horizontal portion 112 extending in a first direction from a first end 109 of the vertical portion 108 and a second horizontal portion 114 extending in a second direction from a second end 110 of the vertical portion 108, the second direction being opposite the first direction. As can be seen in Figs. 2A-B, the first direction in which the first horizontal portion 112 extends is a direction away from the opening 104, and the second direction is the direction towards the center of the opening 104.

The sides, directions and surfaces of the frame 106 are described with refence to the orientation of the frame 106 and sink 115 assembly when mounted in a horizontally arranged countertop 102.

The first horizontal 112 portion is configured to be attached to a countertop 102, for example by gluing.

The sink and frame assembly 100 further comprises a sink 115 comprising a flange 116 located at an upper portion of the sink 115, the flange 116 being configured to rest on an upper side 118 of the second horizontal portion 114 of the frame 106. The sink 115 further comprises self- engaging fastening means 120 for securing the sink 115 to the frame 106, wherein the fastening means 120 are configured to engage with the second horizontal portion 114 when sink 115 is lowered into the frame 106.

The frame 106 is preferably made from, metal, such as aluminum or stainless steel, and it can be easily mass produced by pressing to form the described profile. The frame 106 can be attached to the countertop 102 in several different ways as will be illustrated in the following.

As further illustrated in Figs. 1 and 2A-B, the self-engaging fastening means comprises a plurality of leaf springs 120 attached to a side surface of the sink 115. The second horizontal portion 114 of the frame 106 is arranged and configured to press against the leaf spring 120 when the sink 115 is lowered into the frame 106, so that the leaf spring 120 is pressed towards the side wall of the sink 115.

The leaf spring 120 is arranged so that when an upper portion of the leaf spring 120 passes the second horizontal portion 114 of the frame 106 as the sink 115 is being lowered, the leaf spring 120 snaps into position to lock the sink 115 to the frame 106 by engaging with the lower surface 122 of the second horizontal portion 114.

Even though embodiments of the invention are illustrated using flexible self-engaging fastening means in the form of a leaf spring 120, other fastening means are also possible. The self-engaging fastening means may for example be a sprint (not shown) which is spring-loaded in the horizontal direction, where the end portion of the spring facing the frame is beveled in order to slide over second horizontal portion 114 and to snap into place once under the second horizontal portion 114, locking the accessory into place in the frame. Alternatives available to the skilled person are also feasible. However, the simplicity of the leaf spring 120 makes it an attractive alternative.

A frame 106 having a uniform profile all the way around the opening 104 as illustrated in Fig. 1 increases the rigidity of the frame 106 and thereby also of the countertop 102 as a whole, thereby reducing the risk of damage to the countertop 102 during shipping, transportation and assembly.

Fig. 2A further illustrates that an upper side 118 of the second horizontal portion 114 comprises sealing means 128 such that a watertight seal is formed between the flange 116 of the sink 115 and the frame 106. The sealing means 128 may also comprise an adhesive ensuring a tight seal between the sink and the frame 106. Moreover, the sealing means may be provided in the form of a flexible rubber seal 128 which is either pre-attached to the frame or provided as a separate component to be attached to the frame 106 during assembly.

Fig. 3 illustrates a countertop 102 having an opening 104 comprising a frame 106 and sink 115 assembly, wherein a top surface 124 of the first horizontal portion is attached underneath a protruding ledge 140 of the countertop 102. There can also be glue 130 or another sealant located where the frame 106 meets the countertop, which helps to further ensure that there is no leakage between the frame 106 and the countertop 102.

Fig. 4 illustrates a countertop 102 having an opening 104 comprising a frame 106 and sink 115 assembly, wherein a lower surface 126 of the first horizontal portion 112 is attached to a recessed portion 150 of the countertop 102 such that the upper surface 124 of the frame 106 is located in the same plane as the surface of the countertop 102.

Fig. 5 illustrates a countertop 102 having an opening 104 comprising a frame 106 and sink 115 assembly, wherein a top surface 124 of the first horizontal portion 112 is attached to an underside 160 of the countertop 102. In Fig. 5, the countertop 102 comprises a vertical sidewall 500 reaching down from the countertop 102. The frame 106 may thus be arranged between the countertop 102 and eh vertical wall 500.

Fig. 6A illustrates a cross section of a frame 600 according to an embodiment of the invention. In addition to the parts of a frame 106 described above and illustrated in Fig. 2B, the frame 600 further comprises an angled profile portion 602 extending vertically upwards from an end portion of the second horizontal portion 114. The angled profile portion 602 provides an inner corner 604 for receiving fastening means such as the leaf spring 120.

As illustrated in Fig. 6B, the angled profile portion 602 restricts horizontal movement of the leaf spring 120 when the sink 115 is mounted in the frame 600. The angled profile portion 602 comprises a first vertical section 606 extending upward from the second horizontal portion 114, a first horizontal section 608 extending from an end portion of the first vertical section 606, and a second vertical section 610 extending upward from the first horizontal section 608.

The angled profile portion 602 adds structural stability to the frame 600 and may allow the frame 600 to be made from a thinner material compared to a frame without the angled profile portion 602. Moreover, the angled profile portion 602 provides a recess or trench 612 in which the seal 128 can be arranged ensuring that the seal is correctly positioned and that it does not move overtime. Moreover, if the seal 128 is provided separately, the recess 612 aids a user when arranging the seal 128 in the frame during assembly. A further advantageous effect is that the seal 128 remains in place even if the sink 115 is lowered into the frame at an angle and if pressure on the seal 128 from the sink 115 is applied unevenly. Fig. 7 illustrates a modular accessory and frame assembly 700 where the accessory is a stovetop 702. All of the above features, effects and advantages described with reference to a sink are equally applicable to the stovetop.

A method for manufacturing the accessory and frame assembly 100, 700 in an opening 104 of a countertop 102 comprises the steps of attaching the frame 106, 600 to the countertop 102, which is typically done by gluing the first, upper, horizontal portion 112 of the frame to the countertop 102 in a manner according to any one of the aforementioned examples. After the frame 106, 600 has been properly attached, the sink 115 or stovetop 702 can be lowered into the frame 106, 600 resulting in the leaf springs 120 being pressed towards the accessory 115, 702, and where the leaf springs 120 snap into a locked position when the accessory 115, 702 is fully lowered into the frame 106, 600.

Even though the invention has been described with reference to specific exemplifying embodiments thereof, many different alterations, modifications and the like will become apparent for those skilled in the art.

Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.