No Drip Slab Counter top and Related Method
A method for making a profiled no drip edge countertop in a series of attractive shapes where much of the profiled surface is already polished as it utilizes the factory polished surface of the original slab. This method decreases the amount of skilled labor or expensive tooling required for making this countertop and edge. This method hides lamination seams in joints so that the profiled edge appears as one piece as if it were milled out of a single slab of material.
The present invention relates to a no drip profiled edge countertop made from natural stone slabs, engineered stone slabs and composite plastic slabs.
BACKGROUND AND PRIOR ARTCountertops, particularly those used in domestic kitchens, are prepared from a variety of surfaces such as ceramic tile, plastic laminates, plastic composite solid surface and, more particularly, stone and engineered stone surfaces. Laminated plastic is commercially available from a variety of sources and in a variety of colors, patterns and textures. The countertop is prepared by obtaining sheets of laminated plastic which are cut to pattern and thereafter bonded to a suitable surface such as plywood or, more commonly, a pressed particle board. The countertop also generally includes a coved backsplash along the rear edge of the countertop and, customarily, a raised no-drip edge along the front edge of the countertop. Ceramic tiles can be purchased with a no drip edge profile tile to accomplish the same type of edge.
The no-drip edge includes a slight upraised ridge along the edge of the countertop and terminates in a downwardly depending lip extending below the bottom surface of the countertop. The raised ridge is called a no drip edge because it prevents fluid spills from flowing off the edge of the countertop.
Laminated plastic no drip edge countertops are generally prefabricated in a remote shop location and thereafter shipped to a point of installation in the domestic kitchen. Because these countertops have a special edge, they have to be made on special vacuum form equipment that does not allow for specially shaped islands and counters without many time consuming seams
Ceramic tile no drip edges are done by using a special no drip edge tile at the front profiled edge. Although this performs the function of a no drip edge, tiles include many grout joints which are often disliked by consumers because they are difficult to clean.
Because slab countertops can be made starting out with typical 2 cm thick slab material that is polished on one side, forming a thicker 4 cm profiled edge usually involves laminating a strip of the same material underneath and then grinding and polishing the desired contour. Using routers and other methods can give you a variety of popular edges such as Full Bullnose, Demi Bullnose, Ogee, Dupont, Flat Polished, Eased edge, Pencil Edge, Beveled edge, to name a few (see
Consumers have always had the option of a no drip edge in ceramic tile countertops (using a special no drip edge tile) and in plastic laminate countertops (where the no drip edge is built up in the underlying particle board and then this is covered by the plastic laminate). A No Drip edge is also available in plastic composite countertops but is very labor intensive since it requires laminating another thin layer of the material on top and then routing it first in a separate run, before routing the normal front edge. The seams are not always invisible for this edge depending on the workmanship so it can be very unsightly. If this same procedure were done in natural or engineered stone it would be very labor intensive and very visible, which would make it unmarketable. Although a No Drip edge is preferred by some consumers, it is often required in commercial projects such as dormitories or hospitals where it's performance reduces maintenance and/or increases safety.
This invention is a countertop and method of constructing a no drip profiled edge where much of the profiled surface is already polished because it utilizes the factory polished surface of the original slab. This feature alone decreases the amount of skilled labor or expensive tooling required for making this edge. Additionally, the invented edge hides lamination seams in joints so that the profiled edge appears as one piece; like it was milled out of a single slab of material. This is an improvement to all the profiled edges mentioned above since their laminations are more or less visible depending on the workmanship and pattern in the material.
One of the benefits of this invention is that because the edge does not depend on a great deal of workmanship to hide the lamination, it can be more mechanized and automated, reducing labor significantly. This would allow countries with expensive labor rates to compete with countries with very low labor rates. Another benefit of this invention is that a whole new series of edge profiles with newly marketable appearances can be fabricated using this new method (see
In view of the foregoing, it would be a significant advancement in the art to provide a no drip profiled edge where much of the profiled surface is already polished because it utilizes the factory polished surface of the original slab. This feature alone decreases the amount of skilled labor or expensive tooling required for making this edge.
It is, therefore, an object of this invention to provide improvements in the method of manufacturing a no drip edge for natural stone materials.
Another object of this invention is to provide improvements in the method for manufacturing a no drip edge for engineered stone materials.
Another object of this invention is to provide improvements in manufacturing a no drip edge for solid surface plastic composite materials.
Another object of this invention is to provide a no drip edge in a new variety of attractive edge shapes
It is another object of this invention to provide a no drip edge where much of the profiled surface is already polished because it utilizes the factory polished surface of the original slab
It is another object of this invention is to provide improvements in manufacturing a no drip edge where the process hides lamination seams in joints so that the profiled edge appears as one piece; like it was milled out of a single slab of material.
An even still further object of this invention is to provide improvements in manufacturing a no drip edge where some of the edge can be applied in the field for unexpected situations without time consuming field fabrication.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims taken in conjunction with the accompanying drawing.
It is understood, of course, that while the forms of the invention herein shown and described include the best mode contemplated for carrying out the present invention, they are not intended to illustrate all possible forms thereof. It will also be understood that the words used are descriptive rather than limiting, and that various changes may be made without departing from the spirit or scope of the invention as claimed below.
Added-
Added-
Added-
Added-
Added-
Added-
Added-
Added-
Raw slabs of Natural Stone, Engineered stone and Plastic Composites come in various sizes from about 48″ by 96″ to 72″ by 125″ depending on the material and the color. These raw slabs are then processed to give them profiled finished edges and cut to size for kitchen countertops or vanity tops. The method used in this invention involves first routing and polishing the edge of the granite slab (
The profiling and polishing can be done using existing technology of portable stone routers, in-line routing machines, in-line profiling machines and CNC router machines. The cutting should be done with a bridge saw for accuracy. Importantly, you must be able to change the angle of cut on the bridge saw. Assembly of Part “A” and Part “B” on to Slab “C” (See
The Part “A” and Part “B” on to Slab “C” (See
Of course the easiest edges to construct are shown on
If the edge piece (Number 7) was constructed accurately enough just a wall and table is all that is needed to finish gluing. The weight of the slab itself will help (see
If using the Clamping Jig (
The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims, as those skilled in the art will make modifications to the invention for particular uses.
Claims
1. A no drip slab countertop and method made from natural stone slabs, engineered stone slabs and composite plastic slabs comprised of;
- A polished or finished factory surface cut in three sections and re-assembled exposing a factory finished edge on most outside surfaces.
2. A no drip slab countertop and method as defined in claim 1 wherein the slab is cut in three sections.
3. A no drip slab countertop and method as defined in claim 1 wherein the slab edge is cut at 120 degree angles.
4. A no drip slab countertop and method as defined in claim 1 wherein the edge is cut from natural stone.
5. A no drip slab countertop and method as defined in claim 1 wherein the edge is cut from engineered stone slabs
6. A no drip slab countertop and method as defined in claim 1 wherein the edge is cut from resin based slabs.
7. A no drip slab countertop and method as defined in claim 1 wherein the lamination seams in joints are hidden so that the profiled edge appears as one piece.
8. A no drip slab countertop and method as defined in claim 1 wherein the smaller two sections form a no drip edge section that can be applied in the field to the third slab section.
9. A no drip slab countertop and method as defined in claim 1 wherein the shape of the finished profiled edge can vary as illustrated on FIG. 4 and FIG. 5.
10. A no drip slab countertop and method as defined in claim 1 wherein the finished rectangular countertop slab may be any necessary dimension and may have one edge profiled, two edges profiled, three edges profiled or four edges profiled.
11. A no drip slab countertop and method as defined in claim 1 wherein there is a curved edge made from segments of straight edge and then hand finished to produce a smooth curve.
Type: Application
Filed: Jan 25, 2008
Publication Date: Jul 30, 2009
Inventor: Morris Bendah (San Leandro, CA)
Application Number: 12/019,871