Abstract:
The present invention provides a sink assembly formed from a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing sink assembly. The integrated connection of the side walls, front, back, and bottom panels and sink components simplifies the sink assembly construction. The panels are formed of injection molded plastic to interlock with one another without the need for fasteners or connectors. The system incorporates a minimum number of connectors by integrally forming the connectors into the panels which are snapped together to complete the assembly.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates generally to a mobile sink assembly. More specifically, the present invention relates to a portable or mobile sink assembly utilizing injection molded plastic structural panels having integrally formed connectors. The sink assembly is capable of being packaged and shipped in a knock-down state and assembled into a secure and decorative sink and enclosure assembly without additional fasteners.  
       BACKGROUND OF THE INVENTION  
       [0002]     Portable or mobile sinks are very convenient for use wherever access to a water supply and drain facilities are not readily available. Portable sinks have been used in the past to facilitate the preparation of food outdoors and to provide washing and cleaning facilities for patients in nursing homes and hospitals who do not have ready access to conventional washing facilities. It is also very beneficial if there is an area adjacent the sink that can be used to store items related to the washing or cleaning to be done in the sink.  
       DESCRIPTION OF THE PRIOR ART  
       [0003]     An example of a portable sink is U.S. Pat. No. 5,465,438 which discloses a mobile sink unit for use in a nursing home. The unit includes a fresh water reservoir, a gray water reservoir, a faucet assembly including a control valve, and a soap dispenser. The majority of the space in the sink enclosure is occupied by the fresh water tank and the gray water tank. Any items to be stored must be kept on the top surface of the enclosure. This area is very small as can be seen in the drawings. The enclosure cabinet is formed from an open frame which is overlaid with a sheet material. This type of structure is not subject to being knocked down for shipment and assembly by the consumer at their location.  
         [0004]     U.S. Pat. No. 6,349,715 discloses another type of mobile sink. This sink is used in conjunction with a mobile cooking device. A water supply is connected to the lower portion of the device to supply water to the faucet adjacent the sink. The used water from the sink drains away from the device through an outlet hose. The device comprises a housing formed of front, back, side top and bottom walls which are permanently attached. This construction is also not subject to being knocked down for shipment and assembly by the consumer.  
         [0005]     Another type of portable sink is disclosed in U.S. Pat. No. 6,836,910. This sink is connected to a water supply to provide water for the sink. The drain empties onto the surface on which the sink is placed. This can lead to a messy and unhealthy situation. The sink enclosure has a drawer for storage but this does not provide a large amount of storage space.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention provides a portable or mobile sink assembly formed from a plurality of injection molded plastic panels having integrated connectors. The panels and other components are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing sink and enclosure. The integrated connection of the side wall panels, back wall panel, front wall panel, bottom panel and sink components simplifies the construction of the sink assembly. The panels are formed from injection molded plastic so as to interlock with one another without the need for separate fasteners or connectors. This assembly incorporates a minimum number of components by integrally forming the connectors into the injection molded panels. The panels are then snapped together to complete the assembly. This construction eliminates the need for separate connectors or fasteners to assemble the sink assembly. Injection molding allows the panels to be formed with a single wall having integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or rotationally molded assemblies. The same side wall and bottom panel components can be used to create a variety of different assemblies useful for outdoor entertaining or cookouts. The assembly of these components requires minimal hardware and a minimum number of hand tools.  
         [0007]     The base, front wall and back wall panels have integrally formed, outwardly projecting bosses for interlocking engagement with the left and right side wall panels. The left and right side wall panels are constructed with integrally formed, inwardly contoured sockets for interlocking, cooperative engagement with the bosses formed on the base, front wall and back wall panels. The engagement between the bosses and sockets serve to connect the panels together into a rigid and weather resistant assembly.  
         [0008]     The lower surface of the base panel includes a plurality of integrally formed bosses which are constructed and arranged to cooperate with casters to allow for easy movement of the sink assembly.  
         [0009]     Accordingly, it is an objective of the instant invention to provide a mobile sink assembly composed of panels with integral connectors.  
         [0010]     It is a further objective of the instant invention to provide a mobile sink assembly composed of panels formed by injection molding which provide increased structural integrity of the assembly.  
         [0011]     It is yet another objective of the instant invention to provide a mobile sink assembly wherein the side wall panels, front wall panel, back wall panel, bottom panel and sink are integrally interlocked without the use of separate fasteners or connectors.  
         [0012]     It is a still another objective of the invention to provide a mobile sink assembly constructed of modular panels which has an aesthetically pleasing appearance.  
         [0013]     It is still a further objective of the invention to provide a mobile sink assembly which is capable of being packaged and shipped in a knock-down state and constructed into a secure assembly at a desired site.  
         [0014]     Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0015]      FIG. 1  is a front perspective view of the sink assembly of the instant invention with a lid on the sink.  
         [0016]      FIG. 2  is a front perspective view of the sink assembly of the instant invention with the lid removed from the sink.  
         [0017]      FIG. 3  is an exploded view of the sink assembly shown in  FIG. 1 .  
         [0018]      FIG. 4  is a front planar view of the sink assembly of the instant invention.  
         [0019]      FIG. 5  is a cross-sectional view taken along line  5 - 5  of  FIG. 4 .  
         [0020]      FIG. 6  is a front perspective view of the sink assembly with the faucet in the raised position.  
         [0021]      FIG. 7  is a rear perspective view of the sink assembly of the instant invention.  
         [0022]      FIG. 8  is a rear planar view of the sink assembly.  
         [0023]      FIG. 9  is a bottom view of the sink assembly.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.  
         [0025]      FIGS. 2 and 3  illustrate perspective and exploded views of the sink assembly, generally referenced as  10 , according to a preferred embodiment of the invention. In this preferred, albeit non-limiting, embodiment of the invention the sink assembly is formed from a plurality of panels connected together. These panels include a base panel  100 , a right side panel  200 , a left side panel  300 , a back panel  400 , a front panel  500 , and the sink  600 . In the preferred embodiment the panels and the sink are formed of, but not limited to, a suitable plastic such as polystyrene, polypropylene, or polyethylene, through the process of injection molding. The result is that the panels which form the sink assembly are formed as unitary single wall panels with integral connectors and cross bracing. The sink  600  may be formed from materials other than injection molded plastics. These materials include, but are not limited to, cast plastics, fiberglass and metal.  
         [0026]     The base panel is formed with a top surface  104 , a bottom surface  106 , a front edge  108 , a back edge  110 , a left edge  112  and a right edge  114  ( FIGS. 3 and 9 ). Integrally formed along the left and right base panel edges are a plurality of bosses  116  for attaching the base panel to the left and right side panels. The bosses  116  extend outwardly from each edge to cooperate with integrally formed sockets  210  which extend inwardly along the bottom portions  206  and  306  of the right and left side panels respectively. Although only socket  210  of the left side panel is shown another integrally formed socket  210  extends along the bottom portion  306  of the right side panel. The bosses and sockets are constructed and arranged so that the bosses  116  matingly engage the sockets  210  thereby securing the panels together in a perpendicular and inter-fitting engagement. Detent or spring lock fasteners  118  are integrally formed on the bosses  116 . Apertures  208  are formed in the end portions of sockets  210  ( FIG. 3 ). The spring lock fasteners  118  cooperate with the apertures  208  to secure the bosses in the sockets. Those skilled in the art can appreciate that the spring lock fasteners  118  and socket apertures  208  can be used throughout the sink assembly to mount or secure components to one another and facilitate assembly of the sink assembly from an unassembled state without the use of tools. The overlapping boss  116  and socket  210  arrangement increases the structural integrity of the sink assembly by preventing panels  200 ,  300 ,  400  and  500  from bowing or bending inwardly or outwardly and thus, adversely affecting the appearance or operation of the sink assembly. Also, integrally formed on the bottom of the base panel are ribs  202  and gussets  107  which add structural rigidity and strength to the base panel ( FIG. 9 ).  
         [0027]     As shown in  FIG. 3  the left side panel is configured with a first edge  312  and a second edge  314 . Both edges include integrally formed elongated sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with the bosses  116  provided along an edge of the back panel  400  and the front panel  500 . The top edge of the left side panel is provided with an upstanding lip  315  integrally formed thereon. The lip cooperates with an underside portion of the sink  600  to facilitate their mechanical connection. The interior surface of the left side panel is provided with integrally formed ribs  202  which add structural rigidity and strength to the panel.  
         [0028]     The right side panel is configured with a first edge  212  and a second edge  214 . Both edges include integrally formed elongated sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with the bosses  116  provided along an edge of the back panel  400  and the front panel  500 . The top edge of the right side panel is provided with an upstanding lip  215  integrally formed thereon. The lip cooperates with an underside portion of the sink  600  to facilitate their mechanical connection. The interior surface of the right side panel is provided with integrally formed ribs  202  (not shown) which add structural rigidity and strength to the panel.  
         [0029]     The outer surface of the panels  200 ,  300 ,  400  and  500  are constructed as generally smooth and have a plurality of inwardly curved grooves  230  integrally formed thereon for added strength, structural integrity and aesthetic appearance. The insides of the panels  200  and  300  are provided with strengthening ribs  202  and seen in  FIG. 3 . The ribs add to the structural integrity provided by the grooves  230 . This increase in structural integrity prevents the panels  200 ,  300 ,  400  and  500  from bowing or bending inwardly or outwardly, adversely affecting the appearance or operation of the sink assembly. As illustrated herein these features are achieved by injection molding. Injection molding offers significant strength and stability advantages over blow-molding or rotational molding as utilized in the prior art. In this manner the sink assembly of the present invention is capable of handling a significant amount of weight and abuse as compared to prior art sink assemblies.  
         [0030]     The front panel  500  is attached to the left  300  and right  200  side panels by inserting the bosses  116 , of the front panel, into the sockets  210 , of the left and right side panels, until the spring lock fasteners  118  integrally formed on the bosses  116  engage the apertures  208  in the sockets of the left and right side panels.  
         [0031]     Located below the front panel  500  is a door  502  which provided access to a storage area. The storage area comprises the space below the sink  600 , above the base panel  100 , between the right and left side panels  200  and  300  and between the front and back panels  500  and  400 . This area may be used for the storage of items used in conjunction with the sink or for other cleaning purposes. The door  502  is hingedly mounted to the base panel and front panel by hinge pins  504  integrally formed on the door. The hinge pins fit into and cooperate with apertures  506  integrally formed in the base panel and front panel to permit pivotal opening and closing of the door. A handle  508  may also be provided on the door to assist the opening and closing thereof. The outer surface of the door  502  is constructed as generally smooth and has a plurality of inwardly curved grooves  230  integrally formed thereon for added strength, structural integrity and aesthetic appearance. These are similar to grooves  230  formed in the side, back and front panels.  
         [0032]     The base panel  100  is attached to the right  200  and left  300  side panels by inserting the bosses  116 , integrally formed on the base panel, into sockets  210 , integrally formed in the side panels, until the spring lock fasteners  118  engage the apertures  208  in the sockets of the left and right side panels ( FIG. 3 ). The back panel  400  is attached to the right and left side panels by inserting the elongated bosses  116 , integrally formed on the back panel, into the sockets  210 , integrally formed in the side panels, until the spring lock fasteners  118  engage the apertures  208  in the sockets of the left and right side panels. The front panel  500  is attached to the right and left side panels by inserting the elongated bosses  116 , integrally formed on the front panel, into sockets  210 , integrally formed in the side panels, until the spring lock fasteners  118  engage the apertures  208  in the sockets of the left and right side panels. It will be appreciated that the purpose of the elongated bosses  116  are to align the two joined panels in a perpendicular relationship and to facilitate their mechanical connection. This results in high structural integrity and reliable operation.  
         [0033]     Referring to  FIG. 3  the attachment of the sink  600  will now be described. A plurality of independently formed bosses  120  are inserted into the sockets  210  formed at the upper ends of the first and second edges of the right and left side panels. The spring lock fasteners  118  on the bosses  120  engage the apertures  208  formed in the sockets  210 . The sink is then placed over the top portion of the bosses which extend upwardly beyond the ends of the sockets  210  of the side panels. These top portions of the bosses are inserted into sockets  210  (not shown) formed on the underside of the sink at each corner thereof. Spring lock fasteners  118  on the top portion of the bosses engage apertures  208  (not shown) formed in the sockets  210  formed in the sink. As shown in  FIG. 3 , each boss  120  has two spring lock fasteners  118  formed thereon, thereby assuring that each boss will be securely attached to both the side panel and the sink. An underlying portion of the sink is constructed and arranged to cooperate with the upstanding lips  215 ,  315 ,  415  and  515  of the right, left, back and front panels to align the joined elements in a perpendicular relationship and facilitate their mechanical connection. As a result the sink is securely attached to the other panels. When the sink  600  is formed by injection molding or casting, the sockets  210  are formed simultaneously therewith. The socket may also be machined or cut out of a previously cast or molded sink. Further, if the sink is formed from metal the sockets may be attached subsequently, as by welding, for example.  
         [0034]     The sink also includes a faucet  602  to supply water from a source to the sink. The faucet is pivoted between an upright, operative position as shown in  FIG. 6  and a folded, inoperative position as shown in  FIG. 3 . A water control valve  603  is located in the sink and separate from the faucet, as shown in  FIG. 3 . A drain  604  is provided at the lowermost portion of the sink to remove the contents of the sink ( FIG. 5 ). A drain hose (not shown) connects the drain to the outside of the sink assembly through an aperture  402  provided in a lower portion of the back panel  400 . As shown in  FIG. 1 , a cover  606  is constructed and arranged to cover the sink bowl so that the top portion of the sink assembly may be employed as a work surface or storage area. The cover  606  is stored on the back panel when the sink is in use ( FIG. 7 ).  
         [0035]     Referring now to  FIGS. 3, 7  and  8  the back panel has integrally formed bosses  116  along the length of the left and right edges thereof. The bosses have spring lock fasteners  118  integrally formed thereon. The back panel is attached to the left and right side panels by inserting the bosses  116 , of the back panel, into the sockets  210 , of the left and right side panels, until the spring lock fasteners  118  engage the apertures  208  formed in the sockets  210 . The back panel is provided with an aperture  402  through which a drain hose may be positioned. The opposite end of the drain hose is connected to the drain  604  of the sink to provide a means to drain the fluids from the sink. The back panel is also provided with a fitting  404  which is connectable to a source of water. The fitting is also connected to the faucet  602  via a means not shown.  
         [0036]     A storage area for the sink cover  606  is provided on the back panel. Clips  608  ( FIGS. 7 and 8 ) are positioned on the back panel to hold the sink cover in a vertical position adjacent the panel. The clips  608  located on the upper portion of the back panel are flexible or spring type clips. The sink top is held in its storage position by these clips and can be released therefrom by flexing the clips.  
         [0037]     The perpendicular side, back, front and base panels are brought into an overlapping relationship wherein the bosses  116  enter the corresponding sockets  210  in the right and left side panels respectively. The result is a mechanically secure connection between the panels. The overlapping edges between the panels as described above provides a secure connection, snap-together assembly and offers several advantages. First, the design allows the panels to be connected without the need for separate connectors. Second, the design creates a positive lock which prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to each other.  
         [0038]     Referring now to  FIGS. 3, 4  and  5  casters  122  and caster bosses  124  are illustrated. The casters include a stem  126  that is constructed and arranged to cooperate with an aperture integrally formed into the lower surface of the base panel. To attach the caster to the sink assembly, the stem  126  is inserted into the aperture of the boss  124  until a retaining ring snaps into a corresponding groove formed in the aperture. This results in a mechanically secure connection. The casters are also provided with a manually engagable and releasable lock  130  to prevent the sink assembly from unwanted moves on sloped and uneven surfaces. The lock prevents rotation of the casters when in its engaged position and permits free rotation of the casters when in its disengaged position.  
         [0039]     Referring to  FIGS. 7 and 8 , a shelf  710  is hingedly mounted on one or both side panels of the sink assembly. Each shelf is provided with two hinges  724  and  726 . These hinges are formed separately from the shelf and attached thereto with fasteners. The portion of the hinge which engages the side panel is not attached thereto with fasteners. Hinge  724  is provided with a fixed pin. A portion of the pin extends beyond the hinge. Hinge  726  is provided with a slidable pin. The slidable pin is biased to its extended position by a spring. The portions of the fixed pin and slidable pin which extend beyond the hinges engage apertures  734  formed in the edge portions of the side panels ( FIG. 6 ). This provides a means to attach the shelves to the side panels. Each shelf is also provided with a plurality of supports hingedly mounted to a lower surface of the shelf. If removal of the shelf is desired, the slidable pin is retracted into the hinge which in turn disengages the pin from aperture  734  in the side panel. The shelf can now be pivoted downwardly disengaging the fixed pin from aperture  734  in the side panel and totally disengaging the shelf from the sink assembly. The location of the apertures  734  are identical on both the left and right side panels so that the same shelf may be mounted on either side of the sink assembly.  
         [0040]     All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.  
         [0041]     It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.  
         [0042]     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.