System, method and kit regarding application of a metal edge to a surface

A surface that includes a three-dimensional surface, wherein a notch is present in said three-dimensional surface. The surface further includes a metal edge inserted into the notch and attached to the three-dimensional surface.

BACKGROUND

1. Technical Field

The present invention relates to a system, method and kit regarding application of a metal edge to a surface.

2. Background Information

Furniture with surfaces and/or work surfaces, such as countertops and panels, traditionally lack any identification as to its manufacturer when used by a customer. This can lead to confusion for the customer as to the identification of the manufacturer of the furniture. Such identification could be useful if the customer want to contact the manufacture regarding the surface and/or work surface or wishes to purchase a surface and/or work surface from the manufacturer.

In addition, if delicate edge details were to be added to the above mentioned surfaces and/or work surfaces, it would typically result in high stone fabrication costs.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention regards a surface that includes a three-dimensional surface, wherein a notch is present in said three-dimensional surface. The surface further includes a metal edge inserted into the notch and attached to the three-dimensional surface.

A second aspect of the present invention regards a method of manufacturing a surface that includes forming a notch within a three-dimensional surface and inserting a metal edge within the notch. The method further includes attaching the inserted metal edge to the three-dimensional surface.

One or more aspects of the present invention provide the advantage of identifying the manufacturer of a surface, such as a work surface or a panel,

One or more aspects of the present invention provide the advantage of allowing for the creation of delicate edge details without costly fabrication costs.

The accompanying drawings, which are incorporated herein and constitute part of this specification, and, together with the general description given above and the detailed description given below, serve to explain features of the present invention. Note that the drawings are all depictions of some of the concepts and profiles of the hardware and cross sections of the notched countertop edges with metal profiles applied.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In general, the present invention regards a surface that is machined so as to receive a metal edge so that when viewed as a whole defines a new surface, such as a panel or a work surface, such as a countertop. The machined surface can be decorative in appearance with the inclusion of the metal edge, and the metal edge can be functional in that it can be used to have work performed thereon and it can be used to identify, brand and market the surface and its associated furniture by providing unique manufacturer logos and recognizable edge profiles.

An embodiment of a work surface is shown inFIG. 1is exemplary of basic principles regarding the other embodiments ofFIGS. 2B and 6-19and so will be described herein. In particular, a surface100defines a right parallelepiped. As shown inFIG. 1, the surface100includes a horizontal top surface110, a bottom horizontal surface160, and four vertical side surfaces162, wherein the surfaces110,160and162are integral with one another. Of course, other three dimensional shapes to define the surface are possible. The length, width, thickness of the surface100can be any value depending on the intended use of the surface100. The surface100can be made of any material. An example of a suitable material is quartz, such as the quartz manufactured by Caesarstone.

The surface100is worked with a tool to form a notch102in its sides.FIG. 1shows notches102formed in two of the vertical sides162of surface100. In particular, the notch102can be formed manually by using one or more tools, such as a router or a shaper with a specific router or shaping bit, which can be presented in a tool kit (not shown). The tool kit can also include pieces of a metal edge and a metal cutting tool to cut the pieces to a desired length. The tool kit can include surfacing samples with notching.

The notch102can be polygonal in cross-section and is preferably rectangular in cross-section as shown inFIG. 1. In the embodiment ofFIG. 1, the notch102extends around the side walls104of the surface. As shown inFIGS. 1 and 1A-B, the notch102includes a horizontal top surface164and a horizontal bottom surface166that faces surface164. A vertical side surface165of the notch102is integrally joined with the surfaces164and166. As shown inFIGS. 1 and 1B, the notch102defines a volume (see cross-hatched cross-sectional area of volume shown inFIG. 1B) of space defined by the surfaces164and165, wherein the volume does not extend past the vertical sides162as denoted by the vertical dashed lines167ofFIG. 1B. The volume extends along the entire length of surface165along a direction that is perpendicular to the plane containingFIG. 1B. Note thatFIGS. 1A-Bare illustrative of notch102and are not intended to denote any particular dimensions for the notch102. As shown inFIG. 1, the length of the notch102is substantially greater than either the height or depth of the notch102. Note that the notch can be formed in other areas of the surface100as shown inFIGS. 8-10 and 12-14. For example, a notch can be formed at one of the corners106, one of the edges108and the top surface110. Furthermore, there could be multiple disconnected notches formed at different areas of the surface depending on the desired work surface to be produced.

Within the notch102, a metal edge112is inserted. As shown inFIG. 1, the metal edge112can be made of multiple metal pieces that are interconnected to one another by a male connector114and a female connector116. In particular, the female connector116is a U-shaped slot that receives a complementary male connector114so as to define a male/female connection. As is apparent fromFIG. 1, the male/female connection is similar to an interconnection between two jigsaw pieces that engage one another.

As shown inFIG. 1, a pre-assembled corner piece118is inserted into a portion of a corner of the notch102. The corner piece118has two sides120,122that are integrally formed with one another, wherein side120has a male connector114and side122has a female connector116. The corner piece118has a front, planar surface121that faces in a direction opposite to that faced by corresponding portions of rear surface123. The sides120and122are equal in length and form a right angle. Of course, other shapes and dimensions for the corner piece118are possible, such as having unequal lengths for the sides and the sides form an angle other than 90 degrees.

As shown inFIG. 1, straight pieces124and126are inserted into central sections128and130, respectively, of the notch102. The straight pieces124,126have front, planar surfaces125,127that face in a direction opposite to that faced by corresponding rear surfaces129,131. The male connector114of corner piece118engages a female connector116of the straight piece124and the female connector116of corner piece118engages a male connector114of the other straight piece126. Note that when the above described male/female connection/engagement is made, the pieces118,122associated with the female connectors116extend lengthwise along the same direction that the corresponding pieces118,126associated with the male connectors114extend lengthwise. In addition, when the assembled metal edge112is positioned within the notch102, a front, planar surface (121,125,127) of the metal edge112is parallel to and faces away the surface165of the notch102. Furthermore, when the assembled metal edge112is positioned within the notch102, a rear surface (123,129,131) of the metal edge1121) faces the surface165of the notch102, 2) covers the surface165in its entirety, and 3) is positioned between the front surface of the metal edge112and the surface165of the notch102

Not shown inFIG. 1is that the straight pieces124and126will engage with the male connectors114and female connectors116of corner pieces118at two other corners of the notch102. In addition, a second set of straight pieces124and126are placed in central sections of the notch102that are positioned opposite to the central sections128and130, respectively. The second set of straight pieces124and126are connected with the previously mentioned corner pieces and a fourth corner piece placed in the remaining corner portion of the notch102. The various straight pieces124,126and corner pieces118are attached within the notch102by using an adhesive between the surface of the notch102and a rear side of each of the straight and corner pieces. Of course, other attachment structures between the surface100and the metal pieces118,124, and126. For example, mechanical devices, such as pins, could be used alone or in combination with the adhesive to attach the metal pieces118,124,126to the surface100. When all the above mentioned straight pieces124,126and corner pieces118are attached to one another and positioned with the notch102, a work surface132is formed that includes the notched surface100and a rectangular metal edge134.

The work surface132ofFIG. 1is but an example of a possible result of the use of the metallic pieces and sections mentioned previously. It is envisioned that the straight pieces124and126and the corner pieces118are pre-fabricated by being cut to a size based on a particular work surface or panel to be formed and into various decorative/function profiles and sizes. For example, the length, height, and width of the corner piece118can be varied based on the workpiece to be formed as illustrated inFIGS. 2A and 3. Thus, depending on the width chosen, the corner piece118can be entirely contained within the volume (see cross hatch ofFIG. 1B) defined by notch102, flush with the vertical side162of surface100, or extend past side162. Similarly, the length, height, and width of the straight pieces124and126can be varied as illustrated inFIG. 4. Thus, depending on the width chosen, the straight pieces124and126can be entirely contained within the volume defined by notch102, flush with the vertical side162of surface100, or extend past side162. In addition, besides an outside corner piece118, a prefabricated inside corner piece136of various lengths, heights, and widths can be manufactured as shown inFIG. 2Bso as to provide edging for work surfaces that have an inside corner. Note that under certain circumstances, the outside corner piece118can be flipped to provide an inside corner piece136.

Many types of finishes for the metal pieces are possible, such as stainless steel, brushed stainless steel, polished stainless steel, bronze, carbon, braided metals and copper patina. The use of pre-fabricated corner pieces118and136eliminate the need for miter cutting and joint fitting at corners, which is often a problem with fabricators who are not used to working with metals. Note that in certain circumstances, the metal edge can be a single piece. In addition, the thickness of the metal edge can be constant throughout or variable.

As can be readily understood by the previous description, the work surface132ofFIGS. 1, 2A, 3 and 4provides many advantages. For example, it demonstrates a modular system that can be applied to any building material and is easily stocked, shipped and assembled. The metal edge functions as a joining element, wherein seams become details, materials can be mixed and waste is reduced. Use of the metal edge will result in a reduction in service calls to repair chipped edges since the metal edge provides edge protection at corners and sinks. The use of the metal edge also provides opportunities for providing decorative designs thereon. Also, the metal edge provides the opportunity to laser etch/engrave text on an exterior facing side of either of the sections118,124and126, which can be used to brand the work surface132with a logo, the name of the manufacturer or other identifying symbol, such as a trademark. Examples of such engraved text are shown inFIGS. 5A-G.

Based on the above principles, various work surfaces can be formed. For example, suppose at one of the sides of the notch102ofFIG. 1the straight section124does not have a sufficient length to be connected to the corner pieces118. In this case, the straight section124is cut with the metal cutting tool of the previously mentioned tool kit so as to form two pieces of the same length. The two pieces are inserted and attached with the notch102and attached to the corner pieces118as describe previously. This will result in a gap forming between the two pieces. The gap is hidden by inserting a tab138, as shown inFIG. 6, into the gap. The tab138can have various lengths, heights and widths depending on the work surface being formed. The tab138is attached within the notch102using either an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces118,124, and126. The tab138can also include etching/engraving as previously described with respect to the metal pieces118,124and126.

As another example, suppose at one of the sides of the notch102ofFIG. 1the straight section124is too long to be connected to the corner pieces118. In this case, the straight section124is cut by the metal cutting tool of the previously mentioned tool kit so that a middle portion is removed and the two remaining pieces are of the same length. The combined length of the two remaining pieces is such that when the pieces are connected to the corner pieces118no gap is formed between the straight pieces. The two pieces are inserted and attached with the notch102and attached to the corner pieces118as describe previously.

The previously described edgings regard an edging that surrounds a portion of the surface100and is below the top surface110of the surface100. The edgings can be formed solely on the top surface110or both the top surface110and one or more side surfaces104of the surface100. In the latter case, a handle140can be inserted into an L-shaped notch formed in the top surface110and a side surface104of the surface100. The notch is manufactured using the tools of the tool kit mentioned previously. An example of a handle140to be inserted into the notch is shown inFIG. 7. The length, thickness and the size of the L-shaped cross-section of the handle140can be varied depending on the type of work surface to be formed. The handle140is attached within the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces118,124, and126. Examples of handles140are shown inFIGS. 8-10. Note that the handle140can include etching/engraving as previously described with respect to the metal pieces118,124and126.

Besides the metal edge134ofFIGS. 1-6and the handle140ofFIGS. 7-10, the present invention can be used to form various types of piping elements. An example of a piping element142is shown inFIG. 11. The piping element142is in the form of a parallelepiped, wherein the length, width and height can have various values based on its intended use. One use for the piping element142is as a transition between two surfaces of a counter piece. As shown inFIG. 12, a rectangular groove is formed along the bottom length of a backsplash144that is adjacent to a counter surface146. The notch is manufactured using the tools of the tool kit mentioned previously. The piping element142is attached within the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces118,124, and126.

The piping element142can be used as a bead detail. As shown inFIG. 13, a rectangular groove is formed between an exterior edge148of an inner top surface150and an interior edges152of an outer top surface154. A first piping element142A is attached within a portion of the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces118,124, and126. An end of the first piping element142A abuts against the interior edge152of the outer top surface154. A second piping element142B is attached within the remaining portion of the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces118,124, and126. An end of the second piping element142B abuts against a side of the end of the first piping element142A. A similar example of such a use of plural piping elements is shown inFIG. 14.

In order to illustrate the benefits of the edging of the present invention and in order to instruct others on how to install the edging previously described with respect toFIGS. 1-14, a presentation or sales kit200is stored in a presentation box202shown inFIG. 15. The presentation box202is rectangular in shape and has metallic top and bottom edges204,206, respectively. Of course, other shapes for presentation box202are possible without departing from the spirit of the invention. The presentation box202also may or may not have rectangular openings207formed in its side walls210in other to define handles for carrying the presentation box202. As shown inFIGS. 16 and 17, the presentation box has a hinged top lid212. When the lid212is opened, it reveals a top tray214that has slots to contain samples of straight metal pieces216, handles217, and corner metal pieces218with different profiles and finishes, tabs220having text etched thereon a manual222regarding the edging, and a USB flash drive224. Note that the straight pieces216, the handles217, and the corner pieces218can also include text etched thereon. The tray214may also have slots to receive the previously described piping elements142. The flash drive224can include application instructions, an instructional video of surface machining using the tool kit and installation of the metal pieces previously described with respect toFIGS. 1-14. The flash drive224can also provide application instructions, adhesive and finishing tips, and use and care instructions. When the top tray214is removed, it reveals various sample blocks226that have been machined to receive the straight sections216. The sample blocks have various finishes to allow an observer to envision how a surface similar to a sample block will look when receiving one or more of the previously described straight metal pieces216, handles217, corner metal pieces218and tabs220. The sample blocks226are positioned within corresponding vertical slots228defined by vertical walls/dividers located within the presentation box202and show various materials for the notched surface that is to receive the metal pieces216and218.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof.