Abstract:
A system for creating a floating sub-top into an open space of a counter upon which tiles may be applied. The float characteristic of the sub-top eliminates cracking and breaking of tiled corner pieces and grout due to expansion of the sub-top. Used with the system is a support member attachable to vertical upstanding walls of the counter on the ends of the walls or on the inner surfaces; and attachable to the sub-top.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
   None 
   STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT 
   None 
   BACKGROUND OF THE INVENTION 
   This present invention relates to an improvement in counter construction, and more particularly to the top sections of counters which form the sub-base for tiles to be applied thereon. 
   Conventionally counters are made with the top section either directly and completely covering the vertical perimeter walls forming the counter. In the industry, the top section is generally referred to as the sub-top in that it is the foundation upon which the finished top; i.e., tiles for example, are applied. Most sub-tops are composed of wood though other materials may be used. 
   Typically the sub-tops are fastened [nailed, screwed, glued] onto the vertically-disposed walls of the counter. The attachment of the sub-top to the upstanding vertical walls in this manner is also generally of a permanent nature. Once the sub-top is so attached, cement is applied to it and tiles thereafter are applied to the cement. Tiles placed on the sub-top are so placed such that the edges of one tile do not abut the edges of another tile. They should be, and are, spaced apart from one another. This is done because tiles expand and contract. If the tiles are permanently set in place with the edges of all tile abutting the edges of other tiles, the tiles would crack upon expansion. Grout is applied into the spaces to finish the top. Most finished tiled counters also have corner caps/tiles cemented into place at the corners formed by the top and its adjacent vertical wall to give an even more finished appearance. 
   Wood, as well as the other materials generally used for sub-tops, also expands and contracts. Since the sub-top is permanently affixed to the vertical walls of the counter, such movement [expansion and contraction] of the fixed sub-top would, and does, push outward against the corner caps thereby causing them or the grout between the caps or both to separate or crack. The once finished; crisp, and clean look of the newly tiled counter becomes unsightly and damaged necessitating repairs, replacement, or, in many cases, neglect. The same result occurs with counters abutting walls. The non-floating sub-top expands pushing the tiles cemented thereon into the immovable wall causing the tiles or grout or both to crack or separate. 
   Attempts to correct this result or to prevent it altogether have been made with little success. Such attempts include modifying the joints, inserting expansion joints of various sorts, and use of various brackets and fasteners for and between the tiles. None has been successful in preventing this problem from occurring. 
   The floating sub-top system of the present invention with unique support members, when properly applied, will virtually eliminate the cracking to corner caps caused by the excessive expansion and contraction of a fixed sub-top as mentioned. 
   Accordingly, several objects and advantages of my invention are to:
         a. establish an easy-to-use and easy-to-apply sub-top;   b. eliminate damage to tiles, and in particular, to corner caps, caused by expansion of a sub-top to which the tiles and corner caps are applied; and   c. provide unique mounting members to create a floating sub-top within upstanding perimeter walls.       

   The foregoing has outlined some of the more pertinent objects of the present invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings. 
   BRIEF SUMMARY OF THE INVENTION 
   The above-noted problems, among others, are overcome by the present invention. Briefly stated, the present invention contemplates a system for creating a floating sub-top for use on a counter upon which tiles are to be applied. The float is created by a inserting a sub-top having a lesser length and width than the length and width of the open space into which the sub-top is inserted creating a gap around the perimeter of the sub-top and the inner surface of the upstanding vertical walls forming the counter. Unique support member attach to the inner surface of the vertical walls or on the upper ends of the vertical walls, or onto the sub-top or any combination thereof. In one embodiment, the support member has a support ledge upon which the sub-top is placed after the support member has been attached to the vertical walls. In another embodiment, the support member has a retaining ledge above and parallel to the support ledge defining a mouth into which the sub-top may be inserted and fastened after which the sub-top, with this support member attached, in inserted into the open space of the counter. After installation of the sub-top and tiles thereon, as the sub-top expands and contracts, the gap permit the sub-top to expand into the gap and not to push the vertical wall with the horizontal expansion; i.e., ‘float’ therein. This prevents or greatly reduces cracking and breaking of the finished tiles and grout on the sub-top and corners. 
   The foregoing has outlined the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so the present contributions to the art may be more fully appreciated. Additional features of the present invention will be described hereinafter which form the subject of the claims. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment may be readily utilized as a basis for modifying or designing other structures and methods for carrying out the same purposes of the present invention. It also should be realized by those skilled in the art that such equivalent constructions and methods do not depart from the spirit and scope of the inventions as set forth in the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which: 
       FIG. 1  is a perspective view of a typical conventional prior art sub-top for a counter 
       FIG. 2  is a detailed exploded perspective view of the sub-top of the present invention. 
       FIG. 3  is a detailed perspective view of the sub-top of the present invention. 
       FIG. 4  is a detailed view of one embodiment of a support member for the sub-top. 
       FIG. 5  is a detailed view of another embodiment of a support member for the sub-top. 
       FIG. 6  is a cross-section detailed view of a support member engaging the sub-top. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to the drawings in detail and in particular to  FIG. 1 , reference characters  30 ,  32  generally designate a prior art configuration of counter  30  [or similar structure having upstanding walls] with a top  32  attached, not within the open space of the counter  30 , but securely on top of the upstanding walls of the counter  30 . The top  32  is placed onto the upper ends of the upstanding walls of the counter  30  and typically is permanently affixed thereto. As previously described, cement is applied to the top  32  followed by tile application. Corner pieces are placed on the edge surfaces where the horizontal and vertical planes of the top  32  and counter  30 , respectively, meet. As the surface area of the top  32  expands, the corner tiles applied to prior art structures as illustrated in this figure crack, break, and/or separate. 
     FIGS. 2 and 3  illustrate a floating sub-top constructed in accordance with one embodiment of the present invention. The counter  30  has several upstanding vertically disposed walls exposing, in  FIG. 2 , an open space. The counter  30 , if placed into a corner, may have as few as one vertically disposed wall if placed on a diagonal to the walls forming the corner. The walls forming the corner, though independent of the single separate vertically disposed wall of the counter, nonetheless also contribute to the formation of the counter  30  and, as a result are an integral part of the counter  30  in this configuration and hereby are considered to be two upstanding vertically disposed walls of the counter  30 . Hence, in such a configuration, this type of diagonal counter into a corner has at a minimum three vertically disposed upstanding walls. 
   Counters not abutting walls may consist of a minimum of two vertically disposed upstanding walls with cross-members connected to each of the two vertically disposed upstanding walls to provide support for the counter. Regardless of the counter&#39;s  30  configuration, at least two vertically disposed upstanding walls, or more, are necessary to create the counter  30 . The figures presented herein illustrate counters  30  which are independent of any external sources for their make-up. It must be understood that this is only for illustration purposes and not by limitation as to the inventive steps and structure of the present invention. 
   On the inside inner surface of the counter  30 , there are shown several support members  12 . These support members  12  are horizontally disposed and placed below the upper end of the vertically disposed upstanding walls. The distance from the top surface of the support members  12  to the upper end of the vertically disposed upstanding walls is represented by reference characters X-Y. At least two such support members  12  are required. If only two are used, they must be placed on opposing inner sides of the vertically disposed upstanding walls; ;i.e., on inner front wall and on inner back wall; or on right side inner wall and on left side inner wall. The purpose of the support members  12  is to hold and support the sub-top  32  when it is placed into the open space of the counter  30 . It is, however, better to use at least three or more such support members  12 . 
   The sub-top  32  in all cases must have a surface area less than the surface area of the open space and the linear dimensions of the sub-top  32  should be approximately proportional to the linear dimensions of the open space but must be slightly less. For example, if the length of the open space is L and its width is W, the length of the sub-top  32  must be L-n and its width must be W-n; where ‘n’ represents any distance less than L and W, respectively but not so much less that the sub-top  32 , when placed into the open space is not capable of resting on the support members  12  therein. The thickness or depth of the sub-top  32  is represented by X′-Y′ where X′-Y′ is approximately equal to X-Y. Therefore, once the sub-top  32  is placed into the open space and is supported and resting on the support members  12 , the top surface of the sub-top  32  is approximately even with the upper ends of all the vertically disposed upstanding walls of the counter  30  and creates a complete counter  30  or similar structure upon which cement followed by tiles may be applied. As configured and constructed, the sub-top  32  is a ‘floating’ sub-top  32  in that, because its surface area is less than the surface area of the open space, a gap or spacing  14  is left all around the perimeter of the sub-top  32  giving the finished sub-top  32 , complete with its cemented tiles thereon, room into which to expand and not force the sub-top  32  and its cemented tiles to push into the corner pieces and crack, break, or separate them. 
     FIG. 4  illustrates another embodiment of the support member  20 . This support member  20  will be described based on relative orientation to the counter  30  to which it shall be mounted. It has a horizontal top ledge  22 , an appended vertical, downward extending ledge  24 , and an appended support ledge  26  extending outward from the vertical ledge  24  but extending inward into the open space of the counter  30  when mounted on the vertically disposed upstanding walls. It may have an aperture  28  on the top ledge  22  or an aperture  28 ′ on the support ledge  26  or an aperture  28 ″ on the vertical ledge  24  or on all or any combination thereof. This support member  20  may first be mounted onto and attached to any one or more of the vertically disposed upstanding walls by inserting a suitable fastener  38  through aperture  28  or aperture  28 ″ or both in instances where the support member  20  is configured with at least these two apertures. After one or more support members  20  are so affixed to the vertically disposed upstanding walls, the sub-top  32  may be laid into the open space of the counter  30  and onto the support members  20 . With support members having at least aperture  28 ′ or  28 ″ or both, the sub-top  32  also may be affixed to the support member  20  by use of a suitable fastener  38  through such apertures  28 ′ or  28 ″ or both and into the sub-top  32 . If the support member  20  is affixed to the sub-top  32  in either or both manners, the support member  20  then should ordinarily not be affixed to the vertical upstanding wall also as, more likely than not, this will diminish the floating feature of the sub-top as created and configured. 
   To maintain a relatively level horizontal plane for the sub-top  32  in relation to the ends of the vertically disposed upstanding walls, the length of the vertical ledge  24  should be approximately equal to or greater the distance of the thickness of the sub-top  32 ; i.e., approximately X′-Y′.  FIG. 4  illustrates the thickness of the sub-top  32  as being X′-Y′. The distance from the upper surface of the support ledge  26  to the bottom surface of the top ledged is represented by X-Y. Reference character ‘t’ represents the thickness of the top ledge  22 . It is best that X-Y be approximately equal to X′-Y′, though X-Y may also be approximately equal to (X′-Y′)+‘t’]. Application of cement over the entire top surface area will cover and even-out any dimension irregularities which may be caused by the addition of the top ledge  22  and thickness ‘t’ to the upper ends of the vertically disposed upstanding walls. 
   As described above, application of the sub-top  32  may also be executed by first affixing the support member  20  to the bottom surface of the sub-top  32  by use of a suitable fastener  38  through aperture  28 ′ and into the sub-top  32 . After a suitable number of support members  20  are so affixed, the sub-top  32  may be inserted into the open space with the top ledges  22  placed to rest on the upper ends of the vertically disposed upstanding walls. The top ledges  22  may be, but need not be, fastened to the upper ends of the vertically disposed upstanding walls by placing a suitable fastener  38  through aperture  28  and into the upper end of the vertically disposed upstanding walls. 
   Best use of this support member  20  is to affix the support member  20  to the vertically disposed upstanding walls by use of a suitable faster either through aperture  28  or  28 ″ or through both but not through aperture  28 ′. This process will enhance the floating concept of the present invention. 
   Still another embodiment of a support member is illustrated in  FIGS. 5 and 6 . This support member  120  is similar to the previously described support member  20  in all respects except that it has a retaining ledge  23  extending outward from the top ledge  22  and inward into the open space. The retaining ledge  23  is approximately parallel to the support ledge  26  and parallel to and approximately on the same horizontal plane as the top ledge  22  thereby defining a mouth or opening  29  between the retaining ledge  23  and the support ledge  26 . The width of the mouth is equal to or slightly less than X′-Y′ and thereby, is adapted to receive and securely hold onto the sub-top  32  without the need of any external fastener  38 . 
   This support member  120  may have the same apertures in the same configurations as support member  20 ; i.e., aperture  28  in the top ledge  22 , aperture  28 ′ in the support ledge  26 , and aperture  28 ″ in the vertical ledge  24 . It also may have aperture  48  on the retaining ledge  23 . The primary, though not exclusive, purposes of apertures  28 ′,  28 ″, and  48  would be to affix the support member  120  to the sub-top  32 . As described above, if the support member  120  is affixed to the sub-top  32  it is best not to also affix this support member  120  to the vertical upstanding wall as such may diminish the functionality of the float. The better process is to slip this support member  120 , by way of its mouth  29 , onto the edges of the sub-top  32 . Given the respective thickness of the sub-top  32  and length of the mouth  29  being approximately the same, the support member  120  will grasp onto and hold onto the sub-top. A suitable removable fastener may be inserted through aperture  48  before the sub-top  32  is placed into the open space to ensure the hold of the support member  120  on the sub-top. If this is done, it is best thereafter to remove the fastener from aperture  48  after the sub-top  32  has been placed into the open space of the counter  30 . Once so placed into the open space of the counter  30 , a suitable fastener  38  may be, but need not be, placed through aperture  28  of the top ledge  22  such that the sub-top  32  and support member  120  are more securely affixed to the counter  30 . The configuration of this support member  120 , however, does not necessitate this procedure. 
   After the support member  120  and sub-top  32  are inserted into the open space of the counter  30 , a gap  14  remains between the vertical ledge  24  and the adjacent edge of the sub-top  32  [ FIG. 6  refers]. In instances where the support member  120  was not fastened to the sub-top  32 , this gap  14  permits the sub-top  32  to float within the open space of the counter  30 . In instances where the support member  120  was fastened to the sub-top  32 , the gap  14  will be in the space between the vertical ledge  24  and the vertically disposed upstanding wall of the counter  30 . The functionality of the gaps  14  created, wherever created, is to facilitate and permit a float for the sub-top  32 . 
   The present disclosure includes that contained in the present claims as well as that of the foregoing description. Although this invention has been described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts and method steps may be resorted to without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be determined not by the embodiment[s] illustrated, but by the appended claims and their legal equivalents.