Abstract:
An assembly and method for its use that provides a strong and efficient way of attaching a decorative molding component to a countertop unit or similar furniture piece. The countertop unit consists of a countertop core component with a countertop edge piece that is pre-attached to its unfinished edge before application of a countertop finish surface material. The countertop edge piece has a specially configured groove pre-cut in its bottom surface which in turn creates a wedge-shaped tongue. The decorative molding component has a unique “J”-shaped attachment side with a tongue and groove of its own that interlocks and wedges with the tongue and groove in the countertop edge piece portion of the countertop unit. The interlocking action of this assembly and methodology eliminates the need for clamping while still providing both a tighter fit between components and a precise method for adjusting and aligning component surfaces.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of Invention 
         [0002]    The present invention relates to the construction and attachment of decorative and/or wear-resistant edges to countertops and other similar furniture components. 
         [0003]    2. Background of the Prior Art 
         [0004]    This inventor&#39;s previous U.S. Pat. No. 6,343,454 issued Feb. 5, 2002 which is incorporated in its entirety herewith by reference, describes an improved method of construction and attachment of decorative edges to countertops and similar furniture components. 
         [0005]    While the method of construction and attachment provided by U.S. Pat. No. 6,343,454 works well and represents a major improvement over the prior art, it does nevertheless require a level of machining precision that is not always available to the countertop/furniture fabricator in the field. In the case of the molding component itself, this problem is minimal since this molding component is generally pre-manufactured by a firm that produces the product in sufficient quantities to readily justify the investment in machinery that will allow for production of a consistent, strong and aesthetically pleasing product per the configuration described in U.S. Pat. No. 6,343,454. Indeed this decorative molding art exists primarily because the production of many such edge pieces cannot be cost effectively done by those who fabricate and install countertops or other furniture components in the field—i.e., it is a specialty product. 
         [0006]    The machining problem is more evident with regard to the preparation of the countertop core for receipt of the molding component. As described in detail in U.S. Pat. No. 6,343,454, a specially configured groove is cut in the bottom surface of the countertop core. The groove in turn produces a downward facing, wedge-shaped tongue at the countertop core edge. If this groove is to be machined into the countertop core itself, then, it is done by the countertop fabricator or installer in the field and must be done in a manner that will be precise enough to allow for proper installation of the pre-manufactured decorative edge molding piece. While this machining operation is not particularly complex, it can be tedious or cumbersome for the typical fabricator or installer, given the length and size of countertop sections. Significant inconsistencies in this machining operation, will reduce or negate the advantages of the methodology described in U.S. Pat. No. 6,343,454 and result in problems similar to those involved in earlier forms of the art. 
         [0007]    Another problem that must be recognized, relates to the composition of the countertop core. In most cases, this core is composed of either a composition product such as particle board or of plywood. In either case, the wedge-shaped tongue produced by the groove required for attachment of the decorative edge component per U.S. Pat. No. 6,343,454 may be weaker than necessary to withstand the pressure that is applied when the decorative edge molding piece is being installed. This may cause the tongue to break off the countertop core thereby defeating the advantages of the U.S. Pat. No. 6,343,454 methodology. 
         [0008]    It should be noted that the above described problem of countertop core strength only relates to the decorative edge installation process. If the groove is properly cut and adhesive is applied on each groove and tongue surface as described in U.S. Pat. No. 6,343,454, the countertop core will be an integral, functionally strong, unit once the adhesive has dried. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention corrects the above described problems associated with the installation and attachment of decorative edge molding when using the U.S. Pat. No. 6,343,454 configuration and methodology by providing a separate pre-manufactured, countertop core edge piece. In the preferred embodiment, the countertop core edge piece is manufactured by the maker of the molding component thereby allowing for the matching of these pieces. These pieces are then provided as a set to the countertop fabricator or installer, thus eliminating the need for any related field machining operations. 
         [0010]    Alternatively, in cases where the countertop edge piece is not supplied by the molding component manufacturer, it is much easier for the field fabricator or installer to properly machine this piece because the countertop edge piece as provided by the current invention is far smaller and less cumbersome than the countertop core component. Furthermore, since the countertop edge piece is seldom a visible part of the finished countertop/furniture product, it is possible to make it in lengths shorter than the length of the molding component itself without detracting in any way from the aesthetic quality of the finished product. These shorter countertop edge pieces are applied separately, with ends abutting one another, to the unfinished edge of the countertop core component further easing their fabrication and installation. 
         [0011]    Regardless of the manufacturer of the countertop edge piece, it can be made from material, different from, and stronger than, that of the countertop core component. The material can be selected for its strength which prevents failure during the installation of the molding component. 
         [0012]    Because of the features outlined above, this invention greatly simplifies and expedites the work associated with fabrication of countertops or other furniture components where the U.S. Pat. No. 6,343,454 methodology is utilized. 
         [0013]    The furniture and countertop edge molding attachment system and method for its use comprises a countertop core component, a countertop edge piece, a decorative edge molding component and the countertop surface material. In some cases, the countertop core component may also constitute the countertop surface material. 
         [0014]    The countertop core component has an upper surface, a bottom surface, and an unfinished edge. 
         [0015]    The method of the present invention involves 1) creating a separate countertop edge piece that is generally rectangular and has a top surface, a bottom surface, a front face, and a rear face. The countertop edge piece has a first groove with an angled wall cut in its bottom surface. This groove in turn creates a downwardly facing wedge-shaped tongue between its angled front wall and the front face of the countertop edge piece. The configuration of the countertop edge piece groove and wedge-shaped tongue are identical to those described in detail in U.S. Pat. No. 6,343,454 except that they are machined into the countertop edge piece bottom surface and not into the bottom surface of the countertop core component. 
         [0016]    The second step of the method involves 2) attachment of the countertop edge piece to the front unfinished edge of the countertop core component such that the rear face of the countertop edge piece is in abutting relationship with the unfinished edge of the countertop core component and the upper surface of the countertop edge piece is flush with the upper surface of the countertop core component. Attachment of the countertop edge piece to the countertop core component may be done in any manner that produces a strong bond as long as the attachment method does not obstruct the countertop edge piece groove or the countertop edge piece wedge-shaped tongue. 
         [0017]    After the countertop edge piece has been attached to the countertop core component with their upper surfaces flush, the third step of the method involves 3) application of the countertop surface material as a single piece over the top of the countertop core component and the top surface of the countertop edge piece with the front edge of the countertop surface material being made flush with the front face of the countertop edge piece. 
         [0018]    At this point, the unit created by the attachment of the countertop edge piece to the countertop core component and the application of the countertop surface material is equivalent to the countertop component upon completion of step 1) as described in the summary of invention for U.S. Pat. No. 6,343,454. 
         [0019]    The molding component as described in U.S. Pat. No. 6,343,454 is then attached to the countertop component by following steps 2) thru 4) as described in the summary of invention for that patent. 
         [0020]    It is a feature of the present invention to provide a countertop or furniture assembly that is easier to fabricate and install with commensurate potential for improvement in aesthetic quality. 
         [0021]    A significant advantage of the present invention is to provide a better fit between the molding component and the countertop component of decorative countertops and furniture by increasing the accuracy and reliability of the machining operations required for the attachment of the molding component to the countertop component. 
         [0022]    A further advantage of the current invention is the increased ease of machining of the countertop edge piece because of its smaller, less cumbersome size when compared with machining operations on whole countertop core components. 
         [0023]    A further advantage of the current invention is the avoidance of material failure by strengthening of the prepared countertop component through use of a countertop edge piece that can be separately fabricated from stronger material. 
         [0024]    The above and other objects, features and advantages of the present invention will become apparent from the drawings, the description given herein and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  is a perspective sectional view of a complete countertop assembly configured in accordance with the preferred embodiment of the current invention. 
           [0026]      FIG. 2  is an exploded perspective view showing the parts and construction of a countertop unit prior to installation of the decorative molding component. 
           [0027]      FIG. 3  is a perspective sectional view of the countertop edge piece 
           [0028]      FIG. 4  is a perspective sectional view of a molding component configured in accordance with U.S. Pat. No. 6,343,454 and suitable for use with the current invention. 
           [0029]      FIG. 5  illustrates the dimensional relationships between the component parts of the current invention. 
           [0030]      FIG. 6  illustrates the attachment methodology for assembly of the molding component to the countertop unit when using the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0031]    Referring now to the drawings,  FIG. 1  illustrates the completed countertop assembly of the present invention which is designated by the numeral  10 . The countertop assembly  10  is composed of the countertop core component  20 , a molding component  30  with a decorative face  35 , a countertop surface material  40  and a countertop edge piece  50 . 
         [0032]    Referring to  FIG. 2 , the countertop unit  60  includes a countertop core component  20  made from any appropriate material such as particle board or plywood and having an upper surface  21 , a lower surface  22 , and an exposed unfinished side edge  23 ; a countertop edge piece  50  which is a generally rectangular member made from any appropriate material such as hardwood and having a top surface  51 , a rear face  52 , a front face  53 , and a bottom surface  54 ; and a countertop surface material  40 , whose front edge  41  is made flush with the front face  53  of the countertop edge piece  50  when the countertop unit is assembled. The countertop edge piece  50  has a groove  55  cut in its bottom surface  54  which is opposite the top surface  51  to which the countertop surface material  40  is bonded. The groove  55  runs parallel to the front face  53  of the countertop edge piece to which the decorative edge molding component  30  ( FIG. 1  and  FIG. 4 ) will be attached. 
         [0033]      FIG. 3  illustrates a perspective sectional view of the countertop edge piece  50  and the groove  55  cut in its bottom surface  54 . The front wall  55   a  of groove  55  is not perpendicular to the bottom surface  54  of countertop edge piece  50  rather it is angled slightly in the range of 3 to 5 degrees so that it is closer to the front face  53  of the countertop edge piece  50  at its mouth (bottom surface  54  of edge piece  50 ) than it is at its roof  55   b . In the preferred embodiment of the current invention, the rear wall  55   c  of groove  55  is perpendicular to the bottom surface  54  of countertop edge piece  50 . Alternatively, in the second embodiment of the current invention, the groove rear wall  55   a  is not perpendicular to the bottom surface  54  of the countertop edge piece  50  but is also angled to make it parallel to the groove front wall  55   a  which is angled as described in all cases. 
         [0034]    As can be seen in  FIG. 3 , creation of groove  55  in turn creates a downward facing wedge-shaped tongue  56  whose front face is the lower portion of front face  53  of the countertop edge piece  50  and whose rear side is the angled front wall  55   a  of groove  55  and whose tongue end is the remainder of bottom surface  54  that lies between groove  55  and the front face  53  of the countertop edge piece  50 . 
         [0035]    Note that  FIG. 4  and its description are included herein for continuity and ease of reference only. The  FIG. 4  molding component, and its description below, is identical to the molding component described in U.S. Pat. No. 6,343,454 and is not changed by the present invention. 
         [0036]      FIG. 4  illustrates a perspective drawing of the molding component  30  including a decorative front side  35 . There are many shapes for the decorative front side of a molding component. For example, some may be beveled on top with a flat face such as the one shown in  FIG. 4 . In other cases, the decorative side may be square or a full half round or some other decorative profile. Similarly, the finish surface of the decorative front side  35  varies. Examples include varnished wood, plastic laminate, or solid polymer. It should be recognized that neither the shape of the decorative front side  35  nor its finish are subjects of the current invention. What is important is that the top edge  36  where the finished side  35  meets the flat back joining side  37  is straight and well defined thereby allowing it to fit tightly against the front face  53  (see  FIG. 2 ) of the countertop edge piece  50  while also allowing it to be aligned with the countertop surface material  40  during final assembly. 
         [0037]    Referring again to  FIG. 4 , the core  33  of molding component  30  although shown as  3  pieces for clarity and definition, may, alternatively be milled from one or two pieces of material such as medium density fiberboard, solid wood or solid polymer. 
         [0038]    As shown in  FIG. 4 , the joining side of the molding component  30  is a “J” shape consisting of a flat back joining surface  37  that extends down from the top edge  36  of the molding component decorative side  35  to bottom point  37   a.    
         [0039]    As  FIG. 4  illustrates, a spacer piece  33   a  extends rearward from the lowest point  37   a  on the flat back joining surface  37  and serves to hold an upward facing tongue  33   b  away from the flat back joining surface  37 . The faces  31  and  32  of the upward facing tongue  33   b  are parallel to the flat back joining surface  37 . At the same time, spacer piece  33   a  also creates a groove.  38  above its upper face  39  and between the front face  31  of the upward facing tongue and the flat back joining surface  37 . As can be seen, the groove is open at the top 
         [0040]    Referring to  FIG. 5 , the height D 5  of the flat back joining surface  37  of molding component  30  as measured from the uppermost finished edge  36  to the intersection  37   a  of the flat back joining surface with the top  39  of spacer piece  33   a  is slightly greater than the total thickness D 2  of the countertop unit  60  unfinished front edge which equals the height of the front face of the countertop edge piece  53  plus the thickness of the countertop surface material  41 . The spacer portion  33   a  of molding component  30  is rectangular and serves to hold the upward facing tongue  33   b , which is also rectangular, away from and parallel to the flat back joining surface  37  of the molding component. The width D 6  of the spacer portion  33   a  and the upward facing groove  38  it creates is substantially equal to the midpoint thickness D 7  of the downward facing tongue  56  of the countertop edge piece  50 . The width D 4  of the upward facing tongue  33   b  is substantially equal to the width D 3  of the roof  55   b  of downward facing groove  55  of countertop edge piece  50 . The effective height D 8  of the upward facing tongue  33   b  on the molding component  30  is slightly less than one half D 2 . The depth D 1  of countertop edge piece groove  55  is substantially equal to one half the countertop unit edge thickness D 2 . Countertop edge piece groove  55  front wall  55   a  is at an angle “a” which is in the range of about 3 to 5 degrees from perpendicular to the bottom surface  54  of the countertop edge piece  50 . In the first embodiment of the current invention, the rear wall  55   c  of groove  55  in countertop edge piece  50  is perpendicular to the bottom surface  54  of countertop edge piece  50 . In the second embodiment of the current invention, rear wall  55   c  is parallel to the angled front wall  55   a  of groove  55 . 
         [0041]      FIG. 6  illustrates the assembly methodology for a complete countertop configured in accordance with the present invention. Prior to assembly, the countertop edge piece  50  has a groove  55  cut in its bottom surface as shown in  FIG.3 . The construction of the countertop unit involves attachment of a countertop edge piece  50  to a countertop core  20  such that the rear face  52  of the countertop edge piece  50  is in abutting relationship with the front edge  23  of the countertop core  20  and the top surface  51  of countertop edge piece  50  is flush with the top surface  21  of the countertop core  20 . Attachment of the countertop edge piece  50  to the countertop core  20  may be by any means such as gluing, screwing, nailing, stapling or some combination thereof provided that the method of attachment is sufficiently strong and does not obstruct either the downward facing groove  55  or the downward facing wedge-shaped tongue  56  of the countertop edge piece  50 . 
         [0042]    After the countertop edge piece  50  has been attached to the countertop core  20 , the countertop surface material  40  is then applied as shown in  FIG. 2 . 
         [0043]      FIG. 4  illustrates the configuration of the molding component and  FIG. 5  provides additional dimensional relationships for the proper fitting of the components of the present invention. 
         [0044]    When ready for assembly, a thin coat of glue or other adhesive with a reasonable open time, say 30 minutes, is applied to the countertop unit unfinished front face  63  and the molding component  30  flat back joining surface  37 . A bead of glue or adhesive is run in the bottom of the molding component upward facing groove  38  and on the on the top edge  39  of its upward facing tongue  33   b . After application of the glue or adhesive, molding component  30  is placed below the countertop unit  60  so that its flat back joining surface  37  is parallel to and in planar alignment with the countertop unit&#39;s unfinished front face  63 . The molding component  30  is then raised vertically until the upward facing tongue  33   b  of the molding component  30  enters the downward facing groove  55  of the countertop edge piece and the downward facing tongue  56  of the countertop edge piece  50  enters the upward facing groove  38  of the molding component  30 . As the molding component  30  is raised further, the uppermost forward edge  39   a  of upward facing tongue  33   b  of the molding component  30  contacts the rear angled face  55   a  of the downward facing tongue  56  of the countertop edge piece  50  . Once contact is made, further raising of the molding component  30  wedgeably forces upward facing tongue  33   b  back away from the unfinished face  63  of the countertop unit  60  which in turn forces the flat back joining surface  37  of molding component  30  tighter and tighter against the countertop unit  60  unfinished face  63 . By the time the top edge  36  of molding component  30  is aligned with the top finished surface  40  of the countertop unit  60 , the molding component  30  and the countertop unit  60  are firmly and tightly wedged together. Despite the tightness of this clamping action, as long as the glue or adhesive is wet, the molding component can still be adjusted up or down sufficiently to ensure proper alignment of molding component top edge  36  with countertop component surface  40 . 
         [0045]    As the molding component  30  is raised into position, the beads of glue or adhesive applied to the molding component groove  38  and upward facing tongue  33   b  are forcibly distributed, filling grooves  38  and  55  and covering tongues  33   b  and  56 .