Abstract:
A fast, easy method of attaching and properly adjusting furniture edging that facilitates the improved aesthetic quality of the finished product while also providing an attachment that is both strong and watertight. The countertop assembly defines a edge construction having a unique double tongue and groove configuration that wedgably interlocks a decorative side molding against the exposed edge of a furniture panel by means of a specially configured groove on the bottom side of the furniture panel. This method of edge construction instantly locks and tightens the edge molding against the furniture panel edge thus, eliminating the need for temporary clamping while at the same time allowing for critical vertical adjustment of the edge molding to ensure the proper alignment of the top of the edge molding with the furniture panel. The invention is particularly adaptable for use in the construction of countertops or other furniture parts where a finished surface material such as plastic laminate is bonded to a support decking such as particle board.

Description:
TECHNICAL FIELD 
     The present invention relates to furniture construction. In particular, the invention pertains to the construction and attachment of decorative and/or wear-resistant edges on countertops and the like. 
     BACKGROUND ART 
     In furniture construction, countertops, desktops, shelves, dividers and other similar components most often consist of a support decking hereinafter referred to as a core material to which a finished top surface is applied. The finished top surface may be a plastic laminate, varnished veneer or other decorative material. Thus, while this core/finished surface component results in a durable, aesthetically pleasing plane surface, it leaves the edge of the core material exposed and, because the core material (e.g., particle board or plywood) is selected for its structural rather than aesthetic qualities, its exposed edge is most often considered unsatisfactory for the finished product either because of the visible surface it presents or its vulnerability to damage. Thus, it is common practice to apply a decorative edging that meets the finished surface of the countertop component and hides the edge of the core material. 
     In some countertop designs, the decorative edging may simply consist of coating the edge of the core material with some type of paint. In other countertop designs, the decorative edging may consist of a strip of relatively thin material, similar to the finished countertop surface material, that is glued over the edge of core material to hide it. Using this method, the decorative edging is most often applied to the core material edge prior to the application of the countertop surface itself. After application of the countertop surface material, it is then routed and/or filed flush with the decorative edging. 
     In still other countertop designs, the edging is a decorative molding that constitutes a separate component with a decorative side, a substrate or molding component core and, a joining side. The joining side is the side which is in direct contact with the exposed core edge of the countertop component. The decorative molding component is applied to the exposed core edge of the countertop component using for example glue, splines and/or wire brads to hold the joining side of the decorative edge molding component tightly against the exposed edge of the countertop component core material thus leaving only the finished surface of the countertop component and the decorative side of the decorative molding component exposed. At the same time, in addition to being held tightly together, the top edge of the decorative molding component is intended to align with the finished surface of the countertop component. 
     This latter countertop edging methodology, while it offers great decorative potential, presents some difficult assembly problems that tend to limit its usage. Initially, the difficulty arises from the need to properly bond the decorative molding to the countertop edge in a way that ensures a tight, strong connection without ruining the aesthetic appearance of the molding or the countertop. This often requires extensive simultaneous clamping over the length of a long countertop. The clamping is often complicated, tedious and awkward not only because of its length but also because of the close proximity of finished cabinetwork below and the limited open time of the adhesive. The application is even further complicated by the need to maintain the precise alignment of the top edge of the decorative edge molding with the countertop surface at all points along the entire length of the countertop until the adhesive dries. 
     One proposal for improved attachment of this type edging is described and illustrated in U.S. Pat. Nos. 5,613,342, 5,469,685, 5,157,891 and 4,996,817, all of which are issued to Nelson, entitled “FURNITURE EDGE CONSTRUCTION.” The Nelson invention provides for a generally longitudinal channel, horizontally disposed, formed in a front exposed edge of the countertop core material and a decorative edging piece having a protruding rib on its joining side which is received within the milled channel. 
     In  Fine Homebuilding , March 1998, No. 114, at Pages 88-93, an article entitled “MAKING BEVEL-EDGE LAMINATE COUNTERTOPS,” by Herrick Kimball, (copy attached), further describes the application of plastic laminate clad bevel edge molding to a countertop. The molding described in the article can be either flat-backed or tongue-backed. The tongue-backed molding is similar in structure to the molding described by Nelson. The article illustrates the precision work required to align and then clamp (while maintaining alignment) the molding to the countertop during assembly. The tongued molding when compared to the flat-backed molding may, in some cases, either minimally assist or further complicate correction of the problems as described below. In fact, these problems are characteristic of all currently available methods of attachment. The  Fine Homebuilding  article referenced above shows the need to sand the top edge of the decorative edge molding at the seam where it meets the countertop surface to correct any misalignment in places where the edging is higher than the countertop surface. Such sanding or filing, although common, is highly undesirable and must be very limited because it quickly results in a dark line where the substrate of the plastic laminate is exposed. Such exposure defeats one of the main aesthetic features of this type of edging. Although not addressed in the article, this same critical seam (where countertop surface and the top edge of the edge molding meet) could be misaligned in the other direction, wherein the top of the edge molding is lower than the countertop surface. This problem would not be correctable by filing or sanding but would also result in a highly undesirable black line and potential damage because the front edge of the countertop surface material would be exposed. Finally, if not properly clamped over the entire length of the countertop, this same critical seam could be open wherein the top edge of the edge molding is not held tightly against the countertop surface. These latter two problems could only be corrected by reclamping and applying more pressure in the desired directions wherever needed along the countertop length. This reclamping can only be done on the assumption that the glue is not too hard so as to preclude necessary movement without damage. Left uncorrected, any of these problems or a combination thereof will result in an inferior, if not unsatisfactory, product. 
     It should also be recognized that the alignment and clamping problems discussed above with respect to plastic laminate clad edge moldings are equally applicable to other decorative edge moldings such as finished wood or solid polymer. 
     Other references in the countertop art are U.S. Pat. No. 5,569,505, issued to Nichols, entitled “DECORATIVE PANEL CONSTRUCTION”; U.S. Pat. No. 4,958,888, issued to Livnah, entitled “LOW STRESS CONCENTRATION CUTOUT COUNTERTOP”; and, U.S. Pat. No. 4,333,288, issued to Combs, entitled “BEVEL EDGE TRIM,” none of which meet the needs of the present invention. 
       Cabinetmaker Magazine , July 1998, pages 18-19, in an article entitled “Custom Needs Drive Cabinet Designs” by Ann Marie Moss and Joe Stella, reports on the results of its 10th Annual Kitchen Trends Survey. The survey showed that wood and solid surface trimmed countertops was an up and coming trend for 1998. The growing popularity of all forms of decorative edge moldings for countertops, shelving and the like demands the continued efforts of the furniture industry to increase the efficiency of decorative molding attachment methods. 
     SUMMARY OF THE INVENTION 
     The present invention is substantially different in structure and approach from known edge molding attachment methodologies and results in a higher, more consistent quality finished product by providing a simple solution to all of the misalignment and clamping problems described above. In addition, the present invention significantly expedites fabrication and results in a very strong, watertight interconnection between components. The invention is adaptable to the construction of countertops, shelving or other edged furniture components that use any of the common surfacing materials (e.g., plastic laminate, veneer or solid polymer) applied over a support decking. 
     The method of the present invention involves 1) cutting a groove with an angled face on the underside of the countertop component core material opposite the finished surface and near and, parallel to, the exposed countertop component core edge to which the decorative molding is to be applied. This groove in turn creates a downwardly facing wedge-shaped tongue between its front angled face and the exposed core edge. 
     The second step of the method involves 2) applying the decorative side of the decorative edge molding component which is to be applied to the countertop component. The decorative side can be any of a very wide variety of configurations and finishes as desired by the designer, fabricator or customer as long as its top edge presents a straight, clean line for abutment to the front edge of the countertop component. 
     An object of the present invention is to provide a joining side of the molding component which has a generally “J” shape defined by a flat back joining surface that extends down from the top edge of the decorative molding for a distance that is slightly greater than the total thickness of the countertop component exposed edge. An “L” configuration then extends rearward from the lowest point on the flat back joining surface and then upward thereby creating a tongue that extends upward with its faces parallel to the flat back joining surface. At the same time, a groove is created between the front face of the upward facing tongue and the face of the flat back joining surface of the molding component. This groove is open at the top. In the preferred embodiment, the upward facing tongue extends upward slightly less than half the height of the flat back surface of the decorative molding. 
     The method further includes, 3) glueing, preferably with a water soluble glue with a reasonable open time, say 30 minutes or more. Glue is applied in a thin even coat over the flat back joining surface of the molding component and over the exposed core edge of the countertop component. A small bead of glue is also applied into the bottom of the upward facing groove of the molding component and on the top edge of the upward facing tongue of the molding component. The method further includes 4) mating the molding component and the countertop component by bringing the molding component up vertically from below the countertop component such that the flat back joining surface of the molding component is parallel to and in planar alignment with the exposed core edge of the countertop component. As the molding component is raised vertically, the upward facing tongue of the molding component fits into the specially configured groove in the bottom of the core material of the countertop component and the downward facing tongue at the front edge of the countertop component core material fits into the groove between the flat back surface of the molding component and the upward facing tongue of the molding component. The upward and downward facing tongues thus mate with the downward and upward facing grooves. The angled front face of the groove in the bottom of the countertop core serves as a ramp which wedgeably forces the upward facing tongue of the molding component away from the exposed core edge of the countertop component which in turn draws the flat back joining surface of the molding component tighter and tighter against the core edge of the countertop component as the molding component continues to be raised until the top decorative edge of the molding component is flush with the finished surface of the countertop component and the component pieces are firmly wedged together. While the clamping action of the wedged joint is significant, it should be recognized that until the glue sets, the molding component can still be adjusted vertically in order to ensure proper alignment with the countertop component finished surface. In addition, because of the strength of the clamping action, it is possible to adjust the alignment of the molding component at various points without disturbing the alignment at other points. 
     In view of the above objects, it is a feature of the present invention to provide a countertop assembly which is easy to install. 
     It is another feature of the present invention to provide a countertop assembly which is relatively simple structurally and thus simple to manufacture. 
     A significant advantage of the present invention is the ability to vertically adjust and align the entire longitudinal length of the top edge of the molding component with the top surface of the countertop component to create a flush alignment therebetween during the gluing phase of the countertop assembly installation. 
     A further advantage of the present invention is the tight connection which eliminates the need for clamping. 
     A further advantage of the present invention is the ability to vertically adjust and align the entire longitudinal length of the top edge of the molding component with the top surface of the countertop component to compensate for any manufacturing misalignments or offsets which would otherwise compromise the desired flush alignment between the top edge of the molding component and the top surface of the countertop component. 
     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 DRAWING 
     For a further understanding of the nature and objects of the present invention, reference should be had to the following description taken in conjunction with the accompanying drawings in which like parts are given like reference numerals and, wherein: 
     FIG. 1 is a perspective sectional view of a countertop assembly configured in accordance with the first embodiment of the present invention; 
     FIG. 2 is a perspective sectional view of a countertop component configured in accordance with the first embodiment of the present invention and ready for assembly; 
     FIG. 3 is a perspective sectional view of a molding component configured in accordance with the first embodiment of the present invention; 
     FIG. 4 is an exploded illustration of a side view of the countertop and molding components of the countertop assembly showing dimensional relationships for the first embodiment of the present invention; 
     FIG. 5 is a partial side view of an assembled countertop assembly configured in accordance with the first embodiment of the present invention; 
     FIG. 6 is a partial side view of a countertop component configured in accordance with the second embodiment of the present invention; 
     FIG. 7 is an exploded illustration of a sectional side view of the countertop and molding components showing dimensional relationships for the second embodiment of the present invention; and, 
     FIG. 8 is an end sectional view of an assembled countertop configured in accordance with the second embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, FIG. 1, shows the overall countertop assembly of the present invention which is designated by the numeral  10 . The countertop assembly  10  is comprised of a countertop component  20  and a molding component  30 . 
     Referring to FIG. 2, the countertop component  20  includes a finished surfacing material  21 , such as plastic laminate, which is bonded to a core material  22 , such as particle board or plywood. The core material  22  has a groove  23  cut in its bottom surface  22   a  which is opposite the surface to which the finished surfacing material  21  is bonded. The groove  23  runs parallel to the exposed core sidewall  24  which is to be covered by the decorative molding component  30  (FIG.  3 ). 
     FIG. 2 shows a cross section view of groove  23 . In the first embodiment of the present invention, rear wall  23   a  of groove  23  is perpendicular to the bottom surface  22   a  of core material  22 . The front wall  23   b  of groove  23  is not perpendicular to the bottom surface  22   a  of core material  22  rather it is angled slightly so that groove front wall  23   b  is closer to the exposed core material sidewall  24  at the mouth of groove  23  than it is at the root of groove  23  where front wall  23   b  meets groove roof wall  23   c.    
     As can be seen from FIG. 2, creation of groove  23  in turn creates a downward facing tongue  25  whose front side is the surface of the exposed core material sidewall  24  and whose rear side is the angled front wall  23   b  of groove  23  and whose tongue end  22   b  is the remainder of bottom surface  22   a  of core material  22  that lies between groove  23  and the exposed core material side wall  24  after groove  23  has been cut. 
     Referring to FIG. 4, in the preferred embodiment angle a would be 4 degrees +/−1 degree from perpendicular with the bottom surface  22   a  of the countertop component core  22  and the depth D 1  of groove  23  is slightly greater than one half the total exposed sidewall thickness D 2  of the countertop component  20 . The width D 3  of groove roof wall  23   c , is substantially equal to the width D 4  of the upward facing tongue  33   b  on the molding component  30 . 
     Referring to FIG. 3, the molding component  30  consists of a decorative front side  31 . There are many shapes for the decorative front side of countertop moldings. For example some may be square or beveled on the top with a flat face, or the decorative front side might be a full half round. Similarly, the finish surface material (e.g., plastic laminate, varnish, solid polymer) of the decorative front side  31  of molding component  30  varies. It should be recognized that neither the shape of the decorative front side nor the material used for the finished surface are subjects of the present invention. What is important is that the top edge  31   a  of molding component  30  where the finished side  31  meets the flat back joining face  32  is straight and well defined and is intended to align with, and fit tightly against the front edge  21   a  (FIG. 2) of finished surface  21  of countertop component  20  when the molding component  30  and the countertop component  20  are assembled. Referring again to FIG. 3, the core  33  of molding component  30  although shown as 3 pieces for clarity and definition, may, in fact, be milled from a single piece of material such as medium density fiberboard, solid wood, solid polymer or it may be built up from several pieces of material of adequate size and strength. The joining side of the molding component  30  is a “J” shape consisting of a flat back joining surface  32  that extends down from the top edge  31   a  of the decorative molding component  30  for a distance that is slightly greater than the total thickness of the countertop component exposed sidewall. As FIG. 3 shows, a spacer piece  33   a  then extends rearward from the lowest point  32   a  on the flat back joining surface and serves to hold an upward facing tongue  33   b  away from the flat back joining surface  32  with its faces  34  and  35  parallel to the flat back joining surface  32 . At the same time, spacer piece  33   a  creates a groove  36  above its upper face  37  and between the front face  34  of the upward facing tongue  33   b  and the face of the flat back joining surface  32  of the molding component  30 . As can be seen, this groove is open at the top. In the preferred embodiment, the upward facing tongue extends upward slightly less than half the height of the flat back joining surface  32 . 
     Referring to FIG. 4, the height D 5  of the flat back joining surface  32  of molding component  30  as measured from the uppermost finished edge  31   a  to the intersection  32   a  of the flat back joining surface a and the upper surface  37  of spacer portion  33   a  is slightly greater than the total exposed sidewall thickness D 2  of the countertop component  20 . The width D 6  of spacer portion  33   a  (and of upward facing groove  36  which it creates) is substantially equal to the midpoint thickness D 7  of the downward facing tongue  25  on countertop component  20 . The spacer portion  33   a  of molding component  30  is rectangular and serves to hold upward facing tongue  33   b  away from and parallel to flat back joining surface face  32  of the molding component  30 . In the first embodiment of the present invention, the width D 4  of the top edge  38  of upward facing tongue  33   b  is substantially equal to the width D 3  of the groove roof wall  23   c  on the countertop component  20 . The effective height D 8  of upward facing tongue  33   b  is slightly less than one half D 2  which is the exposed sidewall thickness of the countertop component  20   
     FIG. 5 shows an assembled countertop configured in accordance with the first embodiment of the present invention. Construction of a countertop component  20  in accordance with the present invention involves cutting a groove in the bottom  22   a  of the countertop core material  22  as described in reference to FIGS. 2 and 4 above. The molding component  30  is configured as described in reference to FIGS. 3 and 4 above. When ready for assembly, a thin coat of glue with a reasonable open time, say 30 minutes, is applied to the exposed countertop core edge  24  of countertop component  20  and to the flat back joining surface  32  of the molding component  30 . A bead of glue is then run in the bottom of upward facing groove  36  of molding component  30  and on the top edge  38  of the upward facing tongue  33   b  of molding component  30 . After application of glue, molding component  30  is placed below countertop component  20  so that the flat back joining surface  32  of the molding component  30  is parallel to and in planar alignment with the exposed countertop core edge  24  of countertop component  20 . The molding component is then raised vertically until the upward facing tongue  33   b  of molding component  30  enters the downward facing groove in the countertop component  20  and the downward facing tongue  25  of countertop component  20  enters the upward facing groove  36  in the molding component  30 . As molding component  30  is raised further, the uppermost forward edge  39  of upward facing tongue  33   b  of molding component  30  contacts the rear angled face  23   b  of downward facing tongue  25  of countertop component  20 . Once contact is made, further raising of the molding component  30  wedgeably forces upward facing tongue  33   b  back away from exposed countertop core edge  24  which in turn forces the flat joining surface  32  of molding component  30  tighter and tighter against the countertop core edge  24  of countertop component  20 . By the time the top edge  31   a  of decorative molding component  30  is aligned with the front edge  21   a  of the finished surface  21  of countertop component  20 , the molding component  30  and the countertop component  20  are firmly and tightly wedged together. Despite the tightness of this clamping action, as long as the glue is wet, the molding component  30  can still be adjusted vertically up or down to ensure proper alignment of top edges  31   a  and  21   a  at all points along the countertop assembly. The beads of glue applied in groove  36  and to tongue edge  38  are forcibly distributed as countertop component  20  and molding component  30  are assembled thereby-filling voids  40  and  41  with glue. 
     FIG. 6 shows a countertop component  200  configured in accordance with the second embodiment of the present invention wherein the groove in the bottom surface of the countertop component is cut using a straight router bit, slot cutter or other cutting tool that produces an angled groove whose walls are parallel to one another. In the second embodiment of the present invention, the countertop component  200  consists of a finished surfacing material  221  such as plastic laminate which is bonded to a core material  222  such as particle board or plywood. The core material  222  has a groove  223  cut in its bottom surface  222   a  which is opposite the surface to which the finished surfacing material  221  is bonded. The groove  223  runs parallel to the exposed core material sidewall  224  which is to be covered by the decorative molding  300  (FIG.  7 ). 
     As can be seen in FIG. 6, in the second embodiment of the present invention, rear wall  223   a  of groove  223  is parallel to the front wall  223   b  of groove  223 . Neither the rear wall  223   a  nor the front wall  223   b  of groove  223  are perpendicular to the bottom surface  222   a  of core material  222  rather both are angled slightly so that front wall  223   b  and rear wall  223   a  are both closer to the exposed core material sidewall  224  at the mouth of groove  223  than they are at the root of groove  223  where front wall  223   b  and rear wall  223   a  meet groove roof wall  223   c.    
     In the second embodiment of the present invention only the countertop component differs as described above, the molding component  300  (FIGS. 7 and 8) is identical to the molding component  30  in the first embodiment as described in reference to FIGS. 3 and 4 above. 
     FIG. 7 presents the preferred dimensional relationships for the second embodiment of the present invention. In the preferred embodiment, angle b would be 4 degrees from perpendicular +/−1 degree. Front wall  223   b  and rear wall  223   a  of groove  223  are parallel to each other. The height D 5  of the flat back joining surface face  32  of molding component  300  as measured from the uppermost finished edge  31   a  to the intersection  32   a  of the flat back joining surface face and the upper surface  37  of spacer portion  33   a  is slightly greater than the total exposed sidewall thickness D 12  of the countertop component  200 . The width D 6  of spacer portion  33   a  is substantially equal to the midpoint thickness D 17  of the downward facing tongue  225  on countertop component  200 . The spacer portion  33   a  of molding component  300  is rectangular and serves to hold upward facing tongue  33   b  away from and parallel to flat back joining surface face  32  of the molding component  300 . In the second embodiment of the present invention, the width D 4  of the upward facing tongue  33   b  of molding component  300  is substantially equal to D 24  which is the shortest distance between 2 parallel lines that are perpendicular to bottom surface  222   a  of countertop component  200  and where one of the lines passes through point  125  which is the rear edge of the mouth of groove  223  and the other passes through point  126  which is the deepest point of groove  223 . The effective height D 8  of upward facing tongue  33   b  is slightly less than one half D 12  which is the overall exposed sidewall thickness of the countertop component  200 . The effective depth D 21  of groove  223  as measured to its deepest point  126  is slightly greater than one half of D 12  which is the overall exposed sidewall thickness of countertop component  200 . 
     FIG. 8 shows an assembled countertop configured in accordance with the second embodiment of the present invention. In the second embodiment, construction of a countertop assembly in accordance with the present invention involves cutting a groove in the bottom surface  222   a  of the countertop core material  222  of countertop component  200  as described in reference to FIGS. 6 and 7 above. The molding component  300  is identical to molding component  30  and is configured as described in reference to FIGS. 3 and 7 above. When ready for assembly, a thin coat of glue with a reasonable open time, say 30 minutes, is applied to the exposed countertop core edge  224  of countertop component  200  and to the flat back joining surface  32  of the molding component  300 . A bead of glue is then run in the bottom of upward facing groove  36  of molding component  300  and on the top edge  38  of the upward facing tongue  33   b  of molding component  300 . After application of glue, molding component  300  is placed below countertop component  200  so that the flat back joining surface  32  of the molding component  300  is parallel to and in planar alignment with the exposed countertop core edge  224  of countertop component  200 . The molding component  300  is then raised vertically until the upward facing tongue  33   b  of molding component  300  enters the downward facing groove in the countertop component  200  and the downward facing tongue  225  of countertop component  200  enters the upward facing groove  36  in the molding component  300 . As molding component  300  is raised further, the uppermost forward edge  39  of upward facing tongue  33   b  of molding component  300  contacts the rear angled face  223   b  of downward facing tongue  225  of countertop component  200 . Once contact is made, further raising of the molding component  300  wedgeably forces upward facing tongue  33   b  back away from the countertop core edge  224  which in turn forces the flat joining surface  32  of molding component  300  tighter and tighter against the countertop core edge  224  of countertop component  200 . By the time the top edge  31   a  of decorative smolding component  300  is aligned with the front edge  221   a  of the finished surface  221  of countertop component  200 , the molding component  300  and the countertop component  200  are firmly and tightly wedged together. Despite the tightness of this clamping action, as long as the glue is wet, the molding component  300  can still be adjusted vertically up or down to ensure proper alignment of top edges  31   a  and  221   a  at all points along the countertop assembly. The beads of glue applied in groove  36  and to tongue edge  38  of molding component  300  are forcibly distributed as countertop component  200  and molding component  300  are assembled thereby filling voids  42  and  43  with glue. 
     Because many varying and differing embodiments may be made using the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.