Abstract:
A sink support shell apparatus and method of making a sink support shell are provided. The sink support shell apparatus is a shell shaped to be compatible with the sink that is to be placed in the sink support shell. The sink support shell includes a rim for mounting the shell either above or below the countertop level. The sink sits in the shell and is attached to the shell by a waterproof adhesive, such as silicon glue. The shell further includes an overflow/vent channel and stand-off in the base for attaching the shell to the necessary plumbing fixtures to allow for drainage of the water from the sink. The overflow/vent channel is formed in the material of the shell and allows water to flow down the channel to be drained by the attached plumbing fixtures as well as air to be vented to reduce suction noise. The sink support shell is made of high-impact material, such as a metal or hard plastic material. The high-impact material provides protection for the sink from impacts on the underside of the sink, a leak proof support, and strength so that the sink may be fashioned from thinner material than known sinks. In addition, the sink support shell beautifies the exterior portion of the underside of the sink.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Technical Field  
           [0002]    The present invention is directed to a sink support shell apparatus and a method of making a sink support shell.  
           [0003]    2. Description of Related Art  
           [0004]    The desire of owners of homes, recreational vehicles, boats, aircraft, and the like, to decorate their home/vehicle with unique and elegant fixtures leads manufacturers and interior decorators to use more unique and expensive materials in the creation of such fixtures. This is especially true in the area of bathroom and kitchen fixtures.  
           [0005]    One such material used in the creation of bathroom and kitchen sinks is marble and various types of stone, such as granite. However, the use of marble and stone sinks for the average customer is price and weight prohibitive. The average marble or stone sink weighs as much as 80 pounds due to the amount of material required to provide the necessary strength against breakage and impact. In addition, due to the amount of material used in the fabrication of such sinks, the installed cost can be upwards of five thousand dollars.  
           [0006]    This large weight limits the uses of such marble and stone sinks since weight can greatly affect the performance of aircraft, boats, recreational vehicles, and other potential locations where such sinks might be installed.  
           [0007]    Because of the expense and weight issues surrounding the use of such materials in providing elegant interiors, customers often elect to make use of imitation materials that are less costly and less heavy. However, these materials do not provide the same aesthetic quality that the natural marble and stone materials provide.  
           [0008]    Thus, it would be beneficial to have an apparatus that would allow for lighter and less costly use of materials, such as marble and stone, in the fabrication of sinks. Moreover, it would be beneficial to have a method of making such an apparatus.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention provides a sink support shell apparatus and method of making a sink support shell. The sink support shell apparatus according to the present invention is a shell shaped to be compatible with the sink that is to be placed in the sink support shell (hereafter referred to as the “shell”). The sink support shell includes a rim for mounting the shell either above or below the countertop level. The sink sits in shell and is attached to the shell by a waterproof adhesive, such as silicon glue.  
           [0010]    The shell further includes an overflow/vent channel and stand-off in the base for attaching the shell to the necessary plumbing fixtures to allow for drainage of the water from the sink. The overflow/vent channel is formed in the material of the shell and allows water to flow down the channel to be drained by the attached plumbing fixtures. In addition, the overflow/vent channel provides an air channel that prevents pressure build up in the plumbing fixtures and suction noise during draining of the sink.  
           [0011]    The sink support shell is made of high-impact material, such as a metal or hard plastic material. In a preferred embodiment, the sink support shell is formed from a hard plastic material. The hard plastic sink support shell may be created using thermal formed plastic in which a heated sheet of plastic is placed over a mold of the sink and cooled such that the plastic sheet takes on the form of the sink. Thereafter, the rim, overflow/vent channel, stand-off and drainage hole maybe formed by tooling the cooled plastic shell.  
           [0012]    The high-impact material provides protection for the sink from impacts on the underside of the sink. In addition, the sink support shell provides a leak proof support in the event of cracks or breaks in the sink due to impacts on the upper surface of the sink. Moreover, the sink support shell provides a more aesthetically pleasing exterior for the underside of the sink.  
           [0013]    Most importantly, the sink support shell of the present invention provides a support that provides strength and protection to the sink and thereby allows the sink to be fashioned from less material than prior art sinks. That is, because the sink support shell of the present invention provides the protection and strength needed to mount the sink to the countertop, protect against impacts, and the like, the sink may be fabricated from a thinner material. As a result, the weight and cost of the sink is reduced making it more affordable to customers and less of a concern with regard to installation in locations where weight is an issue.  
           [0014]    These and other features and advantages of the present invention will be described in, or will become apparent to those of ordinary skill in the art in view of, the following detailed description of the preferred embodiments.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:  
         [0016]    [0016]FIG. 1A is an exemplary diagram illustrating a top-down view of a sink support shell according to an exemplary embodiment of the present invention;  
         [0017]    [0017]FIG. 1B is an exemplary diagram of a front view of the sink support shell according to the exemplar embodiment of the present invention shown in FIG. 1A;  
         [0018]    [0018]FIG. 1C is an exemplary cross-sectional view of the sink support shell according to the exemplary embodiment shown in FIG. 1A;  
         [0019]    [0019]FIG. 2 is an exemplary diagram illustrating installation of the sink using the sink support shell of the present invention according to one embodiment of the present invention;  
         [0020]    [0020]FIG. 3 is an exemplary diagram illustrating installation of the sink using the sink support shell of the present invention according to one embodiment of the present invention;  
         [0021]    [0021]FIG. 4A is an exemplary diagram illustrating a top-down view of a faceted sink support shell in accordance with another embodiment of the present invention; and  
         [0022]    [0022]FIG. 4B is an exemplary diagram illustrating a front view of the faceted sink support shell shown in FIG. 4A.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    The present invention provides a sink support shell and a method of making a sink support shell. The present invention is especially suited for use with sinks that are typically fabricated from heavy and/or expensive materials such as marble, granite and other stone materials, metal, glass, ceramics and the like. While the present invention is especially suited for such sinks, the present invention is not limited to such. It should be appreciated by those of ordinary skill in the art while reviewing the exemplary embodiments disclosed herein, that the present invention may be used with sinks of any material and configuration.  
         [0024]    FIGS.  1 A- 1 B illustrate a sink support shell apparatus according to an exemplary embodiment of the present invention. FIG. 1A is an exemplary diagram illustrating a top-down view of a sink support shell according to an exemplary embodiment of the present invention. FIG. 1B is an exemplary diagram of a front view of the sink support shell according to the exemplar embodiment of the present invention shown in FIG. 1A. FIG. 1C is an exemplary cross-sectional view of the sink support shell according to the exemplary embodiment shown in FIG. 1A. These figures will be referenced together through the use of the common reference numbers in the following description.  
         [0025]    As shown in FIGS.  1 A- 1 C, the sink support shell  100  includes a first portion  110  that is formed and configured to conform to a shape of a bowl of a sink that is to be placed inside the concave portion of the sink support shell  100 .  
         [0026]    By stating that the sink support shell  100  is configured to conform to a bowl of a sink, what is meant is that the dimensions, curvature, shape, and the like of the bowl portion  110  of the sink support shell  100  are matched to that of a sink with which the sink support shell  100  is designed to be used. Preferably, the shape and configuration of the sink support shell  100  compliments the shape of the sink such that there is minimal gap between the surface of the sink and the concave surface of the bowl portion  110  of the sink support shell  100  when the sink is placed inside the concave opening of the sink support shell  100 , with the exception of the overflow/vent channel  130 , discussed hereafter. Any gaps that may be present may be filled with a silicon glue or other type of sealant that both seals the junction between the sink and the sink support shell  100  and adhesively attaches the sink to the sink support shell  100  so that the sink does not move relative to the sink support shell  100 .  
         [0027]    On a top edge of the bowl portion  110  of the sink support shell  100  is provided a rim  120  that extends out beyond the top edge. The rim  120  is provided as mechanism by which the sink support shell  100  may be attached to a substrate, such as a cabinet or countertop support structure. The sink support shell  100  may be attached to either a top side or a bottom side of the substrate using the rim  120 . For example, a silicon glue may be used on a surface of the rim  120  to glue the rim  120 , and subsequently the sink support shell  100 , to a top or bottom surface of the substrate. Alternatively, holes may be provided in the rim  120  such that the sink support shell  100  may be fastened to the substrate by way of bolts, screws, or other similar fastening devices. Moreover, the rim  120  may provide a surface by which the sink support shell may be attached via one or more clips to the substrate such as clips that are glued or drilled into the substrate. Such clips are generally known in the art.  
         [0028]    Also provided is a stand-off  140  for coupling the sink support shell  100  to existing plumbing fixtures, such as a drainage pipe or the like. The stand-off  140  has an opening  150 . A drain attachment may extend through an opening in the sink, through opening  150  in the stand-off  140  of the sink support shell  100  and may contact the existing plumbing fixtures and be coupled to them. The contact between the sides of the opening  150  in the stand-off  140  and the drain attachment may be sealed using a sealant for waterproofing the contact.  
         [0029]    An overflow/vent channel  130  is provided in the bowl portion  110  of the sink support shell  100 . In a preferred embodiment, the overflow/vent channel  130  extends from the top edge of the bowl portion  110  to the opening  150  in the stand-off  140 . The overflow/vent channel  130  provides a channel through which fluid may flow in the event of an overflow fluid level occurring in the sink. In such a case, the fluid may flow down the channel to the opening  150  in the stand-off  140  and drain out the drain attachment (which typically has openings provided therein) and plumbing fixture to which it is attached through the opening  150 . The fluid may enter the overflow/vent channel  130  from the sink through an overflow opening in the sink.  
         [0030]    In addition to providing a channel through which fluid may flow in the case of an overflow condition, the overflow/vent channel  130  provides an air channel during non-overflow conditions that suppresses suction noise during drainage of fluid down the plumbing fixture via the opening  150  in the stand-off  140 .  
         [0031]    The sink support shell  100  is preferably fashioned from a high-impact material such as a metal or hard plastic material. While the preferred embodiment shown in FIGS.  1 A- 1 C shows the sink support shell  100  being formed from a single piece of high-impact material, the present invention is not limited to such. Rather, the present invention may be fashioned from any number of separate portions that are coupled and sealed so as to provide a shell structure for supporting a sink.  
         [0032]    In fabricating the sink support shell  100  any method of fabricating a shell structure may be used to fabricate the sink support shell  100 . Some such methods include, for example, injection molding, thermally formed plastic techniques, laid fiberglass, stamped metal and the like.  
         [0033]    In a preferred embodiment, the sink support shell  100  is fabricated using a thermally formed plastic technique. In such a technique, a mold of the sink with which the sink support shell  100  is to be used, is provided. Holes are drilled in the mold to provide for suction in a later step of the process.  
         [0034]    A single sheet of plastic is then heated to a high temperature to make the plastic pliable. The heated plastic sheet is then applied to the sink mold such that the plastic sheet covers the sink mold. Suction is applied to the interior of the sink mold thereby causing the plastic sheet to adhere to the sink mold as much as possible. In this way, the plastic sheet takes on the shape of the sink mold.  
         [0035]    As the plastic sheet cools, the plastic material becomes hardened. The hardened plastic material is removed from the sink mold and tooled to smooth the edges, remove excess material and create the rim  120 . In addition, tooling is performed on the hardened plastic material to create the overflow/vent channel  130 , the stand-off  140  and the opening  150  in the stand-off  140 . After tooling in this manner, the sink support shell  100  is ready for use.  
         [0036]    As mentioned previously, the rim  120  of the sink support shell  100  provides for mounting of the sink support shell  100  to either a top or bottom side of a substrate, such as a structure associated with a cabinet or countertop. FIG. 2 illustrates the installation of a sink, using the sink support shell of the present invention, where the sink support shell is mounted to a top surface of a substrate.  
         [0037]    With reference to FIG. 2, it should be appreciated that the sink may be already assembled with the sink support shell  200  prior to installation. For example, a manufacturer may manufacture both the sink and the sink support shell  200  and assemble them prior to shipping to a customer. Alternatively, the manufacturer may manufacture one or both of the sink and sink support shell  200  and ship them to a third party vendor that assembles the sink and the sink support shell  200  prior to subsequent delivery to an installer of the sink structure.  
         [0038]    In yet another alternative, the sink and sink support shell  200  may be provided as two separate units to an installer who is responsible for assembling the sink and sink support shell  200  and installing them in a cabinet or countertop. Regardless of the particular alternative taken, the result is that the sink support shell  200  is mounted to the substrate with the sink being held within the sink support shell  200 . For purposes of illustration, however, it will be assumed that the sink and sink support shell  200  are provided to an installer as two separate units that are assembled during installation.  
         [0039]    As shown in FIG. 2, the installation of the sink  210  involves mounting the sink support shell  200  to the top side of the substrates  220  and connecting the sink support shell  200  to the existing plumbing fixture  230 . While FIG. 2 illustrates only the left and right sides of the sink support shell  200  being mounted to the substrates  220 , it should be appreciated that the sink support shell  200  will typically be placed in an opening made in the top surface of the substrate  220 . Thus, substrate surfaces will surround the sink support shell  200  and the sink support shell  200  will be fastened to the substrate  220  everywhere the rim of the sink support shell  200  abuts the substrate  220 . The sink support shell  200  may be fastened to the substrate  220  by placing silicon glue or other waterproof adhesive material between the bottom surface of the rim of the sink support shell  200  and the top surface of the substrate  220 .  
         [0040]    Alternatively, fasteners, such as bolts and/or screws, may be used to attach the sink support shell  200  to the substrate  220  through holes fashioned in the rim of the sink support shell  200 . Of course, it would still be beneficial to waterproof the coupling between the sink support shell  200  and the substrate  220  with a waterproof material, such as silicon or caulk. The connection between the plumbing fixture  230  and the sink support shell  200  may also be sealed and waterproofed through the use of silicon glue, a waterproof adhesive, or the like.  
         [0041]    Either before or after the sink support shell  200  is mounted and fastened into place, the sink  210  may be placed in the sink support shell  200 . The sink  210  is preferably aligned so that the drainage hole in the sink  210  matches the drainage hole present in the stand-off of the sink support shell  200  and the plumbing fixture  230 . Additionally, the sink  210  is preferably positioned so that an overflow hole in the sink, or other overflow mechanism, is aligned with the overflow/vent channel formed in the sink support shell  200 . The sink  210  may be sealed and fastened to the sink support shell  200  using silicon glue, a waterproof adhesive, or the like.  
         [0042]    The sink  210  and sink support shell  200  may be secured to the plumbing fixture  230  by way of a drain assembly (not shown) that is inserted into the hole of the sink and which passes through the stand-off to connect with the plumbing fixture  230 . Such drain assemblies are generally known in the art and thus, a detailed description is not provided herein.  
         [0043]    [0043]FIG. 3 is an exemplary diagram illustrating installation of a sink, using the sink support shell of the present invention, where the sink support shell is fastened to a bottom side of a substrate. The installation of the sink  210  is similar to that shown in FIG. 2 with the differences between the two mounting possibilities being that the sink support shell  200  is fastened to a bottom or underside of the substrate  220  and that a lip of the sink  210  is fastened to a top surface of the substrate  220 . In such an embodiment, the sink  210  and sink support shell  200  are formed taking into account the width of the substrate  220  so that the sink  210  and sink support shell  200  still abut one another as much as possible.  
         [0044]    With the use of the sink support shell  200  of the present invention, the sink  210  may be fashioned from a thinner and less costly amount of material that prior art sinks. That is, because the sink support shell of the present invention provides the protection and strength needed to mount the sink to the countertop, protect against impacts, and the like, the sink may be fabricated from a thinner material. As a result, the weight and cost of the sink is reduced making it more affordable to customers and less of a concern with regard to installation in locations where weight is an issue. Thus, with the use of the present invention, owners of aircraft, boats, recreational vehicles, and the like may now have the elegance of real marble and/or stone sinks with less cost and less concern regarding performance due to weight issues.  
         [0045]    While the primary embodiment described above illustrates the sink support shell and the sink to be oval in shape, the present invention is not limited to such. Rather, the sink support shell and sink may take any configuration desired without limitation. Thus, the sink support shell of the present invention can be formed to be compatible with any geometry of sink. One such sink geometry is a multifaceted sink as described hereafter.  
         [0046]    [0046]FIG. 4A is an exemplary diagram illustrating a top-down view of a multifaceted sink support shell in accordance with another embodiment of the present invention. FIG. 4B is an exemplary diagram illustrating a front view of the multifaceted sink support shell shown in FIG. 4A. The multifaceted sink support shell shown in FIGS. 4A and 4B is similar to the sink support shell of FIGS.  1 A- 1 C.  
         [0047]    The multifaceted sink support shell includes a bowl portion  410 , a rim  420 , an overflow/vent channel  430 , a stand-off  440  and an opening  450  similar to that of FIGS.  1 A- 1 C. However, the bowl portion  410  is formed to have a plurality of facets to accommodate a multifaceted sink, such as that described in U.S. Pat. No. D443,683, entitled “Multi-Faceted Sink”, which is commonly owned and hereby incorporated by reference. The rim  420  differs from the rim  120  in that the edge of the rim is not a smooth curve but rather, has a plurality of straight edges at angles to one another in correspondence with the facets in the bowl portion  410  of the sink support shell  400 . Of course any other configuration and geometry of sink support shell may be used without departing from the spirit and scope of the present invention and the present invention should not be interpreted to be limited to the exemplary embodiments discussed herein above.  
         [0048]    The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.