Patent Publication Number: US-9850582-B2

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

Description:
This application claims the benefit of priority under 35 U.S.C. §119(e)(1) of U.S. Provisional Application Ser. No. 61/972,017, filed Mar. 28, 2014, the entire contents of which is incorporated herein by reference. 
    
    
     BACKGROUND 
     1. Technical Field 
     The present invention relates to a system, method and kit regarding application of a metal edge to a surface. 
     2. Background Information 
     Furniture with surfaces and/or work surfaces, such as countertops and panels, traditionally lack any identification as to its manufacturer when used by a customer. This can lead to confusion for the customer as to the identification of the manufacturer of the furniture. Such identification could be useful if the customer want to contact the manufacture regarding the surface and/or work surface or wishes to purchase a surface and/or work surface from the manufacturer. 
     In addition, if delicate edge details were to be added to the above mentioned surfaces and/or work surfaces, it would typically result in high stone fabrication costs. 
     BRIEF SUMMARY OF THE INVENTION 
     One aspect of the present invention regards a surface that includes a three-dimensional surface, wherein a notch is present in said three-dimensional surface. The surface further includes a metal edge inserted into the notch and attached to the three-dimensional surface. 
     A second aspect of the present invention regards a method of manufacturing a surface that includes forming a notch within a three-dimensional surface and inserting a metal edge within the notch. The method further includes attaching the inserted metal edge to the three-dimensional surface. 
     One or more aspects of the present invention provide the advantage of identifying the manufacturer of a surface, such as a work surface or a panel, 
     One or more aspects of the present invention provide the advantage of allowing for the creation of delicate edge details without costly fabrication costs. 
     The accompanying drawings, which are incorporated herein and constitute part of this specification, and, together with the general description given above and the detailed description given below, serve to explain features of the present invention. Note that the drawings are all depictions of some of the concepts and profiles of the hardware and cross sections of the notched countertop edges with metal profiles applied. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       In the drawings: 
         FIG. 1  shows a perspective and exploded view of a first embodiment of a work surface in accordance with the present invention; 
         FIG. 1A  shows a side cross-sectional view of a notch formed in the surface of  FIG. 1 ; 
         FIG. 1B  shows the side cross-sectional view of  FIG. 1A , wherein a cross-sectional area of a volume defined by the notch of  FIGS. 1 and 1A  is shown by cross hatches; 
         FIG. 2A  shows an embodiment of an outer corner piece to be used with the work surface of  FIG. 1  in accordance with the present invention; 
         FIG. 2B  shows an embodiment of an inner corner piece in accordance with the present invention; 
         FIG. 3  shows an embodiment of an outer corner piece to be used with the work surface of  FIG. 1  in accordance with the present invention; 
         FIG. 4  shows an embodiment of a straight piece to be used with the work surface of  FIG. 1  in accordance with the present invention; 
         FIGS. 5A-G  show possible engravements to be used with the work surface of  FIG. 1  and the corner and straight pieces of  FIGS. 2A-B ,  3  and  4 ; 
         FIG. 6  shows a perspective view of an embodiment of a tab in accordance with the present invention; 
         FIG. 7  shows a perspective view of an embodiment of a handle in accordance with the present invention; 
         FIG. 8  shows a perspective view of a first embodiment of work surface that uses the handle of  FIG. 7  in accordance with the present invention; 
         FIG. 9  shows a perspective view of a second embodiment of work surface that uses the handle of  FIG. 7  in accordance with the present invention; 
         FIG. 10  shows an enlarged perspective view of the work surface and handle of  FIG. 9 ; 
         FIG. 11  shows a perspective view of an embodiment of a piping element in accordance with the present invention; 
         FIG. 12  shows a perspective view of an embodiment of backsplash that uses the piping element of  FIG. 11  in accordance with the present invention; 
         FIG. 13  shows a perspective view of a first embodiment of a work surface that uses the piping element of  FIG. 11  in accordance with the present invention; 
         FIG. 14  shows a perspective view of a second embodiment of a work surface that uses the piping element of  FIG. 11  in accordance with the present invention; 
         FIG. 15  shows a perspective view of an embodiment of a sales/presentation kit when an associated presentation box is in a closed position in accordance with the present invention, wherein the sales/presentation kit is to be used for one or more of the work surfaces and metal edges of  FIGS. 1-14 ; 
         FIG. 16  shows the sales/presentation kit of  FIG. 15  when the associated presentation box is in an opened position; 
         FIG. 17  shows the sales/presentation kit of  FIG. 15  when the associated presentation box is in an opened position and when the top tray has been removed; 
         FIG. 18  shows the sales/presentation kit of  FIG. 15  when the associated presentation box is in an opened position and when the contents have been removed; and 
         FIG. 19  shows an enlarged view of the sales/presentation kit of  FIG. 18 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In general, the present invention regards a surface that is machined so as to receive a metal edge so that when viewed as a whole defines a new surface, such as a panel or a work surface, such as a countertop. The machined surface can be decorative in appearance with the inclusion of the metal edge, and the metal edge can be functional in that it can be used to have work performed thereon and it can be used to identify, brand and market the surface and its associated furniture by providing unique manufacturer logos and recognizable edge profiles. 
     An embodiment of a work surface is shown in  FIG. 1  is exemplary of basic principles regarding the other embodiments of  FIGS. 2B and 6-19  and so will be described herein. In particular, a surface  100  defines a right parallelepiped. As shown in  FIG. 1 , the surface  100  includes a horizontal top surface  110 , a bottom horizontal surface  160 , and four vertical side surfaces  162 , wherein the surfaces  110 ,  160  and  162  are integral with one another. Of course, other three dimensional shapes to define the surface are possible. The length, width, thickness of the surface  100  can be any value depending on the intended use of the surface  100 . The surface  100  can be made of any material. An example of a suitable material is quartz, such as the quartz manufactured by Caesarstone. 
     The surface  100  is worked with a tool to form a notch  102  in its sides.  FIG. 1  shows notches  102  formed in two of the vertical sides  162  of surface  100 . In particular, the notch  102  can be formed manually by using one or more tools, such as a router or a shaper with a specific router or shaping bit, which can be presented in a tool kit (not shown). The tool kit can also include pieces of a metal edge and a metal cutting tool to cut the pieces to a desired length. The tool kit can include surfacing samples with notching. 
     The notch  102  can be polygonal in cross-section and is preferably rectangular in cross-section as shown in  FIG. 1 . In the embodiment of  FIG. 1 , the notch  102  extends around the side walls  104  of the surface. As shown in  FIGS. 1 and 1A -B, the notch  102  includes a horizontal top surface  164  and a horizontal bottom surface  166  that faces surface  164 . A vertical side surface  165  of the notch  102  is integrally joined with the surfaces  164  and  166 . As shown in  FIGS. 1 and 1B , the notch  102  defines a volume (see cross-hatched cross-sectional area of volume shown in  FIG. 1B ) of space defined by the surfaces  164  and  165 , wherein the volume does not extend past the vertical sides  162  as denoted by the vertical dashed lines  167  of  FIG. 1B . The volume extends along the entire length of surface  165  along a direction that is perpendicular to the plane containing  FIG. 1B . Note that  FIGS. 1A-B  are illustrative of notch  102  and are not intended to denote any particular dimensions for the notch  102 . As shown in  FIG. 1 , the length of the notch  102  is substantially greater than either the height or depth of the notch  102 . Note that the notch can be formed in other areas of the surface  100  as shown in  FIGS. 8-10 and 12-14 . For example, a notch can be formed at one of the corners  106 , one of the edges  108  and the top surface  110 . Furthermore, there could be multiple disconnected notches formed at different areas of the surface depending on the desired work surface to be produced. 
     Within the notch  102 , a metal edge  112  is inserted. As shown in  FIG. 1 , the metal edge  112  can be made of multiple metal pieces that are interconnected to one another by a male connector  114  and a female connector  116 . In particular, the female connector  116  is a U-shaped slot that receives a complementary male connector  114  so as to define a male/female connection. As is apparent from  FIG. 1 , the male/female connection is similar to an interconnection between two jigsaw pieces that engage one another. 
     As shown in  FIG. 1 , a pre-assembled corner piece  118  is inserted into a portion of a corner of the notch  102 . The corner piece  118  has two sides  120 ,  122  that are integrally formed with one another, wherein side  120  has a male connector  114  and side  122  has a female connector  116 . The corner piece  118  has a front, planar surface  121  that faces in a direction opposite to that faced by corresponding portions of rear surface  123 . The sides  120  and  122  are equal in length and form a right angle. Of course, other shapes and dimensions for the corner piece  118  are possible, such as having unequal lengths for the sides and the sides form an angle other than 90 degrees. 
     As shown in  FIG. 1 , straight pieces  124  and  126  are inserted into central sections  128  and  130 , respectively, of the notch  102 . The straight pieces  124 ,  126  have front, planar surfaces  125 ,  127  that face in a direction opposite to that faced by corresponding rear surfaces  129 ,  131 . The male connector  114  of corner piece  118  engages a female connector  116  of the straight piece  124  and the female connector  116  of corner piece  118  engages a male connector  114  of the other straight piece  126 . Note that when the above described male/female connection/engagement is made, the pieces  118 ,  122  associated with the female connectors  116  extend lengthwise along the same direction that the corresponding pieces  118 ,  126  associated with the male connectors  114  extend lengthwise. In addition, when the assembled metal edge  112  is positioned within the notch  102 , a front, planar surface ( 121 ,  125 ,  127 ) of the metal edge  112  is parallel to and faces away the surface  165  of the notch  102 . Furthermore, when the assembled metal edge  112  is positioned within the notch  102 , a rear surface ( 123 ,  129 ,  131 ) of the metal edge  112  1) faces the surface  165  of the notch  102 , 2) covers the surface  165  in its entirety, and 3) is positioned between the front surface of the metal edge  112  and the surface  165  of the notch  102   
     Not shown in  FIG. 1  is that the straight pieces  124  and  126  will engage with the male connectors  114  and female connectors  116  of corner pieces  118  at two other corners of the notch  102 . In addition, a second set of straight pieces  124  and  126  are placed in central sections of the notch  102  that are positioned opposite to the central sections  128  and  130 , respectively. The second set of straight pieces  124  and  126  are connected with the previously mentioned corner pieces and a fourth corner piece placed in the remaining corner portion of the notch  102 . The various straight pieces  124 ,  126  and corner pieces  118  are attached within the notch  102  by using an adhesive between the surface of the notch  102  and a rear side of each of the straight and corner pieces. Of course, other attachment structures between the surface  100  and the metal pieces  118 ,  124 , and  126 . For example, mechanical devices, such as pins, could be used alone or in combination with the adhesive to attach the metal pieces  118 ,  124 ,  126  to the surface  100 . When all the above mentioned straight pieces  124 ,  126  and corner pieces  118  are attached to one another and positioned with the notch  102 , a work surface  132  is formed that includes the notched surface  100  and a rectangular metal edge  134 . 
     The work surface  132  of  FIG. 1  is but an example of a possible result of the use of the metallic pieces and sections mentioned previously. It is envisioned that the straight pieces  124  and  126  and the corner pieces  118  are pre-fabricated by being cut to a size based on a particular work surface or panel to be formed and into various decorative/function profiles and sizes. For example, the length, height, and width of the corner piece  118  can be varied based on the workpiece to be formed as illustrated in  FIGS. 2A and 3 . Thus, depending on the width chosen, the corner piece  118  can be entirely contained within the volume (see cross hatch of  FIG. 1B ) defined by notch  102 , flush with the vertical side  162  of surface  100 , or extend past side  162 . Similarly, the length, height, and width of the straight pieces  124  and  126  can be varied as illustrated in  FIG. 4 . Thus, depending on the width chosen, the straight pieces  124  and  126  can be entirely contained within the volume defined by notch  102 , flush with the vertical side  162  of surface  100 , or extend past side  162 . In addition, besides an outside corner piece  118 , a prefabricated inside corner piece  136  of various lengths, heights, and widths can be manufactured as shown in  FIG. 2B  so as to provide edging for work surfaces that have an inside corner. Note that under certain circumstances, the outside corner piece  118  can be flipped to provide an inside corner piece  136 . 
     Many types of finishes for the metal pieces are possible, such as stainless steel, brushed stainless steel, polished stainless steel, bronze, carbon, braided metals and copper patina. The use of pre-fabricated corner pieces  118  and  136  eliminate the need for miter cutting and joint fitting at corners, which is often a problem with fabricators who are not used to working with metals. Note that in certain circumstances, the metal edge can be a single piece. In addition, the thickness of the metal edge can be constant throughout or variable. 
     As can be readily understood by the previous description, the work surface  132  of  FIGS. 1, 2A, 3 and 4  provides many advantages. For example, it demonstrates a modular system that can be applied to any building material and is easily stocked, shipped and assembled. The metal edge functions as a joining element, wherein seams become details, materials can be mixed and waste is reduced. Use of the metal edge will result in a reduction in service calls to repair chipped edges since the metal edge provides edge protection at corners and sinks. The use of the metal edge also provides opportunities for providing decorative designs thereon. Also, the metal edge provides the opportunity to laser etch/engrave text on an exterior facing side of either of the sections  118 ,  124  and  126 , which can be used to brand the work surface  132  with a logo, the name of the manufacturer or other identifying symbol, such as a trademark. Examples of such engraved text are shown in  FIGS. 5  A-G. 
     Based on the above principles, various work surfaces can be formed. For example, suppose at one of the sides of the notch  102  of  FIG. 1  the straight section  124  does not have a sufficient length to be connected to the corner pieces  118 . In this case, the straight section  124  is cut with the metal cutting tool of the previously mentioned tool kit so as to form two pieces of the same length. The two pieces are inserted and attached with the notch  102  and attached to the corner pieces  118  as describe previously. This will result in a gap forming between the two pieces. The gap is hidden by inserting a tab  138 , as shown in  FIG. 6 , into the gap. The tab  138  can have various lengths, heights and widths depending on the work surface being formed. The tab  138  is attached within the notch  102  using either an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces  118 ,  124 , and  126 . The tab  138  can also include etching/engraving as previously described with respect to the metal pieces  118 ,  124  and  126 . 
     As another example, suppose at one of the sides of the notch  102  of  FIG. 1  the straight section  124  is too long to be connected to the corner pieces  118 . In this case, the straight section  124  is cut by the metal cutting tool of the previously mentioned tool kit so that a middle portion is removed and the two remaining pieces are of the same length. The combined length of the two remaining pieces is such that when the pieces are connected to the corner pieces  118  no gap is formed between the straight pieces. The two pieces are inserted and attached with the notch  102  and attached to the corner pieces  118  as describe previously. 
     The previously described edgings regard an edging that surrounds a portion of the surface  100  and is below the top surface  110  of the surface  100 . The edgings can be formed solely on the top surface  110  or both the top surface  110  and one or more side surfaces  104  of the surface  100 . In the latter case, a handle  140  can be inserted into an L-shaped notch formed in the top surface  110  and a side surface  104  of the surface  100 . The notch is manufactured using the tools of the tool kit mentioned previously. An example of a handle  140  to be inserted into the notch is shown in  FIG. 7 . The length, thickness and the size of the L-shaped cross-section of the handle  140  can be varied depending on the type of work surface to be formed. The handle  140  is attached within the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces  118 ,  124 , and  126 . Examples of handles  140  are shown in  FIGS. 8-10 . Note that the handle  140  can include etching/engraving as previously described with respect to the metal pieces  118 ,  124  and  126 . 
     Besides the metal edge  134  of  FIGS. 1-6  and the handle  140  of  FIGS. 7-10 , the present invention can be used to form various types of piping elements. An example of a piping element  142  is shown in  FIG. 11 . The piping element  142  is in the form of a parallelepiped, wherein the length, width and height can have various values based on its intended use. One use for the piping element  142  is as a transition between two surfaces of a counter piece. As shown in  FIG. 12 , a rectangular groove is formed along the bottom length of a backsplash  144  that is adjacent to a counter surface  146 . The notch is manufactured using the tools of the tool kit mentioned previously. The piping element  142  is attached within the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces  118 ,  124 , and  126 . 
     The piping element  142  can be used as a bead detail. As shown in  FIG. 13 , a rectangular groove is formed between an exterior edge  148  of an inner top surface  150  and an interior edges  152  of an outer top surface  154 . A first piping element  142 A is attached within a portion of the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces  118 ,  124 , and  126 . An end of the first piping element  142 A abuts against the interior edge  152  of the outer top surface  154 . A second piping element  142 B is attached within the remaining portion of the notch using an adhesive or other attachment structures as previously discussed with respect to the attachment of metal pieces  118 ,  124 , and  126 . An end of the second piping element  142 B abuts against a side of the end of the first piping element  142 A. A similar example of such a use of plural piping elements is shown in  FIG. 14 . 
     In order to illustrate the benefits of the edging of the present invention and in order to instruct others on how to install the edging previously described with respect to  FIGS. 1-14 , a presentation or sales kit  200  is stored in a presentation box  202  shown in  FIG. 15 . The presentation box  202  is rectangular in shape and has metallic top and bottom edges  204 ,  206 , respectively. Of course, other shapes for presentation box  202  are possible without departing from the spirit of the invention. The presentation box  202  also may or may not have rectangular openings  207  formed in its side walls  210  in other to define handles for carrying the presentation box  202 . As shown in  FIGS. 16 and 17 , the presentation box has a hinged top lid  212 . When the lid  212  is opened, it reveals a top tray  214  that has slots to contain samples of straight metal pieces  216 , handles  217 , and corner metal pieces  218  with different profiles and finishes, tabs  220  having text etched thereon a manual  222  regarding the edging, and a USB flash drive  224 . Note that the straight pieces  216 , the handles  217 , and the corner pieces  218  can also include text etched thereon. The tray  214  may also have slots to receive the previously described piping elements  142 . The flash drive  224  can include application instructions, an instructional video of surface machining using the tool kit and installation of the metal pieces previously described with respect to  FIGS. 1-14 . The flash drive  224  can also provide application instructions, adhesive and finishing tips, and use and care instructions. When the top tray  214  is removed, it reveals various sample blocks  226  that have been machined to receive the straight sections  216 . The sample blocks have various finishes to allow an observer to envision how a surface similar to a sample block will look when receiving one or more of the previously described straight metal pieces  216 , handles  217 , corner metal pieces  218  and tabs  220 . The sample blocks  226  are positioned within corresponding vertical slots  228  defined by vertical walls/dividers located within the presentation box  202  and show various materials for the notched surface that is to receive the metal pieces  216  and  218 . 
     It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof.