Patent Publication Number: US-2022232976-A1

Title: Laminated countertop assembly

Description:
BACKGROUND 
     The term “countertop” generally refers to a horizontal work surface for kitchens or other food preparation areas, bathrooms, and so forth. Countertop is frequently installed on or supported by underlying cabinetry. 
    
    
     
       DRAWINGS 
       The Detailed Description is described with reference to the accompanying figures. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items. 
         FIG. 1  is an isometric view illustrating a laminated countertop assembly in accordance with example embodiments of the present disclosure. 
         FIG. 2  is a partial cross-sectional isometric view of the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 3  is an underside isometric view of the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 4  is a partial cross-sectional underside isometric view of the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 5  is an exploded isometric view of the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 6  is a partial cross-sectional exploded isometric view of the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 7  is an isometric view of a laminated substrate for the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 8  is an isometric view of another laminated substrate for the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 9  is a partial top plan view of the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 10  is a detail view of the laminated countertop assembly illustrated in  FIG. 1 . 
         FIG. 11  is a flow diagram illustrating a method of fabricating a laminated countertop assembly, such as the laminated countertop assembly illustrated in  FIGS. 1 through 10 , in accordance with example embodiments of the present disclosure. 
         FIG. 12  is a flow diagram illustrating a method of installing a laminated countertop assembly, such as the laminated countertop assembly illustrated in  FIGS. 1 through 10 , in accordance with example embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Aspects of the disclosure are described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, example features. The features can, however, be embodied in many different forms and should not be construed as limited to the combinations set forth herein; rather, these combinations are provided so that this disclosure will be thorough and complete, and will fully convey the scope. The following detailed description is, therefore, not to be taken in a limiting sense. 
     Referring generally to  FIGS. 1 through 10 , laminated countertop assemblies  100  are described in accordance with example embodiments of the present disclosure. A laminated countertop assembly  100  includes a first generally longitudinal slab  102  and a second generally longitudinal slab  104  configured to abut the generally longitudinal slab  102  (e.g., end-to-side). In some embodiments, the generally longitudinal slab  102  and the generally longitudinal slab  104  can be partially or fully laminated. For example, the generally longitudinal slab  102  includes a first substrate  106  with lamination  108  on at least a countertop side  110  (e.g., top side, work surface side) of the substrate  106 . Similarly, the generally longitudinal slab  104  includes a second substrate  112  with lamination  114  on at least the countertop side  110  of the substrate  112 . 
     In some embodiments, the generally longitudinal slab  102  and the generally longitudinal slab  104  may include a substrate  106  and a substrate  112  made of wood or a wood-like material. For instance, an engineered or composite wood, such as particle board or chip board can be used, e.g., where engineered wood is fabricated by mixing wood chips and/or sawdust with resin. However, particle board or chip board are provided by way of example and are not meant to limit the present disclosure. In other embodiments, the substrate  106  and/or the substrate  112  can be constructed using other various materials, including, but not necessarily limited to: milled lumber, plywood, fiberboard (e.g. medium density fiberboard, high density fiberboard), strand board, and so forth. Further, the generally longitudinal slabs  102  and/or  104  can be formed using other non-wood materials, such as plastic, stone, or stone-like materials. 
     The lamination  108  and lamination  114  applied to the substrate  106  and/or the substrate  112  can be formed of a thin sheet of laminate bonded to, for example, particle board substrate. The laminate can be formed of materials such as paper (e.g., overlay paper, decorative paper, kraft paper) and resin (e.g., melamine resin). The laminate materials can be bonded to the particle board substrate using glue and/or contact cement. An indexing unit can be used to align the laminate to the substrate, a roller can be used to bond the laminate to the substrate, and a press and/or post-forming machine can be used to heat and form (e.g., press) the laminate around the substrate. After the laminate has cured, a trim saw can be used to cut the substrate and laminate to size, forming the generally longitudinal slabs  102  and  104 . 
     The lamination  108  and  114  on the substrate  106  and the substrate  112  can wrap around one or more edges of the substrates. For example, the substrate  106  includes lamination  108  on an edge side  116  of the substrate  106  (e.g., at least generally perpendicular and adjacent to the countertop side  110  of the substrate  106 ). Similarly, the substrate  112  includes lamination  114  on an edge side  118  of the substrate  112  (e.g., at least generally perpendicular and adjacent to the countertop side  110  of the substrate  112 ). The lamination can also extend partially or fully around a substrate to a side of a substrate opposite the countertop sides (e.g., bottom side, underside). 
     As described, the lamination  108  on the edge side  116  of the substrate  106  extends along only a first portion  120  of a length of the edge side  116  of the substrate  106 . There is also an unlaminated second portion  122  of the edge side  116  of the substrate  106 . In embodiments of the disclosure, the unlaminated portion  122  of the edge side  116  of the substrate  106  can be formed by removing the lamination  108  from the portion  122  of the edge side  116 . For example, a trim saw can be used to cut (e.g., rip) the edge of the substrate  106  to expose the unlaminated portion  122  of the edge side  116 . In other examples, different tools, such as a planar, a sander, and/or a grinder can be used to remove the lamination  108  from the portion  122  of the edge side  116 . 
     A first miter cut  124  can be angled into the substrate  106  from where the laminated portion  120  of the edge side  116  of the substrate  106  meets the unlaminated portion  122  of the edge side  116  of the substrate  106 . In some embodiments, the miter cut  124  is angled into the substrate  106  at an angle A (detail view,  FIG. 10 ) of about forty-five degrees (45°). However, this angle is provided by way of example, and other angles greater than or less than forty-five degrees (45°) may be used. For example, the angle could be from about fifteen degrees (15°) to about seventy-five degrees (75°). A corresponding second miter cut  126  can be made at a corner of the substrate  112  where the laminated edge side  118  of the substrate  112  meets an unlaminated end side  128  ( FIG. 8 ) of the substrate  112 . The second miter cut  126  is configured to abut the first miter cut  124 . In some embodiments, a radius R (detail view,  FIG. 10 ) can be machined into the edge side  116  of the substrate  106  (e.g., where the miter cut  124  meets the unlaminated portion  122  of the edge side  116  of the substrate  106 ) and/or at the corner of the substrate  112 . In some embodiments, the radius R can be between about one-eighth inch ⅛″ and about one-quarter inch (¼″). However, the radius R may also have different dimensions. 
     The generally longitudinal slab  102  can include slots  130  extending into the substrate  106  along the unlaminated portion  122  of the edge side  116  of the substrate  106 , where each one of the slots  130  is for receiving a biscuit  132 . Similarly, the generally longitudinal slab  104  can include slots  134  ( FIG. 8 ) extending into the substrate  112  along the unlaminated end side  128  of the substrate  112 , where each one of the slots  134  is also for receiving a biscuit  132 . In embodiments of the disclosure, the slots  130  and  134  are aligned for receiving the biscuits  132  to register the generally longitudinal slab  102  and the generally longitudinal slab  104  together at an interface between the unlaminated portion  122  of the edge side  116  of the substrate  106  and the unlaminated end side  128  of the substrate  112 . 
     In some embodiments, the generally longitudinal slab  104  can include one or more predrilled angled holes  136  (e.g., pilot holes, pocket holes), each for receiving a fastener (e.g., a pocket screw  138 , a bolt, and so forth) to draw the generally longitudinal slab  102  to the generally longitudinal slab  104  by screwing through the holes in the generally longitudinal slab  104  into the generally longitudinal slab  102 . In some embodiments, a predrilled angled hole  136  can be drilled from a side of the substrate  112  opposite the countertop side  110  of the substrate  112  (e.g., bottom side, underside). In some embodiments, a predrilled angled hole  136  can be drilled from a side of the substrate  112  opposite the edge side  118  of the substrate  112  (e.g., back side, wall side). It should be noted that predrilled angled holes in the generally longitudinal slab  104  are provided by way of example and are not meant to limit the present disclosure. In other embodiments, one or more predrilled angled holes can be positioned in the generally longitudinal slab  102  (and possibly in both the generally longitudinal slab  102  and the generally longitudinal slab  104 ). 
     It should be noted that while the two generally longitudinal slabs  102  and  104  are described herein, one or more additional slabs may be affixed to the generally longitudinal slab  102  and/or the generally longitudinal slab  104 . Such additional slabs may be joined using the same apparatus and techniques described with reference to  FIGS. 1 through 10 . For example, a third laminated slab can be joined to the generally longitudinal slab  104  (e.g., at an end side opposite the end side  128 ). 
     The following discussion describes procedures for constructing and/or installing the laminated countertop assemblies  100  described herein. The procedures are shown as a set of blocks that specify operations performed by one or more devices (e.g., equipment including, but not necessarily limited to: saws, mills, joiners, laminators, computer system(s) controlling such equipment, and so forth) and are not necessarily limited to the order shown for performing the operations by the respective blocks. In portions of the following discussion, reference will be made to the laminated countertop assemblies  100  described with reference to  FIGS. 1 through 10 . 
       FIG. 11  depicts a procedure  1100  in an example implementation in which a laminated countertop assembly, such as a laminated countertop assembly  100 , is fabricated. With reference to  FIG. 11 , a first substrate and a second substrate are formed (Block  1110 ). In some embodiments, the substrates  106  and/or  112  are formed of wood or wood-like material, e.g., using an engineered or composite wood, such as particle board or chip board, as previously described. The wood or wood-like material can be formed and/or cut to a dimensional size for countertop installation. For example, the substrate  106  can be formed and/or cut to a longitudinal shape about twenty-five inches (25″) wide, and between about seventy-two inches (72″) and about one hundred and twenty inches (120″) long. The substrate  112  can also be formed and/or cut to a longitudinal shape about twenty-five inches (25″) wide, and between about seventy-two inches (72″) and about one hundred and twenty inches (120″) long. In some embodiments, the substrates  106  and/or  112  may be the full cross-sectional thickness of the material used to construct the substrate (e.g., about one-inch (1″) or more of particle board thickness). However, these dimensions are provided by way of example and are not meant to limit the present disclosure. In other embodiments, the substrates  106  and/or  112  can have different dimensions. 
     As described, the apparatus, systems, and techniques of the present disclosure can reduce or eliminate the need to use a build up kit. For example, in another type of countertop installation, the countertop is constructed from about three-quarter inch (¾″) thick particle board with a profiled edge along one side which protrudes about another (¾″), for a total thickness of about one and one-half inches (1½″) at an edge of the countertop. A build up kit is then used to elevate the countertop to provide clearance for the profiled edge, e.g., so as not to interfere with drawers positioned below the countertop. In contrast, full-thickness substrates as described herein can reduce or eliminate the need for such a build up kit. However, in some embodiments, a build up kit may also be used. For example, the substrates  106  and/or  112  may be formed with a profiled edge. 
     In some embodiments, one or more of the substrates may be laminated (Block  1120 ). For instance, lamination  108  and/or  114  can be applied to the substrate  106  and/or  112 . The lamination  108  and/or  114  can be formed of a thin sheet of laminate bonded to, for example, particle board substrate. As previously described, the laminate can be formed of materials such as paper and resin bonded to the particle board substrate using glue and/or contact cement. An indexing unit can be used to align the laminate to the substrate, a roller can be used to bond the laminate to the substrate, and a press and/or post-forming machine can be used to heat and form (e.g., press) the laminate around the substrate. After the laminate has cured, a trim saw can be used to cut the substrate and laminate to size, forming generally longitudinal slabs  102  and  104 . 
     Referring again to  FIG. 11 , a first edge portion is removed from the first substrate (Block  1130 ). For example, the unlaminated portion  122  of the edge side  116  of the substrate  106  is formed by removing the lamination  108  from the portion  122  of the edge side  116 . In embodiments, a trim saw, a planar, a sander, a grinder, and so forth, may be used to trim the edge of the substrate  106  to expose the unlaminated portion  122  of the edge side  116 . Then, a first miter is angled into the first substrate (Block  1140 ). For instance, the first miter cut  124  is angled into the substrate  106  from where the laminated portion  120  of the edge side  116  of the substrate  106  meets the unlaminated portion  122  of the edge side  116  of the substrate  106 . A second miter is formed at a corner of the second substrate (Block  1150 ). In embodiments, the second miter is configured to abut the first miter. For example, the second miter cut  126  is made at the corner of the substrate  112  where the laminated edge side  118  of the substrate  112  meets the unlaminated end side  128  of the substrate  112 . In some embodiments, radius R can be formed or machined into the edge side  116  of the substrate  106  and/or at the corner of the substrate  112 , e.g., as previously described. 
     As described, the apparatus, systems, and techniques of the present disclosure can reduce or eliminate much of the material that would otherwise be wasted in the fabrication of a countertop. For instance, in another type of countertop installation, a miter is made that extends from an inside corner formed where a first substrate meets a second substrate to an outside corner opposite the inside corner, e.g., where a forty-five degree (45°) angle is cut in two opposing parts to create a ninety degree (90°) corner joint, and where the forty-five degree (45°) angle cut extends the full width of both parts. In contrast, the substrates  106  and/or  112  described herein allow for a reduction in the overall length of countertop needed, as the removal of two full triangular ends worth of material from both substrates is eliminated. Instead, only a thin strip of material along an edge portion of the first substrate is removed (e.g., resulting in a reduction in width of about three-sixteenths inches ( 3/16″) in some instances). Additionally, the laminated countertop assemblies  100  described herein provide a joint which remains perpendicular for nearly the full width of the countertop, providing a cosmetic improvement over, for example, a countertop with a forty-five degree (45°) angle that extends the full width of the countertop. 
     With reference to  FIG. 11 , aligned slots are formed that extend into the first substrate and the second substrate (Block  1160 ). For instance, the generally longitudinal slab  102  includes the slots  130  that extend into the substrate  106  along the unlaminated portion  122  of the edge side  116  of the substrate  106 , where each one of the slots  130  is for receiving a biscuit  132 . Similarly, the generally longitudinal slab  104  includes the slots  134  that extend into the substrate  112  along the unlaminated end side  128  of the substrate  112 , where each one of the slots  134  is also for receiving a biscuit  132 . The slots  130  and  134  are aligned to register the generally longitudinal slab  102  and the generally longitudinal slab  104  together at the interface between the unlaminated portion  122  of the edge side  116  of the substrate  106  and the unlaminated end side  128  of the substrate  112 . 
     In some embodiments, the slots  130  and/or  134  can be formed using a biscuit joiner or plate joiner, e.g., where a circular blade is used to cut crescent-shaped holes in the first and/or second substrates. In some embodiments, the slots  130  and/or  134  can be centered about one-half inch (½″) from a top surface or countertop side  110  of the substrates  106  and/or  112 . However, in other embodiments, the slots  130  and/or  134  can be centered at other distances from the top and/or bottom of the substrates  106  and/or  112 . It should also be noted that a biscuit joiner or plate joiner are provided by way of example and are not meant to limit the present disclosure. In other embodiments, other various equipment and techniques can be used to form slots, including other plunge cutting techniques. Further, the slots are not necessarily crescent-shaped. In some embodiments, the biscuits can be generally oval-shaped (e.g., # 20  biscuits), or may have other shapes or be formed as other spline-like components, such that the two countertop parts are planar prior to final assembly. 
     Referring again to  FIG. 11 , predrilled angled holes may be formed in the first substrate and/or the second substrate (Block  1170 ). For example, the generally longitudinal slab  104  includes the predrilled angled holes  136  (e.g., pilot holes, pocket holes) for receiving pocket screws  138  to draw the generally longitudinal slab  102  to the generally longitudinal slab  104 . In some embodiments, a predrilled angled hole  136  can be drilled from a bottom side of the substrate  112  and another predrilled angled hole  136  can be drilled from a back or wall side of the substrate  112 . 
       FIG. 12  depicts a procedure  1200  in an example implementation in which a laminated countertop assembly, such as the laminated countertop assembly  100 , is installed. With reference to  FIG. 12 , a first substrate and a second substrate are set in place on a supporting structure (Block  1210 ). For instance, the first and second countertop substrates  106  and/or  112  are set in place on underlying kitchen cabinets. In some embodiments, the substrates  106  and/or  112  can be marked (scribed) for fit, removed and cut, and then replaced. Biscuits are placed in slots in the first and second substrates to align the substrates (Block  1220 ). For example, biscuits  132  are inserted into the slots  130  that extend into the substrate  106  along the unlaminated portion  122  of the edge side  116  of the substrate  106 , and into the slots  134  that extend into the substrate  112  along the unlaminated end side  128  of the substrate  112 . As described, the slots  130  and  134  are aligned and register the generally longitudinal slab  102  and the generally longitudinal slab  104  together. 
     The first and second substrates and the biscuits are adhered together (Block  1230 ). For example, the substrates  106  and  112  and the biscuits  132  are connected at the joint using an adhesive, such as a moisture resistant adhesive. In some embodiments, the adhesive is multi-purpose. For example, the adhesive can be a glue that provides an adhesive to the wood joint, provides a moisture barrier to the wood joint, and/or provides a color-matched filler at cracks or gaps at the countertop surface. In some embodiments, the glue may include a dye that is color matched to, for example, the lamination  108  and/or  114 . 
     The first and second substrates are pulled together using fasteners (Block  1240 ). For instance, fasteners (pocket screws  138 , bolts, and so forth) are inserted into the predrilled angled holes  136  (pilot holes, pocket holes) to draw the generally longitudinal slab  102  to the generally longitudinal slab  104  by screwing through the holes in the generally longitudinal slab  104  into the generally longitudinal slab  102 . In this manner, the pocket screws  138  pull the substrates  106  and  112  together tightly at the joint, which can reduce or eliminate the use of clamps that would otherwise be used to hold the substrates together. The techniques of the present disclosure may allow the countertop to be constructed from a standing position (e.g., without requiring access to an underside of the countertop). 
     In another type of countertop installation, where miter bolts are used to draw two countertop parts together, the miter bolts are placed on the underside of the countertop and tightened together, with an installer working from underneath the countertop and inside the cabinets. Using miter bolts, a miter joint may be difficult to bring together and keep planar across the width of the countertop as the miter bolts are tightened. Furthermore, if a crack is present at the miter joint after the bolts are tightened, it can be difficult to permanently fill the crack to both conceal the edge of the laminate as well as to provide moisture resistance. Additionally, this type of installation may take an installer between about forty (40) to fifty (50) minutes, while the apparatus, systems, and techniques of the present disclosure can facilitate a countertop installation in between about ten (10) to fifteen (15) minutes. Moreover, a single person may accomplish the installation of a laminated countertop assembly  100  as described herein, and a professional installer is not necessarily needed. 
     Referring again to  FIG. 12 , the countertop is affixed to the supporting structure ( 1250 ). For example, the laminated countertop assembly  100  can be glued or otherwise attached to underlying cabinetry, such as kitchen cabinets. In embodiments, an adhesive can be used to glue the laminated countertop assembly  100  to the cabinetry. In some embodiments, angle brackets and fasteners, such as screws or bolts, may also be used to fasten the laminated countertop assembly  100  to the cabinetry and/or wall. In some embodiments, a backsplash can be placed ( 1260 ). For example, a backsplash (not shown) can be cut to size and then placed at the back or wall side of the laminated countertop assembly  100 . When the backsplash is not integrally formed with the generally longitudinal slabs  102  and/or  104 , less precise measuring and trimming of the substrates  106  and/or  112  may be required, e.g., as a separate backsplash covers any gaps present between the laminated countertop assembly  100  and the wall. This can further facilitate single person, non-professional installation of a laminated countertop assembly  100 . The backsplash can be connected (e.g., glued) to the wall and/or the countertop. For example, the same or similar multi-purpose adhesive can be used to glue the backsplash to the laminated countertop assembly  100 . 
     End caps can be affixed to one or more ends of the countertop (Block  1270 ). For example, end caps (not shown) can be glued to exposed ends of the substrates  106  and/or  112 . In some embodiments, the end caps can be cut from laminate sheets, glued to one or more ends of the substrates  106  and/or  112 , and trimmed after bonding. In some embodiments, the end(s) of the substrates  106  and/or  112  may also be pre-laminated (e.g., where end caps are not used). One or more ends of the substrates  106  and/or  112  may also remain unlaminated (e.g., where a substrate end abuts a wall). The countertop is sealed to the wall (Block  1280 ). For instance, caulk and/or other sealants can be used to seal the laminated countertop assembly  100  to one or more walls. 
     Although the subject matter has been described in language specific to structural features and/or process operations, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.