Patent Publication Number: US-6986174-B2

Title: Sink mounting device and system

Description:
FIELD OF THE INVENTION 
   This invention relates to mounting devices, and in particular, to mounting devices for securing a sink to a countertop. 
   BACKGROUND OF THE INVENTION 
   The rapid growth of the new home construction and remodeling industries has generated a need for quick and inexpensive construction techniques. This is especially true in respect to kitchen and bathroom installations. Various devices have been developed for mounting a sink to the underside of a countertop. Typically, these devices utilize a hanging clip which engages beneath the sink flange and is secured to the countertop using a threaded fastener and anchor. 
   In a standard undermount sink installation, a cutout corresponding to the dimensions of the sink is made in the countertop using a template. The installer then positions the sink such that the sink flange is equidistant to the cutout and skillfully drills holes on the underside of the countertop to receive the fasteners. The threaded portion of the fastener engages the hanging clip and is tightened against the countertop to secure the clip and sink flange. When working with expensive countertop materials, such as granite and marble, the installer must carefully drill and insert the fasteners to avoid cracking or otherwise damaging the countertop material. Similarly, drilling and inserting fasteners into man-made countertop materials often produces protuberances which mar the appearance of the countertop surface. Furthermore, the installer must also be aware of the specific drills and fasteners that a manufacturer may recommend for use with its countertop materials. For instance, many manufacturers commonly recommend that lead fasteners be used with marble countertops. 
   Given the time, skill and tools required to install mounting devices in this fashion, it is often necessary that the sink be mounted to the countertop at an off-site workshop. This is not feasible in many remodeling applications in which the existing countertop is not being replaced, or when the remodeling must be completed within a short period of time. Furthermore, sinks mounted off-site will invariably require on-site adjustments to fit within the cabinetry. A mounting device comprising of a hanging clip and a fastener drilled into the underside of the countertop will be very difficult to adjust within the confined space beneath the sink. However, such adjustments are crucial to ensure a tight fit between the sink and the countertop, and to prevent the leakage of water into the cabinet and onto the floor. 
   Accordingly, there is a need for a sink mounting device which is relatively easy to install and adjust in confined spaces, and which does not require invasive drilling into the countertop material. 
   SUMMARY OF THE INVENTION 
   In a first aspect, the invention is directed to a mounting device for securing a sink, having a sink flange, to a countertop. The mounting device includes a mounting plate and a support member. The mounting plate has a plurality of perforations which are sufficiently large to permit seaming compound to flow therethrough. The support member includes a mounting flange and a support flange. The mounting flange is adapted to secure the support member to the mounting plate, and the support flange is adapted to contact and support the sink flange. 
   The mounting device may include a mounting plate having an aperture and a mounting flange having a slot. The mounting device includes a bolt which is adapted to extend through the slot and is received within the aperture to secure the mounting plate to the mounting flange. The mounting device may also include a support flange having a fastener for supporting the sink. The support flange may be adapted to couple to said sink flange. 
   The seaming compound may be an epoxy, an acrylic-based, a polyester-based, a cyanoacrylate-based or a urethane-based compound. 
   In a second aspect, the invention is directed to a system for under mount securing a sink having at least one sink bowl and at least one sink flange to a countertop. The system comprises at least a first layer of seaming compound applied to the bottom surface of the countertop. The system further comprises a plurality of mounting devices including a mounting plate having perforations to enable the first layer of seaming compound to flow therethrough. The mounting device includes a support member, the support member has a mounting flange and a support flange. The mounting flange is adapted for retaining the support member to the mounting device. The support flange is adapted to contact the sink flange and support the sink. The plurality of mounting devices are adapted to be spaced horizontally from each other when secured to the countertop. 
   At least one second layer of seaming compound may be generally applied to the mounting device so as to bond the mounting plate integrally with the first and second layers of seaming compound. 
   In a third aspect, the invention is directed to a method of attaching a mounting device for undermount securing a sink to a countertop, wherein the countertop is made from solid materials selected from the group consisting of naturally occurring materials and man-made materials. The method comprises the selection of a sink and a seaming compound, wherein the sink includes at least one sink bowl and at least one sink flange and the seaming compound is intended for creating seams in the solid material. A mounting device is provided, wherein the mounting device includes a mounting plate having a plurality of perforations which are sufficiently large to permit seaming compound to flow therethrough. The mounting device also includes a support member, wherein the support member includes a mounting flange and a support flange. The mounting flange is adapted for retaining the support member to the mounting plate. The support flange is adapted to contact the sink flange and support the sink. The method further comprises applying a first layer of the selected seaming compound to the bottom surface of the countertop and bringing the mounting plate into contact with the seaming compound. The mounting plate is then pressed into the seaming compound to force a portion of the seaming compound through the plurality of perforations and so as to bond the mounting plate with the first layer of the seaming compound. 
   A second layer of selected seaming compound may be applied over the perforations and around the perimeter of the mounting plate to bond the mounting plate integrally with the first and second layers of seaming compound. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a better understanding of the present invention and to show clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings which show preferred embodiments of the present invention and in which: 
       FIG. 1  is a perspective view of a system of mounting devices supporting a sink on the underside of a countertop in accordance with a preferred embodiment of the present invention; 
       FIG. 2  is an exploded view of the components of a mounting device of  FIG. 1 ; 
       FIG. 3  is an enlarged elevation view of the mounting plate of the mounting device of  FIG. 2 ; 
       FIG. 4  is a perspective view of the mounting plate of  FIG. 3  bonded to a first layer of a seaming compound; 
       FIG. 5  is a perspective view of the mounting plate of  FIG. 4  bonded with a first and second layer of the seaming compound; 
       FIG. 6  is a bottom plan view of the mounting device of  FIG. 2 ; 
       FIG. 7  is a side elevation view of the mounting device of  FIG. 6  contacting and supporting a sink flange; 
       FIG. 8  is a side elevation view similar to  FIG. 7  but with an alternate bridge flange; 
       FIG. 9  is a bottom plan view of a system of mounting device and countertop with a cutout for receiving a sink in accordance with the invention; and 
       FIG. 10  is a bottom plan view of the system of  FIG. 9  with mounting devices contacting and securing a sink flange. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference is made to  FIGS. 1 and 2  which illustrate a mounting device  10  made in accordance with a preferred embodiment of the invention. The mounting device  10  is mounted on the underside  12  of a countertop  14 . The countertop  14  comprises a seam  18  and a cutout  20 . The mounting device  10  is adapted for securing a sink  22  having a sink flange  24  to the underside  12  of the countertop  14  using a seaming compound  26 . The mounting device  10  comprises a mounting plate  28  and a support member  30 . The mounting device  10  may be made of any suitable material, such as 12 or 13 gauge stainless steel. The countertop  14  may be made from any naturally occurring materials, such as granite and marble, or man-made materials, such as metal, solid-surface veneer, acrylic and polyester materials, and plastic. 
   Referring to  FIGS. 2 and 3 , the mounting plate  28  may have a generally rectangular shape and has a bottom surface  32 , a top surface  34  and a perimeter  36 . The bottom surface  32  includes a mounting means  38  having an aperture  40  and a fastener  42 . Aperture  40  is adapted to receive the fastener  42  to secure the mounting plate  28  to the support member  30 , as will be discussed further below. Fastener  42  may be any suitable means, such as, for example, a mechanical fastener. 
   Mounting plate  28  includes a plurality of perforations  44  which extend from the bottom surface  32  through to the top surface  34 . The perforations  44  may be generally circular, and may be sized to be sufficiently large to permit the seaming compound  26  that is applied to the underside  12  of the countertop  14  to flow through the perforations  44 . Preferably, the perforations  44  are designed to allow the seaming compound  26  to pass therethrough and onto the bottom surface  32 , as shown in  FIG. 3 . The seaming compound  26  which is forced through the perforations  44  as the mounting plate  28  is pressed against the countertop  14  forms a plurality of buttons  46 , with one button forming under each perforation  44 . It will be noted that the surface area of top surface  34  of the mounting plate  28  and the size of the perforations  44  may be designed so as to maximize the strength of the bond between the mounting plate  28  and the seaming compound  26 . 
   The adhesion occurs in several ways. Firstly, the seaming compound is specially formulated for bonding with the selected countertop material. Secondly, the seaming compound adheres to the surface  34  of the mounting plate  28 . Thirdly, the column of seaming compound which is in the perforation  44  adheres to the wall of the perforation. Fourthly, the button  46  partially adheres to the surface  32  of the mounting plate  28 . 
   Referring to  FIG. 4 , a first layer  48  of seaming compound  26  is applied to the underside  12  of the countertop  14  proximate to the cutout  20 . The top surface  34  of the mounting plate  28  is brought into contact with the first layer  48  of the seaming compound  26 . The mounting plate  28  is pressed vertically into the first layer  48  of seaming compound  26  so that at least a portion of the seaming compound  26  flows through the perforations  44 . The mounting plate  28  will integrally bond with the seaming compound  26  as the first layer  48  of the seaming compound  26  sets and bonds to the underside  12  of the countertop  14 . 
   As shown in  FIG. 5 , a second layer  48  of seaming compound  26  may be applied over the perforations  44  (shown as dashed circles) on the bottom surface  32  (shown as a dashed line) of the mounting plate  28  to integrally bond the mounting plate  28  between the first and second layers  48  and  50  of the seaming compound  26 . Additionally, the second layer  50  of seaming compound  26  may also be applied around the perimeter  36  of the mounting plate  28  to increase the strength of the bond between the mounting plate  28  and the layers  48  and  50  of the seaming compound  26 , and through those layers to the countertop  14 . 
   This second layer  50  of seaming compound  26  adds additional adhering mechanisms. As a fifth mechanism, the second layer  50  of seaming compound  26  bonds to the buttons  46  thereby reinforcing the adherence to the surface  32  and expanding the area of effective adherence. Sixthly, the second layer  50  of seaming compound  26  adheres around the periphery of the mounting plate  28  and bonds directly to the countertop  14  and/or to any seaming material of the first layer  48  which squeezes laterally around the perimeter  36  of the mounting plate  28  as it is pressed against the countertop  14 . Thus, use of the selected seaming compound ensures chemical bonding to the underside  12  of the countertop  14  and excellent mechanical adherence to the mounting plate  28 . 
   The seaming compound  26  may be any suitable material, as for example, acrylic-based, polyester-based, cyanoacrylate-based or urethane-based compounds. The seaming compound  26  may also be any epoxy compound suitable for use with natural and/or man-made countertop materials. Preferably, the seaming compound  26  is used to create seams in solid materials. Most preferably, the same seaming compound  26  which is or was to be used to complete the seam  18  on countertop  14  is also utilized to secure the mounting device  10  to the countertop  14  and support the sink flange  24 . Utilizing the same seaming compound  26  for both the seam  18  of the countertop  14  and the securement of the mounting device  10  is preferable because it simplifies the installation process. It also ensures that the mounting device  10  is secured to the countertop  14  by a compound specifically engineered to bond to the countertop material. Additionally, many countertop manufacturers specify which seaming compounds may be used in association with their products so as to ensure the structural integrity of the finished countertop and to match the pigmentation of the face colour of the countertop. For instance, Formica Corporation specifically recommends the use of Surell® Solid Surfacing Compound with its Formica® line of countertops. Applying a seaming compound other than the type specified by the manufacturer may result in a weak bond between the layers  48  and  50  of seaming compound  26 , the mounting plate  28  and the underside  12  of the countertop  14 . 
   Once the first and second layers  48  and  50  of seaming compound  26  have substantially set, the support member  30  may be secured to the mounting plate  28 . Referring to  FIGS. 6 and 7 , the support member  30  includes a mounting flange  52 , a support flange  54  and a bridge flange  56 . The mounting flange  52  has a slot  58  extending along a portion of the longitudinal axis A—A of the support member  30 . The slot  58  is aligned with the aperture  40  in mounting means  38  of mounting plate  28  to permit the easy pass-through of the fastener  42 . The fastener  42  is adapted to extend through the slot  58  and be received within the aperture  40  to secure the mounting plate  28  to the mounting flange  52  of the support member  30 . The length of the slot  58  is sufficient so as to facilitate substantial adjustment of the support member  30  relative to the mounting plate  28 . The fastener  42  may be releasably tightened in the aperture  40  to permit the support member  30  to be pivotally adjusted into an operable position beneath the sink flange  24 . 
   The bridge flange  56  extends from the mounting flange  52  in a plane that is other than horizontal. For example, the bridge flange  56  may be angled generally downwardly so that the support flange  54  may be positioned beneath any variety of sink flange  24  shapes. Furthermore, the bridge flange  56  may be adapted to enable to the mounting device  10  to be mounted within the confined space within a cabinet. Referring to  FIG. 8 , for example, the bridge flange  56  may extend vertically for installations in which the sink flange  24  is in close proximity to a side panel  60  of the cabinetry  62 . 
   The support flange  54  is a generally rectangular surface that is adapted to contact and support the sink flange  22 . The support flange  54  may include a supporting means  64  comprising a threaded aperture  66  and a set screw  68 . The set screw  68  may be releasably tightened in the threaded aperture  66  to clamp against the sink flange  24  to support the sink  22  and prevent the sink  22  from moving relative to the underside  12  of the countertop  14  during the use of the sink  22 . The set screw  68  may be any suitable type of fastener, such as, for example, a bolt, which can be easily and quickly tightened by the installer installing the sink  22 . 
   Reference is made to  FIG. 9  which shows a system including a plurality of mounting devices secured to the underside  12  of the countertop  14  proximate to the cutout  20 . The mounting devices  10  are spaced from each other in a generally horizontally extending array. The support members  30  have been pivotally adjusted around the fasteners  42  to provide sufficient clearance for the sink  22  (not shown) to be positioned against the underside  12  of the countertop  14 .  FIG. 10  illustrates the sink  22  positioned against the underside  12  of the countertop  14  and the support members  30  operatively positioned beneath the sink flange  24 . Once the desired adjustment to the position of the support member  30  has been made using the aperture  40 , fastener  42  and slot  58 , the set screw  68  may be tightened to contact and support the sink flange  24 . It will be noted that the support flange  54  could alternatively be used to directly contact the sink flange  24  and support the sink  22  in applications where the use of the set screw  68  would damage the sink  22 . For instance, sinks manufactured from fragile materials, such as porcelain, may crack if the set screw  68  is over tightened. 
   In use, a plurality of mounting devices  10  are used to secure a sink  22  having a sink flange  24  against the underside  12  of a countertop  14 . A plurality of first layers  46  of the seaming compound  26  are applied between the underside  12  of the countertop  14  and the top surfaces  34  of the mounting plates  28 , and the mounting plates  28  are pressed into the seaming compound  26 . The mounting plates  28  may be spaced from each other in a generally horizontally extending array. A second layer  50  of seaming compound  26  may be applied to the bottom surfaces  32  and perimeters  36  of the several mounting plates  28  to bond the mounting plates  28  integrally between the layers  48  and  50  of seaming compound  26 , and thereby to the surface  12  of the countertop  14 . The mounting flanges  52  of support members  30  are then releasably secured to the mounting plates  28  using apertures  40 , fasteners  42  and slots  58 . The support flanges  54  are pivotally adjusted into an operable position to contact and support the sink flange  24 . The adjustable mounting devices of the present invention are capable of solidly mounting most commercially available sinks to the underside of a countertop. They also provide a wide range of adjustments which enable the subject mounting device to be installed in confined spaces. 
   It will be noted that while four mounting devices  10  are shown along the sink flange  24  of the sink  22 , any suitable number of mounting devices  10  may be used to support and secure the sink  22 , depending on the nature of the specific application. 
   While what has been shown and described herein constitutes the preferred embodiments of the subject invention, it will be understood that various modifications and adaptations of such embodiments can be made without departing from the present invention, the scope of which is defined in the appended claims.