Patent Abstract:
A sink assembly provides an enhanced overflow system for an under-counter mountable sink. The sink has an overflow cutout with an open top formed adjacent an upper rim of the basin of the sink. When the sink is mounted to the bottom surface of a counter top, the sink and counter together form an overflow opening, thereby permitting the overflow to be more easily concealed and increasing the fill capacity of the sink. Methods of installing such sink assemblies are also disclosed.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    Not applicable. 
       STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0003]    This invention relates to sinks. More particularly this invention relates to undercounter mountable sinks provided with improved overflow structures. 
         [0004]    Conventionally sinks have a rimmed basin mounted to a counter top. Water from a faucet or other water supply is directed into the basin, where it collects and typically then flows down a lower drain. 
         [0005]    However, in some cases, the basin of the sink may become overfilled with water. This can occur if the opening to the drain is blocked while the water is still running. This can occur due to the drain being left closed too long when the water is running, or the speed of the water exceeding the drainage capacity of the drain due to clogging or the like. 
         [0006]    To prevent the spilling of water over the rim into the room in such a situation, many sinks have an integrally formed overflow outlet along the sides of the basin. See e.g. U.S. Pat. Nos. 306,929 and 321,973. Once the water in the basin reaches the level of overflow opening, the excess water pours into the opening, down an overflow channel extending therefrom, and then to a drain. Thus, regardless of whether the main basin drain is closed, the sink is protected against overflows. 
         [0007]    However, from a design perspective such overflows can be ornamentally disruptive. Thus, there have been attempts to partially conceal the overflow opening by locating the overflow on the side of the basin wall nearest to the user. However, for basins with distinctly sloped walls, such an overflow will still be visible from many viewing angles. 
         [0008]    Moreover, such overflows are typically punched through the basin&#39;s side wall at least one-half inch down from the top of the sink, to minimize manufacturing problems. However, that can significantly reduce the volume of water the basin can hold before the overflow starts. Thus, the plan view area of the sink will need to be greater for any given desired volume of water for the fill. 
         [0009]    Hence, a need exists for a sink having an overflow that is more concealed, and has greater fill capacity. 
       SUMMARY OF THE INVENTION 
       [0010]    A sink assembly is disclosed which has a counter having a top surface and a bottom surface, with an opening extending through the counter. An under-counter mountable sink is mounted to the bottom surface of the counter about the opening. The under-counter mountable sink includes a basin having walls extending from an upper rim down to a drain opening. 
         [0011]    A drain passage extends from the drain opening. An overflow cutout is formed along the upper rim of the basin. The overflow cutout has a lower lip below the upper rim and an open top. An overflow channel extends from the overflow cutout to the drain passage to place the overflow cutout in communication with the drain passage. A portion of the bottom surface of the counter and the overflow cutout together define an opening of the overflow channel such that if the water level in the basin exceeds the lower lip of the overflow opening, then the water flows over the lower lip, into the overflow channel, and into the drain passage. In one form of the sink assembly the bottom surface of the counter serves as a wall of the overflow channel. 
         [0012]    In another form of the sink assembly there is a sealant (e.g. a silicone line) located between the upper rim and the bottom surface of the counter. The sealant forms a seal between the upper rim and the bottom surface of the counter, and does so proximate the overflow channel. 
         [0013]    In another aspect the invention provides an under-counter mountable sink having a basin with walls extending from an upper rim down to a drain opening. A drain passage extends from the drain opening. An overflow cutout is formed along the upper rim of the basin. The overflow cutout has a lower lip below the upper rim and an open top. An overflow channel extends from the overflow cutout to the drain passage to place the overflow cutout in communication with the drain passage. 
         [0014]    The sink is mountable under a counter and, if so mounted, and if a level of water in the basin exceeds the lower lip of the overflow cutout, the water would be able to flow over the lower lip, through the overflow channel, and into the drain passage. 
         [0015]    In a particularly preferred form of the under-counter mountable sink, the sink is made of a ceramic material where a portion of the overflow cutout is positioned within one-half inch of the upper rim of the under-counter mountable sink. 
         [0016]    In another form of the invention, the under-counter mountable sink may define only a portion of the overflow channel, such that the open top can permit a counter to form another part thereof. 
         [0017]    In still another form of the invention, the upper rim may have an inner periphery and an outer periphery substantially equally spaced from one another about a perimeter of the upper rim except near the overflow flow channel. Proximate the overflow channel, a distance between the inner periphery and the outer periphery may be locally decreased to provide the overflow channel. 
         [0018]    In other forms a wall of the basin may double as a wall of the overflow channel, the overflow channel may extend in part at an angle towards the drain passage, and the overflow channel may place the basin in communication with the drain passage below the drain opening. 
         [0019]    In yet another aspect of the present invention there is provided a method of installing an under-counter mountable sink to a counter to form an overflow. The sink has a basin having walls extending from an upper rim down to a drain opening. A drain passage extends from the drain opening. An overflow cutout is formed along the upper rim of the basin. The overflow cutout has a lower lip below the upper rim and an open top. An overflow channel extends from the overflow cutout to the drain passage to place the overflow cutout in communication with the drain passage. 
         [0020]    The method involves mounting the under-counter mountable sink to a bottom surface of the counter such that the bottom surface of the counter and the overflow cutout each define a portion of the overflow opening. Optionally, a line of sealant may be positioned between the counter and the under-counter mountable sink. 
         [0021]    As will be better appreciated from the following description and accompanying drawings, the present invention places the overflow closer to the top of the sink, thereby permitting it to be more concealed. Moreover, the sink can be formed without a subsequent punching operation. 
         [0022]    Further, as the overflow opening is located at the top of the basin, the sink can hold more water than a similarly-shaped sink having an overflow opening punched in the side wall of the basin at a lower position. For those tasks which the user is intentionally filling the sink with water (e.g., soaking of clothing, preparing a reservoir for shaving, and the like), this improves the functionality of the sink, better maximizing the depth of the basin. 
         [0023]    These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of one preferred embodiment of the present invention. To assess the full scope of the invention the claims should be looked to as this preferred embodiment is not intended to be the only embodiment within the scope of the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]      FIG. 1  is a left, top, frontal perspective view of an under-counter mountable sink of the present invention installed to create a sink assembly of the present invention; 
           [0025]      FIG. 2  is a view similar to  FIG. 1 , albeit slightly enlarged, and without showing the counter; 
           [0026]      FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 1 ; and 
           [0027]      FIG. 4  is a cross-sectional view taken along line  4 - 4  of  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0028]    Referring first to  FIG. 1 , a sink assembly  10  is shown including a counter  12  and an under-counter mountable sink  14  mounted under the counter  12 . The under-counter mountable sink  14  can be made from any one or more of a number of materials including ceramic, metal, and/or plastic. A faucet and one or more control handles (not shown) may be positioned on top of the counter  12 , adjacent sink  14 . 
         [0029]    As best seen in  FIG. 2 , the under-counter mountable sink  14  has a basin  16  having walls  18  extending down from an upper rim  20  to a drain opening  22 . A drain passage  24 , best seen in  FIG. 3 , extends down from the drain opening  22 . The drain passage  24  typically is then connected to a sewer line in a manner well understood by the art. 
         [0030]    The drain passage  24  could house a controllable plug or stop that can be actuated via a pull-up knob or other means to selectively seal the drain opening  22 . By sealing the drain opening  22 , a user can prevent water from draining out from the bottom of the basin  16 , thus (when the faucet is supplying water) filling the basin  16 . 
         [0031]    An upper rim  20  may be integrally formed with the basin walls  18 . In the embodiment shown the side walls extend down all the way to the drain opening  22 . However, side walls may instead blend into a generally horizontally configured bottom wall, with the bottom wall then linking to the drain opening. 
         [0032]    The upper rim  20  has a substantially planar surface  26  that extends in a generally horizontal direction when the under-counter mountable sink  14  is positioned in a use position (i.e., rim side up and drain side down). The substantially planar surface  26  is bounded by an inner periphery  28 , nearest the basin and defining the transition between the upper rim  20  and the walls  18  of the basin  16 , and an outer periphery  30 . The planar surface  26  of the upper rim  20  is designed to be positioned against the bottom surface of the counter  12 . 
         [0033]    Now with particular reference to  FIGS. 3 and 4 , note that along the inner periphery  28  of the upper rim  20  an overflow cutout  32  is formed. Note that by using the term “cutout” we do not mean to require that anyone have actually cut out that portion. Rather, that structure may also be formed by molding in a shape as if it had been cut out. Thus, “cutout” means a structure shaped like a cutout, regardless of how formed. 
         [0034]    In any event, the overflow cutout  32  has an open top  34  on the planar surface  26  of the upper rim  20 . As best seen in  FIG. 4 , the overflow cutout  32  is substantially U-shaped having a lower lip  38  that curves upward on either lateral side to a pair of side walls  40 . The overflow cutout  32  extends back from the inner periphery  28  to connect to an overflow channel  36 . The overflow channel  36  and the overflow cutout preferably share the open top  34  on the planar surface  26  of the upper rim  20 . 
         [0035]    In the form shown, the inner periphery  28  and the outer periphery  30  are substantially equally spaced from one another about a perimeter of the upper rim  20  except proximate the overflow channel  36 . Proximate the overflow channel  36 , the distance between the inner periphery  28  and the outer periphery  30  is locally decreased to provide for the placement of the overflow channel  36 . However, in other forms the distance between the inner periphery  28  and the outer periphery  30  could be substantially equal even around the overflow channel  36  by increasing the material of the upper rim  20  in this region. 
         [0036]    As best seen in  FIG. 3 , the overflow channel  36  extends from the overflow cutout  32  to the drain passage  24  placing the two in communication with each other. The overflow channel  36  is connected to the drain passage  24  at a junction  42  located downstream of the drain opening  22 . 
         [0037]    The overflow channel  36  is, in part, integrally formed in the under-counter mountable sink  14  and extends back at an angle back towards the drain passage  24 . As such, the overflow channel  36  includes the wall  18  that on one side forms a surface  44  of the basin  16  and on the other side forms a surface  46  of the overflow channel  36 . The overflow channel  36  further includes an outer wall  48  that provides the remaining surfaces of the overflow channel  36 . This outer wall  48  can be generally U-shaped in cross section with each of the ends being joined to the wall  18 . 
         [0038]    Depending on the particular geometry of the under-counter mountable sink  14 , the overflow channel  36  may narrow as it extends from the overflow cutout  32  to the junction  42  between the overflow channel  36  and the drain passage  24 . However, the overflow channel  36  could also have a generally uniform cross-sectional area. 
         [0039]    With reference to  FIGS. 1 ,  3 , and  4 , a preferred particular manner in which the under-counter mountable sink  14  is mounted relative to the counter  12  is shown. The counter  12  has a top surface  50  and a bottom surface  52  with a opening  54  extending through the counter  12 . The opening  54  is generally shaped and sized to match the inner periphery  28  of the upper rim  20 , with the exception of the overflow cutout  32 . The under-counter mountable sink  14  is positioned such that the inner periphery  28  of the upper rim  20  generally aligns with a side wall  56  that defines the perimeter of the opening  54 . 
         [0040]    As the opening  54  is generally sized and shaped to match the inner periphery  28  of the upper rim  20 , the side wall  56  is preferably structured to smoothly transition into the wall  18  of the basin  16 . In the form shown, this means that the side wall  56  extends in an essentially vertical direction to match the essentially vertically extending portions of the wall  18  of the basin  16  near the mounting seam. By doing this, the side wall  56  of the counter  12  can effectively act as an extended wall of the sink. Although the side wall  56  is shown as having sharp  90  degree edges with the top surface  50  and the bottom surface  52  of the counter  12 , these edges could have a bevel, a radius, or the like to provide the desired aesthetic appearance. 
         [0041]    The under-counter mountable sink  14  may be mounted or secured to the bottom surface  52  of the counter  12  in a number of ways. The sink  14  could be secured to the counter  12  using a strong adhesive or the like which permanently bonds the planar surface  26  to the upper rim  20  to the counter  12 . In other forms, the sink  14  could be secured to the counter  12  using brackets, bolts, screws, other fasteners or the like. In some forms, the sink  14  could be additionally supported by structural elements other than the counter  12  to reduce the stress on the counter  12  of supporting the sink  14 . These structural elements may be concealed by a vanity, cabinetry or the like. 
         [0042]    Regardless, most preferably there is a bead line of sealant  58  positioned to form a seal proximate the overflow cutout  32  between the planar surface  26  of the upper rim  20  of the sink  14  and the bottom surface  52  of the counter  12 . The sealant  58  helps prevent water from leaking between the sink  14  and the counter  12 . Preferably the sealant  58  extends around the entire periphery of the upper rim  20  such that, in the event any water collects over the upper rim  20 , the water does not leak between the sink  14  and the counter  12 . It is contemplated that in some forms, the sealant  58  could also be an adhesive that mounts the sink  14  to the counter  12 . 
         [0043]    When the under-counter mountable sink  14  is mounted to the counter  12 , a portion of the bottom surface  52  of the counter  12  and the overflow cutout  32  together define an opening  60  of the overflow channel  36 . The bottom surface  52  of the counter  12  also forms a top wall  62  of the overflow channel  36 . The sealant  58  around the open top  34  of the overflow cutout  32  assists in retaining any water that flows through the overflow channel  36  within it. 
         [0044]    In the event that the drain opening  22  of the under-counter mountable sink  14  is blocked/closed when the sink  14  is already filled with water and water is still running, once the water level rises to the height of the overflow opening  60 , any additional water is routed through the overflow channel  36  and down the drain passage  24 . Once the water level in the basin  16  reaches the level of the opening  60  (and more specifically exceeds the lower lip  38  of the opening  60 ), then the water flows over the lower lip  38 , into the overflow channel  36 , and into the drain passage  24 . Hence, under typical operating conditions, the overflow prevents water from spilling from the sink  14  when the water level becomes too high. 
         [0045]    Thus, an under-counter mountable sink for a sink assembly is provided with an improved overflow capability. It should be appreciated that various other modifications and variations to the preferred embodiment can be made within the spirit and scope of the invention. For example, the top view shape need not be octagonal (as distinguished from rectangular or oval). Therefore, the invention should not be limited to the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced. 
       INDUSTRIAL APPLICABILITY 
       [0046]    The invention provides a sink having improved overflow capability.

Technology Classification (CPC): 4