The present invention is directed to a farmhouse style sink system incorporating a rimless metallic sink that is significantly more durable and hygienic as compared to traditional farmhouse sink systems.
Farmhouse sink systems include a farmhouse sink frame having a sink basin incorporated therein, wherein the farmhouse sink frame is typically mounted below a countertop, flush with the top of an underlying cabinet or cabinets, thereby providing the unique “farmhouse” look and feel. Traditionally, farmhouse sink systems are formed from any number of materials of construction including, but not limited to, fireclay, cast iron, porcelain, quartz, granite, or marble, just to name a few. As is well known in the art, over time, the materials typically used to construct farmhouse sink systems are susceptible to chipping, cracking, etc. Furthermore, a number of these materials are notorious for being difficult to thoroughly clean due to the somewhat irregular surface condition on the inside of the farmhouse sink basin.
In a typical installation of a farmhouse sink system, an opening is created in a cabinet or cabinets which is dimensioned to receive a farmhouse sink frame therein. The supporting framework is secured to portions of the cabinet or cabinets adjacent to the opening created to receive the farmhouse sink frame. The supporting framework is positioned such that the top surface of the farmhouse sink frame is in line and level with the top surface of the cabinet or cabinets. It is also typical for a farmhouse sink frame to include an apron which extends outwardly from the front face of the cabinet or cabinets.
Next, and access opening corresponding generally to the dimensions of the farmhouse sink basin is created through a portion of a countertop. Silicone sealant is applied between the interface along the lower surface of the countertop and the top surface of the farmhouse sink frame. The silicone sealant is typically fully cured in about 24 hours, after which time a faucet, drain, and any other plumbing appurtenances are installed to the farmhouse sink frame, and a typical farmhouse sink system is ready for use.
As noted above, the materials typically used to construct farmhouse sink systems are susceptible to chipping, cracking, etc., and a number of these materials are difficult to thoroughly clean due to the somewhat irregular surface condition on the inside of the farmhouse sink basin. As such, it would be highly beneficial to provide a farmhouse sink system which combines the highly desired aesthetic appeal of the “farmhouse” sink style with a stainless-steel sink basin for substantially improved durability and hygiene. A further advantage may be realized by providing an improved farmhouse sink system having a farmhouse sink frame which is constructed of a lightweight and durable material.
It would also be extremely beneficial to provide a system to retrofit an existing farmhouse sink system with a rimless metallic, e.g., stainless steel or copper, sink basin to overlie and conceal a damaged original farmhouse sink basin, thereby substantially improving durability and hygiene of the existing farmhouse sink system. It would also be advantageous to provide a new farmhouse sink system having typical materials of construction, such as, but not limited to, fireclay, cast iron, porcelain, quartz, granite or marble, which further comprises a rimless metallic sink basin, once again, to substantially improve durability and hygiene of the new farmhouse sink system.
Those known farmhouse sink systems also fail to combine the classic beauty of the farmhouse kitchen sinks with a more modern, easy to maintain, and more structurally stable metallic washbasin.
Therefore, a need exists to overcome the problems with the prior art as discussed above.
The invention provides a farmhouse sink system with a rimless metallic sink that overcomes the herein fore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that includes a recessed mounting flange that rests on a substantially rigid, e.g., stainless steel, frame which sits on stone footings. A stone box is then dropped on to the sink structure and adhered on with acrylic liquid bonding agents. The rimless edge of the stainless-steel sink is preferably not flush with the stone box top surface, but rather it is recessed under a lip around stone box.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a farmhouse sink system with a rimless metallic sink having a cabinet assembly with a lower support surface, a countertop having an upper surface, a lower surface coupled to the cabinet assembly, and defining a sink access opening therethrough and spanning to the lower support surface of the cabinet assembly. Further, the invention includes a farmhouse sink frame having a sidewall with a top surface at least partially superimposed by and mounted below the lower surface of the countertop, with a lower surface opposing the top surface of the sidewall of the farmhouse sink frame, defining a sink frame access opening therethrough, and an upper lip extending laterally inward toward the sink frame access opening on at least two opposing sides of the sidewall of the farmhouse sink frame. The assembly also includes a metallic sink disposed within the sink frame access opening, having a sidewall coupled to a bottom wall to define, with an inner sidewall surface of the sidewall of the metallic sink, at least one bowl. The metallic sink includes a mounting flange member laterally extending outwardly from an outer sidewall surface of the sidewall of the metallic sink, and having a rimless upper edge disposed along and around the sidewall of the metallic sink and superimposed by the upper lip of the farmhouse sink frame. A sink mounting frame assembly may be utilized that includes a metallic lower horizontally oriented frame member disposed proximal to the lower support surface of the cabinet assembly and a longitudinally oriented metallic frame member separating and vertically displacing, with respect to the lower horizontally oriented frame member, an upper horizontally oriented metallic frame member directly coupled to the mounting flange member.
In accordance with a further feature of the present invention, the upper horizontally oriented metallic frame member is coupled to the sidewall and upper lip of the farmhouse sink frame through an adhesive bonding layer, thereby forming a unitary structure.
In accordance with yet another feature of the present invention, the adhesive bonding layer surrounds at least a portion of the upper horizontally oriented metallic frame member and the mounting flange member. The adhesive bonding layer may also be directly coupled to a lower surface of the upper lip and is of thickness of approximately 1-2 inches.
In accordance with another feature, an embodiment of the present invention includes the upper lip having an inner periphery surface at least partially defining the sink access opening, wherein the upper lip defines a lip channel spanning inwardly into the upper lip from the inner periphery surface and haves the rimless upper edge disposed therein.
In accordance with a further feature of the present invention, the mounting flange member extends continuously around a circumference of the outer sidewall surface of the sidewall of the metallic sink.
In accordance with another feature of the present invention, the upper horizontally oriented metallic frame member encloses and defines an upper frame aperture with the metallic sink disposed therein and with the mounting flange member seated around a perimeter of the upper horizontally oriented metallic frame member.
In accordance with an additional feature of the present invention, the mounting flange member is recessed uniformly below the rimless upper edge.
In accordance with a further feature of the present invention, the lower support surface of the cabinet assembly supports at least 90% of an overall weight defined by the farmhouse sink frame, metallic sink, and metallic sink mounting frame assembly.
In accordance with an additional feature, an embodiment of the present invention also includes a plurality of support footings directly coupled to the lower horizontally oriented frame member and directly coupled to the lower support surface of the cabinet assembly.
In accordance with yet another feature of the present invention, the plurality of support footings are of a substantially rigid material and selectively translatably coupled to the lower horizontally oriented frame member.
In accordance with an exemplary feature of the present invention, the upper lip is disposed at an upper terminal edge of the sidewall of the farmhouse sink frame and includes the top surface of the sidewall of the farmhouse sink frame that continuously surrounds an upper periphery of the farmhouse sink frame.
In accordance with a further feature of the present invention, the sidewall encloses the bottom wall defining the at least one bowl. Additionally, the metallic sink may be either of a stainless steel or copper material.
Also in accordance with the present invention, a farmhouse sink system with a rimless metallic sink is disclosed that includes a farmhouse sink frame having a sidewall with a top surface for mounting underneath a lower surface of a countertop, with a lower surface opposing the top surface of the sidewall of the farmhouse sink frame, defining a sink frame access opening therethrough, and an upper lip extending laterally inward toward the sink frame access opening on at least two opposing sides, of the sidewall of the farmhouse sink frame. The assembly may also include a metallic sink disposed within the sink frame access opening, having a sidewall coupled to a bottom wall to define and enclose, with an inner sidewall surface of the sidewall of the metallic sink, at least one bowl, having a mounting flange member laterally extending outwardly from an outer sidewall surface of the sidewall of the metallic sink, and having a rimless upper edge disposed along and around the sidewall of the metallic sink and superimposed by the upper lip of the farmhouse sink frame. The assembly may also include a sink mounting frame assembly with a metallic lower horizontally oriented frame member and a longitudinally oriented metallic frame member separating and vertically displacing, with respect to the lower horizontally oriented frame member, an upper horizontally oriented metallic frame member directly coupled to the mounting flange member, wherein the upper horizontally oriented metallic frame member is coupled to the sidewall and upper lip of the farmhouse sink frame through an adhesive bonding layer, thereby forming a unitary structure.
Also in accordance with the present invention, a method of forming a farmhouse sink system with a rimless metallic sink is disclosed that includes the steps of placing a top surface of a sidewall of a farmhouse sink frame adjacent to a support surface, the farmhouse sink frame having a lower surface opposing the top surface of the sidewall of the farmhouse sink frame and vertically displaced a length from the support surface, defining a sink frame access opening therethrough, and an upper lip extending laterally inward toward the sink frame access opening on at least two opposing sides of the sidewall of the farmhouse sink frame, the upper lip having a lower surface. Next, a user may insert the rimless upper edge of a sidewall of a metallic sink, rimless upper edge first, into the sink frame access opening until reaching the lower surface of the upper lip to define a periphery channel, wherein the sidewall of the metallic sink is coupled to a bottom wall to define and enclose, with an inner sidewall surface of the sidewall of the metallic sink, at least one bowl, and have a mounting flange member laterally extending outwardly from an outer sidewall surface of the sidewall of the metallic sink, wherein the rimless upper edge is disposed along and around the sidewall of the metallic sink. The process may also include inserting an upper horizontally oriented metallic frame member of a sink mounting frame assembly, upper horizontally oriented metallic frame member first, into the sink frame access opening until reaching a lower surface of the mounting flange member and to surround the outer surface of the metallic sink, wherein the sink mounting frame assembly has a metallic lower horizontally oriented frame member and a longitudinally oriented metallic frame member separating and vertically displacing, with respect to the lower horizontally oriented frame member. The upper horizontally oriented metallic frame member and/or the sink mounting frame assembly may have a plurality of support footings each directly coupled to the lower horizontally oriented frame member and each having a terminal end surface defining a support plane disposed and opposing the top surface of a sidewall of a farmhouse sink frame. Next, process would include inserting a malleable adhesive material into the periphery channel and around the outer sidewall surface of the sidewall of the metallic sink and an inner surface of the sidewall of the farmhouse sink frame and then allowing the malleable adhesive material to cure, harden, and form an adhesive bonding layer coupling the upper horizontally oriented metallic frame member and the sidewall and upper lip of the farmhouse sink frame, thereby forming a unitary structure.
Although the invention is illustrated and described herein as embodied in a farmhouse sink system and method of forming the same, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
Other features that are considered as characteristic for the invention are set forth in the appended claims. As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale.
Before the present invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “a” or “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. The term “providing” is defined herein in its broadest sense, e.g., bringing/coming into physical existence, making available, and/or supplying to someone or something, in whole or in multiple parts at once or over a period of time. Also, for purposes of description herein, the terms “upper”, “lower”, “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof relate to the invention as oriented in the figures and is not to be construed as limiting any feature to be a particular orientation, as said orientation may be changed based on the user's perspective of the device. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
As used herein, the terms “about” or “approximately” apply to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. In this document, the term “longitudinal” should be understood to mean in a direction corresponding to an elongated direction of the farm farmhouse sink system spanning from a top surface of the sidewall of the farmhouse sink frame to the lower surface of the sidewall of the farmhouse sink frame.
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present invention.
While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms.
The present invention is directed to a farmhouse sink system with a rimless stainless-steel sink generally as shown as at 10 throughout the figures. With reference to the illustrative embodiment of
Looking once again to the illustrative embodiment of
As further shown in the illustrative embodiment of
Turning next to
With continued reference to the illustrative embodiment of
Turning next to
As further illustrated in
With further reference to the illustrative embodiment of
Looking again to the illustrative embodiment of
In at least one further embodiment, a top coat 65 is applied to the upper seal 64 wherein the top coat 65 is selected based on the color of the top surface 32 of the farmhouse sink frame 30 so as to camouflage the presence of the upper seal 64. The top coat 65, in at least one embodiment, comprises a color matching acrylic, epoxy or polyester resin selected to simulate the color of the top surface 32 of the farmhouse sink frame 30. In yet one further embodiment, the upper seal 64 and/or top coat 65 may be further finished by sanding, buffing, etc., so as to further camouflage the presence of the upper seal 64, thereby enhancing the overall seamless appearance between the stainless steel sink 30 and the farmhouse sink frame 30 along the upper seal 64, such as is shown best in
Turning next to the farmhouse sink frame 30 of the illustrative embodiment of
To effect installation, a bonding agent is applied to the interior bottom surface 34′ and along the sidewalls of the farmhouse sink frame 30, and the stainless steel sink 40 is inserted through the sink mounting aperture 36′ until the rimless upper edge 48 of the stainless steel sink 40 is substantially coplanar with the top surface 32 of the farmhouse sink frame 30. Any voids between the upper rimless edge 48 of the stainless-steel sink 40 and the top surface 32 of the farmhouse sink frame 30 are filled in with boning agent. As before, after the bonding agent fully cures, sanding or grinding may be utilized to remove any rough edges or overspills, so as to assure a seamless interface between the upper rimless edge 48 of the stainless steel sink 40 and the top surface 32 of the farmhouse sink frame 30.
As will be appreciated by those of skill in the art, the top mounted rimless stainless-steel sink 40 in accordance with the illustrative embodiment of
As noted above, the present invention further comprises a method for the installation of a farmhouse sink system having a stainless-steel sink. More in particular, and with reference to the illustrative embodiment of
In accordance with at least one embodiment of the present invention, the present method 100 comprises fabricating a stainless-steel sink with a rimless upper edge 110, wherein the rimless upper edge defines an outer periphery there around. The present method 100 further comprises creating a sink mounting aperture through a farmhouse sink frame 120 between a top surface and an interior bottom surface, wherein the sink mounting aperture comprises an inner periphery dimensioned to receive an outer periphery of a rimless upper edge of a stainless steel sink therein.
With reference to the illustrative embodiment of
The present method 100 further includes securely attaching at least one mounting bracket to the sidewall of the stainless-steel sink 140, wherein the at least one mounting bracket is positioned a predetermined mounting depth below the rimless upper edge of the stainless-steel sink. In one further embodiment, the present method 100 comprises securely attaching a plurality of mounting brackets to the sidewall of the stainless steel sink 140, wherein each of the plurality of mounting brackets is positioned a predetermined mounting depth below the rimless upper edge of the stainless steel sink.
As may be seen from
With reference once again to the illustrative embodiment of
In at least one further embodiment, the present method 100 comprises applying a top coat over the upper seal 180, so as to camouflage the presence of the upper seal. The top coat, in at least one embodiment, comprises a color matching acrylic, epoxy or polyester resin selected to simulate the color of the top surf ace of the farmhouse sink frame.
Since many modifications, variations and changes in detail can be made to the describe embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.
Specifically, with reference to
Referring to
The metallic sink 1002 beneficially includes a mounting flange member 1026 laterally extending outwardly from an outer sidewall surface 1028 of the sidewall 1016 of the metallic sink 1002. In one embodiment, the mounting flange member 1026 may extend continuously (or discontinuously) around a circumference or perimeter of the outer sidewall surface 1028 of the sidewall 1016 of the metallic sink 1002. The mounting flange member 1026 may also be partially located and disposed on two opposing sides of the sidewall 1016 of the metallic sink 1002.
The metallic sink 1002 also includes a rimless upper edge 1022 (as shown in the figures) disposed along and around the sidewall 1016 of the metallic sink 1002 and that is beneficially superimposed by the upper lip 1204 of the farmhouse sink frame 1010. In one embodiment, the mounting flange member 1026 is recessed uniformly below the rimless upper edge 1022, e.g., a distance of approximately 1-3 inches. In some embodiment, the mounting flange member 1026 is located proximal to the rimless upper edge 1022. The mounting flange member 1026 may be pre-formed with the sidewall 1016 of the metallic sink 1002 or may be directly coupled thereto using mechanical methods such as fasteners or welding. In one embodiment, the upper lip 1204 includes an inner periphery surface 1114 at least partially defining the sink access opening 1202, whereby the upper lip 1204 defines a lip channel 1214 (approximately of a depth matching the thickness of the sidewall 1016 of the metallic sink 1002). The lip channel 1214 may span inwardly into the upper lip 1204 from the inner periphery surface 1114 and have the rimless upper edge 1022 disposed therein, thereby giving an outer appearance that discreetly conceals the rimless upper edge 1022.
Beneficially and with reference to
The upper horizontally oriented metallic frame member 1108 may also enclose and define an upper frame aperture 1116 for the metallic sink 1002 to be received and disposed therein. As seen best in
More specifically, as best seen in
The plurality of support footings 1112a-n may be coupled or fastened to and/or selectively translatably coupled to the lower horizontally oriented frame member 1104 using one or more fastener(s) (as depicted best in
Referring back to
More specifically, a method of forming a farmhouse sink system 1000 with a rimless metallic sink 1002 is disclosed in
Next, the process moves to step 1604 of inserting a rimless upper edge 1022 of a sidewall 1016 of a metallic sink 1002, rimless upper edge 1022 first, into the sink frame access opening 1100 until reaching the lower surface 1212 of the upper lip 1204 to define a periphery channel 1508. The periphery channel 1508 may completely surround the perimeter of the sidewall 1016 of the metallic sink 1002 or may be located on one or more sides thereof. The sidewall 1016 of the metallic sink 1002 is coupled to a bottom wall 1018 to define and enclose, with an inner sidewall surface 1024 of the sidewall 1016 of the metallic sink 1002, at least one bowl 1020, and has a mounting flange member 1026 laterally extending outwardly from an outer sidewall surface 1028 of the sidewall 1016 of the metallic sink 1002. The rimless upper edge 1022 may be disposed along and around the sidewall 1016 of the metallic sink 1002 or otherwise as described above.
Next, the process moves to step 1606 of inserting an upper horizontally oriented metallic frame member 1108 of a sink mounting frame assembly 1102, upper horizontally oriented metallic frame member 1108 first, into the sink frame access opening 1100 until reaching a lower surface 1502 of the mounting flange member 1026 and to surround the outer surface 1028 of the metallic sink 1002. As seen best in
Next, the process to step 1608 of inserting a malleable adhesive material 1110 (as discussed above, e.g., liquid acrylic, epoxy, or another type of bonding age) into the periphery channel 1508 and around the outer sidewall surface 1028 of the sidewall 1016 of the metallic sink 1002 and an inner surface 1118 of the sidewall 1012 of the farmhouse sink frame 1010. The thickness of the periphery channel 1508 may vary but may be approximately 1-3 inches in length uniformly spanning around the outer sidewall surface 1028 of the sidewall 1016. While still inverted in the position shown in
Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the embodiments described above refer to particular features, the scope of this disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the above described features.
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Number | Date | Country | |
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Parent | 16243669 | Jan 2019 | US |
Child | 16953614 | US |