US20070186341A1

US20070186341A1 - Mobile sink assembly

Info

Publication number: US20070186341A1
Application number: US11/351,609
Authority: US
Inventors: Michael Uffner; Torrence Anderson
Original assignee: Suncast Corp
Current assignee: Suncast Corp
Priority date: 2006-02-10
Filing date: 2006-02-10
Publication date: 2007-08-16

Abstract

The present invention provides a sink assembly formed from a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing sink assembly. The integrated connection of the side walls, front, back, and bottom panels and sink components simplifies the sink assembly construction. The panels are formed of injection molded plastic to interlock with one another without the need for fasteners or connectors. The system incorporates a minimum number of connectors by integrally forming the connectors into the panels which are snapped together to complete the assembly.

Description

FIELD OF THE INVENTION

This invention relates generally to a mobile sink assembly. More specifically, the present invention relates to a portable or mobile sink assembly utilizing injection molded plastic structural panels having integrally formed connectors. The sink assembly is capable of being packaged and shipped in a knock-down state and assembled into a secure and decorative sink and enclosure assembly without additional fasteners.

BACKGROUND OF THE INVENTION

Portable or mobile sinks are very convenient for use wherever access to a water supply and drain facilities are not readily available. Portable sinks have been used in the past to facilitate the preparation of food outdoors and to provide washing and cleaning facilities for patients in nursing homes and hospitals who do not have ready access to conventional washing facilities. It is also very beneficial if there is an area adjacent the sink that can be used to store items related to the washing or cleaning to be done in the sink.

DESCRIPTION OF THE PRIOR ART

An example of a portable sink is U.S. Pat. No. 5,465,438 which discloses a mobile sink unit for use in a nursing home. The unit includes a fresh water reservoir, a gray water reservoir, a faucet assembly including a control valve, and a soap dispenser. The majority of the space in the sink enclosure is occupied by the fresh water tank and the gray water tank. Any items to be stored must be kept on the top surface of the enclosure. This area is very small as can be seen in the drawings. The enclosure cabinet is formed from an open frame which is overlaid with a sheet material. This type of structure is not subject to being knocked down for shipment and assembly by the consumer at their location.
U.S. Pat. No. 6,349,715 discloses another type of mobile sink. This sink is used in conjunction with a mobile cooking device. A water supply is connected to the lower portion of the device to supply water to the faucet adjacent the sink. The used water from the sink drains away from the device through an outlet hose. The device comprises a housing formed of front, back, side top and bottom walls which are permanently attached. This construction is also not subject to being knocked down for shipment and assembly by the consumer.
Another type of portable sink is disclosed in U.S. Pat. No. 6,836,910. This sink is connected to a water supply to provide water for the sink. The drain empties onto the surface on which the sink is placed. This can lead to a messy and unhealthy situation. The sink enclosure has a drawer for storage but this does not provide a large amount of storage space.

SUMMARY OF THE INVENTION

The present invention provides a portable or mobile sink assembly formed from a plurality of injection molded plastic panels having integrated connectors. The panels and other components are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing sink and enclosure. The integrated connection of the side wall panels, back wall panel, front wall panel, bottom panel and sink components simplifies the construction of the sink assembly. The panels are formed from injection molded plastic so as to interlock with one another without the need for separate fasteners or connectors. This assembly incorporates a minimum number of components by integrally forming the connectors into the injection molded panels. The panels are then snapped together to complete the assembly. This construction eliminates the need for separate connectors or fasteners to assemble the sink assembly. Injection molding allows the panels to be formed with a single wall having integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or rotationally molded assemblies. The same side wall and bottom panel components can be used to create a variety of different assemblies useful for outdoor entertaining or cookouts. The assembly of these components requires minimal hardware and a minimum number of hand tools.
The base, front wall and back wall panels have integrally formed, outwardly projecting bosses for interlocking engagement with the left and right side wall panels. The left and right side wall panels are constructed with integrally formed, inwardly contoured sockets for interlocking, cooperative engagement with the bosses formed on the base, front wall and back wall panels. The engagement between the bosses and sockets serve to connect the panels together into a rigid and weather resistant assembly.
The lower surface of the base panel includes a plurality of integrally formed bosses which are constructed and arranged to cooperate with casters to allow for easy movement of the sink assembly.
Accordingly, it is an objective of the instant invention to provide a mobile sink assembly composed of panels with integral connectors.
It is a further objective of the instant invention to provide a mobile sink assembly composed of panels formed by injection molding which provide increased structural integrity of the assembly.
It is yet another objective of the instant invention to provide a mobile sink assembly wherein the side wall panels, front wall panel, back wall panel, bottom panel and sink are integrally interlocked without the use of separate fasteners or connectors.
It is a still another objective of the invention to provide a mobile sink assembly constructed of modular panels which has an aesthetically pleasing appearance.
It is still a further objective of the invention to provide a mobile sink assembly which is capable of being packaged and shipped in a knock-down state and constructed into a secure assembly at a desired site.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front perspective view of the sink assembly of the instant invention with a lid on the sink.
FIG. 2 is a front perspective view of the sink assembly of the instant invention with the lid removed from the sink.
FIG. 3 is an exploded view of the sink assembly shown in FIG. 1.
FIG. 4 is a front planar view of the sink assembly of the instant invention.
FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4.
FIG. 6 is a front perspective view of the sink assembly with the faucet in the raised position.
FIG. 7 is a rear perspective view of the sink assembly of the instant invention.
FIG. 8 is a rear planar view of the sink assembly.
FIG. 9 is a bottom view of the sink assembly.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
FIGS. 2 and 3 illustrate perspective and exploded views of the sink assembly, generally referenced as 10, according to a preferred embodiment of the invention. In this preferred, albeit non-limiting, embodiment of the invention the sink assembly is formed from a plurality of panels connected together. These panels include a base panel 100, a right side panel 200, a left side panel 300, a back panel 400, a front panel 500, and the sink 600. In the preferred embodiment the panels and the sink are formed of, but not limited to, a suitable plastic such as polystyrene, polypropylene, or polyethylene, through the process of injection molding. The result is that the panels which form the sink assembly are formed as unitary single wall panels with integral connectors and cross bracing. The sink 600 may be formed from materials other than injection molded plastics. These materials include, but are not limited to, cast plastics, fiberglass and metal.
The base panel is formed with a top surface 104, a bottom surface 106, a front edge 108, a back edge 110, a left edge 112 and a right edge 114 (FIGS. 3 and 9). Integrally formed along the left and right base panel edges are a plurality of bosses 116 for attaching the base panel to the left and right side panels. The bosses 116 extend outwardly from each edge to cooperate with integrally formed sockets 210 which extend inwardly along the bottom portions 206 and 306 of the right and left side panels respectively. Although only socket 210 of the left side panel is shown another integrally formed socket 210 extends along the bottom portion 306 of the right side panel. The bosses and sockets are constructed and arranged so that the bosses 116 matingly engage the sockets 210 thereby securing the panels together in a perpendicular and inter-fitting engagement. Detent or spring lock fasteners 118 are integrally formed on the bosses 116. Apertures 208 are formed in the end portions of sockets 210 (FIG. 3). The spring lock fasteners 118 cooperate with the apertures 208 to secure the bosses in the sockets. Those skilled in the art can appreciate that the spring lock fasteners 118 and socket apertures 208 can be used throughout the sink assembly to mount or secure components to one another and facilitate assembly of the sink assembly from an unassembled state without the use of tools. The overlapping boss 116 and socket 210 arrangement increases the structural integrity of the sink assembly by preventing panels 200, 300, 400 and 500 from bowing or bending inwardly or outwardly and thus, adversely affecting the appearance or operation of the sink assembly. Also, integrally formed on the bottom of the base panel are ribs 202 and gussets 107 which add structural rigidity and strength to the base panel (FIG. 9).
As shown in FIG. 3 the left side panel is configured with a first edge 312 and a second edge 314. Both edges include integrally formed elongated sockets 210 extending inwardly in a linear fashion along each edge. The sockets 210 are generally constructed and arranged to cooperate with the bosses 116 provided along an edge of the back panel 400 and the front panel 500. The top edge of the left side panel is provided with an upstanding lip 315 integrally formed thereon. The lip cooperates with an underside portion of the sink 600 to facilitate their mechanical connection. The interior surface of the left side panel is provided with integrally formed ribs 202 which add structural rigidity and strength to the panel.
The right side panel is configured with a first edge 212 and a second edge 214. Both edges include integrally formed elongated sockets 210 extending inwardly in a linear fashion along each edge. The sockets 210 are generally constructed and arranged to cooperate with the bosses 116 provided along an edge of the back panel 400 and the front panel 500. The top edge of the right side panel is provided with an upstanding lip 215 integrally formed thereon. The lip cooperates with an underside portion of the sink 600 to facilitate their mechanical connection. The interior surface of the right side panel is provided with integrally formed ribs 202 (not shown) which add structural rigidity and strength to the panel.
The outer surface of the panels 200, 300, 400 and 500 are constructed as generally smooth and have a plurality of inwardly curved grooves 230 integrally formed thereon for added strength, structural integrity and aesthetic appearance. The insides of the panels 200 and 300 are provided with strengthening ribs 202 and seen in FIG. 3. The ribs add to the structural integrity provided by the grooves 230. This increase in structural integrity prevents the panels 200, 300, 400 and 500 from bowing or bending inwardly or outwardly, adversely affecting the appearance or operation of the sink assembly. As illustrated herein these features are achieved by injection molding. Injection molding offers significant strength and stability advantages over blow-molding or rotational molding as utilized in the prior art. In this manner the sink assembly of the present invention is capable of handling a significant amount of weight and abuse as compared to prior art sink assemblies.
The front panel 500 is attached to the left 300 and right 200 side panels by inserting the bosses 116, of the front panel, into the sockets 210, of the left and right side panels, until the spring lock fasteners 118 integrally formed on the bosses 116 engage the apertures 208 in the sockets of the left and right side panels.
Located below the front panel 500 is a door 502 which provided access to a storage area. The storage area comprises the space below the sink 600, above the base panel 100, between the right and left side panels 200 and 300 and between the front and back panels 500 and 400. This area may be used for the storage of items used in conjunction with the sink or for other cleaning purposes. The door 502 is hingedly mounted to the base panel and front panel by hinge pins 504 integrally formed on the door. The hinge pins fit into and cooperate with apertures 506 integrally formed in the base panel and front panel to permit pivotal opening and closing of the door. A handle 508 may also be provided on the door to assist the opening and closing thereof. The outer surface of the door 502 is constructed as generally smooth and has a plurality of inwardly curved grooves 230 integrally formed thereon for added strength, structural integrity and aesthetic appearance. These are similar to grooves 230 formed in the side, back and front panels.
The base panel 100 is attached to the right 200 and left 300 side panels by inserting the bosses 116, integrally formed on the base panel, into sockets 210, integrally formed in the side panels, until the spring lock fasteners 118 engage the apertures 208 in the sockets of the left and right side panels (FIG. 3). The back panel 400 is attached to the right and left side panels by inserting the elongated bosses 116, integrally formed on the back panel, into the sockets 210, integrally formed in the side panels, until the spring lock fasteners 118 engage the apertures 208 in the sockets of the left and right side panels. The front panel 500 is attached to the right and left side panels by inserting the elongated bosses 116, integrally formed on the front panel, into sockets 210, integrally formed in the side panels, until the spring lock fasteners 118 engage the apertures 208 in the sockets of the left and right side panels. It will be appreciated that the purpose of the elongated bosses 116 are to align the two joined panels in a perpendicular relationship and to facilitate their mechanical connection. This results in high structural integrity and reliable operation.
Referring to FIG. 3 the attachment of the sink 600 will now be described. A plurality of independently formed bosses 120 are inserted into the sockets 210 formed at the upper ends of the first and second edges of the right and left side panels. The spring lock fasteners 118 on the bosses 120 engage the apertures 208 formed in the sockets 210. The sink is then placed over the top portion of the bosses which extend upwardly beyond the ends of the sockets 210 of the side panels. These top portions of the bosses are inserted into sockets 210 (not shown) formed on the underside of the sink at each corner thereof. Spring lock fasteners 118 on the top portion of the bosses engage apertures 208 (not shown) formed in the sockets 210 formed in the sink. As shown in FIG. 3, each boss 120 has two spring lock fasteners 118 formed thereon, thereby assuring that each boss will be securely attached to both the side panel and the sink. An underlying portion of the sink is constructed and arranged to cooperate with the upstanding lips 215, 315, 415 and 515 of the right, left, back and front panels to align the joined elements in a perpendicular relationship and facilitate their mechanical connection. As a result the sink is securely attached to the other panels. When the sink 600 is formed by injection molding or casting, the sockets 210 are formed simultaneously therewith. The socket may also be machined or cut out of a previously cast or molded sink. Further, if the sink is formed from metal the sockets may be attached subsequently, as by welding, for example.
The sink also includes a faucet 602 to supply water from a source to the sink. The faucet is pivoted between an upright, operative position as shown in FIG. 6 and a folded, inoperative position as shown in FIG. 3. A water control valve 603 is located in the sink and separate from the faucet, as shown in FIG. 3. A drain 604 is provided at the lowermost portion of the sink to remove the contents of the sink (FIG. 5). A drain hose (not shown) connects the drain to the outside of the sink assembly through an aperture 402 provided in a lower portion of the back panel 400. As shown in FIG. 1, a cover 606 is constructed and arranged to cover the sink bowl so that the top portion of the sink assembly may be employed as a work surface or storage area. The cover 606 is stored on the back panel when the sink is in use (FIG. 7).
Referring now to FIGS. 3, 7 and 8 the back panel has integrally formed bosses 116 along the length of the left and right edges thereof. The bosses have spring lock fasteners 118 integrally formed thereon. The back panel is attached to the left and right side panels by inserting the bosses 116, of the back panel, into the sockets 210, of the left and right side panels, until the spring lock fasteners 118 engage the apertures 208 formed in the sockets 210. The back panel is provided with an aperture 402 through which a drain hose may be positioned. The opposite end of the drain hose is connected to the drain 604 of the sink to provide a means to drain the fluids from the sink. The back panel is also provided with a fitting 404 which is connectable to a source of water. The fitting is also connected to the faucet 602 via a means not shown.
A storage area for the sink cover 606 is provided on the back panel. Clips 608 (FIGS. 7 and 8) are positioned on the back panel to hold the sink cover in a vertical position adjacent the panel. The clips 608 located on the upper portion of the back panel are flexible or spring type clips. The sink top is held in its storage position by these clips and can be released therefrom by flexing the clips.
The perpendicular side, back, front and base panels are brought into an overlapping relationship wherein the bosses 116 enter the corresponding sockets 210 in the right and left side panels respectively. The result is a mechanically secure connection between the panels. The overlapping edges between the panels as described above provides a secure connection, snap-together assembly and offers several advantages. First, the design allows the panels to be connected without the need for separate connectors. Second, the design creates a positive lock which prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to each other.
Referring now to FIGS. 3, 4 and 5 casters 122 and caster bosses 124 are illustrated. The casters include a stem 126 that is constructed and arranged to cooperate with an aperture integrally formed into the lower surface of the base panel. To attach the caster to the sink assembly, the stem 126 is inserted into the aperture of the boss 124 until a retaining ring snaps into a corresponding groove formed in the aperture. This results in a mechanically secure connection. The casters are also provided with a manually engagable and releasable lock 130 to prevent the sink assembly from unwanted moves on sloped and uneven surfaces. The lock prevents rotation of the casters when in its engaged position and permits free rotation of the casters when in its disengaged position.
Referring to FIGS. 7 and 8, a shelf 710 is hingedly mounted on one or both side panels of the sink assembly. Each shelf is provided with two hinges 724 and 726. These hinges are formed separately from the shelf and attached thereto with fasteners. The portion of the hinge which engages the side panel is not attached thereto with fasteners. Hinge 724 is provided with a fixed pin. A portion of the pin extends beyond the hinge. Hinge 726 is provided with a slidable pin. The slidable pin is biased to its extended position by a spring. The portions of the fixed pin and slidable pin which extend beyond the hinges engage apertures 734 formed in the edge portions of the side panels (FIG. 6). This provides a means to attach the shelves to the side panels. Each shelf is also provided with a plurality of supports hingedly mounted to a lower surface of the shelf. If removal of the shelf is desired, the slidable pin is retracted into the hinge which in turn disengages the pin from aperture 734 in the side panel. The shelf can now be pivoted downwardly disengaging the fixed pin from aperture 734 in the side panel and totally disengaging the shelf from the sink assembly. The location of the apertures 734 are identical on both the left and right side panels so that the same shelf may be mounted on either side of the sink assembly.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.

Claims

1. A sink assembly comprising:

a left side panel for enclosing the left side of said sink assembly;

a right side panel for enclosing the right side of said sink assembly;

a base panel for enclosing the bottom of said sink assembly;

a back panel for enclosing the back of said sink assembly;

a front panel for enclosing the front of said sink assembly; and

a sink for enclosing the top of said sink assembly;

said base panel is adapted to receive means to provide mobility to said sink assembly;

whereby said base panel, said left panel, said right panel, said back panel, said front panel and said sink are constructed and arranged for snap-together assembly without additional fasteners;

wherein said sink assembly can be shipped in a disassembled state and assembled on a desired site.

2. The sink assembly of claim 1 where in at least one of said left side panel and said right side panel includes;

a bottom portion having at least one integrally formed socket constructed and arranged to cooperate with said base panel in an overlapping and interlocking manner;

a top edge having an upwardly extending lip constructed and arranged to cooperate with said sink in an underlying manner;

a first edge having at least one integrally formed elongated socket for connection to said front panel in a perpendicular relationship;

a second edge having at least one integrally formed elongated socket for connection to said back panel in a perpendicular relationship;

an inner surface; and

an outer surface.

3. The sink assembly of claim 2 wherein said at least one elongated socket formed on said first edge is constructed and arranged to interlockingly engage a corresponding at least one boss formed into said front panel resulting in a mechanically secure connection therebetween and wherein said at least one elongated socket formed on said second edge is constructed and arranged to interlockingly engage a corresponding at least one boss formed into said back panel resulting in a mechanically connection therebetween.

4. The sink assembly of claim 3 wherein each of said bosses includes at least one spring lock fastener integrally formed thereto, said spring lock fastener is constructed and arranged to cooperate with at least one aperture integrally formed into said sockets;

wherein said at least one spring lock fastener engages at least one side wall of said aperture for interlocking engagement therewith.

5. The sink assembly of claim 1 wherein said base panel includes;

a top surface constructed and arranged to provide a rigid and generally flat surface;

a bottom surface constructed and arranged to provide rigidity and stability to said preparation station;

a front closed edge and a rear closed edge;

a left edge and a right edge, each having at least one integrally formed boss arranged in a linear fashion and extending outwardly from said left and said right edges, said at least one boss constructed and arranged to cooperate with at least one inwardly extending socket integrally formed into a lower portion of said left and said right panels for interlocking engagement therewith.

6. The sink assembly of claim 5 wherein each of said bosses includes at least one spring lock fastener integrally formed thereto, said at least one spring lock fastener is constructed and arranged to cooperate with at least one aperture integrally formed into said sockets;

7. The sink assembly of claim 5 wherein said bottom surface of said base panel includes at least four integrally formed caster bosses;

each of said caster bosses is constructed and arranged to cooperate with a caster for securement thereof without additional fasteners;

whereby said sink assembly is moveably supported upon said casters.

8. The preparation station of claim 7 wherein at least one of said casters includes a manually engageable lock;

wherein said lock is constructed and arranged to prevent rotation of said caster while said lock is in an engaged position and allow free rotation of said caster when said lock is in a disengaged position.

9. The sink assembly of claim 1 further including a door positioned on the front of said sink assembly, said door extending between said left panel and said right panel, said door extending upwardly between said base panel and said front panel, said door being hingedly secured to said base panel and said front panel, whereby access is provided to the interior of said sink assembly below said sink.

10. The sink assembly of claim 2 wherein said sink includes a socket formed on the bottom thereof and at each corner;

said left and said right side walls include a socket integrally formed at the top portion of said first and said second edges; and

further including a plurality of bosses constructed and arranged to cooperate with the sockets formed in said sink and in said side walls for interlocking engagement therewith.

11. The sink assembly of claim 10 wherein each of said bosses includes at least one spring lock fastener integrally formed thereto;

said at least one spring lock fastener is constructed and arranged to cooperate with at least one aperture integrally formed into said sockets;

whereby said at least one spring lock fastener engages at least one side wall of said at least one aperture for interlocking engagement therewith.

12. The sink assembly of claim 1 wherein said sink includes a faucet, a drain, and a cover;

said faucet is pivotable between an operative position and a stored position;

said drain is adapted to be connected to a drain hose;

said cover is constructed and arranged to cover the bowl portion of the sink when placed thereon; and

said back panel includes means to secure said cover thereto when said cover is removed from said sink.

13. The sink assembly of claim 1 further including a shelf hingedly mounted to an upper portion of said right or said left side panel;

wherein said shelf is pivotable between a vertical stored position and a horizontal operational position.

14. The sink assembly of claim 1 wherein the means to provide mobility to said sink assembly comprises casters mounted to said base panel.

15. The sink assembly of claim 14 wherein at least one of said casters include a releasable lock.