DRAINAGE AND LEAK PREVENTION SUBSTRATE VESSEL FOR SINK VANITY

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application claims the benefit of and priority to U.S. Provisional Ser. No. 63/718,042 filed Nov. 8, 2024, titled “DRAINAGE AND LEAK-PREVENTION SUBSTRATE VESSEL FOR SINK VANITY,” the entire content of which is hereby incorporated herein by reference.

TECHNICAL FIELD

[0002]The present invention relates generally to the field of plumbing products, and more particularly to a substrate vessel for sinks and vanities to provide drainage and prevent leakage, and to methods of manufacturing, installing and using such products.

BACKGROUND

[0003]Architectural surface vanity sinks, including ramp sinks, trough sinks, slot sinks, and other similar designs are typically constructed from panels or slabs of decorative architectural surface materials such as stone, engineered quartz composites, porcelain, gauged porcelain tile panels (GPTP), or another similar material. Because these sinks are fabricated from separate panel sections, they are prone to water leakage at the seams or joints between the panels. Commonly, sealants may be applied around the joints, and the underside of the sink assembly may be covered with epoxy or fiberglass in place of or in combination with sealing the joints in an effort to prevent or reduce potential leaks. Such measures are typically taken in the field by the installer or fabricator during or after assembly of the sink, which can be time consuming and labor intensive, and may be aesthetically unappealing.

[0004]Even small leaks can cause significant and expensive water damage to surrounding construction. As such, commercial and residential property owners, as well as fabricators and installers of architectural surface vanity sinks are rightfully concerned about leaks and liability for repairs. Known methods of attempting to prevent water leakage from architectural surface vanity sinks have been found to be less than fully effective in preventing leaks. Accordingly, it has been found that needs exist for improved leak prevention systems and methods for use with architectural surface vanity sinks. It is to the provision of improved leak prevention systems and methods for use with architectural surface vanity sinks meeting these and other needs that the present invention is primarily directed.

SUMMARY

[0005]In example embodiments, the present invention provides a drainage and leak prevention substrate system and apparatus or sink substrate vessel providing improved leak prevention performance in connection with architectural surface vanity sinks. In example forms, the sink substrate vessel includes a prefabricated, seamless substrate component configured for mounting below a vanity top and around the vanity sink to contain and drain any leakage from the sink and prevent water damage to surrounding construction. The invention further includes methods of manufacturing, installing and using such sink substrate vessel systems and apparatus. Provision and use of the sink substrate vessel according to example forms of the invention may substantially reduce labor and material expenses and/or lower the requisite skill level required for fabrication and installation of architectural surface vanity sinks. Additionally, provision and use of the sink substrate vessel according to example forms of the invention may reduce liability for the expense of repairs, and remove or shift liability from the fabricator and installer of the sink.

[0006]In one aspect, the present invention relates to a sink substrate vessel for use in combination with an architectural surface vanity sink or other plumbing assembly, to prevent leakage and water damage.

[0007]In another aspect, the present invention relates to a method of fabricating such a sink substrate vessel.

[0008]In still another aspect, the present invention relates to a method of installing such a sink substrate vessel.

[0009]These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of example embodiments are explanatory of example embodiments of the invention, and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]Many aspects of the present disclosure can be better understood with reference to the following figures. The components in the figures are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the concepts of the disclosure. Moreover, repeated use of reference characters or numerals in the figures is intended to represent the same or analogous features, elements, or operations across different figures. Repeated description of such repeated reference characters or numerals is omitted for brevity.

[0011]FIG. 1A illustrates a top-down perspective view of an example foldable waterproof slab template according to various aspects and embodiments of the present disclosure.

[0012]FIG. 1B illustrates a cross-sectional side view of the foldable waterproof slab template shown in FIG. 1A taken along the sectional plane A-A according to various aspects and embodiments of the present disclosure.

[0013]FIG. 2A illustrates a top-down perspective view of an example sink substrate vessel according to various aspects and embodiments of the present disclosure.

[0014]FIG. 2B illustrates a top-down view of the sink substrate vessel shown in FIG. 2A according to various aspects and embodiments of the present disclosure.

[0015]FIG. 3A illustrates a top-down perspective view of an example architectural surface vanity sink according to various aspects and embodiments of the present disclosure.

[0016]FIG. 3B illustrates a bottom-up perspective view of the architectural surface vanity sink shown in FIG. 3A according to various aspects and embodiments of the present disclosure.

[0017]FIG. 4 illustrates a top-down perspective view of another example architectural surface vanity sink according to various aspects and embodiments of the present disclosure.

[0018]FIG. 5 illustrates a flow diagram of an example foldable waterproof slab template fabrication method according to various aspects and embodiments of the present disclosure.

[0019]FIG. 6 illustrates a flow diagram of an example sink substrate vessel fabrication method according to various aspects and embodiments of the present disclosure.

[0020]FIG. 7 illustrates a flow diagram of an example architectural surface vanity sink fabrication method according to various aspects and embodiments of the present disclosure.

DETAILED DESCRIPTION

[0021]In particular example embodiments, the present invention includes a sink substrate vessel formed as a prefabricated substrate component that mounts below a vanity top's decorative surface allowing for a more efficient vanity sink cladding process. In example embodiments, the sink substrate vessel remains as a permanently attached, pre-sloped substrate that makes cladding easy and protects against vanity sink leaks and resultant water damage and liability. In example embodiments, the sink substrate vessel is “surface-ready,” for the installer to fabricate a vanity sink by applying an architectural surface slab material veneer. In this manner, the sink substrate vessel may increase shop efficiency, protect against vanity sink leaks, provide a pre-sloped integrated drain trough, and allow for custom and standard size and configuration options. In some example embodiments, the sink substrate vessel may also help protect the finished integrated vanity sink from incurring damage during transport to jobsite or shipping to the installation site from a remote or offsite assembly or fabrication location.

[0022]In further example embodiments, the present invention provides methods of fabrication, installation and use of a sink substrate vessel, as disclosed herein. In particular embodiments, the sink substrate vessel may be used to build and waterproof a ramp sink made from slabs or panels of at least one of stone, quartz composite materials, porcelain, sintered stone, ultra-compact material, gauged porcelain tile panels (GPTP), or other decorative architectural surface materials. These types of decorative “slabs” are also lumped under the term “mineral surfaces”. The sink substrate vessel can be configured for use in connection with both integrated “ramp” sinks and integrated “center drain” sinks, and with such sinks of various sizes and configurations.

[0023]In some example embodiments, the sink substrate vessel includes an integrated pre-sloped drain trough with a pre-drilled drain hole that can be plumbed using any common popup or grid vanity sink drain or drain piping connection. This wet room component can be mounted below a decorative surface of at least one of a porcelain, stone, quartz, gauged porcelain tile panel (GPTP), or architectural surface vanity sink. The sink substrate vessel can provide structural support to the decorative surfacing, increase cladding efficiency, and remain below the cladding as a permanent barrier against vanity sink leaks.

[0024]For context, FIG. 1A illustrates a top-down perspective view of an example foldable waterproof slab template or blank 10 according to various aspects and embodiments of the present disclosure. FIG. 1B illustrates a cross-sectional side view of the foldable waterproof slab template 10 shown in FIG. 1A taken along the sectional plane A-A according to various aspects and embodiments of the present disclosure.

[0025]The foldable waterproof slab template 10 is illustrated as a representative example of a waterproof slab template or blank that can be folded to form a unitary leakproof enclosure. In some cases, such a unitary leakproof enclosure can be implemented as a sink substrate vessel, and in other examples such a sink substrate vessel can be embodied with or coupled to a plumbing drainage apparatus such as an architectural surface vanity sink. The concepts described herein can be extended to use with a range of plumbing drainage apparatuses and sinks of different types, styles, components, and configurations, however. The foldable waterproof slab template 10 is not drawn to any particular scale or size in the drawings. The shape, size, proportion, and other characteristics of the foldable waterproof slab template 10 and the components or features thereof can vary as compared to that shown. For example, the foldable waterproof slab template 10 can accommodate different base and side panel geometries, configurations, and locations, and other variations are within the scope of the examples described herein. Additionally, one or more of the components or features of the foldable waterproof slab template 10, as illustrated in the drawings and described herein, can be omitted in some cases. The foldable waterproof slab template 10 can also include other components or features that are not illustrated.

[0026]Among other components, the foldable waterproof slab template 10 shown in FIGS. 1A and 1B includes a waterproof slab 100 and a panel pattern of grooves 102, 104, 106, 108 formed into a top surface of the waterproof slab 100. The waterproof slab 100 can be embodied as or include at least one of a unitary continuous sheet of waterproof material, an architectural surface slab material, a stone slab, a ceramic slab, a sheet of foam material, a sheet of polymer material, a sheet of high-density foamed polyvinyl chloride, a sheet of acrylonitrile butadiene styrene, a sheet of high-density foam board material, a sheet of polyurethane, a sheet of polyethylene terephthalate, a gauged porcelain tile panel (GPTP), or a sheet, slab, or panel of another waterproof material in some examples.

[0027]The grooves 102, 104, 106, 108 are each formed as a V-shaped groove, V-groove, or V-score in this example, although another groove profile may be relied upon in other examples such as a U-shape, a W-shape, or another shape. The grooves 102, 104, 106, 108 each have a 90 degree (°) angle at a vertex of the groove in the example shown, although another angle may be relied upon in other examples.

[0028]The grooves 102, 106 are offset from and parallel to one another in the example shown, and the grooves 104, 108 are offset from and parallel with one another in this example. The grooves 102, 106 extend perpendicularly across and through the grooves 104, 108, respectively, in this example. Likewise, the grooves 104, 108 extend perpendicularly across and through the grooves 102, 106, respectively, in this example. In this manner, the grooves 102, 104, 106, 108 are formed in a grid pattern on the top surface of the waterproof slab 100 in this example. For instance, the grooves 102, 104, 106, 108 are formed in a grid pattern defined by a first parallel pair of V-shaped grooves 102, 106 formed into the top surface of the waterproof slab 100 and a second parallel pair of V-shaped grooves 104, 108 formed into the top surface of the waterproof slab and extending perpendicularly across and through the first parallel pair of V-shaped grooves 102, 106 as shown.

[0029]The grooves 102, 104, 106, 108 partly define bevel edges of a base panel 110 for a sink substrate vessel in the example shown. For instance, the grooves 102, 106 partly define bevel edges 112, 116, respectively, of the base panel 110. Similarly, although not denoted in the figures for clarity, each of the grooves 104, 108 also partly defines another bevel edge of the base panel 110 on the waterproof slab 100.

[0030]The grooves 102, 104, 106, 108 further partly define bevel edges of one or more side panels 120, 130, 140, 150 for a sink substrate vessel in the example shown. For instance, the groove 102 partly defines a side bevel edge 122 of the side panel 120, an end bevel edge 134 of the side panel 130, and an end bevel edge 156 of the side panel 150. Similarly, although not denoted in the figures for clarity, each of the grooves 104, 106, 108 also partly defines a side bevel edge of one of the side panels 130, 140, 150 and an end bevel edge of two of the side panels 130, 140, 150.

[0031]The foldable waterproof slab template 10 includes four side panels 120, 130, 140, 150 in the example shown, although a number of side panels that is less than or greater than four may be relied on in other examples. Each of the grooves 102, 104, 106, 108 formed into the top surface of the waterproof slab 100 partly defines one of the bevel edges of the base panel 110 and one of the bevel edges of three of the four side panels 120, 130, 140, 150. Each of the grooves 102, 104, 106, 108 partly defines a certain subset of the bevel edges of the base panel 110 and the side panels 120, 130, 140, 150. For instance, the groove 102 partly defines the bevel edge 112 of the base panel 110, the side bevel edge 122 of the side panel 120, the end bevel edge 134 of the side panel 130, and the end bevel edge 156 of the side panel 150 in the example shown. Each of the grooves 102, 104, 106, 108 also partly defines a certain subset of the bevel edges of the base panel 110 and the side panels 120, 130, 140, 150 at a defined angle (α) relative to the top surface of the waterproof slab 100 as shown. For instance, the groove 102 partly defines the bevel edge 112 of the base panel 110, the side bevel edge 122 of the side panel 120, the end bevel edge 134 of the side panel 130, and the end bevel edge 156 of the side panel 150 at the angle α relative to the top surface of the waterproof slab 100 in this example.

[0032]The grooves 102, 104, 106, 108 further partly define folding regions along respective vertices of the grooves 102, 104, 106, 108 in the example shown. For instance, the grooves 102, 104, 106, 108 partly define folding regions 162, 164, 166, 168, respectively, along corresponding vertices of the grooves 102, 104, 106, 108 between the vertices and a bottom surface of the waterproof slab 100 as shown in this example. The folding regions 162, 164, 166, 168 each extend a distance (D₁) between respective vertices of the grooves 102, 104, 106, 108 and the bottom surface of the waterproof slab 100. For instance, the folding regions 162, 166 extend the distance D₁ between the respective vertices of the grooves 102, 106 and the bottom surface of the waterproof slab 100 as shown in FIG. 1B. The distance D₁ can vary in some cases depending on the material selected for the waterproof slab 100 or the intended application of the foldable waterproof slab template 10.

[0033]The foldable waterproof slab template 10 in the example shown further includes a trough 170 formed into the top surface of the waterproof slab 100 at one end of the base panel 110. The trough 170 has a long axis that is parallel to the groove 104 and it is positioned symmetrically or centrally between the grooves 102, 106 in this example. The trough 170 is partly defined by at least one of a sloped or curved trough surface 171 formed into the top surface at a defined angle (θ), grading (e.g., 2 percent (%)), or radius of curvature relative to the top surface of the waterproof slab 100. The foldable waterproof slab template 10 in the example shown further includes a drain hole or aperture 180 formed through the waterproof slab 100 from the trough surface 171 partly defining the trough 170 to the bottom surface of the waterproof slab 100. The drain aperture 180 is formed through the waterproof slab 100 at a location in the trough 170 that corresponds with a minimum distance (D_min) between the trough surface 171 and the bottom surface of the waterproof slab 100 in this example.

[0034]The foldable waterproof slab template 10 in this example also includes removeable sections 101, 103, 105, 107 at corners of the waterproof slab 100 that are partly defined by the grooves 102, 104, 106, 108 as shown in FIG. 1A. For instance, the removeable sections 101, 103, 105, 107 are partly defined at corners of the waterproof slab 100 by the grid pattern of the grooves 102, 104, 106, 108 in this example. The removeable sections 101, 103, 105, 107 can be removed for assembly of a sink substrate vessel described in some examples herein by cutting through each of the folding regions 162, 164, 166, 168 for a defined length (L) into corresponding grooves 102, 104, 106, 108 from outer edges of the waterproof slab 100. The removeable sections 101, 103, 105, 107 can be removed for assembly of a sink substrate vessel described in one example herein by cutting through each of the folding regions 162, 164, 166, 168 for a distance equivalent to an end dimension of the end bevel edges of the side panels 120, 130, 140, 150 into corresponding grooves 102, 104, 106, 108 from outer edges of the waterproof slab 100. For instance, the removeable section 101 can be separated from the waterproof slab 100 by cutting through each of the folding regions 162, 164 for the defined length L along the grooves 102, 104, respectively, until the cuts intersect to detach the removeable section 101 from the waterproof slab 100.

[0035]Side bevel edges of the side panels 120, 130, 140, 150 cooperate with and can be coupled to respective bevel edges of the base panel 110 to at least partly form a sink substrate vessel when the side panels 120, 130, 140, 150 are folded along their folding regions in the example shown. Additionally, end bevel edges at corresponding ends of respective side panels 120, 130, 140, 150 cooperate with and can be coupled to one another to at least partly form a sink substrate vessel when the side panels 120, 130, 140, 150 are folded along their folding regions in this example. For instance, the bevel edge 112 of the base panel 110 cooperates with and can be coupled to the side bevel edge 122 of the side panel 120 when the side panel 120 is folded along the folding region 162. Additionally, the end bevel edge 124 of the side panel 120 cooperates with and can be coupled to the end bevel edge 156 of the side panel 150 when the side panels 120, 150 are folded along the folding regions 162, 168, respectively, in this example. Also, the end bevel edge 126 of the side panel 120 cooperates with and can be coupled to the end bevel edge 134 of the side panel 130 when the side panels 120, 130 are folded along the folding regions 162, 164, respectively, in this example. Similarly, other end and side bevel edges of the side panels 120, 130, 140, 150 also cooperate with and can be coupled to one another and other corresponding bevel edges of the base panel 110, respectively, to at least partly form a sink substrate vessel when the side panels 120, 130, 140, 150 are folded along their folding regions in the example shown. In one example embodiment, the side panels 120, 130, 140, 150 can be folded along the folding regions 162, 164, 166, 168 and bevel edges of the side panels 120, 130, 140, 150 can be coupled to one another and to bevel edges of the base panel 110 to transform the foldable waterproof slab template 10 into a unitary leakproof enclosure such as the example sink substrate vessel described herein and illustrated in FIGS. 2A and 2B.

[0036]FIG. 2A illustrates a top-down perspective view of an example sink substrate vessel 20 according to various aspects and embodiments of the present disclosure. FIG. 2B illustrates a top-down view of the sink substrate vessel 20 shown in FIG. 2A.

[0037]The sink substrate vessel 20 is illustrated as a representative example of a unitary leakproof enclosure formed form a foldable waterproof slab template as described in examples herein. In some cases, such a unitary leakproof enclosure can be implemented as a sink substrate vessel, and in other examples such a sink substrate vessel can be embodied with or coupled to a plumbing drainage apparatus such as an architectural surface vanity sink. The concepts described herein can be extended to use with a range of plumbing drainage apparatuses and sinks of different types, styles, components, and configurations, however. The sink substrate vessel 20 is not drawn to any particular scale or size in the drawings. The shape, size, proportion, and other characteristics of the sink substrate vessel 20 and the components or features thereof can vary as compared to that shown. For example, the sink substrate vessel 20 can accommodate different base panel, side panel, and ramp geometries, configurations, and locations, and other variations are within the scope of the examples described herein. Additionally, one or more of the components or features of the sink substrate vessel 20, as illustrated in the drawings and described herein, can be omitted in some cases. The sink substrate vessel 20 can also include other components or features that are not illustrated.

[0038]Among other components, the sink substrate vessel 20 shown in FIGS. 2A and 2B includes a folded waterproof slab template 200 and a sloped panel or ramp 210 positioned or formed in and coupled to the folded waterproof slab template 200 in this example. The sloped panel or ramp 210 may be omitted from the sink substrate vessel 20 in another example. The folded waterproof slab template 200 is an example embodiment of the foldable waterproof slab template 10 after cutting out the removeable sections 101, 103, 105, 107, folding the side panels 120, 130, 140, 150 along the folding regions 162, 164, 166, 168 toward the base panel 110, and coupling corresponding bevel edges of the base panel 110 and the side panels 120, 130, 140, 150 as described in examples with reference to FIGS. 1A and 1B.

[0039]Side bevel edges of the side panels 120, 130, 140, 150 on the sink substrate vessel 20 are coupled to respective bevel edges of the base panel 110 on the sink substrate vessel 20, and end bevel edges at corresponding ends of respective side panels 120, 130, 140, 150 on the sink substrate vessel 20 are coupled to one another in this example. For instance, the bevel edge 112 of the base panel 110 is coupled to the side bevel edge 122 of the side panel 120, the end bevel edge 124 of the side panel 120 is coupled to the end bevel edge 156 of the side panel 150, and the end bevel edge 126 of the side panel 120 is coupled to the end bevel edge 134 of the side panel 130 in this example. Similarly, other end and side bevel edges of the side panels 120, 130, 140, 150 are coupled to one another and other corresponding bevel edges of the base panel 110, respectively, in the example shown. The side bevel edges of the side panels 120, 130, 140, 150 can be coupled to the bevel edges of the base panel 110 and the end bevel edges of the side panels 120, 130, 140, 150 can be coupled to one another by way of at least one of a solvent weld, a chemical weld, a thermal weld, or an adhesive to form a fluidic seal along the sides and ends of the panels.

[0040]The sloped panel or ramp 210 can be formed of and include a high-density expanded polystyrene (EPS) foam material in some cases. The ramp 210 in the example shown includes decorative veneer of stone or other architectural surface material installed on the ramp 210 and other interior surfaces of the sink substrate vessel 20 such as the trough surface 171 of the trough 170. The ramp 210 can be positioned or formed in and coupled to the folded waterproof slab template 200 at various slope angles relative to the top surface of the waterproof slab 100 to accommodate different applications or sink geometries. The ramp 210 can be formed of a high-density EPS foam material and can be optionally provided for installation inside the sink substrate vessel 20 as shown in FIGS. 2A, 2B, and 3A. The sloped panel or ramp 210 may be used, removed, and altered by a stone fabricator or installer depending on their needs and depending on the finished slope or sink configuration desired for a particular application.

[0041]FIG. 3A illustrates a top-down perspective view of an example architectural surface vanity sink 30 according to various aspects and embodiments of the present disclosure. FIG. 3B illustrates a bottom-up perspective view of the architectural surface vanity sink 30 shown in FIG. 3A.

[0042]The architectural surface vanity sink 30 is illustrated as a representative example of a plumbing drainage apparatus having a sink substrate vessel embodied as a unitary leakproof enclosure formed form a foldable waterproof slab template as described in examples herein. The concepts described herein can be extended to use with a range of plumbing drainage apparatuses and sinks of different types, styles, components, and configurations, however. The architectural surface vanity sink 30 is not drawn to any particular scale or size in the drawings. The shape, size, proportion, and other characteristics of the architectural surface vanity sink 30 and the components or features thereof can vary as compared to that shown. For example, the architectural surface vanity sink 30 can accommodate different base panel, side panel, ramp, and architectural surface vanity geometries, configurations, and locations, and other variations are within the scope of the examples described herein. Additionally, one or more of the components or features of the architectural surface vanity sink 30, as illustrated in the drawings and described herein, can be omitted in some cases. The architectural surface vanity sink 30 can also include other components or features that are not illustrated.

[0043]Among other components, the architectural surface vanity sink 30 shown in FIGS. 3A and 3B includes an architectural surface vanity structure 300 and the sink substrate vessel 20 coupled to the architectural surface vanity structure 300 in this example. The sink substrate vessel 20 is mounted to an underside surface 301 on the architectural surface vanity structure 300 in this example by way of one or more brackets such as brackets 310, 312 shown in FIG. 3B. In some examples, the brackets 310, 312 can be embodied as L-brackets as shown in FIG. 3B.

[0044]FIG. 4 illustrates a top-down perspective view of another example architectural surface vanity sink 40 according to various aspects and embodiments of the present disclosure. The architectural surface vanity sink 40 is an example alternative embodiment of the architectural surface vanity sink 30 described herein and illustrated in FIGS. 3A and 3B. For instance, the architectural surface vanity sink 40 can include at least one of the same or similar structure, components, features, attributes, material, and functional ability as that of the architectural surface vanity sink 30 described herein and illustrated in FIGS. 3A and 3B.

[0045]The architectural surface vanity sink 40 is illustrated as another representative example of a plumbing drainage apparatus having a sink substrate vessel embodied as a unitary leakproof enclosure formed form a foldable waterproof slab template as described in examples herein. The concepts described herein can be extended to use with a range of plumbing drainage apparatuses and sinks of different types, styles, components, and configurations, however. The architectural surface vanity sink 40 is not drawn to any particular scale or size in the drawings. The shape, size, proportion, and other characteristics of the architectural surface vanity sink 40 and the components or features thereof can vary as compared to that shown. For example, the architectural surface vanity sink 40 can accommodate different base panel, side panel, and architectural surface vanity geometries, configurations, and locations, and other variations are within the scope of the examples described herein. Additionally, one or more of the components or features of the architectural surface vanity sink 40, as illustrated in the drawings and described herein, can be omitted in some cases. The architectural surface vanity sink 40 can also include other components or features that are not illustrated.

[0046]Among other components, the architectural surface vanity sink 40 shown in FIG. 4 includes the architectural surface vanity structure 300 and a sink substrate vessel 20′ coupled to the architectural surface vanity structure 300 in this example. The sink substrate vessel 20′ is an example alternative embodiment of the sink substrate vessel 20 described herein and illustrated in FIGS. 2A, 2B, 3A, and 3B. For instance, the sink substrate vessel 20′ can include at least one of the same or similar structure, components, features, attributes, material, and functional ability as that of the sink substrate vessel 20 described herein and illustrated in FIGS. 2A, 2B, 3A, and 3B.

[0047]Although not illustrated in FIG. 4, the sink substrate vessel 20′ is mounted to the underside surface 301 on the architectural surface vanity structure 300 in this example by way of one or more brackets such as the brackets 310, 312 in a similar or same manner as the sink substrate vessel 20 is mounted to the architectural surface vanity structure 300 on the architectural surface vanity sink 30 shown in FIG. 3B. In the example shown in FIG. 4, the ramp 210 is omitted from the sink substrate vessel 20′ on the architectural surface vanity sink 40.

[0048]FIG. 5 illustrates a flow diagram of an example foldable waterproof slab template fabrication method 500 (or “method 500”) according to various aspects and embodiments of the present disclosure. FIG. 5 shows a fabrication sequence for forming a foldable waterproof slab template that can be used to form a drainage and leak prevention sink substrate vessel according to an example embodiment of the present invention. The method 500 can be implemented in some examples to fabricate various sink substrate vessel templates such as the foldable waterproof slab template 10 described herein with reference to FIGS. 1A and 1B. For instance, the method 500 can be implemented to form the foldable waterproof slab template 10 with or without one or both of the trough 170 or the drain aperture 180.

[0049]At 510, the method 500 includes forming or preparing a waterproof slab such as the waterproof slab 100 for machining. For instance, at 510 a unitary continuous sheet of waterproof material can be formed or prepared as a substrate or precursor panel that can be formed into a blank from which the sink substrate vessels 20, 20′ can be fabricated. In example forms, the waterproof slab 100 can be embodied as and include a sheet of high-density foamed polyvinyl chloride (PVC) material. Alternatively, the waterproof slab 100 can be a sheet of acrylonitrile butadiene styrene (ABS plastic), high-density foam board materials such as polyurethane (PU), polyethylene terephthalate (PET), or other waterproof sheet materials. In further alternative embodiments, the foldable waterproof slab template 10 on the sink substrate vessel 20 can be fabricated from an expanded polystyrene (EPS) or PET foam slab that is milled to shape. In example embodiments, the waterproof slab 100 can have a thickness of about 12 millimeters (mm) or ½ inch. In alternate embodiments, the thickness can vary less or greater, depending on a preferred size of a desired finished product, load requirements, or other parameters.

[0050]At 520, the method 500 includes forming a trough into a top surface of the waterproof slab 100 and drain aperture or hole through a thinnest region of the trough. For instance, at 520 a computer numerical control (CNC) machine or other equipment can be used to form the trough surface 171 into the top surface of the waterproof slab 100 to partly define the trough 170 as a sloped trough and the drain hole 180 can then be formed through the thinnest region of the trough 170 between the trough surface 171 and a bottom surface of the waterproof slab 100. In one example, the drain hole 180 can be formed through the trough 170 at its thinnest region and the trough surface 171 and the trough 170 can be formed with a 2% or more slope toward the drain hole 180 from the top surface of the waterproof slab.

[0051]At 530, the method 500 includes forming V-grooves into the waterproof slab 100. For instance, at 530 the grooves 102, 104, 106, 108 can be formed in a grid pattern defined by a first parallel pair of V-shaped grooves 102, 106 formed into the top surface of the waterproof slab 100 and a second parallel pair of V-shaped grooves 104, 108 formed into the top surface of the waterproof slab and extending perpendicularly across and through the first parallel pair of V-shaped grooves 102, 106 as shown and described herein with reference to FIGS. 1A and 1B. In one example, a CNC machine can be used to form each of the grooves 102, 104, 106, 108 into the waterproof slab 100 as a V-groove having a 90° groove profile along and partly defining the folding regions 162, 164, 166, 168.

[0052]At 540, the method 500 includes cutting through the waterproof slab 100 to define a template perimeter for a flat, milled, and foldable “blank” such as the foldable waterproof slab template 10. For instance, a CNC machine can be used to cut through the waterproof slab 100 around the grid pattern of V-shaped grooves 102, 104, 106, 108 as shown to define a template perimeter 190 for the foldable waterproof slab template 10.

[0053]FIG. 6 illustrates a flow diagram of an example sink substrate vessel fabrication method 600 (or “method 600”) according to various aspects and embodiments of the present disclosure. FIG. 6 shows a fabrication and assembly sequence for forming a drainage and leak prevention sink substrate vessel according to an example embodiment of the present invention. The method 600 can be implemented in some examples to fabricate various sink substrate vessels such as the sink substrate vessel 20, 20′ described herein with reference to FIGS. 2A, 2B, 3A, 3B, and 4. For instance, the method 600 can be implemented to form the sink substrate vessel 20 with the ramp 210 or the sink substrate vessel 20′ without the ramp 210.

[0054]At 610, the method 600 includes applying coupling material to surfaces of the grooves 102, 104, 106, 108 formed into a foldable waterproof slab template such as the foldable waterproof slab template 10 that can be fabricated by implementing the method 500 described herein with reference to FIG. 5. For instance, at 610 a coupling material can be applied to one or more bevel edges of the base panel 110 or the side panels 120, 130, 140, 150. In some examples, a coupling material such as at least one of a chemical weld material, a solvent weld material, a medium viscosity two-component methyl methacrylate adhesive, or another coupling material can be applied to one or more bevel edges of the base panel 110 or the side panels 120, 130, 140, 150. In some cases, corresponding bevel edges of the base panel 110 or the side panels 120, 130, 140, 150 can be coupled by way of thermal welding.

[0055]At 620, the method 600 includes folding the side panels 120, 130, 140, 150 along the folding regions 162, 164, 166, 168 toward the base panel 110 to position and seat corresponding bevel edges of the base panel 110 and the side panels 120, 130, 140, 150 against one another to partly form a sink substrate vessel structure such as the folded waterproof slab template 200. For instance, at 620 the folded waterproof slab template 200 can be partly formed as a sink substrate vessel structure from the foldable waterproof slab template 10 after cutting out the removeable sections 101, 103, 105, 107, folding the side panels 120, 130, 140, 150 along the folding regions 162, 164, 166, 168 toward the base panel 110, and coupling corresponding bevel edges of the base panel 110 and the side panels 120, 130, 140, 150 as described in examples with reference to FIGS. 1A and 1B.

[0056]At 630, the method 600 includes securing the folded waterproof slab template 200 in-place until coupling material cures to finalize assembly of the folded waterproof slab template 200 from the foldable waterproof slab template 10. For instance, the folded waterproof slab template 200 can be secured in place at 630 using a clamp as shown in this example until the coupling material applied at 620 cures.

[0057]At 640, the method 600 optionally includes applying a sealant material along folded lines defined along the folding regions 162, 164, 166, 168 and at corner seams inside the folded waterproof slab template 200 as shown in this example. In some cases, the sealant material may be omitted from the folded waterproof slab template 200.

[0058]In alternative embodiments, the sink substrate vessel 20 can be formed by injection molding, additive or subtractive manufacturing methods, or other fabrication processes.

[0059]FIG. 7 illustrates a flow diagram of an example architectural surface vanity sink fabrication method 700 (or “method 700”) according to various aspects and embodiments of the present disclosure. FIG. 7 shows a fabrication and assembly sequence for an architectural surface vanity sink having a drainage and leak prevention sink substrate vessel according to an example embodiment of the present invention. The method 700 can be implemented in some examples to fabricate various architectural surface vanity sinks having sink substrate vessels such as the architectural surface vanity sinks 30, 40 having the sink substrate vessel 20, 20′, respectively, described herein with reference to FIGS. 2A, 2B, 3A, 3B, and 4. For instance, the method 700 can be implemented to form the architectural surface vanity sink 30 having the sink substrate vessel 20 with the ramp 210 or the architectural surface vanity sink 40 having the sink substrate vessel 20′ without the ramp 210.

[0060]At 710, the method 700 includes preparing a sink substrate vessel for mounting to an architectural surface vanity structure. For instance, at 710 the sink substrate vessel 20 can be prepared for mounting to the underside surface 301 on the architectural surface vanity structure 300. In some examples, the sink substrate vessel 20 be applying a coupling material to contact surfaces on the sink substrate vessel 20 that will cooperate with the underside surface 301 on the architectural surface vanity structure 300. For instance, at least one of a chemical weld material, a solvent weld material, a medium viscosity two-component methyl methacrylate adhesive, or another coupling material can be applied to surfaces on the side panels 120, 130, 140, 150 that contact the underside surface 301 on the architectural surface vanity structure 300 when mounted.

[0061]At 720, the method 700 includes mounting the sink substrate vessel to the architectural surface vanity structure. For instance, at 720 the sink substrate vessel 20 can be coupled to the underside surface 301 on the architectural surface vanity structure 300 at least in part by way of the brackets 310, 312 in some examples as described herein with reference to FIGS. 3A and 3B.

[0062]At 730, the method 700 includes installing decorative veneer of stone or other architectural surface material over one or more interior surfaces of the sink substrate vessel 20. For instance, at 730 decorative veneer of stone or other architectural surface material 320 can be installed on and coupled to at least one of the ramp 210, the trough surface 171, or inner facing surfaces of the side panels 120, 130, 140, 150 on the sink substrate vessel 20.

[0063]At 740, the method 700 includes preparing or finalizing fabrication and assembly of an architectural surface vanity sink with a sink substrate vessel mounted to an underside of the vanity sink. For instance, at 740 the fabrication and assembly of the architectural surface vanity sink 30 with the sink substrate vessel 20 mounted to the underside surface 301 on the architectural surface vanity structure 300 can be finalized and prepared for installation in connection with a certain application.

[0064]FIGS. 3A, 3B, and 4 show examples of finished architectural surface vanity sinks constructed with the drainage and leak prevention sink substrate vessels 20, 20′, respectively, according to example embodiments of the invention. The sink substrate vessel 20 can be used in some examples to fabricate various integrated “ramp” sinks (also known as trough sinks, slot sinks, etc.), and various other sink configurations, shower drains, and other plumbing fixtures or assemblies. Also, the sink substrate vessel 20 can have a center drain in some cases that can be used by a fabricator to fabricate a simple center drain integrated vanity sink, or one or more other drain locations and configurations.

[0065]A fabricator or installer has various options for how to install or mount the sink substrate vessel 20. One option is to apply epoxy adhesive around a top perimeter of the sink substrate vessel 20 defined by the folded side panels 120, 130, 140, 150, then mount the sink substrate vessel 20 below or beneath a decorative vanity surface material (e.g., stone, quartz, porcelain, GPTP, etc.) such as the architectural surface vanity structure 300. Another adhesive option is to use polyurethane sealant or silicone instead of the epoxy. Use of the sink substrate vessel 20 can substantially reduce the labor, materials, skill level, and expense involved in fabricating and installing an integrated vanity sink, thus lowering costs and improving efficiency and installation time. Optionally, use of the sink substrate vessel 20 according to the present invention can allow the involved parties (e.g., property owner, general contractor, stone installer or sink fabricator subcontractor, manufacturer of the sink substrate vessel, an insurer of one or more of the other parties, another individual) to selectively allocate risk of liability in the unlikely event of any leaks and resultant damage that may occur, for example by warranty provisions designating liability to the manufacturer of the sink substrate vessel, their insurer, or another party.

[0066]In its various embodiments, the sink substrate vessel 20 provides a leakproof drainage assembly, which substantially reduces or eliminates the potential for damage and liability resulting from water leakage from an architectural surface vanity sink such as the architectural surface vanity sinks 30, 40. The use of a single-piece, unitary and integral blank, folded to form the vessel containment or box, results in fewer seams where leaks might occur. The abutting edges of the folded blank (e.g., the folded waterproof slab template 200) are solvent or chemical welded to form a unitary leakproof containment vessel. Alternatively, thermal welding, adhesive, or other attachment means may be utilized. A drain hole (e.g., 1.25 in. diameter) is preferably formed at the lowest point of the sink substrate vessel 20, to receive a standard sink drain piping connection. In this manner, the sink substrate vessel 20 containment provides a prefabricated leakproof enclosure, presenting a clean and professional aesthetic appearance.

[0067]The features, structures, or characteristics described above may be combined in one or more embodiments in any suitable manner, and the features discussed in the various embodiments are interchangeable, if possible. In the above description, numerous specific details are provided in order to fully understand the embodiments of the present disclosure. However, a person skilled in the art will appreciate that the technical solution of the present disclosure may be practiced without one or more of the specific details, or other methods, components, materials, and the like may be employed. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the present disclosure.

[0068]Combinatorial language, such as “at least one of X, Y, and Z” or “at least one of X, Y, or Z,” unless indicated otherwise, is used in general to identify one, a combination of any two, or all three (or more if a larger group is identified) thereof, such as X and only X, Y and only Y, and Z and only Z, the combinations of X and Y, X and Z, and Y and Z, and all of X, Y, and Z. Such combinatorial language is not generally intended to, and unless specified does not, identify or require at least one of X, at least one of Y, and at least one of Z to be included. The terms “about” and “substantially,” unless otherwise defined herein to be associated with a particular range, percentage, or related metric of deviation, account for at least some manufacturing tolerances between a theoretical design and manufactured product or assembly, such as the geometric dimensioning and tolerancing criteria described in the American Society of Mechanical Engineers (ASME®) Y14.5 and the related International Organization for Standardization (ISO®) standards. Such manufacturing tolerances are still contemplated, as one of ordinary skill in the art would appreciate, although “about,” “substantially,” or related terms are not expressly referenced, even in connection with the use of theoretical terms, such as the geometric “perpendicular,” “orthogonal,” “vertex,” “collinear,” “coplanar,” and other terms.

[0069]Although the relative terms such as “on,” “below,” “upper,” and “lower” are used in the specification to describe the relative relationship of one component to another component, these terms are used in this specification for convenience only, for example, as a direction in an example shown in the drawings. It should be understood that if the device is turned upside down, the “upper” component described above will become a “lower” component. When a structure is “on” another structure, it is possible that the structure is integrally formed on another structure, or that the structure is “directly” disposed on another structure, or that the structure is “indirectly” disposed on the other structure through other structures.

[0070]In this specification, the terms such as “a,” “an,” “the,” and “said” are used to indicate the presence of one or more elements and components. The terms “comprise,” “include,” “have,” “contain,” and their variants are used to be open ended, and are meant to include additional elements, components, etc., in addition to the listed elements, components, etc. unless otherwise specified in the appended claims.

[0071]The terms “first,” “second,” etc. are used only as labels, rather than a limitation for a number of the objects. It is understood that if multiple components are shown, the components may be referred to as a “first” component, a “second” component, and so forth, to the extent applicable. Further, if a component is described as there being “at least one” of said component, it is understood that this may mean “one or more” of said component. Conversely, if a component is described as there being “one or more” of said component, it is understood that this may mean “at least one” of said component.

[0072]As referenced herein in the context of quantity, the terms “a” or “an” are intended to mean “at least one” and are not intended to imply “one and only one.” As referred to herein, the terms “include,” “includes,” and “including” are each intended to be inclusive in a manner similar to the term “comprising.” As referenced herein, the terms “or” and “and/or” are generally intended to be inclusive, that is (i.e.), “A or B” or “A and/or B” are each intended to mean “A or B or both.” As referred to herein, the terms “first,” “second,” “third,” and so on, can be used interchangeably to distinguish one component or entity from another and are not intended to signify location, functionality, or importance of the individual components or entities. As referenced herein, the terms “couple,” “couples,” “coupled,” and/or “coupling” refer to chemical coupling (e.g., chemical bonding), communicative coupling, electrical and/or electromagnetic coupling (e.g., capacitive coupling, inductive coupling, direct and/or connected coupling), mechanical coupling, operative coupling, optical coupling, fluid coupling, thermal coupling, and/or physical coupling.

[0073]It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.