U.S. patent application number 12/328331 was filed with the patent office on 2009-09-10 for modular cabinet, components therefor, kit and method.
This patent application is currently assigned to Spacemaxx Inc.. Invention is credited to Benjamin Murphy.
Application Number | 20090224642 12/328331 |
Document ID | / |
Family ID | 38832309 |
Filed Date | 2009-09-10 |
United States Patent
Application |
20090224642 |
Kind Code |
A1 |
Murphy; Benjamin |
September 10, 2009 |
Modular cabinet, components therefor, kit and method
Abstract
A cabinet is mounted on a vertical wall and comprises four
panels connected by four connectors to form corners. Each connector
has a finger element inserted into a slot near a corner in
horizontal panels and a connector member inserted into a slot near
a corner in an adjacent vertical panel. There is a pair of spaced
slots in each horizontal panel, one slot near each opposed end of
the horizontal panel.
Inventors: |
Murphy; Benjamin; (Rancho
Santa Margarita, CA) |
Correspondence
Address: |
CONNORS ASSOCIATES
1600 DOVE ST, SUITE 220
NEWPORT BEACH
CA
92660
US
|
Assignee: |
Spacemaxx Inc.
Long Beach
CA
|
Family ID: |
38832309 |
Appl. No.: |
12/328331 |
Filed: |
December 4, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US2007/013116 |
Jun 4, 2007 |
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12328331 |
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60810952 |
Jun 5, 2006 |
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Current U.S.
Class: |
312/263 ;
312/111 |
Current CPC
Class: |
A47B 2230/0062 20130101;
A47B 95/008 20130101; F16B 12/46 20130101 |
Class at
Publication: |
312/263 ;
312/111 |
International
Class: |
A47B 87/00 20060101
A47B087/00 |
Claims
1. A corner connector for attaching together a pair of panels to
form a corner, said corner connector comprising a pair of
substantially planar, rigid, elongated support members, each said
support member having an inner end and an outer end, said inner
ends being connected lengthwise to form a substantially right angle
junction, a substantially planar, rigid, elongated finger element
extending lengthwise along an outer end of one of said support
members, said finger element forming an angle with respect to said
one support member and projecting outwardly from an outer side of
said one support member that is opposite the right angle junction,
said finger element being adapted to fit within an elongated slot
in one panel, and a connector member at the right angle junction
and projecting outwardly away from said junction, said connector
member including a gripping structure adapted to fit within and
grip an elongated slot in the other panel.
2. The corner connector of claim 1 where the finger element forms
with respect to said one support member an acute angle
substantially from 5 to 85 degrees.
3. The corner connector of claim 1 where the support members,
finger element, and the connector member are substantially equal in
length and connector member is elongated, rigid, and extends
lengthwise along said junction.
4. The corner connector of claim 1 where the connector member is at
an angle with respect to the other support member.
5. The corner connector of claim 1 being a unitary, extruded
piece.
6. The corner connector of claim 1 where the support members and
the finger element each have substantially flat opposed
surfaces.
7. The corner connector of claim 1 where the gripping structure
comprises a plurality of teeth.
8. The corner connector of claim 1 where the gripping structure
includes enlarged interior portion.
9. The corner connector of claim 8 where the enlarged interior
portion has a dove tail configuration.
10. A connector for attaching a pair of panels together
substantially at a right angle with one panel oriented
substantially horizontally and the other panel oriented
substantially vertically, said connector comprising first and
second elongated support members connected to form a right angle
junction enabling the first support member to be positioned beneath
the horizontally oriented panel with one side of said first support
member abutting the horizontally oriented panel and the second
support member to be positioned next to the vertically oriented
panel with one side of said second support member abutting and
extending downward along the vertically oriented panel, said first
support member having an outer end terminating in a elongated
finger element extending lengthwise along said outer end of said
first support member, said finger element forming an acute angle
with respect to said first support member and projecting outwardly
from said one side of said first support member to enable the
finger element to be inserted into a slot in the horizontally
oriented panel, and a connector member at the right angle junction
and projecting outwardly away from said junction towards the
vertically oriented panel to enable the connector member to be
inserted into and grip a slot in the vertically oriented panel.
11. The corner connector of claim 10 where the elongated support
members are substantially planar and rigid.
12. The corner connector of claim 10 being a unitary, extruded
piece.
13. The corner connector of claim 10 where the support members and
the connector member all have substantially the same length and the
connector member includes a plurality of teeth that grip said slot
in the vertically oriented panel.
14. A corner connector comprising a first substantially planar,
rigid, elongated support member having an inner end and an outer
end, a second substantially planar, rigid, elongated support member
having an inner end and an outer free end, said inner ends of the
support member being connected lengthwise to form a substantially
right angle junction, a substantially planar, rigid, elongated
finger element (a) projecting outwardly from an outer side of said
first support member that is opposite the right angle junction and
(b) extending lengthwise along the outer end of said first support
member and forming an acute angle with respect to said first
support member to point inward and upward away from said right
angle junction, said finger element terminating in an outer free
end, and a substantially planar, rigid, elongated connector member
at or near the right angle junction and extending along said
junction and projecting outwardly away from said junction, said
connector member including a gripping structure and terminating in
an outer free end, said support members, finger element, and
connector member being substantially equal in length, and said
connector member and said second support member being at an angle
substantially from 5 to 85 degrees with respect to each other, said
outer free ends of the second support member, finger element, and
connector member being substantially parallel, said corner
connector being symmetrical about a latitudinal centerline.
15. A combination of a corner connector and a pair of panels
comprising said corner connector attaching said pair of panels
together substantially at a right angle to form a corner with one
panel oriented substantially horizontally and the other panel
oriented substantially vertically, with each panel having
substantially the same predetermined width and positioned to be
connected so that outer longitudinal edges thereof are aligned with
each other, said horizontally oriented panel having a pair of slots
therein in an underside of the horizontally oriented panel, one
slot being near one opposed end of the horizontally oriented panel
and pointing towards said one opposed end and the other slot being
near the other opposed end of the horizontally oriented panel and
pointing towards said other opposed end, each slot having a
terminal open end at a longitudinal edge of the horizontally
oriented panel and being (a) substantially at a right angle with
respect to a longitudinal centerline of the horizontally oriented
panel, (b) extending substantially across the entire width of the
horizontally oriented panel and (c) at the same acute angle with
respect to the underside, said substantially vertically oriented
panel having a slot in an inner side that is substantially at a
right angle with respect to a longitudinal centerline of the
vertically oriented panel and being at a predetermined angle with
respect to the inner side, said corner connector being an integral,
unitary, extruded metal piece that is symmetrical about a
latitudinal centerline and comprising first and second
substantially planar and rigid elongated support members connected
to form a right angle junction enabling the first support member to
be positioned beneath the horizontally oriented panel with an outer
side of said first support member abutting the underside of the
horizontally oriented panel and enabling the second support member
to be positioned next to the vertically oriented panel with an
outer side of said second support member abutting and extending
downward along the vertically oriented panel, said first support
member having an outer end terminating in a elongated finger
element extending lengthwise along said outer end of said first
support member, said finger element forming an acute angle with
respect to said first support member and projecting outwardly from
the outer side of said first support member to enable the finger
element to be inserted into a slot in the horizontally oriented
panel, and a connector member along the second support member at or
near the right angle junction and projecting outwardly away from
said junction towards the vertically oriented panel to enable the
connector member to be inserted into and grip a slot in the
vertically oriented panel, support members, finger element, and the
connector member all have substantially the same length with said
connector member including a plurality of teeth for gripping said
slot in the vertically oriented panel, said symmetrical about the
latitudinal centerline enabling the corner connector to be rotated
180 degrees so said finger element may be inserted into either one
of the slots in the horizontally oriented panel by sliding it
endwise into the terminal open end of either one of the slots in
the longitudinal edge of the horizontally oriented panel.
16. A corner structure comprising a substantially horizontally
oriented panel having a slot in an underside that is substantially
at a right angle with respect to a longitudinal centerline of the
horizontally oriented panel and with respect to the underside is at
acute angle substantially from 5 to 85 degrees, said slot in the
underside having a terminal open end at an edge of the horizontally
oriented panel, a substantially vertically oriented panel having a
slot in an inner side that is substantially at a right angle with
respect to a longitudinal centerline of the vertically oriented
panel and with respect to the inner side is at angle substantially
from 60 to 130 degrees, said horizontally oriented panel having an
end that abuts the vertically oriented panel to form a corner, said
panels being connected together by a unitary, extruded metal corner
connector that fits into said corner, said corner connector
comprising a pair of support members forming a substantially right
angle junction, one of said support members terminating in finger
element that forms with respect to said one support member an acute
angle substantially equal to the acute angle of the slot in the
horizontally oriented panel, said finger element projecting
outwardly from one side of said one support member that is opposite
the right angle junction, said finger element inserted into the
slot in the horizontally oriented panel by sliding it endwise into
the terminal open end of said slot in the horizontally oriented
panel to fit snug therein, and a connector member at said junction
that projects outwardly away from said junction at an angle
substantially equal to the angle that the slot in the vertically
oriented panel forms with said inner side of said vertically
oriented panel, said connector member including a gripping
structure inserted into the slot in the vertically oriented panel
to fit snug within and grip said slot in the vertically oriented
panel.
17. The corner structure of claim 16 where the panels are each of
substantially the same width with edges of the panels being
substantially aligned and the support members, finger element, and
connector member each have a width substantially equal to the width
of the panels.
18. The corner structure of claim 17 where the slot in the inner
side of the vertically oriented panel has a terminal open end at an
edge of the vertically oriented panel.
19. The corner connector of claim 18 where the gripping structure
comprises a plurality of teeth.
20. A corner structure of a modular cabinet mounted to a wall
including a substantially vertically oriented panel substantially
at a right angle to the wall, said vertically oriented panel having
a longitudinal centerline, a predetermined width, an inner side,
and an angular slot in the inner side extending along at least a
portion of the vertically oriented panel's width at substantially a
right angle to the vertically oriented panel's longitudinal
centerline, a substantially horizontally oriented panel
substantially at a right angle to the wall, said horizontally
oriented panel having a longitudinal centerline, a predetermined
width, and an underside having an angular slot therein across at
least a portion of the horizontally oriented panel's width at
substantially a right angle to the longitudinal centerline of the
horizontally oriented panel, a connector for attaching the panels
together to form a corner, said connector comprising first and
second elongated support members connected to form a right angle
junction enabling the first support member to be positioned beneath
the horizontally oriented panel with a side of said first support
member abutting the underside of the horizontally oriented panel
and the second support member positioned next to the vertically
oriented panel with a side of said second support member abutting
and extending downward along said vertically oriented panel, said
first support member having an outer end terminating in a elongated
finger element extending lengthwise along said outer end of said
first support member, said finger element projecting outwardly from
the one side of said first support member and inserted into the
slot in the horizontally oriented panel, and a connector member
including a gripping structure at the right angle junction and
projecting outwardly away from said junction towards the vertically
oriented panel and inserted into the slot in the vertically
oriented panel.
21. The corner structure of claim 20 where the angular slot in the
horizontally oriented panel has a terminal open end at an edge of
the horizontally oriented panel and the elongated finger element is
inserted therein by sliding it endwise into said terminal open end
in the horizontally oriented panel upon attaching the panels
together.
22. The corner structure of claim 21 where the angular slot in the
horizontally oriented panel is at an acute angle with respect to
the underside and faces the vertically oriented panel and the
finger element forms an acute angle with respect to said first
support member that is substantially the same as the acute angle of
the slot in the horizontally oriented panel.
23. A modular cabinet mounted onto a wall comprising a wall hanger
attached to the wall in a horizontal orientation, said wall hanger
having a predetermined, substantially uniform cross-sectional
configuration along a predetermined length of the wall hanger, a
pair of side panels each having a longitudinal centerline, a
predetermined width, a rear edge portion having therein a cut-a-way
section with a configuration substantially identical to the
cross-sectional configuration of the wall hanger, an inner side, an
angular slot in the inner side extending along at least a portion
of the width of the side panel at substantially a right angle to
the side panel's longitudinal centerline, said side panels mounted
to the wall hanger in a spaced apart substantially vertical
orientation with the wall hanger received in the cut-a-way sections
of the side panels, a horizontally oriented panel positioned
between the side panels, said horizontally oriented panel having
opposed ends, an edge, a longitudinal centerline, a predetermined
width, an underside with a pair of angular slots, each slot being
near one of the ends of the horizontally oriented panel and being
spaced the same predetermined distance from said ends, each said
slot being substantially a right angle to the longitudinal
centerline of the third panel, said angular slots being at an acute
angle with respect to the underside and pointing away from each
other, a pair of corner connectors, one at each end of and
connected beneath the horizontally oriented panel, one corner
connector adjacent and attached to one side panel and the other
corner connector adjacent and attached to the other side panel,
each corner connector comprising first and second elongated support
members forming a right angle junction, said first support member
having one side that abuts the underside of the horizontally
oriented panel and the second support member positioned next to an
adjacent vertically oriented side panel, said second support member
having one side adapted to abut and extend downward along said
adjacent vertically oriented side panel, said first support member
having an outer end terminating in a elongated finger element
extending lengthwise along said outer end of said first support
member, said finger element forming an acute angle with respect to
said first support member and projecting outwardly from the outer
side of said first support member into one slot in the underside of
the horizontally oriented panel, said acute angle of the finger
element being substantially equal to the acute angle of said one
slot, said finger element being at a predetermined distance from
the second support member that is substantially equal to the
predetermined distance said one slot is from one end of the
horizontally oriented panel, and a connector member at the right
angle junction and projecting outwardly away from said junction at
a predetermined angle to fit snug into the slot in an adjacent side
panel.
24. The modular cabinet of claim 23 where the slots in the
horizontally oriented panel each extends substantially across the
entire panel's width.
25. The modular cabinet of claim 24 where the slots in the
underside of the horizontally oriented panel each terminate in an
opening in said edge and the finger element of each corner
connector is inserted into one slot by sliding said finger element
endwise into the opening of said one slot.
26. A kit for a modular cabinet comprising a pair of side panels
each adapted to be vertically oriented and each having a
longitudinal centerline, a predetermined width, a rear edge portion
having therein a cut-a-way section, an inner side, an angular slot
in the inner side extending along at least a portion of the width
of the side panel at substantially a right angle to the side
panel's longitudinal centerline, said cut-a-way sections of each
side panel having substantially the same predetermined shape, a
wall hanger adapted to be attached onto a wall in a horizontal
orientation, said wall hanger having a predetermined
cross-sectional configuration substantially identical to the
cut-a-way sections of the side panels to enable the side panels to
be attached thereto in a spaced apart vertical orientation with the
wall hanger received in the cut-a-way sections of the side panels,
a third panel adapted to be horizontally oriented and positioned
between the side panels, said third panel having opposed ends, an
edge, a longitudinal centerline, a predetermined width, an
underside with a pair of angular slots, each slot being near one of
the ends of the third panel and being spaced the same predetermined
distance from said ends, each said slot being at substantially a
right angle to the longitudinal centerline of the third panel, said
angular slots each being at an acute angle with respect to the
underside and pointing away from each other, a pair of
substantially identical corner connectors for attaching the third
panel between the side panels, each corner connector comprising
first and second elongated support members connected to form a
right angle junction enabling the first support member to be
positioned beneath the third panel when horizontally oriented, said
first support member having one side adapted to abut the underside
of the horizontally oriented third panel and the second support
member adapted to be positioned next to an adjacent vertically
oriented side panel, said second support member having a side
adapted to abut and extend downward along said adjacent vertically
oriented side panel, said first support member having an outer end
terminating in a elongated finger element extending lengthwise
along said outer end of said first support member, said finger
element forming an acute angle with respect to said first support
member and projecting outwardly from the one side of said first
support member, said acute angle of the finger element being
substantially equal to the acute angle of the angular slots in the
underside of the third panel, and the finger element being at a
predetermined distance from the second support member that is
substantially equal to the predetermined distance each slot in the
underside of the third panel is from one end of the third panel,
and a connector member at the right angle junction and projecting
outwardly away from said junction at a predetermined angle that
enables the connector member to be inserted into the slot in an
adjacent side panel upon assembly.
27. The kit of claim 26 with the slots in the third panel terminate
in an opening in said edge and extend from said edge substantially
across the entire third panel's width.
28. A method of constructing a cabinet structure directly onto a
wall, said method comprising the steps of (a) attaching a wall
hanger to the wall in a substantially horizontal orientation, said
wall hanger having a predetermined, substantially uniform
cross-sectional configuration along a predetermined length of the
wall hanger, (b) mounting a pair of side panels on the wall hanger,
each side panel having a longitudinal centerline, a predetermined
width, a rear edge portion having therein a cut-a-way section with
a configuration substantially identical to the cross-sectional
configuration of the wall hanger, an inner side, an angular slot in
the inner side extending along at least a portion of the width of
the side panel at substantially a right angle to the side panel's
longitudinal centerline, said side panels being mounted to the wall
hanger in a spaced apart substantially vertical orientation with
the wall hanger received in the cut-a-way sections of the side
panels, (c) positioning adjacent the side panels a horizontally
oriented panel, said horizontally oriented panel having opposed
ends, an edge, a longitudinal centerline, a predetermined width, an
underside with a pair of angular slots, each slot being near one of
the ends of the horizontally oriented panel and being spaced the
same predetermined distance from said ends, said angular slots
being at an acute angle with respect to the underside and pointing
away from each other, and (d) connecting a pair of corner
connectors to the horizontally oriented panel, one corner connector
at each end of and connected beneath the horizontally oriented
panel, one corner connector adjacent and attached to one side panel
and the other corner connector adjacent and attached to the other
side panel, each corner connector comprising first and second
elongated support members forming a right angle junction, said
first support member having an outer side that abuts the underside
of the horizontally oriented panel and the second support member
positioned next to an adjacent vertically oriented side panel, said
second support member having an outer side that abuts and extends
downward along said adjacent vertically oriented side panel, said
first support member having an outer end terminating in a elongated
finger element extending lengthwise along said outer end of said
first support member, said finger element forming an acute angle
with respect to said first support member and projecting outwardly
from the outer side of said first support member to fit into one
slot in the underside of the horizontally oriented panel, said
acute angle of the finger element being substantially equal to the
acute angle of said one slot, and the finger element being at a
predetermined distance from the second support member that is
substantially equal to the predetermined distance said one slot is
from one end of the horizontally oriented panel, and a connector
member at the right angle junction that projects outwardly away
from said junction to fit snug into the slot in an adjacent side
panel.
29. The method of claim 28 where each said slot in the horizontally
oriented panel terminates in an opening in said panel's edge and
said finger element is inserted into the one slot in the
horizontally oriented panel by sliding said finger element endwise
into said opening.
30. A method of constructing a cabinet structure directly onto a
wall, said method comprising the steps of (a) attaching a wall
hanger to the wall in a substantially horizontal orientation, (b)
mounting a pair of side panels on the wall hanger in a spaced apart
substantially vertical orientation, each side panel having an inner
side including a slot extending along at least a portion of the
inner side, (c) positioning adjacent the side panels a horizontally
oriented panel to form corners where the side panels meet the
horizontally oriented panel, said horizontally oriented panel
having an underside with a pair of slots, each slot being near a
corner and said slots being at an acute angle with respect to the
underside, and (d) connecting a corner connector to adjacent panels
at each corner and beneath the horizontally oriented panel, each
corner connector including portions that are received in the slots
in the adjacent panels.
Description
RELATED PATENT APPLICATIONS & INCORPORATION BY REFERENCE
[0001] This is a continuation-in-part application of International
Application No. PCT/US2007/013116, entitled "MODULAR CABINET,
COMPONENTS THEREFOR, KIT & METHOD," filed Jun. 4, 2007, which
claims the benefit under 35 USC 119(e) of U.S. Provisional Patent
Application No. 60/810,952, entitled "MODULAR CABINET, COMPONENTS
THEREFOR, KIT & METHOD," filed Jun. 5, 2006. These related
applications are incorporated herein by reference and made a part
of this application. If any conflict arises between the disclosure
of the invention in this continuation-in-part application or the
PCT application and that in the related provisional application,
the disclosure in this continuation-in-part application shall
govern. Moreover, any and all U.S. patents, U.S. patent
applications, and other documents, hard copy or electronic, cited
or referred to in this application are incorporated herein by
reference and made a part of this application.
DEFINITIONS
[0002] The words "comprising," "having," "containing," and
"including," and other forms thereof, are intended to be equivalent
in meaning and be open ended in that an item or items following any
one of these words is not meant to be an exhaustive listing of such
item or items, or meant to be limited to only the listed item or
items.
[0003] "My system" as used in the specification, unless otherwise
indicated, includes the components for my system, the kit for my
system and my method.
[0004] "Rectangular" includes square.
[0005] The words "substantially" and "essentially" have equivalent
meanings.
BACKGROUND
[0006] Cabinets are typically constructed at a location remote from
the site where they are installed. Such cabinets are usually
attached to a vertical wall by conventional fasteners such as, for
example, French cleats, screws, finger rail systems, etc. In some
situations, cabinet components are shipped to the place of
installation and assembled thereat and the on-site assembled
cabinet is then mounted to the vertical wall. There are several
problems with this manner of construction and installation,
including for example:
[0007] (1) It is difficult for one individual to lift and hold an
elevated cabinet during installation. Typically, a helper,
scaffolding, or props are used to mount the cabinet onto a vertical
wall.
[0008] (2) Such cabinets are usually expensive to construct and
transport to the installation site.
[0009] (3) It is frequently difficult to properly square up or
align the cabinet on the vertical wall.
[0010] (4) Prefabricated cabinets, or cabinets assembled on-site,
sometimes do not have the correct dimensional relationships and do
not fit in the space where they are to be installed, for example,
the cabinet width may be greater than the width dimension of the
space where it is to be installed.
[0011] Another problem in making cabinets is "racking." A
conventional cabinet has a top panel, a bottom panel, a pair of
side panels having their respective top and bottom edges fastened
to the top and bottom panels, and a fifth component such a back
panel or diagonal back brace. The fifth component prevents racking.
This problem of racking is discussed in international patent
application PCT/US2005/006648, entitled "MODULAR STORAGE SYSTEM,
COMPONENTS THEREFOR, STORAGE METHOD & KIT," filed Mar. 2, 2005,
which claims the benefit under 35 USC 119(e) of U.S. provisional
patent application Ser. No. 60/550,252, entitled "MODULAR STORAGE
SYSTEM, COMPONENTS THEREFOR, STORAGE METHOD & KIT," filed Mar.
3, 2004.
SUMMARY
[0012] My system has one or more of the features depicted in the
embodiments discussed in the section entitled "DETAILED DESCRIPTION
OF SOME ILLUSTRATIVE EMBODIMENTS." The claims that follow define my
system in terms that distinguish it from the prior art and point
out its non-obviousness characteristics; however, without limiting
the scope of my invention as expressed by these claims, in general
terms, some, but not necessarily all, of the features of my system
are:
[0013] One, my system comprises a combination of a corner connector
and a pair of panels. The corner connector attaches the pair of
panels together substantially at a right angle to form a corner
with one panel oriented substantially horizontally and the other
panel oriented substantially vertically. Each panel may have
substantially the same predetermined width and may be positioned to
be connected so that outer longitudinal edges thereof are aligned
with each other.
[0014] Two, the corner connector is at a right angle junction where
the panels meet. It includes a portion that projects outwardly away
from the junction including a pair of substantially planar, rigid,
elongated support members, one of which terminates in a finger
element, and a connector member at a point of connection between
the support members. Each support member may have an inner end and
an outer end, with the inner ends being connected lengthwise to
form a substantially right angle junction. The finger element may
be substantially planar, rigid, and elongated and may extend
lengthwise along an outer end of one of the support members. This
finger element may form an acute angle with respect to this one
support member and may project outwardly from an outer side of the
one support member that is opposite the right angle junction. The
support members and the finger element each may have substantially
flat opposed surfaces. The finger element has a predetermined shape
adapted to fit within an elongated slot in one panel.
[0015] Three, the connector member may include a gripping structure
adapted to fit within and grip an elongated slot in one of the
panels. The gripping structure may include an enlarged interior
portion comprising a plurality of teeth, and it may be integral
with the other portions of the connector member and formed
concurrently by extrusion. The support members, finger element, and
the connector member are substantially equal in length and
connector member is elongated, rigid, and extends lengthwise along
the junction.
[0016] Four, the horizontally oriented panel may have a pair of
slots therein in an underside of the horizontally oriented panel.
One slot may be near one opposed end of the horizontally oriented
panel and may point towards the one opposed end and the other slot
may be near the other opposed end of the horizontally oriented
panel and may point towards the other opposed end. Each slot may
have a terminal open end at a longitudinal edge of the horizontally
oriented panel. Also, each slot may be (a) substantially at a right
angle with respect to a longitudinal centerline of the horizontally
oriented panel, (b) extending substantially across the entire width
of the horizontally oriented panel and (c) at the same acute angle
with respect to the underside.
[0017] Five, the substantially vertically oriented panel may have a
slot in an inner side that is substantially at a right angle with
respect to a longitudinal centerline of the vertically oriented
panel and may be at a predetermined angle with respect to the inner
side.
[0018] These features are not listed in any rank order nor is this
list intended to be exhaustive.
[0019] My system includes a modular cabinet mounted onto a wall. A
wall hanger is attached to the wall in a horizontal orientation.
The wall hanger has a predetermined, substantially uniform
cross-sectional configuration along a predetermined length of the
wall hanger. A pair of side panels are used, and each panel has a
longitudinal centerline, a predetermined width, a rear edge portion
having therein a cut-a-way section with a configuration
substantially identical to the cross-sectional configuration of the
wall hanger, an inner side, and an angular slot in the inner side
of the panel that extends along at least a portion of the width of
the side panel at substantially a right angle to the side panel's
longitudinal centerline. The side panels are mounted to the wall
hanger in a spaced apart substantially vertical orientation with
the wall hanger received in the cut-a-way sections of the side
panels. A horizontally oriented panel may be positioned between the
side panels. The horizontally oriented panel may have opposed ends,
an edge, a longitudinal centerline, a predetermined width, an
underside with a pair of angular slots, each slot being near one of
the ends of the horizontally oriented panel and being spaced the
same predetermined distance from the ends. Each slot may be
substantially a right angle to the longitudinal centerline of the
third panel. The angular slots may be at an acute angle with
respect to the underside and point away from each other. A pair of
corner connectors as discussed above attach the panels
together.
[0020] One embodiment of my method includes constructing a cabinet
structure directly onto a wall. This method comprising the steps
of
[0021] (a) attaching a wall hanger to the wall in a substantially
horizontal orientation,
[0022] (b) mounting a pair of side panels on the wall hanger in a
spaced apart substantially vertical orientation, each side panel
having an inner side including a slot extending along at least a
portion of the inner side,
[0023] (c) positioning adjacent the side panels a horizontally
oriented panel to form corners where the side panels meet the
horizontally oriented panel, said horizontally oriented panel
having an underside with a pair of slots, each slot being near a
corner and said slots being at an acute angle with respect to the
underside, and
[0024] (d) connecting a corner connector to adjacent panels at each
corner and beneath the horizontally oriented panel, each corner
connector including portions that are received in the slots in the
adjacent panels.
DESCRIPTION OF THE DRAWING
[0025] Some embodiments of my system will now be discussed in
detail in connection with the accompanying drawing, which is for
illustrative purposes only. This drawing includes the following
figures (Figs.), with like numerals indicating like parts:
[0026] FIG. 1 is a perspective view of one embodiment of my modular
cabinet having its prefabricated components assembled directly onto
and attached to a vertical wall.
[0027] FIG. 1A is a perspective view of one embodiment of my
kit.
[0028] FIG. 1B is an enlarged front view, with sections broken
away, of my modular cabinet shown in FIG. 1.
[0029] FIG. 1C is a perspective view of one of the cabinet
horizontal panels showing its underside.
[0030] FIG. 1D is a perspective view of an alternate embodiment of
the cabinet horizontal panels showing its slots partially extending
across its width.
[0031] FIG. 1E is a perspective view of one of the cabinet vertical
panels showing its inside surface.
[0032] FIG. 1F is a perspective view of an alternate embodiment of
the cabinet vertical panels showing its slots partially extending
across its width starting at one edge and terminating within the
body of the panel.
[0033] FIG. 1G is a perspective view of an alternate embodiment of
the cabinet vertical panels showing its slots having opposed ends
each terminating within the body of the panel.
[0034] FIG. 1H is a cross-sectional view taken along line 1H-1H of
FIG. 1G, showing connectors mounting the horizontal panels to the
vertical panel shown in FIG. 1G.
[0035] FIG. 2 is a perspective view of one embodiment of my corner
connector.
[0036] FIG. 2A is a cross-sectional view taken along line 2A-2A of
FIG. 1.
[0037] FIG. 2B is a cross-sectional view showing a horizontally
oriented panel connected to a vertically oriented panel using of an
alternate embodiment of my corner connector.
[0038] FIG. 2C is a corner cross-sectional view of a modular
cabinet using still another alternate embodiment of my corner
connector to attach a horizontally oriented panel to a vertically
oriented panel.
[0039] FIG. 2D is a cross-sectional view of a corner of a modular
cabinet using yet another alternate embodiment of my corner
connector to attach a horizontally oriented panel to a vertically
oriented panel.
[0040] FIG. 2E is a cross-sectional view of a corner of a modular
cabinet using still another alternate embodiment of my corner
connector to attach a horizontally oriented panel to a vertically
oriented panel.
[0041] FIG. 2F is a cross-sectional view of a corner of my modular
cabinet using still another alternate embodiment of my corner
connector to attach a horizontally oriented panel to a vertically
oriented panel.
[0042] FIG. 3 is a perspective view of one embodiment of the wall
hanger component used to mount onto a vertical wall the modular
cabinet.
[0043] FIG. 4 is a cross-sectional view taken along line 4-4 of
FIG. 1.
[0044] FIG. 4A is a fragmentary end view showing a sheath member
covering a wall hanger for a panel.
[0045] FIG. 4B is a perspective view of the sheath member shown in
FIG. 4A.
DETAILED DESCRIPTION OF SOME ILLUSTRATIVE EMBODIMENTS
[0046] As depicted in FIG. 1, one embodiment of my cabinet,
identified by the numeral 10, comprises prefabricated components
that are mounted directly to a vertical wall 12 at an installation
site, forming the cabinet directly on the wall as the components
are connected together. Because the cabinet is constructed as its
components are attached to the wall 12, or to each other, or both,
a single person can assemble the cabinet in place directly onto the
wall without the assistance of anyone else or props. The installer
may do this without the use of a tool or tools, although the
installer may use a screwdriver if desired in some instances to
attach some of the prefabricated components together. As discussed
subsequently in greater detail, from time to time it may also be
necessary to adjust the width dimension of the cabinet if the
cabinet's predetermined width dimension is too wide to fit in the
limited space where the cabinet is to be installed.
[0047] These modular components may be stored in a kit 14 (FIG. 1A)
that is delivered to the installation site of the cabinet 10. The
kit 14 may comprise a box-type package P containing four panels
16a-16d, four corner connectors 18, and a wall hanger 20 (FIG. 3).
The panels 16a-16d may be rectangular and of identical or different
dimensions and made from wood, plastic, particleboard, or other
suitable materials. The corner connectors 18 are typically
identical in cross-sectional configuration and may all be of
substantially the same length, typically, substantially from 6 to
36 inches. The corner connectors 18 may all have the same length,
which may be substantially equal to the width dimension w of the
panels or their length may be less than this width dimension w.
[0048] A pair of panels forms each corner A through D of the
cabinet 10. Upon assembling the components of the cabinet 10
directly on the substantially flat, planar exterior surface of the
vertical wall 12, one panel of the pair is substantially
horizontally oriented and the other panel of the pair is
substantially vertically oriented. For example, as shown in FIG.
1B, upon constructing the cabinet 10 on the wall 12, the side
panels 16b and 16d are substantially vertically oriented and the
top panel 16a and bottom panel 16c are substantially horizontally
oriented. The top panel 16a and bottom panel 16c each include a
pair of angular slots S1 near each opposed end E4 of these panels.
As best shown in FIGS. 1B and 1C, each slot S1 is spaced the same
distance d.sub.1 from these ends E4, and each slot is at a
substantially right angle to a longitudinal centerline C1 of these
panels. Each angular slot S1 is at an acute angle A (FIG. 2A) with
respect to each panel's underside 13. The pair of slots S1 in each
horizontal panel 16a and 16c point away from each other as best
illustrated in FIG. 1B. In the embodiment depicted in FIG. 1, each
slot S1 extends across the entire width w of the panels 16a and 16c
to terminate in an opening 11a (FIG. 1C) in an outer edge ED2 (FIG.
1B) and an opening 11b (FIG. 1C) in an inner edge ED3.
[0049] As illustrated in FIGS. 1 and 4, each side panel 16b and 16d
has a rear edge portion ED1 having therein a cut-a-way section 30
with a configuration substantially identical, at least in outline,
to the cross-sectional configuration of the wall hanger 20. Each
cut-a-way section 30 in each side panel 16b and 16d is of the same
shape and individual cut-a-way sections 30 are in registration when
these side panels are hung on the wall hanger 20 mounted on the
wall 12. As illustrated in FIG. 1E, in one embodiment, a pair of
angular, elongated slots S3 in an inner side S4 of the side panel
16b, each near one opposed edge ED5, extends at a substantially
right angle to this side panel's longitudinal centerline C1. When
the top panel 16a is flush with the top ends E6 of the vertical
panels 16b and 16d, each of these slots S3 is displaced inward from
its adjacent top edge at a distance d.sub.2 that is substantially
equal to the thickness of the horizontal panel 16a that abuts its
adjoining vertical panel. Each of these slots S3 in the vertically
oriented panels 16b and 16d may extend along only a portion of the
width w of this panel as depicted in FIG. 1F or across
substantially the entire panel's width as depicted in FIG. 1E. As
illustrated in FIGS. 1B, 1E and 1F, each of these slots S3 in the
vertically oriented panels 16b and 16d terminates in an opening 15
in the rear edge ED3 of these panels. Using slots that do not
extend across the entire width of the panels is desirable, because
the strength of a panel is not unduly weakened.
[0050] As best illustrated in FIG. 2, each corner connector 18
includes a pair of substantially planar, rigid, elongated support
members 22 and 24. Each support member 22 and 24 has an inner end
E1 and an outer end E2. The inner ends E1 and E1 respectively of
the support members 22 and 24 are integral and connected lengthwise
to form a substantially right angle junction J. A substantially
planar, rigid, elongated finger element 26 extends lengthwise along
the outer end E2 of the support member 22. As shown in FIG. 2A,
this finger element 26 forms an angle A with respect to the support
member 22 and projects outwardly from an outer side S2 of this
support member 22 that is opposite the right angle junction J. For
example, the finger element 26 forms with respect to the support
member 22 an acute angle substantially from 5 to 85 degrees. In the
corner A, for example, the finger element 26 is adapted to fit snug
within the elongated slot S1 in the underside 13 (FIG. 2A) of the
horizontally oriented panel 16a upon assembly of the cabinet 10
onto the wall 12.
[0051] Each corner connector 18 also includes a connector member
28, which may be elongated and rigid, and which may extend
lengthwise along the junction J. The connector member 28 is at the
junction J and projects outwardly away from this junction. It may
be at an angle substantially from 5 to 175 degrees with respect to
the other support member 24. Along the length of the connector
member 28 are a series of teeth 28a that provide a gripping
structure. In corner A, for example, the series of teeth 28a is
adapted to fit snug within and bite into and grip the slot S3 in
the vertical panel 16b upon assembly on the wall 12 of the cabinet
10. As illustrated in FIGS. 1G and 1H, this configuration allows
the connector member 28 to be snapped, or force fitted, into a slot
S12 that does not open at an edge of a vertical panel 16d'.
[0052] Each corner connector 18 may be an integral, unitary
structure. Typically, the corner connectors 18 are formed by
extruding a metal or plastic. In one embodiment an aluminum rod is
extruded to form the corner connector 18. The support members 22
and 24, finger element 26, and connector member 28 may be
substantially equal in length I.sub.1, which may be substantially
equal to the width w (FIG. 1) of the panels 16a-16d. The support
members 22 and 24 and the finger element 26 each may have
substantially flat opposed surfaces. The support member 24 may
include an elongated groove 24a in its exterior surface that
facilitates driving a pointed tip screw through this support member
to hold it firmly against an adjacent vertical panel.
[0053] As shown in FIG. 4, the wall hanger 20 is an elongated,
rigid component having a hook element 20a that extends outwardly
from a back plate 20b that is fastened to the vertical wall 12 in a
substantially horizontal orientation. It may also be formed by
extruding, for example, an aluminum rod. The extruded structure has
cavities 20e to reduce the amount of material used. An elongated
groove 20c extends lengthwise along the length of the wall hanger
20 to provide a thin wall section 20d forming the bottom of the
groove. Consequently, fasteners such as screws 20f easily penetrate
the thin wall section 20d to secure the wall hanger 20 to the
vertical wall 12. The wall hanger 20 may have a length I.sub.1
substantially equal to the distance d (FIGS. 1 and 1B) between the
outer sides S5 and S6 respectively of the vertically oriented
panels 16b and 16d upon assembly of the cabinet 10, or it may be
substantially longer for mounting thereon a plurality of vertically
oriented panels. It may have a substantially uniform
cross-sectional configuration along its entire length.
[0054] The components in the kit 14 are removed from the package P
and assembled as follows, not necessarily in the order discussed
unless stated expressly otherwise:
[0055] The wall hanger 20 is attached to the vertical wall 12 in a
substantially horizontal orientation. Usually, the corner
connectors 18 are first attached to the side panels 16b and 16d.
The corner connectors' connector members 28 are individually
inserted first into the slots S3 near the ends E4 of the side
panels 16b and 16d. Typically, the connector member 28 is aligned
and in registration with the slot S3 and pushed into this slot,
forcing the teeth 28a of the connector member 28 into this slot.
The teeth 28a resist withdrawing the connector member 28 from the
slot S3. The support members 24 of the corner connectors 18 are
positioned next to, and press against, an adjacent vertically
oriented side panel 16b or 16d, as the case may be. Each support
member 24 has an inner side S7 (FIG. 1B) that abuts and extends
downward along the inside surface S8 (FIG. 1) of an adjacent side
panel 16b or 16d, as the case may be.
[0056] Next, as illustrated in FIG. 1B, the pair of side panels 16b
and 16d with the pair of corner connectors 18 respectively near the
top end E6 and bottom end E7 (FIG. 1B) of these side panels is
mounted to the wall hanger 20. The cut-a-way section 30 of each
side panel 16b and 16d is aligned with a free end of the wall
hanger 20. Each side panel is hung on the wall hanger 20 with the
wall hanger being received in the cut-a-way sections 30 to support
the side panels 16b and 16d so that each panel extends outward from
the vertical wall 12 at a right angle and is vertically oriented.
The side panels 16b and 16d are located along the wall hanger 20 in
a spaced apart relationship at the distance d. Because the side
panels 16b and 16d have substantially identical length and width
dimensions, they are in registration.
[0057] The top panel 16a and bottom panel 16c are lastly positioned
between the side panels 16b and 16d. This may be achieved prior to
mounting the side panels 16b and 16d on the wall hanger 20,
although it is a better practice to mount the side panels onto the
wall hanger first as discussed above. One panel, for example, the
top panel 16a is first attached to the spaced apart side panels 16b
and 16d. The finger elements 26 of the corner connectors 18 at the
top ends E6 of the side panels 16b and 16d are aligned with the
openings 11b of the pair of slots S1. The top panel 16a is pushed
towards the vertical wall 12. The finger elements 26 of each corner
connector 18 are inserted endwise into the openings 11b and slide
along the slots S1 as the top panel 16a is pushed towards the
vertical wall 12. In essentially the same manner the bottom panel
16c is attached between the side panels 16a and 16d.
[0058] When using the side panels 16d', the connector member 28 is
snapped into the slot S12 in this panel, and then this panel is
hung on the wall hanger 20. A horizontal panel, for example, the
top panel 16a is then connected between vertical panels by aligning
the openings 11b of the pair of slots S1 with the finger elements
26 and sliding in this top panel towards the wall 12.
[0059] With the top panel 16a and bottom panel 16c so attached, the
inner sides S9 (FIG. 1B) of the support members 22 of the
connectors 18 abut and firmly bear against the underside 13 of the
top and bottom panels, which have their opposed ends E4 positioned
between and abutting the side panels 16b and 16d as illustrated in
FIG. 1B. Also, the inner sides S7 of the support members 24 of the
connectors 18 abut and firmly bear against the inside surface S8
(FIG. 1) of the side panels 16b and 16d. When the panels 16a
through 16d all have the same width w, their edges are
substantially aligned and flush with each other.
[0060] In the cabinet 10, each panel 16a-16b has substantially the
same width w and upon assembly their opposed outer longitudinal
edges ED2 and ED3 are substantially aligned with each other. As
shown in (FIG. 1C), each slot S1 in the horizontally oriented
panels 16a and 16c terminates at a longitudinal edge in an opening:
the opening 11a in the outer edge ED2 and the opening 11b in an
inner edge ED3 at a longitudinal edge of the horizontally oriented
panel and being (a) substantially at a right angle with respect to
a longitudinal centerline of the horizontally oriented panel, (b)
extending substantially across the entire width of the horizontally
oriented panel and (c) at the same acute angle with respect to the
underside 13 The two slots S1 in each horizontally oriented panels
16a and 16d point away from each other. Each corner connector 18 is
symmetrical about its latitudinal centerline C2. This structural
feature enables the corner connector 18 to be inserted into either
one of the two slots S1 in the horizontally oriented panels 16a and
16d. The corner connector 18 is simply rotated 180 degrees so its
finger element 26 may be inserted into either one of the two slots
S1 in the horizontally oriented panel by sliding the finger element
endwise into the terminal open end of either one of the slots in a
longitudinal edges ED2 or ED3, as the case may be, of the
horizontally oriented panel.
[0061] If the dimensions of the horizontal panels 16a and 16c are
longer than the dimension of the space in which the cabinet 10 is
to be installed, one end E4 of each of these panels may be trimmed
to reduce their lengths so the cabinet will fit into the space at
the installation site. A conventional rotary table saw at the
installation site may then be used to cut another slot in the
underside 13 of the horizontal panels at the distance d1 from the
trimmed end of the horizontal panels 16a and 16c. The saw blade
will be set at the angle A.
Alternate Embodiments
[0062] FIG. 2B illustrates an alternate embodiment, the corner
connector 18a, having a differently sloping connector member 40,
which includes teeth 40a. The main difference between the
connectors 18 and 18a is that the connector member 40 of the corner
connector 18a is at a different angle B than connector member 28
with respect to the support member 24. This illustrates that the
angle B may vary over a wide range, for example, substantially from
60 to 130 degrees. In the corner connector 18 the angle B between
the connector member 28 and the support member 24 is greater than
90 degrees, for example, 115.5 degrees. In the corner connector
18a, the angle B between the connector member 40 and the support
member 24 is less than 90 degrees, for example, 72.5 degrees.
[0063] As discussed above, the horizontal panels 16a and 16c have
their opposed ends E4 between and abutting the sides S8 of the
vertical panels 16b and 16d. As depicted in FIGS. 2B and 2C, the
horizontal panels 16a and 16c are overlapping and abutting the top
ends E6 and bottom ends E7, as the case may be, of the vertical
panels 16b and 16d. In the embodiment shown in FIG. 2B, a slot S10
in the vertically oriented panel 16b points downward at an angle
substantially equal to the angle B formed between the connector
member 40 and the support member 24, namely, 72.5 degrees. As
discussed above, upon assembly of the panels 16a and 16b, the
connector member 40 is pushed into the slot S10. In the embodiment
shown in FIG. 2C, a corner connector 18b employs a connector member
40a that is displaced downward along the support member 24. As
discussed above, upon assembly of the panels 16a and 16b, the
connector member 40a is pushed into a slot S11 in the panel
16b.
[0064] FIG. 2D illustrates an alternate embodiment, the corner
connector 18c, having a connector member 42 shaped as a "dove
tail." This shape may be used in some situations, but is not
equivalent to the connector members 28, 40, or 40a that have the
teeth 28a. For example, this "dove tail" or similar shape with an
enlarged interior portion must slide into a slot having an opening
at an inner edge of a vertically oriented panel and may not be used
with the panel 16d'.
[0065] FIG. 2E illustrates yet an alternate embodiment, the corner
connector 18d, having the right angle support members 22 and 24
each having ends terminating in connector members 42a and 42a'
shaped as "triangular cross-sectional tails." The connector member
42a and 42a' are oriented at right angles from each other and the
connector member 42a extends lengthwise along the outer end E2 of
the support member 22 and the connector member 42a' extends
lengthwise along the outer end E1 of the support member 24. This
shape may be used in some situations, but is not equivalent to the
connector members 28, 40, or 40a that have the teeth 28a. For
example, the connector members 42a and 42a' must slide into a slot
having an opening routed out to accommodate the shape of the
"triangular cross-sectional tails" of the connector members 26a and
42a at an inner edge of a vertically oriented panel 16e and a
horizontally oriented panel 16f.
[0066] FIG. 2F illustrates an alternate embodiment, the corner
connector 18e, having similar to the corner connector 18d, but
"circular cross-sectional tails" at the ends the connector members
26a and 42a. The two "circular cross-sectional tails" 42b and 42b'
are oriented at right angles from each other. The connector members
42b and 42b' are oriented at right angles from each other and the
connector member 42b extends lengthwise along the outer end E2 of
the support member 22 and the connector member 42a' extends
lengthwise along the outer end E1 of the support member 24. This
shape may be used in some situations, but is not equivalent to the
connector members 28, 40, or 40a that have the teeth 28a. For
example, the connector members 42b and 42b' must slide into a slot
having an opening routed out to accommodate the shape of the
"circular cross-sectional tails" of the connector members 42b and
42b' at an inner edge of a vertically oriented panel 16e and a
horizontally oriented panel 16f.
[0067] The modular cabinet may include a sheath member covering at
least a portion of an exterior of the wall hanger to inhibit
splitting of a side panel. The sheath member is configured so that
it fits snugly about the hanger and has essentially the same
profile as the cut-a-way sections in the side panel. An embodiment
of such as sheath member, which may be made of a plastic, is
illustrated in FIGS. 4A and 4B and designated by the numeral 100.
The sheath member 100 covers the wall hanger 20 and its configured
so that it fits snugly about the hanger 20 and has essentially the
same profile as the cut-a-way section 30 in each side panel 16b and
16d. The width w1 of the sheath member 100 is essentially equal to
the thickness t (FIG. 1) of, for example, the side panel 16d. The
thickness t2 of the sheath member 100 is approximately 1/4 inch.
The sheath member 100 inhibits splitting to the panel.
[0068] After reading the above section, one skilled in the art will
understand the benefits my invention provides. These benefits
include, but are not limited to, providing cabinets: (a) that are
delivered to the place of installation as prefabricated components
which may be assembled directly and quickly by a single installer
onto a vertical wall to form the cabinet, (b) that include a corner
connector that is easy to manufacture and enables a pair of panels
to be quickly connected to form a corner of the cabinet, (c) that
are delivered as a kit that includes all the prefabricated
components needed to assemble a cabinet directly onto a vertical
wall, (d) that enable an installer at the installation site, using
a conventional saw, to adjust the dimensions of the prefabricated
panel components so the cabinet fits into the space, at the
installation site, even though it has a dimension, particularly a
width dimension, less than the width dimension of the cabinet, and
(e) that provide a simplified method of installing a modular
cabinet using prefabricated components that may be assembled
without the use of tools onto a vertical wall by a single installer
without the aid of props or other types of supports.
SCOPE OF THE INVENTION
[0069] The above presents a description of the best mode
contemplated of carrying out my invention, and of the manner and
process of making and using it, in such full, clear, concise, and
exact terms as to enable any person skilled in the art to which it
pertains to make and use my invention. My invention is, however,
susceptible to modifications and alternate constructions from the
illustrative embodiments discussed above which are fully
equivalent. Consequently, it is not the intention to limit my
invention to the particular embodiments disclosed. On the contrary,
my intention is to cover all modifications and alternate
constructions coming within the spirit and scope of my invention as
generally expressed by the following claims, which particularly
point out and distinctly claim the subject matter of my
invention:
* * * * *