Abstract:
The present disclosure provides an outdoor kitchen system that includes universal cabinet structures that are modular. The cabinets provided are configured to accommodate a wide range of kitchen components and are also configured to be arranged to form kitchens having various layouts. The system allows for quick and efficient construction of outdoor kitchen systems.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to provisional application Ser. No. 61/481,480 filed on May 2, 2011 titled Universal Outdoor Modular Kitchen System, the entire disclosure of which is hereby incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure provides an outdoor kitchen system with modular units that are configured to universally fit a wide range of kitchen accessories. Related methods are also provided. 
       BACKGROUND 
       [0003]    Outdoor cooking has increased in sophistication from simply including a charcoal grill to full kitchen systems that include multiple components (e.g., gas grills, refrigerators, countertops, bars, storage cabinets, and trash cabinets). The arrangement, size, and shapes of these components vary. To accommodate these variables, the cabinet structures that support these components are often either constructed on site or pre-constructed based on customer specification and shipped fully assembled for installation. There is a need in the art to provide outdoor kitchen systems that are more easily and efficiently constructible. 
       SUMMARY 
       [0004]    The present disclosure provides an outdoor kitchen system that includes universal cabinet structures that are modular. The cabinets provided are configured to accommodate a wide range of kitchen components and are also configured to be arranged to form kitchens having various layouts. The system allows for quick and efficient construction of outdoor kitchen systems. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0005]      FIG. 1  is a perspective view of a kitchen system according to the principles of the present disclosure; 
           [0006]      FIG. 2  is a perspective view of a grill cabinet frame assembly of the kitchen system of  FIG. 1 ; 
           [0007]      FIG. 3  is an assembly view of the cabinet frame assembly of  FIG. 2 ; 
           [0008]      FIG. 4  is an enlarged assembly view of portion A of  FIG. 3 ; 
           [0009]      FIG. 5  is an enlarged assembly view of portion B of  FIG. 3 ; 
           [0010]      FIG. 6  is a portion of the top plane of the cabinet frame assembly of  FIG. 2 ; 
           [0011]      FIG. 7  is a portion of the top plane of the cabinet frame assembly of  FIG. 2 ; 
           [0012]      FIG. 8  is a portion of the front plane of the cabinet frame assembly of  FIG. 2 ; 
           [0013]      FIG. 9  is a portion of the bottom plane of the cabinet frame assembly of  FIG. 2 ; 
           [0014]      FIG. 10  is a portion of the back plane of the cabinet frame assembly of  FIG. 2 ; 
           [0015]      FIG. 11  is a perspective view of a side burner cabinet frame assembly according of the kitchen system of  FIG. 1 ; 
           [0016]      FIG. 12  is an assembly view of the cabinet frame assembly of  FIG. 11 ; 
           [0017]      FIG. 13  is a perspective view of a one hundred thirty-five degrees filler cabinet frame assembly of the kitchen system of  FIG. 1 ; 
           [0018]      FIG. 14  is an assembly view of the cabinet frame assembly of  FIG. 13 ; and 
           [0019]      FIGS. 15-29  depict other variations of the kitchen system that are also in accordance with the principles of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    Referring to  FIG. 1  an embodiment of an outdoor kitchen system according to the principles of the present disclosure is shown. The outdoor kitchen system includes modular units that are configured to universally fit a wide range of kitchen accessories. In the depicted embodiment the kitchen system  10  includes a number of different modular cabinets including a side burner cabinet  12 , a grill cabinet  14 , a filler cabinet  16 , a trash cabinet  18 , a dishwasher cabinet  20 , and a refrigerator cabinet  22 . 
         [0021]    Referring generally to  FIGS. 2-10 , the grill cabinet  14  is described in further detail. In the depicted embodiment the grill cabinet includes a modular frame assembly that is configured to support a kitchen accessory (i.e., a grill unit). It should be appreciated that other types of cabinets have frames that are configured to support other types of kitchen accessories (e.g., trash units, refrigerators, dishwashing machines, sinks, side burners, etc.) In the depicted embodiment, the frame assembly  24  is configured to support a first sheet of backing material attached to the front, top and back planes. The sheet of backing material can be of the type that is designed to withstand prolonged exposure to moisture, for example, cement based boards such as National Gypsum&#39;s PermaBase or HardiBacker Cement Board. The sheet of backing material can be pre-attached to at least some components of the frame via fasteners (e.g., screws, rivets, etc.) and/or attached to the frame at the job site. In the depicted embodiment an outdoor veneer (stone veneer, tile, etc.) can be attached (e.g., glued, cemented) over the backing material. 
         [0022]    Referring more particularly to  FIGS. 3 ,  4 ,  9 , and  10 , the primary components of the frame assembly  24  are described in further detail. In the depicted embodiment, the frame assembly  24  is constructed of a plurality of preassembled, generally planar sub-structures (top sub-structure  26 , back sub-structure  28 , front sub-structure  30 , and bottom sub-structure  32 ), which are configured to be assembled at job sites by aligning mating structures  34  thereon. In the depicted embodiment the mating structures  34  on the bottom sub-structure  32  include first tabs  40  adjacent to posts  42 . The posts  42  are received in post receiving apertures  44  on the front sub-structure  30  and the back sub-structure  28 . When the posts  42  are received in the post receiving apertures, the first tabs  40  are configured to abut second tabs  46 , which are fixed to the front sub-structure  30  and the back sub-structure  28 . Each of the first and second tabs  40 ,  46  include apertures that are configured to align with each other and receive a fastener  48  therethrough. When the kitchen layout includes multiple cabinet frame assemblies arranged adjacent each other, the fasteners  48  can be extended through the first and second tabs of adjacent frame assemblies, thereby securing the modular units together. Since in the depicted embodiment many of the cabinets have generally the same height and depth, the cabinets are modular in nature in that they can be arranged and connected to form kitchen systems having multiple layouts. 
         [0023]    It should be appreciated that the above-described sub-structures can be nested one on top of another to form a compact package for shipping. In the depicted embodiment the assembled frame assembly  24  is 36 inches high, 26 inches deep, and 60 inches wide. Each of the four primary components are 3 inches high including the height of the posts. Therefore, even if the posts are not nested, the package dimensions would be 12 inches high, 26 inches deep, and 60 inches wide. This would result in a shipping size that is ⅓60 of the assembled size. In some applications the posts can be nested or removable, which would thereby further decrease the package. For example, if the posts are nested or removable, the shipping size could be 4 inches high, 26 inches deep, and 60 inches wide. 
         [0024]    Referring more particularly to  FIGS. 2 ,  5 - 8 , the universality of the frame assembly  24  is described in greater detail. In the depicted embodiment, the frame assembly  24  defines two openings: a grill receiving opening  36  and a grill storage compartment opening  38 . Both of these openings are adjustable in shape and size so that they can accommodate many different styles and brands of grills and grill storage compartments. The adjustability of the openings of the frame assembly  24  makes the cabinet universal in that it does not need to be manufactured specifically to fit a particular grill or grill storage compartment. In the depicted embodiment the grill receiving opening  36  is in part defined by the top sub-structure  26  and in part defined by the front sub-structure  30 . Four structural members define the borders of the opening  36 : a first adjustable length member  48 , a first member with slide rails  50 , a first L-shaped member  52 , and a second L-shaped member  54 . The first adjustable length member  48  includes an external face  56  that is in the top plane of the frame assembly  24 . The first member with slide rails  50  includes an external face  58  that is in the front plane of the frame assembly  24 . Both the first adjustable length member  48  and the first member with slide rails  50  extend in widthwise direction of the frame assembly  24 . The first L-shaped member  52  and the second L-shaped member  54  include external faces  60 ,  62  that are both in the top plane and front plane of the frame assembly  24 . The first and second L-shaped members  52 ,  54  are parallel to each other and perpendicular to the first adjustable length member  48  and the member with slide rails  50 . 
         [0025]    In the depicted embodiment the first adjustable length member  48  can be adjusted forward and rearward to accommodate grill units of different depths, and the first and second L-shaped members  52 ,  54  can be adjusted in the widthwise direction to accommodate grill units of different widths. 
         [0026]    In the depicted embodiment the grill storage compartment opening  38  is defined by the front sub-structure  30 . Four structural members define the borders of the opening  38 : a second adjustable length member  64 , a third adjustable length member  66 , a first vertical member  68 , and a second vertical member  70 . In the depicted embodiment, each of the four structural members include external faces  72 ,  74 ,  76 ,  78  in the front plane of the frame assembly  24 . In the depicted embodiment the widthwise distance between the vertical members can be adjusted to accommodate grill storage units that have different widths. 
         [0027]    Still referring to  FIGS. 2 ,  5 - 8 , the example mechanisms for adjusting the size of the openings  36 ,  38  are further described. In the depicted embodiment the first, second, and third adjustable length members  48 ,  64 ,  66  include a telescoping construction including two tubular members each having different cross-sectional dimensions such that one of the tubular members fits within the other. The adjustable length members  48 ,  64 ,  66  are attached between members that include tabbed ends  80  that ride in channels  82  in the slide rails  50  (see  FIG. 5 ). In the depicted embodiment the tabbed ends  80  include a set screw assembly that can be used to secure the connection between the tabbed end  80  and the channel  82  once the desired adjustments have been made. 
         [0028]    Referring particularly to  FIGS. 2 and 7 , an interlock sub-assembly  84  that is configured to engage adjacent frame assemblies for auxiliary support is described in further detail. In the depicted embodiment, the interlock sub-assembly includes auxiliary support rods  86  configured to provide auxiliary support to cantilevered members  88  of the top sub-structure  26 . The support rods  86  are attached to the cantilevered members  88  at a first end and include second ends that slide into engagement with the frame assemblies of an adjacent cabinet. In the depicted embodiment adjacent cabinets have holes configured to receive the support rods  86 . In addition to providing auxiliary support to the cantilevered members  88 , the support rods  86  further connect the modular cabinets into a single structure, thereby increasing the stability and structural integrity of the of overall system. 
         [0029]    Referring to  FIGS. 11 and 12 , the frame assembly  90  of the side burner cabinet  12  is shown. Referring to  FIGS. 13 and 14 , the frame assembly  92  of the filler cabinet  16  is shown. Both the frame assembly  90  of the side burner cabinet and the frame assembly  92  of the filler cabinet share features of the frame assembly  24  of the grill cabinet and therefore will not be described herein in detail. It should be appreciated that many other alternative frame assembly configurations, which are in accordance with the principles of the present disclosure, are possible. 
         [0030]    The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.