Abstract:
A method of securing a face frame to a cabinet box whereby spring clamps clamp the face frame to the cabinet box during the gluing process. The method eliminates the need for nails, staples, pocket screws or the like. The spring clamp of the invention enables the face frame to be secured to the outer ends of the cabinet box.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention relates to a method and means for securing a face frame to a cabinet box. More particularly, this invention relates to a method and means for securing a face frame to a cabinet box without the use of nails, staples, pocket screws, splines, biscuits, tongue and groove, dowels or bar clamps. 
     Description of the Related Art 
     Conventional face frame cabinets are comprised of a cabinet box or carcass which may be a base cabinet, a wall cabinet or a tall cabinet. The typical cabinet has a horizontally disposed upper wall member having an outer end, an inner end, a first end, a second end, an upper surface and a lower surface. The cabinet box also includes a vertically disposed first side wall member having an outer end, an inner end, an upper end, a lower end, an outer surface and an inner surface. The cabinet box further includes a vertically disposed second side wall member having an outer end, an inner end, an upper end, a lower end, an outer surface and an inner surface. The cabinet box further includes a horizontally disposed bottom wall member having an outer end, an inner end, a first end, a second end, an upper surface and a lower surface. 
     The first end of the upper wall member is secured to the upper end of the first side wall member. The second end of the upper wall member is secured to the upper end of the second side wall member. The first end of the lower wall member is secured to the lower end of the first side wall member. The second end of the lower wall member is secured to the lower end of the second side wall member. 
     In conventional face frame cabinets, a face frame is secured to the outer ends of the upper wall member, the first side wall member, the second side wall member and the lower wall member. In some prior art methods, the face frame is secured to the cabinet box by nails extending through the face frame into the outer ends of the wall members of the cabinet box. In that situation, the nail holes must be filled with wood putty or the like in an effort to conceal the nail holes. Sometimes, the wood putty will have a different appearance than the face frame. In other installations, nails are toe-nailed into the face frame and the wall members of the cabinet box. In other installations, pocket screws are extended through the outer ends of the wall members into the face frame. All of the above described methods of securing a face frame to a cabinet box result in labor intensive steps and efforts to conceal the fastening elements. 
     SUMMARY OF THE INVENTION 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter. 
     The invention relates to two different methods of securing a face frame to a cabinet box or carcass. Both of the methods require the use of a conventional spring clamp which has been modified somewhat. 
     The spring clamp which is used in both of the disclosed methods is similar to a spring clamp marketed by Menard, Inc. having a product number 249-1316. The spring clamp of Menard, Inc. is modified somewhat to enable the spring clamp to be used to clamp a face frame to a cabinet box or carcass. The spring clamp of this invention includes an elongated and generally slightly curved first lever arm having a handle portion at one end thereof and a clamping portion at the other end thereof. The first lever arm terminates in a clamping jaw with the clamping jaw normally having a pad or sleeve mounted thereon. The handle portion of the first lever arm has a pair of spaced-apart ears extending transversely therefrom between the handle portion and the clamping portion thereof. The spring clamp also includes an elongated slightly curved second lever arm having a handle portion at one end thereof and a clamping portion at the other end thereof. A sleeve or pad embraces the handle portion of the second lever arm. The length of the clamping portion of the second lever arm is shorter than the length of the clamping portion of the first lever arm. 
     The second lever arm has a pair of spaced-apart ears extending therefrom between the handle portion and the clamping portion thereof. A pivot pin pivotally secures the ears of the first lever arm to the ears of the second lever arm whereby the lever arms may be moved between conventional clamping and non-clamping positions. A spring is mounted on the pivot pin and engages the inner sides of the lever arms to yieldably urge the lever arms to their clamping positions. 
     A spring clamp also includes an elongated pin, shaft or rod having an inner end and an outer end. The inner end of the elongated pin is secured to the clamping jaw of the second lever arm so that the pin extends outwardly therefrom in a generally parallel relationship to the clamping portion of the second lever arm. The pin of the second lever arm has a length whereby the outer end thereof will engage the inside of the pad or sleeve at the outer end of the clamping portion of the first lever arm when the clamping portions are in the clamping position. 
     The traditional cabinet box or carcass  14  to which the face frame will be attached has varying heights, widths and depths. The cabinet box will initially be described as being in a vertically disposed position as when it is secured to a wall or the like. The cabinet box includes a horizontally disposed upper wall member having a first end, a second end, an inner end, an outer end, an outer surface and an inner surface. An opening is drilled in the outer surface of the upper wall member which extends partially thereinto. The cabinet box also includes a vertically disposed first side wall member having an upper end, a lower end, an inner end, an outer end, an inner surface and an outer surface. The first side wall member has a plurality of spaced-apart openings or holes drilled therein which partially extend inwardly from the outer surface thereof inwardly of the outer edge thereof. 
     The cabinet box also includes a vertically disposed second side wall member having an upper end, a lower end, an inner end, an outer end, an inner surface and an outer surface. The second side wall member has a plurality of spaced-apart openings or holes drilled therein which partially extend inwardly from the outer surface thereof inwardly of the outer end thereof. 
     The cabinet box also includes a horizontally disposed lower wall member having a first end, a second end, an inner end, an outer end, an inner surface and an outer surface. At least one opening or hole is drilled into the outer surface of the lower wall member which extends partially thereinto. 
     The upper end of the first side wall member is secured to the first end of the upper wall member with the upper end of the second side wall member being secured to the second end of the upper wall member. The lower end of the first side wall member is secured to the first end of the lower wall member and the lower end of the second side wall member is secured to the second end of the lower wall member. 
     The face frame which is to be attached to the cabinet box includes a top rail, a bottom rail, a first stile and a second stile. The face frame may include a mid-rail which extends between the first and second stiles. 
     After the cabinet box has been assembled, the cabinet box will usually be placed on a horizontally disposed work surface so that the wall members of the cabinet box are vertically disposed with the inner ends thereof resting on the work support. Glue is then placed on the outer ends of the wall members. The face frame is then positioned on the glued outer ends of the wall members of the cabinet box. The spring clamps disclosed above are then clamped into position. The handle portions of the lever arms are squeezed together against the force of the spring incorporated therewith. The outer end of the spring of the spring clamp of the clamping jaw of the spring clamp is inserted into one of the openings formed in the outer surface of the side wall members with the clamping jaw of the first lever arm being positioned above one of the rails or stiles of the face frame. The worker then permits the lever arms to move to their clamping position. The spring clamp clamps the rail or stile of the face frame onto the cabinet box. The above-described steps are repeated for each of the spring clamps which are used to clamp the face frame onto the outer ends of the cabinet box. 
     In those cabinet boxes having shelf adjustment holes on the inner surfaces of the side wall members, it is not necessary to drill the holes in the outer sides of the wall members. In that situation, the pins of the spring clamps are inserted into the shelf adjustment openings on the inner surfaces of the side wall members of the cabinet box with the clamping portions thereof being positioned on the upper surfaces of the stiles of the face frame to securely clamp the face frame to the cabinet box during the gluing process. 
     A principal object of the invention is to provide an improved method and means for securing a face frame to a cabinet box. 
     A further object of the invention is to provide an improved method and means for securing a face frame to a cabinet box which eliminates the need for nails, staples, pocket screws, splines, biscuits, tongue and groove, dowels or bar clamps. 
     Yet another object of the invention is to provide an improved spring clamp which enables a face frame to be glued onto the outer ends of the wall members of the cabinet box. 
     These and other objects will be apparent to those skilled in the art. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  is a perspective view of one of the spring clamps which are used in the attachment of a face frame onto a cabinet box according to the method of this invention; 
         FIG. 2  is a side elevational view of the spring clamp of this invention; 
         FIG. 3  is an exploded perspective view of the cabinet box to which a face frame is to be secured; 
         FIG. 4  is an exploded perspective view of the cabinet box and face frame and which illustrates glue being applied to the outer ends of the wall members of the cabinet box; 
         FIG. 5  is an end sectional view illustrating the manner in which the face frame is clamped onto the outer ends of the side wall members of the cabinet box; 
         FIG. 6  is a partial perspective view illustrating the face frame being clamped onto the outer ends of the first side wall member and the upper wall member; 
         FIG. 7  is a top elevational view illustrating the top rail, the bottom rail, the first stile and the second stile of the face frame being clamped onto the outer ends of the wall members of the cabinet box; 
         FIG. 8  is an exploded perspective view of a face frame and a second style of a cabinet box which illustrates glue being applied to the outer ends of the cabinet box; and 
         FIG. 9  is a partial perspective view illustrating a pair of the spring clamps of  FIG. 1  being used to clamp the face frame onto the cabinet box of  FIG. 8 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Embodiments are described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims. 
     The numeral  10  refers to a spring clamp, a plurality of which are used to attach a face frame  12  to a face frame cabinet box or carcass  14  as will be described in greater detail hereinafter. Spring clamp  10  is similar to a spring clamp marketed by Menard, Inc. having a product number 249-1316. The spring clamp of Menard, Inc. is modified somewhat to enable the spring clamp to be used to clamp a face frame to the cabinet box or carcass. 
     Spring clamp  10  includes an elongated and generally slightly curved first lever arm  16  having a handle portion  18  at one end thereof and a clamping portion  20  at the other end thereof. The first lever arm  16  terminates in a clamping jaw  22 . The clamping jaw  22  normally has a pad or sleeve  24  thereon. Handle portion  18  normally has a sleeve  25  which embraces the outer end thereof. The first lever arm  16  has a pair of spaced-apart ears  26  and  28  extending transversely therefrom between the handle portion  18  and the clamping portion  20  thereof. 
     Spring clamp  10  also includes an elongated slightly curved second lever arm  30  having a handle portion  32  at one end thereof and a clamping portion  34  at the other end thereof. Sleeve  35  embraces handle portion  32 . The second lever arm  30  terminates in a foreshortened clamping jaw  36 . As seen, the length of the clamping portion  34  of lever arm  30  is shorter than the length of clamping portion  20  of lever arm  30 . 
     The second lever arm  30  has a pair of spaced-apart ears  38  and  40  extending therefrom between the handle portion  32  and the clamping portion  34 . A pivot pin  41  pivotally connects the ears  26  and  28  to the ears  38  and  40  whereby the lever arms  16  and  30  may be moved between conventional clamping and non-clamping positions, as seen in  FIG. 2 . A spring  42  is mounted on the pivot pin  41  and engages the inner sides of lever arms  16  and  30  to yieldably urge the lever arms  16  and  30  to their clamping positions, as seen in  FIG. 2 . 
     The numeral  43  refers to an elongated pin, shaft or rod having an inner end  46  and an outer end  45 . The inner end  44  of pin  43  is secured to the clamping jaw  36  so that pin  43  extends outwardly therefrom in a generally parallel relationship to clamping portion  34 . The pin  43  has a length whereby the outer end  45  of pin  43  will engage the inside of pad or sleeve  22  at the outer end of the clamping portion of the first lever arm when the clamping portions  20  and  34  are in the clamping position of  FIG. 1 . Preferably the pin  43  has serrations  46  on its outer surface. 
     The traditional cabinet box or carcass  14  will have varying heights, widths and depths. The cabinet box  14  will be described as being in its vertically disposed position as when secured to a wall or the like. Cabinet box  14  will usually be constructed of wood, laminated wood or other material. Cabinet box  14  includes a horizontally disposed upper wall member  47  having a first end  48 , a second end  50 , an inner end  52 , an outer end  54 , an outer surface  56  and an inner surface  58 . An opening or hole  59  is drilled in the outer surface  56  of upper wall member  47  which extends partially thereinto. It is preferred that the hole  59  has a diameter of approximately 5 mm. It is preferred that the hole  59  is spaced approximately 1.25 inches from the outer end  54 . 
     Cabinet box  14  also includes a vertically disposed first side wall member  60  having an upper end  62 , a lower end  64 , an inner end  66 , an outer end  68 , an inner surface  70  and an outer surface  72 . Side wall member  60  has a plurality of spaced-apart openings or holes  74  drilled therein which partially extend inwardly from the outer surface  72  inwardly of outer end  68 . It is preferred that the holes  74  have at least a diameter of 5 mm. It is preferred that the holes  74  be spaced approximately 1.25 inches from outer end  68 . 
     Cabinet box  14  also includes a vertically disposed second side wall member  76  having an upper end  78 , a lower end  80 , an inner end  82 , an outer end  84 , an inner surface  86  and an outer surface  88 . Side wall member  76  has a plurality of spaced-apart openings or holes  90  drilled therein which partially extend inwardly from the outer surface  88  inwardly of outer end  84 . It is preferred that the holes  90  have at least a diameter of 5 mm. It is preferred that the holes  74  be spaced approximately 1.25 inches from outer end  84 . 
     Cabinet box  14  also includes a horizontally disposed lower wall member  92  having a first end  94 , a second end  96 , an inner end  98 , an outer end  100 , an inner surface  102  and an outer surface  104 . At least one opening or hole  106  is drilled into the outer surface  104  of lower wall member  92  which extends partially thereinto. It is preferred that the hole  106  has at least a diameter of 5 mm. It is preferred that the hole  106  is spaced approximately 1.25 inches from outer end  100 . 
     The upper end of side wall member  60  is secured to the first end  48  of upper wall member  47  by screws  108  nails, staples or the like in a transverse manner. The upper end  78  of side wall member  76  is secured to the second end  50  of upper wall member  47  by screws  110 , nails, staples or the like. 
     The lower end  64  of side wall member  60  is secured to the first end  94  of lower wall member  92  by screws  112 , nails, staples, or the like. The lower end  80  of side wall member  76  is secured to the second end  96  of lower wall member  92  by screws  114 , nails, staples, or the like. 
     The face frame  12  includes a top rail  116 , a bottom rail  118 , a first side stile  120  and a second side stile  122 . Face frame  12  may include a mid-rail  124  which extends between stiles  120  and  122 . 
     After the cabinet box  14  has been assembled, the cabinet box  14  will usually be placed on a horizontally disposed work support so that the wall members  47 ,  60 ,  76  and  92  are vertically disposed with the inner ends thereof resting on the work support. Glue  126  is then placed on the outer ends  54 ,  68 ,  84  and  100  of wall members  47 ,  60 ,  76  and  92  respectively. The face frame  12  is then positioned on the glued outer ends of the wall members  47 ,  60 ,  76  and  92  as depicted in  FIGS. 4 and 7  and partially depicted in  FIGS. 5 and 6 . The spring clamps  10  are then clamped into position as illustrated in  FIGS. 5-7 . Inasmuch as each of the spring clamps  10  are clamped onto the face frame  12  and the wall members of cabinet box  14 , only one such clamping step will be described. The handle portions  18  and  32  of lever arms  16  and  30  are squeezed together against the force of the spring  42 . The outer end  45  of the pin  43  on clamping jaw  36  is inserted into one of the openings or holes  59 ,  74 ,  90  or  106  with the clamping jaw  22  of lever arm  16  being positioned above one of the rails or stiles of face frame  12 . The worker then permits the lever arms  16  and  30  to move to their clamping position. Spring  42  clamps the rail or stile of face frame  12  onto the cabinet box  14 . The serrations  46  on pin  43  serve to increase the connection between the pin  43  and the respective wall member. The above-described steps are repeated for each of the spring clamps  10 . In some cases, it may not be necessary to utilize spring clamps on the top and bottom rails of the face frame although it is preferred to do so. When the glue has set, the clamps  10  are removed. 
     In those cabinet boxes having shelf adjustment holes on the inner surfaces of the side wall members, it may not be necessary to drill the holes  59 ,  74 ,  90  and  106 . Such a case is illustrated in  FIGS. 8 and 9  wherein the cabinet box  14  has shelf adjustment holes  128  formed in the inner surface of side wall member  60  and shelf adjustment holes  130  formed in the inner surface of side wall member  76 . The pins  41  of the spring clamps  10  are inserted into the shelf adjustment holes  128  or  130  to clamp the face frame  12  onto the cabinet box  14 . In this case, it may be necessary to drill holes in the inside surfaces of wall members  47  and  92 . The design of the spring clamp  10  allows the pressure of the clamp to be at the centerline of the glue line so as to not pull the face frame  12  out of alignment when the glue is in the wet stage. Further, the padded surface  25  of the lever arm  16  allows the face frame to be pre-finished prior to it being attached to the cabinet box. 
     If any of the clamp holes or openings must be hidden, plastic caps may be inserted thereinto. A thin finish panel or veneer may also be applied to the cabinet box at the finish ends thereof to hide the holes or openings. 
     It can therefore be seen that a unique spring clamp has been provided to secure a face frame to a cabinet box without nails, pocket screws, staples, etc. 
     Although the invention has been described in language that is specific to certain structures and methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and/or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed invention. Since many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.