Modular cabinet design

A cabinet structure is provided. The cabinet structure includes two side frames, and at least one vertical sectional bar connecting the side frames via at least two frame elements. The frame elements include first and second frame elements. The first frame element includes a connecting face that has a frontal cavity and a plurality of guide elements. The second frame element includes a receiving face configured to receive the guide elements of the first frame element, and a through hole aligned with the frontal cavity of the first frame. The frame elements also include a securing element configured to be screwed into the frontal cavity via the through hole to forge a secure interlocking fitting of the first and second frame elements.

FIELD OF THE INVENTION

The present invention relates generally to the field of cabinet and rack assembly design, specifically to modular structural elements used to fabricate cabinets and enclosures.

BACKGROUND

Cabinets and enclosures are used to house and protect a wide variety of items, which may vary greatly in size and shape. A variety of cabinet configurations have been developed for the protection of items such as electrical and electronic assemblies, vacuum tubes and state-of-the-art compact high speed hybrid and digital circuits. Today, electronic assemblies differ as to the space and proportions necessary to house them. There are many cabinet and enclosure structures available in many sizes. A cabinet that measures several cubic feet may be necessary to house a high voltage system or a multi-server system, while a cabinet that measures the size of a pack of cigarettes may be sufficient to house a compact electrical or embedded electronics arrangement. However, users of such enclosures are limited to either choosing a standard size enclosure, which may be too large for their applications; or fabricating a custom size enclosure, which may require welding, a large amount of machining, and/or high tooling and other significant costs.

In many situations, it is beneficial to use a cabinet with multiple compartments. For example, in the case of an electrical circuit or circuits, it may be desirable to separate a high voltage section from a low voltage section, or a particularly noise-sensitive circuit from other circuits. In such cases, custom fabrication becomes considerably more difficult and costly. Means for construction of a cabinet or enclosure, or a set of modular interconnected cabinets or enclosures, that provide strength, ease of assembly, and appropriate size for a particular application, large or small, have yet to be realized.

A number of attempts have been made to provide a cabinet which satisfies these criteria, but typically the cost or the complexity, the size, versatility or strength have been less than desirable. By way of example, the following U.S. Patents disclose either welded or modular frame assemblies representative of cabinet structures developed in the prior art.

U.S. Pat. No. 2,167,525 to Rosendale (hereinafter Rosendale) and U.S. Pat. No. 3,265,419 to Durnbaugh, et al. (hereinafter Durnbaugh) both disclose welded cabinet structures. Rosendale employs gussets—triangular pieces of metal—welded in each corner to hold three mutually perpendicular struts in a corner arrangement. Durnbaugh eliminates such gusset members and welds the strut members directly to each other at their intersection. However, the three strut members which form each corner have different cross-sectional configurations and end profiles. Thus, the manufacture and construction of the frame is complicated. Additionally, four welds are desired to join the struts to create a rigid frame structure. The cabinet structures of Rosendale and Durnbaugh therefore, are very labor intensive.

U.S. Pat. No. 3,182,846 to La Kaff (hereinafter La Kaff) and U.S. Pat. No. 3,919,603 to Salvati (hereinafter Salvati) disclose cabinet configurations that involve mechanical assembly. In La Kaff, side frame struts are coupled to the top and base members using engaging elements formed of generally rectangular aluminum blocks, which are attached by welding to the top and bottom members and struts. The engaging elements have frustoconical portions configured to fit snugly together. The top and base members are matted via the engaging elements and bolted together. Both manufacturing cost and lack of versatility make this frame an undesirable alternative. Salvati discloses a switchgear framework including a corner tie for supporting three structural corner members together. The corner tie has three rectangular-shaped perpendicular legs with three sides and outwardly facing flanges, the three struts being slid over the leg portions. However, the struts and leg portions have different cross-sectional configurations, and the corner tie is of a generally complex configuration, such that this frame structure is not conducive to low-cost manufacturing techniques.

Finally, U.S. Pat. No. 5,066,161 to Pinney (hereinafter Pinney) discloses a simplified cabinet frame structure element. However, the simplified cabinet frame structure element of Pinney requires bends, cuts at angles on corners, and a welding process. Thus, the simplified cabinet frame structure element of Pinney is not conducive to low-cost manufacturing techniques.

In view of the foregoing, what is needed is an enclosure and cabinet system that allows for rapid, low-cost, custom fabrication of high-strength, modular enclosures. For example, an enclosure and cabinet system that require little or no welding, and little or no machining is ideal.

SUMMARY

Embodiments of the invention concern a cabinet structure. The cabinet structure includes two side frames, and at least one vertical sectional bar connecting the side frames via two frame elements. The frame elements include first and second frame elements. The first frame element includes a connecting face that has a frontal cavity and a plurality of guide elements. The second frame element includes a receiving face configured to receive the guide elements of the first frame element, and a through hole aligned with the frontal cavity of the first frame. The frame elements also include a securing element configured to be screwed into the frontal cavity via the through hole to forge a secure interlocking fitting of the first and second frame elements.

In some embodiments, the plurality of guide elements includes two block-like, parallelepiped guide elements and the receiving face comprises slots to receive the two block-like, parallelepiped guide elements. In alternative embodiments, one of the plurality of guide elements includes four block-like, parallelepiped guide elements. The receiving face can include slots to receive the four block-like, parallelepiped guide elements. In some embodiments, the plurality of guide elements can include two semi-circle guide elements guide elements. The receiving face can include slots to receive the two semi-circle guide elements. In some embodiments, the securing element includes an assembly screw with a self-tapping thread engaging in the through hole of the second frame element. In some embodiments, the first frame element can be secured within one of the at least two vertical sectional bars via additional fixing elements. Similarly, the second frame element can be secured within one of the at least two side frames via additional fixing elements. Alternatively, the first frame element can be secured within one of the at least two vertical sectional bars via spot welding. In some embodiments, the second frame element can be secured within one of the at least two side frames via spot welding.

DETAILED DESCRIPTION

Embodiments of the present invention provide interlocking frame elements used to join frames of an enclosure and cabinet system. The interlocking frame elements are not only able to join frames, but can also support the weight, stress and shear that cabinets encounter. Furthermore, the interlocking frame can vary in cross-sectional shapes to allow for rapid, low-cost, custom fabrication of high-strength, modular enclosures that require little or no welding, and little or no machining. In this disclosure, all of the components can be pre-fabricated separately to reduce costs associated with transportation and storage. Because cabinet systems are typically welded, construction is typically required before transportation and storage. Therefore, consumers typically receive large shipments of the full sized cabinet structure completely assembled. In this disclosure, the entire enclosure and cabinet system can be assembled on site. The claimed frame element can be installed between the left and the right frame with an interlocking mechanism. The interlocking mechanism can be secured utilizing a threaded bolt or a screw. Thus, the interlocking frame elements allow for shipping and storing flat packs for the enclosure and cabinet system. Thus, the costs associated with transportation and storage can be further reduced.

FIG. 1is an exploded view of an exemplary cabinet10for subassemblies and equipment. The cabinet10can include a top cover1, a left frame2, a right frame3, base frames4A and4B, vertical sectional bars5A and5B connecting the left frame2and right frame3. The vertical sectional bars5A and5B are interconnected by means of the frame elements20A and20B to the left frame2and the right frame3. The frame elements20A and20B and the integration into cabinet10are discussed in greater detail below. The cabinet10can be formed from metal, plastic, composite, or a combination thereof and can be configured to support the weight of any electrical and electronic assemblies disposed therein. In certain embodiments, the cabinet10and its components can be made of sheet metal using conventional metal fabrication techniques such as bending, forming, and stamping. As a result, the cabinet10can, in some embodiments, be made very inexpensively. Alternatively, the cabinet10and its components can be made of aluminum alloy, steel alloy, or any combination thereof. It should be realized that the cabinet10and its components can be made of any material with low cost of construction and durability to house electrical and electronic assemblies of varying weight. The materials mentioned above are only for example, and not to limit this disclosure. Thus, the present disclosure contemplates that any material or combination of materials can be used in the various embodiments without limitation.

Now turning toFIG. 2, there is shown a close-up of an exploded view of an exemplary set of frame elements20A and20B in accordance with some embodiments. In certain embodiments, the frame elements20A and20B can be formed from a hollow aluminum pressure die casting. The present disclosure contemplates that any material or combination of materials can be used in the various embodiments without limitation. It should be realized that the frame elements20A and20B can be made utilizing any process that allows for low construction cost. The process of hollow aluminum pressure die casting mentioned above is only for example, and not to limit this disclosure. Frame element20A can include a male connecting face21with two block-like, parallelepiped guide elements24extending therefrom. The connecting face21can include a frontal cavity27extending through frame element20A. Frame element20B can include a female connecting face22that includes two slots for receiving the parallelepiped guide elements24of frame element20A. In some embodiments, the fit between the male frame element and the female frame element can be exact to provide a more solid support piece once combined. In other embodiments, the fit between the male frame element and the female frame element can be loose to facilitate assembly on site. Furthermore, designing the male frame element and the female frame element to have a loose assembly, or less tolerance, can reduce the cost of production. A loose assembly may include, for example, tapered guide elements. In this configuration, the design tolerance can be lower while the strength and stability of the frame elements can be maintained. This exemplary design is discussed in further detail below.

AlthoughFIG. 2shows only two guide elements, in some embodiments, the frame element20A can include a varying number of block-like, parallelepiped guide elements. For example, inFIG. 4the frame element40A is shown with four block-like, parallelepiped guide elements44. Likewise, the frame element40B can include four slots for receiving the parallelepiped guide elements44of frame element40A.FIG. 5shows the frame element50A with two semi-circle guide elements54. Likewise, the frame element50B can include two slots for receiving the semi-circle guide elements54of frame element50A. Further, the guide elements can be rounded, or tapered at the end to allow for more density of the frame element50B. In some embodiments, the guide elements can be rounded, or tapered at the end to allow for more density of the frame element50B.FIG. 6shows the frame element60A with two tapered guide elements64. As illustrated by way of example, various guide elements can be implemented to interlock a male frame element with a female frame element. Regardless of the orientation, a female frame element would be configured to correspond to the configuration of a corresponding male frame element. In some embodiments, the frame elements may have embody the configuration of both have male and female components. For example, each frame element may be configured such to have a guide element and a receiving element corresponding to the other's guide element.

Referring back toFIG. 2, the frame element20B can also include a through hole26for receiving a fixing element23. In this embodiment the fixing element23can include an assembly screw29with a thread28on the front shank engaging in the through hole26. The fixing element23can be screwed into the frontal cavity27of the connecting face21of the frame element20A. In some embodiments, the through holes26are provided at their exit openings with spot facings, which can be used for collecting the turnings or material thrown up during screwing in.

The frame element20A can be fixed within the vertical sectional bar5A via additional fixing elements, for example, the vertical sectional bar5A can include through holes51,52,53and54. The additional fixing elements can secure the frame element20A within the vertical sectional bar5A via the through holes51,52,53and54. Conversely, the frame element20A can be fixed within the vertical sectional bar5A by implementing a spot welding process. That is, the through holes51,52,53and54can alternatively serve as welding points of a spot welding process to secure frame element20A in place. It should be realized that the process of securing the frame element20A within the vertical sectional bar5A can be accomplished by any means preferably with low costs of construction while maintaining durability to house electrical and electronic assemblies of varying weight. The processes mentioned above are only for example, and not to limit this disclosure. A person having ordinary knowledge in the art may affix the frame element20A within the vertical sectional bar5A by implementing any process in accordance with the disclosure.

Similarly, the frame element20B can also be fixed within the right frame3implementing additional fixing elements. The right frame3can include through holes30,31,32,33and34. It should be noted that the right frame3can include additional through holes not shown herein. Through hole30can be configured to receive the fixing element23. The additional fixing elements can secure the frame element20B within the right frame3via the through holes31,32,33and34. Conversely, the frame element20B can be fixed within the right frame3by implementing a spot welding process. That is, as discussed above with frame elements20A, the through holes31,32,33and34can serve as welding points of a spot welding process. It should be realized that the process of securing the frame element20B within the right frame3can be accomplished by any means preferably with low costs of construction while maintaining durability to house electrical and electronic assemblies of varying weight. The processes mentioned above are only for example, and not to limit this disclosure. A person having ordinary knowledge in the art may affix the frame element20B within the right frame3by implementing any process in accordance with the disclosure.

FIG. 3is a close-up of the assembled view of the frame elements20A and20B. Once secured within the vertical sectional bar5A and the right frame3, the frame elements20A and20B can be secured together to forge a secure interlocking frontal fitting. The guide elements24of frame20A interlock with the receiving slots of the frame element20B to create a solid structure. During the frontal fitting of the frame elements20A and20B, the frontal cavity27of the connecting face21aligns with the through hole26. Thus, the fixing element23can be screwed into the frontal cavity27, of the connecting face21, of the frame element20A, via the through hole26, thereby creating a secure interlocking frontal fitting of the frame elements20A and20B. The frame elements20A and20B can be secured together to create a secure interlocking frontal fitting to connect the vertical sectional bar5A to the left frame2. Similarly, the frame elements20A and20B can be secured together to create a secure interlocking frontal fitting to connect the base frames4A and4B to the left frame2and the right frame3to complete the construction of the cabinet10.