Apparatus and method for maintaining a gap

A method and apparatus for maintaining a fixed distance between two cabinets during installation are provided. An elongated rail with two stops and two clamps are used. The stops are fixed to the elongated rail with opposing faces placed the fixed distance apart. The assembly is placed between the cabinets and a clamp is used to pinch a cabinet wall of each cabinet against a stop. The cabinets are installed and the apparatus is removed. In some embodiments a second apparatus may be used, one at the top of the cabinets and one at the bottom.

FIELD

The present invention generally relates to products and apparatus for maintaining a spacing between two or more objects. In particular, the apparatus and methods may be used for maintaining a spacing during the installation of cabinets.

BACKGROUND

During the installation of cabinets, such as in a kitchen installation, it is often necessary to maintain a consistent and precise space between two cabinets that are being installed. For example, many appliances such as stoves and dishwashers have standard widths and cabinets need to be installed on either side of a gap with the correct width to allow the appliance to be installed later.

While it would seem that maintaining such a width would be easily accomplished by simply measuring, this is not the case. During the cabinet installation process, the cabinets are placed into position and then must be leveled. During the leveling process, the cabinets can encroach into the gap and consequently render the gap too small for the later installation of the appliance.

This effect is exacerbated by the close tolerances that may be desired. Large gaps between the appliances and the cabinets are not only unsightly, but also create unwanted crumb and dirt traps after installation is complete. Accordingly, it is very desirable to maintain any spacing between cabinets designed for an appliance as accurately as possible.

SUMMARY OF THE EMBODIMENTS

Objects of the present patent document are to provide improved methods and apparatus for maintaining a gap between cabinets during and installation. While the apparatus can be used for maintaining a gap between any two objects, its preferred use is to maintain a gap between cabinets during the installation of the cabinets, for example in a kitchen.

A method for maintaining a fixed distance between two cabinets during installation is provided. In a preferred embodiment, the method comprises adjusting a first stop along an axial length of an elongated rail. Then, fixing the first stop in a first position such that a first flat surface of the first stop is perpendicular to the axial length. Adjusting a second stop along the axial length of the elongated rail. Then, fixing the second stop in a second position such that a second flat surface of the second stop is perpendicular to the axial length and is parallel and facing an opposite direction from the first flat surface, wherein the first flat surface and the second flat surface are the fixed distance apart. Once the stops are positioned and fixed to the elongated rail, the elongated rail with the first stop and second stop is placed between the two cabinets such that the first surface interfaces with a first cabinet of the two cabinets and the second flat surface interfaces with a second cabinet of the two cabinets. Then, a first clamp is adjusted along the axial length of the elongated rail. Once the first clamp is positioned, it may be fixed in a third position adjacent the first stop such that a first wall of the first cabinet is between the first stop and the first clamp. The first clamp is tightened to squeeze the first wall between the first stop and the first clamp. Next, a second clamp is adjusted along the axial length of the elongated rail. Once the second clamp is in place, it is fixed in a fourth position adjacent the second stop such that a second wall of the second cabinet is between the second stop and the second clamp. The second clamp is tightened to squeeze the second wall between the second stop and the second clamp. Once everything is secured, the first cabinet and second cabinet can be fixed in place by screwing or gluing or some other method or any combination thereof. Finally, once the cabinets are installed and fixed in place, the first clamp and the second clamp can be loosened and the elongated rail with the first stop, second stop, first clamp and second clamp removed from between the two cabinets.

In some embodiments, the elongated rail has a channel that runs along the axial length. In some embodiments, the cross-section of the channel is dovetail shaped.

In general, the stops and clamps may be secured to the rail using many different methods. In one embodiment, the first stop, second stop, first clamp and second clamp are all fixed to the rail by tightening a fastener with a flange coupled to the fastener within the channel. In some embodiments, the flange may be a t-nut.

In preferred embodiments, the first stop and second stop each have ridges that extend into the channel. The ridges preferably fill most of the gap between the channel in order to help keep the stops perpendicular to the axial length of the rail and not allow the stops to rotate with respect to the axial length of the rial. Even more preferably, the first stop and second stop each have two ridges that extend into the channel on either side of a fastener.

In preferred embodiments, the first clamp and second clamp each have a tip that is designed to squeeze an object against a stop and is adjustable along an axial length of the first clamp and second clamp via a thread.

In some embodiments, the first clamp and second clamp each have two fasteners and two flanges that couple the first clamp and the second clamp to the elongated rail respectively.

In preferred embodiments, the elongated rail has preset positions along the axial length for the first stop and the second stop to allow the first stop and second stop to be positioned the fixed distance apart. The preset positions may be at 30 inches, 36 inches and 48 inches to name a few.

In another aspect of the embodiments taught herein, an apparatus for maintaining a fixed distance between two objects is provided. In preferred embodiments, the apparatus comprises an elongated rail with an axial length and a channel running along the axial length. A first stop releasably coupled to the elongated rail such that the first stop is adjustable along the axial length of the elongated rail and fixable in various positions along the axial length of the elongated rail. The first stop has a first flat surface that is perpendicular to the axial length when the first stop is in a first fixed position along the axial length of the elongated rail. Preferably, the first stop has a first ridge that extends into the channel. A second stop releasably coupled to the elongated rail such that the second stop is adjustable along the axial length of the elongated rail and fixable in various positions along the axial length of the elongated rail. The second stop has a second flat surface that is perpendicular to the axial length and facing in an opposite direction from the first flat surface when the first stop is in a second fixed position along the axial length of the elongated rail. Preferably, the second stop has a second ridge that extends into the channel. A first clamp that is releasably coupled to the elongated rail such that the first clamp is adjustable along the axial length of the elongated rail and fixable in various positions along the axial length of the elongated rail. The first clamp has a first tip designed to press an object against the first stop. Preferably, the first tip is adjustable along the axial length of the first clamp. A second clamp releasably coupled to the elongated rail such that the second clamp is adjustable along the axial length of the elongated rail and fixable in various positions along the axial length of the elongated rail. The second clamp has a second tip designed to press an object against the second stop. Preferably, the second tip is adjustable along the axial length of the second clamp.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present patent application discloses an apparatus, device or tool that maintains a fixed and precise distance between two material bodies during an installation or fabrication process. The distance is maintained by the device even during a leveling process of the material bodies or other movements that may be required for installation of the bodies.

The device maintains the precise fixed distance by clamping on to the materials and maintains the fixed dimension after clamps are engaged. The device accommodates for a range of material thickness and distances.

By utilizing rods, clamps and stops in concert with one another, the device maintains the desired fixed dimension of space between bodies. In addition to the precise spacing it maintains, the device also keeps material bodies parallel and plumb.

The device consists of a system of components that includes various rod lengths and can be packaged as a system of stops and clamps.

Components

FIG.1illustrates an isometric view of one side of one embodiment of an apparatus for maintaining a fixed distance between two objects10. As may be appreciated, the apparatus10is coupled to a cabinet inFIG.1. In some embodiments, the apparatus10is coupled between to cabinets or stated another way, coupled to two cabinets, one on each end of the apparatus10.

As may be seen inFIG.1, the apparatus10includes a rail12. The rail12is an elongated body with an axial length extending along its elongated body. The rail12can be manufactured in any length. Common lengths of gaps that need to be maintained in the cabinet industry are30″,36″,48″, and60″. The length of the rail12needs to be longer than the desired opening size or gap that needs to be maintained. To this end, the axial length of the rail12is preferably thirty inches or more. The rail12can be made of any ridged material such as, aluminum, wood, steel, copper, cobalt, plastic, ceramic, iron, cast iron. Preferably, the rail12is made from an extruded aluminum or steel.

In preferred embodiments, rail12has a flat surface29along the entire axial length. It will be understood from the teachings below, flat surface29is important to allow stops to be coupled to the rail12with surfaces perpendicular to the axial length of the rail12. However, in other embodiments the rail12could be cylindrical and the stops could be coupled around the rail and fixed with a set screw or other means of securing.

FIG.2illustrates a cross-sectional view of a preferred rail12showing a dove tail type channel15running the entire length of the rail12. Although not required, preferably the rail has a long channel, slot or groove15running the entire length. In some embodiments, the channel15may not run the entire length but only a portion of the length. In embodiments where the channel15does not run the entire length of the rail12, the channel15is preferably found at each distal end of the rail12and absent in the middle of the rail12.

Preferably, the channel15has a dove tail shape but other shapes are possible such as rectangular or U-shaped or other shapes. The key to the channel shape is that it works to help capture the components of the apparatus as they are adjusted, and preferably slidably adjusted, along the length of the rail12. To this end, regardless of the ultimate shape of the channel15, it preferably has lips11that help form a channel that can retain any slidable components. In other embodiments, the rail12has no channel15and the components may be releasably coupled to the exterior of the rail12.

FIG.3illustrates an isometric view of one embodiment of a stop14for use in an apparatus for maintaining a fixed distance between two objects. Stop14can be any device that may be coupled to rail12and be locked into a particular position at different distances along the axial length of the rail12. In preferred embodiment, stop14is slidably coupled to rail12and more preferably, slidably coupled to the channel15in the rail12. In embodiments with a channel15, the stop is preferably captured by the channel15. By captured it is meant that the stop14can be loosened and slid along the axial length of the rail12but it will not easily separate from the rail12. In embodiments that don't include a slot or channel15, the stop may be coupled to an outside surface of the rail12. Importantly, the stop14needs to be coupled in a way that is lockable in different positions along the axial length of the rial12.

In the embodiment shown inFIG.3, the stop14is generally blocked shaped. However, stops14can be any other shape but should have at least one flat surface13. Preferably stop14is made from a ridged material such as metal, preferably aluminum or steel. However, any metal may be used and plastics, ceramics and other rigid materials may also be used without departing from the scope of the embodiments. Ideally, the stop is rigid so it cannot be compressed. This is important for maintaining the exact distance between the objects desired. However, in some embodiments, a thin compressible layer of material may be added to surface13to protect the objects stops14will interface to. This thin compressible material may be rubber or a similar material. The compressible nature of this material should be within the allowable tolerances of the gap that needs to be maintained such that in operation the compression of the material does not modify the desired gap distance.

The stop is as accompanied by an adjustable fastener24. In the embodiment shown inFIG.3, the adjustable fastener24is a threaded fastener. However, in other embodiments, the adjustable fastener24may be a clip, spring, spring lock, slide-lock, screw or any other type of fastener that can be adjusted to releasably couple the stop14to the rail12.

In some embodiments, the stop14may also have a capture flange17. In the embodiment shown inFIG.3, the capture flange17is a T-nut17. However, any type of flange may be used. Preferably, the capture flange17is coupled to the adjustable fastener17such that it can be tightened and loosened with respect to the body of the stop14. The capture flange17is designed to fit within the channel15behind lips11. This allows the stop to be captured in the channel15and to the rail12but slidably connected to the rail12. Stops14can be made from a solid block of material or L-shaped bracket. A stop14has a surface13that when the stop14is fixed to the rail12, surface13is perpendicular to the axial length of the rail12.

Stops14can be slid in either direction in the groove15of the rail12for desired placement. The apparatus10has two stops, one at each distal end. Both stops14are adjusted to the desired opening, then tightened down (secured) using a fastener24and capture flange17. In the embodiment shown inFIG.3, a threaded fastener such as a cap screw is used in combination with a T-Nut17. The threaded fastener24passes through a hole in the stop14. The flange17is placed under the lips11of the channel15and when the stop14is located the correct distance along the rail12, the screw24is tightened with a tool such as an allen wrench or similar to lock the stop14into the desired position along the axial length of the rail12. At this stage, surface13is perpendicular to the axial length of the rail12.

In some embodiments, stop14has a threaded insert to allow fastener24to thread into the stop14.

In addition, the surface of stop13that interfaces with rail12is perpendicular to surface13. In some embodiments, stop14has a pair of ridges22. Ridges22extend down from the stop14and are designed to extend into channel15. Preferably, ridges22are located on either side of the fastener24on a surface perpendicular to surface13. Ridges22ensure that surface13is perpendicular to the axial length of the rail12when the stop is locked into position along the rail12.

FIG.4illustrates an isometric view of a second embodiment of a stop14for use in an apparatus for maintaining a fixed distance between two objects. The stop14inFIG.4is similar and works in a similar manner to the stop14inFIG.3. The stop ifFIG.4is shaped in the shape of a cube with ridges22protruding from the surface designed to interface with the rail12. InFIG.4, the capture flange17is a square nut.

FIG.5illustrates a plan view of another embodiment of a stop14mounted to a rail12for use in an apparatus for maintaining a fixed distance between two objects. The stop14inFIG.5is similar and works in a similar manner to the stop14inFIG.4. The stop ifFIG.5, has a capture flange17that is shaped to fit in the dove tail channel15. In particular, the capture flange17has a cross-section that allows a portion of the capture flange17to fit up in between lips11of the channel15. Although the embodiments of stops14have been shown with a single fastener24and capture flange17, in other embodiments the stops14may have two, three or more fastener/capture flange combinations.

In operation, at least two stops14are used and slidably coupled to the rail12. The stops are mounted to the rail12with their flat surfaces13facing away from each other. The stops14are adjusted along the rail12until the distance between the outside edges or surfaces13of each stop14defines the gap to be maintained. The stops14are then secured to the rail12such that they cannot move with respect to each other or the rail12. This is preferably done by tightening the fastener24of each stop14.

In preferred embodiments, the rail12may be manufactured with preset positions for the stops at particularly common distances. To this end, there may be notches or other changes in the rail that allow the stops to easily be located such that their surfaces13are at exactly 30 inches apart or other commonly used distances. As just one example, the rail12may have small holes or dents and the stops14may be manufactured with a spring captured ball that seats into the holes in the rail12to allow predetermined spacing of the stops14. Markings could be added to the rail12to allow visual confirmation of the spacing of the stops at any predetermined locations.

FIG.6illustrates one embodiment of a clamp for use in an apparatus for maintaining a fixed distance between two objects. In the embodiment shown inFIG.6, the clamp includes a plate16. Plate16is used to couple the clamp18to the rail12and in other embodiments other coupling methods may be used. The plate16is made from a ridged material and the clamping device is coupled to the plate16by either fasteners24or permanently such as in welding or construction from a single piece.

Similar to the stop14, the clamp18needs to be able to be locked into particular locations along the axial length of the rail12and is in preferred embodiments captured to the rail and slidably coupled to the rail12. The clamp18moves along the longitudinal axis of the rail12and may be fixed in place anywhere along the longitudinal axis of the rail12. In preferred embodiments, the clamp18can slide along the rail12using the grove or channel15to couple the clamp assembly to the rail12just like the stop14.

FIG.7illustrates a side view of the clamp18ofFIG.6. Clamp18may be designed in many different ways. In the embodiment shown inFIG.7, the clamp18includes a plunger device21mounted parallel to the plate16. The plunger21is coupled to a lever (handle)25at the distal end of the plunger21. At the opposite end of the plunger21from the lever25is a tip19.

As may be appreciated inFIG.7, a bracket29is secured to the plate16with a fastener. The bracket29is an L shaped bracket with a hole that holds the plunger21in a parallel position to the plate16. The bracket29has sleeve23to ensure the plunger21remains parallel to the plate16.

In operation, the plunger21can traverse back and forth along the longitudinal length of the plate16by operation of the handle25, which is attached to the distal end of the plunger21. In the embodiment shown inFIG.7, the plunger handle25is attached with a pivot31over a fulcrum such that when the handle25is pressed down, the plunger21is fixed in place.

In the embodiment shown inFIG.7, the interface between the tip19and the plunger21is threaded. This allows for a fine adjustment of the tip19even when the clamp18is fixedly locked in position on the rail12.

The distal end of the plunger21opposite the handle25has the tip. The tip may be made from a material that compresses slightly such a rubber. In preferred embodiments, the tip19is made from a firm rubber. However, in other embodiments it may be made from other materials. Unlike the stops which have to maintain a fixed distance, the clamps19just lock the apparatus10together such that they tip19does not have the same tolerance requirements for the compression of the tip discussed in relation to the stop14. To this end, the tip19may be made of a softer material that compresses as long as it can hold the apparatus10in place on the cabinet or other object.

The plunger21handle25and tip19may be part of a straight line toggle clamp or other type of clamp. The clamp is coupled to the plate16and the plate16interfaces with the rail12. As may be appreciated, there are a pair of fasteners24and capture flanges17that go through holes in the plate16and allow the clamp18to be captured to the rail12, slidably adjusted and locked into position in the same way the stop14is. In particular, once in the desired location, the user can turn the screw24to reduce the gap between the capture flange17and the under side of the channel15to fix the clamp18in place. Of course, in this embodiment the clamp has a pair of fasteners/capture flanges and the stop only has one. However, in other embodiments the clamp18may have only one screw/capture flange or it may have more than two.

The screws24and capture flanges24pass through one or more holes in the plate16. As discussed, this allows the clamp18to be slidably coupled to the rail12but also fixed in a single position.

FIG.8illustrates an isometric view of one end of an apparatus10for maintaining a fixed distance between two objects with the stop14and clamp18coupled to the rail12. In operation, the stop14, along with the second stop on the opposite distal end of the rail, are distanced apart such that their surfaces13are the exact distance of the gap that is required to be maintained between objects. Once the correct distance apart, the stops14are locked in place by turning fastener24. The apparatus10is then slid between the objects such that each surface13of one of the stops14interfaces with one of the objects and separates them by the desired distance. The clamp18is then translated along the axial length of the rail12such that it is in position to firmly hold to the object when the handle25of the clamp is depressed and the tip19is translated along the axial length of the rail towards the stop14. Once the clamp18is in position it is fixed or locked down to the rail by turning screws24on the clamp18. Ideally, the same type of fasteners or at least fastener interfaces are used on all fasteners such that a single tool can be used for tightening and loosening the fasteners24. The same steps are repeated on the opposite distal end of the apparatus with the second stop and second clamp. In preferred embodiments, more than one apparatus may also be used such that two or more apparatus are placed between objects where it is desired to maintain a fixed distance between the objects. In the preferred embodiments, two apparatus are used, one near the top of the objects and one near the bottom. In other embodiments, a single apparatus is used in the middle of the objects or at the top or bottom of the objects.

As discussed, coupling the tip19to the plunger21with threads allows fine adjustment of the position of the tip19with respect to the clamp18and, thus, the amount of force applied through the object to the stop14when the clamp18is locked down with the handle25. The clamp18can be adjusted to the desired pressure on the object, depending on the texture and sensitivity of the material, by adjusting the tip19via the threaded coupling. The clamp18is released by simply pulling the handle25up and allowing the plunger21to travel parallel to the plate16away from the stop14.

As may be appreciated inFIG.8, when the lever (handle)25is utilized, the plunger21translates parallel to the plate16which corresponds to along the axial length of the rail12. The translation causes the tip19to engage securely against the object that is trying to be located and holds the apparatus to the object by squeezing a side of the object between the stop14and the clamp18.

FIG.9illustrates a view of the plate16without the clamping mechanism attached. As may be appreciated, the plate16can include a plurality of holes35. The plurality of holes allow the clamping mechanism to be coupled to the plate in various different locations. While as part of typical use the clamping mechanism will not need adjusted with respect to the plate16, the additional holes35allow for overall adjustment. In preferred embodiments, the holes35are predrilled threaded holes.

As may also be seen inFIG.9, cap screws may be used as the fasteners24that attach the clamp18to the rail12in combination with the capture flange17.

FIG.10illustrates the plate16ofFIG.9with nothing attached to it.

Similar to the stops14, the apparatus10includes a first and second clamp18each at opposite distal ends of the rail12with their tips pointing towards the middle and towards the respective stops14.

As may be appreciated, the clamps18are used to secure the device10into the gap by squeezing a side wall or other portion of the cabinet or other object between the clamp18and the stop14. As may be seen inFIG.1, a stop14is on one side of the cabinet and the clamp18on the other. The clamp18applies pressure through the cabinet to the stop14. This is repeated on the other side, opposite distal end, of the gap with an additional stop14and clamp18coupled to the same rail12on the opposite distal end, and thus the system is secured into the gap. Once attached on both sides and secured, the apparatus10will ensure the exact cap is maintained between the two objects.

In use, the components of the apparatus10may be coupled to the rail12and are preferably slidably coupled to the rail12. In addition, other elements such as levels or other components may be coupled to the rail12. The groove15allows both the stop14and clamp18to be securely positioned anywhere along the rail12.

Motivating Challenge Addressed

As just one example of the device's use, the device may be used to maintain a fixed dimension of separation between two cabinets to accommodate an appliance such as a range or dishwasher. The precise opening needs to be maintained while leveling cabinets on both sides. In the process of leveling cabinets, the gap between the cabinets may often change. The apparatus described herein prevents a change in the dimensions of the gap and thus, allows easier installation of objects such as cabinets.

In the case of kitchen cabinet installation, the dimensions of the opening are determined by the width of the appliance which becomes the fixed dimension. Both cabinets on the left and right need to be maintained at a precise distance from one another and stay parallel in order to later accommodate the appliance. Once the cabinets are levelled attached to the wall, or other anchor point, the device can be removed.

Some Example Use Cases

Though there are many possible uses for this device, following are two simple use cases.

Use Case 1

A cabinet installer would use the device for appliance openings such as refrigerator, washer/dryer, dishwasher, range, microwave, or a hood vent. The Device/tool can be left engaged for any desired amount of time. The device would be removed once appliances are ready to be installed or removed after counter tops are installed.

In a preferred embodiment, the system would consist of 1 rail, two stops and two clamps. More than one system may be used at a time for a single gap and extra stops and clamps may be provided.

In operation, the installer would determine the size of the gap needed between two cabinets. The stops would be slid manually along the longitudinal length of the rail and secured in place on opposite distal ends at the exact spacing the installer wishes to maintain. One end of the device is then secured to a first cabinet by adjusting a first clamp along the longitudinal length of the rail to squeeze the cabinet wall between the first clamp and the stop. A second clamp is used on the opposite end to secure the device onto the second cabinet on the other side of the gap, thus maintaining the gap. In some embodiments, the steps are repeated with a second device.

Use Case 2

In addition, to cabinet installers, the device could be used for numerous other cases where a consistent gap needs to be maintained. For example, a welder could benefit from use of this device while welding a rectangle. Both material bodies must be held a fixed distance and parallel to each other. Once clamps and stops are positioned and engaged, this allows the welder to fabricate other sides. Once fabrication is complete, the device can be removed.