Frame kit and methods therefor

A frame kit comprises a plurality of improved corner connectors and a plurality of rail members both having a plurality of holes, a plurality of fasteners for coupling each one of the corner connectors to one end of three rail members of the plurality of rail members and at least one set of instructions located in at least one container suitable for constructing at least one frame assembly. The frame kit may also comprise at least one of a plurality of leveling feet, a plurality of casters adapted for coupling to a portion of at least one of the corner connectors, a plurality of rib members for strengthening at least one frame assembly and a plurality of accessory members adapted to couple to at least one of the plurality of rail members. A method for assembling the frame kit and constructing at least one frame assembly is also disclosed.

FIELD OF THE INVENTION

This invention relates generally to frame kits and more specifically to a frame kit comprising at least a plurality of improved connecting corners, a plurality of rail members and a plurality of fasteners.

BACKGROUND OF THE INVENTION

Various manufacturers have provided equipment frame assemblies and equipment enclosures for storing electronic equipment. Most such enclosures and frame assemblies were supplied by these manufacturers in a fully assembled state and therefore required customization to comply with the needs of consumers. Consequently, costs for such enclosures were relatively high, and in an after-market sense, modification of such enclosures by consumers was difficult to achieve. Additionally the cost of shipping such enclosures was high because of the size of such enclosures.

Subsequently, certain knock-down components were offered in the market, which required tedious construction and specialized hardware and tools for constructing the knock-down components into a full enclosure. Amongst limitations that exist for such knock-down components are: standardization in sizes, custom ordering for non-standard sized enclosures, assortment of parts needed for construction of the enclosure, time to construct the enclosure and strength considerations of the components and final enclosure.

The present inventor recognized the need for an improved system for constructing enclosures (otherwise termed frame assemblies in this application), and previously disclosed improved corner connectors for knock-down racks (U.S. application Ser. No. 10/361,403, filed Feb. 10, 2003). Subsequently, the present inventor has recognized an advantage in providing such improved corner connectors (otherwise termed corner members in this application) in combination with rail members and fasteners in a kit form which may be easily transported and which provides all elements necessary for simple construction of a frame assembly, as well as other similar assemblies that make use of the improved corner connectors, rail members and fasteners as base elements of structures.

SUMMARY OF THE INVENTION

Accordingly, it is an object of this disclosure to provide a plurality of improved corner members, a plurality of rail members and a plurality of fasteners in a kit form for construction of a frame assembly.

It is a further object of this disclosure to provide a plurality of improved corner members, a plurality of rail members and a plurality of fasteners in a kit form for construction of a multiple frame assembly.

It is a still further object of this disclosure to provide a plurality of improved corner members, a plurality of rail members and a plurality of fasteners in a kit form for simple construction of a variety of enclosures.

It is a yet further object of this disclosure to provide a method for assembling a frame kit as described above.

It is a further object of this disclosure to provide a method for constructing a frame assembly from a frame kit as described above.

PREFERRED EMBODIMENTS OF THE INVENTION

In accordance with one embodiment of this invention, a frame kit is disclosed. The frame kit comprises, in combination a plurality of rail members, each one of the rail members having a plurality of holes and a plurality of corner connectors, each one of the plurality of corner connectors including a base member having a plurality of holes and a reinforcing rib coupled to the base member, a pair of leg members, each having a plurality of holes, each one of the pair of leg members including a reinforcing rib coupled to each one of the pair of leg members, a first leg member of the pair of leg members substantially perpendicular to a second leg member of the pair of leg members, each one of the pair of leg members substantially perpendicular to the base member, a portion of the base member and a portion of the first leg member of the pair of leg members having a first inner slot, a portion of the base member and a portion of the second leg member of the pair of leg members having a second inner slot, a portion of the first leg member and a portion of the second leg member having a third inner slot, and a portion of the base member including a rail stop adjacent to a portion of each one of the pair of leg members. The first inner slot of each one of the plurality of corner connectors receives one end of a first rail member of the plurality of rail members, the second inner slot of each one of the plurality of corner connectors receives one end of a second rail member of the plurality of rail members and the third inner slot of each one of the plurality of corner connectors receives one end of a third rail member of the plurality of rail members, the rail stop prevents contact of the one end of the first rail member with both the one end of the second rail member and the one end of the third rail member. The frame kit further comprises, in combination a plurality of fasteners adapted to selectively couple each one of the plurality of rail members to the base member and to each one of the pair of leg members of each one of the plurality of corner connectors thereby providing at least a portion of a frame assembly, and at least one container, the plurality of corner members, the plurality of rail members and the plurality of fasteners located in the at least one container thereby providing the frame kit.

In accordance with a second embodiment of this invention, a method for assembling a frame kit is disclosed. The method for assembling a frame kit comprises the steps of providing a plurality of rail members, each one of the rail members having a plurality of holes and providing a plurality of corner connectors, each one of the plurality of corner connectors including a base member having a plurality of holes and a reinforcing rib coupled to the base member, a pair of leg members, each having a plurality of holes, each one of the pair of leg members including a reinforcing rib coupled to each one of the pair of leg members, a first leg member of the pair of leg members substantially perpendicular to a second leg member of the pair of leg members, each one of the pair of leg members substantially perpendicular to the base member, a portion of the base member and a portion of the first leg member of the pair of leg members having a first inner slot, a portion of the base member and a portion of the second leg member of the pair of leg members having a second inner slot, a portion of the first leg member and a portion of the second leg member having a third inner slot, and a portion of the base member including a rail stop adjacent to a portion of each one of the pair of leg members. The method further comprises the steps of providing the first inner slot of each one of the plurality of corner connectors receives one end of a first rail member of the plurality of rail members, the second inner slot of each one of the plurality of corner connectors receives one end of a second rail member of the plurality of rail members and the third inner slot of each one of the plurality of corner connectors receives one end of a third rail member of the plurality of rail members, the rail stop preventing contact of the one end of the first rail member with both the one end of the second rail member and the one end of the third rail member and providing a plurality of fasteners adapted to selectively couple each one of the plurality of rail members to the base member and to each one of the pair of leg members of each one of the plurality of corner connectors thereby providing at least a portion of at least one frame assembly. The method further comprises the steps of providing at least one container and locating the plurality of corner members, the plurality of rail members and the plurality of fasteners in the at least one container thereby providing the frame kit in preparation for constructing the at least one frame assembly.

In accordance with a third embodiment of this invention, a method for constructing a frame assembly from a frame kit is disclosed. The method comprises the steps of providing the frame kit comprising a plurality of rail members, each one of the rail members having a plurality of holes and providing the frame kit further comprising a plurality of corner connectors, each one of the plurality of corner connectors including a base member having a plurality of holes and a reinforcing rib coupled to the base member, a pair of leg members, each having a plurality of holes, each one of the pair of leg members including a reinforcing rib coupled to each one of the pair of leg members, a first leg member of the pair of leg members substantially perpendicular to a second leg member of the pair of leg members, each one of the pair of leg members substantially perpendicular to the base member, a portion of the base member and a portion of the first leg member of the pair of leg members having a first inner slot, a portion of the base member and a portion of the second leg member of the pair of leg members having a second inner slot, a portion of the first leg member and a portion of the second leg member having a third inner slot, and a portion of the base member including a rail stop adjacent to a portion of each one of the pair of leg members. The method further comprises the steps of providing the frame kit further comprising the first inner slot of each one of the plurality of corner connectors receives one end of a first rail member of the plurality of rail members, the second inner slot of each one of the plurality of corner connectors receives one end of a second rail member of the plurality of rail members and the third inner slot of each one of the plurality of corner connectors receives one end of a third rail member of the plurality of rail members, the rail stop preventing contact of the one end of the first rail member with both the one end of the second rail member and the one end of the third rail member and providing the frame kit further comprising a plurality of fasteners adapted to selectively couple each one of the plurality of rail members to the base member and to each one of the pair of leg members of each one of the plurality of corner connectors thereby providing at least a portion of at least one frame assembly. The method further comprises the steps of providing the frame kit comprising at least one container housing the plurality of corner members, the plurality of rail members, the plurality of fasteners and at least one set of instructions for constructing the at least one frame assembly, unpacking the plurality of corner members, the plurality of rail members, the plurality of fasteners and the one set of instructions from the at least one container and constructing the at least one frame assembly according to the at least one set of instructions.

The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more detailed description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.

DESCRIPTION OF THE INVENTION

The disclosure of U.S. application Ser. No. 10/361,403 in the name of the current inventor, filed Feb. 10, 2003 (published as U.S. Publication No. 2004/0155002 A1) is incorporated by reference in the current application. According toFIG. 1, in one embodiment of a frame kit100, the frame kit100comprising a plurality of corner connectors10, a plurality of rail members12having the same length, a first container14including a plurality of fasteners16, at least one set of instructions18and a second container20with each one of the plurality of corner connectors10, the plurality of rail members12, the first container14including the plurality of fasteners16and the at least one set of instructions18is located in the second container20. Referring toFIG. 2, in a second embodiment of a frame kit200, a portion of the frame kit200comprising a plurality of corner connectors10, a plurality of rail members12with a first set of the plurality of rail members12abeing of different length to a second set of the plurality of rail members12band a first container14including a plurality of fasteners16(not shown) is suitable for being located in the second container20ofFIG. 1. Referring further toFIG. 3, in a third embodiment of a frame kit300, a portion of the frame kit300comprising a plurality of corner connectors10, a plurality of rail members12with a first set of the plurality of rail members12abeing of different length to a second set of the plurality of rail members12band a third set of the plurality of rail members12cbeing of different length to both the first set of the plurality of rail members12aand the second set of the plurality of rail members12band a first container14including a plurality of fasteners16(not shown) is suitable for being located in the second container20ofFIG. 1. It is understood that in each embodiment of the frame kit100,200and300described above, the second container20may be suitably sized to accommodate the plurality of corner connectors10, the plurality of rail members12, the first container14including the plurality of fasteners16and the at least one set of instructions18. It is further understood that the first container14may comprise any suitable packaging such as a cardboard box, at least one plastic bag and the like suitable for enclosing the plurality of fasteners16, or alternatively, the plurality of fasteners16may also be loosely included in the second container20. Furthermore, it is understood that the second container20may also be any suitable packing such as a cardboard box, at least one plastic bag and the like suitable for enclosing the plurality of corner connectors10, the plurality of rail members12, the first container14including the plurality of fasteners16and the at least one set of instructions18as described above.

According toFIG. 4, as previously disclosed in U.S. Publication No. 2004/0155002 A1, each corner connector10of the plurality of corner connectors10includes a base member30having a plurality of holes32(see alsoFIG. 5) and a reinforcing rib34acoupled to the base member30, a pair of leg members36, each having a plurality of holes32, each one of the pair of leg members36including each one of a reinforcing rib34b,34ccoupled to the pair of leg members36respectively, a first leg member36aof the pair of leg members36substantially perpendicular to a second leg member36bof the pair of leg members36, each one of the pair of leg members36substantially perpendicular to the base member32, a portion of the base member32and a portion of the first leg member36aof the pair of leg members36defining a first inner slot38a, a portion of the base member32and a portion of the second leg member of the pair of leg members36defining a second inner slot38b, a portion of the first leg member36aand a portion of the second leg member36bdefining a third inner slot38c, and a portion of the base member32including a rail stop40adjacent to a portion of each one of the pair of leg members36. It is understood that when the base member30of each one of the plurality of corner connectors10includes the reinforcing rib34acoupled to a portion of the base member30and each one of the pair of leg members36of each one of the plurality of corner connectors10includes a reinforcing rib34b,34ccoupled to a portion of each one of the pair of leg members36a,36beach one of the plurality of corner connectors10is thereby strengthened. Furthermore referring toFIG. 5, in each corner connector10, the first inner slot38aof each one of the plurality of corner connectors10receives one end of a first rail member12of the plurality of rail members12, the second inner slot38bof each one of the plurality of corner connectors10receives one end of a second rail member12of the plurality of rail members12and the third inner slot38cof each one of the plurality of corner connectors10receives one end of a third rail member12of the plurality of rail members12, the rail stop40preventing contact of the one end of the first rail member12with both the one end of the second rail member12and the one end of the third rail member12. As further shown inFIG. 5, each one of the rail members12of the plurality of rail members12having a plurality of holes32and the plurality of fasteners16is adapted to selectively couple each one of the plurality of rail members12to the base member30and to each one of the pair of leg members36of each one of the plurality of corner connectors10thereby providing at least a portion of any one of a frame assembly100a,200aand300aas described below. Preferably each one of the plurality of corner connectors10comprises a material selected from the group consisting of a metal, a plastic and a fiber reinforced plastic and more preferably the metal is aluminum. Preferably, as previously disclosed in U.S. Publication No. 2004/0155002 A1, both the plurality of holes32of the base member30and the plurality of holes32of the pair of leg members36a,36bof each one of the plurality of corner connectors10has a counter sunk shape to accommodate a head portion of each one of the plurality of fasteners16. In addition, preferably each one of the plurality of rail members12is substantially L-shaped and thereby adapted to conform to each one of the inner slots38a,38b,38cof each one of the plurality of corner connectors10.

Turning now toFIG. 6, a perspective view of a frame assembly100ais shown having the plurality of corner connecters10ofFIG. 1and the plurality of rail members12, each rail member12having the same length with the frame assembly100ahaving a substantially cube shape. Specifically, the frame assembly100ais constructed from the frame kit100ofFIG. 1and comprises each one of the at least twelve rail members12of the plurality of rail members12having the same length thereby providing a cube shaped frame assembly100a. The frame assembly100acomprises at least eight corner connectors10of the plurality of corner connectors10and the plurality of fasteners16. In a preferred embodiment at least ninety-six fasteners are used, although it is understood that less than this number of fasteners may also be effective. It is understood that the frame assembly100amay be sized as required by a user of the frame assembly100a.

Referring toFIG. 7, a perspective view of a frame assembly200ais shown having the plurality of corner connecters10ofFIG. 2and the plurality of rail members12with a first set of four rail members12ahaving the same length and a second set of eight rail members12bhaving the same length, but of different length to the first set of rail members12aofFIG. 2and the frame assembly200ahaving a substantially rectangular prismatic shape. Specifically, the frame assembly200ais constructed from the frame kit200ofFIG. 2, each one of a first set of four rail members12aof the twelve rail members12having the same length and each one of a second set of eight rail members12bof the twelve rail members12having the same length, the first set of the twelve rail members12abeing of different length to the second set of the twelve rail members12bthereby providing a rectangular prismatic shaped frame assembly200a. The frame assembly200acomprises at least eight corner connectors10of the plurality of corner connectors10and the plurality of fasteners16. In a preferred embodiment at least ninety-six fasteners are used, although it is understood that less than this number of fasteners may also be effective. It is understood that the frame assembly200amay be sized as required by a user of the frame assembly200a.

Referring now toFIG. 8, a perspective view of a frame assembly300ais shown having the plurality of corner connecters10ofFIG. 3and the plurality of rail members12with a first set of four rail members12ahaving the same length, a second set of four rail members12bhaving the same length, and a third set of rail members12chaving the same length but the first set of rail members12a, the second set of rail members12band the third set of rail members12chaving different lengths and the frame assembly300ahaving a substantially rectangular prismatic shape. Specifically, the frame assembly300ais constructed from the frame kit300ofFIG. 3, each one of a first set of four rail members12aof the twelve rail members12having the same length, each one of a second set of four rail members12bof the twelve rail members12having the same length and a third set of four rail members12cof the twelve rail members12having the same length, the first set of the twelve rail members12abeing of different length to the second set of the twelve rail members12b, and the third set of the twelve rail members12cbeing of different length to both the first set of four rail members12aand the second set of four rail members12bthereby providing a rectangular prismatic shaped frame assembly300a. The frame assembly300acomprises at least eight corner connectors10of the plurality of corner connectors10and the plurality of fasteners16. In a preferred embodiment at least ninety-six fasteners are used, although it is understood that less than this number of fasteners may also be effective. It is understood that the frame assembly300amay be sized as required by a user of the frame assembly300a.

According toFIG. 9in a fourth embodiment of a frame kit400, the frame kit400comprising each one of a plurality of corner connectors10, a plurality of rail members12, a plurality of reinforcing members24, a plurality of casters22and a first container14including a plurality of fasteners16(not shown) is suitable for being located in a second container20similar to the second container20ofFIG. 1. It is understood that in the fourth embodiment of the frame kit400described above, the second container20may be suitably sized to accommodate the plurality of corner connectors10, the plurality of rail members12, the plurality of reinforcing members24, the plurality of casters22, the first container14including the plurality of fasteners16and at least one set of instructions18(not shown inFIG. 9, but shown inFIG. 1). Referring toFIGS. 9A and 9Band previously disclosed U.S. Publication No. 2004/0155002 A1, the base member30of each one of the plurality of corner connectors10may have at least one threaded hole and the base member30of each one of the plurality of corner connectors10is selectively coupled to one of a leveling foot26, a caster22and an accessory member28. It is understood that any one of the frame kits100,200and300may further comprise a plurality of leveling feet26, a plurality of casters22and a plurality of accessory members28. The accessory member28may be a substantially flat sheet having a plurality of holes32for coupling to at least one of the rail members12of the plurality of rail members12, such as a shelf, a bracket or any other desired shape such as a rod and the like.

Referring now toFIG. 10, a perspective view of a frame assembly400ais shown having the plurality of corner connecters10ofFIG. 9, the plurality of rail members12ofFIG. 9, the plurality of reinforcing members24ofFIG. 9coupled to a portion of the plurality of rail members12, and each one of four casters22of the plurality of casters22ofFIG. 9coupled to each one of four corner connectors10of the plurality of corner connectors10. Specifically, the frame assembly400ais constructed from the frame kit400ofFIG. 9and the frame assembly400acomprises at least one reinforcing member24for coupling to two of the rail members12thereby providing further structural rigidity for the frame assembly400a, the at least one reinforcing member24located in the at least one container20. It will be appreciated that any one of the frame kits100,200and300and the corresponding frame assemblies100a,200aand300amay comprise the at least one reinforcing member24. The frame assembly400acomprises at least eight corner connectors10of the plurality of corner connectors10and the plurality of fasteners16. In a preferred embodiment at least ninety-six fasteners are used, although it is understood that less than this number of fasteners may also be effective. It is understood that the frame assembly400amay be sized as required by a user of the frame assembly400a.

STATEMENT OF METHOD FOR ASSEMBLING A FRAME KIT

A method for assembling a frame kit such as100a,200a,300aand400acomprises the steps of providing a plurality of rail members12, each one of the rail members12having a plurality of holes32; providing a plurality of corner connectors10, each one of the plurality of corner connectors10including a base member30having a plurality of holes32and a reinforcing rib34acoupled to the base member30, a pair of leg members36, each having a plurality of holes32, each one of the pair of leg members36including a reinforcing rib34b,34ccoupled to each one of the pair of leg members36, a first leg member36aof the pair of leg members36substantially perpendicular to a second leg member36bof the pair of leg members36, each one of the pair of leg members36substantially perpendicular to the base member30, a portion of the base member30and a portion of the first leg member36aof the pair of leg members36having a first inner slot38a, a portion of the base member30and a portion of the second leg member36bof the pair of leg members36having a second inner slot38b, a portion of the first leg member36aand a portion of the second leg member36bhaving a third inner slot38c, and a portion of the base member30including a rail stop40adjacent to a portion of each one of the pair of leg members36; providing the first inner slot38aof each one of the plurality of corner connectors10receiving one end of a first rail member12of the plurality of rail members12, the second inner slot38bof each one of the plurality of corner connectors10receiving one end of a second rail member12of the plurality of rail members12and the third inner slot38cof each one of the plurality of corner connectors10receiving one end of a third rail member12of the plurality of rail members12, the rail stop40preventing contact of the one end of the first rail member12with both the one end of the second rail member12and the one end of the third rail member12; providing a plurality of fasteners16adapted to selectively couple each one of the plurality of rail members12to the base member30and to each one of the pair of leg members36of each one of the plurality of corner connectors10thereby providing at least a portion of at least one frame assembly100a,200a,300aand400a; providing at least one container20; and locating the plurality of corner members10, the plurality of rail members12and the plurality of fasteners16in the at least one container20thereby providing the frame kit100,200,300and400in preparation for constructing the at least one frame assembly100a,200a,300aand400a. The method further comprises the steps of providing at least one of a plurality of leveling feet26, a plurality of casters22and a plurality of accessory members28; and locating the at least one of a plurality of leveling feet26, the plurality of casters22and the plurality of accessory members28in the at least one container20of the frame kit100,200,300and400thereby extending the usability of the at least one frame assembly100a,200a,300aand400a. The method further comprises the steps of providing at least one reinforcing member24for coupling to two of the rail members12thereby providing further structural rigidity for the frame assembly100a,200a,300aand400a; and locating the at least one reinforcing member24in the at least one container20of the frame kit100,200,300and400.

A method for constructing a frame assembly100a,200a,300aand400afrom a frame kit100,200,300and400further comprises the steps of unpacking the plurality of corner members10, the plurality of rail members12, the plurality of fasteners16and one set of instructions18from the at least one container20; and constructing the at least one frame assembly100a,200a,300aand400aaccording to the at least one set of instructions18. It is understood that at least one of a plurality of leveling feet26, a plurality of casters22, a plurality of accessory members28and a plurality of reinforcing members24may also be unpacked from the at least one container20.

While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. In particular, a frame kit may further comprise a first frame assembly comprising a first set of the plurality of corner members10, the plurality of rail members12and the plurality of fasteners16located in the at least one container20and a second frame assembly comprising a second set of the plurality of corner members10, the plurality of rail members12and the plurality of fasteners16located in at least a second container20, each one of a co-planar set of the plurality of corner members10of the first frame assembly being coupled to each one of a co-planar set of the plurality of corner members10of the second frame assembly may provide a multiple frame assembly. The first frame assembly and the second frame assembly may be any of the frame assemblies100a,200a,300aand400adescribed above. It is understood that more than two of the above described frame assemblies may be coupled to provide a multiple frame assembly. It is further understood that multiple containers may be provided for each one of a plurality of corner connectors10, a plurality of rail members12and the at least one of a plurality of leveling feet26, a plurality of casters22and a plurality of rib members24.