Abstract:
An appliance kit is disclosed. The kit includes an upper cabinet, and first and second support members. The first and second support members may be attached to the upper cabinet to place the appliance in operational form. The first and second support members are also used as structural support inside a shipping container for shipping the appliance, the first and second support members being located astride the upper cabinet to support the shipping container against crushing.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Large full sized gas grills normally consist of a firebox containing a cooking system, a lid that attaches to the firebox, side shelves that attach to the firebox and a frame that supports the firebox. These are normally shipped in corrugated cardboard boxes with supplemental expanded plastic foam pads for support and protection. The corners of the box may have corner posts to support vertical loads made of fiberboard or folded corrugated paper with structural properties approximating wood. Upon unpacking, the firebox and lid are often preassembled but the side shelves must be assembled to the firebox, the frame must be assembled, and the firebox set atop the frame. Often, formed steel angles and channels are mated with flat sheets of steel to form a stressed structure to support the firebox. The firebox normally is made of sheet steel or cast aluminum and is attached to the frame structure directly or through intermediate brackets with the use of threaded fasteners. 
         [0002]    There are several significant shortcomings to the current art. The first of these has to do with the assembly of the grill at point of sale or point of use. The majority of grills are shipped in a partially or nearly completely disassembled configuration. Assembly of major components and even subassemblies may be required. Often the number of parts needed to be assembled is considerable and requires a large array of different types of fasteners leading to prolonged time required for assembly. 
         [0003]    The second shortcoming is that the package required to ship the grill components must perform two distinct roles. It must contain and protect the subassemblies and components, and it must support the weight of several packages being stacked atop each other for shipment and storage in the product distribution system. This is normally done by use of corrugated paper products (e.g., cardboard). Sheets of cardboard may be used having multiple flutes and sheets engineered to carry out the two roles by itself, or cardboard may be used in conjunction with corner posts mentioned above. However, such material can lose up to 30% of its strength with storage in high humidity conditions, requiring significant overdesign and additional material with associated costs and environmental impact. A third shortcoming of the traditional methods is that the traditional grill subassemblies and components do not form an inherently rigid structure, and most assembled grills demonstrate some perceptible deflection of structure under even moderate loads. 
         [0004]    What is needed is a system and method to address the above, and related, concerns. 
       SUMMARY OF THE INVENTION 
       [0005]    The invention of the present disclosure, in one embodiment thereof, comprises an appliance kit. The kit includes an upper cabinet, and first and second support members. The first and second support members may be attached to the upper cabinet to place the appliance in operational form. The first and second support members are also used as structural support inside a shipping container for shipping the appliance, the first and second support members being located astride the upper cabinet to support the shipping container against crushing. 
         [0006]    In some embodiments, the upper cabinet is the firebox of a cooking grill. In some embodiments, the first and second support members further comprise first and second portions, respectively, of a lower cabinet that, when placed astride the upper cabinet in the shipping container, provides support against lateral loads on sides of the shipping container. The first portion of the lower cabinet may be preassembled with at least one attached door. A shelf unit may also be included that fits into the lower cabinet when assembled, and rests upon the upper cabinet in the shipping container providing resistance against damage to the cabinet. Also included with the kit may be a set of wheels that are attachable to the lower support members when attached to the upper cabinet to mobilize the assembled kit. 
         [0007]    The first and second support members comprise frames constructed from tubular steel members. The kit may include a plurality of connectors used for joining the first and second support members together to construct a lower cabinet. At least one of the plurality of fasteners may comprise a threaded member that inserts partially into a first receiving end of one of the tubular steel members of the first support member, and inserts partially into a second receiving end of one of the tubular steel members of the second support member, the threaded member providing a first threaded connection adjacent an opening in the first receiving end and a second threaded connection adjacent an opening in the second receiving end, the first and second threaded connections accepting first and second threaded fasteners for retaining the first and second receiving ends to the threaded member. 
         [0008]    The shipping container may be configured to at least partially surround the first and second support members protecting the first and second support members from abrasion damage during shipping and handling. The shipping container may comprise a cardboard structure internally supported by the first and second support members. The kit may also include a lower guide member having a surface contoured to locate the upper cabinet and the first and second support members in a predetermined relationship for packaging. A lower platform may also be included for supporting the lower guide member and providing a rigid bottom side of a shipping container. 
         [0009]    The invention of the present disclosure, in another embodiment thereof, comprises a method of shipping an appliance. The method includes providing an appliance, providing first and second support members that may be assembled into a cabinet for supporting the appliance, and arranging the first and second support members around the appliance in a predetermined relationship inside a shipping container, the predetermined relationship of the first and second support members preventing crush damage to the appliance inside the shipping container. 
         [0010]    In some embodiments, the method includes providing a lower guide member in the shipping container, the lower guide member having a surface contour corresponding to correct placement of the first and second guide members relative to the appliance to prevent damage to the appliance inside the shipping container. The method may also include providing a shelf that may be placed in the cabinet when assembled, and placing the shelf atop the appliance in the shipping container to prevent damage to the container from a high pressure point. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is an exploded perspective view of a frame assembly according to aspects of the present disclosure. 
           [0012]      FIG. 2A  is an exploded inferior perspective view of a portion of the frame assembly of  FIG. 1 . 
           [0013]      FIG. 2B  is an assembled view of the illustration of  FIG. 2A . 
           [0014]      FIG. 3  is a perspective view of an assembled grill appliance utilizing the frame assembly of  FIG. 1 . 
           [0015]      FIG. 4  is an exploded perspective view of a disassembled appliance utilizing an included support cabinet as support for its own shipping container. 
           [0016]      FIG. 5  is a more detailed exploded perspective view of a disassembled appliance utilizing an included support cabinet as support for its own shipping container. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0017]    Referring now to  FIG. 1 , an exploded perspective view of a frame assembly  100  according to aspects of the present disclosure is shown. The frame assembly  100  of the present embodiment includes two major portions that serve as the basis for a lower support cabinet ( 300 ,  FIG. 3 ) as described more fully below. The frame assembly includes a front subframe  102  and a rear subframe  104 . Each of the subframes  102 ,  104  may include various support members arranged in a generally orthogonal fashion. For example, each of the subframes  102 ,  104  includes an upper lateral member  106  and a lower lateral member  108 . Adjoining at right angles to these members are upright members  110 . The front subframe  102  includes a plurality of connecting members  112  proceeding generally toward the rear subframe  104 . Correspondingly, the rear subframe  104  includes a plurality of connecting members  112  proceeding generally toward the front subframe  102 . 
         [0018]    The subframes  102 ,  104  and each of the various constituent members may be made from welded tubular steel. In other embodiments, the tubular members may be bolted together or fastened by some other means. It is also contemplated that, in some embodiments, at least a portion of the front subframe  102  and/or rear subframe  104  may comprise a durable polymer. 
         [0019]    In the present embodiment, four connectors  114  serve to selectively attach the front subframe  102  to the rear subframe  104 . When the front subframe  102  and rear subframe  104  are adjoined via the connectors  114 , bolts  115  may be used to finalize the connection and complete construction of the frame  100 . Referring now also to  FIG. 2A , an exploded inferior perspective view of a portion of the frame assembly of  FIG. 1  is shown. In  FIG. 2A , additional detail is provided regarding the fitment of the front subframe  102  to the rear subframe  104 . It can be seen that each of the connecting members  112  has a receiving end  118  into which the connector  114  fits in a slidable fashion. The connector  114  may be a bent segment of metal or polymer sized to fit within the respective openings  118 . In the present embodiment, the connector  114  defines threaded openings  122 . These threaded openings  122  correspond to openings  120  and the connecting members  112 . In other embodiments, the connector  114  may employ a captive fastener rather than a threaded opening  122 . 
         [0020]    Referring now also to  FIG. 2B , it can be seen that when the ends  118  are joined together over the connector  114 , the bolts  115  may be inserted to secure the two connecting members  112  together. It will be appreciated that, by completing this process with respect to all four corners of the frame  100 , the front subframe  102  and rear subframe  104  may be completely fastened together, forming the basis of the lower support cabinet  300 . 
         [0021]    Referring now to  FIG. 3 , a perspective view of an assembled grill appliance utilizing the frame assembly of  FIG. 1  is shown. It can be seen that, once the frame  100  is assembled, various coverings may be provided that give the frame  100  the appearance and function of a lower cabinet  300 . It can also be seen that the front subframe  102  and the rear subframe  106  form a front support member  301  and a rear support member  302 , respectively. It will also be appreciated that the frame  100  and/or front and rear subframes  102 ,  104  need not necessarily be bare when assembled. For example, as long as the ends  118  of the connecting members  112  are accessible, the front subframe  102  and rear subframe  104  can be assembled prior to being joined together. 
         [0022]    When the front and rear support members  301 ,  302  made from the front and rear subframes  102 ,  104  are joined together to complete the cabinet  300 , the cabinet  300  may be used to support an appliance  303  at a useful height. In the present embodiment, the appliance  302  is a cooking grill. However, in other embodiments, the appliance could be another useful device that a user might prefer to have at a taller height, and which would benefit from the packing methods described below. In one respect, the grill or appliance  303  may be considered as an upper cabinet positioned on the lower cabinet  300 . 
         [0023]    As the supported appliance, or upper cabinet  303 , in the present embodiment is a cooking grill, the frame lower cabinet  300  is shown assembled into a storage cabinet accessible via doors  304 . Ventilation louvers  307 , as well as other utilitarian and/or decorative features may also be provided on the frame cabinet  300 . The present embodiment also includes a side shelf  308  and a side burner  310 . It is understood that these items are provided only for illustration as other accessories and implements could also be attached to the grill  302  and/or frame lower cabinet  300 . 
         [0024]    Referring now to  FIG. 4 , an exploded perspective view of a disassembled appliance utilizing an included support cabinet as support for its own shipping container is shown. Here, it can be seen that the frame or cabinet  300  has been disassembled into the front lower support member  301  and the rear lower support member  302 . As described above, in some embodiments the front and rear lower support members  301 ,  302  are packed and shipped in a substantially intact configuration as shown. The respective frames  102 ,  106  serves as rigid attachment points for covers, panels, and doors  304 . The doors  304  may be shipped attached to the frame  102 . This prevents user error and frustration in having to attach doors  304  upon unpacking. In the present embodiment, pre-attached doors  304  are one benefit of splitting the lower cabinet  300  into front and rear support members  301 ,  302 , rather than dividing it laterally. 
         [0025]    In the present embodiment, a portion of a shipping container is shown as a lower platform  402 . The lower platform  402  may comprise a rigid or resilient structure, capable of being moved by a forklift without damage, for example. In addition to the lower platform  402 , a lower guide member  404  may be provided. The contour of the surface of lower guide member  404  may include features that aid in retaining the appliance  303 , and front and rear support members  301 ,  302  in a predetermined location relative to one another. 
         [0026]    When placed in the configuration shown in preparation for shipping, the various components such as the appliance  303  and the front and rear support members  301 ,  302 , may be considered a shipping unit  405 . In the present embodiment, the lower guide member  404  provides a front wall  406  designed to fit against the front support member  301  and a portion of the grill  303 . The lower guide member  404  also has a rear wall  408  designed to fit against the rear support member  302  and a portion of the grill  303 . Also shown as part of the shipping unit in the present embodiment are the removable wheels  306  and a shelf  410 . The shelf  410  may be utilized within the cabinet  300  formed by the front and rear support members  102 ,  104 . 
         [0027]    With reference back to  FIG. 3 , it can be seen that, when the front and rear support members  301 ,  302  are assembled into the lower cabinet  303 , the front support member  301  would face the front of the grill  303  with the doors  304  on the front as well. Additionally, the rear support member  302  would be located on the rear side of the grill  303 . With reference to  FIG. 4 , it can be seen that in some embodiments, the front support member  301  and the rear support member  302  may be rotated with respect to the grill  303  approximately 90 degrees. This allows the front and rear support members  301 ,  302 , when configured as a shipping unit  405 , to be able to protect the grill  302  from crush damage, even though, when assembled as the completed lower cabinet  300 , they may have substantially the same footprint as the grill  302 . Additionally, the structure of the front and rear support members  301 ,  302  may protect items packed as part of the shipping unit  405  against a certain amount of damage from single high pressure points, such as bumps by forklifts or other dock equipment. 
         [0028]    Referring now to  FIG. 5 , another exploded perspective view of a disassembled appliance utilizing its own cabinet for support in a shipping container is shown.  FIG. 5  illustrates additional detail and packing material. Here, all of the components of the shipping unit  405  are shown with respect to the entirety of the associated shipping container. In the present embodiment, the shipping container includes the lower platform  402 , the lower guide member  404 , as well as various pieces of auxiliary impact protective packing material  502 . These may be made of Styrofoam®, cardboard, or another inexpensive packing material. The shipping container may also comprise corner pieces  504  that may be made of cardboard, wood, Styrofoam®, or another impact resistant material. Internal spacing material  506  may also be included to help insure that the shipping unit  405  remains in proper relative position with respect to its constituent pieces. Finally, an outer covering  510  may be provided that aids in holding the shipping unit  405  and other pieces of the shipping container in place. 
         [0029]    In the present embodiment, the outer covering  510  is shown as a component that slides down over the pieces it contains, and attaches to the lower platform  402 . However, it is understood that the outer covering may also be pre-attached to the lower platform  402 , and the shipping unit  405  may be inserted through the top. The outer covering  510  may be cardboard or another inexpensive material. When the shipping container and the shipping unit  405  are assembled for shipment, it can be appreciated that the front and rear support members  301 ,  302  define a region inside the shipping container that will be protected from crushing forces. In this manner, the pieces of the shipping container itself may be made lighter and thinner, and therefore less expensive, while the front and rear support members  301 ,  302  of the cabinet  300  of the appliance  303  serve as internal structure. Once the shipping container arrives at its final destination, there will be relatively less waste material to discard when the appliance  303  is placed into operation. 
         [0030]    Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the invention as defined by the claims.