Abstract:
Extruded profiles for use in assembling panels comprises a rigid peripheral frame of extruded material which serves as a base structure onto which are put flat surfacing materials such as glass, metal, wood or any of a variety of composite materials normally used for making cabinetry.

Description:
[0001]     This application is a continuation of parent application Ser. No. 10/699,194 filed Oct. 30, 2003  
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates generally to doors and cabinetry but more particularly to a method of assembly for extruded profile panels for multipurpose usage such as doors or cabinetry doors.  
       BACKGROUND OF THE INVENTION  
       [0003]     Extruded frames have been known and used for years, especially in the making of window frames as several patents attest to. Extruded profiles have also been used for creating various structures but many of these frames are meant to be permanent once they are assembled. Those that are meant to be dissassemblable usually require visible exposed screws or similar mechanical fastening means. These visible mechanical fastening means can mar an otherwise esthetically pleasing surface. There is therefore a need for an assembly process and method to make easily assemblable and disassemblable panels having invisible fastening means.  
       SUMMARY OF THE INVENTION  
       [0004]     In view of the foregoing disadvantages inherent in the known devices now present in the prior art, the present invention, which will be described subsequently in greater detail, is to provide objects and advantages which are:  
         [0005]     To provide for a set of simple parts used for assembling a variety of panel types in a simple, efficient and secure manner.  
         [0006]     To provide for a panel that, once assembled, does not show any visible screws or mechanical fasteners of any kind.  
         [0007]     To provide for a panel that allows for easy replacement of defective or broken parts and which can be assembled as a kit.  
         [0008]     To provide for a panel that is easy to manufacture without no need for bending or folding tools and does not require any welding of parts at all.  
         [0009]     To provide for a panel that can accept most of the standard accessories used in cabinetry such as hinges and handles.  
         [0010]     To attain these ends, the present invention generally comprises a rigid peripheral frame of extruded material which serves as a base structure comprised of base elements. Thed base elements are used in combination to create profiles. The profiles have slits and slots which are used in combination with threaded mechanical fasteners. The base elements are comprised of a first, second, third, and fourth element wherein the first element has a flat surface and a pair of hooks, the second element has an edge, channels, and a profile fin, the third element has a hookable groove, channels and clips, and the fourth element has a hook, and a trim face. The profiles combine to create a panel by having four profiles intersecting in order to form a frame having four sides.  
         [0011]     An intersection creating a corner wherein two intersecting profiles are being partially assembled by being loosely connected by way of the threaded mechanical fasteners moving within a range allowed by the slots and a spacing block used for setting a relative distance between the profiles.  
         [0012]     A first fascia is inserted and then the profiles are moved so as to completely encase the first fascia within the slits. The threaded mechanical fasteners are then tightened so as to secure the frame. A second fascia is inserted by bending it convexedly and then relaxing it so that the edges along its length can slide into the slits of the second element and the second fascia is slid along its length so that its first wide side can be fitted into one of the slits. A wide side has a gap filled in by the fourth element that engages the third element by way of the fourth element&#39;s hook which engages a complementary notch of the third element.  
         [0013]     The panel thus assembled is versatile (flush panel, glazed panel, door panel, single or double panel, etc.). It can be used indoors as well as outdoors, and its use includes kitchen cabinets, garage or basement storage cupboards but also for use in commercial applications such as laboratories, offices, workshops and so on.  
         [0014]     Because there are no visible mechanical fasteners, the finished surface can be made very smooth. Moreover, it can be made entirely of aseptic materials such as stainless steel and/or aluminum so it can produce cabinet frames and doors that will not harbor germs, which is ideal for hospitals and laboratories.  
         [0015]     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.  
         [0016]     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.  
         [0017]     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.  
         [0018]     Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.  
         [0019]     These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter which contains illustrated preferred embodiments of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]      FIGS. 1   abcd  cross sectional views of the base elements of the profiles.  
         [0021]      FIGS. 2   ab  cross sectional views of sample profiles.  
         [0022]      FIGS. 3   abc  front elevation of a frame being assembled in its open configuration with partial profiles in top elevations.  
         [0023]      FIGS. 3   de  continuing with the frame being assembled in semi closed, and closed configuration respectively.  
         [0024]      FIG. 4  Perspective view of frames prior to assembly with block spacer.  
         [0025]      FIGS. 5   abc  front face of a panel, top side of a panel, and side cross section of a panel, respectively.  
         [0026]      FIGS. 6   ab  Front elevation of a panel with hinges and and front elevation of a panel with a handle, respectively.  
         [0027]      FIGS. 7   abcd  Show various front elevations of combinations of profiles to make a variety of panels.  
         [0028]      FIGS. 8   ab  front elevation of a glazed panel and top elevation of the profile, respectively.  
         [0029]      FIGS. 9   abc  side, front and back views of a panel, respectively. 
     
    
     DETAILED DESCRIPTION  
       [0030]      FIGS. 1   a - d  show the 4 base elements from which all profiles are built. Element  1   a  ( 100 ) has a flat surface ( 12 ) and a pair of hooks ( 14 ).Element  1   b  ( 200 ) has an edge ( 16 ), channels ( 56 ), and a profile fin ( 18 ). Element  1   c  ( 300 ) has a hookable groove ( 20 ), channels ( 56 ), and clips ( 46 ). Element  1   d  ( 400 ) has a little hook ( 22 ) and a trim face ( 24 ). Element  1   d  ( 400 ) has a little hook ( 22 ) and a trim face ( 24 ).  
         [0031]     Using these elements in combination produces profiles ( 500 ,  600 ) such as in  FIGS. 2   ab  where elements  1   b ,  1   c , and  1   d  ( 200 ,  300 ,  400 ) are co-joined to create profile  2   a  ( 500 ). Using elements  1   a ,  1   b , and  1   c  ( 100 ,  200 ,  300 ) produces profile  2   b  ( 600 ). Element  1   c  ( 300 ) has legs ( 46 ) which snap into receiving protrusions ( 48 ) which are part of element  1   b  ( 200 ).  
         [0032]     Profiles  2   a  ( 500 ) and  2   b  ( 600 ) show other components not part of the profiles per se such as a locking trim ( 26 ) which has both a decorative and a useful purpose which will be explained later.  
         [0033]     Once a profile ( 500  or  600 ) is partially assembled, finishing surfaces known as fascia ( 28 ) are inserted, but more on that later. With these two profiles ( 500  and  600 ), a frame ( 30 ) can be assembled.  
         [0034]     Looking at  FIG. 3   a , the first step in assembling the frame ( 30 ) is in having corner threaded mechanical fasteners ( 32 ), that is one pair per each corner of the frame ( 30 ) in position AA as determined by the position of threaded mechanical fasteners ( 32 ) in relation to their slots ( 34 ).  
         [0035]     The vertical section of the frame ( 30 ′) has two vertical slots while the horizontal section of the frame ( 30 ″) has two horizontal slots and all of the slots are designed to afford a certain range of motion to each section of the frame ( 30 ′,  30 ″).  
         [0036]     At any rate, the orientation of the slots ( 34 ) is always so that their long side is running parallel to the length of that particular section of frame ( 30 ′or  30 ″), whether these sections are from profiles  2   a  or  2   b  ( 500 ,  600 ).  
         [0037]     At the intersection of both frames ( 30 ′,  30 ″) Only elements  1   b  ( 200 ) as per  FIGS. 3   bc  but beyond the intersection, element c ( 300 ) can be added. In position AA the frame ( 30 ) is expanded and can receive a first fascia ( 28 ) (shown in  FIG. 5   a ), the size of the fascia ( 28 ) is such that it is slightly larger than what the inner perimeter of the frame ( 30 ) will be once closed, that way, when moving from position AA to position BA as per  FIG. 3   d , where the vertical section of the frame ( 30 ′) is closed in, the edges of the fascia are inserted into slits ( 42 ) as seen in  FIG. 5   bc.    
         [0038]     The threaded mechanical fasteners ( 32 ) are still accessible and remain accessible even when moving to position BB as per  FIG. 3   e  where both the horizontal and vertical sections of the frame ( 30 ′,  30 ″) are closed in. Once closed in, the mechanical fasteners can be tighten to secure the assembled frame. Of course, the order in which the frame is closed in whether the horizontal side of the frame or the vertical side is of no importance.  
         [0039]      FIG. 4  shows a block spacer ( 70 ) which lies between frame ( 30 ′) and frame ( 30 ″), the thickness of the block spacer ( 70 ) depends upon the thickness of the edge ( 16 ).  
         [0040]     An assembled panel ( 38 ) can be seen in  FIG. 5   a  where the frame ( 30 ) holds in the fascia ( 28 ). After the first fascia ( 28 ) is put in, a solid core ( 36 ) can be fitted inside the frame ( 30 ) to add strength to the panel ( 38 ). In the configuration shown in  FIGS. 5   abc , the frame ( 30 ) is made up of element  1   b  ( 200 ) for the top and bottom horizontal frame ( 30 ) and profile  2   b  ( 600 ) is used for the left and right sides.  
         [0041]     Of course permutations are possible and element  1   b  ( 200 ) could be placed vertically and profile  2   b  ( 600 ) horizontally, it all depends on the orientation of the panel ( 38 ) as a whole and the terms horizontal and vertical are strictly to facilitate description in the context of  FIGS. 5   abc.    
         [0042]     Also,  FIG. 9   abc  shows both the front and back of a panel with the difference when the front side  FIG. 9   b  has element  1   d  ( 400 ) at the top and  FIG. 9   c  which shows the back of the panel without element  1   d  ( 400 ). The apparent frame is the edge ( 16 ) of element  1   b  ( 200 ).  
         [0043]     As can be best appreciated from  FIG. 4   b , fascia ( 28 ) is inserted into slits ( 42 ) of element  1   b  ( 200 ) while the solid core ( 36 ) is encased within elements  1   a  ( 100 ) on at least two sides, possibly all four.  
         [0044]     This is but one of many possible panel ( 38 ) configurations. Inserting a second fascia ( 28 ′) as in  FIG. 2   a  for the second face of the panel ( 38 ) is different than inserting the first fascia ( 28 ). As explained earlier, after inserting the first fascia ( 28 ) the frame ( 30 ) is closed in so that the second fascia ( 28 ′) can hardly be inserted in a way where its perimeter is inserted into the slits ( 42 ).  
         [0045]     In order to achieve insertion of the second fascia ( 28 ′), it is first bent convexedly and then relaxed so that the edges along its length can slide into slits ( 42 ) of element  1   b  ( 200 ) and then it is slid along its length so that its first wide side can be fitted into yet another slit ( 42 ).  
         [0046]     At this point, 3 out of 4 sides are properly inserted into slits ( 42 ), now for the second wide side, the final side, the second fascia ( 28 ′) having been cut slightly shorter in length than the first fascia ( 28 ), has a gap left between it and the fourth slit ( 42 ), this gap is filled in by element  1   d  ( 400 ) as per  FIG. 2   a  which is fitted so that its little hook ( 22 ) engages a  20  complementary notch ( 44 ), part of element  1   c  ( 300 ).  
         [0047]     Inserting element  1   d  ( 400 ) thusly still leaves a little gap which is filled by the spacer trim ( 26 ) inserted between element  1   d  ( 400 ) and the edge ( 16 ).  
         [0048]     This method of installation, with minor variations, is applied to the various panel ( 38 ) configurations. Looking back at  FIG. 5   a , one side shows a configuration as per  FIG. 7   a  while the other side, because it is framed using element  1   a  ( 100 ) would look more like  FIG. 7   b  or  FIG. 7   d.    
         [0049]     For a panel with glass as per  FIG. 8   a , profile  2   a  ( 600 ) is used with a pane of glass ( 50 ) along with element  1   a  ( 100 ) on either side acting as a framing device. A seal ( 52 ) can be readily accepted by element  1   c  ( 300 ). Sealing gaskets ( 54 ) can also be inserted in available channels ( 56 ) made into element  1   b  ( 200 ) and element  1   c  ( 300 ).  
         [0050]     Element  1   b  ( 200 ) can have different thicknesses while keeping the rest of its profile identical, this allows for various thicknesses in panels.  
         [0051]     Doors such as for cupboards can be made by adding hinges ( 58 ) and a handle ( 60 ) as in  FIGS. 6   ab.    
         [0052]     As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.  
         [0053]     With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.  
         [0054]     Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.