Patent Publication Number: US-10779643-B2

Title: Cabinet system and method for assembling a cabinet system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to PCT Application No. PCT/US2017/049149 filed Aug. 29, 2017 and U.S. Provisional Patent Application No. 62/382,105, filed Aug. 31, 2016, the entire contents of which are incorporated by reference herein. 
    
    
     BACKGROUND 
     The present disclosure relates to cabinet systems, and more particularly to components of modular cabinet systems and methods for assembling and disassembling such cabinet systems. 
     SUMMARY 
     A cabinet system includes a frame at least partially defined by a plurality of vertical legs and a shelf defining a first plane and supported by the plurality of vertical legs. The legs extend transverse to the first plane. A countertop is supported by the plurality of vertical legs. A body panel is coupled to the frame and a door is coupled to the frame and operable to selectively provide access to the shelf. Posts are fastened to the frame and extend transverse to the first plane. The body panel and the door are coupled to the frame via the plurality of posts. 
     A cabinet system includes a frame having a plurality of frame members securable to one another and first and second mounting brackets, each of which is removably couplable to one of the frame members and presents an extension. A panel is configured for attachment to the frame via the extension of the first mounting bracket and the extension of the second mounting bracket. 
     A cabinet system includes a frame at least partially defined by a plurality of vertical legs and a shelf defining a first plane and supported by the plurality of vertical legs. The vertical legs extend transverse to the first plane. A countertop is supported by the plurality of vertical legs. A body panel is coupled to the frame and has a plurality of apertures. A door is coupled to the frame and operable to selectively provide access to the shelf. The door has a plurality of apertures. Posts are coupled to the frame and extend transverse to the first plane. Each post of the plurality of posts is configured to extend through (i) an associated aperture of the plurality of apertures in the body panel to couple the body panel to the frame or through (ii) an associated aperture of the plurality of apertures in the door to couple the door to the frame. 
     A cabinet system includes a frame having a plurality of frame members securable to one another and first and second mounting brackets, each of which is configured to removably couple to one of the frame members. Each of the first and second mounting brackets includes a post. A panel has a first aperture and a second aperture. The post of the first mounting bracket is configured to extend through the first aperture and the post of the second mounting bracket is configured to extend through the second aperture to couple the panel to the frame. 
     Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a cabinet system. 
         FIG. 2A  is a perspective view of a frame of the cabinet system of  FIG. 1 . 
         FIG. 2B  is an enlarged perspective view of a portion of a vertical leg of the frame. 
         FIG. 3A  is a perspective view of a lower post assembly. 
         FIG. 3B  is a perspective view of an upper post assembly. 
         FIG. 4  is a perspective view of a door assembly. 
         FIG. 4B  is an enlarged perspective view of a tab and lower post assembly arrangement of the door assembly of  FIG. 4A . 
         FIG. 5  is an internal front view of a side panel assembly. 
         FIG. 5B  is an enlarged perspective view of a tab and lower post assembly arrangement of the side panel assembly of  FIG. 5A . 
     
    
    
     Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a cabinet system  10  includes a plurality of support beams or legs  12 , shelves  14 , drawers  16 , panels  20 A,  20 B, and a countertop  18 . Collectively, the legs  12  and shelves  14 , in addition to connectors  30  and crossbeams  38 , form a frame  74 . Although shown as a floor-mounted base kitchen cabinet system, the cabinet system  10  may alternatively be a non-floor mounted cabinet system, such as a wall-mounted cabinet system. 
     Referring also to  FIG. 2A , the beams or legs  12 , which may comprise, e.g., four legs, six legs, eight legs, etc., in total depending on the configuration of the system  10 , each have a square cross-section with filleted or chamfered corners and extend between a foot end  24  (at a ground surface) and an upper end  26  (abutting the countertop  18  when the cabinet system  10  is assembled). The legs  12  may alternatively have a rectangular, circular, or other suitable cross-section. As shown in greater detail in  FIG. 2B , each leg  12  includes indents  28  spaced at intervals (e.g., one inch intervals) along the length of the leg  12  and positioned at each fillet or chamfer (or otherwise at one or more, but preferably each, of the corners) around the leg perimeter. 
     Each shelf  14  includes an outer frame portion  32  and an inner support portion  34 . The outer frame portion  32  includes a plurality of outer frame members  36  terminating and fixed to connectors  30 . Connectors  30  are in the form of tapered collets made of steel, or other suitable materials. The connectors  30  are hollow and include a rectangular interior profile sized to slide over the legs  12  and engage inner nylon collets (not shown) axially fixed to the indents  28  on the legs  12 . The inner nylon collets may include two halves that snap into engagement with one another, protrusions within the two halves engaging the indents  28  upon assembly. The inner nylon collets are tapered, allowing the connectors  30  to slidably engage the external profile of the inner collets without allowing further axial translation. Therefore, the connectors  30  are only removable by axial translation upward along the leg  12 . As shown, each connector  30  is fixed to two of the outer frame members  36 , forming a right angle therebetween. More particularly, the outer frame members  36  include first members  36 A defining the depth of the shelf  14  and second members  36 B defining the width of the shelf  14 . As shown, the second members  36 B and the first members  36 A collectively form a rectangular sub-frame. 
     The inner support portion  34  includes cross members  40  spanning the gap defined by the outer frame portion  32 . As shown in  FIG. 2A , the inner support portion  34  may include members  40  of similar length to the second members  36 B to span the width of the gap. Alternatively, or additionally, the inner support portion  34  may include members of similar length to the first members  36 A to span the depth of the gap. Further still, as shown in  FIG. 2A , the shelf  14  may include a wire frame  42  including rigid wires spanning the gap in one or more directions. Further, crossbeams  38  may span between legs  12  or outer frame members  36  to provide additional structural rigidity while not necessarily functioning as a shelf. 
     Drawers  16 , such as the ones shown in  FIG. 1 , may be utilized in place of one or more of the shelves  14 . For example, as shown, the cabinet system  10  includes two shelves  14  on a left side and four drawers  16  on a right side. The drawers may be attached or coupled to the legs  12 , frame members  36 , or other crossbeams  38  via a rail system (not shown). 
     The countertop  18 , when assembled, is located above the shelves  14  and legs  12 , extending in an upper plane transverse to the lengthwise direction of the legs  12  (i.e., parallel to the shelves  14 ). The countertop  18  may include first apertures  44  for sinks  46  and second, smaller apertures  48  for electrical lines, water lines, or other utilities. As shown, the countertop  18  overhangs the legs  12  to define a lip  50  on the front and sides of the cabinet system  10 . The countertop  18  may, for example, be made of metal (e.g., food-grade stainless steel), plastic, ceramic, wood, concrete, or stone. 
     Panels  20 , such as body panels  20 A and door panels  20 B, when assembled, are located around the sides of the cabinet system  10  to enclose the shelves  14 , and prevent access thereto. The body panels  20 A cover an opening defined between two of the legs  12  and prevent access to the interior volume of the shelves  14  through the opening at all times. The body panels  20 A may be formed of a single sheet of metal, cut and bent to size. Portions  52  of the body panel  20 A may be bent about an edge of the panel  20 A to provide additional structural rigidity. As shown, the body panels  20 A are rectangular, including four corners, each corner associated with a tab  54  ( FIG. 5 ) extending transverse to the plane of the panel. As shown, the body panel  20  includes side portions  22  extending from the edges of the panel  20  (i.e., bent at ninety degree angles), the side portions  22  each supporting two of the tabs  54 . Each tab includes an aperture  56  sized to engage a mounting bracket or post assembly  58 , as will be further described below. 
     As shown in  FIG. 4 , the door panels  20 B are rotatable about an axis  60  upon assembly between a closed position and an open position such that the door panels  20 B hinder access to the shelves  14  when in the closed position, and provide access to the shelves  14  when in the open position. The axis  60  is located adjacent an inside edge  62  of the door panel  20 B. The door panels  20 B may be formed of a sheet of metal, cut and bent to size. Further, a handle  64  may be fixed to the door panel  20 B adjacent an outside edge  68  of the door panel, the outside edge  68  opposite the inside edge  62 . Portions  66  of the door panel  20 B may be bent about an edge of the door panel  20 B to provide additional structural rigidity. As shown, the body panels  20 B are rectangular, including four corners, two corners associated with the inside edge  62 , the other two corners associated with the outside edge  68 . The corners associated with the inside edge  62  each include a tab  70  extending transverse to the plane of the door panel  20 B. Each tab  70  includes an aperture  72  sized to engage a mounting bracket or post assembly  58  as described below. Both the body panels  20 A and the door panels  20 B are supported on the frame  74  of the cabinet system  10  via a plurality of post assemblies  58 . 
     As shown in  FIGS. 3A-3B , the post assemblies  58  include a bracket  76  and a plurality of extensions or posts  84 . 
     The cross-section of the bracket  76  is generally C-shaped with three complete sides  76 A,  76 B,  76 C and a fourth side  76 D, which defines a centered space or discontinuity or gap  86 . Sides  76 A,  76 B,  76 C and  76 D define an interior opening  88  sized to accommodate an individual leg  12  of the cabinet system  10 . Specifically, the opening  88  is configured to receive one of the legs  12  such that the assembly  58  is slidable along the length of the leg  12 . Therefore, the post assemblies  58  may include circular, rectangular, or other internal cross-sections to accommodate the cross-sectional shape of the legs  12 . 
     The fourth side  76 D of the post assembly  58  further defines two channels  78 ,  80  axially aligned with one another and extending through each respective portion of fourth side  76 D. The first channel  78  includes a first circular opening  90  on side  76 C with a first cross-sectional area at a first end and a second circular opening at the gap  86  (not shown) having a cross-sectional area less than the first cross sectional area. The channel  78  abruptly changes in cross-sectional area between the first opening  90  and the second opening and serves as a countersink for a fastener as well as a travel stop. The portion of the channel  78  with the first cross-sectional area may be unthreaded and the portion of the channel  78  with the second cross-sectional area may be threaded. 
     The second channel  80  includes a circular opening  92  located at the gap  86  and axially aligned with the second circular opening of the first channel  78 . The cross-sectional area of the second channel  80  is constant and is similar to the circular cross-sectional area of the adjacent portion of the first channel  78 . The second channel  80  may extend axially from the gap  86  through the outside edge of side  76 A, or may terminate before reaching the outside edge of side  76 A. The second channel  80  may additionally be threaded. Alternatively, the second channel  80  may mirror the first channel  78  (i.e., including two portions, a first larger portion and a second smaller threaded portion) such that the post assembly is mirrored about the gap  86 . 
     A fastener  96  (e.g., screw, bolt) may be threaded into the first and second channels  78 ,  80 . The head  98  of the fastener  96  as assembled is located within the unthreaded portion of the first channel  78  such that it does not protrude outside of the post assembly  58 . Alternatively, the channels  78 ,  80  may be unthreaded, and a nut (not shown) may be used opposite the fastener  96  to secure the fastener  96  relative to the post assembly  58 . 
     The post assemblies  58  further include two posts  84  extending from the bracket  76 . The posts  84  are cylindrical and extend at an orientation orthogonal to a surface  82  of the bracket  76 . As illustrated in  FIG. 3B , the posts  84  are not integral to the bracket  76  but are coupled to the bracket  76  via a recess  94  using a secondary assembly process (e.g., friction welding, interference fit, press fit, adhesive). Alternatively, the posts  84  may be formed integrally with the bracket  76 . 
     The posts  84  of different brackets  76  are of different extension lengths depending upon their final assembly location within the cabinet system  10 . As shown in  FIG. 3A , “lower” post assemblies  58 A include posts  84 A that extend up from the surface  82  and are a first length (e.g., 0.75 inches, 1 inch, etc.) along a longitudinal axis  100 A,  100 B. As shown in  FIG. 3B , “upper” post assemblies  58 B include posts  84 B that extend from the side opposite to surface  82  and are a second length along a longitudinal axis  100 C,  100 D, in which the second length is longer than the first length (e.g., 0.25 inches longer, 0.5 inches longer, etc.). 
     Assembling the cabinet system  10  includes assembling the frame assembly  74 , attaching the countertop  18 , and adding the body and door panels  20 A,  20 B. The frame assembly  74  is assembled by locating the legs  12  relative to one another and coupling the shelves  14  to the legs  12  by positioning the connectors  30  about the respective legs  12  at a desired height along the legs  12 . Specifically, the nylon portion of the connector  30  is placed at the desired height, engaging with the indents  28 , and the steel portion of the connector  30  is slid into engagement with the nylon portion. Depending on the structure of the shelf  14 , the associated connectors  30  may need to be positioned about the legs  12  concurrently. Drawers  16  are also mounted using a rail system (not shown). As shown in  FIG. 1 , the countertop  18  is attached to the frame  74  at the legs  12  or the outer frame portion  32  of the shelves  14 . The countertop  18  may be attached via adhesive or fasteners (e.g., screws, bolts, etc.). Utility connections in the form of faucets, sinks  46 , electrical outlets, etc., may be attached to the countertop  18  before or after assembly to the frame  74 .  FIG. 2  is but one example of a large number of possible configurations of leg, shelf, and drawer spacing for an assembled cabinet system  10 . 
     Assembling one of the door panels  20 B includes positioning two post assemblies  58 A,  58 B along a respective leg  12 , thereby coaxially aligning the respective posts  84 A,  84 B of the upper and lower post assemblies  58 A,  58 B. Specifically, one post  84 A,  84 B from each post assembly  58 A,  58 B will align with the axis  60  of the door panel  20 B adjacent the inside edge  62  when assembled. The post assembly  58 A,  58 B may be slid over an end of the leg  12  and translated to the desired height. Alternatively, the gap  86  in the bracket  76  may permit elastic deformation of the post assembly  58 A,  58 B such that the gap  86  widens to the size of the leg  12 , allowing for direct positioning of the assembly  58 A,  58 B at the desired height. Once the assembly  58 A,  58 B is located at the desired height on the leg  12 , the fastener  96  is positioned within the channels  78 ,  80  and tightened, pulling the second channel  80  towards the first channel  78  and decreasing the size of the gap  86  and consequently the interior opening  88 , thereby securing the respective post assembly  58 A,  58 B relative to the leg  12 . 
     The spacing between the two post assemblies  58 A,  58 B on a leg  12  permits the assembly of the door panel  20 B to the leg  12  without further movement of the post assemblies  58 A,  58 B. Specifically, after securing assemblies  58 A,  58 B to a leg  12 , the shortest distance between axially aligned posts  84 A,  84 B is less than the distance between the aligned tabs  70  on the door panel  20 B. Therefore, to assemble the door panel  20 B to the post assemblies  58 A,  58 B, the aperture  72  in the upper tab  70  of the panel  20 B is slid onto the post  84 B of the upper post assembly  58 B until the lower tab  70  clears the post  84 A in the lower post assembly  58 A. As shown in  FIG. 4B , the door panel  20 B is then lowered onto the post  84 A of the lower post assembly  58 A, i.e., the aperture  72  in the lower tab  70  is slid onto the post  84 A. Since the length of the upper post  84 B is greater than the length of the lower post  84 A, assembly is completed without moving or adjusting either post assembly  58 A,  58 B, with each post  84 A,  84 B extending through one of the apertures  72  and providing support and an axis of rotation ( 60 ) for the door panel  20 B. In some assemblies, the lower post  84 A may be capped to prevent removal of the door panel  20 B without first removing the cap. 
     Assembling one of the body panels  20 A includes positioning four post assemblies  58 A,  58 B, and in particular locating two post assemblies  58 A,  58 B along one of the legs  12  and locating the other two post assemblies  58 A,  58 B along another of the legs  12 , which coaxially aligning the posts  84 A,  84 B of the lower and upper post assemblies  58 A,  58 B. Assembly of the post assemblies  58 A,  58 B to the legs is carried out in a similar manner to the assembly of the door panels  20 B. 
     The spacing between the upper post assemblies  58 B and the lower post assemblies  58 A on each leg permits the assembly of the body panel  20 A to the post assemblies  58 A,  58 B without further movement of the post assemblies  58 A,  58 B. In order to assemble the body panel  20 A to the post assemblies  58 A,  58 B, the aperture  56  in each upper tab  54  is slid onto the posts  84 B of the respective upper post assemblies  58 B until the lower tabs  54  clear the posts  84 A in the lower post assemblies  58 A. As shown in  FIG. 5B , the body panel  20 A is then lowered onto the posts  84 A of the lower post assemblies  58 A. Similar to the assembly of the door panels  20 B to the frame  74 , assembly is completed without moving any post assemblies  58 A,  58 B, and each post  84 A,  84 B extends through one of the apertures  56 , providing support for the body panel  20 A and preventing a force transverse to the plane of the body panel  20 A from removing the body panel  20 A. 
     If a body panel  20 A is located adjacent another body panel  20 A or a door panel  20 B, the other of the posts  84 A,  84 B not utilized by the body panel  20 A may be used to secure an adjacent panel  20 . Therefore, adjacent panels  20  can be located at similar heights. Further, door panels  20 B and body panels  20 A can be swapped or removed to vary the assembly without removing or moving the post assemblies  58 . 
     Various features of the disclosure are set forth in the following claims.