Patent Publication Number: US-2010116762-A1

Title: Closet and Cabinet Cleat

Description:
FIELD OF THE INVENTION 
     The present invention relates to a cleating system for use in supporting cabinetry and/or closet components. 
     DESCRIPTION OF RELATED ART 
     Closets have traditionally taken a number of forms in residential and commercial applications. Many companies today are in the market of providing custom closets. Furthermore, hardware stores, in particularly big box hardware stores, provide do-it-yourself closet assemblies. 
     Many of these prior art systems rely on traditional cabinet techniques such as locating studs and screwing rear panels of cabinet boxes directly to studs. In typical closet installations, it is often advantageous to find studs and then screw retention systems to those studs such as a bracket to support other components of the closet system such as a wire closet system. In other applications sleeve anchor/screw assemblies are utilized in systems designed to engage just sheetrock. While various competitors provide closet systems to the market that are attractive and/or functional for the market, there remains a perceived need for a fast and efficient system and method of installing closets which can greatly improve the efficiency of the closet and/or cabinet installation process while continuing to provide attractive options to the market place. 
     Specifically, a need exists to potentially eliminate locating and marking each specific framing stud and then determining where individual supports should be located. Connecting separate supports to specific framing studs while maintaining an installed product level as would be expected to the users of these systems can be difficult, or at least time consuming with many prior art systems known to the applicant. 
     Furthermore, although some companies have been powder coating wood specifically MDF (medium density fiberboard) for a number of years, the articles these companies have printed routinely discuss the precision required to maintain moisture content as well as a need for a carefully maintained elevated surface temperature of wood based MDF (medium density fiberboard) prior to applying a powder coating and then curing for consistent results. 
     In wood powder coated products purchased by the applicant, the applicant has observed that a corona occurs where a connection is made to the wood product by some type of hanger. A corona is an area of paint or coating of poor quality whereby in the case of a painted part may be only partially painted and/or unpainted at that specific location. A corona can be as small as an eraser head or even be as big as a dime, quarter or larger. Normally, the provider is careful to ensure that this corona occurs on an obverse side of the part painted (i.e., a side which is not viewed when installed). Even the samples provided by a provider to applicant reflecting coating options have a dime sized corona covered by a sticker on a back side of the samples. However, if a part is to be utilized for which visual access may be had on both sides such as an elevated shelf such as a closet shelf, a corona would likely result in a failing quality for the part. 
     Orange peel defects are possible in powder coated wood based on uneven coating applications of a part. This may not be particularly noticeable in some applications may be extremely pronounced and unacceptable in others. 
     The applicant became interested in a possibility of powder coating MDF and possibly other wood products themselves. As applicant was not particularly interested in the prospects of modifying an existing metal powder coating set up to have a capability of providing the surface temperatures in that elevated range prior to powder coating, the applicant discovered a need to provide alternative methods of powder coating MDF and possibly other wood based products as well as a need to eliminate unsightly coronas. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present embodiment of the present invention to provide a closet and/or cabinet installation system having an improved cleat which cooperates with framing studs behind the wall or the one framing stud behind a wall such as a sheetrock wall which can be relatively quickly installed in a level manner and then the remainder of the closet cleat quickly assembled relative to the cleat connected to the wall. 
     It is another object of the present invention to provide improved closet and/or cabinet installation system. 
     It is another object of the present invention to provide an improved closet and/or cabinet system principally comprised of powder coated wood components. 
     It is another object of the present invention to provide an improved cleat for use with closet and cabinet installations. In accordance with the presently preferred embodiment of the present invention, a cleat connection system is provided whereby an elongated cleat member is provided with a plurality of indications preferably in the form of bores at specific intervals with corresponding indications spaced 16 inches from other indications (i.e., the expected stud spacing). One example might be an indication such as at 1 inch intervals, 2 inch intervals, 4 inch intervals, 8 inch intervals and/or 16 inch intervals. Accordingly, when a stud is located and a connector such as a screw goes through the indication, the operator can quickly determine where to drill the next connector in order to provide a secure connection of the cleat to the wall (presuming that the framer correctly observed the 16 inch stud intervals as specified by code). 
     Accordingly, a quick measurement to measure the desired height for the cleat would preferably be recommended by the manufacturer at a location on a first stud through a first indication with a first connector. With the first connector in the first stud, then a second connector can be provided through a second indication in a second stud with the cleat being verified level during the process such as with a level. Additional connectors can be provided through the cleat as desired such as at additional 16 inch intervals or otherwise on the wall. With the cleat at a desired location as specified by the manufacturer, the cabinet and/or closet can be hung thereon. The side wall members are preferably equipped with a cutout which has a cooperating foot extending into the cutout which is received by shoulder on an upper end of the cleat. Gravity may assist in maintaining the side panel portion in a desired location. Then, additional components can be connected to side wall members such as shelving, bottoms, tops (which may be securely connected thereto to form a box-like structure rather than an ability to have adjustable shelving in some embodiments), if not already connected as a cabinet portion. Furthermore, most side panels can be utilized to assist in supporting closet rods and/or shelving with or independent of box type cabinet structure or even cabinetry in some embodiments. 
     Cleats may have at least an upper angled shoulder at an upper surface as well as possibly having a symmetrical surface towards the bottom surface so that the cleat can be utilized in an upside down configuration in an identical manner. The top of the cleat provides a flat portion to assist in maintaining a rear of a shelf stable thereon. Cleats, shelves, side panels, and possibly other components may preferably be powder coated wooden products that are powder coated, preferably at lower temperatures, such as less than 200 F, and more preferably less than 150 F, if not less than 100 F, in a presently preferred embodiment. 
     A shelf bracket may be retained to the cleat through one or more of the indicators. The bracket may or may not be metal and provide an upper surface extending away from the wall to be coplanar with the flat portion of the upper surface of the cleat to assist in supporting a shelf thereon. The bracket extends in a cantilevered manner and possibly is provided with a truss style brace. A closet rod may also be connected along a portion of the bracket such as in a hook. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which: 
         FIG. 1  is a perspective view of a closet system showing use of a cleat support system of a presently preferred embodiment of the present invention; 
         FIG. 2  is an exploded view of the portion shown in Detail A of  FIG. 1 ; 
         FIG. 3  is a side plan view of a Detail A showing a corner of the system shown in  FIG. 1 ; 
         FIG. 4  is a perspective view of Detail B shown in  FIG. 1 ; 
         FIG. 5  is a side plan view of Detail B shown in  FIG. 4 ; 
         FIG. 6  is an alternatively preferred embodiment of a cleat as is used in  FIG. 1 ; 
         FIG. 7  is a front plan view of the cleats shown in  FIGS. 1 and 6 ; 
         FIG. 8  shows a diagrammic view of a powder coating line transporting a wooden article, such as a shelf shown in  FIG. 1 , towards a powder coating station in accordance with a presently preferred embodiment of the present invention; 
         FIG. 9  shows side plan view of a preferred embodiment of a staple remover removing a hanger from a product coated as shown in  FIG. 8 ; and 
         FIG. 10  shows a front plan view of the detail A shown in  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows a system  10  of the presently preferred embodiment of the present invention. This system  10  is configured for a closet but other systems could be configured for cabinetry whether for kitchen cabinetry, washroom cabinetry, shelving and/or garage cabinetry and/or shelving. Illustrated in  FIG. 1  are a plurality of elongated cleats  12 , 14 , 16  or cleat portions which are located on two walls  18 , 20  meeting at corner  22 . 
     Cleats  12 , 14 , 16  are maintained at a top edge as parallel to the floor  24  and/or ceiling (which are not shown in detail but would be understood by those of ordinary skill in the art). Additional cleats, namely cleats  26 , 28 , 30  are useful to support shelves independent of supporting planar vertical panels such as panel  32  as a single panel or panels such as  34 , 36  or  38 , 40  which essentially form portions of cabinetry such as corner cabinets  42  which has an open front or book shelf style cabinet  44 . Cabinet doors could also be provided as would be understood by those of ordinary skill in the art. 
     Cabinet portions  42 , 44  preferably have a top  46 , 48  as well as bottom  50 , 52  which can be securely connected to respective side panels  34 , 36  and  38 , 40 . By securely connecting the top  46 , 48  and the bottoms  50 , 52  to the respective side panels, namely  34 , 36  and  38 , 40 , a rigid cabinet member such as  42 , 44  can be provided. Shelves such as shelves  54 , 56 , 58 , 60 , 62 , 64  can be adjustable type shelving as is known in the art or at least some of them can be fixed at specific positions to possibly provide further structural integrity to the respective cabinets  42 , 44  at least in some embodiments. 
     The system  10  is believed to be a significant advantage over prior art designs in that it can be installed extremely fast. Specifically, the cleats  12 , 14 , 16  can be placed at a desired elevation which may be specified by the manufacturer depending on the height of panels such as panel  32 , 34 , 36 , 38 , 40  and/or closet rods  122 , 132 . Uppermost portions of upper shoulders  84  of cleats  12 , 14 , 16  can form a horizontal plane parallel to a floor or ceiling. Cleats  14 , 16  meet at a right angle at corner  22 . 
     As can thus be seen from  FIG. 7 , cleats are preferably provided with a plurality of indications  66  on a surface such as front face  68  of one or more of the various cleats such as cleat  16  illustrated. In order to secure the cleat  16 , the wall indication  66  are preferably provided at intervals such as at 1¼ inches (i.e., 32 mm) but 1 inch spacing could also be desirable so that one could quickly connect cleat  16  through indication  66  and then drive another connector through another indication to connect to two spaced apart studs behind the wall  20  (i.e., at 16 inch intervals). Cleats  16  are a length sufficient to span two studs on the wall  20 . Specifically, the operator will most likely utilize a stud finder or start at a corner and secure one portion of the cleat  16  through an indicator  66  to a stud and then skip the correct interval to an anticipated location of a next stud and provide another connector therethrough while maintaining the cleat  16  level. 
     Indications  66  are preferably through holes or bores such as 3/16 of an inch (5 mm) and may be spaced at other intervals as well such as 2 inches, 4 inches, 8 inches, 16 inches or other desired spacing. Bores extend through cleat (i.e., from the front to the back surface). Furthermore, although one row  70  of indications  66  is illustrated, multiple rows  70  could be provided. It is preferred that the spacing per length  72  be maintained relatively consistent, such as 32 mm or otherwise, as it relates to indicators  66 . It will be understood that the spacing relative to the height  74  may be varied as so desired. By locating the indications  66  at the center of cleat  16 , applicant has not experienced a significant splitting of the cleat  16 . Other and/or additional locations could be employed in other embodiments such as towards a top of the cleat  16  as is shown in phantom in  FIG. 7 . 
     Cleat  16  is preferably provided as a painted medium density fiberboard (MDF) product. Lengths  72  as well as heights  74  can be as desired by the manufacturer. Anticipated lengths  72  may be 5 or 8 feet and the height  74  may be four inches, but other lengths and heights could be provided. After installing the first cleat such as cleat  16 , and the other cleats  12 , 14 , the cleats  12 , 14 , 16  can then support vertical panels such as panels  32 , 34 , 36 , 38  which can then be installed. Panels  32 , 34 , 36 , 38  may be similarly or dissimilarly constructed. Cleats or cleat portions can provide a coplanar upper surface  76  relative to adjacent cleats  14 , 16 . Depending on the length of the closet or application, multiple cleats or cleat portions such as cleats  12 , 14  may need to be placed end  78  to end  80  to continue an overall length as is shown in  FIG. 1 . 
     Cabinets  42 , 44  may be prebuilt or built on site and/or be apart until portions are hung from the cleats  12 , 14 , 16  as will be described in further detail below. Cabinet  42  is a corner cabinet. Shelf  120  and portions of cleats  12 , 14  extend between cabinets  42 , 44 . 
     The first panel  32  is hung on cleat  16  as is shown in  FIG. 1  and shown in better detail in  FIGS. 2 and 3 , specifically with cleat  16  connected to wall  20  vertical panel  34  which may at least in some embodiments have a downwardly extending foot  82  extending into cut out  81  which is received on a shoulder  84  of the cleat  16  as can be seen in  FIG. 3  and as will be understood by review of  FIG. 2  as the vertical panel  32  is placed on the cleat  16 . The shoulder  84  is preferably provided with an upper planar portion  88  spaced by gap  89  from wall  20  as may be utilized at least in some embodiments to assist in supporting a rear  90  of shelf  92  along with adjustable shelf brackets (not shown) which are utilized through bores  94 , 96  to support the shelf  92 . The foot  32  is retained in gap  39  when installed. Depending on the length of the shelf  92 , intermediate shelf support brackets  98  may also prove useful. A rear surface  93  of the panel  32  can contact the wall when installed. The first panel has left and right faces (the left face  95  illustrated, the right face opposite thereto) with the cutout  81  extending therebetween. 
     The embodiments of  FIGS. 1-3  provide a one angled cleat having a first angled upper shoulder  18  forming an acute angle with wall  20  when installed. The foot  82  contacts the angled upper shoulder  18  along the angle which assists in providing a force to pull the panel  32  and others towards wall  20 . At a base  100  of the cleat  16  a flat bottom  102  may be found useful for increased stability against a wall  20  when installed. Other embodiments may take different forms such as that of  FIG. 6  which has a second angle  104 . These other embodiments are useful as it means that there is effectively no top and bottom of the cleat  16  and in such an embodiment, the top and bottom are the same. This provides part symmetry and an easy install as the angle  104  together with the shoulder  106  allows the option of either end to the upper portion. Notch  86  is useful to provide a void above and/or behind the shoulder when installed to potentially assist in locating the panel  32  on the cleat  16  and/or removing the panel  32  from the cleat  16 . 
     Regardless of which cleat embodiment is utilized, with cleats  12 , 14 , 16  positioned various panels such as  32 , 24 , 26 , 28 , 40  can be positioned at their approximate locations and the shelf  92  can be installed with the cleats  12 , 14 , 16  extending past one of the left and right faces of the panel  32 , 24 , 26 , 28 , 40 . Cleat  26  if not already installed can be installed below cleat  16  and then be utilized to support a shelf  108 . The difference between the construction for cleat  26  supporting shelf  108  and cleat supporting shelf  92  is that the cleat  16  extends out laterally to be flush with outer wall surface  110  whereas cleat  26  is roughly approximately flush to an interior wall (as shown in  FIG. 2 ) of vertical wall panel  32 . Nevertheless, an upper surface such as that similar as shown in  88  in reference to cleat  16  can assist in supporting a rear portion of shelf  108  with cleat  16 . Once again, adjustable shelf hangers or other connections may be useful to support the shelf  108  by the vertical wall panel  32 . 
     Closet rod  112  which is illustrated supported by a bracket  114  and receiver  116 . The corresponding receiver is obscured from view where connected to vertical wall panel  32 . Each connection assists in locating closet rod  112  at a desired elevation. The shelf  108  can also connect to vertical panel  34  in a somewhat similar or different manner as connect the other end of the shelf  102 , 108  connects to a vertical wall panel  32 . Depending on whether the top and bottom  22 , 50  of the cabinet  42  have been connected to the vertical panel  34  the components need to be assembled if not already provided and possibly utilizing bracket  118  and or others to assist in supporting portions of the top  22  and bottom  50  at a desired location. This can assist in locating vertical wall panel  36  in the desired position. Shelves  54 , 56  could be provided in a permanent location or with adjustable shelf brackets. Cabinets  42  and  44  can support similar shelf structure as shelf  120 , closet rod  122 , shelf  124 , and closet rod  126 . These can be supported in a similar manner as those shown against wall  20 . The cabinet  44  can be located such as a similar or dissimilar cabinet is located. Closet rods and/or shelves  128 , 130 , 132 , 134  can then be installed. 
     The shelves  128 , 130  and closet rods  132 , 134  connect with a bracket  136  shown in further detail in  FIGS. 4 and 5 . Bracket has a face  138  which cooperates with cleat  12  such as by providing a connector through bore  140  as well as through corresponding indicator (obscured from view) through which bore  140  may preferably align therewith. Furthermore, additional bore  142  or bores may also be provided to assist in providing further strength or stability with the face  138  and the cleat  12  being further secured possibly to a stud as well as possibly corresponding to one or more indicator(s). Truss member  144  is useful to assist in providing structural integrity to the bracket  136  which can provide an upper surface  146  which receives a bottom surface  148  of shelf  130  and also can provide a depending end  150  which receives closet rod  134  from hook  152 . Another end of closet rod  134  is supported by a bracket  154 . In a similar manner, the other end of the closet rod  134  as illustrated as well as many of the closet bars such as  112 , 122 , 126  can be supported. Additional shelf brackets (obscured from view behind the shelf  130  in  FIG. 5 ) can be connected to the wall panel  40  in this view. Once again, cleat  12  is illustrated supporting foot  156  with shoulder  158 . 
     After installing one of the systems  10 , it is anticipated that one of the closet installation systems can be installed in time frames of roughly five to ten minutes or less. This is believed to be a huge improvement over prior art closet systems. By providing prepackaged assemblies, it may further be possible that little, if not absolutely no cutting needs to be done on the work site. This can further expedite the speed of installation. Once installed, the closet system  10  can be provided in various painted wood or metal configurations to provide a desired level of attractiveness. 
     In an effort to utilize existing powder coating equipment which principally utilized by the applicant for powder coating metal products, the applicant obtained a quantity of Alesta® ULB (ultra violet bake) from DuPont® and attempted to powder coat medium density fiberboard (MDF) with the existing equipment.  FIG. 8  shows powder coating system  210  of the presently preferred embodiment having powder coating station  212 , track  214  and curing oven  216 . 
     Optional preheat station  218  is also illustrated and wood products  220 , such as cleats  12 , 14 , 16 , 28 , 30 , shelves  108 , 120 , 124 , 128 , 130 , side panels  32 , 34 , 36 , 38 , 40  and/or other components, are represented by wood product  220  illustrated being supported by hanger  222  supported by a connector  224  to tab  226 .  FIG. 8  may be a part of curing oven  216  such as if track  214  is U-shaped or has another suitable configuration so that track  214  can direct wood product  220  through preheat station  218  and then through coating station  212  and then into curing oven  216 . This, in fact, is how the applicant&#39;s metal powder coating set up is configured which is the set up anticipated to be at least initially utilized by the applicant in this endeavor. 
     In powder coating configurations, the oven consisting of pre-heater  218  and curing oven  216  would be heated to approximately 500° Fahrenheit and metal parts, after being washed would be provided to the preheater  218  and then travel a significant distance into the paint station  212  where they would be coated and then sent on to the curing oven  216  and then cooled afterwards. In attempting to switch over to ultra low bake powder from DuPont, while turning the oven down to 300° Fahrenheit or less, the applicant discovered that upon entered the coating station, the surface temperature of the wood product  220  was less than 150° Fahrenheit and was, in fact, less than 120° Fahrenheit at about 115° Fahrenheit. The applicant had been advised by the published article in  Surface  &amp;  Panel Magazine  that surface temperatures at about 200° Fahrenheit and moisture contents were critical. Nevertheless, the applicant discovered that although a corona developed around an eye bolt hanger, the remainder of the wood product  220  appeared to coat satisfactorily after being processed through the curing oven  216  and cooling. The eye bolt initially utilized by the applicant had as much, if not more, material outside of as opposed within an internal portion of board  220  when installed. 
     The applicant then switched to utilizing a hanger  222  in the form of a staple which had a length of one inch and a width between external portions of prongs  228 , 230  of ¼ inch. The wire size of the staple was a little less than 1 mm. Leaving about a ¼ inch of the staple exposed with a crossbar where it was installed and having at least ½ inch the other ¾ inch or so or at least ⅔ of the staple in the wood product  220 , the applicant discovered after coating with the coating station  212  and curing with curing oven  216 , there were no coronas. Not only were the wood products fully coated, the exposed portion of the hanger  222  was coated, even the connector  224  in the form of a paper clip was also evenly coated. The important thing to remember here was that there were no coronas. There was also no orange peel texture on the wood product  220 . In short, a satisfactory product was obtained ready for use in another component and/or delivery to a customer depending on the particular application of the coated wood product  220 . 
     In conducting further experimentation utilizing the hanger  222  of the presently preferred embodiment, it was discovered that wood based products  220  such as MDF could be transported from the refrigerator or freezer, hung on track  214  and run through powder coater  212  either with or without passing through preheater  218 . After curing through curing oven  216 , excellent quality coated products resulted when using hanger  222 . Furthermore, spraying moisture on the wood boards  220  prior to preheating and then coating in the coater station  212  and curing in the curing station still resulted in excellently coated products. Nothing seemed to affect the quality of the coated products when using preferred hanger  222 . Accordingly, the teachings as published in the prior art are believed to be overcome through the to at least through the use of novel hangers  222  to at least assist in removing coronas. Apparently by distributing a significant conductivity internal to the board  220  by a significant enough degree relative to potentially a de minimis portion of hanger  222  being external to the board  220 , coating is at least partially assisted to provide an evenly coated product with no coronas. 
     In conducting these tests, grade A MDF was utilized and a one inch staple utilized. It is anticipated that other length of staples can be utilized in other embodiments. 
     When applying coating in the coating station, a small hose rather than a larger hose was found to provide a more satisfactory coating than the bigger hose. Furthermore, reclamation during the coating process in the coating station  212  is recommended to reclaim unused powder. At least 96% of the powder is believed to be usable on products such as wood product  220 . The powder coating station  220  was a Nordson powder coater but other powder coating equipment is available on the market. 
     Applicant also believes pretreating wood products  220  such as with a primer coat prior to putting on the final coat may provide additional benefits for some applications. Primer coats with conductive material may prove effective. 
     It is the removal of the coronas that the applicant has consistently been receiving from a provider that prompted applicant to attempt to utilize the powder coating equipment of applicant without adding additional equipment such as preheating station to elevate surface temperature to 200° Fahrenheit before coating. 
     Although coronas are usually acceptable on obverse faces (i.e., a face not exposed to view) in many applications, the applicant was attempting to provide a shelf to the marketplace in which both the top and bottom of the shelf could be viewed by end users. Accordingly, this leaves only the edges to be supported by a hanger. In the products provided by a provider to the applicant, the connectors for connecting the wooden products have consistently been connected on side faces and not edges. Thus, the coronas left would be particularly problematic in such applications. Even the samples provided for showing the various color schemes provided to the applicant from the provider have stickers identifying the manufacturer covering dime sized coronas. 
       FIGS. 9 and 10  show staple puller  240  of the presently preferred embodiment of the present invention specifically stapler puller  240  is somewhat lever activated in that a lever  242  connects to a pivot  244  has an operator handle position  246  with at least one foot  248  coupled thereto therebetween. The at least one foot  248  is shown pivotably connected to lever  242 . The at least one foot is configured to contact a surface  250  of the wood product  220  having the hanger  222  disposed therein in a preferred embodiment. At least one foot  248  is shown in  FIG. 3  having two feet  252 , 254  preferably with resilient coatings  256 , 258  where the at least one foot  248  contacts the surface  250  to prevent inadvertently marring the surface  250  while removing hanger  222 . 
     In order to remove the hanger  222 , the operator  246  is preferably downwardly directed so that the at least one foot  248  contacts the surface  250  and continues downwardly so that with the extension  260  retaining the crossbar  262  between the prongs  228 , 230 , continued down force pushes the board  20  away from the crossbar  62  thereby pulling the prongs  28 , 30  from the wood product  220 . In the preferred embodiment, pivot  244  is securely mounted relative to a face  262  from which extension  260  cantileveredly extends therefrom. Two “pinholes” of less than about 1 mm diameter are left in wood product  220  after pulling the hanger  222  therefrom. 
     Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. 
     Having thus set forth the nature of the invention, what is claimed herein is: