Patent Publication Number: US-6209976-B1

Title: Cabinet box

Description:
FIELD OF THE INVENTION 
     The present invention relates to a cabinet box. More particularly, the present cabinet box is preferably formed from metal and is capable of being assembled or disassembled with relative ease using a knock down system. The cabinet box has a tightly jointed interior formed from the assembly of novel side panels, top and bottom panels and a back panel. 
     BACKGROUND OF THE INVENTION 
     Cabinet boxes, and particularly, metal cabinet boxes, come in a multitude of designs, shapes and manners of construction. For example, in U.S. Pat. No. 4,296,982 to Kullander, a knock down cabinet assembly is taught. This assembly comprises a cabinet having interconnected walls by means of specially shaping the adjacent portions thereof so that assembly of the cabinet can occur without fastening means. In Viklund, U.S. Pat. No. 4,295,693, a cabinet having a rear wall, two side walls and a frame-shaped front wall forming a box-like structure is shown. This cabinet of Viklund also requires no fastening devices and interconnected portions thereof also serve as means for receiving shelf supports. Other examples of some knock down cabinets can be seen in Znamirowski et al., U.S. Pat. No. 4,288,132 and Radi, U.S. Pat. No. 3,104,140. These prior art devices, and others, attend to their intended purpose of forming cabinets but do not attend to the advantages taught by the present invention. 
     SUMMARY OF THE INVENTION 
     A cabinet box having a tightly jointed interior is shown and described herein. Two Side panels each have an inset wall face formed by, and relative to, recessed or pocketed ends located at the top and bottom thereof, respectively. In addition, the rear of the side panels incorporates a separate pocket for receiving the back panel. The side panels are identical in shape and configuration. Top and bottom panels are configured so that their ends fit snugly into the side panel pockets. A back panel also has an inset face formed by, and relative to, recessed or pocketed ends located at the top and bottom thereof, respectively. The components are fastened to one another by self tapping screws, rivets, or other conventional means. A door may be added, as well as leveling legs if the box is to rest above the ground surface. Further, means are provided to allow the cabinet box to be wall mounted. 
     It is thus an object of the present invention to provide a novel side panel having top, bottom and rear ends where pockets are located at those ends. 
     It is still another object of the present invention to provide a cabinet box that is formed from novel side panels having top, bottom and rear ends where pockets are located at those ends. 
     It is still another object of the present invention to provide a novel back panel having receiving recesses formed at the top and bottom thereof to accept mating ends of top and bottom panels, and novel side edges for being matably received by the rear ends of the said side panels. 
     It is still yet another object of the present invention to provide a cabinet box that is formed of sheet metal which has bends in side and back panels such that the bends form pockets or recessed compartments at the top and bottom of each said panel. 
     It is still another object of the present invention to provide a knock down metal cabinet having prefabricated holes for fastening components thereof by self tapping screws or other similar means. 
     It is still another object of the present invention to provide a cabinet box that can be shipped unassembled permitting assembly to be performed away from the manufacturing facility without special equipment and by personnel unfamiliar with the manufacturing process. 
     It is still yet another object of the present invention to provide a cabinet box whose side panels may be attached at either the left or right sides of the box. 
     It is still yet another object of the present invention to provide side panels that are capable of universal fastening of a door for either right or left handed attachment. 
     It is still yet another object of the present invention to provide leg leveling means and/or wall attachment means to assist in the assembly and installation of the disclosed cabinet box. 
    
    
     THE DRAWINGS 
     Other objects and advantages of the present invention will become apparent from the following detailed description of preferred embodiments thereof taken in conjunction with the accompanying drawings which include: 
     FIG. 1 is a perspective view of the present invention shown schematically in disassembled form; 
     FIG. 2 is a plan view of the side panel of the present invention showing bend lines in dashes; 
     FIG. 2A is a cross section view of the side panel shown after pockets have been formed from bend lines taken along line  2 A of FIG. 2; 
     FIG. 2B is a cross section view of the side panel shown after a pocket has been formed from bend lines at the rear of the panel and front edge bends have been made along front bend lines taken along line  2 B of FIG. 2; 
     FIG. 3 is a plan view of the top panel of the present invention showing bend lines in dashes, the bottom panel being a mirror image thereof; 
     FIG. 3A is a cross section view of the top/bottom panel shown after bends have been taken along line  3 A of FIG. 3; 
     FIG. 3B is a cross section view of the top/bottom panel shown after bends have been taken along line  3 B of FIG. 3; 
     FIG. 3C is a cross section view of the top and bottom panels of the present invention connected to a side panel of the present invention; 
     FIG. 4 is a plan view of the back panel of the present invention showing bend lines in dashes; 
     FIG. 4A is a cross section view of the back panel shown after pockets have been formed from bend lines taken along line  4 A of FIG. 4; 
     FIG. 4B is a cross section view of the back panel shown after pockets have been formed from bend lines taken along line  4 B of FIG. 4; 
     FIG. 4C is a broken, cross section view of the present invention depicting securement of the back panel of the present invention to the top and bottom panels thereof; 
     FIG. 4D is cross section view of the leg component of the present invention secured to the bottom panel thereof; 
     FIG. 4E is a plan view of a leg support channel member; 
     FIG. 5 is a plan view of the wall hang rail component of the present invention where bend lines are represented by dashes, and; 
     FIG. 5A is a cross section view of the wall hang rail component of the present invention after bends are completed in the bend lines thereof. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Referring to FIG. 1, a preferred embodiment of the cabinet box  10  is shown. It is preferred that box  10  be manufactured of sheet metal, though any conventional construction material may be used. The dimensions of the sheet metal are established to suit the required height, width and depth of the finished box  10 , allowing for the necessary metal bends, as depicted in the drawings, around the perimeter of the respective panels. The gauge of sheet metal may vary depending upon the strength, size, and economic requirements of the finished box  10 . Various shaped cut outs and holes are made in each piece of sheet metal to accommodate the final bending, fastening and hardware placement requirements of the panels as hereinbelow described. 
     Cabinet box  10  is comprised of two side panels  12 , which may be identical to one another; a top panel  14  and a bottom panel  16 , which also may be identical to one another, and; a back panel  18 . Optionally, other components may be added such as doors, drawers, shelves or accessories (not shown). 
     FIG. 2 depicts side panel  12  shown in the preferred embodiment of sheet metal construction material. Bend locations are shown in dashed lines and bends are to form 90 degree angles throughout this Specification unless otherwise described. Panel  12  comprises a top edge  20 , an opposed bottom edge  21 , and a rear edge  22  and opposed front edge  23 . The side panel  12  has a wall face  24  which will comprise the interior wall component of the side panel  12  when forming the box  10 . As shown, side panel  12  is substantially rectangular. Bend gaps  25  permit unobstructed formation of side panel  12  configuration so that 90 degree bends result in substantially tight fitting joints of the cabinet box  10 . The bend gaps  25  can measure up to two inches (2″) in length, but the preferred length is approximately one-eighth inch (⅛″). 
     Pockets  26  are formed by bending at the dashed lines along the top edge  20 , bottom edge  21  and rear edge  22  of side panel  12 . The bend profiles of pockets  26  may be readily seen in FIGS. 2A and 2B. These bend profiles are achieved by bending top flange  27  and bottom flange  27 ′ along the respective bend line (dashed lines) closest to the wall face  24  in a direction opposite of the wall face  24  and substantially 90 degrees thereto. Thereafter, each subsequent bend line is bent so that a pocket  26 , or substantial U-shape, is formed. The pocket  26  is then secured and/or reinforced by bending front flange  28  such that the bend line on front flange  28  closest to the wall face  24  is bent in a direction opposite that of the wall face  24  and substantially 90 degrees thereto. The remaining bend line on flange  28  is bent so as to achieve as substantial U-shape cross section as shown in FIG. 2B (see front edge  23 ). The purpose of creating this substantial U-shaped cross section for flange  28  is to enhance the stiffness of the front edge  23  of the side panel  12 . Thus, the preferred embodiment of side panel  12  is substantially rectangular in shape. Additionally, for ease of assembly, any number of pre-punched holes  29  may be added to the side panel  12  to permit fastening means such as self tapping screws to secure one panel of the cabinet box  10  to other cabinet boxes or for hardware mounting purposes. 
     The pocket  26  formed from the rear edge  22  of side panel  12  is created in similar fashion to the pockets  26  formed along the top edge  20  and bottom edge  21 . The first bend in rear flange  27 ″ is directed away from the wall face  24  and substantially 90 degrees thereto. The remaining bends form substantially a U-shape pocket  26  as represented in FIG.  2 B. 
     FIG. 3 illustrates the top panel  14  of the cabinet box  10 . The bottom panel  16  is a mirror image of the top  14 , though incomplete panels known as stretchers may also be employed for top and/or bottom panels. The top panel  14  is comprised of a front edge  40 , and an opposed rear edge  41 . The top panel  14  also is comprised of opposed side edges  42  and  43 , respectively. The corners  44  of each edge of top panel  14  (reference numerals  40 ,  41 ,  42  and  43 ) are beveled, or angled at 45 degrees preferably. The beveled corners permit an adjacent fit with one another when the panel  14  is formed as discussed below. Dashed lines represent bend lines for top panel  14 . Side flanges  45  and  46  respectively, front flange  47  and rear flange  48  of top panel  14  each depict two bend lines. Ninety degree bends are made in the respective flanges at the bend lines closest to the face  49  of the top panel  14  and in a direction opposite to that of, or away from, the face  49 , so that the face  49  of top panel  14  can form the interior of the top component of the cabinet box  10 . The remaining bend line on each flange of the top panel  14  is formed at an angle of 90 degrees from the first bend resulting in a bend profile from front edge  40  to rear edge  41  having a substantial C-shape (see FIG.  3 A). A similar, substantial C-shape is profiled in FIG. 3B after bending the top panel  14  from side edge  42  to side edge  43 . The C-shape profiles disclosed in this top panel  14  are formed in the same direction as one another, and away from the face  49 . The side edges,  42  and  43 , respectively, of top panel  14 , after bending and in the top panel&#39;s substantial C-shape configuration, are alignable with, and formed to engage, the upper pocket  26  of each of two side panels  12 , resulting in a tightly fitted joint between each side edge of top panel  14  and the upper pockets  26  of side panels  12 . 
     The bottom panel  16  is constructed and bent identically to that of the top panel  14 , and its C-shaped side edges are engagable with the lower pockets  26  of each of the two side panels  12  (which are fitted with the top panel) forming the floor  50  of the cabinet box  10 . Pre-punched holes  51  may be added to the top panel  14  and bottom panel  16  to permit fastening means such as self tapping screws  52  or rivets to secure those panels to the side panels  12  (see FIG.  3 C). 
     FIG. 4 illustrates the back panel  18  of cabinet box  10 . Dashed lines again represent bend lines with the back panel  18  as with the side, top and bottom panels. Back panel  18  has an opposed top edge  60  and a bottom edge  61 . Back panel is further framed by two opposed side edges  62  and  63  respectively. Top flange  64  of the top edge  60  of back panel  18  comprises three bend lines. The top flange  64  is bent back, and away from, the face  65  at the first such bend line closest to the face  65  of back panel  18  at an angle in excess of 90 degrees and approximately 135 degrees. Then the unbent portion of the top flange  64  located at the bend line second closest to the back face  65  is bent in a direction parallel to the face and in a direction opposite of the bottom edge  61  forming a lip  70  (FIG.  4 B). The final bend of top flange  64  at the bend line farthest away from the face  65  is made at approximately 90 degrees and toward the back face  65  which creates a pocket  26 ′. 
     The back panel  18  also has a bottom flange  66 , which is opposite that of the top flange  64 . A second pocket  26 ′ is formed at the bottom edge  61  of panel  18  as seen in FIG.  4 B. This second pocket  26 ′ is achieved by bending flange  66  along the bend line (dashed lines) closest to the wall face  65  in a direction opposite of the wall face  65  and substantially 90 degrees thereto. Thereafter, each subsequent bend line is bent so that a pocket  26 ′, or substantial U-shape, is formed. 
     The back panel also has opposed side flanges  67  and  68 , respectively. Each of these flanges,  67  and  68 , has a two bend lines. The respective flanges are each bent at the line closest to the face  65  in a direction behind the face and at the second bend line toward one another forming a substantial C-shape cross section as represented in FIG.  4 A. The back panel flanges may contain pre-punched holes  69  for connection of the back panel  18  to the side panels  12 , the top panel  14  and bottom panel  16  of cabinet box  10  by self tapping screws  52 , rivets or other means (see FIG.  4 C). 
     The cabinet box  10  is thus assembled at the least by utilizing two side panels  12 , one top panel  14 , one bottom panel  16 , and one back panel  18  secured together by conventional means as disclosed above forming the box  10 . Once all bends are made as recited above, the rear edges  41  of the top panel  14  and bottom panel  16 , are matably inserted into upper and lower pockets  26 ′ of the back panel  18  resulting in tightly fitted joints. Then, side edges,  62  and  63 , of the back panel  18  and the side edges  45  and  46  of the top and bottom panels,  14  and  16 , respectively, are inserted into the top, bottom and rear pockets  26  of side panels  12  forming tightly fitted joints. Fasteners are used to secured the components together. 
     Leg support channels  80  may be employed optionally if desired to support the box  10  on legs. FIGS. 4C and 4D depict the channel members  80  in a diagonal placement in the four bottom corners of the underside of the bottom panel  16 , and secured in place with self tapping screws  52 . The web  81  of channel  80  is wedged horizontally in the underside of the bottom panel  16  and downwardly facing the ground surface. A deep drawn hole  82  is located in the web  81  of channel  80  for the purpose of receiving a leg  83 . The hole  82  may be threaded for receiving a matably threaded leg  83  for height adjustment and leveling of the box  10 . 
     The cabinet box  10  may have an optional door (not shown). If a door is desired, hardware back up plates  90 , shown in FIG. 1, are designed with holes  91  spaced between 25 and 40 centimeters apart, and preferably 32 centimeters, center to center, which preference is the current standard hole spacing for door hinge mounting plates (not shown). These holes  91  may be plain to receive self tapping fasteners or pre-tapped to receive machine screws. The plates  90  are to be affixed to the side panels  12  and to the exterior of the cabinet box  10 , opposite the door hinge mounting plates. The plates  90  receive mounting screws (not shown) from the door hinge mounting plates which are inserted through the elongated holes  92  located on the side panel  12  (FIG. 2) toward the front edge  23  thereof, in an alignment to receive the standard dimensions of the door hinge mounting plates. The purpose of having elongated holes  92  is to allow the hinge location to adjust vertically. This adjustment allows the door hinge to be spaced equally from both its top and bottom edges. In this manner, the same door can be mounted on the right or left side of the box  10 , eliminating the need for hinging doors right specific or left specific. 
     Further, if it is desired to have a wall hung cabinet box  10 , a wall hang rail  100  is shown in FIG.  5 . The rail  100  has a top edge  101  and a bottom edge  102 . The bottom edge  102  is deformed along a bend line (represented by dashed lines) at less than 90 degrees to that of the top edge  101  and forms a pocket  103 . Pocket  103  is formed to receive lip  70  of back panel  18  in a matable relationship. The rail  100  is secured to a wall (not shown) by fasteners inserted through pre-punched holes  104 . FIG. 5A depicts the profile of the rail  100  after bending as disclosed herein. The wall hang rail  100  can be fabricated in various materials, preferably sheet metal, and cut in different lengths as required by the installation. 
     In describing the invention, reference has been made to preferred embodiments. Those skilled in the art, however, and familiar with the disclosure of the subject invention, may recognize additions, deletions, modifications, substitutions and/or other changes which will fall within the purview of the subject invention as defined by the following claims.