Patent Publication Number: US-9839286-B2

Title: Fold-out cabinet assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of U.S. patent application Ser. No. 15/138,938, filed Apr. 26, 2016, currently pending, the contents of which are herein incorporated by reference which is the Non-Provisional of U.S. Provisional Patent Application Ser. No. 62/161,533 filed on May 14, 2015, the disclosure of which is incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates generally to cabinets, and more particularly to a fold-out cabinet that allows for rapid and simple assembly while providing a reduced pre-assembled footprint for storage, shipping and merchandising. 
     2. Description of Prior Art and Related Information 
     Many conventional cabinets are manufactured in their fully or partially assembled state, where the footprint of the cabinet offered for sale is the same as the footprint of the installed cabinet. While this pre-assembled manufactured cabinet results in minimal effort prior to installation, the shipping, storage and merchandising of such cabinets requires substantial space. 
     As a solution to the above, several companies began to offer ready-to-assemble (RTA) cabinets. These cabinets are provided in a relatively flat box where the sides, back and bottom are joined together by the user prior to installation. This approach does help reduce the packaging size, but also requires a significant time input for the assembly of the cabinet. Moreover, these cabinets are usually completely disassembled, requiring attachment all components together, taking significant time and effort. 
     However, even with a ready-to-assemble cabinet, the back panel is often the largest component. Thus, the packaging required for shipping and storage of the cabinet must be as large as the back panel. Many times, shipping rates are based on the overall package dimensions. Therefore, when large back panels are involved, the overall package dimensions can be quite large. 
     As can be see, there is a need for a cabinet that can be easy to assemble while occupying a relatively small packaging, shipping and merchandising volume. 
     SUMMARY OF THE INVENTION 
     It is one aspect of the present invention to provide a fold-out cabinet comprising a back panel; first and second side panels pivotably attached along first and second pivot axes to opposing ends of the back panel; and one or more pivoting connections formed in the back panel, the pivoting connections permitting the back panel to fold. 
     Another aspect of the present invention is to provide a fold-out cabinet comprising a back panel; first and second side panels pivotably attached along first and second pivot axes to opposing ends of the back panel; one or more pivoting connections formed in the back panel, the pivoting connections permitting the back panel to fold, the pivoting connections having a back panel pivot axis substantially parallel to the first and second pivot axes; a top panel attached to a top edge of the first and second side panels and the back panel; and a bottom panel attached to a bottom edge of the first and second side panels and the back panel, wherein the first and second side panels sandwich the back panel therebetween when the fold-out cabinet is in a folded configuration. 
     According to some aspects of the present invention, optional features may be included with the fold-out cabinet. These optional include one or more doors, one or more shelves, one or more doors, a workbench type top panel, or combinations thereof. 
     An additional aspect of the present invention is to provide a method for assembling a cabinet, comprising pivoting, along a first pivot axis, a first side panel to a 90 degree angle relative to a back panel; pivoting, along a second pivot axis, a second side panel to a 90 degree angle relative to a back panel; straightening a back panel by unfolding the back panel along a third pivot axis; attaching a top panel to a top edge of the first side panel, the second side panel and the back panel; and attaching a bottom panel to a bottom edge of the first side panel, the second side panel and the back panel. 
     The methods may further include positioning the various optional features into the cabinet structure, such as one or more doors, one or more shelves, one or more doors, a workbench type top panel, or combinations thereof. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements. 
         FIG. 1  shows a front perspective view of a fold-out cabinet according to an exemplary embodiment of the present invention; 
         FIG. 2  shows a top view of the back and side panels of the fold-out cabinet of  FIG. 1  in a folded configuration; 
         FIG. 3  shows a top view of the back and side panels of the fold-out cabinet of  FIG. 1  in a partially unfolded configuration; 
         FIG. 4A  shows a detailed perspective view of a back panel folding mechanism according to an exemplary embodiment of the present invention; 
         FIG. 4B  shows a back view of a fold-out cabinet using the back panel folding mechanism of  FIG. 4A ; 
         FIG. 5  shows a top perspective view of the fold-out cabinet of  FIG. 1  in a fully unfolded configuration; 
         FIG. 6  shows a top perspective view of the unfolded cabinet of  FIG. 5  with a top panel attached; 
         FIG. 7  shows a detailed back view of the unfolded cabinet of  FIG. 6 , with the top panel attached, illustrating an outward turning lip forming a recessed back panel; 
         FIG. 8A  shows a perspective view of the unfolded cabinet of  FIG. 5 , in an upside-down orientation, illustrating attachment of the bottom panel; 
         FIG. 8B  shows a detailed perspective view of the mounting holes in a front corner of the fold-out cabinet; 
         FIG. 9A  shows a detailed perspective view illustrating placement of a door mounting member on the bottom panel of the fold-out cabinet; 
         FIG. 9B  shows a detailed perspective view illustrating mounting of the door on the door mounting member; 
         FIG. 10A  shows a perspective view illustrating attachment of the door onto the door mounting member on the bottom panel and a hole in the top panel, where the cabinet is shown in an upside-down configuration; 
         FIG. 10B  shows a detailed perspective view illustrating insertion of the door pin into a hole in the top panel of the fold-out cabinet, where the cabinet is shown in an upside-down configuration; and 
         FIG. 11  shows an alternate use of the fold-out cabinet to create a set of drawers therein, according to an exemplary embodiment of the present invention. 
     
    
    
     The invention and its various embodiments can now be better understood by turning to the following detailed description wherein illustrated embodiments are described. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the invention as ultimately defined in the claims. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE OF INVENTION 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
     In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims. 
     In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details. 
     The present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below. 
     Broadly, the present invention provides a fold-out cabinet that can include a folding back panel that is pivotably attached to side panels so that the back panel can be sandwiched at least partially between the side panels when in a folded configuration. When unfolded, top and bottom panels are attached to complete the cabinet structure. The fold-out cabinet can be rapidly assembled and takes up a minimal footprint when packaged for storage, shipping or merchandising. Optional accessories may be included with the cabinet, including a workbench type top surface, one or more shelves, one or more drawers, and one or more doors. When assembled, the cabinet is structurally stable and functional, but requires little time for complete assembly. 
     Referring now to  FIG. 1  a fold-out cabinet  10  (also referred to as cabinet  10 ) can include first and second side panels  12  (also collectively referred to as side panels  12 ) defining opposite sides of the cabinet  10 , a back panel  14  that interconnects the two side panels  12 , a top panel  16  and a bottom panel  20 . In some embodiments, one of more shelves  22  may be disposed inside the cabinet  10 . In some embodiments, one or more doors  18  may be disposed to removably cover a front face  28  of the cabinet  10 . 
     While the cabinet  10  appears and functions like any typical cabinet when assembled, the cabinet  10  provides for a rapid, simple assembly while being able to be packaged into a relatively small package. For example, the cabinet  10 , as described in greater detail below, can be packaged in packaging that has an area (length times width) less than an area of the back panel  14  of the cabinet  10 . 
     Referring now to  FIG. 2  through  FIG. 5 , the cabinet  10  can be provided with the side panels  12  pivotably attached to the back panel  14 . The side panels can include a bend to create back panel portions  12 - 1  fixed to the side panels  12 . In some embodiments, the bend is a 90 degree bend to form the back panel portions  12 - 1 . The back panel  14  can be pivotably attached to a distal end (distal of the bend) of the back panel portions  12 - 1 . In addition, the back panel  14  can include at least one pivoting connection  26  that allows the back panel  14  to fold upon itself. The pivot axes of the side panels  12  to the back panel  14 , as well as the pivot axis of the pivoting connection  26 , can be substantially parallel to each other. Thus, when folded, as shown in  FIG. 2 , the back panel  14  can be sandwiched entirely or at least partially between the side panels  12 . In some embodiments, a space  82  between the back panel portions  12 - 1 , when the back panel  14  is sandwiched between the first and second side panels  12  in a folded configuration, is less than a thickness  84  of the back panel  14 . Typically, the back panel portions  12 - 1  can be disposed physically contacting each other when in the folded configuration, where the back panel  14  is disposed within a cavity formed by the side panels  12  and the back panel portions  12 - 1 . 
     The pivoting connection  26  can include various connectors, such as one or more hinges  26 - 1 , as shown in  FIGS. 2 and 3 , a spring clip, a piano hinge, a ball and socket, or the like. In some embodiments, as shown in  FIGS. 4A and 4B , a cutout  70  may be formed in a side portion  72  of each back panel  14  such that the cutouts  70  align when the back panel  14  is fully opened (as shown in  FIG. 5 ). A spring member  74 , or other similar tubular assembly, may loop through the cutouts  70  on adjacent side portions  72  of each back panel  14 . This configuration may permit the back panels  14  to fold in the same manner as with the hinge  26 - 1  shown in  FIG. 3 . 
     The Figures show the back panel  14  folded into two sections, thus providing a cabinet having a length (length being defined as the distance between side panels  12 ) of about two times the depth (the depth being the width of the side panels  12 ). However, in some embodiments, the cabinet of the present invention can be made in various lengths. For example, the cabinet can be made twice as long as the cabinet shown in the Figures by providing two additional pivoting connections  26  on the back panel  14 . In this case, the back panel  14  will still fold to be at least partially sandwiched between the side panels  12 . Thus, unlike conventional cabinetry, where the packaging must be at least as large as the back panel of the cabinet, the packaging for the cabinet of the present invention would only need to be slightly larger than the length and width of the side panel  12 . 
     Referring to  FIG. 5  through  FIG. 7 , a plurality of holes  24  can be disposed in a lip  36  formed along a top edge of the side panels  12  and a lip  34  formed along a top edge of the back panel  14 . The top panel  16  can attach to the back panel  14  and the side panels  12  by passing an attachment member, such as a bolt  30 , through the top panel  16  and through the holes  24 . A mating attachment member, such as a nut  32 , can secure the top panel  16  to the back panel  14  and the side panels  12 . The lip  36  of the side panels  12  may be turned inward, so that the nuts  32  cannot be seen from viewing the exterior side of the cabinet  10 . The lip  34  of the back panel  14 , however, may be turned outward to form a recess in the back of the cabinet to receive the nuts  32 , where the nuts are not visible when the cabinet  10  is placed against a surface, such as a wall. Of course, other configurations may be used to attach the top panel  16  to the back panel  14  and the side panels  12 . For example, a twist lock member may be integrated into the top panel and a receiving member may be integrated into the back and side panels, where, when the top panel is placed on the back and side panels, the twist lock member may be turned to engage the receiving member to assemble the components. 
     Referring to  FIG. 8A  and  FIG. 8B , the cabinet  10  is shown upside-down, where the bottom panel  20  is attached to the sides panels  12  and the back panel  14 . In an exemplary embodiment, the bottom panel  20  can include a front hole  40  and a rear hole  38 . During attachment of the bottom panel  20  to the side panels  12  and the back panel  14 , the front hole  40  and the rear hole  38  are kept open in anticipation of the attachment of a door  18 , as described below. If a door is not to be installed, the front hole  40  and the rear hole  38  may be used to receive an attachment member, such as a bolt. Typically, the bottom panel  20  can connect to the side panels  12  and the back panel  14  in a manner similar to that which the top panel  16  attaches. However, other attachment mechanisms and methods, as may be known in the art, may be used to make this connection. 
     Referring to  FIG. 9A  through  FIG. 10B , the door  18  may be attached to cover the front of the cabinet  10 . In some embodiments, a single door may be used, as shown in the Figures. However, the cabinet of the present invention may use more than one door, such as two doors, swinging from each side of the cabinet, to cover the front of the cabinet  10 . In some embodiments, the door may be excluded entirely, leaving the cabinet open. 
     The door  18  may include a bottom pin  48  and a top pin  44 . The top pin  44  may be inserted into a hole  42  in the top panel  16 , as shown in  FIG. 10B . Typically, this is performed with the cabinet  10  upside-down, as shown in  FIG. 10A . This results in the door  18  being attached to the top panel  16 . 
     To attach the door  18  to the bottom panel  20 , a door mounting member  41  may be first attached to the rear hole  38  of the bottom panel  20  with a bolt  30 , for example. The bottom pin  48  of the door  18  may be fitted into a pin receiving hole  43  in the door mounting member  41 . Once the bottom pin  48  is fitted into the pin receiving hole  43 , the door mounting member  41  may be rotated to complete the mounting to the bottom panel  20  by inserting a bolt  30  through the door mounting member  41  and the front hole  40 . 
     The door  18  may include one or more accessories, such as a handle (shown as molded into the design of the door, but could also include one or more separate handles, pulls, or the like) or a lock  50 . The door  18  may attach to either side of the cabinet to provide a left-hand or a right-hand opening door. 
     When the cabinet is longer than that shown in the Figures, as discussed above where the back panel includes more than one pivoting connection  26 , the top panel  16 , bottom panel  20 , and even the shelf  22  may include a top pivoting connection to permit folding of the various members. Of course, one or all of these members may still be provided as a single, solid piece. 
     Once the door  18  is attached, the cabinet  10  may be turned upside-up and the optional shelf  22  may be installed therewithin. The shelf  22  may attach in various manners, such as with pins, with protrusions in the side panels  12  and the back panel  14 , with fasteners, or the like. 
     As discussed above, the cabinet  10  may be formed to receive one or more shelves  22  or may be kept completely open. Referring to  FIG. 11 , in some embodiments, one or more drawers  52  may be disposed inside the cabinet  10 . The drawers  52  may be disposed in a manner known in the art. For example, drawer slides may be attached to the side panels  12  to permit the drawers  52  to slide in and out of the cabinet. A lock  54  may optionally be disposed to lock one or more of the drawers  52 . 
       FIG. 11  also shows an alternate embodiment for the top panel  16  described above. In this embodiment, a solid top panel  16 A, such as a solid wood top panel, may be attached to the side panels  12  and the back panel  14  so that the attachment members (such as the bolts  30  described above) are not visible from the top panel  16 A. For example, wood screws (not shown) may be used to secure the solid top panel  16 A to the side panels  12  and back panel  14 . 
     Some embodiments of the present invention include a method for assembling a cabinet, where the cabinet is unfolded, as shown from  FIG. 2  to  FIG. 5 . More specifically, the side panels  12  can be separated to cause the back panel  14  to straighten. The side panels  12  can then be positioned at a 90 degree angle relative to the back panel  14 . The top panel  16  can then be attached to the back panel  14  and the side panels  12 . At this point, the cabinet may be turned upside down so that the bottom panel  20  can be easily attached to the side panels  12  and the back panel  14 . At this point, the cabinet is complete and optional items may be added. These optional items can include one or more doors, one or more drawers, one or more shelves, or combinations of these items. 
     Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different ones of the disclosed elements. 
     The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification the generic structure, material or acts of which they represent a single species. 
     The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination. 
     Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. 
     The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention.