Patent Publication Number: US-8528280-B2

Title: Composite hutch door

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Application No. 61/442,712, filed Feb. 14, 2011, the contents of which are herein incorporated by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     Embodiments of the present invention relate generally to office furniture, and more specifically to a composite hutch door. 
     SUMMARY 
     Provided herein is a door including a one piece molded outer frame having a framing member, each framing member having a front edge, an inner face, and a back edge; a one piece molded inner frame having a framing member; and a transparent panel secured therebetween, the outer frame and inner frames being coupled via a clip component and clip receiving component. In some embodiments, the outer frame includes the clip component attached to the framing member of the outer frame. 
     In some embodiments, the clip component includes an anchor section attached to the inner face of an outer frame framing member; an engaging section including a inner face, a front edge, and a back edge, the front edge of the engaging section attached to the anchor section; and a wedge-shaped locking section having a wide end and a narrow end, the locking section being attached to the inner face of the engaging section. 
     In some embodiments, the inner frame includes the clip receiving component attached to the framing member of the inner frame. In some embodiments, the clip receiving component includes an aperture and a lip configured to lock the clip component into the clip receiving component. 
     In some embodiments, the inner frame is dimensioned to fit within the outer frame. 
     In some embodiments, the door includes a hinge receiving component molded into the inner frame. 
     In some embodiments, at least one of the inner frame and outer frame comprises a polymer or a metal. 
     Also provided is a method of assembling a door. The method includes securing a transparent panel between a one piece molded outer frame and a one piece molded inner frame, where the outer frame and inner frame are coupled via a clip component and clip receiving component. 
     While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of a composite hutch door according to one embodiment. 
         FIG. 2  is a rear view of the composite hutch door according to the embodiment shown in  FIG. 1 . 
         FIG. 3A  is a front view of an outer frame according to one embodiment. 
         FIG. 3B  is a back view of the outer frame according to the embodiment shown in  FIG. 3A . 
         FIG. 3C  is a side view of the outer frame according to the embodiment shown in  FIG. 3A . 
         FIG. 3D  is a cross sectional side view of the outer frame. 
         FIG. 3E  is a cross sectional side view of the outer frame and showing detail of a clip component according to the embodiment shown in  FIG. 3A . 
         FIG. 4A  is a front view of an inner frame according to one embodiment. 
         FIG. 4B  is a back view of the inner frame according to the embodiment shown in  FIG. 4A . 
         FIG. 4C  is a close up view of a hinge receiver component on the back surface of the inner frame according to the embodiment shown in  FIG. 4A . 
         FIG. 4D  is a side view of the inner frame according to the embodiment shown in  FIG. 4A . 
         FIG. 4E  is a second side view of the inner frame according to the embodiment shown in  FIG. 4A . 
         FIG. 5  is an exploded view of a composite hutch door according to one embodiment. 
         FIG. 6  is back view of a composite hutch door according to one embodiment. 
         FIG. 6A  is a back view of the composite hutch door according to the embodiment shown in  FIG. 6  showing a close up view of engaged clip components of the outer and inner frames. 
         FIG. 7  is a cross sectional side view of a composite hutch door according to one embodiment. 
         FIG. 7A  is a cross sectional side view of the composite hutch door according to the embodiment shown in  FIG. 7  showing a close up view of engaged clip components of the outer and inner frames. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present invention relate generally to office furniture, and more specifically to a door (e.g., hutch or cabinet door) which includes an inner frame, a transparent panel, and an outer frame.  FIGS. 1-7A  depict a door  100  according to embodiments of the present invention. As illustrated in  FIGS. 1 and 2 , door  100  includes an outer frame  200  and an inner frame  400  with a transparent panel  300  interposed therebetween. 
     As used herein, the term “couple” is used in its broadest sense to refer to elements which are connected, attached, and/or engaged, either directly or integrally or indirectly via other elements, and either permanently, temporarily, or removably. 
     As illustrated in  FIGS. 3A-3E , outer frame  200  is molded as a single piece. Outer frame  200  includes first and second vertical parallel framing members  202 ,  204  and first and second horizontal parallel framing members  206 ,  208  defining a generally rectangular shaped frame. The framing members  202 ,  204 ,  206 ,  208  have front edges  202   f ,  204   f ,  206   f ,  208   f , inner faces  202   i ,  204   i ,  206   i ,  208   i , and back edges  202   b ,  204   b ,  206   b ,  208   b . Each framing member  202 ,  204 ,  206 ,  208  includes a flange  210  projecting laterally from the front edge  202   f ,  204   f ,  206   f ,  208   f  toward the opposite framing member. 
     Outer frame  200  additionally includes a clip component  220  on the inner face of at least two of the framing members  202 ,  204 ,  206 ,  208 . If a clip component  220  is included on only two framing members of outer frame  200 , a clip component  220  is preferably included on the inner face of each of two opposing framing members (i.e., vertical framing members  202 ,  204  or horizontal framing members  206 ,  208 ). In some embodiments, more than one clip component  220  is included on the inner face of a framing member. 
       FIG. 3D  is a cutaway side view of outer frame  200  showing clip component  220 . As illustrated in  FIGS. 3E and 7A , clip component  220  includes an anchor section  222 , an engaging section  224  including a inner face  224   i , a front edge  224   f , and a back edge  224   b , and a wedge-shaped locking section  226  having a wide end  226   f  and a narrow end  226   b . Anchor section  222  attaches to the inner face of the framing member and connects with at least a portion of front edge  224   f  of engaging section  224 , which extends from where it attaches to anchor section  222  generally parallel with the inner face of the framing member toward the back of the door  100  when assembled, but not beyond the back edge of the framing member. Locking section  226  is attached to inner face  224   i  of engaging section  224  such that the wide end  226   f  of locking section  226  is positioned nearer to the front edge  224   f  of engaging section  224  relative to the narrow end  226   b . Locking section  226  of clip component  220  is oriented such that the wide end  226   f  extends further from the inner face  224   i  of engaging section  224  than the narrow end  226   b.    
     As illustrated in  FIGS. 4A-4E , inner frame  400  is molded as a single piece Inner frame  400  includes first and second vertical parallel framing members  402 ,  404  and first and second horizontal parallel framing members  406 ,  408  defining a generally rectangular shaped frame. The framing members  402 ,  404 ,  406 ,  408  have front faces  402   f ,  404   f ,  406   f ,  408   f , outer edges  402   o ,  404   o ,  406   o ,  408   o , inner edges  402   i ,  404   i ,  406   i ,  408   i , and back faces  402   b ,  404   b ,  406   b ,  408   b . At least two framing members  402 ,  404 ,  406 ,  408  of inner frame  400  include a clip receiving component  420  that extends from the outer edge of the framing members toward the back of the door  100  when assembled, and is configured to couple and lock with clip components  220  on the outer frame  200 . In some embodiments, as illustrated in  FIGS. 6A and 7A , clip receiving component  420  is an aperture including a lip  422 , which is configured to allow insertion of clip component  220  with the wide end  226   f  of locking section  226  locking clip component  220  into clip receiving component  420 . See  FIG. 7 , showing a cutaway section of outer frame  200  and inner frame  400  coupled via clip component  220  and clip receiving component  420 . 
     As shown in  FIGS. 4B and 4C , outer frame  400  additionally includes a hinge receiving component  440  located on back face  402   b  of framing member  402 . In some embodiments, hinge receiving component  440  is an aperture for receiving a hinge (not shown) that extends from back face  402   b . In other embodiments, hinge receiving component  440  is recessed into back face  402   b . In some embodiments, hinge receiving component  440  is associated with additional components, such as components useful for facilitating attachment of a hinge to back face  402   b . For example, in some embodiments as shown in  FIGS. 4B and 4C , hinge receiving component  440  is associated with receptacles  442  for screws or bolts. 
     In some embodiments, one or both of molded frames  200  and  400  include elements for strengthening the structure of frames  200  and  400 . For example, in some embodiments, inner frame  400  includes an integrally molded inner lip  450  extending backward from the inner edges  402   i ,  404   i ,  406   i ,  408   i  of framing members  402 ,  404 ,  406 ,  408 , as illustrated in  FIG. 5 . In some embodiments, inner frame  400  includes an integrally molded outer lip  460  containing clip receiving components  420  and extending backward from the outer edges  402   o ,  404   o ,  406   o ,  408   o  of framing members  402 ,  404 ,  406 ,  408 . Inner and outer lips  450 ,  460  can be shaped as appropriate to provide structural strength. As shown in  FIG. 4E , in some embodiments, outer lip  460  includes additional features, such as an opening  470  to accommodate a hinge portion. 
     Transparent panel  300  is dimensioned such that transparent panel  300  fits within outer frame  200 . Outer frame  200  and inner frame  400  are configured to secure transparent panel  300  between them when door  100  is assembled as shown in  FIG. 5 , preventing transparent pane  300  from passing through the opening defined by flange  210  of the outer frame  200  and the opening defined by inner edges  402   i ,  404   i ,  406   i ,  408   i  of inner frame  400 . The outer and inner frames are further dimensioned such that inner frame  400  fits within the opening defined by inner faces  202   i ,  204   i ,  206   i ,  208   i  of outer frame  200  and clip components  220  couple with clip receiving components  420 . See  FIGS. 6 and 7 , showing clip components  220  coupled with clip receiving components  420  in assembled door  100 . 
     Flange  210  of the outer frame  200  can be dimensioned to provide an opening of a desired size through which transparent pane  300  can be viewed. Similarly, the opening defined by inner edges  402   i ,  404   i ,  406   i ,  408   i  of inner frame  400  can be dimensioned to provide an opening of a desired size through which transparent pane  300  can be viewed. The openings defined by flange  210  and inner edges  402   i ,  404   i ,  406   i ,  408   i  can be the same or different sizes. In some embodiments, the opening defined by inner edges  402   i ,  404   i ,  406   i ,  408   i  can be smaller than the opening defined by flange  210 . In some embodiments, flange  210  and/or inner edges  402   i ,  404   i ,  406   i ,  408   i  can be shaped to provide a desired appearance of the respective opening. 
     Inner and outer frames  200 ,  400  are molded from any appropriate material as desired for strength and/or flexibility. For example, a material can be selected to be rigid enough to support a pane of glass, yet flexible enough to allow clip component  220  to slide into clip receiving component  420  and resilient enough to allow clip component  220  to lock into clip receiving component  420  once engaged. Materials suitable for molded frames  200 ,  400  include, without limitation, polymers (e.g., ABS, nylon, polycarbonate, polycarbonate/acrylic alloys, TPO, polycarbonate/PBT alloys, modified PPOs, modified PPEs, polypropylene, polypropylene copolymers, and the like) and metals (e.g., aluminum, stainless steel). 
     Transparent panel  300  can be made from any suitable material, such as glass or plexiglass. In some embodiments, transparent panel  300  is semitransparent (e.g., frosted). In other embodiments, transparent is fully transparent. 
     Door  100  is dimensioned as appropriate for use with a selected opening. In one embodiment, door  100  is dimensioned to cover an opening to a cabinet. In another embodiment, door  100  is dimensioned to fit in a doorway. Outer frame  200 , inner frame  400 , and transparent panel  300  are dimensioned as appropriate to accommodate the overall door  100  dimensions, and can be adjusted to provide the desired properties (e.g., weight, strength, aesthetic properties) in the assembled door  100 . In one embodiment, door  100  is dimensioned for use as a cabinet door having a height of about 14 to about 15 inches (e.g., about 14.5 inches), a width of about 14 to about 15 inches (e.g., about 14.5 inches), and a depth of about 0.5 to about 1.5 inches (e.g., about 1 inch). In another embodiment, door  100  is dimensioned for use as a door having a height of about 16 to about 20 inches (e.g., about 18 inches), a width of about 15 to about 19 inches (e.g., about 17 inches), and a depth of about 0.5 inches to about 1 inch (e.g., about 0.75 inches). In other embodiments, door  100  can be dimensioned to be larger or smaller, depending on the size of the opening that door  100  is designed to cover. 
     Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the above described features.