Abstract:
The present invention provides a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing preparation station for use in outdoor food service. The integrated connection of the side walls, front, back, cover and bottom panel components simplifies the preparation station assembly construction. The panels are formed of injection molded plastic to interlock with one another without the need for fasteners or connectors. The system incorporates a minimum number of components by integrally forming the connectors into the panels which are snapped together to complete the assembly.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates generally to a portable food and beverage preparation station for use in outdoor food service. More specifically, the present invention relates to a food preparation station assembly utilizing injection molded plastic structural panels having integrally formed connectors. The preparation station is capable of being packaged and shipped in a knock-down state and assembled into a secure and decorative preparation station without additional fasteners.  
       BACKGROUND OF THE INVENTION  
       [0002]     Portable food and beverage preparation stations are very convenient for outdoor picnics and cookouts. Normally the foods are prepared indoors prior to cooking on the grill. Furthermore, foods which do not require cooking are also prepared indoors prior to their being served outdoors. The necessity of transporting various foodstuffs, condiments and the like from the interior to the exterior becomes problematic. For example, in the summer months, when cookouts are very popular, it is desirable to maintain the house in a cool condition with the use of air-conditioning. Constant entering and exiting from a house will permit hot, moist air from the outside to enter the house and defeat the air-conditioning. Also, in many areas, insects will be permitted to enter the house. It is very helpful if there is an area outdoors that food and other items can be prepared prior to their being served. This invention provides such an area.  
       DESCRIPTION OF THE PRIOR ART  
       [0003]     An example of a known portable food preparation station is U.S. Pat. No. 3,984,162 which discloses a cabinet on wheels with provisions to carry cooking and serving equipment for use with meals prepared outdoors. The cabinet includes a hinged top which covers a generally planar shelf. This shelf is used to carry and store the cooking equipment. Below the shelf are compartments designed to hold additional items, including chairs or seats. Casters are provided on the bottom of the cabinet to allow it to be moved around outdoors to any desired location. This cabinet is constructed of wood and is assembled prior to its sale to the customer. This makes it relatively heavy and bulky to bring home from the place of purchase. Also, the wood is subject to deterioration if constantly exposed to the elements outdoors. This cabinet does not provide a light weight and element resistant station as does the plastic construction of the instant invention. Also, the instant invention allows the cabinet to the shipped in a broken down state and assembled by the user without the use of tools.  
         [0004]     U.S. Pat. No. 5,683,157 relates to portable camping equipment and more particularly to a portable kitchen for storing and preparing food. The portable kitchen comprises a main box which has a table, a detachable sink, a storage area inside the box, and a front cover to close off access to the storage area. The portable kitchen is made from suitable molded plastics. While this is advantageous for use outdoors, the portable kitchen cannot be broken down for ease of shipping.  
         [0005]     Another portable cooking cabinet is disclosed in U.S. Pat. No. 1,216,030. This cabinet has a hinged top which opens to reveal a compartment which houses a stove for the preparation of the food. Storage areas in the cabinet below the stove are provided for the storage of items used in the preparation and serving of the food. The cabinet appears to be constructed from wood and would require assembly at the factory prior to delivery to the customer. Therefore it must be shipped in its fully assembled state.  
         [0006]     U.S. Pat. No. 6,533,372, discloses a beverage cart which is formed from plastic panels. These panels are mounted on a frame which is preferably made from steel to support the weight of the cart. The frame is provided with wheels for movement of the entire assembly. The beverage cart includes a top panel for serving the beverages, a plurality of storage shelves and a sink.  
         [0007]     Such prior art food preparation assemblies, while working well for the purposes for which they were intended, have not met all the needs of the manufacturers, retailers or end users by providing a food preparation station that can be easily manufactured, packaged and shipped to the consumer in a knock-down state.  
         [0008]     What is required is a food preparation station having walls which resist panel separation, buckling, racking and weather infiltration. Structural integrity is a further consideration. The station formed by the panels must tie into the cover and bottom in such a way as to unify the entire enclosure.  
         [0009]     Finally, there are ergonomic needs that a food preparation station must satisfy in order to achieve acceptance by the user. The station assembly must be easily and quickly assembled using minimal or no hardware and requiring a minimal number of tools. Further, the preparation station must not require excessive strength to assemble or include heavy component parts. The preparation station must assemble together in a manner which will not detract from the internal storage volume.  
       SUMMARY OF THE INVENTION  
       [0010]     The present invention provides a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knock-down state and constructed to form an aesthetically pleasing mobile food preparation station. The integrated connection of the side walls, cover, intermediate support, and bottom panel components simplifies the station construction. The panels are formed from injection molded plastic to interlock with one another without the need for separate fasteners or connectors. The system incorporates a minimum number of components by integrally forming the connectors into the injection molded panels which are snapped together to complete the assembly. This construction eliminates the need for separate connectors or fasteners to assemble the station assembly. Injection molding allows the panels to be formed with a single wall having integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or rotationally molded assemblies. The same side wall and bottom panel components can be used to create a variety of different assemblies useful for cookouts or outdoor entertaining and the assembly of these requires minimal hardware and a minimum number of hand tools.  
         [0011]     The base, intermediate support, and back wall panels have integrally formed outwardly projecting bosses for interlocking engagement with the left and right side wall panels. The left and right side wall panels are constructed with integrally formed inwardly contoured sockets for interlocking cooperative engagement with the bosses on the edges of the base, intermediate support, and back wall panels. The engagement between the bosses and the sockets serve to rigidly connect the components together into a weather resistant assembly.  
         [0012]     The lower surface of the base panel includes integrally formed bosses constructed and arranged to cooperate with casters to allow easy movement of the food preparation station.  
         [0013]     Accordingly, it is an objective of the instant invention to provide a preparation station composed of panels with integral connectors.  
         [0014]     It is a further objective of the instant invention to provide a preparation station with panels formed by injection molding for increased structural integrity.  
         [0015]     It is another objective of the instant invention to provide a preparation station wherein the side walls, cover, intermediate support and bottom panels are integrally interlocked without the use of separate fasteners or connectors.  
         [0016]     It is still another objective of the invention to provide a preparation station constructed of modular panels having an aesthetically pleasing appearance.  
         [0017]     It is yet another objective of the invention to provide a preparation station which houses the essential items used in preparing meals outdoors.  
         [0018]     It is still a further objective of the invention to provide a preparation station that is capable of being packaged and shipped in a knock-down state and constructed into a secure assembly at a desired site.  
         [0019]     Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0020]      FIG. 1  is a front perspective view of the preparation station of the instant invention.  
         [0021]      FIG. 2  is an exploded view of the preparation station shown in  FIG. 1 .  
         [0022]      FIG. 3  is a side perspective view of the preparation station illustrating the manner in which the handles are attached to the doors.  
         [0023]      FIG. 4  is a perspective of the preparation station illustrating side shelves and a tray.  
         [0024]      FIG. 5A  is a side perspective view of the preparation station illustrating one of the shelves.  
         [0025]      FIG. 5B  is a partial view of the side illustrating the shelf assembly.  
         [0026]      FIG. 6  is a front perspective view illustrating the corner posts for attaching the cover.  
         [0027]      FIG. 7  is a perspective view of the bottom of the preparation station. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0028]     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.  
         [0029]      FIGS. 1 and 2  now referenced illustrate perspective and exploded views of the preparation station, generally referenced as  10 , according to a preferred albeit non-limiting embodiment of the invention. The preparation station is formed from a plurality of panels connected together. These panels include a base panel  100 , a right side panel  200 , a left side panel  300 , a back panel  400 , a front portion  500 , a cover panel  600 , and an intermediate support panel  700 . The front portion  500  comprises two doors  510  and  520 , hingedly mounted to the preparation station. In the preferred embodiment the panels and doors are formed of, but not limited to, a suitable plastic such as polystyrene, polypropylene, or polyethylene, through the process of injection molding. The result is that the panels which form the preparation station  10  are formed as unitary single wall panels with integral connectors and cross bracing. The doors are formed as single wall doors with integral hinges and cross bracing. As shown in  FIGS. 1 and 2 , strengthening ribs  102  are formed within the inner surfaces of the side panels, back panel, and doors to enhance the rigidity of the panels and doors.  
         [0030]     The base panel has a top surface  104 , a bottom surface  106 , a front edge  108 , a back edge  110 , a left edge  112 , and a right edge  114  ( FIGS. 2 and 7 ). Integrally formed along the left and right base panel edges are a plurality of bosses  116  for attaching the base panel to the left and right side panels. The bosses  116  extend outwardly from each edge to cooperate with sockets  210  extending inwardly along the bottom portions  206 ,  306  of the right and left side panels respectively. The bosses and sockets are constructed and arranged so that the bosses  116  matingly engage the sockets  210 , securing the panels together in a perpendicular and inter-fitting engagement. Detent or spring lock fasteners  118  cooperate with apertures  208  to secure the bosses  116  to the sockets  210 . Those skilled in the art can appreciate that the spring lock fasteners  118  and socket apertures  208  can be used throughout the preparation station  10  to mount or secure components to one another and facilitate assembly of the preparation station from an unassembled state without the use of tools. The overlapping boss  116  and socket  210  arrangement increases the structural integrity of the preparation station by preventing the panels  200 ,  300 , and  400  from bowing or bending inwardly or outwardly and thus, adversely affecting the appearance or operation of the preparation station. Also, integrally formed on the bottom of the base panel are gussets  107  which add structural rigidity and strength to the base ( FIGS. 5A and 7 ).  
         [0031]     The right side panel  200  is configured with a first edge  212  and a second edge  214 . Both edges include integrally formed elongated sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with the bosses  116  provided along either edge of the back panel  400 . The top edge of the right side panel is provided with an upstanding lip  215  integrally formed thereon.  
         [0032]     The left panel  300  is configured having a first edge  312  and a second edge  314 . Both edges  312  and  314  include integrally formed elongated sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with bosses  116  provided along either edge of the back panel  400 . The top edge of the left side panel is provided with an upstanding lip  315  integrally formed thereon.  
         [0033]     The outer surface of the panels  200 ,  300 , and  400  are constructed as generally smooth and have a plurality of inwardly curved grooves  230  for added strength and aesthetic appearance. The insides of the panels  200 ,  300 , and  400  are constructed with a plurality of strengthening ribs  202  extending along the height of the panels. A plurality of gussets  204  are also provided on the inside surfaces of the panels to further strengthen the panels. The ribs  202  and gussets  204  increase the structural integrity of the preparation station by preventing the panels  200 ,  300 , and  400  from bowing or bending inwardly or outwardly, adversely affecting the appearance or operation of the preparation station  10 . As illustrated herein panels with all of these features may be formed by injection molding. Injection molding offers significant strength and stability advantages over blow-molding or rotational molding as utilized in the prior art. In this manner the preparation station of the instant invention is capable of handling a significant amount of weight and physical abuse as compared to prior art preparation stations.  
         [0034]     The base panel  100  is attached to the right  200  and left  300  side panels by inserting the bosses  116 , of the base panel, into the sockets  210 , of the side panels, until the spring lock fasteners  118  engage the apertures  208  in the sockets  210  of the right and left panels ( FIG. 2 ). The back panel  400  is attached to the right  200  and left  300  panels by inserting the elongated bosses  116 , of the back panel, into the sockets  210 , of the side panels, until the spring lock fasteners  118  integrally formed on the bosses  116  engage the apertures  208  in the sockets of the right and left panels ( FIG. 2 ). It will be appreciated that the purposes of the elongated bosses  116  are to align the two joined panels in a perpendicular relationship and to facilitate their mechanical connection. This results in high structural integrity and reliable operation.  
         [0035]     Referring to  FIGS. 2 and 6 , perspective views of the preparation station are shown illustrating the attachment of the cover panel. A plurality of independently formed bosses  120  are inserted into the sockets  210  formed at the upper ends of the first and second edges of the right and left sided panels. The spring lock fasteners  118  on the bosses engage the apertures  208  in the sockets  210 . The cover is then placed over the top portion of the bosses  120  which extend upwardly beyond the sockets of the side panels. These portions of the bosses are inserted into sockets  210  integrally formed at each corner of the cover panel. Spring lock fasteners  118  on the bosses engage apertures formed in the cover sockets. As shown in  FIG. 6  each boss  120  has two spring lock fasteners  118  formed thereon, thereby assuring that each boss will be securely attached to both the side panel and the cover panel. An underlying portion of the cover is constructed and arranged to cooperate with the upstanding lips  215  and  315  of the right and left side panels to align the two joined elements in a perpendicular relationship and facilitate their mechanical connection. As a result the cover panel is securely attach end to the side panels.  
         [0036]     Referring now to  FIG. 2  the intermediate support panel  700  is attached to the right  200  and left  300  side panels by inserting bosses  116 , integrally formed on the intermediate support panel, into sockets  210 , integrally formed in the side panels until the spring lock fasteners  118 , formed on the bottom portion of the boss  116  (not shown), engage the apertures  208  formed in the sockets  210  of the side panels (not shown).  
         [0037]     Referring to  FIG. 2  the back panel  400  is attached to the right  200  and left  300  side panels by inserting bosses  116 , integrally formed on the back panel, into sockets  210 , integrally formed in the side panels, until spring lock fasteners  118  engage the apertures  208  in the sockets of the side panels.  
         [0038]     The perpendicular side, back and intermediate support panels are brought into an overlapping relationship wherein the bosses  116  enter the corresponding sockets  210  in the right and left panels respectively. The result is a mechanically secure connection between the panels. The overlapping edges between the panels as described above provides a secure connection and offers several advantages. First, the design allows the panels to be connected without the need for separate connectors. Second, the design creates a positive lock which prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to each other.  
         [0039]     Referring now to FIGS.  3  ands  4 , the front panel comprises two doors, upper door  510  and lower door  520 . The upper door is configured having a first side edge  512 , a second side edge  514 , an upper edge  516  and a lower edge  518 . The lower door  520  is configured having a first side edge  522 , a second side edge  524 , and upper edge  526  and a lower edge  528 . The outer surfaces of the doors are generally smooth and have a plurality of inwardly curved grooves  230  for added strength and aesthetic appearance. The inside of the doors are constructed with a plurality of strengthening ribs  202  and gussets  530  to add further strength to the doors. Although only the inside of the upper door  510  is illustrated, the construction of the inside of the lower door  520  is the same. The integrally formed ribs  202  and gussets  530  are facilitated by injection molding. The upper and lower doors are hingedly mounted by hinge pins  532  and  534  integrally formed in the upper and lower doors respectively. The hinge pins fit into and cooperate with apertures  536  integrally formed in the base panel, intermediate support panel, and cover to facilitate pivotal opening and closing of the doors. A handle  538  is provided on the upper door and a handle  540  is provided on the lower door to assist in opening and closing the doors. The handles are provided with threaded studs  542  which are constructed and arranged to pass through apertures  544  provided in the doors. The handles are mounted onto the front of the doors by inserting the threaded studs through the apertures in the doors. A nut is then attached to each of the studs to secure the handle to the door. Each of the doors is also provided with an integrally formed latch  546 . The latches are constructed and arranged to cooperate with a portion of the first edge  312  of the left side panel to hold the doors in a closed position.  
         [0040]     Referring now to  FIGS. 2 and 7 , the casters  122  and caster bosses  124  are illustrated. The casters include a stem  126  that is constructed and arranged to cooperate with an aperture  128  integrally formed into the lower surface of the base panel. To attach the caster to the preparation station, the stem  126  is inserted into the aperture  128  of the boss  124  until a retainer ring snaps into a corresponding groove formed in the aperture. This results in a mechanically secure connection. The casters are also provided with a manually engageable and releasable lock  130  to prevent the preparation station from unwanted moves on sloped and uneven surfaces. The lock prevents rotation of the caster when in its engaged position and permits free rotation of the caster when in its disengaged position.  
         [0041]     Referring now to  FIGS. 1, 2 ,  5 A and  5 B, a shelf  720  is hingedly mounted on both left and right side panels. Each shelf is constructed with a plurality of integrally formed gussets  722  on the underside to strengthen the shelf and increase its load carrying capacity by preventing the shelf from bowing or bending. The integrally formed gussets are facilitated by injection molding. Each shelf is also provided with two hinges  724  and  726 . These hinges are formed separately from the shelf and attached thereto with fasteners. The portion of the hinge which engages the side panel is not attached thereto with fasteners. Hinge  724  is provided with a fixed hinge pin  728 . A portion of the pin  728  extends beyond the hinge, as seen in  FIG. 1 . Hinge  726  is provided with a slidable pin  730 , as seen in  FIG. 1 . Slidable pin  730  is biased to its extended position by a spring  732  mounted in the hinge. The portions of the fixed pin and slidable pin which extend beyond the hinge engage the apertures  734  formed in the edge portions of the side panels. This provides means to attach the shelves to the side panels. Each shelf is also provided with integrally formed tabs  736  which engage slots  738  integrally formed in the cover  600 . These tabs provide a means to attach the shelves to the cover and assist in securing the shelves to the preparation station.  
         [0042]     Each shelf is also provided with a plurality of hingedly mounted supports  740 , as seen in  FIG. 5B . These supports are hingedly mounted on flanges  742  which are integrally formed on the lower surface of the shelves. A portion of the support opposite the hingedly mounted portion is provided with an engagement portion  744 . The engagement portions are constructed and arranged to cooperate with a support mount  746  integrally formed in the side panels adjacent the edge portions to support the supports  740  when they are extended from the lower portion of each shelf ( FIG. 5B ). This in turn will support the shelf in its horizontal, extended, operative position.  
         [0043]     Should the use of the shelf not be required the supports can be disengaged from the support mounts and folded up, under the shelf. The shelf may then be lowered to its retracted, vertical position, as shown in  FIG. 2 . If removal of the shelf is desired, the slidable pin  730  is retracted into the hinge which disengages the pin from aperture  734  in the side panel. The shelf can then be pivoted downwardly disengaging tabs  736  from slots  738  in the cover. Also fixed pin  728  will disengage from aperture  734  in the side panel. The shelf is now completely disengaged from the preparation station and may be moved to any desired location. Assembly of the shelf onto the preparation station involves the opposite procedure of removal of the shelf from the preparation station. The location of the apertures  734  and support mounts  746  are identical on both the left and right side panel so that the same shelf may be mounted on either side of the preparation station.  
         [0044]     A tray  800  is provided for holding utensils utilized in the preparation of food or other items utilized in the service of the food. The tray is located on top of the intermediate support panel  700 . Access to the tray is gained through the opening enclosed by door  510 . The tray is provided with a plurality of vertical walls  810  which divide the tray into a plurality of compartments  812 . These compartments are utilized to hold the utensils. The tray is also provided with two handles  814 , one at each end of the tray. The handles enable the tray to be easily removed from the preparation station and carried to any desired location.  
         [0045]     All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.  
         [0046]     It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.  
         [0047]     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.