The present invention relates improved moisture resistant cabinets and vanities, including cabinets used to support plumbing fixtures, particularly in residential or high-end environments.
Residential communities such as houses, townhomes, and/or apartment complexes often face the need for fixture repair or replacement, especially in high moisture areas such as bathrooms. Additionally, in some communities such as vacation rental homes or apartments, where guests may stay in their leased residences for relatively short periods of time, fixtures such as cabinets and vanities can be subject to wear and tear, again especially in high moisture areas. Owners or maintenance personnel may be required to repair and replace damaged or worn cabinets, bathroom vanities, etc. to ensure that the residences may be rented and/or sold after the current occupants leave.
These problems can be especially noticeable when liquids such as water come into frequent contact with the surfaces of bathroom vanities and other cabinets near water sources, which can lead to water stains, mold, mildew, and other damage. Since such cabinets like bathroom vanities are typically constructed from wood or wood-based products such as particle board, plywood, fiberboard (e.g. MDF), etc., the damaging effects from water can greatly shorten the useful life of the cabinet.
Previous attempts to use plastic, such as plastic furniture, to avoid the above issues have been lacking. Plastic presents a cheap appearance unsuitable for vacation rental homes or high-end apartments and residences and is generally not suited to accommodate granite or other high-end solid surface countertops, sinks, and/or basins that are increasingly common in houses, townhouses, and nicer apartments. Additionally, plastic can be difficult to manufacture and install, as plastic vanities cannot generally be assembled using typical joinery used in woodworking/cabinetmaking.
Thus, there exists a need for improved fixtures for use in high moisture areas (e.g., vanities or cabinets for bathrooms, kitchens, laundry rooms, ships, etc.) that are constructed of durable materials, are water resistant and/or resistant to the negative effects of water, are fire resistant, and are easy to work with and install, while at the same time presenting a high-end appearance.
Embodiments of the present disclosure addresses the limitations and problems associated with the related art by providing a vanity cabinet (hereafter “vanity”) that is constructed from an improved plastic material. Such a vanity provides certain benefits not realized by prior vanity cabinet structures. For example, a vanity constructed in accordance with the present invention is water resistant and therefore resists mold, mildew, and stains, as well as the other harmful or damaging effects of water moisture, while at the same time providing better fire resistance than typical wood-based vanities.
A vanity constructed in accordance with the present disclosure is also lighter than prior vanities constructed from wood and the like, while at the same time strong enough to support granite or other high-end solid surface countertops, sinks, basins, etc. The lighter weight afforded by the improved plastic material allows the vanity to be more easily shipped and moved, while the nature of the material also allows for easier assembly using traditional joinery or cabinetmaking techniques employed for traditional wood-based cabinets. At the same time, the improved vanity avoids the low-end appearance of plastic furniture, providing a similar appearance to current high-end wood cabinets, and allowing for a variety of finishes to be applied (e.g., paint, laminates, etc.).
Embodiments of the present disclosure achieve the above benefits by providing an improved and novel cabinet or vanity for use in bathrooms, kitchens, laundry rooms or the like which is constructed from an improved plastic material. In an embodiment, the vanity comprises a base cabinet constructed from a plurality of boards formed from an improved plastic material comprising a base plastic component, a calcium-zinc based stabilizer, a foaming agent, and calcium carbonate. The improved plastic material is formed in an embodiment into substantially flat sheets that may of uniform thickness or may be of varying thickness, while in other embodiments the improved plastic material may be formed into curved sheets as desired. The sheets may then be cut or otherwise formed into boards for assembly. The The assembly may be accomplished using traditional joinery methods. A top may be attached to the base cabinet, and the top may comprise a countertop with one or more sinks.
In another embodiment, methods for making such vanities or cabinets are also provided. One exemplary method comprises the steps of: manufacturing an improved plastic material into substantially flat panels, where the improved plastic material comprising a base plastic component, a calcium-zinc based stabilizer, a foaming agent, and calcium carbonate; cutting the panels of the improved plastic material into boards; assembling the boards into a vanity casing and one or more vanity components; and applying a finish.
Further features and advantages of the present disclosure will be apparent from the specific embodiments illustrated in the drawings and discussed below.
Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:
Detailed descriptions of specific embodiments are now discussed in detail with reference to the drawing figures that were briefly described above. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the improved vanity or cabinet can be implemented and do not represent an exhaustive list of all of the ways they may be embodied. As used herein, the word “exemplary” is used expansively and should be understood to refer to embodiments that serve as illustrations, specimens, models, or patterns. It will be understood that the vanity or cabinet and/or the method described herein may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to ease understanding of the disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention. Unless otherwise indicated, like parts are referred to with like reference numerals.
Vanities in accordance with the present disclosure may be constructed of an improved plastic material. In an embodiment, this improved material may have as its main content polyvinyl chloride (PVC) to which a foaming agent, a calcium-zinc (Ca—Zn) based or composite stabilizer, a foam regulator, a lubricant, calcium carbonate, and other non-wood materials may be added during manufacturing to form the improved plastic material. In an embodiment the Ca—Zn stabilizer is used for stabilizing foaming to make the foaming more even and/or the density more evenly spread. In another embodiment, the Ca—Zn composite stabilizer may be instead or additionally used as a heat stabilizer during the preparation or manufacture of the improved plastic material through foaming extrusion or other suitable process to create a PVC-based foam board for example.
The improved plastic material may be manufactured into flat panels or sheets, similar to an MDF or plywood sheet. In other embodiments, the panels or sheets may be curved instead of flat. In some embodiments the panels or sheets may be generally rectangular in shape, while in other embodiments, the panels or sheets may be formed into a non-rectangular shape as desired. The panels or sheets may have a thickness between 5 mm and 25 mm, and the thickness of the panel or sheet may depend on one or more of: how the sheet is formed, the type of vanity being constructed, the component of a vanity being constructed, another factor, or a combination thereof. These panels of sheets of the improved plastic material may then be cut into pieces or “boards” that may be used to manufacture cabinets of any desired shape, feature, or dimension. Advantageously, these panels of improved plastic material may be cut, routed, shaped, or sized using typical cutting methods and tools used for wood, without the need for (or expense of) special cutting or shaping tools. The pieces or “boards” of the improved plastic material may also be attached, assembled, or joined together using typical methods, tools, and fasteners used for wood (e.g. screws or pocket screws, glue, biscuits, nails, etc.). Similarly, the assembled vanity casing may be finished using typical methods, tools, and processes used for wood (e.g. paint, attaching veneer, etc.) without the need for special glues or preparations needed for finishing plastics.
Referring to
The right section 12a roughly forms a box with an open right top 13a constructed from right outside wall 18a, right inside wall 20a, right back wall 14a, right bottom 22a, and right front brace 24a. As illustrated in
In the illustrated embodiment of
Finally, in the illustrated embodiment vanity 10 also includes a center section 12c formed from the inside wall 20a of the right section 12a, the inside wall 20b of the left section 12b, center bottom 22c, top 13c, and a back wall (not illustrated). In the illustrated embodiment, top 13c of the center section 12c is closed as there is no need to accommodate a sink or basin in this portion of vanity 10, and top 13c may be a board of the improved plastic material. Additionally, the illustrated center section 12c is configured with a front having two separate openings, such as a top opening to accommodate a drawer and a bottom opening to accommodate shelves, or cabinet doors. Center section 12c may be configured differently in other embodiments, or may be omitted entirely, such as when a narrower vanity 10 is desired to fit into a particular bathroom space.
As will be understood, the arrangement of vanity 10 of
Turning to
The right section 112a roughly forms a box with an open right top 113a constructed from right outside wall 118a, right inside wall 120a, right bottom shelf 122a, and right front brace 124a. As illustrated in
In the illustrated embodiment of
Vanity 100 of
In the illustrated embodiment of
Vanity 100 also includes a center section 112c formed from the inside wall 120a of the right section 112a, the inside wall 120b of the left section 112b, and center bottom shelf 122c. In the illustrated embodiment, top 113c of the center section 112c is open, but is configured with bracers 115c similar to bracers 115a of right section 112a and bracers 115b of left section 112b. Additionally, the illustrated center section 112c is configured with a front having multiple openings above the bottom shelf 122c which may remain open as shelves in the final vanity 100 or may accommodate drawers. Similarly, center section 112c is also configured with an opening formed between bottom shelf 122c and lower bottom shelf 130c which also may remain open as a shelf in the final vanity 100 or may accommodate a drawer. Center section 112c may be configured differently in other embodiments, or may be omitted entirely, such as when a narrower vanity 100 is desired to fit into a particular bathroom space.
Vanity 100 of
The finish may be applied to vanity 100 after assembly of the boards into the casing illustrated in
Additionally, countertop 250 includes two sinks 252a, 252b or basins, which in an embodiment may be separate components that are separately installed or attached to the countertop 250, such as with adhesive and/or screws or bolts. In another embodiment one or more of sinks 252a, 252b may be formed into/with countertop 250 such that sinks 252a, 252b and countertop 250 are one component and/or installed together.
As will be understood, the size and shape of countertop 250 and/or sinks 252a, 252b may vary as desired, and in some embodiments, sinks 252a, 252b may be “drop in” basins the top of which extend above the top surface of countertop 250. It will also be understood that although a countertop 250 has been shown in
Vanity 200 of
Vanity 200 includes a set of bottom drawers 240a, 240b, 240c at the bottom front of each of right section 212a, left section 212b, and center section 212c respectively. The upper front of center section 212c does not have doors but instead is configured with a series of center drawers 242c arranged vertically (i.e. “stacked” on top of each other). It will be understood that other configurations for the center section 212c are possible, and that in other embodiments center section 212c may have more or fewer drawers 242c than illustrated or may be configured with one or more doors (not illustrated) or open shelves (not illustrated) rather than drawers 242c. All such variations are intended to be within the scope of the present disclosure.
Also, although a bathroom vanity fixture has been shown and described, the present disclosure is not limited to such fixtures. It is envisioned that other cabinet structures such as other cabinets (e.g., kitchen sink vanity cabinets, laundry room cabinets, outdoor cabinets, built in cabinets, cabinets on a boat or ship, etc.) and the like may be constructed in accordance with the present disclosure and such cabinets or vanities would provide similar benefits to those discussed above with regard to lighter weight; ease of construction; durability; water, stain, moisture, mold, and/or mildew resistance; fire resistance; etc.
Turning to
In block 412, the improved plastic material is formed into sheets or panels. This may be accomplished to by foaming extrusion or other suitable process to create a PVC-based foam panel for example. Although illustrated as separate steps, block 410 and 412 may be combined in some embodiments such that the improved plastic material is created and manufactured into panels or sheets in one step, rather than as two separate steps. Regardless of the number of steps, the improved plastic material is manufactured into panels or sheets. In an embodiment the panels or sheets may be substantially flat and rectangular, similar to an MDF or plywood sheet. In other embodiments, the panels or sheets may be curved rather than flat and/or formed into non-rectangular shapes. In an embodiment, the panels or sheets are of uniform thickness, while in other embodiments the panels or sheets may vary in thickness as desired. The thickness of the panel or sheet may vary or depend on one or more of: how the sheet is formed, the type of vanity being constructed, the component of a vanity being constructed, another factor, or a combination thereof. In an embodiment, the thickness of the panels or sheets may be and/or may vary between 5 mm and 25 mm.
Once formed, the sheets or panels of the improved plastic material may be cut into pieces or “boards” in block 414. Such boards may be of any desired shape, feature, or dimension suitable for the vanity or cabinet being built and may include boards for assembling into a cabinet base, shelves, doors (such as frame and panel doors), drawers, legs, tops, etc. For example, the boards may be substantially flat or may be curved as desired and/or the boards may be substantially rectangular in shape or may be non-rectangular in shape as desired. The improved plastic material may be cut, routed, shaped, or sized using typical cutting methods and tools used for wood, without the need for (or expense of) special cutting or shaping tools.
In block 416 the pieces or boards of the improved plastic material may be attached, assembled, or joined together into the casing and/or other components of the vanity. Assembly may occur using typical methods, tools, and fasteners used for wood (e.g. screws or pocket screws, glue, biscuits, nails, etc.). As will be understood, it is possible, but not necessary, that a single panel is used to make one vanity. For example, boards from one panel (which may have a first thickness) may be used to assemble casings for a set of vanities, while boards from a second panel (which may have a second thickness) may be assembled into drawers or doors for the same set of vanities, and boards from a third panel (which may have a third thickness) may be assembled or fitted into tops for the same set of vanities. In an embodiment one or more of the first, second, and third thicknesses may be between 5 mm and 25 mm.
Moving to block 418, the assembled vanity casing and/or other vanity components may be finished using typical methods, tools, and processes used for wood (e.g. paint, attaching veneer, etc.) without the need for special glues or preparations needed for finishing plastics. Although block 418 is illustrated as being after the vanity is assembled the step of applying finish of block 418 may occur at other times in various embodiments, and where the finishing of block 418 occurs may depend on the finish being applied.
For example, in a vanity where a wood veneer is desired, such veneer may be applied to the improved plastic material immediately after block 412 when the sheets or panel of improved plastic material are formed. Such veneer or film may be applied through a heat press process or other means. In another example, in a vanity where a paint finish is desired, block 418 may occur after block 412 where the sheets or panels are formed, may occur after block 414 after the sheets or panels have been cut into boards (if for example doors will receive a different color than the casing), or may occur after block 416 as illustrated in
Finally, in block 420 a top may be applied to the vanity. In an embodiment, the top may be a countertop 250 illustrated in
Having described exemplary embodiments of the improved vanity and an exemplary method of manufacturing an improved vanity with reference to the attached figures, it will be appreciated that changes and modifications may be made to any of the exemplary embodiments shown and/or described herein without departing from the spirit or scope of the disclosure.
Within the scope of this application it is intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the drawings may be considered or taken independently or in any combination thereof. It will be understood that features or elements described in connection with, or relation to, one embodiment are applicable to all embodiments unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated into, or combined with, any of the other embodiments disclosed herein, and the features or elements extracted from one embodiment may be included in addition to, or in replacement of, one or more features or elements of another embodiment. Similarly, a feature, or combination of features, of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment and/or a feature, or combination of features, of an embodiment may be omitted from that embodiment.
Number | Date | Country | |
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62876641 | Jul 2019 | US |