Patent Application
20220288810
This invention relates generally to cabinets, and more particularly to a new and improved cabinet system for outdoor applications.
An outdoor cabinet in accordance with the present invention refers to a device which is made of metal or non-metallic material, exposed to the influence of the natural climate.
Conventional cabinets and cabinet systems have been in use for centuries and are well known. Conventional cabinets are widely used in both commercial and residential establishments and serve many purposes, both functional and aesthetic. For example, cabinets not only offer suitable storage space for items and objects, but cabinets may also be some of the more ornate fixtures in any homeowner's elaborate kitchen, bath, garage, or other similar space.
However, conventional cabinets are not designed nor constructed for outdoor applications. Conventional cabinets have been installed in outdoor locations, but they are not constructed to withstand the elements such as rain, snow, frost, direct sunlight and high humidity. Most significantly, conventional cabinets are susceptible to water damage, because the materials used to construct them are highly susceptible to liquid. For example, conventional cabinets are often constructed with plywood, particle board or chipboard, or medium-density fiberboard (“MDF”). Water damage in conventional cabinets often leads to panel expansion, delamination, failure of the joints and ultimately failure of the cabinet.
Accordingly, there is a need in the cabinetry market for a cabinet that solves the above-mentioned problems. Specifically, there is a need for a cabinet that is designed and constructed expressly for outdoor installation.
The present invention is directed to an outdoor cabinet and includes at least one carcass fabricated from a waterproof engineered wood. The carcass has plurality of walls and a waterproof facing on at least one of the walls. The cabinet includes at least one door fabricated from a thermoplastic polymer. The door is attached to the carcass by at least one hinge. The engineered wood may be medium density fiberboard. The thermoplastic polymer may be high density polyethylene. The waterproof facing may be melamine.
The cabinet may include at least one decorative panel disposed on at least one wall of the carcass, where the decorative panel is fabricated from, for example, a thermoplastic polymer. The thermoplastic polymer may be a high-density polyethylene. The walls of the carcass may be stapled together, nailed together, doweled and glued together or any combination thereof.
The cabinet may have at least one shelf made of the melamine-faced waterproof medium density fiberboard composite. The cabinet may include at least one drawer made of the melamine-faced waterproof medium density fiberboard composite. A decorative panel may be attached to a wall of the drawer. The decorative panel may be fabricated from high density polyethylene material. The high-density polyethylene may be solid, marine-grade, high density polyethylene.
It should be understood that the phraseology and terminology used below for the purpose of description and should not be regarded as limiting. The use herein of the terms “comprising,” “including,” “having,” “containing,” and variations thereof are meant to encompass the structures and features recited thereafter and equivalents thereof as well as additional structures and features. Unless specified or limited otherwise, the terms “attached,” “mounted,” “affixed,” “connected,” “supported,” “coupled,” and variations thereof are used broadly and encompass both direct and indirect forms of the same.
The present invention is directed to a combination of the solid, marine-grade thermoplastic polymer, for example, high density polyethylene (HDPE), doors and decorative panels mounted on a waterproof carcass made from an engineered wood (for example, waterproof medium-density fiberboard (MDF)), having a waterproof facing (for example, a resin based facing such as melamine), to provide a cabinet box that performs like a wooden cabinet, thereby allowing an installation contractor to easily modify and connect plural cabinets together. The thermoplastic polymer (e.g., HDPE) doors and decorative panels are suited for direct exposure to the elements (e.g., sun, rain, snow, frost). The melamine-faced waterproof engineered wood (e.g., MDF) carcass of the cabinet of the present invention can be cut and drilled using standard wood blades and drill bits. It can also be stapled, nailed and glued therefore allowing the carcasses of the cabinets to be glued together, unlike prior art outdoor cabinets made entirely of HDPE, which cannot be glued together stapled and/or nailed and require the use of stainless-steel screws, which can be easily stripped out.
As used herein, the terms “cabinet box” and “carcass” are used interchangeably to refer to the main framework or body of a cabinet, not including any coverings, doors, front face panels (including frames for the front face panels) and nonstructural shelves.
Referring now to the drawing figures wherein like reference numbers refer to like elements throughout the several views, there is shown in
As illustrated in
The side walls 14 and 16, back wall 18, top wall 20, and bottom wall 22 of the carcass 12 are constructed from a melamine-faced waterproof engineered wood (e.g., waterproof medium density fiberboard (MDF)) composite material 50. An example of such a waterproof, engineered wood composite material is sold under the tradename, All-Weatherboard® sold by Weatherstrong, an Ideal Cabinetry Company. As can be seen in
The melamine facing 54 of the composite material 50 of an exemplary embodiment of the present invention is a thermo-fused low pressure laminate skin. More specifically, the melamine facing 54 may comprise a decorative paper impregnated with a resin. The melamine is laminated onto the side surfaces of the engineered wood 52 using a low-pressure lamination process. In this process, the resin impregnated decorative paper is pressed onto the side surfaces 52A, 52B of the engineered wood 52 under extreme heat and pressure using a press plate. The heat activates the resin in the decorative paper, which fuses the paper to the side surfaces of the MDF panel to create the composite material 50. Therefore, the resulting melamine facing essentially becomes part of the MDF panel. The texture of the press plate is transferred to the melamine facing to provide the melamine facing and therefore, the MDF panel, with a certain finish. This finish can include, for example, a matte, gloss, stipple, or woodgrain finish. The edges of the MDF panel can be sealed with a waterproof PVC banding 56.
The composite material 50 of the carcass 12 can be assembled together to form the carcass using a conventional wood dowel and a glue system, with the addition of stainless steel staples.
The shelves 30 (
As illustrated in
Any of walls 14, 16, 18, 20, 22 of the carcass 12 and/or front wall(s) (not visible) of the drawer(s) 40 that are to be exposed to the external environment, may be covered with a decorative panel 28 made of, for example, the solid, marine-grade, HDPE material that is attached to the corresponding wall 14, 16, 18, 20 of the carcass 12. The decorative HDPE panels 28 can be attached to the walls 14, 16, 18, 20 of the carcass 12 with conventional fasteners, such as stainless-steel screws or a construction adhesive such as Liquid Nails®. For example, as illustrated in the embodiment of the cabinet 10 shown in
The drawer 40 of the embodiment of the cabinet 10 illustrated in
In some embodiments, the solid, marine-grade, HDPE doors 24 and decorative panels 28 can be ⅝″ thick. The solid, marine-grade, HDPE doors 24 and decorative panels 28 can be routed with different decorative patterns and finishes (solid colors or woodgrain colors; not shown).
A plurality of the outdoor cabinets 10, 10′, 10″ can be assembled together to build an outdoor kitchen or an indoor kitchen.
As noted, the combination of the solid, marine-grade HDPE doors 24 (and decorative panels 28) mounted on a melamine-faced waterproof MDF carcass 12 provides a cabinet box that performs like a wooden cabinet, thereby allowing an installation contractor to easily modify and connect plural cabinets 10, 10′, 10″ together, while the HDPE doors 24 (and decorative panels 28) are suited for direct exposure to the elements (sun, rain, snow, frost). In particular, the melamine-faced waterproof MDF carcass 12 of the cabinet 10, 10′, 10″ of the present disclosure can be cut and drilled using standard wood blades and drill bits. It can also be stapled, nailed and glued therefore allowing the carcasses of the cabinets to be glued together, unlike prior art outdoor cabinets made entirely of HDPE, which cannot be glued together stapled and/or nailed and require the use of stainless-steel screws, which can be easily stripped out. Although HDPE can be cut and drilled HDPE with wood blades and drill bits, such cutting and drilling requires extra care.
It should be understood that the invention is not limited to the embodiments illustrated and described herein. Rather, the appended claims should be construed broadly to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.
This application claims priority to U.S. Provisional Patent Application No. 63/160,487, entitled Outdoor Cabinet, filed Mar. 12, 2021, pending.
| Number | Date | Country | |
|---|---|---|---|
| 63160487 | Mar 2021 | US |
