ROLL-OUT TRAY FOR A CABINET SYSTEM

FIELD OF THE TECHNOLOGY

The present disclosure relates generally to cabinet systems, and more particularly to improved devices, systems, assemblies, and methods for roll-out trays for cabinets. The present disclosure relates to drawer assemblies for a cabinet system. The present disclosure may relate to roll-out trays, roll-out tray kits, and/or to roll-out tray assemblies, for example, corner assemblies. The inventions may be considered a bracket for a roll-out tray.

BACKGROUND

Cabinets traditionally are stock inclusions in new construction operationally. Options for the front look of cabinets abound and receive much attention, however, the operation and structure of the inside of the cabinets receive much less consideration typically and offer less flexibility.

Cabinets conventionally sold by retailers or installed as “builder grade” units in new housing developments often do not have roll-out trays included in the base cabinets. Instead, they are supplied with a single, height-adjustable shelf that is half the depth of the cabinet. These shelves provide minimal storage and are inconvenient for homeowners, requiring the homeowner to get down on hands-and-knees to access items in the back of a fully stocked cabinet. Tall pantry-style cabinets are traditionally equipped with full depth shelves but reaching into the 24″ depth is inconvenient as well.

Custom and semi-custom cabinet manufacturers have offered a version of roll-out trays as an accessory option, but with an upcharge that is often rejected by new home buyers. If the homeowner later desires roll-out trays, custom wood trays can be ordered and installed through a local cabinet maker, but usually also at a premium price. Alternatively, the homeowner or a handyman can purchase wire basket roll-out units from a home center. These kits are typically stocked in only a few widths. Since the American cabinet industry typically incorporates eight stock base cabinet widths (12″ through 36″ in 3″ increments) the kits can either be too wide for a given cabinet opening or too narrow, creating considerable wasted space when installed. The dimensions are restrictive and ill-fitting for retrofit overall, installation is difficult for homeowners to undertake themselves, and expense can be prohibitive.

With traditional roll-out trays, Applicant realizes there are challenges with cost, fit, sizing, stability, durability, and retrofit. It is to these and additional challenges that the invention is directed.

Therefore, Applicants desire assemblies, devices, systems, methods, and kits for cabinet roll-out drawers/trays to improve efficiency, durability, flexibility in sizing, and cost effectiveness, without the drawbacks presented by the traditional systems and methods.

SUMMARY

In accordance with the present disclosure, roll-out tray systems, devices, assemblies, and methods are provided for use in cabinets. This disclosure provides improved systems and devices that are convenient, efficient, cost saving, and easy for the user, particularly when used in cabinets and the like.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to be used to limit the claimed subject matter's scope. The summary, along with the following figures and detailed description provide examples and are explanatory only. Accordingly, the following summary and detailed description should not be considered to be restrictive. Further, features or variations may be provided in addition to those set forth herein. For example, embodiments may be directed to various feature combinations and sub-combinations described in the summary and detailed description.

In one embodiment, the inventions of the present disclosure include a Quick-Assembly Roll-out Tray (QRT) System designed for use in, but not limited to, kitchen and/or bathroom cabinets. Roll-out Trays (AKA interior drawers or sliding shelves) may be an alternative to the fixed or adjustable shelves that come standard in base cabinets or tall pantry style cabinets. In some instances, the roll-out tray may be a retro-fit roll-out tray.

Certain embodiments include a QRT kit, in some examples, including an assembly to fit into standard 24″ deep kitchen base cabinets. Other cabinet dimensions are considered within the scope of the disclosure. The kit, in one example, may include a set of components to build one or more roll-out tray, by way of example, two roll-out trays. The kit may include an undermount drawer runner set, in some examples, one or more undermount runner set for each roll-out tray. The kit may include one or more pilasters that mount to the cabinet sides and provide height adjustment. By way of example, four pilasters may be included.

Other examples include a method of assembling and/or installing a QRT. The method may include a an easily assembled, cost effective construction that enables Do-It-Yourself (DIY) tray construction useful for consumers. The methods may include custom fitting scalable width trays for a custom fit in various cabinet applications. The methods may include easy installation and provide tool-free height positioning in the cabinet.

Embodiments may include a QRT system. In one example, a QRT system may include an extendable tray for positioning inside a cabinet. The QRT system may include Undermount Drawer Runners (UMR) that provide motion for the QRT. The system may include an Adjustable Pilaster System (APS) which may mount to the inner walls of a cabinet and provide mounting surfaces for drawer runners.

In examples of the QRT system, economy may be achieved by utilizing injection-molded-plastic corner brackets to connect a set of four wood sides of the tray with screws. In this example, this eliminates traditional joinery methods such as wood dowels or dovetail machining which may be time consuming and require sophisticated woodworking equipment with skilled labor.

A method for assembly of a QRT may include connecting a set of wood sides, front and back, and a bottom to one or more Front Corner Brackets (FCB) and Rear Corner Brackets (RCB). Connection may be made with any connection means, by way of example, with screws, bolts, adhesive, etc. Both corner brackets may provide unique features in addition to connecting the wood sides, front and back together.

In certain embodiments, inventions of the present disclosure include a Front Corner Bracket (FCB). A FCB may include an inner vertical surface which serves as a positive stop against the drawer runner when the QRT is closed. An outer vertical edge may serve as a bumper against a partially opened door when the QRT is extended. A bottom flange may cover the front edge of a metal undermount drawer runner/s, which may result in desirable aesthetics for the consumer. A front flange/s may conceal frayed edges of a wood drawer front after it is cut to length.

A conventional roll-out tray using undermount runners often requires that the drawer back be notched for clearance of the runners. Some examples may include a RCB. Two RCBs may be mounted to a shortened drawer back and replace the sections where the notches would normally be. This may eliminate, in certain embodiments, machining two cutouts for a simpler and scalable back panel. Two holes may be bored, with undermount runners, in a conventional drawer back, above the notches, to receive the rear hook components of the runners. The RCB may include a molded ledge to receive these hooks, thus eliminating the need for bored holes. Flanges may conceal the rear edges of the wood drawer back. This enables covering any unsightly fraying of the wood when the back is cut to length.

In certain embodiments, under-mount runners may determine the Roll-Out Tray to be of a specific length, therefore the wood sides of the tray may be accordingly supplied in a fixed length. The wood sides may have the mounting holes pre-bored, so no additional preparation is required. Additional systems, apparatus, and kits for 21″ depth bathroom vanity cabinets are also within the scope of this disclosure.

Embodiments may include a roll out tray for a cabinet system including a set of FCBs and a set of RCBs.

Inventions of the present disclosure may include a front corner bracket and/or a rear corner bracket.

Examples may include a QRT adapted to fit into standard American kitchen cabinet widths. In one example, a QRT may fit into cabinets 24″ wide or less, and in other examples, a QRT may fit into cabinets up to 36″ wide. As interior widths of cabinets vary by different manufacturers, the front, back and bottom wood components may be cut to size according to the desired sizing. Installation of the front and rear corner brackets, in one example, may require no pre-boring of the wood front and back components for assembly, making it an easy process for custom fitting. The components may be resized with simple straight cuts using standard wood cutting tools (table saw, miter saw, jig saw, etc.).

In certain embodiments, an Adjustable Pilaster System may be included.

One embodiment may be considered a system for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure.

One embodiment may be considered an apparatus for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure. Another embodiment may be considered methods for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure. Still other embodiments may include a kit for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure.

Certain embodiments may include a corner bracket for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure.

Examples may include a roll-out tray for a cabinet system including a pair of sides, a back and a front, a bottom, a set of front corner brackets and a set of rear corner brackets. Each front corner bracket may interface with the front at a first channel and a side at a second channel. Each rear corner bracket may interface with the back along a back ledge and a side along a side ledge. The terminating ends of the front may be secured within the first channels of the set of front corner brackets. The terminating ends of the sides may be secured within the second channels of the set of front corner brackets. In certain examples, the front corner brackets may include recesses. The recesses may be covered by a cap. An attachment may fit within the recess and the cap encloses a portion of the attachment inside the recess.

In some examples, tray sides, back, and front may be referenced as walls. The walls may include tray sides, back, and front in portions, with the FCB and/or RCB forming a portion of a tray wall. In some instances, a front wall may align perpendicularly at a front terminating end with each side wall at a 90 degree angle along an inner face of each side.

Other embodiments may include a corner bracket system for a roll-out tray including a corner bracket, a first channel, and a second channel. A first channel along one side of the corner bracket may be included for accepting a front or back. A second channel along the other side of the corner bracket may be formed for accepting a side. A recess may be included along an outer edge of the corner bracket.

The above summary was intended to summarize certain embodiments of the present disclosure. Embodiments will be set forth in more detail in the figures and description of embodiments below. It will be apparent, however, that the description of embodiments is not intended to limit the present inventions, the scope of which should be properly determined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate various embodiments of the present disclosure. The drawings may contain representations of various trademarks and copyrights owned by the Applicant. In addition, the drawings may contain other marks owned by third parties and are being used for illustrative purposes only. All rights to various trademarks and copyrights represented herein, except those belonging to their respective owners, are vested in and the property of the Applicant. The Applicant retains and reserves all rights in its trademarks and copyrights included herein, and grants permission to reproduce the material only in connection with reproduction of the granted patent and for no other purpose.

The drawings, photographs, pictures, and the like may contain text or captions that may explain certain embodiments of the present disclosure. This text is included for illustrative, non-limiting, explanatory purposes of certain examples and elements detailed in the present disclosure.

Embodiments of the disclosure will be better understood by a reading of the Description of Embodiments along with a review of the drawings, in which:

FIG. 1A is a front perspective view of a cabinet system according to an embodiment of the disclosure;

FIG. 1B is an exemplary cutaway perspective view of the cabinet system of FIG. 1A with sections cut-away and opened to provide an inside view of the cabinet;

FIG. 2 is a front cutaway view of another embodiment of a cabinet system including a roll-out drawer/tray assembly according to an embodiment of the disclosure;

FIG. 3A is a side perspective view of one example of a roll-out tray assembly tray according to an embodiment of the disclosure;

FIG. 3B is an exploded view of one example of the tray of FIG. 3A according to an embodiment of the disclosure;

FIG. 4 is a side perspective view of a side and runner of a roll-out drawer/tray assembly according to an embodiment of the disclosure;

FIG. 5A is an exploded view of a front corner bracket according to an embodiment of the disclosure;

FIG. 5B is an outside view of front corner bracket according to FIG. 5A;

FIG. 5C is an inside view of a front corner bracket according to FIG. 5A;

FIG. 5D is another outside view of front corner bracket according to FIG. 5A;

FIG. 6A is an exploded view of a rear corner bracket according to an embodiment of the disclosure;

FIG. 6B is an outside view of rear corner bracket according to FIG. 6A;

FIG. 6C is an inside view of a rear corner bracket according to FIG. 6A;

FIGS. 7A-7B show examples of assembly of a roll-out drawer/tray according to an embodiment of the disclosure;

FIGS. 8A-8B show further examples of assembly of a roll-out drawer/tray according to an embodiment of the disclosure;

FIGS. 9A-9B show back perspective views of the outside rear corner bracket of a roll-out drawer/tray according to an embodiment of the disclosure;

FIGS. 10A-10C show examples of assembly of a tray into the roll-out drawer/tray assembly;

FIG. 11A is a side perspective view of one embodiment of a cabinet system including a roll-out drawer/tray assembly according to an embodiment of the disclosure; and

FIG. 11B is a side, cut-away perspective view of one embodiment of a cabinet system including a roll-out drawer/tray assembly according to an embodiment of the disclosure

DESCRIPTION OF EMBODIMENTS

In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.

It will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified may be considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.

Certain examples and elements are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure and are made merely to provide a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

The following detailed description refers to the accompanying drawings, photographs, pictures, and the like. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. The present disclosure may contain headers. It should be understood that the headers are used as references and are not to be construed as limiting upon the subject matter disclosed under the header.

Details with regards to examples and assemblies are provided below. Although examples and assemblies are disclosed with specific functionality, it should be understood that functionality may be shared between examples and assemblies, with some functions split between examples and assemblies, while other functions duplicated by the examples and assemblies. Furthermore, the name of each example and element should not be construed as limiting upon the functionality of the example and element. Moreover, each component disclosed within each example and assembly can be considered independently, without the context of the other components within the same example, different examples and assemblies. Each component may contain functionality defined in other portions of this specification. In the present disclosure, each element can be claimed on its own and/or interchangeably with other elements of other examples and embodiments.

The following may depict an example of a method, of a plurality of methods, that may be performed by at least one of the aforementioned embodiments, or components thereof. Further, although the elements here may be disclosed in a particular order, it should be understood that the order is disclosed for illustrative purposes only. Elements may be combined, separated, reordered, and various intermediary stages may exist. Accordingly, it should be understood that the various assemblies, in various embodiments, may be performed/assembled in orders that differ from the ones disclosed below. Moreover, various steps may be added or removed without altering or departing from the fundamental scope of the depicted methods and systems disclosed herein.

The foregoing summary, and the following detailed description provide examples and are explanatory only. Accordingly, the foregoing summary and the following detailed description should not be considered to be restrictive. Further, features or variations may be provided in addition to those set forth herein. For example, embodiments may be directed to various feature combinations and sub-combinations described in the summary and detailed description.

In accordance with the present disclosure, roll-out tray systems, devices, assemblies, and methods are provided for use in cabinets. This disclosure provides improved systems and devices that are convenient, efficient, retrofittable, cost saving, and easy for the user, particularly when used in cabinets and the like.

Referring now to the drawings in general, it will be understood that the illustrations are for the purpose of describing embodiments of the disclosure and are not intended to limit the disclosure or any invention thereto. FIGS. 1A-1B show examples of a cabinet system 100. Cabinet system 100 may include a base cabinet. Cabinet system 100 is used in an exemplary manner and inventions of the present disclosure may include other cabinets and cabinetry components, by way of example, upper cabinets, kitchen cabinets, pantry cabinets, and/or bathroom cabinets. An exemplary cabinet system 100 (shown here as a base cabinet) may dimensionally, by way of example, be around 34.5″ in height and function as the foundation for a countertop. There are numerous configurations, in this example cabinet system 100 includes a carcass or shell that forms the outer perimeter of the cabinet structure. In one example, cabinet system 100 may include cabinet sides 101, a cabinet door 108, a back for mating with a wall surface, a top that may be covered or be open to receive a covering, a shelf 106, and/or one or more drawer 120 having a drawer face 110. The door 108 may be mounted on hinges 109 to the cabinet system 100. Drawer face 110 may include a decorative panel. The drawer 120 moves in and out of the cabinet system 100, in one example, by means of a set of mechanical drawer runners 130.

Cabinet system 100 may include multiple components, by way of example, that form the structure. In one example, a cabinet system 100 may include one or more components, examples of which are shown in FIGS. 1A-2. Cabinet system 100 may include sides (left and right) 101, a floor 102, a back 103, vertical frame members (stiles) 104, and/or horizontal frame rails 105. To provide vertical adjustment for a shelf 106, adjustment holes 107 may be provided. Adjustment holes 107 may be bored in columns in the cabinet sides. Cabinet system 100 may include one or more roll-out tray assembly 160. Other cabinet system 100 configurations may include, in some embodiments, multiple drawers in place of, or accompanying a door and or included in a tall utility or pantry type cabinet which may include any combination of drawers and doors.

Movement of a cabinet system 100 drawer 120, within the cabinet system, may be accomplished by way of a pair of drawer runners 130. Drawer runners 130 may include multiple holes stamped into the side rail component that enables mounting to a cabinet side 101, for example with screws. This would be an exemplary procedure when mounting a drawer runner to a cabinet without a front face-frame which are commonly found in countries outside of the USA and known as “Frameless” or “European” cabinets. With face-frame cabinets, the drawer runners 130 may be mounted to the front frame and to the cabinet back 103. Specific “face-frame-version” drawer runners may have extended side rails that connect to rear-mounting brackets 131 that are attached to a cabinet back 103, for example, with screws or bolts. The front of the drawer runners 130 may be secured with attachments, for example screws, to the vertical frame members 104, by way of example frame stiles.

A drawer 120 may include one or more of structural components, by way of example, drawer sides 121, a drawer back 123, a drawer front 122, a drawer bottom 124, and/or a drawer face 110. A drawer runner 130 may be, in certain examples, an undermount drawer runner and connects to the bottom 124 of the drawer 120 in the back 123, for example, by drawer hooks on the runner 130 that engage to the drawer back in bored holes and in the front by locking devices 133 that are mounted to the drawer front 122 and latch to the drawer runner 130.

Drawer components may be joined at the corners, for example as is traditionally used, by blind dowel joints. Wood dowels may be glued and inserted to assist with aligning and securing joints. While this type of drawer may be made with pre-finished drawer side material that is pre-grooved and pre-sized, this construction may present challenges for more custom construction and/or retrofit or differential sizing of cabinets. In another example, drawer components may be joined by dovetail joints, with the drawer sides, drawer back, and drawer front milled with sophisticated machinery to form an interlocking joint. Assembly may include glue application to the many interlocking surfaces and clamping until the glue dries. This type of drawer can be made of pre-finished drawer material, but the exposed dovetail pins on front and back parts, which were milled, may need to be touched-up with finish after the drawer is completed. Further, notches in the drawer back and hook locator holes may need to be milled after the drawer is assembled, which often requires a dedicated machine and intricate finishing.

In some examples of drawer type roll-out trays, there may be no panel attached to the fronts, with the fronts often including a scooped profile 161. Drawer runners for roll-out type trays 165 may be mounted to the cabinet system 100 in various ways. In one example, pilasters 163 (by way of example adjustable pilasters with vertical mounting holes) may be included and connect with the drawer runners 165. Pilasters 163 may rest on the floor 102 of the cabinet and may be mounted to the sides 101, for example with screws. Because, in this example, roll-out trays are mounted inside the cabinet, and behind the door, a consideration of adequate clearance may be of use for the trays to open without interfering with the cabinet frame or door hinges 109. Pilaster width may also be a consideration. Traditionally, the fronts of drawer runners may be exposed beneath, and to the sides, of conventional wood roll-out trays. This may be an undesirable situation as the runners are often zinc coated steel and do not have an aesthetic appearance. Applicant realizes this and other challenges are overcome by inventions of the present disclosure.

In one embodiment, a cabinet system 100 may include an improved drawer assembly 200′. Drawer assembly 200′ may include a roll-out tray 200. The invention in some examples may be considered a roll-out tray 200. In some examples, a roll-out tray 200 may be considered a Quick-Assembly-Roll-Out Tray (QRT). A QRT provides multiple advantages for cabinet manufacturers and the DIY community. Some examples not only provide the ability to quickly build roll-out trays, but also may enable a roll-out tray custom fit to various cabinet widths and configurations. A QRT may be designed, in certain embodiments, to be mounted on a specific type of undermount drawer runner that does not, in this example, require front locking devices, and features tool-free connection to the roll-out tray.

FIG. 3A shows one example of a QRT 200 according to an embodiment of the disclosure. QRT 200 may include tray sides 201, a tray front 210, a tray back 215, a tray bottom 220, a front corner bracket 230 and a rear corner bracket 240. The front corner bracket 230 may include a front corner cap 235. Attachments 250, 252 may secure the front corner brackets 230 and/or the rear corner brackets 240 with the tray 200.

In certain examples, a QRT 200 may include in a tray perimeter of four parts (2 tray sides 201, a tray front 210, and a tray back 215) in one example, made of a ½″×3″ vinyl wrapped composite wood profile with an integral groove for accommodating a ¼″ drawer bottom 220. These components may be joined in the corners by brackets 230, 240. The brackets 230, 240 may be plastic brackets in some embodiments. Tray sides 201 may be of a fixed length to match with undermount drawer runners. Tray sides 201 may be pre-bored to accept the runners and the corner brackets 230, 240. By way of example, 5 mm through bores may accommodate mounting holes for the corner brackets 230, 240 for some embodiments. In other examples, 6 mm bores may accommodate runner locator pins and, still in other examples, 8 mm bores may accommodate runner locking pins. Tray back 215 and tray front 210 may be variable length and cut to size to match the interior cabinet width. Pre-bored holes for assembly are not required, making retrofit simple and economical.

Tray bottom 220 may have a fixed depth to match a drawer runner 300 and may also be variable in length and cut to size to match a cabinet interior width. Front corner brackets 230 and rear corner brackets 240 may, in some examples, be symmetrical and made of injection molded plastic. In some examples, undermount drawer runners 300 may be pin-connect/pin mount style undermount drawer runners. Embodiments may include a roll-out drawer assembly 200′ for a cabinet system 100 that is a full-extension model with an option of soft-close dampening. In some examples, a drawer assembly is interchangeable with tray assembly and may only differ by selection of a decorative front face or height of the drawer/tray in the cabinet system.

A drawer assembly 200′ may include an undermount drawer runner 300 (see FIG. 4). An undermount drawer runner 300 may include a locator pin 301 and/or a locking pin 302. Undermount drawer runner 300 may mate with a tray side 201. Tray side 201 may include a side groove 202. Tray side 201 may include holes for mounting 203, receiver holes 204 for receiving a locator pin 301. Tray side 201 may include receiving holes 205 for receiving lock pin 302.

A cabinet system 100 may include a drawer (tray) assembly 200′. Examples of a drawer assembly 200′ may include a QRT (roll-out tray) 200. A QRT 200 may include a Front Corner Bracket (FCB) 230 and a Rear Corner Bracket (RCB) 240.

A Front Corner Bracket (FCB) 230, as exemplified in FIGS. 5A-5D, may include a first channel 230a and/or a second channel 230b. First channel 230a may form a channel for accepting an end of front 210. Second channel 230b may form a channel for accepting an end of side 201. In some examples, first channel 230a and second channel 230b may be aligned perpendicular to one another. Channels 230a and/or 230b may include a lip 260. FCB 230 may accept the ends of the front 210 and/or the side 201 into the FCB 230 along an inner surface of the FCB 230. The front 210 may intersect with the side 201 perpendicularly within the FCB 230. The FCB 230 may include a recess 251. Front 210 may be nestled in first channel 230a between an outer wall of the FCB 230 and the lip 260. Attachments 252 may pass through holes in the lip 260 and into the front 210, securing the front into the channel 230a. A recess 251 may be included on an outer surface along a tray side. Side 201 may tuck into the channel 230b adjacent to recess 251. Recess 251 may be separated from side 201 by a wall of the FCB 230. Attachments 250, by way of example screws, may secure into the recess 251, through the wall and into side 201, securing the side in the FCB 230. Attachment 250 may be, in some embodiments recessed attachments and terminate at an entry end inside the recess 251. A cap 235 may fit with recess 251. Cap 235 may be a front corner cap for a FCB 230. Cap 235 may cover the attachments 250 so that the attachments 250 are not visible along an outside surface of the roll-out tray 200.

In some examples, an FCB 230 may form a corner between a front 210 and a side 201. FCB 230 may align lengthwise along a plane P1 formed by the front 210. FCB 230 may extend beyond a plane P2 formed by the side 201.

A Front Corner Bracket kit may include, in some examples, a pair of FCBs. A drawer assembly 200′ may include, in some examples, a set of FCBs 230, a drawer front 210, a set of drawer sides 201, and/or an undermount drawer runner 300.

A Rear Corner Bracket (RCB) 240, as exemplified in FIGS. 6A-6C, may include a back ledge 240a and a side ledge 240b. A back ledge 240a may provide an intersection for the back 215 to adjoin the RCB 240 along one RCB side and a side ledge 240b may provide an intersection for the side 201 to adjoin the RCB along an opposite side. The RCB may be inline with the back 215 in a plane P3 formed by the back 215. The RCB 240 may separate and be between the back 215 and the side 201, such that the back and the side do not touch one another. The RCB may include mounting holes for mounting the RCB with attachments 250 that go through the holes 203 and into the RCB 240. Attachments 252 may go through ledge 240a and into back 215 securing back 215 in the RCB. The back 215 and the side 201 may secure to the RCB in perpendicular alignment to one another. An outer surface of the RCB 240 may form a part of the back, along with back 215, of the tray 200.

In some examples, an RCB 240 may form a corner between a back 215 and a side 201. RCB 240 may align lengthwise along a plane P3 formed by the back 215. A Rear Corner Bracket kit may include, in some examples, a pair of RCBs. A drawer assembly 200′ may include, in some examples, a set of RCBs 240, a drawer back 215, a set of drawer sides 201, and/or an undermount drawer runner 300.

In some examples, a set of RCB's may mount to a shortened drawer back (shortened from the width of the tray from side 201 to side 201) and frame the back 215 on each back terminal end. This may eliminate, in certain embodiments, machining two cutouts for a simpler and scalable back panel. Two holes may be bored, with undermount runners 300, in a back, above the notch/groove, to receive rear hook components of the runners 300. The RCB 240 may include a molded edge to receive these hooks, thus, in some embodiments, eliminating the need for bored holes. Flanges may conceal the rear edges of the wood drawer back. This enables covering any unsightly fraying of the wood when the back is cut to length.

The roll-out tray 200 is adjustable by the length of the sides 201 and width of the front 210 and back 215. The sides 201, front 210 and/or back 215 may be cut to desired size for a cabinet system 100 and then the FCB 230 and RCB 240 attached to form the tray (and corners) structure for the assembled roll-out tray 200. In use, after the front 210, back 215 and bottom 220 are cut to size, the components may be mounted at the front and back corners with the FCB 230 and RCB 240.

As seen in FIG. 7A-8B, details of assembling an embodiment of the FCB 230 to the sides 201 and front 210 are shown. FCB 230 may, in some embodiments, include a side surface having a side face and a front surface having a front face. A decorative face may, in some examples be attached to the FCBs along the front 210 to allow the tray front to be covered by a decorative front. The cut to size components may be assembled with the sides 201 slid into the respective channels 230a, 230b. The front 210 may be slid into FCBs on each terminating end of the front. The attachments 250, 252 may secure the front and sides to the FCBs, forming each front corner of the tray. The bottom 220 may slide into a groove 202 in each side 201. The back 215 may be secured to the RCBs 240 on each terminating end. The back with the RCBs may be secured to the sides 201 at the back of the tray with attachments 250.

The roll-out tray 200, in some embodiments, may secure to the undermount drawer runner 300. An example, as shown in FIGS. 9A-10, shows a RCB may include a RCB hook receiver 242. An undermount drawer runner rear hook 303 on the undermount drawer runner 300 may fit with the receiver 242 and removably secure the tray 200 to the runner 300. The roll-out tray may be easily removable from the runner by way of a hook-receiver-release assembly. With the tray 200 angled, the runner 300 and runner rear hook 303 may engage. With the hook-receiver-release assembly engaged, the tray may be lowered onto the length of the runner 300 and the tray sides engage with the pins 301 on the runner. Locking pins 302 may then be engaged with the side 201, securely supporting the tray on the runners. The tray may be extendable and roll-out of the cabinet housing. The tray may be extendable and roll full-length out of the cabinet housing.

FIGS. 11A and 11B show embodiments of a cabinet system 100 including a roll-out tray assembly 200′ having a QRT 200. The QRT 200, in this example, includes a set of FCBS 230 and a set of RCBs 240. One embodiment of the inventions of the present disclosure include a Quick-Assembly Roll-out Tray (QRT) System designed for use in, but not limited to, kitchen cabinets. Roll-out Trays (AKA interior drawers or sliding shelves) may be an alternative to the fixed or adjustable shelves that come standard in base cabinets or tall pantry style cabinets. In some instances, the roll-out tray may be a retro-fit roll-out tray.

Certain embodiments include a QRT kit, including an adjustable fit tray assembly to fit with a cabinet. Any cabinet dimensions are considered within the scope of the disclosure. The kit, in one example, may include a set of components to build one or more roll-out tray, by way of example, two roll-out trays. The kit may include an undermount drawer runner set. The kit may include one or more pilasters that mount to the cabinet sides and provide height adjustment. By way of example, four pilasters may be included. A kit may include a set of QRTs for outfitting a kitchen with cabinets including roll-out trays.

Other examples include a method of assembling and/or installing a QRT. The method may include a Do-It-Yourself (DIY) tray construction useful for consumers. The methods may include enabling scalable width/length trays for a custom fit in various cabinet applications. The methods may include enabling easy installation and provide tool-free positioning in the cabinet.

Embodiments may include a QRT system. In one example, a QRT system may include an extendable tray for positioning inside the cabinet. The QRT system may include Undermount Drawer Runners (UMR) that provide motion for the QRT. The system may include an Adjustable Pilaster System (APS) which mounts to the inner walls of the cabinet and provides the mounting surfaces for the drawer runners.

In examples of the QRT system, economy may be achieved by utilizing injection-molded-plastic corner brackets to connect a set of four walls of a tray, and a bottom, with screws securing each wall to the corner brackets. In this example, this eliminates traditional joinery methods such as wood dowels or dovetail machining which may be time consuming and require sophisticated woodworking equipment with skilled labor.

A method for assembly of a QRT may include connecting a set of wood sides and a bottom to one or more Front Corner Brackets (FCB) and Rear Corner Brackets (RCB). Connection may be made with any connection means, by way of example, with screws. Both corner brackets may provide unique features in addition to connecting the wood sides together.

A drawer system may include a pair of FCBs, a pair of RCBs, two drawer sides, a drawer back, a drawer bottom, a drawer front, and/or any combination of components listed.

A cabinet system may include one or more cabinets having one or more drawers including at least one of a pair of FCBs, one pair of RCBs, two drawer sides, a drawer back, a drawer bottom, and/or a drawer front.

In certain embodiments, undermount slides may determine the Roll-Out Tray to be of a specific length, therefore, the wood sides of the tray may be accordingly supplied in a fixed length. The wood sides may have the mounting holes pre-bored, so no additional preparation is required. Additional systems, apparatus, and kits for 21″ depth bathroom vanity cabinets, are considered within the scope of this disclosure.

In certain embodiments, an Adjustable Pilaster System may be included, and one example of a suitable Adjustable Pilaster System may be Quik-Tray, manufactured by Tenn-Tex of Colfax, NC.

One embodiment may be considered a system for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure. One embodiment may be considered an apparatus for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure. Another embodiment may be considered methods for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure. Still other embodiments may include a kit for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure. Certain embodiments may be considered a corner bracket for a QRT according to any of the embodiments, and/or combination of embodiments, and/or elements, disclosed in the present disclosure.

The terms tray and drawer may, in some instances, be used interchangeable within the present disclosure.

Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. Many of the novel features are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the disclosure, to the full extent indicated by the broad general meaning of the terms in which the general claims are expressed. It is further noted that, as used in this application, the singular forms “a,” “an,” and “the” include plural referents unless expressly and unequivocally limited to one referent.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein, and every number between the end points. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10, as well as all ranges beginning and ending within the end points, e.g. 2 to 9, 3 to 8, 3 to 9, 4 to 7, and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 contained within the range.

Any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection is to be defined by the issued claim(s) rather than the description set forth herein.

Elements and terms used herein refer to that which one of ordinary skill would understand such a term to mean based on the contextual use of the term herein. To the extent that the meaning of a term used herein—as understood by the ordinary artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by one of ordinary skill should prevail.

Regarding applicability of 35 U.S.C. § 112, ¶6, no claim element is intended to be read in accordance with this statutory provision unless the explicit phrase “means for” or “step for” is actually used in such claim element, whereupon this statutory provision is intended to apply in the interpretation of such claim element.

All rights, including copyrights herein, are vested in and the property of the Applicant.

The specification includes examples, the disclosure's scope is indicated by the following claims, and furthermore, while the specification has been described in language specific to structural features and/or methodological acts, the claims are not limited to the features or acts described above. Rather, the specific features and acts described above are disclosed as examples for embodiments of the disclosure. Insofar as the summary and description above and the accompanying drawing disclose any additional subject matter that is not within the scope of the claims below, the disclosures are not dedicated to the public and the right to file one or more applications to claims such additional disclosures is reserved.

ROLL-OUT TRAY FOR A CABINET SYSTEM

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