Patent Grant
9596933
The following relates to framed cabinetry and more specifically relates to novel and improved face frames for cabinets which enable substantially increased access through the front opening into the interior of the cabinet over traditional framed cabinets.
Traditional framed wood cabinets have supporting face frames which are typically made up of narrow depth rectangular strips of hardwood surrounding the cabinet box front opening. Cabinet carcasses or cabinet boxes were usually constructed separately from the face frame. The face frame provides stability and integrity to the overall cabinet, as well as the ability to adjust and maintain the squareness of the cabinet box. The face frame also provides a surface on which to mount hinges for doors. The frame is assembled as one complete unit by connecting multiple solid wood members together and then applying the frame to the cabinet box at final assembly. Materials other than solid wood may be used for the frame. An example of a face frame is shown in
More recently, with the introduction of modern engineered wood, such as particle board and fiberboard, cabinet boxes can be made more square. However, the face frame members, namely, the vertical “stiles” and horizontal “rails” protrude into and overlap the entrance or front opening of the cabinet and interfered with access to the cabinet interior. Moreover, the narrowed openings created by the face frame further reduce the volume and accessibility of space available for shelves, drawers and internal accessory components, resulting in wasted interior space. A more extensive discussion of the distinctions in cabinet construction can be found in Wikipedia under “Kitchen Cabinet,” the entirety of which is incorporated herein by reference.
With reference primarily to
In contrast, and in an attempt to overcome the limitations of face frame cabinets, frameless cabinets were developed in Europe following World War II. Frameless or full access cabinets utilize thicker, engineered wood, such as particle board, plywood or fiberboard to construct a cabinet box without a face frame. Top panels or stretchers are required and the side, top and bottom panels made of such thicker wood products provide the needed stability and reinforcement provided by the face frames in traditional cabinets. By eliminating the face frame, frameless cabinet boxes result in better utilization of interior space than the face frame cabinet boxes, among other advantages. Nevertheless, frameless cabinet boxes also have disadvantages, including requiring the use of thicker, heavier panels to achieve satisfactory stability and a top panel or stretcher to maintain squareness of the cabinet box due to the absence of a face frame. As used herein, the term cabinet box includes box panel assemblies with or without doors, including cabinets and bookcases. In addition, another disadvantage is the lack of a uniform aesthetic appearance to the front of the cabinet box, especially when adjacent cabinet boxes, bookcases or fillers are made from different materials. Plastic or wood corner blocks may also be needed for additional squareness and rigidity.
A further and more recent attempt to address cabinet construction has resulted in the introduction of a semi-frameless cabinet. Examples of semi-frameless cabinets are found in U.S. Pat. Nos. 7,306,299 and 7,451,535, owned by MasterBrand Cabinets, Inc of Jasper, Ind. Semi-frameless cabinets are made using the frameless cabinet model, but relatively thin wood veneers or edge strips are added to the front edge of the side, top and base panels to provide for a more finished “frame-like” appearance to the front of the box panel assembly or cabinet box.
In addition, compared to a framed cabinet box, thicker panels are required in a frameless cabinet box. This necessarily adds weight and cost to the end cabinet box. In addition, the width of a cabinet box made in this manner is limited. The horizontal panels or stretchers will sag or bend under their own weight, or due to the weight of objects placed thereon, if the width spans a greater distance. Such sagging may also compromise drawer construction and operation. Further still, because each panel 82, 84 and 86 has a separate veneer 80 on the front edge, cabinet boxes made in this manner have a lower aesthetic quality. This latter disadvantage results from the way in which frameless cabinet boxes are made and assembled. Typically, a wood veneer is affixed to the front edge of the side, top and bottom panels to give the front of the frameless cabinet box an aesthetic wood appearance. The veneer is added to each of the cabinet box panels separately. Often the individual panels are made separately and stored in inventory for later assembly. Thus, it is not unusual for the front aesthetic veneers to vary in color not only within one cabinet box but also within adjacent cabinet boxes. Further still, there will always be seams between each discrete edge or piece of veneer 80 where one panel is positioned adjacent to another panel. In addition, there is no ability to have a single piece rail or horizontal edge of any relatively long distance, such as is the case with a row of adjacent cabinets or bookcases joined together, because each horizontal rail of each cabinet box is made with a separate piece of veneer. Nor is there any ability to add custom detailing, such as by routing, to any length of horizontal rail. In addition, there is no ability to add a custom extension, for example, when spanning a gap to abut a wall or when dealing with a non-plumb wall surface, or to eliminate a toe kick, without creating more seams.
In view of the foregoing, there continues to be a need for framed cabinets, but which do not reduce the opening size of the entrance in relation to the cabinet interior, particularly across the width between the stiles. There also continues to be a need for stiles to have a deeper or longer depth to provide an extended solid wood securement surface and to accommodate a greater variety of hinges. There also continues to be a need for cabinet boxes that blend the advantages of framed and frameless cabinets while eliminating the disadvantages of both. The embodiments of the present invention solve this long-felt need.
According to one embodiment of the present invention, a semi-full access framed cabinet box is provided. A semi-full access framed cabinet box utilizes a face frame. However, the vertical frame components or stiles mounted on the front of the cabinet box are inverted or rotated ninety degrees (90°), in a manner to be described below, so that the inner surface of the stile is substantially flush with the inner surfaces of the cabinet box side panel to eliminate interference and interior access issues. Yet, by retaining a face frame, necessary reinforcement or structural support to the cabinet box is provided, allowing box panels to be made from thinner, lighter and less expensive components and, if desired, eliminated the need for a top panel. Moreover, by inverting the stile orientation ninety degrees (90°), the dimension of the stiles is longer in depth (parallel to the surface of the side panels) than width. The additional depth enables and enhances mounting of hardware, such as Eurohinges and drawer guides, flush to the interior surface of the frame stile rather than the interior surface of the side panels. Mounting the hinges and drawer guides to a solid wood frame member instead of a non-solid wood side panel provides a superior longer lasting mounting. In this embodiment, it should be appreciated that the top and bottom rails are not reoriented or inverted so that the access or opening size is increased only across the width of the entrance.
In accordance with the first embodiment, in another aspect of the invention, a method of making and assembling a framed cabinet is provided, the method comprising:
obtaining a box panel assembly including two side panels, a bottom panel, and a rear panel, each panel having an inner surface and an outer surface, wherein when assembled the inner surface of each panel faces an interior space defined by the box panel assembly and the outer surface of each panel forms an exterior surface of the box panel assembly, the box panel assembly having a front end with an opening having a height and a width;
obtaining at least two stiles and at least two rails, the stiles and rails each having a generally rectangular cross section, the stiles and rails each having an inner surface and an outer surface spaced apart from each other and two opposed end surfaces spaced apart from each other, wherein the inner and outer surfaces are wider that the end surfaces;
attaching a first stile to the front edge of a first side panel such that the inner surface and outer surface are oriented approximately parallel to the side panel and a the end surfaces are oriented approximately perpendicular to the side panel;
attaching a second stile to the front edge of a second side panel such that the inner surface and outer surface are oriented approximately parallel to the side panel and a the end surfaces are oriented approximately perpendicular to the side panel;
attaching a first rail to the front edge of a bottom panel;
assembling the side panels, bottom panel and rear panel into a box shape such that the first rail extends between the two stiles;
positioning a second rail between the two stiles and spaced from the first rail;
interconnecting the first and second rails to the first and second stiles for form a face frame at the front end of the box panel assembly, whereby the orientation of the two stiles permit substantially full access into the interior space of the box panel assembly across the width of the opening, and whereby the face frame provides structural support to the panel assembly to permit utilization of a box panel assembly.
According to a second embodiment, a full access framed cabinet box is provided. In this embodiment, a face frame is also provided but both the stiles and rails are inverted or rotated ninety degrees (90°) so that the inner surfaces are substantially flush with the interior panel surfaces without substantial or significant overlap. In full access framed cabinet boxes the stiles and rails generally are deeper than they are wide. In other words, the frame members generally retain their overall rectangular cross-section, but the longer dimension is in the direction of the depth of the cabinet—extending in the same direction as the respective interior and exterior surfaces of the panels to which they are attached.
In accordance with the second embodiment, the method of making and assembling the cabinet box may be quite similar, except that the horizontal frame members or rails are oriented with the longer dimension parallel to the bottom panel. Alternatively, the face frame may be fully assembled and aesthetically finished and in a subsequent step affixed to the cabinet box as a single piece.
With regard to semi-full access or full access framed cabinet boxes, it should be appreciated that the stiles or rails need not be absolutely flush with the panel surfaces but may have a slight overlap. This enables placement of a skin or finishing veneer on the inner and outer surfaces of the panels in the event of scratching, damage, etc. The slight exterior overlap of the inner surface with respect to the inner surface of the panel also prevents scoring or gouging of the edges of the side panels, for example, when the drawers or internal fittings are being mounted. The slight overlap exterior overlap of the outer surface of the stile relative to the outer surface of the side panel permits a veneer to be added to the outer surface of the side wall of an end cabinet to cover scratching or damage incurred during shipping and installation.
With either semi-full access or full access framed cabinet boxes, it should be appreciated that different dimensioned frame members may be utilized as may be appropriate for the final installation. Thus a bottom frame member or rail associated with a base panel may extend to the floor in situations where a toe kick is not desired. Similarly, stiles or frame members associated with side panels may extend laterally outwardly to fill gaps between adjacent cabinets or between an end cabinet and a wall. In each of these scenarios, by utilizing a single solid wood piece, seams are eliminated and a higher custom finish is achieved. Similarly, rails and stiles may be customized such as with routing to add aesthetic detail. In the same light, a single continuous solid wood frame member may extend across a row of multiple cabinets and/or bookcases to provide a uninterrupted valance and decorative rail elements, particularly with open face cabinet boxes, without adding cost or complexity, but eliminating seams and non-matching finishes. Further still, the frame may be stained and finished all at one time to ensure uniformity in aesthetics not only among the frame members of a single cabinet box, but also the frame members of all cabinet boxes in an overall construction project.
Accordingly, the semi-full access framed cabinetry and full access framed cabinet boxes retain a number of advantages of framed cabinet boxes over frameless cabinet boxes and incorporate access advantages of frameless cabinet boxes, while eliminating the drawbacks of standard framed cabinet boxes and standard frameless cabinet boxes. For example, framed cabinet boxes restrict the opening to the interior of the cabinet box and reduce accessibility and storage capabilities; restrict the width capacity of internal accessories due to the face frame opening restriction; and require the use of compact hinges that are not as strong and versatile as larger or European type hinges. At the same time framed cabinet boxes overcome a number of weaknesses in frameless cabinet boxes; namely, susceptibility to “racking” (being out of square) due to absence of a legitimate wood frame; use of thick and heavy panels which are required for rigidity, robustness and component connection; and use of a sealed top panel or substantial stretcher that inhibits or prevents access to the interior of the box from the top when installing and manufacturing and also adds weight and cost. In addition, manufacturing and construction of frameless cabinet boxes typically requires greater precision to achieve necessary flush front and end surfaces of the panels as there is no face frame to conceal imperfect front edges. Also because of the absence of a face frame all frameless box ends are visible. As a result, when the front ends are damaged in shipment or installation, the entire cabinet box must be replaced. Alternatively, if a veneer is applied to the box end face of a frameless cabinet, damage to the veneer would leave the front end of the damaged panel visibly exposed, thus creating an unattractive, unfinished look to the cabinet face.
In a preferred embodiment, a stile in a semi-full access frame or a stile and rail in a full access frame has a depth to width ratio of 2:1, but the ratio may vary from as little as approximately 1:1 to 3:1. Of course this does not include frame members with extended surfaces, for example as is illustrated in
Cabinet making has existed for centuries. While a long felt need has existed for greater access to and utilization of the internal volume of a cabinet and greater quality construction at reduced material and manufacturing cost, this need has not been fully or effectively satisfied by the introduction of frameless cabinets and/or semi-frameless cabinets with front edge veneers within the last half-century. As explained herein, numerous disadvantages exist with frameless and semi-frameless cabinet construction. The concepts and embodiments of the present invention overcome these known disadvantages and, in doing so, have satisfied a decades-long continuous need in the field of cabinets and cabinet making.
The above and other objects advantages and features will become more readily understood from a consideration of the following detailed description when taken together with the accompanying drawings in which:
It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted from these drawings. It should be understood, of course, that the invention is not limited to the particular embodiments illustrated in the drawings.
Referring to first alternative embodiments shown in
As illustrated in more detail in the embodiment of
In the embodiments of
In the form of cabinet shown in
In one assembly process, the panels comprising the cabinet box are joined together in accordance with well known manufacturing practices, and the face frame is assembled to the cabinet box by gluing along the joints between the interfitting portion and the rails assembled between the stiles and temporarily secured together, such as, by gluing. Once tightly assembled together to meet dimensional requirements the frame members are permanently fastened by nails or dowels. This design preserves the strength of a traditional face frame cabinet box but gives substantially improved accessibility like a frameless cabinet box. The use of inverted frame members also permits the use of a less thick end or rear panel material because the strength of the cabinet is preserved in the frame and, to a lesser extent, the panel. In addition, because the frame stiles are oriented in an inverted position with a longer depth there are also multiple methods of securing the frame including deep dados (currently being used), lock dados, doweling, biscuits and others. Examples of these types of available connections are shown in
In addition, the longer or deeper dimension of the stiles 36 in the direction of the side panels enables a more secure mounting of a greater variety of drawer guides and hinges, including quick-release hinges 21, commonly referred to as Eurohinges, to the solid wood frame, rather than to the panels. A solid wood frame provides a more substantial mounting material for wood screws resulting in a longer lasting, more sturdy assembly. One such hinge is manufactured and sold by Grass Company of Kernersville, N.C.
In contrast are the semi-full access and full access cabinet boxes of
Thus, it should be appreciated that a traditional face frame cannot accommodate the same quick release hinge as well or other hinges having long base plates because of the limited dimension of the frame parallel and perpendicular to the side panel and that the frameless and semi-frameless cabinet boxes do not allow for attachment to solid wood components.
Another modified form of corner detail is illustrated in
In the second embodiment, shown in
As shown in
The corner detail views of
The concepts of the semi-full access inverted frame and/or a full access inverted frame may also be incorporated into cabinet boxes with inset doors.
Regarding hinges, the hinges 21 used in the traditional cabinet of
There are also aesthetic differences.
Incorporating either a semi-full access inverted frame or a full access inverted frame into the cabinet construction also allows the cabinet to utilize current efficiency manufacturing methods in including face “frame down assembly” and “dado joining” of box components vs labor intensive doweling and case clamping.
From the foregoing, it will be apparent that the framed cabinetry of the type described avoids a number of weaknesses of traditional framed cabinetry as well as frameless cabinetry while at the same time retaining a number of the favorable characteristics of both types of cabinetry. Specifically, with respect to framed cabinetry, it offers the same superior strength compared to frameless, lends itself well to applied end skins and interior skins to repair cabinetry when needed, allows for extended stiles and fillers to be applied to the face frame members and composed of the same material as the box face, allows for construction and manufacturing methods that are very efficient and cost effective, flexibility of installation, for example, utilizing a more open top for ease of access to interior, allows for flexibility of movement from cabinet to cabinet or cabinet to wall if needed, and is able to utilize solid wood secured together with greater strength and securing than non-solid components.
It is therefore to be understood that while different embodiments are herein set forth and described, the above and other modifications and changes may be made in the construction and arrangement of elements as well as intended use of the apparatus without departing from the spirit and scope thereof. For example, the corner details shown are given more for the purpose illustration but not limitation. It is also understood that while not a preferred method one could also potentially create a frame a similar nature using square stiles instead on deeper stiles. This however would be very week and nature and would likely not be accepted.
Although the preferred embodiments of present invention have been described herein, the above description is merely illustrative. The preferred embodiments disclosed will not limited the scope of the present invention. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims.
The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, sub combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. The features of the embodiments of the invention may be combined in alternate embodiments other than those discussed above.
Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations, combinations, and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
This application is a continuation-in-part of U.S. patent application Ser. No. 13/486,730 filed Jun. 1, 2012, which claims the benefit of U.S. Provisional Application Ser. Nos. 61/492,049 filed Jun. 1, 2011 and 61/599,739 filed Feb. 16, 2012, the entirety of each is incorporated herein by this reference.
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| Number | Date | Country | |
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| 20130257243 A1 | Oct 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61599739 | Feb 2012 | US | |
| 61492049 | Jun 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13486730 | Jun 2012 | US |
| Child | 13905461 | US |
