FURNITURE PIECE WITH PLASTIC SPACERS FOR DRAWER SLIDES

Abstract

A molded plastic spacer for securing a drawer slide to a cabinet panel. The plastic spacer may have one or more lugs extending orthogonally from a cabinet panel contact face and configured to interface with corresponding recesses in the cabinet panel. The one or more lugs may further include a tapered central bore capable of receiving a pin. Driving the pin through the bore causes the lug to expand such that a ribbed exterior surface of the lug engages with the cabinet panel and secures the plastic spacer in place. Each of the one or more lugs having space above the respective pin for robotically driving the pin.

Claims

1. A furniture item comprising a drawer slide affixed to a cabinet panel, the drawer slide being offset from the cabinet panel by a spacer, the spacer comprising: a body portion extending between a cabinet panel contact face having a longitudinal axis and an opposite drawer slide contact face, the body portion having a perimeter flange portion with a sloped edge portion opposite an inset edge portion, a first flange tab unitary with the sloped edge portion, a second flange tab unitary with the inset edge portion defining a recess, the cabinet panel contact face on the first and second flange tabs; a first lug having a tapered central bore extending orthogonally from the cabinet panel contact face, the first lug configured to interface with a corresponding recess in the cabinet panel; a first pin configured to be placed in the tapered central bore of the first lug such that insertion of the first pin displaces outside edges of the first lug radially outward; a second lug having a tapered central bore extending orthogonally from the cabinet panel contact face, the second lug configured to interface with a corresponding recess in the cabinet panel; a second pin configured to be placed in the tapered central bore of the second lug such that insertion of the second pin displaces an outside edges of the second lug radially outward; wherein the first pin is positioned in the recess defined by the inset edge portion, and wherein the drawer slide contact face is secured to the drawer slide with a fastener.

2. The furniture item of claim 1, wherein the first lug and the second lug are unitary with the first flange tab and the second flange tab respectively.

3. (canceled)

4. The furniture item of claim 1, wherein an angle between the sloped edge portion and the longitudinal axis of the cabinet panel contact face is between 50 and 65 degrees.

5-6. (canceled)

7. The furniture item of claim 1, wherein the body portion has a webbing extending between the sloped edge portion and the inset edge portion.

8. The furniture item of claim 1, wherein one or more gussets extend between the sloped edge portion and the inset edge portion.

9. (canceled)

10. The furniture item of claim 1, wherein the body portion has a boss at the drawer slide contact face.

11. The molded furniture item of claim 1, wherein the cabinet panel contact face at the first flange tab is coplanar with the cabinet panel contact face at the second flange tab.

12-14. (canceled)

15. The molded furniture item of claim 1, the first flange tab has an aperture distal to the first lug for receiving a screw.

16. The molded furniture item of claim 1, the second flange tab has an aperture distal to the second lug for receiving a screw.

17. The molded furniture item of claim 1, wherein an axial length of the cabinet panel contact face is between 80 and 120 millimeters.

18. (canceled)d

19. The molded furniture item of claim 1, wherein the drawer slide contact face is located on a line perpendicular to the cabinet panel contact face extending through the first pin in the first lug at the inset edge portion.

20. A method for installing a molded plastic drawer slide spacer on a cabinet panel, the spacer having a body portion with a pair of flange tabs at a cabinet panel contact face, each flange tab having an outwardly extend lug with an aperture and a pin inserted therein, the body portion having a boss at a drawer slide contact face, the method comprising: inserting glue into a pair of holes in the cabinet panel; aligning each of the pair of lugs of the molded plastic spacer with corresponding lug recesses in the cabinet panel; inserting each of the pair of lugs into the corresponding recess in the cabinet panel such that the cabinet panel contact face is confronting the cabinet panel; and driving the pins towards the cabinet panel, wherein each step is done robotically.

21. The method of claim 20 further comprising: providing a drawer slide; aligning an aperture of the drawer slide with the boss in the drawer slide contact face; and securing the drawer slide to the drawer slide contact face with a fastener.

22. (canceled)

23. The method of claim 20, wherein the drawer slide spacer has a perimeter flange portion extending between each of the flange tabs and the drawer slide contact face, the perimeter flange portion having an inset portion adjacent one of the flange portions, and wherein the method comprises robotically inserting a hammer portion in the inset portion such that the hammer portion is above the pin, and wherein the boss is above the pin.

24. A furniture item comprising a cabinet portion with a plurality of stacked drawers therein, the cabinet formed of a pair of wood product side wall panels, a rear panel extending between the side wall panels, and a front panel with openings for receiving the plurality of stacked drawers; wherein each of the plurality of stacked drawers having a pair of drawer slides attaching the respective drawer to the pair of side panels by way of a pair of polymer cantilever spacers, each drawer slide having a rail portion and a cooperating slide portion, the rail portions secured to the polymer cantilever spacers and the slide portion secured to the drawers; wherein each of the polymer spacers has a panel engagement end and a rail engagement end, the spacer comprising a body portion extending between the panel engagement end and the rail engagement end, the spacer further comprising a pair of oppositely extending flange tabs unitary with the body portion at the panel engagement end of the spacer, the tabs each having a planar engagement surface in engagement with the interior surface of the side wall panel and each having a split ribbed lug portion extending in a direction away from the body portion, the split ribbed lug portions each having a pre-insertion maximum diameter greater than 7 mm, an axis extending in a direction perpendicular to the planar engagement surfaces, a central opening extending through the respective flange tab and into the split ribbed lug portion, an elongate metal expander pin in the opening, the split ribbed lug portion having a plurality of legs that are compressed between the elongate metal expander pin and an interior surface of the hole, thereby anchoring each lug into a hole and securing the spacer on the panel side wall.

25. The furniture item of claim 24, wherein there is cured glue in each of the holes in the side wall panel.

26. The furniture item of claim 24, wherein the spacer body portion extending from the upper flange tab portion is positioned below an axis of the split ribbed lug portions by at least 4 mm.

27. The furniture item of claim 24, wherein each spacer is connected to the respective side wall panel by only two connections.

28. The furniture item of claim 24, wherein each spacer is connected to the respective side wall panel by two connections utilizing lugs and a screw through an opening in a flange tab.

29. The furniture item of claim 28, wherein each of the expander pins has a space thereabove for hammering in the respective expander pin.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1A is a perspective back view of a tall plastic spacer according to an embodiment of the disclosure.

[0024] FIG. 1B is a top view of a tall plastic spacer according to an embodiment of the disclosure.

[0025] FIG. 1C is a side view of a tall plastic spacer according to an embodiment of the disclosure.

[0026] FIG. 1D is a bottom view of a tall plastic spacer according to an embodiment of the disclosure.

[0027] FIG. 2A is a perspective front view of a short plastic spacer according to an embodiment of the disclosure.

[0028] FIG. 2B is a top view of a short plastic spacer according to an embodiment of the disclosure.

[0029] FIG. 2C is a side view of a short plastic spacer according to an embodiment of the disclosure.

[0030] FIG. 2D is a bottom view of a short plastic spacer according to an embodiment of the disclosure.

[0031] FIG. 3A is a comparison of the side view of a tall plastic spacer according to an embodiment of the disclosure with corresponding prior art.

[0032] FIG. 3B is a comparison of the side view of a short plastic spacer according to an embodiment of the disclosure with corresponding prior art.

[0033] FIG. 4 is a cross-sectional view of a tall plastic spacer installed in a cabinet panel according to an embodiment of the disclosure.

[0034] FIG. 5 is a perspective front view of a cabinet according to an embodiment of the disclosure.

[0035] FIG. 6 is an interior surface of a cabinet side panel before installing spacers according to an embodiment of the disclosure.

[0036] FIG. 7 is an interior surface of a cabinet side panel according to an embodiment of the disclosure with spacers installed.

[0037] FIG. 8 is a partial perspective view of the interior of a cabinet side panel and a cabinet front panel according to an embodiment of the disclosure.

[0038] FIG. 9 is a side view of a drawer according to an embodiment of the disclosure.

[0039] FIG. 10 is a perspective view of a picking tool according to an embodiment of the disclosure.

[0040] FIG. 11 is a bottom perspective view of a placing tool according to an embodiment of the disclosure.

[0041] FIG. 12 is a partial perspective view of a manufacturing facility according to an embodiment of the disclosure.

[0042] FIGS. 13A-13E is a front view of a spacer station assembly with assembly steps according to an embodiment of the disclosure.

DETAILED DESCRIPTION

[0043] FIGS. 1A-2D depict a plastic drawer slide spacer 10 according to embodiments of the disclosure. Referring to FIGS. 1A-1D, a tall plastic spacer 100 is illustrated having a cabinet panel contact face 11 with a longitudinal axis 12 opposite and parallel to a drawer slide contact face 13. The plastic spacer 10 has a body portion 15 that extends from the cabinet panel contact face 11 to the drawer slide contact face 13. The body portion 15 has an edge portion 16 configured as a perimeter flange extending from a first flange tab or pad 16.2 continuously about the body portion to a second flange tab or pad 16.4. A webbing 16.6 spans between the perimeter flange 16 on opposite sides of the spacer. The perimeter flange 16 has a sloped edge portion 17 that joins and is unitary with the flange pad 16.4 with the cabinet panel contact face 11 at an angle 19 between 50 and 65 degrees. In some embodiments, the sloped edge portion 17 forms an angle 19 of about 59.8 degrees with the cabinet panel contact face 11. In embodiments, the angle 19 is about 60 degrees. The body portion 15 includes an edge portion 21 opposite the sloped edge portion 17 that is inset and defines a recess 23. In embodiments, the recess 23 may have a profile that is generally “U” shaped. In embodiments, the recess 23 may have a wider opening than a “U” shape. For example, the recess 23 may define an angle that is between 89 and 181 degrees. In embodiments, the recess 23 may define a recess angle 24 that is about 141.5 degrees. In embodiments, the recess 23 may define a recess angle 24 that is about 90 degrees. The recess provides space for a hammer portion described below.

[0044] A lug 27 extends orthogonally outward from cabinet panel contact face 11. The lug 27 defines a tapered central bore 29 extending throughout and capable of receiving a pin 33. In embodiments, the lug 27 has a ribbed surface 31 defining outside edges 31.2. In embodiments, the ribbed surface 31 may include one or more notches which can act as a glue relief. In embodiments, the central bore 29 is widest at the cabinet panel contact face 11. In embodiments, the central bore 29 tapers from a diameter of about 2 millimeters down to a diameter of about 1 millimeter. A lug 27 length L1 may be between 5 and 20 millimeters. In some embodiments, a lug 27 length is about 10 millimeters. In embodiments, the length of the pin exceeds the length of the lug. Examples of a pin 33 for purposes of this disclosure may include any combination of nails, screws, bolts, pegs, rods, rivets, and the like. In embodiments, pin 33 is a nail. Pin 33 may be between 10 and 25 millimeters long. In embodiments, pin 33 is about 15 millimeters long. Pin 33 may have a head with a diameter of about 4.5 millimeters. The pin 33 has a starting configuration wherein the pin 33 is partially inserted into the central bore 29 such that a portion of the pin 33 remains exposed. In embodiments, a portion of pin 33 extends in a direction opposite the lug 27 by a pin offset 34 from the cabinet panel contact face when pin 33 is in the starting configuration. In embodiments, a pin offset 34 may be about 7 millimeters.

[0045] A first lug 27 may be positioned axially forward of the sloped edge portion 17. A notch 35 may be formed in the sloped edge portion 17 to permit access to the central bore 29. A second lug 27 may be positioned axially rearward of the upwardly facing edge portion 21. In embodiments, the central bore 29 of the second lug 27, and a corresponding second pin 33 are located within recess 23. The first and second lug 27 may have an axial separation 41 of between 50 and 80 millimeters. In embodiments, the first and second lug 27 have an axial separation 41 about 64 millimeters.

[0046] The cabinet panel contact face 11 may have an axial length 14 of between 80 and 120 millimeters. In embodiments, the cabinet panel contact face 11 has an axial length 14 of about 101 millimeters. The cabinet panel contact face 11 may have an aperture 25 axially forward of the first lug 27 configured to receive a fastener. The cabinet panel contact face 11 may have an aperture 25 axially rearward of the second lug 27 configured to receive a fastener. Examples of fasteners for purposes of this disclosure may include any combination of welds, rivets, screws, nails, lugs, bolts, glue, and the like in addition to associated components such as washers or nuts.

[0047] A plastic spacer 10 may have one or more structural ribs 43 or gussets extending between the upwardly facing edge portion 21 and the sloped edge portion 17. The one or more structural ribs 43 may form a rib angle 45 between 40 and 60 degrees with respect to the cabinet panel contact face 11. In embodiments, one or more structural ribs 43 forms a rib angle 45 of about 50.2 degrees with respect to the cabinet panel contact face 11.

[0048] A tall plastic spacer 100 may have a height 16 between the cabinet panel contact face 11 and the drawer slide contact face 13 of between 65 and 85 millimeters. In embodiments, a tall plastic spacer 100 has a height 16 of about 76 millimeters. A drawer slide contact face 13 of a tall plastic spacer 100 may have an axial length between 28 and 45 millimeters. In embodiments, a drawer slide contact face 13 of a tall plastic spacer 100 has an axial length of about 38 millimeters. A drawer slide contact face 13 may include a bore 47 configured to receive a fastener. In embodiments, the bore 47 is countersunk.

[0049] One skilled in the art will appreciate that a plastic spacer 10 may be manufactured through known methods such as injection molding. Common materials for injection molded components include thermoplastics and thermosetting polymers. Although plastics are referenced, other materials or combinations of materials are not beyond the scope of this scope of this disclosure. For example, a plastic spacer 10 may comprise a metallic body portion 15 and a plastic lug 27.

[0050] Referring to FIGS. 2A-2D, a short plastic spacer 200 is illustrated having a cabinet panel contact face 11 opposite and parallel to a drawer slide contact face 13. The short plastic spacer 200 has a body portion 15 that extends from the cabinet panel contact face 11 to the drawer slide contact face 13. The body portion 15 has a sloped edge portion 17 that intersects the cabinet panel contact face 11 at an angle 19 between 50 and 65 degrees. In some embodiments, the sloped edge portion 17 forms an angle 19 of about 59.8 degrees with the cabinet panel contact face 11. The body portion 15 includes a upwardly facing edge portion 21 that defines a recess 23.

[0051] In embodiments, a short plastic spacer 200 has a height 16 between the cabinet panel contact face 11 and the drawer slide contact face 13 of between 45 and 65 millimeters. In embodiments, a short plastic spacer 200 has a height 16 of about 52 millimeters. In embodiments, a drawer slide contact face 13 of a short plastic spacer 200 has an axial length between 20 and 28 millimeters. In embodiments, a drawer slide contact face 13 of a short plastic spacer 200 has an axial length of about 24 millimeters. In embodiments, a drawer slide contact face 13 has a bore 47 configured to receive a fastener. In embodiments, the bore 47 is countersunk.

[0052] FIG. 3A illustrates a comparison of a tall plastic spacer 100 with a similarly scaled piece of prior art. The tall plastic spacer 100 and the prior art both contain connection points including a lug 27, an aperture 25 and a bore 47. As illustrated in FIG. 3A, the connection points of the tall plastic spacer 100 generally axially align with the corresponding connection points as shown in the prior art. Additionally, a tall plastic spacer 100 has a similar height 16 to the prior art. As such, an installer is able to utilize a tall plastic spacer 100 in place of the prior art, and gain some of its advantages, without the requirement of changing any other aspect of the installer's other components or parts.

[0053] FIG. 3B illustrates a comparison of a short plastic spacer 200 with a similarly scaled piece of prior art. The short plastic spacer 200 and the prior art both contain connection points including a lug 27, an aperture 25 and a bore 47. As illustrated in FIG. 3B, the connection points of the short plastic spacer 200 generally axially align with the corresponding connection points as shown in the prior art. Additionally, a short plastic spacer 200 has a similar height to the prior art. As such, an installer is able to utilize a short plastic spacer 200 in place of the prior art, and gain some of its advantages, without the requirement of changing any other aspect of the installer's other components or parts.

[0054] FIG. 4 illustrates a tall cabinet spacer 100 installed in a cabinet side panel 315. As seen in FIG. 4, lug 27 is seated within a pre-drilled hole 318. Pin 33 drives through central bore 29, expanding the outer edges of the lug 27 into the pre-drilled hole 318. In some embodiments, pin 33 may extend beyond the end of the lug 27 and into the cabinet side panel 315.

[0055] FIG. 5 illustrates a cabinet 300 with a drawer 311. The cabinet has a cabinet side panel 315 and a cabinet front panel 317. When a drawer 315 is in a closed position, a drawer face panel 313 may be flush with cabinet front panel 317. Cabinet side panel 315 may be fixedly attached to cabinet front panel 317. Examples of fixed attachments for purposes of this disclosure may include any combination of welds, rivets, screws, nails, lugs, bolts, glue, and the like in addition to associated components such as washers or nuts. In embodiments, cabinet side panel 315 may be integral with cabinet front panel 317. In embodiments, cabinet front panel 317 may have an axial width 321 between 45 and 85 millimeters. In embodiments, cabinet front panel 321 may have an axial width generally corresponding to the height 16 of a plastic spacer 10.

[0056] In embodiments, panels (313, 315, 317) and drawers 311 may comprise wood or wood products, such as hardwood, engineered wood, oriented strand board, plywood, or particle board. In embodiments, panels (313, 315, 317) and drawers 311 may be formed of alumina, aluminum alloys, magnesium alloys, steel, or other sheet metals or alloys known to one skilled in the art. In embodiments, drawers and panels may be comprised of plastics or polymers. In embodiments, panels (313, 315, 317) and drawers 311 may include any combination of wood and metal products. For example, a cabinet side panel 315 may comprise a sheet of plywood with a layer of melamine.

[0057] FIG. 6 depicts an interior surface 319 of the cabinet side panel 315. A lug receptacle 323 is configured to receive lug 27. A cabinet panel may have as many lug receptacles 323 as required to match the number of lugs 27 in a plastic spacer 10. In embodiments, the lug receptacles 323 may be pre-formed to accommodate a variety of configurations, such that not all lug receptacles 323 are utilized in a single cabinet 300. This permits a cabinet side panel 315 to be pre-fabricated and used in a variety of cabinet 300 configurations.

[0058] FIG. 7 illustrates pairs of plastic spacers 10 aligned in horizontal rows on a cabinet side panel 315. In embodiments, additional plastic spacers 10 may be added to the horizontal rows as required. Additional spacers may offer load distribution and stability based on drawer 311 characteristics such as depth, width, and weight. More or fewer horizontal rows may be required based on the number of drawers 311 installed in cabinet 300.

[0059] FIG. 8 depicts a guide rail 343 fixedly attached to a pair of plastic spacers 10 along the interior surface 319 of cabinet side panel 315. For example, a slide mounting screw 347 may be used to secure the guide rail 343 to bore 47. Plastic spacer 10 creates separation between the cabinet side panel 15 and guide rail 343 that is generally equivalent to the axial width 321 of cabinet front panel 317. Guide rail 343 may be generally flush with cabinet front panel 317. In some embodiments, guide rail 343 may slightly overlap cabinet front panel 317. In embodiments, guide rail 343 may be fixedly attached to cabinet front panel 317. FIG. 9 illustrates a slide 345 affixed to the side of drawer 311. Slide 345 is configured to interface with guide rail 343 allowing drawer 311 to easily move within cabinet 300. When drawer 311 is fully inserted in cabinet 300, an outer surface of drawer face panel 313 should generally align with an outer surface of cabinet front panel 317.

[0060] FIG. 10 illustrates a picking tool 400 that may be used to pick up and manipulate a plastic spacer 10. For example, picking tool 400 may have one or more pneumatic suction cups 411 configured to grasp the same side of the body portion 15 of a plastic spacer 10. The picking tool 400 may then rotate freely to orient the plastic spacer 10 into a desired position. The picking tool may be on a conventional industrial robot.

[0061] FIG. 11 depicts a placing tool 500 for installing a plastic spacer 10 in a cabinet side panel 315 in a single continuous motion or two motions. Placing tool 500 may secure the plastic spacer 10 between a front clamp 511 and a back clamp 513 (FIG. 13A). When a cabinet side panel 315 is placed beneath the placing tool 500 such that the lug receptacles 323 align with the lugs 27 (FIGS. 13B and 13C), the placing tool 500 may install the plastic spacer 10 in a single downward motion. The placing tool 500 lowers the plastic spacer 10 until the lugs 27 are inserted into the lug receptacles 323, and then the nail insertion block 515 continues lowering such that the nail head hammer portions 517 drives the pin 33 downward (FIG. 13D). Driving the pin 33 through the central bore 29 causes the ribbed surface 31 of the lug 27 to separate and engage with the lug receptacle 323, thereby securing the plastic spacer 10 in place. The pin 33 may also be driven into the cabinet side panel 315, further securing the plastic spacer 10 to the cabinet side panel 315. The placing tool 500 then releases the plastic spacer 10 and retracts (FIG. 13E). Additional fastening means are possible as well. In embodiments, an installer may use glue or similar adhesives in the receptacles 323 or along the cabinet panel contact face 11. In embodiments, an installer may insert additional fasteners through the apertures 25 in the cabinet panel contact face 11.

[0062] Referring to FIGS. 12-13E details of an assembly process of the spacers into a cabinet side panel are illustrated. FIG. 12 shows part of a manufacturing facility 600 having an assembly line 606 for automated installation of plastic spacers 10. The assembly line may include a conveyor belt 610 that moves cabinet side panels 315 toward and through the processing stations. A drilling station 617 drills holes 318 into the cabinet side panel therebelow. A glue station 630 injects glue 631 into the holes 318 of the cabinet side panel therebelow. Referring also to FIGS. 13A-13E, a spacer install station 640 with a placing tool 500 clamps onto an individual spacer at a spacer pickup region 644, see FIG. 13A, the placing tool lifts the spacer by way of an translation means 648, such as tracks, and moves across the conveyor to an attachment position above the cabinet side panel 315, see FIG. 13B. The placing tool 500 lowers the spacer such that the spacer is flush on the surface of the side panel with the lugs seated in a pair of holes of the side panel, see FIG. 13C. The hammer portions 517 of the placing tool 500 then drives down the pins The placing tool then unclamps from the spacer, elevates and moves back to the spacer pick up region 644. Spacers are moved into the spacer pick up region such as by an industrial robot 660 with a picking tool 400as shown in FIG. 10.

[0063] The following reference are incorporated herein for all purposes: US Pat. Pub. 2004/0224086.

[0064] For purposes of this disclosure, stated measurements or dimensions are accurate within 10% of the stated values. Similarly, measurements or dimensions stated to be “generally” or “about” a specific value are considered accurate within 10% of the stated value.

[0065] The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. Components illustrated in such patents may be utilized with embodiments herein. Incorporation by reference is discussed, for example, in MPEP section 2163.07(B).

[0066] All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0067] Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0068] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed The above references in all sections of this application are herein incorporated by references in their entirety for all purposes.

[0069] Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications 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.