MOISTURE RESISTANT CABINETS AND VANITIES

Abstract

A fixture and method for making the same. The fixture may be a bathroom vanity comprising a base cabinet constructed from a plurality of boards formed from plastic material comprising a base plastic component, a calcium-zinc based stabilizer, a foaming agent, and calcium carbonate. The plastic material is formed into sheets that may be substantially flat or curved and that may be of varying thickness or of uniform thickness. The formed sheets are then cut into boards for assembly using traditional joinery methods. A top may be attached to the base cabinet, and the top may comprise a countertop with one or more sinks.

Claims

1. An improved fixture, comprising: a base cabinet constructed from a plurality of boards formed from an improved plastic material, the improved plastic material comprising; a base plastic component, a calcium-zinc based stabilizer, a foaming agent, and calcium carbonate, wherein the improved plastic material is formed into sheets; and a top attached to the base cabinet.

2. The fixture of claim 1, wherein the top comprises a countertop with one or more sinks.

3. The fixture of claim 2, wherein the fixture comprises a bathroom vanity.

4. The fixture of claim 2, wherein the fixture comprises a kitchen cabinet.

5. The fixture of claim 1, wherein the top comprises of the improved plastic material.

6. The fixture of claim 1, wherein the base plastic component is polyvinyl chloride (PVC).

7. The fixture of claim 6, wherein the improved plastic material is formed by foaming extrusion.

8. The fixture of claim 1, wherein the base cabinet comprises side walls, a back wall, a bottom, a front brace, and doors made from boards of the improved plastic material.

9. The fixture of claim 8, wherein the boards are cut from the same sheet of the improved plastic material.

10. The vanity of claim 8, wherein the boards for the doors are cut from a first sheet of the improved plastic material and the boards for the side walls, back wall, and bottom are cut from a second sheet of the improved plastic material.

11. The vanity of claim 10, wherein the first sheet of the improved plastic material has a first thickness and the second sheet of the improved plastic material has a second thickness, the first thickness different than the second thickness.

12. A method for producing an improved fixture comprising the steps of: manufacturing an improved plastic material into panels, the improved plastic material comprising a base plastic component, a calcium-zinc based stabilizer, a foaming agent, and calcium carbonate; cutting the panels of the improved plastic material into boards; assembling the boards into a vanity casing and one or more vanity components; and applying a finish.

13. The method of claim 12, further comprising: attaching a top to the vanity casing.

14. The method of claim 13, wherein the top comprises a countertop with one or more sinks.

15. The method of claim 14, wherein the fixture comprises a bathroom vanity or a kitchen cabinet.

16. The method of claim 13, wherein the top comprises of the improved plastic material.

17. The method of claim 12, wherein the base plastic component is polyvinyl chloride (PVC) and the improved plastic material is formed by foaming extrusion.

18. The method of claim 12, wherein the finish comprises paint applied after the boards are assembled into the vanity casing and the one or more vanity components.

19. The method of claim 12, wherein the finish comprises a veneer applied prior to cutting the panels of improved plastic material into boards.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

[0012] FIG. 1 is a perspective view of an exemplary uncompleted vanity according to an embodiment of the present invention;

[0013] FIG. 2 is a perspective view of an exemplary uncompleted vanity according to another embodiment of the present invention;

[0014] FIG. 3 is a perspective view of an embodiment of the vanity of FIG. 2 after completion; and

[0015] FIG. 4 is a flow diagram of an exemplary embodiment of a method of producing a cabinet or vanity such as the vanity illustrated in any of FIG. 1, FIG. 2, or FIG. 3.

DETAILED DESCRIPTION

[0016] Detailed descriptions of specific embodiments are now discussed in detail with reference to the drawing figures that were briefly described above. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the improved vanity or cabinet can be implemented and do not represent an exhaustive list of all of the ways they may be embodied. As used herein, the word exemplary is used expansively and should be understood to refer to embodiments that serve as illustrations, specimens, models, or patterns. It will be understood that the vanity or cabinet and/or the method described herein may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to ease understanding of the disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention. Unless otherwise indicated, like parts are referred to with like reference numerals.

[0017] Vanities in accordance with the present disclosure may be constructed of an improved plastic material. In an embodiment, this improved material may have as its main content polyvinyl chloride (PVC) to which a foaming agent, a calcium-zinc (CaZn) based or composite stabilizer, a foam regulator, a lubricant, calcium carbonate, and other non-wood materials may be added during manufacturing to form the improved plastic material. In an embodiment the CaZn stabilizer is used for stabilizing foaming to make the foaming more even and/or the density more evenly spread. In another embodiment, the CaZn composite stabilizer may be instead or additionally used as a heat stabilizer during the preparation or manufacture of the improved plastic material through foaming extrusion or other suitable process to create a PVC-based foam board for example.

[0018] The improved plastic material may be manufactured into flat panels or sheets, similar to an MDF or plywood sheet. In other embodiments, the panels or sheets may be curved instead of flat. In some embodiments the panels or sheets may be generally rectangular in shape, while in other embodiments, the panels or sheets may be formed into a non-rectangular shape as desired. The panels or sheets may have a thickness between 5 mm and 25 mm, and the thickness of the panel or sheet may depend on one or more of: how the sheet is formed, the type of vanity being constructed, the component of a vanity being constructed, another factor, or a combination thereof. These panels of sheets of the improved plastic material may then be cut into pieces or boards that may be used to manufacture cabinets of any desired shape, feature, or dimension. Advantageously, these panels of improved plastic material may be cut, routed, shaped, or sized using typical cutting methods and tools used for wood, without the need for (or expense of) special cutting or shaping tools. The pieces or boards of the improved plastic material may also be attached, assembled, or joined together using typical methods, tools, and fasteners used for wood (e.g. screws or pocket screws, glue, biscuits, nails, etc.). Similarly, the assembled vanity casing may be finished using typical methods, tools, and processes used for wood (e.g. paint, attaching veneer, etc.) without the need for special glues or preparations needed for finishing plastics.

[0019] Referring to FIG. 1, a perspective view of an exemplary uncompleted vanity according to an embodiment of the present disclosure is depicted. FIG. 1 illustrates an exemplary vanity 10 during construction, and in particular, FIG. 1 illustrates a vanity 10 composed of the improved plastic material after the boards of a PVC-based foam board panel have been cut and joined into the cabinet or casing of vanity 10. In the illustrated embodiment, vanity 10 comprises a base with three sections 12a (the right portion of vanity 10), 12b (the left portion of vanity 10), and 12c (the center portion of vanity 10).

[0020] The right section 12a roughly forms a box with an open right top 13a constructed from right outside wall 18a, right inside wall 20a, right back wall 14a, right bottom 22a, and right front brace 24a. As illustrated in FIG. 1, the front of the right section 12a is open apart from front brace 24a, such as to accommodate a separate cabinet door or set of cabinet doors (see FIG. 3) that may be added later in construction. The right top 13a of the vanity 10 is open to accommodate a sink or basin (see FIG. 3), such as a sink attached to a countertop fastened to the top of vanity 10 (see FIG. 3). In other embodiments, the right top 13a may be closed or covered by another board of the improved plastic material, such as embodiments where no sink is needed for the right section 12a of vanity 10. Similarly, an opening 16a is formed in the right back wall 14a in order to accommodate pipes or other plumbing necessary to couple a sink or basin to a water supply, drain, disposal, etc.

[0021] In the illustrated embodiment of FIG. 1, vanity 10 also includes a left section 12b identical to right section 12a. In other embodiments, left section 12b may be configured differently than right section 12a or left section 12b may be omitted entirely as desired. The left section 12b of FIG. 1 roughly forms a box with an open left top 13b constructed from left outside wall 18b, left inside wall 20b, left back wall 14b, left bottom 22b, and left front brace 24b. As illustrated in FIG. 1, the front of the left section 12b is open apart from left front brace 24b in order to accommodate a separate cabinet door or set of cabinet doors (see FIG. 3) that may be added later in construction. The left top 13b of the vanity 10 is open to accommodate a sink or basin (see FIG. 3), such as a sink attached to a countertop fastened to the top of vanity 10 (see FIG. 3). In other embodiments, the left top 13b may be closed or covered by another board of the improved plastic material, such as embodiments where no sink is needed for the left section 12b of vanity 10. Similarly, an opening 16b is formed in the left back wall 14b in order to accommodate pipes or other plumbing necessary to couple a sink or basin to a water supply, drain, disposal, etc.

[0022] Finally, in the illustrated embodiment vanity 10 also includes a center section 12c formed from the inside wall 20a of the right section 12a, the inside wall 20b of the left section 12b, center bottom 22c, top 13c, and a back wall (not illustrated). In the illustrated embodiment, top 13c of the center section 12c is closed as there is no need to accommodate a sink or basin in this portion of vanity 10, and top 13c may be a board of the improved plastic material. Additionally, the illustrated center section 12c is configured with a front having two separate openings, such as a top opening to accommodate a drawer and a bottom opening to accommodate shelves, or cabinet doors. Center section 12c may be configured differently in other embodiments, or may be omitted entirely, such as when a narrower vanity 10 is desired to fit into a particular bathroom space.

[0023] As will be understood, the arrangement of vanity 10 of FIG. 1 is exemplary. In other embodiments, other arrangements or configurations of vanity 10 are possible. For example, in another embodiment (not illustrated) vanity 10 may be comprised of left section 12b and center section 12c, without right section 12a. Additionally, it will be understood that the vanity 10 may be constructed differently than discussed above for FIG. 1. For example, rather than separate back walls 14a and 14b, a single back wall may extend across the entirety of the back of vanity 10 if desired (with the appropriate openings 16a, 16b formed in the single back wall as needed to accommodate plumbing for the desired number of sinks or basins). All such variations are intended to be within the scope of this disclosure.

[0024] Turning to FIG. 2, a perspective view of an exemplary uncompleted vanity according to another embodiment of the present disclosure is illustrated. FIG. 2 shows a vanity 100 during construction, and in particular, FIG. 2 illustrates a vanity 100 composed of the improved plastic material after the boards of a PVC-based foam board panel have been cut and assembled and after the resulting casing has been painted. Among the benefits of the present disclosure is the ability to apply paint, and other finishes, to give a wood-like appearance without the negatives of using wood or wood-based products in a high-moisture environment. In the illustrated embodiment of FIG. 2, vanity 100 (like vanity 10 of FIG. 1) comprises a base with three sections 112a (the right portion of vanity 100), 212b (the left portion of vanity 100), and 112c (the center portion of vanity 100).

[0025] The right section 112a roughly forms a box with an open right top 113a constructed from right outside wall 118a, right inside wall 120a, right bottom shelf 122a, and right front brace 124a. As illustrated in FIG. 2, the front of the right section 112a also has a lower bottom shelf 130a creating two openings in the front of right section 112a. The top opening may accommodate a separate cabinet door or set of cabinet doors (see FIG. 3) that may be added later in construction. The bottom opening formed between the bottom shelf 122a and lower bottom shelf 130a may remain open as a shelf or may accommodate a drawer as desired.

[0026] In the illustrated embodiment of FIG. 2 there is no back wall for section 112a and instead the back of section 112a is a large opening 116a which may facilitate installation of the vanity 100 in various bathrooms where plumbing, pipes, drains, etc. may not be evenly spaced. The right top 113a of the vanity 100 is open to accommodate a sink or basin (see FIG. 3), such as a sink attached to a countertop fastened to the top of vanity 100 (see FIG. 3). The right top 113a of vanity 100 is also configured with a set of right bracers 115a at the corners which may provide additional support for right section 112a and/or an attached countertop. In other embodiments, the right top 113a may be closed or covered by another board of the improved plastic material, such as embodiments where no sink is needed for the right section 112a of vanity 100.

[0027] Vanity 100 of FIG. 2 also includes a left section 112b identical to right section 112a. In other embodiments, left section 112b may be configured differently than right section 112a or left section 112b may be omitted entirely as desired. The left section 112b of FIG. 2 roughly forms a box with an open left top 113b, the box constructed from left outside wall 118b, left inside wall 120b, left bottom 122b, and left front brace 124b. As illustrated in FIG. 2, the front of the left section 112ba also has a lower bottom shelf 130b creating two openings in the front of left section 112b. The top opening may accommodate a separate cabinet door or set of cabinet doors (see FIG. 3) that may be added later in construction. The bottom opening formed between the bottom shelf 122b and lower bottom shelf 130b may remain open as a shelf or may accommodate a drawer as desired.

[0028] In the illustrated embodiment of FIG. 2 there is no back wall for section 112b and instead the back of left section 112b is a large opening 116b which may facilitate installation of the vanity 100 in various bathrooms where plumbing, pipes, drains, etc. may not be evenly spaced. The left top 113a of the vanity 100 is open to accommodate a sink or basin (see FIG. 3), such as a sink attached to a countertop fastened to the top of vanity 100 (see FIG. 3). The left top 113b of vanity 100 is also configured with a set of left bracers 115b at the corners which may provide additional support for left section 112b and/or an attached countertop. In other embodiments, the left top 113b may be closed or covered by another board of the improved plastic material, such as embodiments where no sink is needed for the left section 112b of vanity 100.

[0029] Vanity 100 also includes a center section 112c formed from the inside wall 120a of the right section 112a, the inside wall 120b of the left section 112b, and center bottom shelf 122c. In the illustrated embodiment, top 113c of the center section 112c is open, but is configured with bracers 115c similar to bracers 115a of right section 112a and bracers 115b of left section 112b. Additionally, the illustrated center section 112c is configured with a front having multiple openings above the bottom shelf 122c which may remain open as shelves in the final vanity 100 or may accommodate drawers. Similarly, center section 112c is also configured with an opening formed between bottom shelf 122c and lower bottom shelf 130c which also may remain open as a shelf in the final vanity 100 or may accommodate a drawer. Center section 112c may be configured differently in other embodiments, or may be omitted entirely, such as when a narrower vanity 100 is desired to fit into a particular bathroom space.

[0030] Vanity 100 of FIG. 2 has also had a finish applied, with in the illustrated embodiment is paint although other finishes are possible. Another advantage of the improved materials used for vanity 100 is that special plastic-adhesive paints need not be used. Instead paints typically used for wood-based cabinets or vanities may be used, allowing for wider varieties of paint finishes, and providing a higher-end appearance than possible with traditional painted PVC. For example, high-end paint finishes such as milk paint are possible for vanity 100 of the present disclosure for a custom appearance not possible with PVC.

[0031] The finish may be applied to vanity 100 after assembly of the boards into the casing illustrated in FIG. 2 in some embodiments, while in other embodiments the finish may be applied in whole or in part to the boards before they are assembled or joined together to form vanity 100, or may be applied to the panel or sheet of improved plastic material before it is cut into boards. Additionally, it will be understood that the arrangement of vanity 100 of FIG. 2 is exemplary. In other embodiments, other arrangements or configurations of vanity 100 are possible. For example, in another embodiment (not illustrated) vanity 100 may be comprised of left section 112b and center section 112c, without right section 112a. Vanity 100 may also be constructed differently than discussed above for FIG. 2. All such variations are intended to be within the scope of this disclosure.

[0032] FIG. 3 is a perspective view of an embodiment of the vanity 100 of FIG. 2 after completion. As illustrated in FIG. 3, assembly of vanity 200 has been completed, including the attachment of countertop 250 to the top end of vanity 200. Countertop 250 in the illustrated embodiment may be a stone-type material such as granite or marble or may be a manufactured (or partially manufactured) material such as quartz, acrylic, polymer, cement, or other solid surface. Countertop 250 may be installed onto vanity 200 by adhesive, screws, bolts, and/or other fastening mechanisms that may be used for wood-based vanities. In an embodiment, bracers 115a, 115b, 115c (see FIG. 2) may serve as anchor points for screws or bolts to help secure countertop 250 to the base of vanity 200.

[0033] Additionally, countertop 250 includes two sinks 252a, 252b or basins, which in an embodiment may be separate components that are separately installed or attached to the countertop 250, such as with adhesive and/or screws or bolts. In another embodiment one or more of sinks 252a, 252b may be formed into/with countertop 250 such that sinks 252a, 252b and countertop 250 are one component and/or installed together.

[0034] As will be understood, the size and shape of countertop 250 and/or sinks 252a, 252b may vary as desired, and in some embodiments, sinks 252a, 252b may be drop in basins the top of which extend above the top surface of countertop 250. It will also be understood that although a countertop 250 has been shown in FIG. 3, the present disclosure is not so limited. Other tops including, but not limited to, fiat horizontal surfaces may be used instead of or in addition to countertop 250. If a flat surface is to be incorporated, the surface same may be constructed (formed, cut, etc.) from the same improved plastic material used to construct the rest of vanity 200 (or vanity 100 or FIG. 1).

[0035] Vanity 200 of FIG. 3. includes a right set of doors 234a attached at the front of right section 212a and a left set of doors 234b attached at the front of left section 212b. Doors 234a, 234b may be attached via hinges (not shown), may be sliding/barn-style doors, or may be attached or operate using any desired means. Additionally, in some embodiments more or fewer doors 234a, 234b may be used. For example, in another embodiment, right section 212a may have one, larger door 234a (not illustrated) while left section 212b has two or more doors 234b as desired.

[0036] Vanity 200 includes a set of bottom drawers 240a, 240b, 240c at the bottom front of each of right section 212a, left section 212b, and center section 212c respectively. The upper front of center section 212c does not have doors but instead is configured with a series of center drawers 242c arranged vertically (i.e. stacked on top of each other). It will be understood that other configurations for the center section 212c are possible, and that in other embodiments center section 212c may have more or fewer drawers 242c than illustrated or may be configured with one or more doors (not illustrated) or open shelves (not illustrated) rather than drawers 242c. All such variations are intended to be within the scope of the present disclosure.

[0037] Also, although a bathroom vanity fixture has been shown and described, the present disclosure is not limited to such fixtures. It is envisioned that other cabinet structures such as other cabinets (e.g., kitchen sink vanity cabinets, laundry room cabinets, outdoor cabinets, built in cabinets, cabinets on a boat or ship, etc.) and the like may be constructed in accordance with the present disclosure and such cabinets or vanities would provide similar benefits to those discussed above with regard to lighter weight; ease of construction; durability; water, stain, moisture, mold, and/or mildew resistance; fire resistance; etc.

[0038] Turning to FIG. 4, a flowchart illustrating a method of producing or manufacturing a vanity or cabinet. In an embodiment, the vanity or cabinet may be vanity 10 of FIG. 1, vanity 100 of FIG. 2 or vanity 200 of FIG. 3. Method 400 begins in block 410 where the improved plastic material is created or manufactured with non-wood-based additives. Such improved plastic material may have as its base or main component PVC or other suitable plastic material and may include non-wood materials such a foaming agent, CaZn composite stabilizer, a foam regulator, a lubricant, calcium carbonate, and/or other non-wood materials. These additives or materials may be added in desired amounts and in desired order during manufacturing to form the improved plastic material.

[0039] In block 412, the improved plastic material is formed into sheets or panels. This may be accomplished to by foaming extrusion or other suitable process to create a PVC-based foam panel for example. Although illustrated as separate steps, block 410 and 412 may be combined in some embodiments such that the improved plastic material is created and manufactured into panels or sheets in one step, rather than as two separate steps. Regardless of the number of steps, the improved plastic material is manufactured into panels or sheets. In an embodiment the panels or sheets may be substantially flat and rectangular, similar to an MDF or plywood sheet. In other embodiments, the panels or sheets may be curved rather than flat and/or formed into non-rectangular shapes. In an embodiment, the panels or sheets are of uniform thickness, while in other embodiments the panels or sheets may vary in thickness as desired. The thickness of the panel or sheet may vary or depend on one or more of: how the sheet is formed, the type of vanity being constructed, the component of a vanity being constructed, another factor, or a combination thereof. In an embodiment, the thickness of the panels or sheets may be and/or may vary between 5 mm and 25 mm.

[0040] Once formed, the sheets or panels of the improved plastic material may be cut into pieces or boards in block 414. Such boards may be of any desired shape, feature, or dimension suitable for the vanity or cabinet being built and may include boards for assembling into a cabinet base, shelves, doors (such as frame and panel doors), drawers, legs, tops, etc. For example, the boards may be substantially flat or may be curved as desired and/or the boards may be substantially rectangular in shape or may be non-rectangular in shape as desired. The improved plastic material may be cut, routed, shaped, or sized using typical cutting methods and tools used for wood, without the need for (or expense of) special cutting or shaping tools.

[0041] In block 416 the pieces or boards of the improved plastic material may be attached, assembled, or joined together into the casing and/or other components of the vanity. Assembly may occur using typical methods, tools, and fasteners used for wood (e.g. screws or pocket screws, glue, biscuits, nails, etc.). As will be understood, it is possible, but not necessary, that a single panel is used to make one vanity. For example, boards from one panel (which may have a first thickness) may be used to assemble casings for a set of vanities, while boards from a second panel (which may have a second thickness) may be assembled into drawers or doors for the same set of vanities, and boards from a third panel (which may have a third thickness) may be assembled or fitted into tops for the same set of vanities. In an embodiment one or more of the first, second, and third thicknesses may be between 5 mm and 25 mm.

[0042] Moving to block 418, the assembled vanity casing and/or other vanity components may be finished using typical methods, tools, and processes used for wood (e.g. paint, attaching veneer, etc.) without the need for special glues or preparations needed for finishing plastics. Although block 418 is illustrated as being after the vanity is assembled the step of applying finish of block 418 may occur at other times in various embodiments, and where the finishing of block 418 occurs may depend on the finish being applied.

[0043] For example, in a vanity where a wood veneer is desired, such veneer may be applied to the improved plastic material immediately after block 412 when the sheets or panel of improved plastic material are formed. Such veneer or film may be applied through a heat press process or other means. In another example, in a vanity where a paint finish is desired, block 418 may occur after block 412 where the sheets or panels are formed, may occur after block 414 after the sheets or panels have been cut into boards (if for example doors will receive a different color than the casing), or may occur after block 416 as illustrated in FIG. 4.

[0044] Finally, in block 420 a top may be applied to the vanity. In an embodiment, the top may be a countertop 250 illustrated in FIG. 3 that includes or can accommodate one or more sinks or basins. In other embodiments the top may be any other desired top for the vanity and may include a flat surface made of the same improved plastic material as the rest of the vanity. In some embodiments (such as where the top is the same material as the rest of the vanity), block 420 may not be a separate step, but may instead be accomplished as part of another step such as block 416 where the boards are assembled into the vanity casing and/or other components. It will be understood that method 400 is one exemplary method and variations to method 400, such as rearranging the illustrated blocks, combining one or more blocks, or omitting one or more blocks are possible while still accomplishing the purpose of method 400.

[0045] Having described exemplary embodiments of the improved vanity and an exemplary method of manufacturing an improved vanity with reference to the attached figures, it will be appreciated that changes and modifications may be made to any of the exemplary embodiments shown and/or described herein without departing from the spirit or scope of the disclosure.

[0046] Within the scope of this application it is intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the drawings may be considered or taken independently or in any combination thereof. It will be understood that features or elements described in connection with, or relation to, one embodiment are applicable to all embodiments unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated into, or combined with, any of the other embodiments disclosed herein, and the features or elements extracted from one embodiment may be included in addition to, or in replacement of, one or more features or elements of another embodiment. Similarly, a feature, or combination of features, of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment and/or a feature, or combination of features, of an embodiment may be omitted from that embodiment.