Easy Assemble Storage Unit

Abstract

The invention provides a pre-fabricated cabinet frame structure (1) including two opposing side wall elements (2, 3) each having an inside surface (4, 4′), a front edge (5, 5′), a rear edge (6, 6′), a base portion (7, 7′), and a top portion (8, 8′). At least two spacer arms, moveable between a folded configuration and an extended configuration, are also provided. Each spacer arm is hingedly connected by wall hinges at one end to an inside surface of one side wall element, and at the other end to an inside surface of the other opposing side wall element. At least one spacer arm extends adjacent the front edge of each wall element and at least one spacer arm extends adjacent the rear edge of each wall element. The at least one spacer arm adjacent the front edge is offset from the at least one spacer arm adjacent the rear edge such that they do not interfere with each other in the folded configuration.

Claims

1. A pre-fabricated cabinet frame structure including: two opposing side wall elements each having an inside surface, a front edge, a rear edge, a base portion, and a top portion; at least one pair of spacer arms located proximate either the base portion or the top portion, the pair of spacer arms being moveable between a folded configuration and an extended configuration, each spacer arm being hingedly connected by wall hinges at one end to an inside surface of one side wall element, and at the other end to an inside surface of the other opposing side wall element, wherein the pair of spacer arms includes a front spacer arm extending adjacent the front edge of each wall element and at least one spacer arm extends adjacent the rear edge of each wall element, wherein a rear spacer arm is mounted vertically offset from the rear spacer arm such that they do not interfere with each other in the folded configuration.

2. (canceled)

3. A pre-fabricated cabinet frame structure according to claim 1, wherein each spacer arm is a folding arm having an arm fold hinge connector permitting movement of each folding arm between the folded configuration, where the folding arms lie generally parallel to the side wall elements, and the extended configuration, where the folding arms extend generally transverse to the side wall elements.

4. A pre-fabricated cabinet frame structure according to claim 3, wherein each folding arm includes two arm elements interconnected by the arm fold hinge connector.

5. A pre-fabricated cabinet frame structure according to claim 4, wherein each arm element is of equal length.

6. A pre-fabricated cabinet frame structure according to claim 1, wherein in the folded configuration the two opposed wall elements are relatively closely spaced for packaging and transport, and wherein in the extended configuration, the two opposing side walls are spaced away from each other a predetermined distance to define a storage space therebetween.

7. A pre-fabricated cabinet frame structure according to claim 3, including at least two locking mechanisms to hold each folding arm in the folded configuration and/or the extended configuration.

8. A pre-fabricated cabinet frame structure according to claim 7, wherein each locking mechanism is operatively associated with each wall hinge and/or each arm fold hinge connector.

9. A pre-fabricated cabinet frame structure according to claim 7, wherein each locking mechanism includes an over centre mechanism that biases each folding arm from a partially extended position to either the folded configuration and/or the extended configuration.

10. A pre-fabricated cabinet frame structure according to claim 1, wherein each wall hinge is a flat fold hinge.

11. A pre-fabricated cabinet frame structure according to claim 2, including four folding arms.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0021] FIG. 1 is a perspective view of a first embodiment cabinet frame structure according to the invention illustrated in the collapsed transport configuration;

[0022] FIG. 2 is an enlarged view of one of the hinged arm connectors illustrated in the collapsed configuration as shown in FIG. 1;

[0023] FIG. 3 is a perspective view of the frame structure of FIG. 1 shown in a partially expanded orientation;

[0024] FIG. 4 shows enlarged perspective views of the arm hinges in fully folded, partially opened and fully opened orientations;

[0025] FIG. 5 is a perspective view of the frame structure of FIG. 1 shown in a fully expanded orientation;

[0026] FIG. 6 is an enlarged view of one of the hinged arm connectors illustrated in the fully extended configuration as shown in FIG. 5;

[0027] FIG. 7 is a perspective view of the frame structure of FIG. 5 with means to attach a shelf and base;

[0028] FIG. 8 is an enlarged perspective view of a shelf support as shown in FIG. 7;

[0029] FIG. 9 shows the partially assembled cabinet frame structure of FIG. 7 with means to attach doors and a lower kick board;

[0030] FIG. 10 is an enlarged perspective view of the door hinge arrangement shown in FIG. 9;

[0031] FIG. 11 is an enlarged perspective view of the kickboard connecting clip arrangement shown in FIG. 9; and

[0032] FIG. 12 is an enlarged perspective view of the cabinet of FIG. 9 with doors fully assembled and means to attach the basin to the cabinet.

PREFERRED EMBODIMENTS OF THE INVENTION

[0033] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings which should be considered in all respects as illustrative and non-restrictive. In the drawings, the same elements are denoted by the same reference numerals throughout. In the following description, detailed descriptions of known functions and configurations incorporated herein have been omitted for conciseness and clarity.

[0034] The embodiment illustrated in FIGS. 1 to 12 relates to a cabinet frame structure as shown in the final almost as fully assembled bathroom vanity cabinet in FIG. 12.

[0035] Turning first to FIGS. 1 to 6 there is shown a first embodiment cabinet frame structure 1 according to the invention. The frame structure is illustrated in FIG. 1 in the collapsed transport and packaging configuration and includes two opposing side wall elements, a left wall element 2 and right wall element 3. Each wall element respectively has an inside surface 4 and 4′, a front edge 5 and 5′, a rear edge 6 and 6′ a base portion 7 and 7′ and a top portion 8 and 8′.

[0036] The wall elements 2 and 3 are interconnected by at least two spacer arms. In the present embodiment, the at least two spacer arms are in the form of four separate folding arms, each folding arm being moveable between a folded configuration and an extended configuration. The first two 9 and 10 are connected adjacent front edges 5 and 5′, and the second two 11 and 12 connected adjacent the rear edges 6 and 6′.

[0037] As best seen in FIGS. 3 and 5, front arms 9 and 10 are located adjacent the top and base edges 8, 8′ and 7, 7′ so as to maximise the front opening. The rear arms 11 and 12 are located vertically intermediate, or vertically spaced, the front arms 9 and 10 along an axis parallel to the wall elements. In this way when the arms are folded, they are all offset from each other, so they can fold and extend without interference.

[0038] Each of the folding arms are in the form of two preferably equal length elements that are interconnected at a mid-point by means of an arm fold hinge connector 14. This connector can be of any suitable form that ideally enables a neat butt joint in the fully extended configuration, while also facilitating a neat flat fold in the folded configuration as shown in FIG. 1. One example of a suitable hinge is shown in more detail in FIG. 4.

[0039] The distal ends of each folding arm are connected to the inside surfaces 4, 4′ of the walls 2 and 3 by wall hinges in the form of flat fold hinges 15. As best seen in enlarged FIGS. 2 and 6, these hinges each have a rear flange 16 that secures to the inner surfaces of the side walls, and a front hinge 17 that connects to an inside surface of each end of each arm. In the folded configuration, the front and rear flanges 16 and 17 are generally parallel as shown in FIGS. 1 and 2, and in the extended configuration are at 90 degrees to each other as shown in FIGS. 5 and 6. Preferably, these hinges include either some form of over centre biasing mechanism to urge the hinge to the expanded 90 degree orientation, and/or some form of integral locking mechanism that helps to hold the hinge in the expanded 90 degree orientation. Optionally, other locking mechanisms may be provided which may form part of the wall hinges and/or the arm hinges or comprise independent elements. In the preferred form illustrated, the flat fold hinges 15 include an over centre spring mechanism that once moved from the folded configuration, biases the hinges toward a locked expanded 90 orientation and automatically locks. A release tab is provided which needs to be moved to a release position before the hinges can be returned to the collapsed position, should that be required.

[0040] As can be seen from FIGS. 1 to 6, assembly of the frame structure is incredibly simple. The frame structure is the collapsed transport and packaging configuration shown in FIG. 1, where each folded arm is in the folded configuration.

[0041] The two wall elements 2 and 3 are then pulled apart until fully expanded as shown in FIG. 5. At this point the arrangement of hinges, and accurate pre-assembly of the components, contributes to a structurally stable and rigid assembly, which gains further strength and stability as the additional components are added which also provide further bracing.

[0042] In this particular embodiment, the next steps of adding in shelves, doors and basin or bench top are relatively simple as shown in FIGS. 8 to 12. For example, the shelves 18 can be installed by using conventional post mounts 19 as shown in FIGS. 7 and 8. These mounts 19 include a horizontal spigot 20 which is configured for an interference fit within pre-machined holes 21 formed in the inside surface of the sides walls as shown. The shelves are then provided with pre-machined blind holes in the underside of the shelves that are sized to snugly receive the post formations 22. When the shelves are inserted over the mounts, they can be pushed down over the post formations. This provides an accurate and rigid connection of the shelf to the assembled frame structure, again adding further bracing to the finished structure.

[0043] The doors 23 can be attached using any suitable door hinge 24 such as those shown in FIGS. 9 and 10. These two-part hinges are widely used. Each part could be pre-assembled or secured into pre-drilled or pre-marked locations. The doors are then connected by pushing the extending hinge arm 25 connected to each door, into the hinge gate 26 provided on the inside surface of the side walls.

[0044] Depending on the intended purpose and proposed location of the cabinet, it may be desirable to include some form of fascia board or kick board 27 such as the one shown in FIG. 9. While these can be attached in any suitable manner, in most instances they have only aesthetic purpose and as such a simple clip in fastener system 28 such as that shown in more detail in FIG. 11 is sufficient and fast to install.

[0045] To complete the vanity unit of this particular embodiment, the final step is to attach the basin top 29. In the example shown, locating dowels 30 are used to accurately position the top and locate it laterally. Additional fixtures or adhesives may also be used.

[0046] While the illustrated embodiment uses spacer elements in the form of folding arms, it will be appreciated that the expandable and collapsible structure could be achieved by other means such as using telescoping arm elements, which may also be hingedly interconnected with the walls, or use some other form of linearly extendible connector structures such as a “scissor jack” type arm.

[0047] Additionally, while the embodiment illustrated uses a total of four folding arms to create the frame structure, it could be possible to use only two or three and provide additional stiffening bracing by other means such as further slide in or clip in spacers.

[0048] While the rear of the cabinet described is open to the rear, some form of rear panel could be provided if required which again could be secured by clips, cam fasteners, internal corner angles or again any suitable means.

[0049] It should also be noted that while the embodiment described illustrates use of the storage unit frame structure to create the carcass of a storage cabinet, that same storage unit frame structure principle could be used to create drawer units for cabinets that are made the same way or by other conventional means.

[0050] It should be appreciated that in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, Figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

[0051] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

[0052] While there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as falling within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.