Semi-full access and full access framed cabinetry

Abstract

A semi-full access and full access face frame for a cabinet box is provided, together with a method for making and assembling cabinet boxes. In a semi-full access face frame, the vertical stiles are rotated ninety degrees compared to a traditional face frame. In a full access face frame the vertical stiles and the horizontal rails are rotated ninety degrees compared to a traditional face frame.

Claims

1. A cabinet comprising: a cabinet box configured to affix to a wall comprising: a panel assembly including a first side panel, a second side panel and a bottom panel, each panel having an interior surface and an exterior surface, the interior surface of each panel faces an interior space of the cabinet box and the exterior surface of each panel faces the exterior of the cabinet box, the panel assembly having a front end with an opening that provides access to the interior space, the opening having a height and a width and defining an opening plane; a face frame assembly, comprising: a first vertical frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the depth of the first vertical frame member is greater than the width of the first vertical frame member; a second vertical frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the depth of the second vertical frame member is greater than the width of the second vertical frame member, and wherein the second vertical frame member is spaced apart from the first vertical frame member by approximately the width of the opening of the cabinet box; wherein at least one of the first vertical frame member and second vertical frame member comprise a first portion and a second portion joined by one or more of the following types of connections: deep dado joint, lock dado joint, dowel joint, partial dovetail joint, biscuit joint, reversed dado joint, finger jointing, nailing and miter joint a first horizontal frame member extending between the first vertical frame member and the second vertical frame member, the first horizontal frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the width of the first horizontal frame member is greater than the depth of the first horizontal frame member, and the first horizontal frame member having a first end directly connected to the first vertical frame member and a second end directly connected to the second vertical frame member; and a second horizontal frame member extending between the first vertical frame member and the second vertical frame member, the second horizontal frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the width of the second horizontal frame member is greater than the depth of the second horizontal frame member, and the second horizontal frame member having a first end directly connected to the first vertical frame member and a second end directly connected to the second vertical frame member; wherein the face frame is connected to the front end of the panel assembly to provide structural support to the cabinet box; at least one door mounted to the face frame assembly; and wherein, when the door is open, substantially full access into the interior space of the cabinet box across the width of the opening is provided between the first vertical frame member and the second vertical frame member, and the first horizontal frame member and the second horizontal frame member do not permit full access across the height of the opening.

2. The cabinet of claim 1, wherein the depth of the first vertical frame member and of the second vertical frame member enables full mounting of a euro style hinge to at least one of the first vertical frame member and the second vertical frame member and not to a side panel alone.

3. The cabinet of claim 1, wherein the depth of the first vertical frame member and of the second vertical frame member enables full mounting of a drawer guide to at least one of the first vertical frame member and the second vertical frame member and not to a side panel alone.

4. The cabinet of claim 1, wherein the first portion is adapted to attach to a side panel of a cabinet box and the second portion is connected to the first portion and extends laterally outwardly away from the first portion.

5. The cabinet of claim 1, wherein the cabinet box comprises multiple cabinet boxes linearly positioned adjacent each other, and wherein at least one of the first horizontal frame member and the second horizontal frame member comprise a single piece and extends without seams horizontally across the adjacent cabinet boxes.

6. The cabinet of claim 1, wherein the cabinet box comprises a single box having one opening, and the face frame comprises at least three vertical frame members, and wherein at least one of the first horizontal frame member and the second horizontal frame member comprise a single piece and extends without seams horizontally across the at least three vertical frame members.

7. The cabinet of claim 1, wherein the cabinet box further comprises a top panel and the first horizontal frame member is interconnected to the top panel.

8. The cabinet of claim 1 wherein at least the vertical frame members are interconnected to the cabinet box by one or more of the following types of connections: deep dado joint, lock dado joint, dowel joint, partial dove tail joint, biscuit joint, reversed dado joint, finger jointing and nailing.

9. The cabinet of claim 1, wherein the first vertical frame member is joined to at least the first horizontal frame member by at least one of a deep dado forty-five degree miter joint, a deep dado lock miter joint, deep dado joint, lock dado joint, dowel joint, partial dovetail joint, biscuit joint, reversed dado joint, finger jointing, nailing and miter joint.

10. The cabinet of claim 1, wherein at least one of the first and second horizontal frame members comprise a first portion and a second portion joined together whereby the first portion attaches to the cabinet box and the second portion extends away from the opening of the cabinet box with an outer surface oriented parallel to the opening of the cabinet box.

11. The cabinet of claim 10, wherein the first portion of the at least one of the first and second horizontal frame members is joined to the second portion of the at least one of the first and second horizontal frame members by at least one of the following types of connections: deep dado joint, lock dado joint, dowel joint, partial dovetail joint, biscuit joint, reversed dado joint, finger jointing, nailing and miter joint.

12. The cabinet of claim 1, further comprising the absence of any frame members other than the face frame.

13. The cabinet of claim 1, further comprising a stretcher extending between the first and second side panels.

14. The cabinet of claim 1, wherein the first and second vertical frame members and the first and second horizontal frame members are made from wood.

15. The cabinet of claim 1, wherein the first vertical frame member comprises an inner surface substantially parallel with the inner surface of the first side panel, and an outer surface substantially parallel with the outer surface of the first side panel, and wherein the width of the first vertical frame member is greater than the width of the first side panel such that the outer surface of the first vertical member is spaced outwardly from the outer surface of the first side panel; and, wherein the second vertical frame member comprises an inner surface substantially parallel with the inner surface of the second side panel, and an outer surface substantially parallel with the outer surface of the second side panel, and wherein the width of the second vertical frame member is greater than the width of the second side panel such that the outer surface of the second vertical member is spaced outwardly from the outer surface of the second side panel.

16. The cabinet of claim 1, further comprising a wall nailer extending between the first and second side panels.

17. The cabinet of claim 1, wherein the ratio of the depth to the width of the first and second vertical frame members is about 2:1 and the ratio of the width to the depth of the first and second horizontal frame members is about 2:1.

18. The cabinet of claim 1, wherein the cabinet box comprises a row of adjacent cabinet boxes, and wherein the first horizontal frame member and the second horizontal frame member separately comprise a single piece and extend horizontally across the row of adjacent cabinet boxes without seams.

19. The cabinet of claim 1, further comprising a euro hinge flush mounted on the inner surface of the first vertical frame member and first side panel, with at least two screws connecting the hinge to the first vertical frame member and at least one screw connecting the hinge to the side panel.

20. The cabinet of claim 1, further comprising a drawer guide flush mounted on the inner surface of the first vertical frame member and the inner surface of the first side panel and wherein at least one end of the drawer guide is attached to the first vertical frame member by at least two screws and the opposite end of the drawer guide is attached to the side panel by a screw.

21. The cabinet of claim 1, further comprising a rear panel, the absence of any frame member extending between the first and second side panels proximate the rear panel.

22. A cabinet, comprising: a panel assembly configured to affix to a wall, the panel assembly comprising: a first side panel, a second side panel, a bottom panel, and a rear panel, each panel having an inner surface and an outer surface, the inner surface of each panel faces an interior space of the panel assembly and the outer surface of each panel forms an exterior surface of the panel assembly, the panel assembly having a front end with an opening having a lateral width and a vertical height, the panel assembly having a depth defined as the direction between the front end and the rear panel, and wherein there is an absence of any frame member extending along substantially the full depth of the panel assembly; and a face frame connected to the front end of the panel assembly, the face frame including: a first stile interconnected to the first side panel and having an inner surface and an outer surface, the inner surface being substantially flush to the inner surface of the first side panel and the outer surface extending laterally outward of the outer surface of the first side panel, the first stile having a longer dimension extending parallel to the first side panel and a shorter dimension extending perpendicular to the first side panel; a second stile interconnected to the second side panel and having an inner surface and an outer surface, the inner surface being substantially flush to the inner surface of the second side panel and the outer surface extending laterally outward of the outer surface of the second side panel, the second stile having a longer dimension extending parallel to the second side panel and a shorter dimension extending perpendicular to the second side panel; wherein at least one of the first stile or the second stile comprises a first portion wherein the inner surface of the first portion is substantially flush to the inner surface of the side panel to which the at least one of the first and second stile is attached, and the outer surface extending laterally outward of the outer surface of the side panel to which the stile is attached, and further comprising a second portion that extends laterally outwardly from the outer surface of the first portion and is adapted to fill a gap between the cabinet and an adjacent structure; a top rail extending horizontally between the first stile and the second stile, the top rail having a depth that extends approximately perpendicular to the opening of the cabinet box and a width that extends approximately parallel to the opening of the cabinet box, wherein the width of the top rail is greater than the depth of the top rail, and the top rail having a first end directly connected to the first stile and a second end directly connected to the second stile; and a bottom rail extending horizontally between the first stile and the second stile, the bottom rail having a depth that extends approximately perpendicular to the opening of the cabinet box and a width that extends approximately parallel to the opening of the cabinet box, wherein the width of the bottom rail is greater than the depth of the bottom rail, and the bottom rail having a first end directly connected to the first stile and a second end directly connected to the second stile; whereby the orientation of the first stile and the second stile permit substantially full access into the interior space of the panel assembly across the lateral width of the opening, and whereby the face frame provides structural support to the panel assembly.

23. The cabinet of claim 22, wherein the ratio of the depth to the width of the stiles is about 2:1 and the ratio of the width to the depth of the rails is about 2:1.

24. The cabinet of claim 22, wherein the cabinet comprises a row of adjacent cabinet boxes, and wherein the top rail and the bottom rail separately comprise a single piece and extend horizontally across the row of adjacent cabinet boxes without seams.

25. The cabinet of claim 22, further comprising a euro hinge flush mounted on the inner surface of the first stile and first side panel, with at least two screws connecting the hinge to the stile and at least one screw connecting the hinge to the side panel.

26. The cabinet of claim 22, further comprising a drawer guide flush mounted on the inner surface of the first stile and the inner surface of the first side panel and wherein at least one end of the drawer guide is attached to the first stile by at least two screws and the opposite end of the drawer guide is attached to the side panel by a screw.

27. The cabinet of claim 22, further comprising the absence of any frame member extending between the first and second side panels proximate the rear panel.

28. The cabinet of claim 22, further comprising the absence of any frame members other than the face frame.

29. The cabinet of claim 22, wherein the first stile is joined to the first side panel by at least one of a deep dado joint, lock dado joint, dowel joint, partial dovetail joint, biscuit joint, reversed dado joint, finger jointing, nailing and miter joint and the second stile is joined to the second side panel by at least one of a deep dado joint, lock dado joint, dowel joint, partial dovetail joint, biscuit joint, reversed dado joint, finger jointing, nailing and miter joint.

30. The cabinet of claim 22, further comprising a wall nailer extending between the first and second side panels.

31. The cabinet of claim 22, wherein the depth of the first stile and of the second stile enables full mounting of a euro style hinge to at least one of the stile and the second stile and not to a side panel alone.

32. The cabinet of claim 22, wherein the depth of the first stile and of the second stile enables full mounting of a drawer guide to at least one of the first stile and the second stile and not to a side panel alone.

33. The cabinet of claim 22, wherein the cabinet comprises multiple cabinet boxes linearly positioned adjacent each other, and wherein at least one of the top rail and the bottom rail comprise a single piece and extends without seams horizontally across the adjacent cabinet boxes.

34. The cabinet of claim 22, wherein the cabinet comprises a single box having one opening, and the face frame comprises at least three stiles, and wherein at least one of the top rail and the bottom rail comprise a single piece and extends without seams horizontally across the at least three stiles.

35. The cabinet of claim 22, wherein the cabinet further comprises a top panel and the top rail is interconnected to the top panel.

36. The cabinet of claim 22 wherein at least the stiles are interconnected to the cabinet by one or more of the following types of connections: deep dado, lock dado, dowel, partial dove tail, biscuit, reversed dado, finger jointing and face nailing.

37. The cabinet of claim 22, wherein the first stile is joined to at least the top rail by a deep dado forty-five degree miter joint or a deep dado lock miter joint.

38. The cabinet of claim 22, wherein at least one of the top and bottom rails comprise a first portion and a second portion joined together whereby the first portion attaches to the cabinet and the second portion extends away from the opening of the cabinet with an outer surface oriented parallel to the opening of the cabinet.

39. The cabinet of claim 38, wherein the first portion of the at least one of the top and bottom rails is joined to the second portion of the at least one of the top and bottom rails by at least one of the following types of connections: deep dado joint, lock dado joint, dowel joint, partial dovetail joint, biscuit joint, reversed dado joint, finger jointing, nailing and miter joint.

40. The cabinet of claim 22, further comprising a stretcher extending between the first and second side panels.

41. The cabinet of claim 22, wherein the first and second stiles and the top and bottom rails are made from wood.

42. The cabinet of claim 22, wherein the cabinet has a depth defined as the direction generally perpendicular to the opening plane, and wherein there is an absence of any frame member extending along substantially the entire depth of the cabinet.

43. The cabinet of claim 22, wherein the first stile comprises an inner surface substantially parallel with the inner surface of the first side panel, and an outer surface substantially parallel with the outer surface of the first side panel, and wherein the width of the first stile is greater than the width of the first side panel such that the outer surface of the first stile is spaced outwardly from the outer surface of the first side panel; and, wherein the second stile comprises an inner surface substantially parallel with the inner surface of the second side panel, and an outer surface substantially parallel with the outer surface of the second side panel, and wherein the width of the second stile is greater than the width of the second side panel such that the outer surface of the second stile is spaced outwardly from the outer surface of the second side panel.

44. A cabinet comprising: a cabinet box configured to affix to a wall comprising: a panel assembly including a first side panel, a second side panel and a bottom panel, each panel having an interior surface and an exterior surface, the interior surface of each panel faces an interior space of the cabinet box and the exterior surface of each panel faces the exterior of the cabinet box, the panel assembly having a front end with an opening that provides access to the interior space, the opening having a height and a width and defining an opening plane; a face frame assembly, comprising: a first vertical frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the depth of the first vertical frame member is greater than the width of the first vertical frame member; a second vertical frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the depth of the second vertical frame member is greater than the width of the second vertical frame member, and wherein the second vertical frame member is spaced apart from the first vertical frame member by approximately the width of the opening of the cabinet box; a first horizontal frame member extending between the first vertical frame member and the second vertical frame member, the first horizontal frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the width of the first horizontal frame member is greater than the depth of the first horizontal frame member, and the first horizontal frame member having a first end directly connected to the first vertical frame member by a deep dado forty-five degree miter joint or a deep dado lock miter joint and a second end directly connected to the second vertical frame member; and a second horizontal frame member extending between the first vertical frame member and the second vertical frame member, the second horizontal frame member having a depth that extends approximately perpendicular to the opening plane of the cabinet box and a width that extends approximately parallel to the opening plane of the cabinet box, wherein the width of the second horizontal frame member is greater than the depth of the second horizontal frame member, and the second horizontal frame member having a first end directly connected to the first vertical frame member and a second end directly connected to the second vertical frame member; wherein the face frame is connected to the front end of the panel assembly to provide structural support to the cabinet box; at least one door mounted to the face frame assembly; and wherein, when the door is open, substantially full access into the interior space of the cabinet box across the width of the opening is provided between the first vertical frame member and the second vertical frame member, and the first horizontal frame member and the second horizontal frame member do not permit full access across the height of the opening.

45. The cabinet of claim 44, wherein the depth of the first vertical frame member and of the second vertical frame member enables full mounting of a euro style hinge to at least one of the first vertical frame member and the second vertical frame member and not to a side panel alone.

46. The cabinet of claim 44, wherein the depth of the first vertical frame member and of the second vertical frame member enables full mounting of a drawer guide to at least one of the first vertical frame member and the second vertical frame member and not to a side panel alone.

47. The cabinet claim 44, wherein at least one of the first vertical frame member and second vertical frame member comprise a first portion and a second portion, and wherein the first portion is adapted to attach to a side panel of a cabinet box and the second portion is connected to the first portion and extends laterally outwardly away from the first portion.

48. The cabinet of claim 44, wherein the cabinet box comprises multiple cabinet boxes linearly positioned adjacent each other, and wherein at least one of the first horizontal frame member and the second horizontal frame member comprise a single piece and extends without seams horizontally across the adjacent cabinet boxes.

49. The cabinet of claim 44, wherein the cabinet box comprises a single box having one opening, and the face frame comprises at least three vertical frame members, and wherein at least one of the first horizontal frame member and the second horizontal frame member comprise a single piece and extends without seams horizontally across the at least three vertical frame members.

50. The cabinet of claim 44, wherein the cabinet box further comprises a top panel and the first horizontal frame member is interconnected to the top panel.

51. The cabinet of claim 44 wherein at least the vertical frame members are interconnected to the cabinet box by one or more of the following types of connections: deep dado join, lock dado joint, dowel joint, partial dove tail joint, biscuit joint, reversed dado joint, finger jointing and nailing.

52. The cabinet of claim 44, wherein the first vertical frame member is joined to at least the first horizontal frame member by a deep dado forty-five degree miter joint or a deep dado lock miter joint.

53. The cabinet of claim 44, wherein at least one of the first and second horizontal frame members comprise a first portion and a second portion joined together whereby the first portion attaches to the cabinet box and the second portion extends away from the opening of the cabinet box with an outer surface oriented parallel to the opening of the cabinet box.

54. The cabinet of claim 53, wherein the first portion of the at least one of the first and second horizontal frame members is joined to the second portion of the at least one of the first and second horizontal frame members by at least one of the following types of connections: deep dado join, lock dado joint, dowel joint, partial dovetail joint, biscuit joint, reversed dado joint, finger jointing, face nailing and miter joint.

55. The cabinet claim 44 further comprising the absence of any frame members other than the face frame.

56. The cabinet of claim 44, further comprising a stretcher extending between the first and second side panels.

57. The cabinet of claim 44, wherein the first and second vertical frame members and the first and second horizontal frame members are made from wood.

58. The cabinet of claim 44, wherein the cabinet box has a depth defined as the direction generally perpendicular to the opening plane, and wherein there is an absence of any frame member extending along substantially the entire depth of the cabinet box.

59. The cabinet of claim 44, wherein the first vertical frame member comprises an inner surface substantially parallel with the inner surface of the first side panel, and an outer surface substantially parallel with the outer surface of the first side panel, and wherein the width of the first vertical frame member is greater than the width of the first side panel such that the outer surface of the first vertical member is spaced outwardly from the outer surface of the first side panel; and, wherein the second vertical frame member comprises an inner surface substantially parallel with the inner surface of the second side panel, and an outer surface substantially parallel with the outer surface of the second side panel, and wherein the width of the second vertical frame member is greater than the width of the second side panel such that the outer surface of the second vertical member is spaced outwardly from the outer surface of the second side panel.

60. The cabinet of claim 44, further comprising a wall nailer extending between the first and second side panels.

61. The cabinet of claim 44, wherein the ratio of the depth to the width of the first and second vertical frame members is about 2:1 and the ratio of the width to the depth of the first and second horizontal frame members is about 2:1.

62. The cabinet of claim 44, wherein the cabinet box comprises a row of adjacent cabinet boxes, and wherein the first horizontal frame member and the second horizontal frame member separately comprise a single piece and extend horizontally across the row of adjacent cabinet boxes without seams.

63. The cabinet of claim 44, further comprising a euro style hinge flush mounted on the inner surface of the first vertical frame member and first side panel, with at least two screws connecting the hinge to the first vertical frame member and at least one screw connecting the hinge to the side panel.

64. The cabinet of claim 44, further comprising a drawer guide flush mounted on the inner surface of the first vertical frame member stile and the inner surface of the first side panel and wherein at least one end of the drawer guide is attached to the first vertical frame member by at least two screws and the opposite end of the drawer guide is attached to the side panel by a screw.

65. The cabinet of claim 44, further comprising a rear panel, the absence of any frame member extending between the first and second side panels proximate the rear panel.

Description

DETAILED DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a front perspective view of a traditional face frame for a cabinet box.

(2) FIG. 2 is a front perspective view of one embodiment of a traditional framed cabinet box.

(3) FIG. 3 is a rear perspective view of the interior of an alternative embodiment of a traditional framed cabinet box.

(4) FIG. 3A is a top plan view of one embodiment of a traditional frame member connected to the front end of a cabinet box panel.

(5) FIG. 3B is a top plan view of a second embodiment of a traditional frame member connected to the front end of a cabinet box panel.

(6) FIG. 4 is an exploded view of a semi-frameless cabinet box.

(7) FIG. 5 is an expanded view of the edging material or veneer that is connected to the front edge or face of a cabinet box panel.

(8) FIG. 6 is a front perspective view of one embodiment of a semi-full access framed cabinet box.

(9) FIG. 7 is a rear perspective view of the interior of an alternative embodiment of a semi-full access framed cabinet box.

(10) FIG. 8 is a fragmentary perspective view of a modified form of front corner detail on a semi-full access framed cabinet box of the type shown in FIGS. 6 and 7.

(11) FIG. 8A is a fragmentary perspective view of the stile illustrated in FIG. 8.

(12) FIGS. 9A-9H are cross-sectional views of eight additional types of connections for connecting a panel to an inverted frame member.

(13) FIG. 10 is a fragmentary perspective view of another form of front corner detail for a semi-full access framed cabinet box of the type illustrated in FIGS. 6 and 7.

(14) FIG. 10A is a fragmentary perspective view of the stile shown in FIG. 10.

(15) FIG. 11 is a fragmentary perspective view of still another form of corner detail in a semi-full access cabinet box of the type illustrated in FIGS. 6 and 7.

(16) FIG. 11A is a fragmentary perspective view of the stile illustrated in FIG. 11.

(17) FIG. 12 is a fragmentary perspective view of another front corner detail on a semi-full access framed cabinet box of the type shown in FIGS. 6 and 7.

(18) FIG. 12A is a fragmentary perspective view of the stile shown in FIG. 12.

(19) FIG. 13 is a fragmentary perspective view of a face frame rail in combination with the stile illustrated in FIGS. 12 and 12A.

(20) FIG. 14 is a front perspective view of one embodiment of a full access framed cabinet box having inverted stiles and rails.

(21) FIG. 15 is a rear perspective view of the interior of an alternative embodiment of a full access framed cabinet box.

(22) FIG. 16 is a fragmentary perspective view of a modified form of front corner detail on a full access framed cabinet box of the type illustrated in FIGS. 14 and 15.

(23) FIG. 16A is a fragmentary perspective view of the stile shown in FIG. 16.

(24) FIG. 17 is a fragmentary perspective view of a modified form of front corner detail in a full access framed cabinet box of the type illustrated in FIGS. 14 and 15.

(25) FIG. 17A is a fragmentary perspective view of the stile shown in FIG. 17.

(26) FIG. 18 is a fragmentary perspective view of a modified form of front corner detail in a full access framed cabinet box of the type illustrated in FIGS. 14 and 15.

(27) FIG. 18A is a fragmentary perspective view of the stile shown in FIG. 18.

(28) FIG. 19 is a fragmentary perspective view of a modified form of front corner detail in a full access framed cabinet box of the type illustrated in FIGS. 14 and 15.

(29) FIG. 19A is a fragmentary perspective view of the stile shown in FIG. 19.

(30) FIG. 20 is a fragmentary perspective view of a modified form of front corner detail in a full access framed cabinet box of the type illustrated in FIGS. 14 and 15.

(31) FIG. 20A is a fragmentary perspective view of the stile shown in FIG. 20.

(32) FIG. 21 is a fragmentary perspective view of a fully inverted face frame rail and adjoining stile for a full access framed cabinet box.

(33) FIG. 22 is a fragmentary, exploded perspective view of an inverted face frame top rail and stile in combination with a top panel and side panel.

(34) FIG. 23 is a fragmentary perspective view of the full access frame components of FIG. 22 in an assembled configuration.

(35) FIG. 24 is a perspective view of a semi-full access cabinet box having an extended width and made according to embodiments of the present invention, showing an integral single piece top rail, bottom rail and laterally extending side stile.

(36) FIG. 24A is an expanded top view of the interconnection of the top rail, stile and side panel of FIG. 24, further showing a laterally extending stile joined to side panel with a deep dado lock miter joint of the type shown in FIG. 9H.

(37) FIG. 25 is a perspective view of a semi-full access cabinet box, in the form of a bookcase, made according to the embodiments of the present invention, further showing custom aesthetics.

(38) FIG. 26 is an exploded front perspective view of an assembled semi-full access frame and a cabinet box.

(39) FIG. 27 is a front perspective view of an assembled full access frame for a cabinet box.

(40) FIG. 28A is a plan view of the inside surface of a side panel of a full access cabinet box further showing a drawer guide, 2-screw European mounting plate and 3-screw European face frame base plate attached thereto.

(41) FIG. 28B is a plan view of the inside surface of a side panel of a frameless cabinet box further showing a drawer guide, 2-screw European mounting plate and 3-screw European face frame base plate attached thereto.

(42) FIG. 28C is a plan view of the inside surface of a side panel of a semi-full access cabinet box further showing a drawer guide, 2-screw European mounting plate and 3-screw European face frame base plate attached thereto.

(43) FIG. 28D is a plan view of the inside surface of a side panel of a semi-frameless cabinet box of the type shown in U.S. Pat. Nos. 7,306,299 and 7,451,535.

(44) FIG. 28E is a plan view of the inside surface of a side panel of a traditional framed cabinet box further showing a drawer guide and European face frame base plate partially attached thereto.

(45) FIG. 29 is a front perspective view of a plurality of full access base cabinet boxes affixed to a wall in an installed orientation and a pair of full access upper cabinet boxes further showing an integral 1-piece top and bottom rail and single center stile affixed to a wall in an installed orientation.

(46) FIGS. 30A and 30B are perspective views of cabinet boxes with inset doors, with the door in an open position. FIG. 30A is a cabinet box with a semi-full access inverted face frame. FIG. 30B is a cabinet box with a traditional face frame.

(47) FIGS. 31A and 31B are perspective views of the cabinets of FIGS. 30A and 30B, respectively, with the inset doors closed.

(48) FIGS. 32A and 32B are top perspective views of the cabinets of FIGS. 30A and 30B, further showing door hinge hardware.

(49) FIGS. 33A and 33B are each perspective views of a pair of cabinet boxes in abutting relationship alone one side panel. FIG. 33A shows a pair of cabinet boxes with a semi-full access inverted face frames. FIG. 33B shows a pair of cabinet boxes with a traditional face frame.

(50) 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.

DETAILED DESCRIPTION

(51) Referring to first alternative embodiments shown in FIGS. 6 and 7, like elements to those illustrated in FIGS. 2 and 3 are correspondingly enumerated. Specifically, the same box panel assembly or cabinet box 10 is comprised of the side panels 22, bottom panel 24, rear panel 26 and door 18. In FIG. 7, the rear panel 26 has rear frame members 28 placed behind it. The first embodiment illustrates a semi-full access framed cabinet in which the face frame is comprised of top and bottom rails 32 and 34, respectively, extending between front inverted stiles 36 on opposite sides of the frame. An exploded view of a semi-full access frame and cabinet is shown in FIG. 26. A full access frame is shown in FIG. 27, but without the cabinet.

(52) As illustrated in more detail in the embodiment of FIGS. 8 and 8A, each stile 36 is formed with a dado/rabbet, the dado defined by a generally U-shaped groove 37 extending the length of the stile 36 with opposite side walls 38 on either side of the groove 37 being of substantially equal thickness and the groove 37 being dimensioned to receive a notched end 39 of each side panel 22. The notch 40 of the notched end 39 is formed along the inner surface of the front end of the side panel 22 and is generally of a thickness t substantially equal to that of the side wall 38 on one side of the groove 37. The opposite side wall 38 overlaps the outer surface of the side panel 22. The stiles 36 are inverted with respect to the side panels, i.e., the stiles are rotated ninety degrees (90) relative to the orientation of a traditional stile frame member. As a result, the stiles are oriented with greater depth (in the same direction as the side panel) than in width. In other words, the larger dimension of the stile, its depth, is parallel to the side panel 22 and perpendicular to the plane defined by the opening of the cabinet box. In addition, the inner surface of each stile 36 is flush or substantially flush with the inner surface of the side panel 22 so as to afford the widest possible opening into the interior of the cabinet. A small overhang, where the stile extends slightly into the opening of the box, such as is shown in FIG. 8, may be desired to accommodate a veneer sheet as needed.

(53) In the embodiments of FIGS. 6 to 13 the rails 32 and 34 complete the face frame but are not inverted; i.e., the wider dimension extends perpendicular to the side panels 22, bottom panel 24 and top panel 26, and parallel to the plane defined by the opening of the cabinet. Conversely, the narrower dimension is parallel to the panels and perpendicular to the opening defined by the cabinet. Further, the rails are dimensioned to extend between inner surfaces of the stiles 36 and are positioned in abutting relation to the stiles 36. FIG. 13 is a fragmentary perspective view of the corner detail between a non-inverted rail 32 and inverted stile 36.

(54) In the form of cabinet shown in FIGS. 6 and 7, a raised or stepped portion 67 may be provided by the bottom rail 34 at the front of the cabinet box to protect the bottom panel from being scraped by utensils or pots and pans when advanced into the cabinet.

(55) 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 FIGS. 9A-9F. Because of the depth of the frame material, additional frame shapes and profiles can be milled into the frame. Examples might include forty-five degree (45) angled cabinets or lock miters joints for extended stiles and frame widths shown in FIGS. 9G and 9H. The joint technique illustrated in FIG. 9H permits laterally extending stiles of a variable lateral dimension by connecting two or more portions together to fill gaps between the cabinet box and adjacent walls or to provide an enlarged laterally extending surface for a custom finish. For example, see FIG. 24A. It should be appreciated that this type of joint may be used in connection with a stile connected to any side panel, or with a rail connected to a top panel or a bottom panel to form face frame extensions at any of these locations. Other joints types, such as shown in FIGS. 9A-9F, may also be used to form these extensions.

(56) 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.

(57) FIGS. 28A-28E illustrate advantages of the semi-full access and full access face frames of the present disclosure with respect to the securement of drawer guides, hinges and other accessories compared to traditional face frame cabinet boxes, frameless cabinet boxes and semi-frameless cabinet boxes. For example, FIG. 28E illustrates a side panel 22 of a traditional face frame cabinet box, further showing a drawer guide 70 and a quick release European-style hinge 21 with a 3-screw European faceless frame base plate 72. Because the inner surface 16 of the stile 36 extends into the opening of the cabinet box (see FIGS. 3 and 3A), the drawer guide 70 must be spaced from the inner surface of the side panel 22 in order that the front end of the drawer guide can attach to the inner surface 16 of the stile 36. As a result, a custom rear mounting bracket 74 is required to secure the rear end of the drawer guide 70 to the rear panel 26 or nailer 28. Importantly, the screw holes 76 in the middle and rear end of the drawer guide cannot be used.

(58) FIG. 28B illustrates a drawer guide 70 and quick release hinges 21 mounted on a frameless cabinet box. Here, a rear mounting bracket 74 is not needed. Rather, the drawer guide is flush mounted on the inner surface of the side frame 22. Front, middle and rear screw holes 76 may be utilized, but the screws are mounted into a panel made of plywood, particle board or some other composite material inferior to solid wood for mounting purposes. Similarly, the 3-screw European frameless base plate 72 and the 2-screw European mounting plate 78 are attached to the same panel.

(59) FIG. 28D illustrates a semi-frameless cabinet box side panel 22 with a wood veneer front edge piece 80 of the type shown in U.S. Pat. Nos. 7,306,299 and 7,451,535. The veneer 80 is purely aesthetic and offers no structural advantage. This cabinet box is the same as a European frameless cabinet box and suffers the same disadvantages in mounting accessories such as hinges 21 and drawer guide 70.

(60) In contrast are the semi-full access and full access cabinet boxes of FIGS. 28A and 28C, respectively. Here, stile 36 is inverted and attached to the side pane 22 such that its depth is substantially greater than stile 36 in the traditional framed cabinet box of FIG. 28E. More specifically, the front end of the drawer guide 70 is attached to the solid wood stile 36, and the entire drawer guide is mounted flush on the inner surface of the side panel 22 resulting in a longer lasting and more secure attachment. Moreover, the rear mounting bracket 74 is eliminated and the drawer itself is wider than a drawer used with a similar sized traditional framed cabinet box because the stile 36 does not extend into the open space. Further still, the 3-screw European frameless base plate 72 is also mounted flush with the stile 36 and side panel 22 such that all three screw holes may be used, with two screws placed in solid wood and one in the side panel further securing the frame to the cabinet. In addition, the 2-screw European mounting plate is also attached entirely to the solid wood stile 36.

(61) 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.

(62) FIGS. 10 and 10A illustrate a modified corner detail for a rabbet joint in which an inverted stile 36 is notched or recessed at 42 across its width to receive the full width of the end of the panel 22. A side wall 44 of the notched end 42 overlaps the outer surface of the side panel 22.

(63) Another modified form of corner detail is illustrated in FIGS. 11 and 11a and once again illustrates a stile 36 with a dado cut forming a groove 37 to receive a tongue 46 at the end of a side panel 22. In each of FIGS. 10 and 11, the top rails 32 and 34 are non-inverted or square to the ends of the side panels 48 as illustrated in FIGS. 6 and 7. Also, FIGS. 11 and 11a illustrate a stile with a wider sidewall 38 than sidewall 44 in FIG. 10.

(64) FIG. 12 illustrates another corner detail commonly referred to as a rabbet/rabbet. The stile 36 corresponds to that of FIGS. 10 and 10a with a corner notched end 42 and outer sidewall 44. However, the side panel 22 has a notched end 50 symmetrically opposite to the notched end 42 of the stile 36 shown in FIG. 10. In addition, the outer sidewall 44 of the stile 36 in FIG. 12 is wider than the sidewall 38 of FIG. 10 and also protrudes beyond the outer surface of the side panel 22.

(65) In the second embodiment, shown in FIGS. 14 and 15, a full access cabinet is illustrated. Again, like elements to those illustrated in FIGS. 2 and 3 are correspondingly enumerated. The box panel assembly 10 comprises side panels 22, bottom panel 24, rear panel 26 and front door 18. In FIG. 15, rear nailers 28 are behind rear panel 26. In the full access framed cabinet, the face frame may be fully assembled before connecting with the cabinet panels. The face frame of a semi-full access cabinet box may also be pre-assembled before connection to the cabinet box. A fully assembled full access face frame is shown in FIG. 27. A fully assembled semi-full access face frame is shown in FIG. 26. For example, compare FIG. 22, which shows an assembled partial frame together with unassembled top and side panels, to FIG. 23 which shows the same components in an assembled state. As part of the assembly process, the face frame members are connected, filled, sanded and finished as one unit which thereby fills any seams or voids between attaching members and provides a uniform finish. This gives a much higher end look of true furniture and quality to the face of the cabinet. In addition this allows the use of integral, single piece valances and decorative rail elements 14 and laterally extending side stiles 36, as illustrated in FIGS. 24 and 24A. As should be appreciated, these elements may comprise decorative shapes and details which are attractive, particularly when used on open face cabinets without doors covering the face. For example, FIG. 25 shows a cabinet box in the form of a bookcase. Both the bottom rail 14 and top rail 12 are decorative with custom detailing. In addition, a decorative middle rail 80 is also included. It should be appreciated that this can be accomplished in either a semi-full or full access frame.

(66) As shown in FIGS. 14 and 15, the face frame, which is mounted on the front end of the box panel assembly 10, is made up of top and bottom inverted rails 62 and 64 extending between inverted stiles 66; and a door panel 18 is mounted in hinged relation to the face frame by means of hinges 21 in the same manner as described in the first embodiment, for example, as shown in FIG. 28A. Accordingly, the entire face frame made up of the rails 62 and 64 in combination with the stiles 66 is inverted with respect to the panels 22 and 24 so as to increase the effective size of the front opening both vertically and laterally.

(67) The corner detail views of FIGS. 16 to 20 correspond to those of FIGS. 8 to 12, respectively, with respect to mounting of the inverted stiles with respect to the side panels and are correspondingly enumerated. The same is true of the individual stiles illustrated in FIGS. 16A to 20A which correspond to those of FIGS. 8A to 13A respectively. However, the rails 62 illustrated in FIGS. 16 to 20 are shown in the inverted position.

(68) FIG. 29 illustrates multiple cabinet boxes made according to embodiments of the present invention, and further mounted to a wall. Lower cabinet boxes 82 are assembled with individual full access face frames. Upper cabinet boxes 84 are assembled with a single full access face frame having a single piece, seamless top rail 12, bottom rail 14 and center stile 16. The frames may be fully assembled, sanded and finished prior to joining with the cabinet box to provide a uniform aesthetic finish. Alternatively, the frame members may be separately finished, but at the same time to provide a uniform finish, and then jointed to the cabinet box as part of the installation process.

(69) 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. FIGS. 30A-33A illustrate a semi-full access frame and cabinet box assembly with an inset door. For illustrative purposes, FIGS. 30B-33B show a traditional framed cabinet box with an inset door. A number of differences are present. As best shown in FIGS. 32A and 32B, the traditional framed cabinet of FIG. 32B has a smaller opening. The stiles 16 shown in FIG. 32B extend laterally into the opening of the cabinet box. This is not the case with the frame and cabinet box of FIG. 32A. In FIG. 32A, the inner surface 16 of the stiles 16 are flush or substantially flush with the inner surface of the side panels 22. As a result, and as seen in comparing FIG. 31A to FIG. 31B, the inset door 18 in FIG. 31B is smaller than the door shown in FIG. 31A. A difference in hardware also is evident.

(70) Regarding hinges, the hinges 21 used in the traditional cabinet of FIG. 32B mount to the back surface 16 of the stile, while the hinge 21 used in association with the semi-full access inverted frame cabinet of FIG. 32A mount to the stile itself, similar to as shown in FIG. 28A. In addition, because the inner surface 16 of the stile in the traditional framed cabinet is not flush or substantially flush with the inner surface of the side panel 22, a drawer guide 70 must be connected to the rear panel 26 as shown in FIG. 28E.

(71) There are also aesthetic differences. FIGS. 33A and 33B illustrate a pair of abutting cabinet boxes. In FIG. 33A, because the stiles 16 are inverted a more symmetrical and aesthetically pleasing cabinet face is provided. Assuming a typical face frame having cross-sectional dimensions of 1.5 inches by 0.75 inches, because the stiles 16 are inverted in FIG. 33A, the width of each stile across the face of the cabinet is 0.75 inches. Accordingly, the abutting stiles 16 have a combined width of 1.5 inches. This is the same width for the rails 12 and 14. In contrast, as shown in FIG. 33B, because the stiles 16 are not inverted, the abutting stiles 16 have a combined width of 3.0 inches, which is twice the width as the rails 12 and 14.

(72) 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.

(73) 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.

(74) 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.

(75) 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.

(76) 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.

(77) 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.

(78) 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.