Abstract
A storage cabinet may include a top substrate. A storage cabinet may include a bottom substrate and a plurality of wall panels. It may include at least one door substrates, where each of the top substrate and the bottom substrate include a slot extending along a perimeter of a corresponding one of the top substrate and the bottom substrate. A storage cabinet may include a locking ring configured to be inserted into the slot while the plurality of wall panels are place in position with one end in the slot, so as to fix the wall panels to the corresponding one of the top substrate and the bottom substrate.
Claims
1. A storage cabinet comprising: a top substrate; a bottom substrate; a plurality of wall panels; at least one door substrates; wherein each of the top substrate and the bottom substrate include a slot extending along a perimeter of a corresponding one of the top substrate and the bottom substrate; and an insert is configured to be inserted into the slot while the plurality of wall panels are place in position with one end in the slot, so as to fix the wall panels to the corresponding one of the top substrate and the bottom substrate.
2. The storage cabinet according to claim 1, wherein the slot is annular and the insert forms a closed ring.
3. The storage cabinet according to claim 1, wherein the slot comprises a plurality of slots arranged along the perimeter of the top substrate or bottom substrate.
4. The storage cabinet according to claim 1, wherein an inner side wall of the insert conforms to an inner side wall of the slot, an outer side wall of the insert conforms to an inner surface of the wall panels.
5. The storage cabinet according to claim 4, wherein the slot comprises at least one concave portions, the insert comprises at least one convex portions at respective corresponding locations, and the wall panels comprise bend portions corresponding to the concave portions of the slot and convex portions of the insert.
6. The storage cabinet according to claim 1, wherein the insert comprises a plurality of insert sections.
7. The storage cabinet according to claim 1, wherein a plurality of protrusion barbs are provided on a side wall of the insert.
8. The storage cabinet according to claim 1, wherein the insert is hollow.
9. The storage cabinet according to claim 1, wherein the top substrate and the bottom substrate are identical.
10. The storage cabinet according to claim 8, wherein the top substrate and the bottom substrate are made of molded plastic.
11. The storage cabinet according to claim 1, wherein the wall panels comprise single-wall construction.
12. The storage cabinet according to claim 1, wherein the at least one door substrates are adapted to receive at least one accessory.
13. The storage cabinet according to claim 1, wherein in a packaging of the storage cabinet, the top and bottom substrates form an enclosure in which the wall panels and door substrates are stacked and confined.
14. The storage cabinet according to claim 13, wherein each of the top and bottom substrates comprises a plurality of feet that are adapted to support the storage cabinet when assembled, and in the package, the plurality of feet are used as sides of the enclosure.
15. The storage cabinet according to claim 1, wherein each of the top and bottom substrates comprises a single integral substrate.
16. The storage cabinet according to claim 1, wherein each of the top and bottom substrates comprises four substrate components, and in packaging of the storage cabinet, the substrate components are arranged at respective corners of the packaging.
17. The storage cabinet according to claim 1, further comprises a bottom support that is attached to the bottom substrate along the perimeter of the bottom substrate in the storage cabinet to reinforce the storage cabinet.
18. The storage cabinet according to claim 17, wherein the bottom support comprises a plurality of bottom support sections.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention, together with the above and other objects and advantages, will be best understood from the following detailed description of the preferred embodiment of the invention shown in the accompanying drawings, wherein:
[0021] FIG. 1 is an overview of one embodiment of the device.
[0022] FIGS. 2A-2D are detailed views of one embodiment.
[0023] FIG. 3 shows the details of the top and bottom substrates, per one embodiment.
[0024] FIGS. 4A-4B show a detailed view of the accessory feature, used in some embodiments.
[0025] FIG. 5 shows the details of the leak-proof tray shelf, per one embodiment.
[0026] FIG. 6 shows the details of the sheet metal side panels.
[0027] FIGS. 7A-7D depict several different embodiments showing different internal configurations.
[0028] FIGS. 8A, 8B, and 9 show a number of accessories that can be fitted into the cabinet, including post storage, a door slide, a wood top, and others.
[0029] FIGS. 10A-10E show a variety of configurations, including accessories such as a wooden top.
[0030] FIG. 11 shows a front perspective view of a cabinet according to one embodiment.
[0031] FIGS. 12A-12C show the bottom substrate of the cabinet according to one embodiment.
[0032] FIGS. 13A-13C show the bottom ring of the cabinet according to one embodiment.
[0033] FIGS. 14A-14C show the back wall and one of the panels thereof according to one embodiment.
[0034] FIGS. 15A-15B show the left side wall of the cabinet according to one embodiment.
[0035] FIG. 16A-16D show the left side door of the cabinet according to one embodiment.
[0036] FIGS. 17A-17C show the shelf panel of the cabinet according to one embodiment.
[0037] FIG. 18A-18C show the packaging of the cabinet according to one embodiment.
[0038] FIG. 19 shows the strap of the packaging that can be used for an anti-tip kit according to one embodiment.
[0039] FIGS. 20A-20F show steps for assembling the cabinet according to one embodiment.
[0040] FIGS. 21A-21B show a shelf panel according to another embodiment.
[0041] FIG. 22 shows a pin according to another embodiment.
[0042] FIGS. 23A-23B depict a shelf panel according to another embodiment.
[0043] FIGS. 24A and 24B depict a bottom support according to another embodiment.
[0044] FIGS. 25A-25D depict a hanger system according to another embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The foregoing summary and the following detailed description of certain embodiments of the present invention will be better understood when read in conjunction with the appended drawings.
[0046] As used herein, an element or step recited in the singular and proceeded with the word a or an should be understood as not excluding plural said elements or steps unless such exclusion is explicitly stated. Furthermore, references to one embodiment of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments comprising or having an element or a plurality of elements having a particular property may include additional such elements not having that property.
[0047] Turning to FIG. 1, depicted therein is an example embodiment 10 of a cabinet 12. The cabinet includes a front opening with at least one door 14. Each door 14 comprises single wall construction and includes at least one molded door feature 16. In the example shown in FIG. 1, the door feature 16 comprises an insert the details of which will be described below.
[0048] The door 14 is manufactured with single-wall construction in the depicted embodiment. The use of sheet metal with bends and plastic components in the single-wall construction can achieve required levels of rigidity and strength, yet still lower the cost of the unit.
[0049] The door feature 16 comprises an integrated plastic insert which is a truss designed with plastic components and used to strengthen the panels, while adding organizational tools to the door 14. In one embodiment, the door feature 16 comprises a pegboard for additional organization of the cabinet 12. The door feature 16 is integrally molded into the door 14, resulting in it not protruding into the main body 18 of the cabinet 12.
[0050] The interior of the cabinet 12 includes versatile shelving 20. The shelves comprise multiple different materials and are doubled sided inch deep shelves, in the depicted embodiment 10. A first shelf 22 is lined with a thin galvanized scratch-resistant steel while a second type of shelf 20 includes a leak proof tray shelf 24.
[0051] The cabinet 12 is easy to assemble with visual cues provided, such as plastic shelf supports 26, which are tinted a different color.
[0052] The top substrate 30 of the cabinet 12 (and an analogous bottom substrate 32) comprises a molded plastic. The feet 34 on the bottom 32 and similar structures on the top provide additional storage supports for applications such as storing of lumber, pipes, plastic bags or totes, without worrying about the products falling off the top substrate 30. As shown in FIG. 1., the feet 34 are integrally molded in both the top substrate 30 and the bottom 32 making the two substrates interchangeable and making the assembly of the cabinet 12 easier.
[0053] As shown in FIG. 1, the shelves are adjustable. In one embodiment, the adjustment occurs with a spring-loaded latch, such that shelf location and height can be readily adjusted. The cabinet 12 no longer relies on clip location guesswork that is used in prior art cabinets.
[0054] In the embodiment shown in FIG. 1, the pivot point of the doors is outside the interior and the body of the cabinet 12. This allows complete access to the inside of the cabinet 12 and prevents the formation of dead corners where certain parts of the cabinet are not readily accessible.
[0055] While the doors shown in FIG. 1 open on a hinge, in at least one embodiment, the doors are removable and in sliding communication with each other.
[0056] The top and bottom panels include openings 36 that avoid safety concerns, which are common with prior art devices. The top substrate 30 includes openings to install a tip-over protection tether system to prevent the cabinet 12 from tipping over.
[0057] As shown in FIG. 1, the door 14 includes molded components which can be painted and repainted to hide scratches, dents, and dings, which makes it less likely that an end-user will return the cabinet 12.
[0058] The back panel 38 includes cable management openings which allow for running cords behind the shelves, and provides power to battery powered tools, especially ones on a leak-proof tray shelf 24.
[0059] The cabinet 12 includes multiple features that make the manufacturing of the cabinet 12 particularly advantageous. The side panels 40 allow for overspray of hard-to-reach areas, resulting in an orange peel texture. The undulations of the door 14 panels allow for use of light powder coating that lowers the paint cycle time and material during the painting of the doors 14. The use of a galvanized back panel 38 makes the interior of the cabinet 12 reflect the light and helps to balance the painting process during the manufacturing of the panels. The indented panel construction allows for nesting of the components, making for a smaller footprint and the elimination of packaging material.
[0060] The cabinet 12 eliminates rivets, nuts, bolts, clips, and other fasteners. The versatile shelving 20 arrangements can be repositioned by using the plastic shelf supports 26, which replace all fasteners. The panels that are applied to sheet metal can use adhesive that is well-known in the art, including automotive adhesive that has been used in industry for more than four decades.
[0061] The elimination of rivets and other fasteners brings a number of benefits, including the labor costs needed to apply the rivet and the washer, quality control issues during the riveting process, stack tolerances, and others.
[0062] The end cabinet 12 has a clean look, which makes the product look much better.
[0063] As shown in FIGS. 2A-2D, the cabinet 12 can include a door magnet 44. The cabinet 12 can have a variety of sizes, such as the embodiment 50 shown in FIG. 2D.
[0064] The door feature 16 details shown in FIG. 2A, shows how the door feature 16 can be used with multiple embodiments such as the first embodiment 10 of FIG. 1 and the second embodiment 50 in FIG. 2D.
[0065] For the smaller embodiment 50 of FIG. 2D, the top surface can be used for large storage 52.
[0066] Other accessories 54 used on top of the smaller embodiment 50 include a cord organizer which is suitable for use with under lighting options, a wire-formed tool holder, a tape measure clip, top storage ears, and under drawer and hanging pegboard.
[0067] The details of the top substrate 30 and bottom substrate 32 are shown in FIG. 3. It should be noted that both the top substrate 30 and bottom substrate 32 are identical in one embodiment. The substrate comprises feet 34 which are used as storage protrusions when the substrate is used as a top cover.
[0068] A benefit of the top substrate 30 is that no paint is needed. It is completely repeatable with high stack-up tolerances. The substrate provides the largest and most stable footprint, while still providing a substantial flat area suitable for storage. The substrate has additional protrusions to allow for storage options, such as hooks or straps.
[0069] The substrate is stronger than prior art cabinet tops made out of sheet metal, but is scratch and dent-proof. It is waterproof and rustproof in damp areas, which increases the life of the product. It is stronger in assembly, requires only strews to hold everything together. It reduces the amount of assembly steps required, while providing features for the end user. It can be moved with a pallet jack.
[0070] The substrate eliminates off the shelf parts that are normally screwed and welded in place. It provides areas to attach wheels with no screws needed. It is easy to stack and secure. The feet are non-marring and has a built-in tip over prevention bracket. It is safer for the end-user as there are no sharp edges.
[0071] FIGS. 4A-4B show detailed views of the accessory feature, such as the door feature 16. A different version can be used for installation on a side panel 56.
[0072] The addition of accessories as on the ones shown in FIGS. 4A-4B provides a number of benefits. The plastic accessories dampen the sound associated with sheet metal. The panels are held in place with adhesive, in one embodiment, or can be repositioned by the end-user in another embodiment. The use of the accessories allows for single-wall construction, as the accessories provide additional rigidity and structural integrity to the walls and door.
[0073] The cabinet 12 can therefore use plastic panels, which are less likely to scratch and also hide scratches, without resorting to double-wall construction.
[0074] The accessory panels are used to separate the different panels during shipment and so prevent the panels from hitting each other during shipping. The accessories help the end-user during assembly in that the accessories help in orienting the panels. The accessories also facilitate the molding of warnings, date codes, part numbers and other information into the device.
[0075] In the embodiment shown in the figures, the accessories are made from a brightly-colored plastic and so they call attention to the feature.
[0076] FIG. 5 shows the details of the leak-proof tray shelf 24. The shelf includes three shelf tab contacts, with a total side contact area of 10.4 instead of four small clips with very small surface areas. The shelf includes single side spring loaded locking tabs for easy installation and removal, with no clips to be installed or aligned. The shelves are 1/2 inches in height and lock together when installed or can be broken apart to create six half-width 1/2 inch shelves or three full shelves, depending on the needs of the end-user. A galvanized skin of 0.04 depth is applied to create a scratch resistant surface. The shelves can be molded with instructions, warnings, ICONs and can add accessories such as sensors, RFID identifiers, inventory trackers, scales, and other accessories. The shelves do not rust, even in damp areas. Bright colors are used to make the shelves visible even inside the housing. The edges of the shelves can include hooks or other hangers.
[0077] The details of the sheet metal side panels are shown in FIG. 6. The bends in each of the panels, (0.04) provide a great deal more strength than a typical smooth surface. As shown in FIG. 6, there are NO U shaped bends or channels at the top or bottom of the panels which have a variety of benefits: the number of units per pallet are much greater when assembling kits, the stability of the work in progress pallet being transported are more stable, the bending time and consistent geometry of the normally seen channel is no longer a problem, the hard to reach dead space during the painting process are eliminated nesting nature of the panels allow for a tight and more stable packing process during transport, minimalization of waste of material during the notching process prior to bending.
[0078] As shown in FIG. 6, there are holes located at the top and bottom of the panels that lock into the molded top and bottom molded parts. The holes at the top and bottom are points to hang the product during the painting process. The hole locations are hidden after assembly, so the ghost image caused by the hanging hooks that are seen during the paint process is no longer a perceived quality problem. The panel includes rectangular shelf locking holes, which provide additional benefits: the holes are larger than they need to be in the drawing and can be made smaller, so that if the enduser requires it, the sheet metal seam are bent downward to provide additional support strength for the shelves, the rectangular holes allow for a much greater support of the adjustable shelf, and ensures that the shelf remains square to the cabinet walls regardless of where the loads are applied, (edge, side, off-center).
[0079] Due to the use of these panels, additional storage platforms can be hung on the OUTSIDE of the cabinets by the easy-to-access rectangular holes.
[0080] FIGS. 7A-7D depict several different embodiments showing different aspect ratios, sizes, and internal configurations.
[0081] FIGS. 8A, 8B, and 9 show a number of accessories that can be fitted into the cabinet, including post storage, a door slide, a wood top, and others.
[0082] FIGS. 10A-10E show a variety of configurations, including accessories such as a wooden top. A wooden top surface provides many advantages and benefits. For example, a wood top is durable when made from high-quality hardwoods like oak, walnut, and maple. A wooden top can withstand years of use and resist wear with proper care. Even if scratches occur, a wooden top can be restored to its original appearance by sanding, refinishing, or repainting, erasing significant damage. Wooden tops also accept fasteners and other accessories, which can be mounted with simple wood screws, hooks, and the like.
[0083] Turning to FIGS. 11-25, the details of embodiments are described.
[0084] FIG. 11 depicts a front perspective view of the cabinet 100. Similar to the cabinet 12, the cabinet 100 comprises a bottom substrate 102, a top substrate 104, a left side wall 106, a right side wall 108, a back wall 110, a left side door 112, a right side door 114, which together create an interior space 130 for storage. In addition, the cabinet 100 also includes a bottom ring 120 on the bottom substrate 102 along its peripheral and a top ring (not seen in FIG. 11) on the top substrate 104 along its peripheral. The bottom ring and top ring also contact the side walls and back wall and thus hold the structure of the cabinet 100, which will be described in detail.
[0085] The cabinet 100 further includes a plurality of shelf panels 116 and 118 placed in the interior space 130 as needed. A plurality of stops 132 are distributed along the height of the left and right side walls. The stops 132 are used to support the shelf panels 116 and 118. In one embodiment, the stops 132 are formed by punching the side walls 106 and 108, thus forming a protrusion protruding towards the inner space and extending horizontally. As a result, a concave or opening is formed on the outer side of the side walls at the location corresponding to the protrusion. In another embodiment, the stops may be formed in other ways, for example, by molding the protrusion, attaching the protrusion to the side walls, and so on. In addition, each of the shelf panels 116 and 118 has a width that is approximately half of the depth of the inner space of the cabinet, that is, about half of the depth of the side walls. Therefore, an end user may put two shelf panels side by side on the same level, as shown by the top shelf in FIG. 11, so as to completely partition the spaces above and below the shelf panels 116. Alternatively, the end user may also put one shelf panel 118, as shown by the lower shelf in FIG. 11. In this case, the half shelf leaves the adjacent space connected to the spaces below and above the shelf, which may be used to store longer items while shorter items may still be placed on the shelf panel 118. This provides additional flexibility for end users and also promotes space utilization. In other embodiments, depending on the depth of the cabinets, a full shelf may be comprised of more than two shelf panels.
[0086] FIGS. 12A-12C depict the bottom substrate 102 of the cabinet 100. FIG. 12A is a top perspective view of the bottom substrate 102, and FIG. 12B is a bottom perspective view of the bottom substrate 102. The bottom substrate 102 is formed as a rectangular panel with four feet 134 attached at the respective four corners of the rectangular panel.
[0087] As shown in FIG. 12A, the bottom substrate 102 includes an annular slot 136 extending along the perimeter of the bottom substrate that is concaved in the upper surface. The outer side wall 136a of the slot 136 conforms to the outer surface of the left side wall 106, right side wall 108, and back wall 110 at the respective corresponding locations. A plurality of concave portions 138 are formed in the outer side wall 136a that correspond to convex portions on the left side wall 106, right side wall 108, and back wall 110. In addition, a plurality of protrusions 131 is provided on the outer side wall 136a of the slot 136. These protrusions 131 engage with corresponding openings on the on the left side wall 106, right side wall 108, and back wall 110 to facilitate assembling of these components and prevent disassembly. The left side wall 106, right side wall 108, and back wall 110 are fixed to the bottom substrate 102 through the engagement of the bottom ring 120, which will be described further in detail later.
[0088] In addition, at least one opening 140 is formed as through holes in the bottom substrate 102 for cable management. In the embodiment shown in FIGS. 12A-B, two openings 140 are formed in the bottom of the slot 136 at the positions corresponding to the concave portions 138. The bottom substrate 102 is relatively thin at the slot 136 and has sufficient area for forming the openings 140. However, at least one opening may be formed in the bottom substrate 120 at a location other than the slot 136 as desired.
[0089] At each of the respective corners of the bottom substrate 102, a through hole 133 is provided. Two of the through holes 133 are used for a pin to insert so as to form the door hinges. In addition, in the packaging, the through holes 133 may also facilitate the packaging, which will be described later. Furthermore, the low end of the through holes 133 may be formed with an internal thread. Four nuts (not shown) may be screwed into the through holes 133. The depth of each nut screwed into the through hole 133 is adjustable, thus the nut is used as a leveling foot. Alternatively, casters or wheels may be attached to the through holes 133 so that the cabinet can be used as a rolling cabinet.
[0090] As shown in FIG. 12B, each of the feet 134 includes plate-like portions 134a and 134b that extend along the respective sides of the rectangular bottom substrate 102. The plate-like portions 134a and 134b are formed in a trapezoidal shape. However, they may be of other shapes as needed. The plate-like portions 134a and 134b are located along the perimeter of the bottom substrate 102. In addition, along the longer sides of the bottom substrate 120, two side bars 142 and 144 that are slightly elevated above the bottom surface of the bottom substrate 102 are provided. In other embodiments, a different quantity of side bars may be provided, and may be provided on the shorter sides of the substrate. In addition, in another embodiment, the feet 134 may extend a longer length or even fully along the edge of the bottom substrate 102, thus providing more support and a neat appearance in the assembled cabinet. In the package of the cabinet 100, the feet 134 and the side bars 142 and 144 are also used as stoppers to confine the other components within the package, which will be described in detail later.
[0091] In addition, at least one concave portion 146 is formed in the bottom surface of the bottom substrate 102. These concave portions 146 reduce the material for forming the substrate 102.
[0092] In this embodiment, the bottom substrate 102 is comprised of four components 102a, 102b, 102c, and 102d. The four components 102a-d have approximately the same area and aspect ratio and are attached to each other along the center axes x and y. In addition, the bottom substrate 102 is substantially symmetric along the center axes x and y, respectively. The four components 102a-d may be engaged with each other through key-slot engagement, pin-opening engagement, and so on.
[0093] FIG. 12C depicts the assembly of the substrate components 102a-d into the bottom substrate 102. As shown in FIG. 12C, the substrate components 102a-d are attached and fixed to each other with pin-cavity engagement. Six pin-cavity engagements are provided. However, more or fewer engagements may be provided as long as there is at least an engagement structure between every two of the components to be attached to each other.
[0094] As shown in FIG. 12C, a cavity 141a is formed in a surface of substrate component 102a facing the adjacent substrate component 102b, and a cavity 141b is formed in the adjacent substrate component 102b at the corresponding location. A pin 143 is inserted into the cavity 141b. The pin 143 may be fixed in the cavity 141b through an interference fit, transition fit, adhesive, or thread fit. A part of the pin 143 extends beyond the substrate component 102b. When the components 102a and 102b are attached to each other, the remaining part of the pin 143 is fitted into the cavity 141a thus securing the engagement between the two components 102a and 102b. The pin 143 may be fixed in the cavity 141b through interference fit, transition fit, adhesive, and so on.
[0095] In addition, an engagement between pin 147 and hollow tubes 145a and 145b is provided between the substrate components 102a and 102b. Since the location of the engagement is provided in the slot 136, the thickness of slot 136 is not sufficient. A hollow tube 145a is provided in the slot 136 of the substrate component 102a, a hollow tube 145b is provided at a corresponding location in the slot 136 of the substrate component 102b. Likewise, a pin 147 is inserted into the cavity of the hollow tube 145b. The pin 147 may be fixed in the cavity of the hollow tube 145b through an interference fit, transition fit, adhesive, or thread fit. A part of the pin 147 extends beyond the substrate component 102b. When the components 102a and 102b are attached to each other, the remaining part of the pin 147 is fitted into the cavity of the hollow tube 145a thus securing the engagement between the two components 102a and 102b. The pin 143 may be fixed in the cavity 141b through interference fit, transition fit, adhesive and so on.
[0096] The remaining engagements are similarly configured as the engagements between the substrate components 102a and 102b, thus the description is omitted.
[0097] The top substrate 104 is exactly the same as the bottom substrate 102, thus a detailed description is omitted. When assembled into the cabinet 100, the top substrate 104 is flipped and placed in an upside-down position compared to the bottom substrate 102. In this case, the concave portion 146 may be used to contain small items on the top substrate 104. This design reduces the number of components in manufacturing. In addition, by this design, users do not have to differentiate components for bottom substrate from those for top substrate when assembling the cabinet 100.
[0098] FIGS. 13A-13B depict the bottom ring 120 of the cabinet 100. FIG. 13A is a top perspective view of the bottom ring 120 and FIG. 13B is an explosive view of the bottom ring 120. The bottom ring 120 is configured to fit into the slot 136 of the bottom substrate 102 while the respective lower ends of the left side wall 106, right side wall 108, and back wall 110 are inserted into the slot 136, so that the left side wall 106, right side wall 108, and back wall 110 are sandwiched and fixed between the bottom substrate 102 and the bottom ring 120. Specifically, the inner side wall 150 of the bottom ring 120 conforms to the inner side wall 136b of the slot 136, while the outer side wall 152 of the bottom ring conforms to the inner surfaces of the left side wall 106, right side wall 108, and back wall 110 at the respective corresponding locations. As shown in FIG. 13A, the bottom ring 120 includes convex portions 156 at a location corresponding to the concave portion 138 of the slot 136 of the bottom substrate 102 (see FIG. 12A). In addition, as shown in FIG. 13A, a plurality of barbs 157 are provided on the inner side wall 150 and the outer side wall 152. In the assembled cabinet, the barbs 157 provide a tightend fitting and increased friction at the respective locations and may grab the slot 136 of the bottom or top substrate or the corresponding side wall or back wall. Therefore, the barbs 157 prevent disengagement of the ring 120 from the slot 136 especially in the event of an unforeseen action trying to remove the ring from the bottom or top substrate. In addition to or as an alternative of the barbs on the ring, the barbs may be provided on the wall panels or the innter side wall of the slot.
[0099] FIG. 13C is an enlarged view of the circle C in FIG. 13A showing the barbs 157. As shown in FIG. 13C, each of the barbs 157 is a protrusion on the side wall of the ring 120 that includes a hook at its end.
[0100] In addition, around the corners of the bottom ring 120, plate-like protrusions 154 are provided. The protrusions 154 contact the inner surfaces of the left side wall 106, right side wall 108, and back wall 110 so as to strengthen the structure, especially at the corners of the cabinet 100.
[0101] At least one openings 148 are formed as through holes in the bottom ring 120 at the respective locations corresponding to the openings of 140 formed in the slot 136 of the bottom substrate 102 for cable management. In some embodiments, an opening 140 may be provided elsewhere in the bottom substrate 102 other than in the slot 136. In this case, the bottom ring 120 does not include a corresponding opening.
[0102] The bottom ring 120 may also be configured as hollow as shown in FIG. 13B, so as to reduce the use of materials while keeping the strength of the bottom ring 120. In addition, a plurality of cross walls 158 may be distrusted inside the hollow bottom ring 120 to further strengthen the bottom ring 120.
[0103] As shown in FIG. 13B, the bottom ring 120 is comprised of four sections 120a, 120b, 120c, and 120d. The sections 120a and 120c are formed in U shape that will sandwich both the side wall 106 or 108 and the back wall 110, which may facilitate assembling of the cabinet 100. In addition, a plurality of cross walls may be distributed inside the bottom ring 120 to further increase the rigidity of the bottom ring 120. The hollow bottom ring sections with cross walls may be formed integrally through molding, punching, 3D printing, and so on.
[0104] FIGS. 14A-14C depict the back wall 110 and one of the panels thereof. As shown in FIG. 14A, the back wall 110 includes two back wall panels 160 and 162. Depending on the width of the back wall and its aspect ratio as desired, the back wall 110 may include more or fewer panels.
[0105] Each of the back wall panels 160 or 162 has a cross-section that is not completely linear but includes some bend portions or steps. For example, the side wall panel 160 or 162 includes a convex portion 164 protruding towards the outside at about the middle part and extending vertically, thus forming a corresponding concave portion 166 in the inner side. Two steps 168a and 168b are formed along both sides of the concave portion 166. This structure can be formed by bending a single panel. In the assembled cabinet 100, the concave portion 166 conforms to and engages with the convex portion 156 of the bottom ring 120, and the convex portion 164 conforms to and engages with the concave portion 138 in the bottom substrate 102. Therefore, the contact area among these components is increased. The structure also prevents the wall panels from moving horizontally relative to the top and bottom substrates. In addition, these steps create an overall corrugated form that provides additional strength. Furthermore, in the packaging of the components for the cabinet, these concave or convex portions also prevent movement of the components relative to each other so as to reduce potential damage during transportation.
[0106] FIG. 14B depicts a front view of the left back wall panel 160 and FIG. 14C depicts an enlarged top view of the left back wall panel 160. As shown in FIGS. 14B and 14C, the left edge of the wall panel 160 includes a bend 170 that will overlap and interlock with a corresponding bend of the left side wall 106. This would also produce additional strefngth and reduce the need for additional fasteners. The right back wall panel 162 includes a similar bend to engage with the right side wall 108.
[0107] In addition, a pegboard 161 may be provided on the back wall panel 160. The pegboard 161 may be formed by a molded pegboard attached to the back wall panel 160 or an array of perforations. The pegboard 161 can be used for attaching hooks and accessories as well as providing a visual reference of the direction the wall panels should be during assembly.
[0108] A plurality of openings 163 is provided at both ends of the back wall panel 160. The protrusions 131 (see FIG. 12A) on the top and bottom substrates will engage with the openings 163 to facilitate users when assembling the cabinet and prevent disassembly. At least one seams 165 are provided on the edges of the left back wall panel 160 for additional stiffness. The seams 165 also provide a load-bearing area that is thicker than the rest of the wall panel 160. When the wall panels are stacked in packaging, the seams 165 become the contact point between wall panels, reducing the contact area between wall panels and thus reducing the chances of scratch damage.
[0109] The right back wall panel is substantially in a mirror relationship to the left back wall panel. Thus, its description is omitted.
[0110] FIGS. 15A and 15B depict the left side wall 106. FIG. 15A is a right-perspective view of the left side wall 106, and FIG. 15B is a schematic, enlarged top view of the left side wall 106. As shown in FIG. 15A, the left side wall 106 includes a single panel. Similar to the back wall panel, the left side wall 106 includes a convex portion 172 protruding towards the outside at about the middle part and extending vertically, thus forming a corresponding concave portion 174 in the inner side. Two steps 176a and 176b are formed along both sides of the concave portion 174. Likewise, the features along the profile of the left side wall 106 strengthen the engagement of side wall with bottom and top substrates. An overall corrugated form provides additional strength. In the packaging of the components for the cabinet, these concave or convex portions also prevent movement of the components relative to each other so as to reduce potential damage during transportation.
[0111] As aforementioned, a plurality of stops 132 are distributed along the height of the left side wall. The stops 132 are used to support the shelf panels 116 and 118 together with the stops on the right side wall.
[0112] In addition, as shown in FIGS. 15A and 15B, the right edge of the side wall 106 includes a bend 178 that will overlap and engage with the corresponding bend 170 of the back wall 110. In addition, the left edge of the side wall 106 includes a bend 180 to provide tolerance between the side wall 106 and the adjacent door panel. As shown in FIG. 15A, the side wall 106 further includes openings 173 and seams 175 that are similar to the openings 163 and seams 165 on the back wall panels.
[0113] The right side wall 108 is in mirror relation to the left side wall 106. The description of the right side wall 108 is thus omitted.
[0114] FIG. 16A-16D depict the left side door 112 of the cabinet 100. FIG. 16A shows the front side, that is, the outer side of the left side door 112, FIG. 16B shows the back side, that is, the inner side of the left side door 112, FIG. 16C is a cross-section view of the main panel 182 of the left side door 112, and FIG. 16D is a top view of the left side door 112.
[0115] As shown in FIGS. 16A and 16B, the left side door 112 includes a main panel 182, a top bar 184, and a bottom bar 186. The main panel 182 comprises a door feature 188. The door feature 188 comprises an integrated plastic insert that strengthens the panel and may be used to install a lock, add organizational tools, or attach a mirror. In one embodiment, the door feature 16 comprises a pegboard for the additional organization of the cabinet 12. The door feature 188 is integrally molded into or attached to the door 112, resulting in it substantially flush with the surface of the main panel 182 and not protruding beyond the surface of the main panel 182.
[0116] FIG. 16C is a cross-sectional view of the main panel 182 taken along the line A-A in FIG. 16B. As shown in FIG. 16C, the main panel 182 is bent in the middle and thus comprises a step 190. The bending main panel increases the rigidity compared with a large flat panel. In addition, the bend or step 190 may be used to help position other smaller panels, such as the shelf panel in the packaging, which will be described later. However, in other embodiment, the panel of the door may be flat or include an additional stop, bend, or other features as desired. FIG. 16D is a top view of the left side door 112 and shows the top bar 184. The outer edge 192 of the top bar 184 conforms to the top edge of main panel 182 and extends towards the back side of the left side door 112, that is, towards the inner space of the cabinet 100 when the door is closed. In addition, an opening 198 is provided on one end of the top bar 184. When the door is assembled, a pin is inserted through the corresponding through hole 133 on the bottom substrate 102 (see FIG. 12A) into the opening 198 and thus forms a door hinge.
[0117] As shown in FIGS. 16A and 16C, the top bar 184 further comprises two slots 200 extending vertically through the top bar 184. These slots 200 accommodates edges and bends of other panels in the packaging to keep panels parallel to each other, which will described later.
[0118] The bottom bar 186 is substantially the same as and in a mirror relation to the top bar 184. Thus, the description of the bottom bar 186 is omitted.
[0119] As shown in FIG. 16B, additional features may be added to the top bar 184. The top bar 184 comprises at least one hook 201 for hanging items such as clothes or tools.
[0120] FIGS. 17A-17C depict the shelf panel 118 of the cabinet 100. FIG. 17A is a top side view of the shelf panel 118, FIG. 17B is a bottom side view of the shelf panel 118, and FIG. 17C is an enlarged view of one end of shelf panel 118 in the circle B of FIG. 17A.
[0121] As shown in FIG. 17A, the shelf panel 118 is formed as a tray comprising a rim 206 extending along the peripheral of the shelf panel 118. The shelf panel 118 may be made of plastic through molding or metal sheet through bending and punching.
[0122] In other embodiments, the shelf panel 118 may formed as a flat plate without the rim, or a tray with a rim that is only provided on some of the edges, for example, the edges on the ends 202 and 204. A slot 210 is provided on each of the rim 206 on one end 202 and the rim 206 on the other end 204. Similar to the slot 200 in the door panels (see FIG. 16B), these slots 210 accommodate edges and bends of other panels in the packaging to keep panels parallel to each other, which will described later.
[0123] As shown in FIG. 17B, the bottom of the shelf panel 118 comprises struts 208 that form a grid to strengthen the shelf panel 118.
[0124] FIG. 17C depicts one end of the shelf panel 118, that is, the right end 204 of the shelf panel 118. As shown in FIG. 17C, a pull handle 212 is provided on the end 204 of the shelf panel 118. The pull handle 212 comprises a movable block 212a and a concave portion 212b. The movable block 212a is housed and movable in the concave portion 212b. The movable block 212a is biased by a biasing device, such as a spring (not shown), so that when there is no external force exerted, the movable block 212a extends beyond the edge of the shelf panel 118, as shown in FIG. 17C. The movable block 212a comprises or is attached with a handle 212c. When a user pulls the handle 212c as shown by the arrow F against the biasing device, the movable block 212a retracts in the direction of the arrow F. Therefore, when a user is attaching the shelf panel 118 into the cabinet 100, the user may pull the handle 212c, put the shelf panel 118 at an appropriate position, and release the handle, the movable block 212a will then protrude beyond the edge of the shelf panel 118 and make contact with the side wall of the cabinet 100 and lock the shelf panel 118 in position. When the user is removing the shelf panel 118 out of the cabinet 100, the user may pull the handle 212c and then easily take the shelf panel 118 out.
[0125] In this embodiment, only one of the two ends of the shelf panel 118 is provided with the pull handle 212. However, in another embodiment, the other end may be provided with a pull handle as well.
[0126] In addition, as shown in FIG. 17C, at least one tabs 214 (two shown in FIG. 17C) are provided on the end 204 of the shelf panel 118. On the opposite end 202 of the shelf panel 118, at least one tabs are also provided. The tabs 214 form contact points when the shelf panels are stacked on each other or on other panels, so as to reduce scratch damage and keep the balance of the stack.
[0127] Below, the packaging 300 of the cabinet 100 will be described by referring to FIG. 18A-18C. FIG. 18A is a top side view of the packaging 300, FIG. 18A is a left side exploded view of the packaging 300, and FIG. 18C is a front-exploded view of the packaging 300.
[0128] As shown in FIG. 18A, the packaging 300 overall appears to be a compact plate-like cuboid and takes much less space than the cabinet. The packaging 300 requires almost no packing materials or extra components that are not comprised in or usable for the assembled cabinet 100. All the sides of the packaging are substantially flat and may be stacked without other tools.
[0129] The enclosure of the packaging 300 is formed by the bottom substrate 102 and top substrate 104. The top and bottom substrates 102 and 104 are used as the top and bottom of the enclosure, while the feet 134 are used as the sides of the enclosure. In this embodiment, since other panels including side wall, back wall and door panels, are longer than the top and bottom substrates 102 and 104, the top and bottom substates 102 and 104 are evenly divided into four parts 102a-d and 104a-d. The respective parts 102a-d and 104a-4 are positioned at the respective corners of the enclosure of the packaging 300 with spaces between them. These spaces are substantially smaller than the side wall, back wall, and door panels. Thus, the side wall, back wall and door panels are stacked and securely confined in the enclosure of the packaging 300 formed by the top and bottom substrates 102 and 104.
[0130] In other embodiments, depending on the dimensions of the top and bottom substrates, as well as the side wall, back wall, and door panels, the top and bottom substrates may form the enclosure without having to be divided into a plurality of parts.
[0131] As shown in FIG. 18A, in the packaging 300, a strap 220 is placed between the top and bottom substrates 102 and 104 at each end of the packaging 300. The strap 220 helps with the alignment of the top and bottom substrates 102 and 104 and can be used to fix the back wall of the cabinet to a wall so as to prevent tipping over. A detailed description of the strap 220 will be provided later.
[0132] FIGS. 18B and 18C depict an explosive view of the packaging 300 viewed from the right side and front side, respectively.
[0133] As shown in FIGS. 18B and 18C, the side wall panels 106 and 108, back wall panels 160 and 162, door panels 112 and 114, the shelf panels 116 and 118 and back wall panels 160 and 162, and components of the rings 120 are stacked upon each other between the top and bottom substrates 102 and 104.
[0134] Specifically, the side wall panels 106 and 108 and back wall panels 160 and 162 are stacked right upon each other. Since the side wall panels 106 and 108 and back wall panels 160 and 162 have a similar profile and comprise a bend. The bends of the respective panels are aligned with each other, thus reducing the thickness of the stack while restricting the panels from moving relative to each other in the packaging 300. The bends 175 and 178 on the wall panels make contact points between these wall panels, greatly reducing the contact areas between the panels, thus reducing scratch damage. In addition, since the bends 175 and 178 are provided on the top and bottom end of the wall panels, which will not be readily seen in the assembled cabinet 100. Therefore, the surface damage at these ends would not affect the appearance of the cabinet.
[0135] The shelf panels 116 and 118 are stacked next to the wall panels 106, 108, 160 and 162. The slot 210 of the shelf panels 118 that face the wall panel 106 is aligned with the bend 178 of the wall panel 106. Therefore, the bend 178 is accommodated in the slot 210, further reducing the thickness of the stack, maintaining the stack flat, and restricting the relative movement between adjacent panels. In another embodiment, a door panel 112 or 114 may be stacked next to the wall panels. In this case, the slot 200 of the door panel 112 or 114 is aligned with the bend on the edge of the wall panels. As shown in FIG. 18B, the depth of shelf panels 116 and 118 is smaller than the depth of the door panels 112 and 114. When the depth of shelf panels is equal or smaller than the depth of the door panels, the shelf panels may be shipped inside the door cavity. This ratio prevents damage and reduces or eliminates packing material. As shown in FIG. 18B, the step 190 or a bend of the door panel helps to lock the shelf in place in the packaging. However, further features can be made in the door panels and shelf panels to further lock the shelf panens in place. For example, features similar to the slots 210 of the shelf panels and the bend 178 of the wall panels may be provided between the door panels and the shelf pannels. In addition, other nested features and stand offs may be added to the door panels or shelf panels, so that the door panels and shelf panels make contact with each other and prevent movement in the packaging.
[0136] As shown in FIGS. 18C and 18C, the door panel 114, additional shelf panels, another door panel 112, and components of the rings 120 are further stacked. Since each ring 120 comprises four components 120a-102d. These components 120a-120d do not have to be placed in an assembled state in the packaging and may be placed at wherever there is an appropriate space.
[0137] The door panels 112 and 114 are placed with their respective steps 190 facing against each other. In another embodiment, they can also be placed with their respective steps 190 facing each other.
[0138] The order of the components stacked in the packaging 300 is just exemplary. The components may be stacked in another order. For example, the shelf panels may be placed between, above, and below the door panels, or the wall panels as needed.
[0139] As shown in 18A and 18B, a strap 220 is placed between the top and bottom substrate 102 and 104 at the end of the packaging 300. In FIG. 18C, the strap 220 is omitted. As shown in FIG. 19, the strap 220 is provided with a plurality of openings arranged along its length. In the packaging 300, the strap 220 is placed the packaging 300 between the top and bottom substrate 102 and 104. Two of the openings 222 are aligned with the openings 133 (see FIG. 12A) of the top and bottom substrates. A pin 224 is inserted into the openings 133 and the corresponding opening 122, thus aligning the top and bottom substrate 102 and 104 and locking them in position. In this embodiment, the opening 133 of the top and bottom substrates 102 and 104 are provided at the corners thereof, since the openings 133 are also used to insert the pin for the door hinge. Therefore, in the packaging 300, the strap 220 is provide on one end of the packaging 300. The other end of the packaging 300 may include a strap 220 similarly. In another embodiment, the strap may be provided in another location instead of the ends of the packaging. In that case, the strap will need to be placed in an appropriate layer to prevent interference with the panels and may also be used to restrict movement of at least some of the panels in the package.
[0140] The pins 224 may be used as the pin for the door hinge in the assembled cabinet 100. In addition, the pins 224 and the strap 220 may be used as a tip-over kt. Specifically, the strap 220 may be attached to a wall by nails, screws, adhesives or hooks, then the back wall of the cabinet may be attached to the strap by using the pin 224 applied to the holes 133 located opposite of the door hinge point at the top of the cabinet after assembly is complete. Because of the length of the pin no other attachment method to the cabinet is needed. Alternatively, a user may use nails, screws, adhesives or hooks to attach the back wall of the cabinet to the strap 220. Therefore, the gripping of the cabinet from the wall is provided to prevent the cabinet from tipping over. In addition, the strap 220 may be formed in other shapes. For example, in another embodiment, the strap 220 may be formed with a bend. In one embodiment, the pins 224 is made of a solid rod. In order for the pins 224 to be used for the door hinge, the pins 224 further comprise a cap on one end of the rod. In another embodiment, the pins 224 may be made of a tube. One end of the tube may be flared to eliminate the need to attach a cap. In this embodiment, the opposite end of the flared end of the tube may be provided with an internal thread. When the pins 224 is used in the door hinges (see FIG. 20F), the internal thread of the pin may be used to attach a wheel or caster so that the cabinet can be used as a rolling cabinet. Alternatively, the internal thread of the pin 324 may be used to attach a nut for adjusting the leveling of the cabinet or elevating the cabinet further above the ground.
[0141] The packaging 300 offers multiple benefits.
[0142] The molded top and bottom substrates 104 and 102 of the cabinet 100 form an enclosure of the packaging 300, which is not only used for packaging of the large panels and doors but also the small parts, including but not limited to: shelving, door hinge pins, nuts and bolts, locking rings and other accessories that can be attached to the outer cabinet, such as small shelf or peg board accessories. The custom storage items eliminate additional packaging and prevent damage that may be caused by movement during shipment.
[0143] The packaging 300 requires almost no other filler or containing components. All the components of the packaging 300, including the enclosure and components for aligning and fixing panels, such as the strap 220 and the pins 224 can be used in assembling the cabinet 100. Panels are provided with seams to reduce contact areas in the stack so as to reduce scratch damage. The sides of the top and bottom substrate facing the inner space in the cabinet become the outer sides of the packaging 300, and the top and bottom substrates may well confine and protect the panels, thus a box or other packaging materials may be eliminated.
[0144] The packaging 300 has a low profile and takes much less space than traditional cabinet packaging. It can also be easily stacked on one another. It further reduces the cost for storage and transportation.
[0145] The packaging 300 can be easily formed by stacking the components and inserting the pins 224 without any tools or extra joints. Thus, it is time and cost efficient to manufacture and provide convenience for end users to restore the cabinet when not in use.
[0146] As shown in the figures, the cabinet components nest into a single packaging 300 with the components nesting together with the pieces secured together. The design provides significant shipping, convenience, and environmental benefits. As nested parts reduce the overall volume required for packaging, the cabinets described herein require less space in shipping containers, leading to more cost-effective transportation. The nesting minimizes or eliminates the need for additional packaging materials, reducing waste and making the shipping process more sustainable. For manufactuers, these nesting features streamline logistics and decrease packaging expenses, while for customers the nesting features means less disposal material and a lower environmental footprint.
[0147] Below, the method to assemble the cabinet 100 is described by referring to FIGS. 20A-20F. The assembly of the cabinet 100 is intuitive and may be conducted without any tools.
[0148] First, the bottom substrate 102 is prepared. In this embodiment, since the top substrate 104 and bottom substrate 102 are identical, therefore, the user does not have to differentiate the components for top substrate from bottom substrate. In this embodiment, each of the top and bottom substrates comprises four components. As shown in FIG. 12C, the four components 102a-d may be assembled into the bottom substrate 102 by aligning the components 102a-d and inserting the respective pins 143 and 147 into corresponding slots 136 or hollow tubes 145a.
[0149] Next, as shown in FIG. 20A, the side walls 106 and 108 and back wall panels 162 and 164 are placed in position by inserting their respective bottom ends to the respective corresponding locations in the slot 136 of the bottom substrate 102. As indicated by the arrows in FIG. 20A, The protrusions 131 (see FIG. 12A) on the side wall of the slot 136 are inserted into the respective corresponding ones of the openings 163 (see FIG. 14B) of the back wall panel 162 and 164, and opening 173 (see FIG. 15A) of the side wall 106 and 108. The engagement between the protrusions 131 and the openings on the wall panels facilitates the placement of the wall panels at the right position.
[0150] Next, as shown in FIG. 20B, the ring 120 is inserted into the slot 136 while maintaining the wall panels 106, 108, 162 and 164 in position. In this embodiment, the ring 120 comprises four components 120a-d, which can be inserted into the slot 136 one by one or all together, as indicated by the arrows in FIG. 20B. The ring 120 is tightly fitted into the slot 136 so as to sandwich and fix the wall panels 106, 108, 162 and 164 between the slot 136 and the ring 120 and form the structure as shown in FIG. 20D. In addition, the barbs 157 (see FIG. 13C) further increase the friction between the ring 120 and the wall panels or the slot, thus further securing the engagement and preventing the ring from being removed with unexpected external force or impact.
[0151] FIG. 20C depict an alternative way to fix the wall panels onto the bottom substrate 102. As shown FIG. 20C, the side wall 106 and the back panel 160 are firstly placed into the slot 136 at the propriate position. Then, the corresponding component 120a of the ring 120 is fitted into the slot 136 so as to fix the side wall 106 and the back panel 160 in position. The remaining wall panels and ring components may then be similarly assembled onto the bottom substrate 102 to form the structure as shown in FIG. 20D.
[0152] In another embodiment, the ring 120 may be fitted into the slot 136 first, and the wall panels 106, 108, 162 and 164 may then be inserted into the gap between the slot 136 and the ring 120. The snap between the protrusions 131 (see FIG. 12A) of the slot 136 and the openings 163 (see FIG. 14B) of the back wall panel 162 and 164 and the opening 173 (see FIG. 15A) of the side wall 106 and 108 may provide a confirmation of appropriate attachment.
[0153] As can be seen from FIG. 20D, in order to hold the structure, the component 120D of the ring 120 is not necessary. Therefore, in another embodiment, the ring may be substituted with a tube with a C or U shape. In addition, the tube does not have to be continuous in the assembled cabinet as long as the tube may fix the respective wall panels to the top and bottom substrates, as shown in FIG. 3.
[0154] Following the status shown in FIG. 20D, the top substrate 104 and top ring (not seen) are attached to the structure shown in FIG. 20D similarly, as shown in FIG. 20E.
[0155] Finally, as shown in FIG. 20F. the door panels 112 and 114 are attached by inserting the pins 224 along the arrows. The cabinet 100 is assembled.
[0156] The cabinet 100 may also be easily dissembled in a reverse order, and the components may be stacked as shown in FIGS. 18A-18C for storage and transportation.
[0157] The assembly of the cabinet does not need any extra tools or joints such as nails, screws, or adhesives. It is user-friendly for both manufacturers and end users.
Other Embodiments
[0158] Although exemplary implementations of the invention have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, substitutions, and the like can be made without departing from the spirit of the invention.
[0159] For example, in the embodiment shown in FIGS. 12A-12C, the top and bottom substrates are formed by four components, and thus in the packaging, the four components may be arranged at the respective corners of the packaging. However, as shown in FIG. 3, each of the top and bottom substrate may also be formed as an integral substrate. In this case, the top and bottom substrate may be stacked in the packaging just like other panels and substrates.
[0160] In addition, when a specific profile of the wall panels and a corresponding profile of the slot and ring have been described, the profiles of them may be adjusted as desired.
[0161] In addition, though in the embodiments, the locking ring may be assembled into the top or bottom substrate without any extra tools or joints such as nails, screws, or adhesives, screws may still be additionally used to pass through the locking ring or side panels into the top or bottom substrate, to better secure the components together.
[0162] FIGS. 21A and 21B depict a shelf panel 310 according to another embodiment. Instead of a molded plastic shelf panel and a thin sheet metal skin, the shelf panel 310 includes a main body 316 and two ends 312 and 314 attached to the main body 316. As an example, two ends 312 and 314 may be attached to the main body 316 by an adhesive. The main body 316 is made of a U shaped steel panel with two edges 316a and 316b vertically extending to prevent items placed on the shelf panel from slipping out. At one end 314, a locking and pulling mechanism 318 is provided, which is similar to the pull handle 212 described by referring to FIG. 17A.
[0163] In addition, the shelf panel 310 is supported by rods 320 that may be inserted into bores in the respective ends 312 and 314 instead of stops 132 formed on the side wall (see FIG. 15A). FIG. 21B is an enlarged view of the circle D in FIG. 21A showing one end 314. As shown in FIG. 21B, a bore 322 is formed in the end 314. The rod 320 may include a bend on the other end as shown in FIG. 21A and be hung on the back wall or side wall of the cabinet. The shelf panel 310 may be installed by having the rod 320 inserted into the bore 322 in each end, thus creating a floating shelf appearance. In other embodiment, the rod 320 may be attached to the back wall or side wall of the cabinet in another way, such as adhesive, screw, or welding.
[0164] FIG. 22 depicts a pin 324 according to another embodiment. The pin 324 may be used in a similar way as the pin 224 in the packaging to position and fix panels in place, and in the cabinet as door hinge. As shown in FIG. 22, the pin 324 comprises a hollow tube 326. On one end of the tube 326, a cap 330 is provided. The cap 330 may be formed by flaring the end of the tube 326 or by attaching the cap 330 onto the tube 326. On the other end of the tube 326, an internal thread 328 is formed.
[0165] When the pin 324 is used as the pin for the door hinge, referring to the pin 224 in FIG. 20F, the internal thread of the pin 324 may be used to attach a wheel or caster so that the cabinet can be used as a rolling cabinet. Alternatively, the internal thread of the pin 324 may be used to attach a nut for leveling the cabinet or elevating the cabinet further above the ground.
[0166] FIGS. 23A and 23B depict a shelf panel 340 according to another embodiment.
[0167] The shelf panel 340 includes stiffeners 346 attached to the main body of the shelf panel 340, specifically, to the underside of the shelf panel 340. The stiffeners 346 are formed as U shape channel from materials such as steel to reinforce the shelf panel 340, thus, the main body of the shelf panel may be made of a thinner gauge steel.
[0168] FIG. 23B is a partially enlarged view of one of the two ends 342, 344 of the shelf panel 340 as indicated by the circle E in FIG. 23A. As shown in FIG. 23B, two pull tabs 348 are arranged on either side of the end 342. Each pull tab 348 further includes at least one tooth 350 to engage with side walls of the cabinet. In addition, the stiffener 346 is attached along the edge of the end 342, to act as a stop to help locate the tooth 350 while reinforcing the shelf panel 340.
[0169] FIGS. 24A and 24B depict a bottom support 350 according to another embodiment. The bottom support 350 may be attached to the bottom substrate 362 of the cabinet 360 as shown in FIG. 24B to reinforce the structure of the cabinet 360. The bottom support 350 is inserted along the perimeter of the bottom substrate 362 from its bottom side. The bottom support 350 comprises first to third bottom support sections 352, 354, and 356 formed as a U shape channel beam. Threaded nuts may be welded to the bottom support for installing adjustment feet of the cabinet.
[0170] FIGS. 25A-25D depict a hanger system 370 according to another embodiment. The cabinet 380 may include a hanger system 370 integrated into it. Specifically, the hanger system 370 may be molded as a part of the top substrate or bottom substrate of the cabinet.
[0171] The hanger system 370 include a K shaped rail 374 that may be attached to an appropriate position of the cabinet 380, for example, the top portion of along the sides of the cabinet 380 as shown in FIG. 25A. The hook 372 may be attached to the rail 374 and move along the rail 374.
[0172] FIG. 25B depicts the cross section of the rail 374. As shown in FIG. 25B, the cross section of the rail 374 includes a vertical portion 378 and at least one arm 380 extending from the vertical portion 378 obliquely. In the embodiment shown in FIG. 25B, two arms 380 are provided, one extending upwardly and the other extending downwardly. Thus, the cross section of the rail 374 appears the shape of K. However, in another embodiment, only one arm 380 may be provided or more than two arms may be provided. At the location where the arm 380 intersects with the vertical portion 378, a concave 382 is provided on the vertical portion 378.
[0173] As shown in FIG. 25C, the hook 372 is made by a wire and includes a horizontal bar 386 and two L shaped bars 388 connected to the horizontal bar 386 through a curved portion 390 at the respective ends of the horizontal bar 386. The horizontal bar 386 may engage with the concave 382 of the rail 374 while the curved portions 390 are supported by the arm 384, so that the hook 372 is engaged with the rail 374 and the bars 388 may be used to hang objects thereon.
[0174] FIG. 25D depicts the cross-section of the rail 400 according to another embodiment. In addition to concave 382, an additional concave 402 that is wider than concave 382 is provided. Therefore, the concave 402 may engage with another hook made of wire of a different diameter.
[0175] The hanger system as shown in FIGS. 25A-25D is exemplary. Modifications may be applied to the hanger system as desired. Alternatively, a known hanger system comprised of rails may be integrated into the cabinet via molding or other means of attachments.
[0176] Although exemplary implementations of the invention have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, substitutions, and the like can be made without departing from the spirit of the invention, and these are therefore considered to be within the scope of the invention as defined in the following claims.
[0177] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the invention, they are by no means limiting, but are instead exemplary embodiments.
[0178] Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms including and in which are used as the plain-English equivalents of the terms comprising and wherein. Moreover, in the following claims, the terms first, second, and third, are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. 112, sixth paragraph, unless and until such claim limitations expressly use the phrase means for followed by a statement of function void of further structure.
