FIELD OF THE INVENTION This invention relates generally to a drawer cabinet kit constructed of plastic structural panels. More specifically, the present invention relates to a cabinet constructed of injection molded plastic panels to contain a plurality of drawers with modular snap-in guides and which is capable of being packaged and shipped assembled or in a knocked-down state and constructed into a secure drawer cabinet at a desired site.
BACKGROUND INFORMATION Throughout the home, a need exists to store a large variety of different items. This is particularly true of garage and utility areas where a vast array of products have been developed to increase the comfort level of living. The accumulation of these various objects and products gives rise to a need for adequate storage of those items when not in use.
Various cabinets for storing household items such as gardening tools, automotive supplies, barbeque accessories and the like are well known. One of the more popular type of cabinets for storing household items is a cabinet with a plurality of pull-out drawers. Cabinets of this type are generally shipped to a consumer or a supplier fully assembled. Shipping fully assembled cabinetry requires a considerable amount of space available within a shipping medium. Because space is limited, the cost associated with shipping assembled cabinets is comparatively high.
Alternatively, drawer cabinet assemblies are customized for the consumer based on the consumer's needs. With customized cabinets, the consumer selects the cabinet material, the size of the associated drawers and the drawer guides needed to guide the drawers in and out of the cabinet. Numerous devices have been utilized throughout history to guide drawers in and out of drawer cabinets. The simplest mechanism is a box in which the drawer slides. Other methods of control include runners on either side of the drawer or a single runner under the bottom of the drawer with notches to hold the drawer in alignment with the cabinet. All of these basic guide systems have high levels of friction between the drawer and the cabinet and, consequently, rapidly wear out. Numerous low friction devices have been designed to facilitate movement of drawers in and out of cabinets including ball bearings, wheels, and sliders. Most of these low friction devices require unsightly tracks along the side of the drawers and wide spaces between the sides of the drawers and the drawer face to allow passage of the low friction devices from the inside of the drawer cabinet to the outside when the drawer is extended.
Side play of the drawer when extended is another difficult problem, particularly in the basic forms of drawer guides. Often the drawer must be moved from side to side and up and down in order to get it to return to the drawer cabinet. As the guides become worn, the problem becomes even more severe. Even drawer slides utilizing rollers, ball bearings and sliders have binding problems, especially when the drawers are heavily loaded or the slide parts have become slightly worn.
The ball bearing type of drawer slide creates a different problem. Because there is virtually no side play in a ball bearing slide the drawer cabinet must be perfectly aligned with the drawer slide in order to eliminate binding as the drawer is moved in and out. Skilled labor and time are required to properly position a ball bearing slide.
Fabrication costs of low friction slide arrangements are another problem. The slide arrangements must be specially made for each different length of drawer. A long drawer requires a long slide arrangement and a short drawer requires a short slide arrangement. Manufacturers are required to maintain supplies of many different lengths of drawer slides or modify slides for each customer.
Full extension drawer slides are a variation of the typical drawer slide and are used to permit full extension of drawers such that the back of the drawer is fully accessible. Such drawer guides usually use three or more rails with one rail (cabinet rail) being attached to the cabinet, one rail (drawer rail) being attached to the drawer and one rail (floating rail) gliding between the drawer and cabinet rails. Examples of such drawer guides are disclosed in Card, U.S. Pat. No. 1,537,067, Tobey, U.S. Pat. No. 2,099,148, Schaffert, U.S. Pat. No. 1,129,831, Bullock et al, U.S. Pat. No. 3,203,749, Vander Ley, U.S. Pat. No. 4,004,841, Lautenschalager U.S. Pat. No. 5,733,027, Fleisch, U.S. Pat. No. 5,895,102, Fraccaro, U.S. Pat. No. 6,390,574. In these systems, rollers or ball bearings are provided on racks between the floating rail and the cabinet and drawer rails to provide free gliding movement between each of the rails.
One of the problems associated with such systems is that they tend to be rather large and bulky which limits their use on smaller drawers. Further, such systems are relatively complicated and difficult to fabricate, resulting in high costs to consumers.
Such prior art systems have not met all of the needs of manufacturers to provide a product that can be easily manufactured, packaged and shipped, or the needs of consumers requiring economical and versatile do-it-yourself storage kits. Moreover, because the prior art devices do not break down they are difficult and expensive to ship from the manufacturer to the consumer.
Paramount among such needs is an easy to assemble kit which can be easily assembled by an average homeowner. Structure is a further consideration, the cabinet formed by the panels must create cabinet walls which resist panel separation, buckling and racking in such a way as to unify the entire enclosure.
Also, from a versatility standpoint, a cooperating drawer and guide should be present which can be easily assembled or modified after assembly of the side, top, bottom and back panels, and which provides security and dependable access to the contents of the drawers without the complex and difficult to assemble mechanisms associated with the prior art.
There are also commercial considerations that must be satisfied by any viable drawer cabinet system or kit; considerations which are not entirely satisfied by state of the art products. The drawer cabinet must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The drawer cabinet must also be capable of being packaged and shipped in a knocked-down state.
In addition, there are ergonomic needs that a drawer cabinet system must satisfy in order to achieve acceptance by the end user. The system must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the system must not require excessive strength to assemble or include heavy component parts. Moreover, the system must assemble together in such a way so as not to detract from the internal storage volume of the resulting wall cabinet or otherwise negatively affect the utility of the drawer cabinet.
BRIEF DESCRIPTION OF THE INVENTION The present invention provides an assembly, or kit, of injection molded panels having integrated connectors which combine to form a drawer cabinet with a plurality of snap-in drawer guide members and cooperating pull out drawers. The cabinet panels are formed of injection molded plastic and include integrally formed connectors to interlock with one another without the need for separate fasteners. The integrated connection of the side walls and top and bottom panels simplifies the drawer cabinet construction and minimizes the number of components required to assemble the drawer cabinet. Injection molding allows the panels to be formed with integral cross-bracing, ribs and gussets for increased rigidity. When supplied as a kit, assembly of the drawer cabinet requires minimal hardware and a minimum number of hand tools.
The drawer cabinet assembly includes a base panel, a back panel, left and right side panels and a top panel. The base panel is constructed with integrally formed outwardly extending contoured locking posts for interlocking cooperative engagement with sockets formed into the ends of the left, right and back panels. The engagement between the locking posts and the sockets serve to rigidly connect the components together, preventing the panels from bowing inwardly or outwardly under loads to provide a structurally sound cabinet with a pleasing aesthetic appearance.
The interior portion of the cabinet includes integrally molded vertical rails extending along each side. The rails extend from the base panel to the top panel. Each rail is constructed to accept a plurality of snap-in drawer guide members in a vertically spaced and generally parallel arrangement to cooperate with a combination of drawers to fill the cabinet. This construction allows the consumer to customize the drawer cabinet for a particular storage requirement. Cooperating with the vertical rails are snap-in drawer guide members having a rotatably mounted roller secured within the front portion thereof. The snap in guide members minimize complexity of completing the assembly while increasing versatility by allowing the consumer to customize the assembly for specific needs. The snap-in construction of the drawer guides eliminate the need for skilled tradesmen to line-up and mount complicated hardware within the cabinet. In this manner the consumer can select a plurality of drawers having various heights, snap in the drawer guides, and thereafter slide in the drawers to complete the assembly.
The drawers are pre-constructed of polymeric material including a first roller rotatably mounted on each lower rear corner and a second roller rotatably mounted on each upper rear corner. The first rollers are adapted to cooperate with an adjacent lower drawer guide to support the rear portion of the drawer and the second rollers are adapted to cooperate with an adjacent upper guide to prevent the drawer from tipping as it is pulled outwardly.
In operation, as a loaded drawer is pulled outward it rolls freely on the fixed position guide roller and the rollers at the bottom rear of the drawer. As the guide roller and the drawer rollers get closer together the weight in the drawer causes a cantilever action across the guide roller and the rollers positioned at the upper rear of the drawer roll along the lower portion of the adjacent guide above. This construction allows the drawers to be easily opened with heavy loads without requiring complex sliding track mechanisms to prevent tipping of the drawer.
Accordingly, it is an objective of the present invention to provide a polymeric drawer cabinet assembly having a plurality of modular cooperating drawer and guide assemblies.
It is a further objective of the present invention to provide a modular snap-in drawer guide device, by which a cooperating drawer can be smoothly guided inwardly and outwardly of a cabinet body without the need for complex metal guiding mechanisms.
Yet a further objective of the present invention is to provide a modular polymeric drawer guide device which allows the drawer to be guided a sufficient distance out of the cabinet body to provide access to the interior of the drawer.
Still yet a further objective of the present invention is to provide a drawer cabinet assembly constructed from panels having integrated connectors which accommodate injection molding plastic formation of the panel components for increased structural integrity.
Another objective of the present invention is to provide a drawer cabinet storage kit in which the side walls, top panel, and bottom panel are interlocked without the need for separate fasteners.
Yet another objective of the present invention is to provide a kit for a drawer cabinet that is capable of being packaged and shipped in a knocked-down state and constructed into a secure drawer cabinet.
Still yet another objective of the present invention is to provide a drawer and guide assembly which allows an end user to customize a drawer cabinet to suit an individual application.
Other objectives and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURESFIG. 1 is a perspective view of the instant invention;
FIG. 2 is an exploded view of the instant invention, illustrated with the drawers and drawer guides omitted for clarity;
FIG. 3 is a partial exploded view of the instant invention, illustrating a drawer guide and the inner surface of a side panel;
FIG. 4 is a perspective view of a drawer utilized in the instant invention;
FIG. 5 is a section view taken along line1-1 ofFIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
FIGS. 1 and 2 which are now referenced illustrate perspective and exploded views of the drawer cabinet assembly, generally referenced as10, according to a preferred embodiment of the present invention. The drawer cabinet is made up of abase panel100 andtop panel200,left side panel300,right side panel400, rear panel500 (FIG. 2), drawer guides600 (FIG. 3) anddrawers700. In the preferred embodiment, the panels comprising the assembly are formed of but not limited to a suitable polymeric material, through the process of injection molding. The result is that the panels comprising thedrawer cabinet assembly10 are formed as unitary panels with integral connectors, and cross bracing. Strengtheningribs120,220 (FIG. 5) are integrally formed within the lower surfaces of the top andbase panels100,200 in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes, as shown inFIG. 1. Injection molding offers significant strength and stability advantages over wood or metal construction as utilized in the prior art. In this manner the enclosure of the instant invention is capable of handling a significant amount of weight as compared to wooden or sheet metal cabinets.
Thebase panel100 has anupper surface102, lower surface (not shown),front edge104,rear edge106, leftedge108 andright edge110. Adjacent to each of the rear, left, andright edges106,108,110 is a means of attaching the base panel to theleft side panel300,right side panel400, andback panel500 illustrated herein as a plurality of formed lockingposts112 extending outwardly from the upper surface. The integrally formed lockingposts112 are constructed and arranged to cooperate withsockets310 extending inwardly in a linear fashion along the upper and lower edges of the left300, right400, and back500 panels. The locking posts112 andsockets310 are constructed and arranged so that the lockingposts112 enter and mateably engage thesockets310 securing the panels together in an inter-fitting perpendicular engagement. In a most preferred embodiment, the basepanel locking posts112 each include at least one integrally formed spring-tab114. The spring-tabs are constructed and arranged to cooperate withapertures314 provided in the lockingsockets310 for positively maintaining secure coupling engagement between thebase panel100 and the left, right andback panels300,400 and500.
Thetop panel200 has anupper surface202,lower surface204,front edge206,rear edge208, leftedge210 andright edge212. Adjacent to each of the rear, left andright edges208,210, and212 respectively is a means of attaching the top panel to theleft side panel300,right side panel400, andback panel500. The means of attaching the panels is illustrated herein as a plurality of formed lockingposts112 extending outwardly from thelower surface204. The formed lockingposts112 are constructed and arranged to cooperate withsockets310 extending inwardly in a linear fashion along the upper and lower edges of the left300, right400, and back500 panels. The locking posts112 andsockets310 are constructed and arranged so that the lockingposts112 enter and mateably engage thesockets310 securing the panels together in an inter-fitting perpendicular engagement. In a most preferred embodiment, the toppanel locking posts112 each include at least one integrally formed spring-tab114. The spring-tabs are constructed and arranged to cooperate withapertures314 provided in the lockingsockets310 for positively maintaining secure coupling engagement between thebase panel100 and the left, right andback panels300,400 and500.
Theback panel500 is constructed and arranged for enclosing the back of thedrawer cabinet10. Theback panel500 includes atop edge502, abottom edge504, aleft edge506, and aright edge508. Thetop edge502 andbottom edge504 include a means for attaching the back panel to thebase panel100 and thetop panel200 in a perpendicular relationship. The attachment means is illustrated herein as a plurality of lockingsockets310 arranged in a linear fashion extending inwardly along the top and bottom edges. The locking sockets preferably include at least oneaperture314. Theapertures314 are constructed and arranged to cooperate with the lockingpost spring tabs114 for positively maintaining secure coupling engagement between theback panel300 and the base andtop panels100,200.
Theleft side panel300 is constructed and arranged for enclosing the left side of the drawer cabinet. Theleft side panel300 includes atop edge302, abottom edge304, afront edge306, aback edge308, aninner surface312 and an outer surface (not shown). Thetop edge302 and thebottom edge304 include a means for attaching the left side panel to thebase panel100 and thetop panel200 in a perpendicular relationship. The attachment means is illustrated herein as a plurality of lockingsockets310 arranged in a linear fashion extending inwardly along the top andbottom edges302,304. The lockingsockets310 preferably include at least oneaperture314. Theapertures314 are constructed and arranged to cooperate with the lockingpost spring tabs114 for positively maintaining secure coupling engagement between theleft side panel300 and the base andtop panels100,200. Theinner surface312 includes an integrally formed means for mounting a plurality of drawer guides in a vertically spaced and generally parallel relationship. The drawer guide mounting means is illustrated herein as a pair of like-constructedvertical rails316 integrally molded on theinner surface312 of theleft side panel300. One of thevertical rails316 is positioned generally adjacent to thefront edge306 and one of thevertical rails316 is positioned generally adjacent to therear edge308 of theleft panel300. Thevertical rails316 extend from about thebottom edge304 of the panel to about thetop edge302 of the panel. Thevertical rails316 each include a plurality of vertically spacedapertures318 which are constructed and arranged to cooperate with a plurality of drawer guides600 for removable attachment thereof.
Theright side panel400 is constructed and arranged for enclosing the right side of thedrawer cabinet10. Theright side panel400 includes atop edge402, abottom edge404, afront edge406, aback edge408, an inner surface (not shown) and anouter surface414. Thetop edge402 and thebottom edge404 include a means for attaching theright side panel400 to thebase panel100 and thetop panel200 in a perpendicular relationship. The attachment means is illustrated herein as a plurality of lockingsockets310 arranged in a linear fashion extending inwardly along the top andbottom edges402,404. The lockingsockets310 preferably include at least oneaperture314. Theapertures314 are constructed and arranged to cooperate with the lockingpost spring tabs114 for positively maintaining secure coupling engagement between theright side panel400 and the base andtop panels100,200. The inner surface includes an integrally formed means for mounting a plurality of drawer guides in a vertically spaced and generally parallel relationship. The drawer guide mounting means is illustrated herein as a pair of like-constructedvertical rails316 integrally molded on the inner surface of theleft side panel400. One of thevertical rails316 is positioned generally adjacent to thefront edge406 and one of thevertical rails316 is positioned generally adjacent to therear edge408 of theleft panel400. Thevertical rails316 extend from about thebottom edge404 of the panel to about thetop edge402 of the panel. Thevertical rails316 each include a plurality of vertically spacedapertures318 which are constructed and arranged to cooperate with a plurality of drawer guides600 for removable attachment thereof.
The left, right andback panels300,400 and500 are attached to the top andbottom panels100 and200 by inserting the locking posts112 into lockingsockets310 until thespring tabs114 integrally formed into the locking posts112 engage theapertures314 in thesockets310 of the left, right andback panels300,400 and500. It will be appreciated that the purpose of the locking posts112 are to align two panels in a perpendicular relationship and to facilitate their mechanical connection. The perpendicular panels are brought into a coupled relationship wherein the locking posts112 enter the correspondingsockets310 in the left, right andback panels300,400 and500. The result is a mechanically secure engagement between the panels. The coupling engagement between the panels as described above provides a secure connection and offers several advantages. First, the design allows the panels to be connected without the need for separate fasteners. Second, the design creates a positive lock that prevents separation of the panels. Third, the design maintains alignment of the panels and prevents bowing or bending of either panel relative to one another. The resultant drawer cabinet created by the combination of the interlocking panels benefits from high structural integrity and reliable operation.
Referring toFIGS. 3 and 4, to accommodate a combination of varioussized drawers700 to fill the drawer cabinet, a plurality of drawer guides600 are provided. The drawer guides600 are constructed and arranged to cooperate with the mounting means provided on the inner surfaces of the left andright side panels300,400 and thedrawers700 to provide support and prevent tipping and canting of thedrawers700, while the drawers are moved inwardly and outwardly of the cabinet assembly.
The drawer guides600 are constructed and arranged to securely support the drawers while evenly distributing the weight thereof within the cabinet assembly. The drawer guides are generally L-shaped and include avertical leg602, ahorizontal leg604, afront portion606, and aback portion608, and means for removable securement within the cabinet assembly. In a preferred, albeit non-limiting embodiment, thevertical leg602 includes a means for removably securing the drawer guides600 to the inner surfaces of the left andright side panels300,400 in a vertically spaced generally parallel relationship, illustrated herein as a pair of outwardly extending locking posts610. One of the locking posts610 is integrally formed into thefront portion606 of thevertical leg602 and one of the locking posts is integrally formed into theback portion608 of the vertical leg of thedrawer guide600. The locking posts are preferably constructed and arranged to have a conjugate shape to theapertures318 provided in the left and right side panelvertical rails316. In a most preferred embodiment, the drawerguide locking posts610 each include at least one integrally formed spring-tab114. The spring-tabs114 are constructed and arranged to cooperate withapertures318 provided in thevertical rails316 for positively maintaining secure coupling engagement between the drawer guides600 and the left andright side panels300,400. For supporting and facilitating easy movement of a loadeddrawer700, the drawer guides600 include at least oneroller616 rotatably mounted in thefront portion606 of thehorizontal leg604. Theroller616 is sized and positioned between anupper surface612 and alower surface614 of thehorizontal leg604 of thedrawer guide600 so that a portion of the roller protrudes above the top surface. The upper surface of thehorizontal leg604 of thedrawer guide600 also includes an outwardlyprotruding detent618. Thedetent618 is integrally formed into therear portion608 of the drawer guide and is constructed and arranged to cooperate with rollers720 (FIG.4) rotatably mounted on the lower rear portion of the drawers for releasably securing adrawer700 within thedrawer cabinet10. Pulling outward on thedrawer700 allows the rollers to release from theguide detents618. Thelower surface614 of thehorizontal leg604 of each drawer guide also includes an integrally formed and outwardly protruding stop tab620 (FIG. 5). Thestop tab620 is constructed and arranged to cooperate with a stop722 (FIG. 4) formed into the upper rear portion of thedrawers700 to prevent the drawers from being extended completely out of the drawer cabinet.
In operation, the drawer guides600 may be positioned on the inner surface of the left and right side panels to accommodate a combination of various sized drawers to fill the drawer cabinet by sliding the locking posts600 into theapertures318 until the spring-tab114 engages the left or right side panel. The result is a mechanically secure inter-fitting engagement between the guides and the panels. The design allows the drawer guides to be connected to the panels without the need for separate fasteners.
Referring toFIGS. 4 and 5, a plurality ofdrawers700 are provided for enclosing the front of thewall cabinet10 and providing storage within the cabinet. Thedrawers700 include afront portion702, arear portion704, aleft side706, aright side708 and abottom surface714. Theleft side706 and theright side708 each include at least oneupper roller710 and at least onelower roller720 rotatably mounted thereto. In the preferred embodiment therollers710 and720 are mounted within integrally formed roller pockets712. Theupper rollers710 are rotatably mounted within the upper roller pockets to extend partially outward therefrom to cooperate with thelower surface614 of an adjacent drawer guide, and wherein thelower rollers720 are rotatably mounted within the lower roller pockets to extend partially outward therefrom to cooperate with theupper surface612 of anadjacent drawer guide600. In this manner, the cooperating rollers and said drawer guides prevent the drawer from tipping as the drawer is extended outwardly from the drawer cabinet. Thelower surface714 of thedrawers700 include a pair of integrally formeddetents716. The pair ofdetents716 are constructed and arranged to cooperate with therollers616 rotatably mounted in thefront portion606 of the drawer guides600 for releasably securing adrawer700 within the drawer cabinet.
Thus, a drawer cabinet kit with a plurality of drawer guides and cooperating drawers has been shown and described. The kit is comprised of injection molded components having integrated connectors which may be assembled on a desired site without requiring separate fasteners or tools.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.