FRAME STRUCTURE
A frame for making outdoor kitchens or other frame structures. The frame includes an elongate rail section and an elongate joint section. The rails sections have inner bridges that are proximate to the ends of the rail sections. These inner bridges nest within outer bridges on the elongate joint sections. A central fastener may join the two bridges, more securely lining joint sections and the rail sections.
The present invention relates to devices adaptable for use in construction of outdoor kitchens.
BACKGROUNDOutdoor cooking is a popular pastime of numerous enthusiasts. Portable outdoor gas or wood grills or smokers have been used for a number of years for backyard cooking. Such devices are adequate for cooking food but they have a number of drawbacks. They usually include minimal, if any, stable surfaces needed for food preparation. Without such surfaces, the cook will either prepare items indoors or attempt to use patio tables or similar structures as ad hoc surfaces on which to prepare food. In addition, because a portable outdoor gas grill does not allow for refrigeration, items which must be kept cold are either refrigerated indoors, or kept in a cooler on ice near the grill.
One solution to this problem is to create an outdoor grill system that could include both a grill, work surfaces, storage compartment, a refrigerator if desired, and other features. A number of outdoor kitchens have been proposed. For example, U.S. Pat. App. Pub. 2004/0065313 discloses a modular outdoor kitchen comprised of a number of weather resistant modules. The modules are releasably connected together, allowing assembly and configuration. A number of the outer faces include panels to provide a weather resistant outer surface.
U.S. Pat. App. Pub. 2005/0133018 discloses a method and system for constructing a grill island or support structure. This structure includes modular units, which may be configured to hold the grill, enclose a refrigerator, store a trash bin or storage drawers, or be adapted for other purposes. Each modular unit includes a frame of interconnecting elements defining an open interior and a covering extending over the frame, generally to create a face and a top. A number of these modular units are connected together to form a unitary structure, such as a grill island.
There is presently a need for a frame system that is easy to assemble, requires only minimal tools, and is structurally strong. Such a system could be adaptable to shipping in a compact manner. The framework could serve as the frame structure for a number of different structures that require a frame.
SUMMARYThe embodiments of the presently described device include a frame structure including a plurality of rails (or a first elongate frame member) and a plurality of elongate joint sections (or second elongate frame member). Both the rails of first elongate frame member and the joint sections or second elongate frame member have associated bridge structures, with the rails or first frame member having inner bridges that nest within outer bridges on the joint sections or second frame member. At least some of the joint sections may have a tab with a central hole or other floor mounting structure. In other embodiments, the inner bridges and outer bridges may have aligning holes to allow for a fastener to join the two parts. In another embodiment, at least some of the rails may have a return flange. The joint section may also have one or more ends that join two perpendicular rail sections.
BRIEF DESCRIPTION OF THE DRAWINGS
First Frame Design
With reference to
Once this corner cube module is assembled it may be attached to adjacent module 40. Such modules may be of a standardized height and width to allow standard size appliances to fit into the outdoor kitchen counter or island built from these modules. Module 40 is joined to an adjacent module which holds gas grill 42. This module is shown having an attached face 50 and counter top 52. This face and counter top may be selected from commercially available materials, such as granite, slate, butcher block wood, or other commercially available materials. The countertops may be attached in the conventional manner, the same way as indoor kitchen countertops.
The illustrated outdoor kitchen includes corner module 44, and bar counter modules 47, 48 including bar counter 46. All of the modules may be assembled using rails having a single cross sectional diameter. In addition, only the corner module requires braces while all the other modules require only a uniform connector. This simplicity makes the device simpler and cheaper to manufacture and assemble.
With reference to
Each rail is U-shaped in cross section. This cross section is the same for each rail, simplifying manufacturing and assembly. The rails have a width w and a depth d. As seen with rails 74, 78, 80, and 82, the rails are oriented such that the internal space within the module is greatest. The illustrated cube is assembled using rails of three different lengths. Four rails of each length are required.
With reference to
With reference to
Referring again to
The rest of the rails 131a, 131b, 137, 133, 138, 153, 132, 134, 136, 160, 169, and 151 are attached together using connectors 143, 154, 135, 161, 163, 148 150, 152, 159, 162, and 142 as illustrated. This creates a module for an outdoor kitchen as shown in
With respect to
Two additional types of corner braces are shown in
The illustrated module for making an outdoor kitchen allows simple assembly of frames which provide a durable structure for constructing outdoor kitchens. These kitchen counters may be constructed as a counter, an island, or other configuration. It may be in a L shape, a U-shape or as a line counter. The kitchen may be constructed to hold a gas grill, an under-the-counter refrigerator, a trash receptacle, drawers or cabinets for storage or other selected kitchen components. The steel or other material used for the frame is strong and durable. A variety of different counter tops and faces could be placed on the top and front of the cabinets.
The present frames could be used in a number of ways. The various modules could be assembled off site and sold as completed units. The units could be sold either with face and tops attached or without, and either as pre-fabricated modules to be joined together or as a singular, ready to use unit. Alternatively, the modules could be assembled on-site. The fact that relatively few different parts are used would allow for simple and rapid on-site assembly.
Second Frame Design
The frame design described in conjunction with
As in the first frame design, the frame may be manufactured in a number of modules. These modules may be similar to the modules shown in
With reference to
In this module a counter top is added. Side sections 308 and 306 extend to the top of the bar counter. Sections 332 and 334 are “L”-shaped, forming the sides of the bar counter. Section 338 and 336 then form the top and back of the counter respectively. Brace sections 328 and 330 give the section added rigidity.
In the illustrated frame, a door 300 is mounted to the front of the frame.
This illustrated bar top module has fewer than 20 sections (including the door). The frame sections can be disassembled and shipped flat to a user. The elongate sections can nest within each other for shipping.
A unique aspect of the present deign is a bridge on bridge method of coupling the elongate sections. Each bridge consists of an area of sheet metal that has been lanced on two sides. The bridge is punched out to the required height. In the center of the bridge a hole is punched which creates a lead hole for a fastener. The bridge is “punched out” such that the exterior surface of the rail or joint section is a level surface, and the bridge is counter sunk. This allows a screw to be inserted into the bridge's central hole and screwed in until the head of the screw is flush with the surface of the rail or is countersunk. This creates a “bridge” structure. A second, slightly smaller bridge structure on a joining part allows the two parts to be joined together. The center cut holes then can be more securely attached together with a fastener, such as a self-tapping sheet metal screw. Any appropriate alternative fastener, such as a rivet, bolt and nut, etc. may be used. One advantage of the use of screws is that the use of screws allow for assembly with tools already owned by most homeowners. Other means of attaching the elongate sections together, such as welding or gluing are possible, but are less practical and not as adaptable for on site assembly.
For example,
For rail section 404 shown in
Rail section 408 of
Finally, for joint section 412 of
Bridges 412e and 412f mate with a rail at the rear of the counter. Bridges 412b allow attachment to a rail section that acts as the top crossbar of the bar counter (like section 338 of
The bridge-on-bridge fasteners have a number of advantages. First, the bridges are placed to locate the joined sections at specific locations. Once the two bridges mate, the assembler is assured that the parts are correctly positioned in relation to each other. The bridge-on-bridge connection also strengthens the structure. Each of the bridges is sunk below the front face of each section. A screw may be inserted into the hole and the head of the screw will be at or below the front face level. The fact that the bridges are countersunk allows flush surfaces (or a flush surface), which aids in the attachment of surface structures to the frame. The central hole in the bridge is adapted for use with self-tapping screws, which are quite easy to insert.
The present groups of rail sections and joint sections allows construction of basic frame cubes and linear bar tops without the need for additional connectors. For corner bar counter frames, connectors are needed. With reference to
A second type of connector used for bar counters is shown in
A number of alternatives to the illustrated embodiments will be readily apparent. The present device is illustrated as used in modules for outdoor kitchens. The frames could also be adapted to other structures requiring a frame. This could include other outdoor structures, such as benches, fireplaces among other structures. In addition, the frame cold be adapted to form equipment cabinets, sheds or other structures, or any other structure in which a frame is used.
The present device may be made of steel sections, which are relatively simple to manufacture and are strong and durable. Alternative materials, including plastic, could also be used.
The disclosed frames are very easy to assemble and disassemble. This may be enhanced by the use of some indicia on the various parts as to assembly. This indicia could use colors, a letter or number, arrows, or any other indication of which sections or which parts of sections mate together.
Claims
1. A frame structure comprising:
- a plurality of rails, each rail having a first and a second end;
- a plurality of inner bridges on said rails;
- a plurality of elongate joint sections; and
- a plurality of outer bridges on said joint sections, wherein said inner bridges are able to nest within said outer bridges when said plurality of rails are joined to said plurality of joint sections.
2. The frame structure at claim 1, wherein at least two of the plurality of rails have a floor mounting structure.
3. The frame structure of claim 1, wherein said plurality of rails and said plurality of joint sections include rails and joint sections for a bar top.
4. The frame structure of claim 1, wherein said inner bridges and said outer bridges have aligning holes.
5. The frame structure of claim 1, wherein at least two of the plurality of rails have a return flange.
6. The frame structure of claim 1, wherein at least one of the plurality of rails is an L-shaped brace.
7. The frame structure of claim 1, wherein said joint section has at least one end that can join to two perpendicular rails.
8. A frame structure comprising:
- a plurality of first elongate frame members;
- at least one inner bridge proximate to each end of said first elongate frame members;
- a plurality of second elongate frame members;
- at least one outer bridge proximate to each end of said first elongate frame member, wherein said at least one inner bridge is able to nest within said at least one outer bridge, thereby joining said first and said second frame members.
9. The frame structure of claim 8, further including a plurality of fasteners extending through each pair of inner and outer bridges.
10. The frame structure of claim 9, wherein said fastener is a screw.
11. The frame structure of claim 8, wherein at least two of the first elongate frame members include a tab positioned to allow floor mounting of the frame member.
12. The frame structure of claim 8, wherein at least two of the second elongate frame members include a return flange running a majority of a length of the at last two of the second elongate frame members.
Type: Application
Filed: May 8, 2006
Publication Date: Nov 8, 2007
Inventors: Sean Kenny (Morgan Hill, CA), David Wershiner (Aromas, CA), Steven Matthews (Los Banos, CA)
Application Number: 11/382,211
International Classification: A47G 29/00 (20060101);