CABINETRY SYSTEM HAVING REMOVABLE CABINET FACES AND REVERSIBLE INSERTS

Abstract

A face panel assembly for a cabinet is disclosed herein that includes a reversible insert with different designs on its forward and reverse surfaces. The assembly also includes a face panel frame having a central opening formed through a thickness thereof and a cavity formed in an inward-facing surface thereof. The cavity extends around the opening and is sized to receive the forward and reverse surfaces of the reversible insert so that, when the reversible insert sits within the cavity, one of the forward and reverse surfaces is visible through the opening. The assembly further includes magnets coupled to the inward-facing surface of the frame that are configured to couple the frame to a cabinet box. The magnetic coupling system and reversible inserts permit a user to quickly and easily change the outward appearance of the cabinet.

Description

BACKGROUND OF THE INVENTION

Embodiments of the invention relate generally to cabinetry, and, more particularly, to a cabinetry system wherein the exterior surface elements or face panel assemblies of the cabinetry system include interchangeable face panel frames and reversible inserts and are removably coupled to the internal bodies or frames of the cabinet box of the cabinetry system in a manner that facilitates quickly changing the appearance of the cabinetry system.

Replacing cabinetry accounts for a large percentage of the cost of a room renovation. In the case of a kitchen, for example, kitchen cabinets may account for fifty percent or more of the entire cost of the renovation. A large portion of the cost of a cabinet is accounted for in the cabinet's interior body or box, which constitutes the bulk of the material of the cabinet and is costly to ship due to its size and weight.

Additionally, people who entertain at their homes at various times of the year often decorate their homes according to what time of year it is. For example, people decorate their homes according to the seasons of the year (spring, summer, fall, and winter), a sport season (for example, football season, baseball season, basketball season, hockey season, etc.), and holidays (for example, Christmas, Halloween, Valentine's Day, New Year's Day, Independence Day, Thanksgiving, etc.). People also decorate according to special events such as birthdays, major sporting events (for example, the Super Bowl, a collegiate national championship game, etc.), and graduations. Businesses often decorate their locations in a similar manner and further include displays that include corporate logos/trademarks and advertising material. However, traditional cabinet systems cannot be easily changed to correspond to the different times of the year or different events. Further, advertising displays and decorations for the different seasons, holidays, and events described above are frequently disposable or temporary and do not have a permanent or strong construction that can last many years.

Therefore, it would be desirable to design a cabinetry system that includes cabinet faces that can be easily removed from the base structure of the cabinetry system and interchanged with other sets of cabinet faces to quickly and easily change the appearance of the cabinets without replacing the costly interior structure of the cabinets. It would also be desirable to design the cabinet faces so that the appearance of the cabinets can be quickly and easily changed for different events and holidays and advertising purposes.

BRIEF DESCRIPTION OF THE INVENTION

In accordance with one aspect of the invention, a face panel assembly for a cabinet includes a reversible insert with a forward surface having a first design thereon and a reverse surface opposite the forward surface. The reverse surface has a second design thereon different from the first design. The face panel assembly also includes a face panel frame having a central opening formed through a thickness thereof and a cavity formed in an inward-facing surface thereof, wherein the cavity extends around the central opening and is sized to receive the forward and reverse surfaces of the reversible insert so that, when the reversible insert sits within the cavity, one of the forward and reverse surfaces is visible through the central opening. The face panel assembly further includes a plurality of magnets coupled to the inward-facing surface of the face panel frame, the plurality of magnets configured to couple the face panel frame to a cabinet box. A thickness of the reversible insert is equal to or substantially equal to a depth of the cavity.

In accordance with another aspect of the invention, a cabinet assembly includes a cabinet box and at least one face panel assembly coupled to at least one outward-facing surface of the cabinet box. The at least one face panel assembly includes a face panel frame having an opening formed through a thickness thereof and a cavity formed through a thickness thereof and surrounding a perimeter of the opening. The at least one face panel assembly further includes a central insert sized to be received within the cavity of the face panel frame. The central insert includes a first surface having a first design and a second surface opposite the first surface and having a second design different from the first design. The cabinet assembly also includes a plurality of magnets coupling the at least one face panel assembly to the at least one outward-facing surface of the cabinet box. The central insert is reversible within the face panel frame so that either of the first and second surfaces may be shown through the opening of the face panel frame.

In accordance with a further aspect of the invention, a method of manufacturing a cabinet assembly includes constructing a cabinet box. The method also includes constructing a face panel frame having an opening formed through a thickness thereof and a cavity formed through a thickness thereof and surrounding a perimeter of the opening. The method further includes positioning a central insert within the cavity of the face panel frame. The central insert includes a first surface having a first design and a second surface opposite the first surface and having a second design different from the first design, wherein the central insert is reversible within the face panel frame so that either of the first and second surfaces may be shown through the opening of the face panel frame. In addition, the method includes coupling the face panel frame to an outward-facing surface of the cabinet box via a plurality of magnets.

Various other features and advantages will be made apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate preferred embodiments presently contemplated for carrying out the invention.

In the drawings:

FIG. 1 is a perspective view of a cabinetry system, according to an embodiment of the invention.

FIG. 2 is an exploded perspective view of the bar cabinet assembly included within the cabinetry system of FIG. 1, according to an embodiment of the invention.

FIG. 3 is a front view of the bar cabinet assembly of FIG. 1, according to an embodiment of the invention.

FIG. 4 is a front view of the bar cabinet assembly of FIG. 1 with the front face panel assemblies removed, according to an embodiment of the invention.

FIG. 5 is a side view of the bar cabinet assembly of FIG. 1, according to an embodiment of the invention.

FIG. 6 is a top view of the bar cabinet assembly of FIG. 1, according to an embodiment of the invention.

FIG. 7 is a rear view of the bar cabinet assembly of FIG. 1, according to an embodiment of the invention.

FIG. 8 is a rear view of a face panel assembly with a removable center insert useable with the cabinetry system of FIG. 1, according to an embodiment of the invention.

FIG. 9 is a rear perspective view of the face panel assembly of FIG. 8, according to an embodiment of the invention.

FIG. 10 is a front view of the face panel assembly of FIG. 8 showing the center insert oriented to display a first design through an opening in the face panel assembly, according to an embodiment of the invention.

FIG. 11 is a front view of the face panel assembly of FIG. 8 showing the center insert oriented to display a second design through an opening in the face panel assembly, according to an embodiment of the invention.

FIG. 12 is a detailed view of hardware components used to align and attach a face panel assembly of the cabinetry system of FIG. 1 to a cabinet box of the cabinetry system of FIG. 1, according to an embodiment of the invention.

FIG. 13 is a perspective view of a bar cabinet assembly, according to another embodiment of the invention.

FIG. 14 is a detail view of a portion of FIG. 13 taken along line 14-14 of FIG. 13.

FIG. 15 is a perspective view of a bar cabinet assembly, according to another embodiment of the invention.

FIG. 16 is a perspective view of a modular corner cabinet box useable with the bar cabinet assemblies of FIGS. 1, 13, and 15, according to an embodiment of the invention.

FIG. 17 is a perspective view of a modular forward cabinet box useable with the bar cabinet assemblies of FIGS. 1, 13, and 15 according to an embodiment of the invention.

FIG. 18 is a perspective view of a cabinet box, according to an embodiment of the invention.

DETAILED DESCRIPTION

Embodiments of the invention are directed to a cabinetry system that includes removable or interchangeable face panel assemblies, which permit the entire outward appearance of the cabinetry system to be changed within a short period of time. The face panel assemblies include interchangeable or removable face panel frames that are coupled to the cabinet boxes and interior frame structure of the cabinetry system using a magnetic attachment system, which functions to consistently self-align these panel frames with the internal cabinet structure and enables removal of the panel frames with no (or minimal) tools. The removable face panel assemblies include reversible or rotatable inserts within the face panel frames that are also removable or interchangeable. The reversible inserts may be manufactured having different designs, ornamentations, decorations, and/or patterns on the front and rear sides or surfaces of the inserts so the outward appearance of the cabinetry system may be quickly and easily changed by rotating the orientation of the reversible inserts. After being removed from the cabinetry system, one set of face panel frames and/or reversible inserts may be stored while a second set of face panel frames and/or reversible inserts are in use.

Such a system enables a home or business owner to have a perceived “new” cabinetry system with minimal time and effort. The home or business owner may purchase different sets of removable face panel frames and/or reversible inserts as often as they desire. For example, a home or business owner may purchase different sets of face panel frames and/or reversible inserts for use during different seasons or events or may purchase a different set of face panel frames and/or reversible inserts based on changing tastes, design trends, and advertising needs.

While the cabinetry system is described herein in the context of a cabinetry system in the form of a residential or commercial bar, it is contemplated that the concepts disclosed herein may be extended to other cabinet applications including residential kitchen, living room, bathroom, and utility cabinets as well as cabinetry systems used in commercial office settings, restaurants, sporting and entertainment venues, and hotel rooms, as non-limiting examples.

FIG. 1 illustrates a cabinetry system 10 according to one embodiment of the invention. As shown, cabinetry system 10 includes a bar cabinet assembly 12 and a wall cabinet assembly 14. Still referring to FIG. 1 and to FIGS. 2-3 where appropriate, bar cabinet assembly 12 includes a cabinet box or structural frame 16 and a plurality of brackets 18 coupling a foot rail assembly 20 to cabinet box 16 via a plurality of fasteners (not shown) such as screws or bolts, as non-limiting examples. Cabinet box 16 includes two cabinet box sections 24, 26 coupled together by a plurality of fasteners (not shown) such as screws or bolts. In another embodiment cabinet box 16 may be constructed as a single, larger cabinet box section. In yet another embodiment, cabinet box 16 may include more than two sections. Bar cabinet assembly further includes two front face panel assemblies 28, 30, a left side face panel assembly 32, and a right side face panel assembly 34 magnetically attached to cabinet box 16. Each of front face panel assemblies 28, 30 and side face panel assemblies 32, 34 includes a face panel frame 36 and a reversible or rotatable center insert 38.

Each reversible insert 38 includes a first or forward side or surface 40 having a first design 42 and a second or reverse side or surface 44 having a second design 46. In the exemplary embodiment illustrated in FIG. 2, first design 42 is a color design, and second design 46 is a bead board design. According to alternative embodiments, first design 42 and second design 46 may differ from one another in colors, textures, finishes, logos, images, stickers, and/or labels than those shown. As one non-limiting example, first design 42 may be a stained surface finish that matches a surface finish of face panel frame 36 and second design 46 may include a sports team color and/or logo. In another non-limiting example, first design 42 may include one sports team color and/or logo and second design 46 may include a different sports team color and/or logo, thereby permitting the user to change the appearance of bar cabinet assembly 12 to correspond to a desired sports event or sporting season. In yet another embodiment, one or both of first design 42 and second design 46 may include a three-dimensional surface finish corresponding to a particular door style, such as, for example, a prairie, craftsman, shaker, cathedral, louvered, or bead board.

Bar cabinet assembly 12 additionally includes an upper countertop section 48 and a lower countertop section 50. In one embodiment, cabinet box 16 is constructed of a cost-effective material such as, for example, a melamine substrate, particle board, or medium-density fibreboard (MDF) core material.

While bar cabinet assembly 12 is illustrated as a free-standing bar cabinet assembly with one cabinet box 16, two front face panel assemblies 28, 30, one left side face panel assembly 32, and one right side face panel assembly 34 of substantially the same size and shape, one skilled in the art will recognize that the concepts set forth herein are not limited to any particular arrangement of cabinets and may be adapted to bar cabinet assemblies having more or less cabinet boxes, front face panel assemblies, and/or side face panel assemblies than that shown in FIG. 1 and to bar cabinet assemblies having cabinet boxes, front face panel assemblies, and side face panel assemblies that differ in size and shape from those illustrated in FIG. 1. For example, alternative bar cabinet assembly configurations may include, as non-limiting examples, U-shaped, L-shaped, or O-shaped configurations. Further, it is contemplated that the concepts set forth herein may be extended to wall-mounted and floor-mounted bar cabinet assemblies including one or more individual cabinet sections. In addition, the individual face panel assemblies of bar cabinet assembly 12 may differ in size and/or shape from one another.

Wall cabinet assembly 14 is an upper cabinet assembly including a cabinet box 52 having a center wall cabinet 54 and two end wall cabinets 56, 58 on either side of center wall cabinet 54. As shown, center wall cabinet 54 includes an electronic display 60 installed therein. Alternatively, center wall cabinet 54 may be an open cabinet used to display knick knacks, trophies, or any other items to decorate wall cabinet assembly 14. In another embodiment, center wall cabinet 54 includes a mirror (not shown) mounted on a rear panel (not shown) of cabinet box 52. In yet another embodiment, center wall cabinet 54 includes glass, plexiglass, or another type of transparent sheet (not shown) at an opening 64 to center wall cabinet 54. In still another embodiment, center wall cabinet 54 includes a door (not shown) so that center wall cabinet 54 may be used to store drinking glasses, liquor bottles, or other items of a similar nature a user may wish to keep hidden and/or protected.

End wall cabinets 56, 58 include door assemblies 66, 68. Door assemblies 66, 68 open by sliding door panels 70 away from center wall cabinet 54 via a guide assembly (not shown) mounted to end wall cabinets 56, 58 that permits sliding door panels 70 to translate horizontally outward from a cabinet box portion 72 of end wall cabinets 56, 58. In other words, door assembly 66 slides open to the left, and door assembly 68 slides open to the right. In another embodiment, door assemblies 66, 68 open via one or more hinge assemblies (not shown) coupled to cabinet box 52. Door panels 70 include door panel frames 76 and reversible or rotatable inserts 78 within door panel frames 76. Reversible inserts 78 include a first or forward side or surface 80 showing first design 42 and a second or reverse side or surface (not shown) with second design 46. According to various embodiments, first design 42 and the second design 46 have different colors, textures, finishes, logos, images, stickers, and/or labels to permit the appearance of wall cabinet assembly 14 to be quickly and easily changed by rotating or flipping reversible inserts 78 by 180 degrees.

While wall cabinet assembly 14 is illustrated as an upper cabinet assembly with three upper cabinets in a single-wall configuration, one skilled in the art will recognize that the concepts set forth herein are not limited to any particular arrangement of cabinets and may be adapted to wall cabinet assemblies having more or less individual cabinets than that shown in FIG. 1. For example, alternative wall cabinet assembly configurations may include, as non-limiting examples, U-shaped, L-shaped, or galley configurations, and wall cabinet assemblies including lower cabinets only or upper and lower cabinets together. Further, it is contemplated that the concepts set forth herein may be extended to wall-mounted and floor-mounted cabinetry as well as free-standing cabinetry systems including one or more individual cabinet sections.

Door panel assemblies 66, 68 of wall cabinet assembly 14 and front face panel assemblies 28, 30 and side face panel assemblies 32, 34 of bar cabinet assembly 12 are mounted in a full overlay configuration, as shown in FIG. 1. As used herein, the term “full overlay” refers to a frameless or Euro-style cabinet configuration wherein door panel assemblies 66, 68 and face panel assemblies 28, 30, 32, 34 overlay substantially all of the front-facing and/or side-facing surfaces of the cabinet boxes or internal structural frames of the cabinets above brackets 18 when face panel assemblies 28, 30, 32, 34 are attached and when door panel assemblies 70 are in a closed position. A minimal gap 84 exists between adjacent side surfaces 86 of each door panel assembly 66, 68 and/or face panel assembly 28, 30, 32, 34 such that outer or outward-facing surfaces 88, 90 (not shown) of cabinet boxes 16, 52 are not visible behind door panel assemblies 66, 68 and face panel assemblies 28, 30, 32, 34.

Additional views of bar cabinet assembly 12 and the elements thereof are provided in FIGS. 2-9. FIG. 2 shows an exploded view of bar cabinet assembly 12 to illustrate the interrelationship of the structural elements provided within bar cabinet assembly 12. FIG. 3 shows a front view of bar cabinet assembly 12. FIG. 4 shows a front view of bar cabinet assembly 12 without front face panel assemblies 28, 30 coupled to cabinet box 16. FIGS. 5-7 are a side, top, and rear views of bar cabinet assembly 12. FIG. 8 is a rear view of front face panel assembly 28. FIG. 9 is a rear view of front face panel assembly 28 with reversible insert 38 and a plurality of magnets exploded out from face panel frame 36. FIG. 10 is a front view of front face panel assembly 28 with first design 42 showing. FIG. 11 is a front view of front face panel assembly 28 with second design 46 showing. FIG. 12 is a detailed view of hardware components used to align and attach face panel assemblies 28, 30, 32, 34 to cabinet box 16. The construction of bar cabinet assembly 12 is described below with reference to FIGS. 2-12 together where appropriate.

As shown in FIGS. 2-3, 5, and 8-9, each reversible insert 38 is retained against an insert receiving surface 92 within a cavity 94 of one face panel frame 36 by a plurality of rotatable clips or tabs 96 and is viewable through a central opening or window 98 of one face panel frame 36. Tabs 96 are positioned within recesses 100, which are below or flush with a rear or inward-facing surface 102 of each face panel frame 36. Tabs 96 are coupled to face panel frames 36 via fasteners 104. In FIGS. 2 and 8, tabs 96 are illustrated in an extended, closed, or retaining position in which tabs 96 extend over reversible inserts 38 so that reversible inserts 38 are retained within cavities 94. In FIG. 9, tabs 96 are illustrated in a retracted, open, rotating, or reversing position in which tabs 96 are retracted into recesses 100 formed in face panel frames 36 around cavity 94. When tabs 96 are in the retracted position, reversible inserts 38 may be removed from cavities 94 so that reversible inserts 38 may be flipped to show the other surface or exchanged for another reversible panel (not shown) with a different design.

As shown in FIGS. 2, 4, and 8-9, bar cabinet assembly 12 further includes a magnetic coupling or attachment system 108, which includes a set or plurality of magnets 110 embedded within inward-facing surface 102 of each face panel frame 36 and a set or plurality of magnets 112 embedded within outward-facing surfaces 88 of cabinet box 16. In the embodiment shown in FIGS. 2-9, each of magnets 110 is positioned within a corresponding circular recess 118 formed within each face panel frame 36, and each of magnets 112 is positioned within corresponding circular recesses (not shown) formed within cabinet box 16. Face panel assemblies 28, 30, 32, 34 may be coupled to cabinet box 16 via magnetic coupling system 108 by aligning magnets 110 with magnets 112. While magnetic coupling system 108 is shown as having four circular magnets 110 embedded within each face panel frame 36 and four circular magnets 112 embedded in cabinet box 16 corresponding to magnets 110 in each face panel frame 36, magnetic coupling system 108 may include more or less or larger or smaller magnets 110, 112 and/or magnets of different shapes. In an exemplary embodiment, magnets 110, 112 are circular rare-earth disc magnets manufactured by Magcraft® and measuring 0.5 inches (1.27 cm) in diameter and 0.375 inches (0.9525 cm) in thickness with a pull force of approximately 16 lbs. It is contemplated that the size and pull force of magnets 110, 112 may vary in alternative embodiments based on differing design specifications.

Magnetic coupling system 108 allows a user to quickly and easily decouple face panel assemblies 28, 30, 32, 34 from cabinet box 16 so that the user is able to quickly and easily change the appearance of bar cabinet assembly 12. The user may exchange face panel frames 36 with different face panel frames (not shown) having a different color, texture, finish, and or pattern. The user may also access tabs 96 to rotate or exchange reversible inserts 38. Further, the user may exchange both face panel frames 36 and reversible inserts 38 to create a completely different face panel assembly (not shown).

As shown in FIGS. 2, 4, 8-9, and 12, bar cabinet assembly 12 also includes self-centering locating pin assemblies 122, which aid in aligning magnets 110 with magnets 112. Self-centering locating pin assemblies 122 include pin bodies 124 having a base portions 126 positioned within recesses 128 formed on cabinet box 16 and stem or pin portions 130 extending outwardly from base portions 126. Self-centering locating pin assemblies 122 also include receiving bodies or mating receptacles 132 that are positioned within recesses 134 formed on face panel frames 36 and having central openings 136 sized to receive stem portions 130. In an exemplary embodiment mating receptacles 132 are metal inserts, however, it is contemplated that mating receptacles 132 may alternatively be formed of a rigid plastic. In another embodiment, openings may be formed within the bulk material of cabinet box 16 for receiving stem portions 130 in place of mating receptacles 132. While bar cabinet assembly 12 is shown as having two self-centering locating pin assemblies 122 for each face panel assembly 28, 30, 32, 34, bar cabinet assembly 12 may include more or less or larger or smaller self-centering locating pin assemblies 122 and/or self-centering locating pin assemblies 122 of different shapes. In an alternative embodiment, pin bodies 124 may be provided within face panel frames 36, with corresponding mating receptacles 132 provided within cabinet box 16.

As shown in FIGS. 2 and 8-9, face panel assemblies 28, 30, 32, 34 further include finger holds 138 inset within an edge surface of face panel frames 36. Finger holds 138 provide a gripping surface to facilitate decoupling magnetic attachment system 108 and removing face panel assemblies 28, 30 32, 34 from cabinet box 16. In various embodiments, face panel assemblies 28, 30, 32, 34 also include optional finger holds 140 to provide multiple gripping surfaces by which to decouple magnetic attachments system 108.

As shown in FIG. 2, in various embodiments, bar cabinet assembly 12 further includes optional key lock assemblies 142. Only one key lock assembly 142 is shown embedded within front face panel 34 for clarity. Key lock assemblies 142 include rotatable locking mechanisms 144 that are embedded within face panel assemblies 28, 30, 32, 34 and are positioned to align with corresponding mating receptacles 146 formed within the cabinet box 16. In one embodiment locking mechanisms 144 include rotatable tabs (not shown) that engage mating receptacles 146. In another embodiment, key lock assemblies 142 has a tumbler design similar to a deadbolt. In either embodiment, locking mechanisms 144 may be rotated to transition the key lock assemblies 142 between a locked position and an unlocked position by inserting a key (not shown) into the locking mechanisms 144 and rotating. When the key lock assemblies 142 are in the unlocked position, the locking mechanisms 144 may be inserted into corresponding mating receptacles 146 in cabinet box 16 that are aligned with and sized to receive the tabs. Face panel assemblies 28, 30, 32, 34 may then be secured to cabinet box 16 by rotating the locking mechanisms 144 to the locked position. Face panel assemblies 28, 30, 32, 34 may then be removed from cabinet box 16 by rotating the locking mechanisms 144 back to the unlocked position. Thus, the key lock assemblies 142 add security to bar cabinet assembly 12 while maintaining the flexibility of a changeable design.

As shown in FIGS. 2-7, foot rail assembly 20 is coupled to cabinet box 16 under each of front face panel assemblies 28, 30. In another embodiment, foot rail assembly 20 is formed having a continuous construction that extends around cabinet box 16 under each face panel assembly 28, 30, 32, 34. In yet another embodiment, foot rail assembly 20 is includes multiple sections (not shown) coupled to cabinet box 16 under front face panel assemblies 28, 30, left side face panel assembly 32, and right side face panel assembly 34.

In the embodiment shown in FIGS. 2 and 6-7, bar cabinet assembly 12 includes a two-level countertop assembly 84 with an upper countertop section 48 and a lower countertop section 50. As shown, upper countertop section 48 is mounted on a top surface 148 of an extended portion 150 of cabinet box 16 that extends out from a base portion 152 of cabinet box 16 at outer surfaces 88 of cabinet box 16. Lower countertop section 50 is mounted on a top surface (not shown) of base portion 152. In another embodiment, extended portion 150 only extends out from base portion 152 at front outer surface 88. In yet another embodiment, bar cabinet assembly 12 is constructed having a single-level countertop assembly wherein lower countertop section 50 covers the entire top surface of base portion 152 of cabinet box 16.

As shown in FIGS. 2, 4, and 7, cabinet box sections 24, 26 include a shelf 160 positioned within an interior storage cavity 162 of cabinet box sections 24, 26. While cabinet box sections 24, 26 are shown with only one shelf 160, cabinet box sections 24, 26 may include multiple shelves or no shelves in alternative embodiments. Cabinet box sections 24, 26 include optional openings 164 (shown in phantom) that are formed in front outer surface 88 and openings 166 in a rear surface 168. Openings 164 permit access to interior storage cavity 162 of cabinet box sections 24, 26 when face panel assemblies 28, 30, 32, 34 are removed from cabinet box 16. Such openings 164 advantageously permit a user to easily access items (for example, heavy or large items) that are stored within interior storage cavity 162 near face panel assemblies 28, 30, 32, 34. In another embodiment, bar cabinet assembly 12 include door assemblies (not shown) for cabinet box sections 24, 26 to cover openings 166. In another embodiment, openings 166 are combined into a single large opening (not shown) covering the rear surface 168 in its entirety.

Referring now to FIG. 13, a bar cabinet assembly 170 is illustrated according to an alternative embodiment of the invention. Bar cabinet assembly 170 is similar to bar cabinet assembly 12 (FIG. 1), except bar cabinet assembly 170 includes piano hinges 172 coupling cabinet box 16 to face panel assemblies 174, 176, 178, 180 having face panel frames 36 and reversible inserts 182 having a first surface 184 with a color design 186 and a second surface 188 with bead board design 46. Accordingly corresponding elements of bar cabinet assembly 12 and bar cabinet assembly 170 are referred to with the same part numbers as appropriate. As shown, piano hinges 172 are coupled to a rear surface 102 of face panel frames 36 and to outer surfaces 88 of cabinet box 16 via fasteners 190, such as screws, as a non-limiting example. A detailed view of piano hinges 172 is illustrated in FIG. 14 along line 14-14 of FIG. 13. Piano hinges 172 fixedly couple one side of face panel frames 36 to cabinet box 16, while a magnet coupling system 108 is used to couple the other side of face panel frames 36 to cabinet box 16. Such use of piano hinges 172 may be advantageous for use in commercial, high traffic environments where face panel frames 36 magnetically attached in the manner described with respect to FIGS. 1-9 may be inadvertently knocked off or removed by bar patrons. However, each reversible insert 38 may still be rotated or exchanged by decoupling magnet coupling system 108 and rotating face panel frame 36 away from cabinet box 16 to expose rear surface 102 and access tabs 96. Thus, bar cabinet assembly 170 is useful to a user who wants the flexibility of a changeable design with added security. In various embodiments, bar cabinet assembly 170 may also include the key locking assembly described above with respect to bar cabinet assembly 12 for additional security.

Referring now to FIG. 15, a bar cabinet assembly 192 is illustrated according to another embodiment of the invention. Bar cabinet assembly 192 includes a number of similar components as bar cabinet assembly 12 (FIG. 1), which are referenced herein with common part numbers as appropriate. However, as opposed to including face panel assemblies that are arranged side-by-side in the manner similar to face panel assemblies 28, 30, 32, 34 (FIG. 1) and that extend from upper countertop section 48 of bar cabinet assembly 192 to foot rail assembly 20, face panel assemblies 194, 196, 198, 200, 202, 204 of bar cabinet assembly 192 are stacked vertically such that top face panel assemblies 194, 200, center face panel assemblies 196, 202, and bottom face panel assemblies 198, 204 each occupy approximately a third of the space between upper countertop section 48 and foot rail assembly 20. Face panel assemblies 194, 196, 198, 200, 202, 204 have a similar construction as face panel assemblies 28, 30, 32, 34 and include removable and reversible inserts 206, 208 similar to inserts 38 of FIG. 1. Face panel assemblies 194, 196, 198, 200, 202, 204 are coupled to cabinet box 16 via magnets 112 in a similar manner as face panel assemblies 28, 30, 32, 34, although the number and or placement of magnets 112 may be adjusted to account for the different weight distribution of face panel assemblies 194, 198, 208.

Reversible inserts 206, 208 are provided having a first side or surface 214 with color design 42 and a second side or surface 216 with color design 186 that differs from color design 42. Face panel assemblies 194, 198, 200, 202 are showing color design 42, while face panel assemblies 196, 202 are showing color design 186. However, a user may display reversible inserts 206, 208 or another reversible insert (not shown). The face panel assembly arrangement of bar cabinet assembly 192 allows for even more flexibility for a user to change the appearance of bar cabinet assembly 192.

While bar cabinet assembly 12 (FIG. 1), bar cabinet assembly 170 (FIG. 13), and bar cabinet assembly 192 (FIG. 15) are shown with a single cabinet box 16, bar cabinet assemblies 12, 170, and 192 may also be constructed using a number of modular cabinet boxes such as modular corner cabinet box 218 and modular forward cabinet box 220 shown in FIGS. 16-17. Referring now to FIG. 16, modular corner cabinet box 218 includes an extended portion 222 having a top surface 224 and a base portion 226 having a top surface 228. Modular corner cabinet box 218 also includes two outer or outward-facing surfaces 230 including optional openings 232, embedded magnets 234 to which face panel assemblies, such as face panel assemblies 28, 30, 32, 34, could be coupled, and pin bodies 235, such as pin bodies 124. Modular corner cabinet box 218 further includes an inner surface 236 having an opening 238 therein and an inner surface 242 having opening 238 therein. Openings 232 of outer surfaces 230 and openings 238 of inner surfaces 236, 242 provide access to a cabinet 244 including a shelf 246. Face panel assemblies, such as face panel assemblies 28, 30, 32, 34, 174, 176, 178, 180, could be coupled to magnets 234 of outer surfaces 230 and any of inner surfaces 236, 242 that are exposed (in other words, not coupled to another inner surface 236, 242. Fasteners, such as screws and/or bolts (not shown), may be used to couple inner surfaces 242 and/or 236 of modular corner cabinet box 218 to a second modular corner cabinet box (not shown) to effectively form a larger cabinet box for a bar cabinet assembly, such as, for example, the bar cabinet assembly shown in FIG. 1.

Referring now to FIG. 17, modular forward cabinet box 220 includes an extended portion 250 having a top surface 252 and a base portion 254 having a top surface 256. Modular forward cabinet box 220 also includes one outer or outward-facing surface 230 including optional opening 232, embedded magnets 234 to which a face panel assembly, such as face panel assembly 28, 30, 32, 34, 174, 176, 178, 180, could be coupled, and pin bodies 235, such as pin bodies 124. Modular forward cabinet box 220 further includes inner surface 236 having opening 238 and inner surface 242 having opening 238. Modular forward cabinet box 220 additionally includes a rear surface 258 having an opening 260 providing access to a cabinet 262 including a shelf 264. In a manner similar to that described with respect to modular corner cabinet box 218, fasteners, such as screws and/or bolts (not shown), may be used to couple inner surfaces 236 and/or 242 of modular forward cabinet box 220 to a second modular forward cabinet box (not shown) or a first modular corner cabinet box (not shown) to effectively form a larger cabinet box for a bar cabinet assembly.

Therefore, modular corner cabinet boxes 218 and modular corner cabinet boxes 220 may be used in combination to quickly construct larger cabinet boxes of any desired size. Once a larger cabinet box (not shown) is constructed, an upper countertop section (not shown) may be mounted onto top surfaces 224, 252 of adjacent edge portions 222, 250, and a lower countertop section may be mounted onto top surfaces 228, 256 of adjacent base portions 226, 254. Panel assemblies, such as face panel assemblies 28, 30, 32, 34, door panel assemblies, and foot rails, such as foot rail assembly 20, may also be added to the larger cabinet box where appropriate to create a bar cabinet assembly, such as bar cabinet assemblies 12 (FIG. 1), 170 (FIG. 13), 192 (FIG. 15).

Referring now to FIG. 18, an L-shaped cabinet box 266 constructed from modular corner cabinet boxes 218 (FIG. 16) and modular forward cabinet boxes 220 (FIG. 17) is illustrated according to one embodiment of the invention. Cabinet box 266 is constructed so that inner surface 242 (FIG. 16) of a first modular corner cabinet box 268 is coupled to inner surface 236 (FIG. 17) of a first modular forward cabinet box 270, inner surface 242 (FIG. 17) of first modular forward cabinet box 270 is coupled to inner surface 236 (FIG. 16) of a second modular corner cabinet box 272, and inner surface 242 (FIG. 16) of modular corner cabinet box 272 is coupled to inner surface 236 (FIG. 17) of a second modular forward cabinet box 274. Outward-facing surfaces 230 (FIGS. 16-17) of coupled modular cabinet boxes 268, 270, 272, 274 are substantially aligned with each other so that cabinet box 266 includes a left outward-facing surface 276, a front outward-facing surface 278, and a right outward-facing surface 280.

Extended portions 222, 250, top surfaces 224, 252, base portions 226, 254, and top surfaces 228, 256 of modular cabinet boxes 268, 270, 272, 274 are also substantially aligned so that cabinet box 266 includes one extended portion 282 having one top surface 284 and one base portion 286 having one top surface 288. In addition, inner surface 236 (FIG. 16) of first modular corner cabinet box 268 is substantially aligned with rear surface 258 of first modular forward cabinet box 270 so that cabinet box 266 includes a first rear surface 290 and a second rear surface 292. While cabinet box 266 is shown as an L-shaped cabinet box having four modular cabinet boxes 268, 270, 272, 274, cabinet box 266 may be constructed using a different number of modular cabinet boxes 218, 220 and in different configurations, such as a U-shaped configuration and an I-shaped configuration, as non-limiting examples.

Beneficially, embodiments of the invention thus provide a bar cabinet assembly including face panel assemblies coupled to a cabinet box via a magnetic attachment system for quick and easy removal. The face panel assemblies include face panel frames with reversible inserts recessed therein that are visible through central openings in the face panel frames. The reversible inserts may be rotated between a first side having a first design and a second side opposite the first side and having a second design. The first design and the second design may differ significantly so as to provide a completely different appearance for the bar cabinet assembly. The face panel frames and the reversible inserts are also interchangeable with other face panel frames and reversible inserts of similar sizes and shapes. The bar cabinet assembly may further provide additional security features such as piano hinge coupling the face panel assemblies to the cabinet box and key lock mechanisms securing the face panel assemblies to the cabinet box.

Therefore, according to one embodiment of the invention, a face panel assembly for a cabinet includes a reversible insert with a forward surface having a first design thereon and a reverse surface opposite the forward surface. The reverse surface has a second design thereon different from the first design. The face panel assembly also includes a face panel frame having a central opening formed through a thickness thereof and a cavity formed in an inward-facing surface thereof, wherein the cavity extends around the central opening and is sized to receive the forward and reverse surfaces of the reversible insert so that, when the reversible insert sits within the cavity, one of the forward and reverse surfaces is visible through the central opening. The face panel assembly further includes a plurality of magnets coupled to the inward-facing surface of the face panel frame, the plurality of magnets configured to couple the face panel frame to a cabinet box. A thickness of the reversible insert is equal to or substantially equal to a depth of the cavity.

According to another embodiment of the invention, a cabinet assembly includes a cabinet box and at least one face panel assembly coupled to at least one outward-facing surface of the cabinet box. The at least one face panel assembly includes a face panel frame having an opening formed through a thickness thereof and a cavity formed through a thickness thereof and surrounding a perimeter of the opening. The at least one face panel assembly further includes a central insert sized to be received within the cavity of the face panel frame. The central insert includes a first surface having a first design and a second surface opposite the first surface and having a second design different from the first design. The cabinet assembly also includes a plurality of magnets coupling the at least one face panel assembly to the at least one outward-facing surface of the cabinet box. The central insert is reversible within the face panel frame so that either of the first and second surfaces may be shown through the opening of the face panel frame.

According to yet another embodiment of the invention, a method of manufacturing a cabinet assembly includes constructing a cabinet box. The method also includes constructing a face panel frame having an opening formed through a thickness thereof and a cavity formed through a thickness thereof and surrounding a perimeter of the opening. The method further includes positioning a central insert within the cavity of the face panel frame. The central insert includes a first surface having a first design and a second surface opposite the first surface and having a second design different from the first design, wherein the central insert is reversible within the face panel frame so that either of the first and second surfaces may be shown through the opening of the face panel frame. In addition, the method includes coupling the face panel frame to an outward-facing surface of the cabinet box via a plurality of magnets.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A face panel assembly for a cabinet comprising:

a reversible insert comprising: a forward surface having a first design thereon; and a reverse surface opposite the forward surface, the reverse surface having a second design thereon different from the first design;

a face panel frame having a central opening formed through a thickness thereof and a cavity formed in an inward-facing surface thereof, wherein the cavity extends around the central opening and is sized to receive the forward and reverse surfaces of the reversible insert so that, when the reversible insert sits within the cavity, one of the forward and reverse surfaces is visible through the central opening; and

a plurality of magnets coupled to the inward-facing surface of the face panel frame, the plurality of magnets configured to couple the face panel frame to a cabinet box.

2. The face panel assembly of claim 1 wherein the plurality of magnets are recessed within the inward-facing surface of the face panel frame.

3. The face panel assembly of claim 1 further comprising a plurality of tabs positioned around the cavity of the face panel frame, the plurality of tabs movable between a retaining position and a reversing position and positioned to engage the reversible insert.

4. The face panel assembly of claim 3 wherein the plurality of tabs are positioned within a plurality of recesses positioned around the cavity of the face panel frame and one of below and flush with the inward-facing surface of the face panel frame, the plurality of tabs coupled to the face panel frame within the recesses via a plurality of fasteners.

5. The face panel assembly of claim 3 wherein in the insert retaining position, the plurality of tabs are configured to retain the reversible insert within the cavity of the face panel frame; and

wherein in the insert reversing position, the plurality of tabs is configured to allow the reversible panel to be reversed.

6. The face panel assembly of claim 1 wherein the first design comprises a stained surface finish; and

wherein the reverse surface comprises a painted surface finish.

7. The face panel assembly of claim 1 wherein the first design comprises a first color scheme; and

wherein the second design comprises a second color scheme different from the first color scheme.

8. A cabinet assembly comprising:

a cabinet box;

at least one face panel assembly coupled to at least one outward-facing surface of the cabinet box, the at least one face panel assembly comprising: a face panel frame having an opening formed through a thickness thereof and a cavity formed through a thickness thereof and surrounding a perimeter of the opening; and a central insert sized to be received within the cavity of the face panel frame, the central insert comprising: a first surface having a first design; and a second surface opposite the first surface and having a second design different from the first design;

a plurality of magnets coupling the at least one face panel assembly to the at least one outward-facing surface of the cabinet box; and

wherein the central insert is reversible within the face panel frame so that either of the first and second surfaces may be shown through the opening of the face panel frame.

9. The cabinet assembly of claim 8 wherein the cabinet box further comprises an opening formed in the at least one outward-facing surface.

10. The cabinet assembly of claim 8 wherein the at least one face panel assembly is further coupled to the at least one outward-facing surface of the cabinet box with a piano hinge.

11. The cabinet assembly of claim 8 wherein the at least one face panel assembly further comprises a plurality of tabs positioned within a plurality of recesses around the cavity and rotatable between a closed position in which the plurality of tabs retain the central insert within the cavity of the face panel frame and an open position in which the central insert is removable from the face panel frame.

12. The cabinet assembly of claim 8 wherein the at least one face panel assembly comprises:

a first face panel assembly; and

a second face panel assembly;

wherein the first and second face panel assemblies are coupled to the same outward-facing surface of the cabinet box; and

wherein the each of the first and second face panel assemblies comprise:

a respective face panel frame having an opening formed through a thickness thereof and a cavity formed through a thickness thereof and surrounding a perimeter of the opening; and

a respective central insert sized to be received within the cavity of its respective face panel frame.

13. The cabinet assembly of claim 12 wherein first surfaces of the central inserts of the first and third face panel assemblies are visible through the openings of the face panel frames of the first and third face panel assemblies; and

wherein a second surface of the central insert of the face panel frame of the second face panel assembly is visible through the opening of the face panel frame of the second face panel assembly.

14. The cabinet assembly of claim 8 wherein the plurality of magnets comprises:

a first set of magnets recessed within an inward-facing surface of the face panel frame at least one face panel assembly; and

a second set of magnets recessed within the at least one outward-facing surface of the cabinet box for coupling to the first set of magnets.

15. The cabinet assembly of claim 8 further comprising a self-centering locating pin assembly comprising:

a pin body comprising: a base portion recessed within the at least one outward-facing surface of the cabinet box; and a stem portion extending outwardly from the base portion; and

a receiving body positioned within an inward-facing surface of face panel frame and sized to receive the stem portion; and

wherein, when the plurality of magnets couple the at least one face panel assembly to the at least one outward-facing surface of the cabinet box, the locating pin is received within the mating receptacle.

16. The cabinet assembly of claim 8 wherein the at least one outward-facing surface of the cabinet box comprises a first outward-facing surface and a second outward-facing surface substantially perpendicular to the first outward-facing surface; and

wherein the at least one face panel assembly comprises a first face panel assembly coupled to the first outward-facing surface and a second face panel assembly coupled to the second outward-facing surface.

17. A method of manufacturing a cabinet assembly comprising:

constructing a cabinet box;

constructing a face panel frame having an opening formed through a thickness thereof and a cavity formed through a thickness thereof and surrounding a perimeter of the opening;

positioning a central insert within the cavity of the face panel frame, the central insert comprising: a first surface having a first design; a second surface opposite the first surface and having a second design different from the first design; and wherein the central insert is reversible within the face panel frame so that either of the first and second surfaces may be shown through the opening of the face panel frame; and

coupling the face panel frame to an outward-facing surface of the cabinet box via a plurality of magnets.

18. The method of claim 17 further comprising:

embedding a first set of magnets of the plurality of magnets within the outward-facing surface of the cabinet box;

embedding a second set of magnets of the plurality of magnets within an inward-facing surface of the face panel frame; and

coupling the first set of magnets to the second set of magnets.

19. The method of claim 18 further comprising:

embedding a pin body within the outward-facing surface of the cabinet box;

embedding a receiving body within the inward-facing surface of the face panel frame; and

aligning the receiving body with the pin body so that the first set of magnets is aligned with the second set of magnets.

20. The method of claim 17 further comprising forming an opening in the outward-facing surface of the cabinet box, the opening positioned behind the face panel frame and central insert when the face panel frame is coupled to the outward-facing surface of the cabinet box.