CABINET ASSEMBLY

Abstract

A cabinet assembly includes a back panel, and first and second side panels mounted to the back panel. Each of the side panels have a front edge and a rear edge and each of the front edges define a channel. A securing device is attached to at least one of the back panel, the first side panel and the second side panel. A support bar is partially disposed in each of the channels of the side panels. The cabinet assembly further includes an end panel disposed about the support bar and engaging the securing device to mount the end panel to the back and side panels.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates, generally, to a cabinet assembly that requires minimal or no tools to be assembled.

2. Description of the Related Art

Cabinet assemblies known in the art generally include a back panel, side panels, and end panels coupled to a top and bottom. Cabinet assemblies may be hung on a wall, rest on a shelf, rest on a floor surface, or be otherwise supported. When the cabinet assembly is supported on a floor surface, the cabinet assembly generally includes a support assembly coupled to the base to space the base from the floor surface.

Typically, configurations of cabinet assemblies are assembled with threaded fasteners or similar. Fasteners simplify the design of the cabinet and may be replaced by a user. In order to assemble the cabinet, a tool such as a screwdriver, wrench, or drill may be necessary to tighten the threaded fasteners.

Cabinets that can be assembled or disassembled with minimal tools or without the use of tools are also available in the art. To accomplish this, a cabinet is assembled by interlocking certain panels.

While cabinet assemblies known in the prior art may have utilized interlocking panels, there remains a need in the art for an improved cabinet assembly that is less expensive to manufacture and easier to assemble.

SUMMARY OF THE INVENTION AND ADVANTAGES

One embodiment of a cabinet assembly is provided. The cabinet assembly comprises a back panel having an end edge and opposing side edges. The cabinet assembly includes first and second side panels, each of the side panels have a front edge and a rear edge and each of the front edges define a channel. The rear edge of the first panel is mounted to one of the side edges of the back panel, and the rear edge of the second panel is mounted to the opposing side edge of the back panel. The cabinet assembly further includes a securing device coupled to at least one of the back and side panels. A support bar is disposed in each of the channels in the side panels. An end panel is disposed about the support bar and engages the securing device to mount the end panel to the back and side panels.

A method for assembling a cabinet is provided. The method includes a step of partially inserting the support bar into the channel of each side panel to define a first assembly position. The method further includes a step of arranging the end panel to partially overlap the support bar. Additionally, the method includes a step of simultaneously engaging the end panel with the securing device to mount the end panel to the back and side panels, and moving the support bar from the first assembly position to a second assembly position with the support bar inserted further into the channel of each side panel.

The assembly overcomes the disadvantages in the related art in a cabinet assembly configured to be assembled or disassembled without using tools or using only minimal tools. In this way, the cabinet assembly of the present invention provides improved functionality and usability and, at the same time, reduces the time and effort required to assemble the cabinet assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

FIG. 1 is a perspective view of a cabinet assembly.

FIG. 2 is a perspective view of a back panel for the cabinet assembly of FIG. 1.

FIG. 3 is a perspective view of the back panel and a first side panel for the cabinet assembly of FIG. 1.

FIG. 4 is a perspective view of back and side panels for the cabinet assembly of FIG. 1.

FIG. 5 is a perspective view of a back and side panels and a support bar for the cabinet assembly shown in FIG. 1.

FIG. 6 is a perspective view of the cabinet assembly of FIG. 4 showing the support bar in a first assembly position.

FIG. 7 is a perspective view of the cabinet assembly showing the support bar in the first assembly position and an end panel.

FIG. 8 is a perspective view of the cabinet assembly of FIG. 6 showing the end panel abutting the back and side panels and engaged with a securing device.

FIG. 8A is an enlarged perspective view of the cabinet assembly of FIG. 8 showing the securing device.

FIG. 9A is a cross-sectional view of the cabinet assembly of FIG. 8 taken along line 9A.

FIG. 9B is a cross-sectional view of the cabinet assembly of FIG. 8 taken along line 9B.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the Figures, wherein like numerals indicate like parts throughout the several views, a cabinet assembly 10 is generally shown in FIG. 1. Generally, the cabinet assembly 10 includes a back panel 12 and side panels 14, 16 secured to the back panel 12. The cabinet assembly 10 additionally includes an end panel 18 mounted to the back and side panels 12, 14, 16 defining an interior 20. The cabinet assembly 10 may additionally include shelves 22 or drawers disposed within the interior 20 and coupled to one of the back panels 12, and side panels 14, 16. As such, the cabinet assembly 10 may be an enclosed cabinet, such as shown, an open cabinet or book shelf without doors, a cabinet with drawers, a cabinet with doors, a cabinet with a combination of drawers and doors, or a cabinet as a sub-component of a desk. The back panel 12 may comprise one panel or a plurality of panels coupled to each other. The cabinet assembly 10 may further include doors 24 coupled to the side panels 14, 16 to close off the interior 20 from the surrounding environment. Alternatively, the interior 20 may be open to the surrounding environment for easy access. The cabinet assembly 10 may be comprised of a solid material such as metal, plastic, or wood, and may be of any suitable configuration.

The cabinet assembly 10 further includes a support bar 26. When fully assembled, the support bar 26 is disposed within the end panel 18 and the side panels 14, 16. The end panel 18 and the support bar 26 may be at either a top or a bottom of the cabinet assembly 10. The cabinet assembly 10 may also include a second end panel and a second support bar, wherein each end panel 18 is mounted to a support bar 26 on opposite ends of the cabinet assembly 10.

As shown in FIGS. 2-6, the back panel 12 has an end edge 28 and opposing side edges 30, 32. The end edge 28 may be located at a top or bottom of the back panel 12. In an exemplary embodiment, the back panel 12 is further defined as a first back panel and a second back panel, each having four sides. The first back panel includes a tab 34 and the second back panel includes a slot 36. The first back panel is planarly coupled to the second back panel along one side by engaging the tab 34 and the slot 36.

As shown in FIGS. 3 and 4, the side panels 14, 16 each have a front edge 38 and a rear edge 40. The side panels 14, 16 additionally have a top and a bottom. The rear edge 40 of the side panels 14, 16 includes one of either a tab 42 or a slot 44. The tab 42 and slot 44 of the side panels 14, 16 engage with the other of the tab 34 and slot 36 on the back panel 12 to couple the side panels 14, 16 to the back panel 12.

Referring to FIG. 8A, the cabinet assembly may further include a snap clip 76 and a snap slot 78 on edges of the back panels 12 and side panels 14, 16. The snap clip 76 is springably engaged with the snap slot 78 when adjacent panels are coupled. The snap clips 76 prevent the tabs 34, 42 from disengaging with the respective slot 36, 44 during assembly. For example, the first back panel includes two snap clips 76 and the second back panel includes two snap slots 78. During assembly the tabs 34 engage the slots 36 by hooking the tabs 34 into the slots 36. When the tabs 34 are hooked to the slots 36 the snap clips 76 engage the snap slots 78, securing the first back panel to the second back panel.

Each side panel 14, 16 further defines a channel 46, 48. The channels 46, 48 are along the front edge 38 of the side panels 14, 16. The channels 46, 48 are generally square and extend from the top to the bottom of the side panels 14, 16. The channels 46, 48 are open to the top and bottom to receive the support bar 26. Additionally, a notch 49 is defined at the top of each channel. The notch 49 provides clearance for the support bar 26 when fully assembled.

Shown in FIGS. 2-8, and 9A the cabinet assembly 10 further includes a securing device 50. The securing device 50 has a top and bottom. The bottom of the securing device 50 is attached to one of the back and side panels 12, 14, 16. The securing device 50 may be attached to the back or side panels 12, 14, 16 by riveting, welding or other suitable attachment methods. The top of the securing device 50 is bent to define a chamfered opening to a cavity defined between the securing device 50 and the back panel 12. The securing device 50 may be of any suitable length such that the securing device 50 substantially extends from the first side edge 30 to the second side edge 32.

The securing device 50 may be further defined as a plurality of securing devices, with one of the securing devices attached to each of the back and side panels 12, 14, 16. The securing device 50 is sprung against the back and side panels 12, 14, 16 to create a clamp force. The clamp force holds the end panel 18 in engagement with the back and side panels 12, 14, 16.

Shown in FIGS. 5-7, the support bar 26 is defined by a cross-member 52 having a first leg 54 coupled to one end and a second leg 56 coupled to an opposing end of the cross-member 52. The cross-member 52 is elongated with a generally U-shaped profile; however, the cross member can have other profile shapes. The legs 54, 56 are coupled to the ends of the cross-member 52 at a right angle. The legs 54, 56 are elongated with a generally U-shaped profile; however, the legs 54, 56 can have other profile shapes. The legs 54, 56 have a width that is smaller than the channels 46, 48 in the side panels 14, 16 such that the legs 54, 56 are disposed in the channels 46, 48.

The support bar 26 defines a first assembly position as shown in FIG. 6. In the first assembly position, the support bar 26 is partially disposed in each of the channels 46, 48. The first leg 54 of the support bar 26 is disposed in the channel 46 of the first side panel 14. The second leg 56 of the support bar 26 is disposed in the channel 48 of the second side panel 16. The legs 54, 56 are part-way inserted into the channels 46, 48 to define the first assembly position. In the first assembly position, the cross-member 52 is spaced from the side panels 14, 16, further discussed below.

The support bar 26 additionally defines a second assembly position. The cabinet assembly 10 is shown in FIGS. 9A and 9B with the support bar 26 in the second assembly position. In the second assembly position, the support bar 26 is fully disposed in each of the channels 46, 48. In the second assembly position, the legs 54, 56 are fully inserted into the channels 46, 48 until the cross-member 52 contacts the side panels 14, 16 and is in the notch 49.

Shown in FIGS. 8 and 8A, the end panel 18 abuts the back and side panels 12, 14, 16. The end panel 18 engages the securing device 50 when the end panel 18 is mounted to the back and side panels 12, 14, 16.

As shown in FIGS. 8 and 8A, the end panel 18 further includes at least one flange 58, 60, 62 extending from the end panel 18. The flanges 58, 60, 62 generally extend from edges of the end panel 18. In an exemplary embodiment, the end panel 18 is formed from a metal sheet and the flanges 58, 60, 62 are bent edges of the end panel 18. The flanges are further defined as a first flange 58, a second flange 60, and a rear flange 62. The first and second flanges 58, 60 abut the first and second side panels 14, 16 respectively. The rear flange 62 abuts the back panel 12. The flanges 58, 60, 62 engage the securing device 50 when the end panel 18 is mounted to the back and side panels 12, 14, 16. To engage the securing device 50, the flanges 58, 60, 62 are disposed between the securing device 50 and one of the back and side panels 12, 14, 16.

Shown in FIGS. 8A and 9A, each flange 58, 60, 62 may further include a hook portion 64. The hook portion 64 is angled away from each flange 58, 60, 62 to create a barb. The hook portion 64 is configured to retain the flanges 58, 60, 62 in the securing device 50. The hook portion 64 is trapped in the cavity defined by the securing device 50 to retain the end panel 18 to the side panels 14, 16 and thereby the support bar 26. The flanges 58, 60, 62 engage a majority of the length of the securing device 50 to increase engagement of the end panel 18 and the back and side panels 12, 14, 16.

Shown in FIG. 9A, the end panel defines a front pocket 66. The front pocket 66 is disposed about the support bar 26 when the end panel 18 is mounted to the back and side panels 12, 14, 16. The front pocket 66 is generally U-shaped to receive the support bar 26 when the end panel 18 is mounted to the back and side panels 12, 14, 16. The front pocket 66 opens toward the interior 20 of the cabinet assembly 10 and faces the back panel 12. A front wall 70 extends from the end panel 18 and has a lower wall 72 extending therefrom. The front wall 70 and the lower wall 72 form the front pocket 66. The lower wall 72 may further include a stop wall 74. The stop wall 74 extends from the lower wall 72 away from the end panel 18. The stop wall provides support for doors that may be fitted to the cabinet assembly 10. The front pocket 66 has a width larger than the cross member 52 such that the support bar 26 is disposed in the front pocket 66.

Shown in FIGS. 7 and 9B, the end panel 18 further defines two notches 68 in the front pocket 66. The notches 68 provide clearance for the legs 54, 56 when the support bar 26 is received in the front pocket 66. The notches 68 are located on opposing ends of the front pocket 66 and allow the legs 54, 56 to extend downward out of the front pocket 66.

A method for assembling the cabinet assembly 10 includes a step of coupling each of the side panels 14, 16 to the back panel 12. The rear edges 40 of the side panels 14, 16 are aligned with the back panel 12 and the tab 42 or slot 44 of each side panel 14, 16 is inserted into the other of the tab 34 or slot 36 on the back panel 12. The side panels 14, 16 are generally coupled perpendicular to the back panel 12.

Following the step of coupling the side panels 14, 16 to the back panel 12, the side panels 14, 16 are aligned in a substantially parallel position. During assembly, parts of the cabinet assembly 10 may be misaligned prohibiting further assembly of the cabinet assembly 10. Aligning the side panels 14, 16 parallel to each other and perpendicular to the back panel 12 allows the cabinet assembly 10 to be assembled completely. The steps of coupling the back and side panels 12, 14, 16 may be performed differently, and even using tools without deviating from the scope of the invention.

The method for assembling the cabinet assembly 10 includes a step of partially inserting the support bar 26 into the channel 46, 48 of each side panel 14, 16. The support bar 26 is inserted into the first assembly position and is spaced from the side panels 14, 16.

The method further includes the step of arranging the end panel 18 to partially overlap the support bar 26. The end panel 18 is placed over the support bar 26 with the cross member 52 aligned with the front pocket 66. The end panel 18 is slid towards the back panel 18 to nest the support bar 26 in the front pocket 66. The end panel 18 overlaps the support bar 26 such that the support bar 26 is disposed in the front pocket 66.

To mount the end panel 18 to the back and side panels 12, 14, 16, the end panel 18 simultaneously engages the securing device 50 and the support bar 26 is moved from the first assembly position into the second assembly position. The end panel 18 is moved nearer to the side panels 14, 16 forcing the cross member 26 and therefore the legs 54, 56 further into the channels 46, 48. In the second assembly position the legs 54, 56 of the support bar 26 are inserted into the channel 46, 48 of each side panel 14, 16 further than in the first assembly position.

The method further includes a step of simultaneously generating a feedback signal when the end panel 18 is engaged with the back and side panels 12, 14, 16. The securing device 50 generates the feedback signal to indicate that the hook portion 64 of the flange 58, 60, 62 is properly engaged with the securing device 50. As the end panel 18 engages the securing device 50, the hook portion 64 biases the securing device 50 away from the side panel 14, 16. When the hook portion 64 is fully engaged, the securing device 50 rapidly snaps against the side panel 14, 16 generating the feedback signal. The feedback signal may be an audible signal, such as a click indicating the end panel 18 is engaged with the back and side panels 12, 14, 16.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.

Claims

1. A cabinet comprising:

a back panel having an end edge and opposing side edges;

first and second side panels with each of said side panels having a front edge and a rear edge and with each of said front edges defining a channel, said rear edge of said first side panel being mounted to one of said side edges of said back panel, and said rear edge of said second side panel being mounted to the opposing side edge of said back panel;

a securing device attached to at least one of said back panel, said first side panel and said second side panel;

a support bar partially disposed in each of said channels of said side panels with said support bar defining a cross-member having a first leg coupled to one end and a second leg coupled to an opposing end of said cross-member, said first leg being disposed in said channel of said first side panel and said second leg being disposed in said channel of said second side panel; and

an end panel disposed about said cross member, said end panel including a flange with said flange abutting both said securing device to mount and at least one of said back and side panels as said end panel is mounted to said back and side panels.

2. (canceled)

3. The cabinet as set forth in claim 1, wherein said first and second legs are partially seated in said channels of said side panels in a first assembly position and said first and second legs are fully seated in said channels of said side panels when said end panel is mounted to said back and side panels.

4. The cabinet as set forth in claim 1, wherein said securing device is further defined as a plurality of securing devices with one of said securing devices attached to said back and side panels.

5. (canceled)

6. The cabinet as set forth in claim 1, wherein said end panel abuts said back and side panels and said flange is disposed between said securing device and one of said back and side panels when said end panel is mounted to said back and side panels.

7. The cabinet as set forth in claim 1, wherein said flange is further defined as at least a first flange, a second flange, and a rear flange with said first flange of said end panel abutting said first side panel, said second flange of said end panel abutting said second side panel and said rear flange of said end panel abutting said back panel when said end panel is mounted to said back and side panels.

8. The cabinet as set forth in claim 1, wherein said flange includes a hook portion.

9. The cabinet as set forth in claim 1, wherein said end panel defines a front pocket with said front pocket disposed about said support bar when said end panel is mounted to said back and side panels.

10. The cabinet as set forth in claim 9, wherein said front pocket is U shaped to receive said support bar when said end panel is mounted to said back and side panels.

11. The cabinet as set forth in claim 10, wherein said end panel defines two notches in said front pocket with said notches receiving said support bar when said end panel is mounted to said back and side panels.

12. The cabinet as set forth in claim 1, wherein each of said back and side panels have a top and a bottom and wherein said end panel is further defined as a top panel and a bottom panel.

13. The cabinet as set forth in claim 1, wherein said back panel is further defined as at least a first back panel having four sides and a second back panel having four sides wherein one side of said first back panel is planarly coupled to one side of said second back panel.

14. The cabinet as set forth in claim 1, wherein at least one of said first side panel and said second side panel includes either of a tab and a slot and wherein said back panel includes another of a tab and a slot, said tab engaging said slot to couple said first side panel and said second side panel to said back panel.

15. A method for assembling a cabinet, the cabinet comprising a back panel, first and second side panels each including a front edge defining a channel, a securing device attached to at least one of the back and side panels, a support bar having a cross-member and first and second legs, and an end panel, said method comprising the steps of:

partially inserting the first leg of the support bar into the channel of the first side panel and the second leg of the support bar into the channel of the second side panel to define a first assembly position;

sliding the end panel to at least partially overlap the cross-member of the support bar toward the back panel when the support bar is in the first assembly position;

simultaneously engaging the end panel with the securing device to mount the end panel to the back and side panels, and moving the support bar from the first assembly position to a second assembly position with the support bar inserted further into the channel of each side panel.

16. (canceled)

17. The method according to claim 15, further including the step of coupling each of the side panels to the back panel prior to inserting the support bar into the channel of each side panel.

18. The method according to claim 15, further including a step of aligning the side panels in a substantially parallel position prior to inserting the support bar into the channels of each side panel.

19. The method according to claim 15, further including a step of simultaneously generating a feedback signal when the end panel is engaged with the back and side panels.

20. The method according to claim 19, wherein the step of simultaneously generating a feedback signal is further defined as a step of simultaneously generating an audible signal when the end panel is engaged with the back and side panels.

21. The method according to claim 15, wherein the end panel includes a flange, and wherein the step of simultaneously engaging is further defined as simultaneously engaging the flange with the securing device with the flange being disposed between and abutting the securing device and at least one of the back and side panels as the end panel is mounted to the back and side panels.