OUTDOOR MODULAR KITCHEN ASSEMBLED FROM FLAT-PACKED COMPONENTS

Abstract

An outdoor kitchen modular assembly includes a plurality of kitchen modules formed from a plurality of components which can be flat-packed. The components include a generally planar pan serving as a base with structural components supporting the planar pan. The structural components include means to interconnect the module to an adjacent module.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application No. 63/450,760, filed on Mar. 8, 2023, the contents of which are incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to outdoor kitchens and, more particularly, to outdoor modular kitchen assemblies.

BACKGROUND OF THE INVENTION

The popularity of outdoor kitchens has increased significantly in recent years. Such outdoor kitchens often include an outdoor structure or “island” that is permanently or semi-permanently constructed of a variety of materials. These outdoor kitchens may include tabletop surfaces, gas burners, grills and other associated cooking surfaces. Some even include refrigerators for cold food storage, drawers and cabinets for the storage of utensils and other articles. Unfortunately, such permanently constructed outdoor kitchens are expensive and difficult and time-consuming to construct. In addition, it is impractical to move or alter a permanently constructed outdoor kitchen to suit changing needs or preferences.

Another way to build outdoor kitchens is to pre-fabricate custom cabinets. Labor costs can be lowered and flexibility can be increased by building custom cabinets in a factory. However, the costs for materials, storage and shipping assembly may increase dramatically. In addition, custom cabinets, whether pre-fabricated or built-to-order, generally contains many unique parts, driving up both complexity and cost including the cost of assembly, packaging and shipping. Furthermore, pre-fabricated custom cabinets provide far fewer choices for the end user in what can be assembled.

Pre-fabricated modules are large, and therefore stocking them in a store or warehouse is expensive; it requires a relatively large amount of storage space and also ties up capital in a relatively expensive product. Also, extensive protective packaging must be employed to protect the modules during shipping and handling.

There is a need to provide an outdoor kitchen assembly which can accommodate various configurations, be simple to inventory and ship and less costly to assembly.

SUMMARY OF THE INVENTION

The present invention is directed to an outdoor modular kitchen assembly which includes a plurality of kitchen modules interconnected from a plurality of components wherein the components are capable of being flat-packed delivered to the assembly location.

In a preferred embodiment, each module includes a pair of generally planar members forming an upper pan and a spaced apart lower pan. Four elongate corner posts each extend from the upper pan to the lower pan. Each corner of the upper pan and the lower pan includes a bendable tab and each post includes tab receiving slots for receiving said bendable tabs to secure the posts to the pans. Two posts of one of the modules is interconnected to two posts of another module to place the modules in a side-by-side adjacent array. Planar side pans are attached to the posts of the modules not interconnected to adjacent modules.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-6 are various renderings of an outdoor modular kitchen assembly of the present invention.

FIGS. 7-12 show the construction and arrangement of a typical module of the outdoor kitchen assembly of the present invention.

FIG. 13 shows an exploded view of one typical module.

FIGS. 14-26 and 28 show various arrangements of different modules of the kitchen module assembly of the present invention.

FIGS. 27 and 27A show a grill base (and grill) which can be formed from a pair of side-by-side left and right hand cabinets.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention relates to an outdoor kitchen assembly which may be formed from a plurality of individual assembled modules. The present invention provides for enhance flexibility and variety in the components that can be made from the components.

Each of the assembly modules can be assembled without the use of specialized tools or fasteners and therefore may be considered to be “tool-less”. Adjacent modules can be assembled together using standard hardware. The modules in the assembly can be formed on site or at another location other than the factory in which the components were manufactured.

The present invention therefore lowers freight and inventory costs as a wide variety of modules can be formed from similar components. Most, if not all, of the components are designed to be flat-packed, to be stored and shipped on standardize pallets. This allows the components to be more easily moved to a desired location and can be transported with smaller vehicles. Shipping the components of the modules in this matter uses less packing material, results in less waste and a reduced opportunity for damage during shipping and assembly. Moreover, the assembly may be reconfigurable as desired.

With reference to the drawings, a preferred embodiment of the present invention may now be described.

FIGS. 1-6 show a typical array forming an outdoor modular kitchen assembly 10. The assembly 10 is formed of a plurality of assembled kitchen modules generally denoted as 12. Each module 12 of the assembly 10 may take different configurations for differing purposes and uses. For discussion with regard to FIGS. 1-13, the generic module 12 will be described.

The configurations shown in FIGS. 1-6 are representative of the assembly 10 that can be formed using different arrangements and assembly of individual modules 12.

With additional references to FIGS. 7-11, construction and assembly of a typical module 12 may be described. Each module includes a pair of planar surfaces or pans 14 including an upper pan 14a and a lower pan 14b. The pans 14 are connected to a plurality of elongate vertically positioned posts 16. Each post 16 is constructed as an integrally formed pair of oppositely facing U-shaped channels 16a and 16b. One of the channels 16a is designed to interconnect the pans, shelves and drawers as will be described in further detail hereinbelow. The other channel 16b is designed to support a pair of side panels or to be interconnected to similar posts of an adjacent module as also will be described in further detail hereinbelow. The posts 16 serve to support the upper and lower pans as well as serve as support legs for each module.

As more fully shown in FIGS. 7 and 13, each module 12 may also include a plurality of adjustable legs 18 which are mounted to the lower pan 14b which allow for leveling and height adjustment.

Referring now to FIG. 11, the interconnection of the posts 16 to the pans 14a, 14b are shown. The pans 14 have at their respective corners an extending tab 20 shown in details A and B of FIG. 11. The tabs 20 are designed to be inserted into slots 22 which extend in a spaced apart manner along the channel 16a of post 16. As shown in detail B of FIG. 11, tab 20 of the lower pan 14b is inserted to the lower slot 22 of post 16 and the tab 20 of upper pan 14b is inserted into the upper slot 22 of post 16.

As shown in detail A of FIG. 11, the tab 20 is secured in the slot 22 by bending the tab downwardly within the slot. This secures the pan to the post. While a suitable tool may be used to facilitate bending the tab 20 in the slot 22, the attachment is essentially tool less.

In addition to the posts serving to secure the pans, the posts are also employed to secure one assembled module 12 to an adjacent module 12. In that regard, the U-shaped channel 16b of posts 16 include holes for affixing fastening hardware.

Referring to FIG. 12, two generally similar modules 12 are secured together in side-by-side relationship by using the U-shaped channels 16b of posts 16 to secure it to a similar location in the post 16b of an adjacent module 12. Any common fastener such as a screw 19 may be used for such securement. In this way, two modules 12 can be interconnected in forming the modular kitchen assembly 10 shown in FIGS. 1-6. It may be appreciated that additional modules 12 of different configurations may be sequentially added in this fashion.

Referring now to FIG. 13, an exploded view of the assembly of a module 12 is shown. In this configuration, module 12 includes upper pan 14a, lower pan 14b, two opposite side pans 14c and 14d, and back pan 14e which encloses the module on three sides. Suitable hardware may be used for such attachment in a manner similar to which the adjacent posts 16 are interconnected as described above. The side pans 14c, 14d and back pan 14e are optional. Side pans 14c are not needed on the sides where one module 12 is interconnected to another module 12. Back pan 14e is optional where the module is mounted against a wall. In addition, shown in FIG. 13, is the attachment of the leveling legs 18 to the bottom of the pan using appropriate hardware 18a. This embodiment also shows a section of decorative countertop 28, which is affixed to upper pan 14a.

In the configuration shown here, the front of the module 12 includes a door 24 which can be affixed to the front two posts 16 of the module 12 with suitable hinge hardware 24a. This module shown in FIG. 13 may also include a slidable drawer 26 which is attached within the module using slide drawer hardware 26a.

Having described the general construction and assembly of a typical module 12 of the present invention, details of various different configurations of modules may now be described.

Referring to FIGS. 14 and 15, the specific module type 12A is shown. 12A is hollow cabinet module having a hinged front door 24 extending from upper pan 14a to lower pan 14b attached in hinged fashion with hardware 24a. Side pans 14c, 14d are shown but, as mentioned above, these are optionable.

Referring to FIGS. 16 and 17, a cabinet module 12B is shown. This cabinet module also includes a front door 24 hinged to the post 16 and an upper drawer 26 accessible upon opening the door 24. Cabinet module 12B also shows a decorative countertop 28.

FIGS. 18 and 19 show a cabinet module 12C which is substantially similar to cabinet module 12B but includes a plurality of vertically spaced drawers 26 therealong. In this regard, the mounting of the drawers in vertical fashion within cabinet 12C is facilitated by the spaced apart slots 22 along the posts 16 (FIG. 11).

FIGS. 20 and 21 show cabinet module 12D which includes a lower hinged door 30 and a pair of upper exteriorly accessible decorative drawers 32. Mounting of the door 30 and drawers 32 may be achieved in similar fashion to that described above.

FIGS. 22 and 23 show a cabinet 12E which includes a hinged door 24, a slidable drawer 26 and a slidable platform 34 which may be used to mount a member such as a barbeque grill tank 36. The platform 34 may be slidably mounted with appropriate hardware 34a attached to the slots 22 of posts 16.

FIGS. 24 and 25 show a cabinet 12F similar to cabinet 12E having a slidable platform 38 which may accommodate a trash bin 29 or the like.

FIG. 26 shows a module cabinet 12G which may be used to house a beverage dispenser such a beer dispenser (not shown). It is similar to the above cabinet module 12F having a front door 24 and a decorative countertop 28a. However, the decorative countertop 28a may include an opening for a beer dispenser as well as accommodation for a drip receptacle.

FIG. 28 shows a cabinet module 12I which supports an inserted double sink 42. This cabinet module is substantially similar to the module described above with respect to modules 12A-12G, but is wider to accommodate the double sink. A configured countertop 28c is constructed to surround sink 42.

The present invention further contemplates forming a large grill base from a pair of left and right hand modules. These modules while similar to those described above are designed and constructed to be the left and right hand sides of a split grill base. The pair of left and right modules, when combined, are of sufficient size to accommodate an inserted grill which may be up to 62 inches wide.

Heretofore, a grill base of this dimension could not be accommodated in a single standard pallet, which necessitated a special size pallet for shipping increasing the cost and complexity of shipping.

The grill base 12H shown in FIGS. 27 and 27A is formed from two similar but oppositely constructed “half” bases, right base 12R and left base 12L. These bases are constructed in a manner similar to the modules described above, each having four posts 16 which support a planar pan 29, the front posts are shorter than the rear posts such that the planar pan 29 is supported and distanced spaced from the upper end.

The right and left bases 12 R and 12L are connected together in a similar fashion as two adjoining modules described above. When assembled in this manner, a recess 31 is formed into which the grill is inserted. A configured countertop 28b is used to surround the grill. Doors and side panels may be affixed as described in the above embodiment.

Lastly, referring to FIGS. 1-6, in order to provide for an angled arrangement of the assembly 12, corner modules may be provided. Corner modules 12J may be formed and attached in a similar fashion to the module described above.

While the preferred embodiment of the present invention includes corner posts serving as the structural components, it is contemplated that other structural components such as end panels may be employed to support pans of the module and to interconnect one module to the adjacent module.

The present invention therefore provides the ability to construct, arrange and assemble numerous configurations of an outdoor module kitchen assembly where most, if not all of, the components can be flat-packed using standardized pallets and can be assembled at a location other than the factory where the components are manufactured thereby increasing flexibility and reducing costs.

Various changes to the foregoing described and shown structures would now be evident to those skilled in the art. Accordingly, the particularly disclosed scope of the invention is set forth in the following claims.

Claims

1. An outdoor kitchen modular assembly including:

a plurality of kitchen modules being interconnectable, said assembly including: each said module being formed of a plurality of components capable of being flat-packed having: a generally planar pan serving as a base; structural components supporting the planar pan; wherein the structural components include means to interconnect said module to an adjacent module.

2. An outdoor kitchen modular assembly of claim 1 further including:

a pair of generally planar members forming an upper pan and a spaced apart lower pan;

four elongate corner posts forming the structural components each extending from the upper pan to the lower pan;

each corner of the upper pan and the lower pan including a bendable tab and each post including tab receiving slots for receiving said bendable tabs to secure the posts to the pans;

two posts of one of said modules being interconnected to two posts of another said module of said plurality to place said modules in a side-by-side adjacent array; and

a plurality of generally planar side pans; one said side pan being attached to said post of said modules not interconnected to said adjacent modules.

3. An outdoor kitchen modular assembly of claim 2 further including said posts of one module having said tab receiving slots at opposite ends of said post and wherein said upper pan forms a top pan and said lower surface forms a bottom pan.

4. An outdoor kitchen modular assembly of claim 2 further including said posts, one module having side tab receiving slots at an intermediate location along the length of said posts and to support a platform.

5. An outdoor modular kitchen assembly of claim 2 wherein the corner posts serve as support legs for each said module.

6. An outdoor modular kitchen of claim 2 wherein said plurality of components fit on a standard shipping pallet.

7. An outdoor modular kitchen of claim 1 further including side pans forming the structural components.

8. A grill base assembly for use with an outdoor modular kitchen assembly comprising:

a first grill base portion forming one half of the grill base assembly and a second grill base portion forming the other half of the grill base assembly, each grill base half portion including components which can be flat-packed on a standard pallet;

each grill base half portion being assembled from said flat-packed components;

the assembled grill base half portions being interconnected to form said grill base assembly for insertable accommodation of a grill.