It is particularly adapted to cabinets used in kitchens, but may also be utilized for cabinets elsewhere.

Many methods, and many materials of construction, have been proposed and used for the construction of kitchen cabinets. A common practice at present is to nail or screw and/or glue together modular components to assemble cupboard carcasses from chipboard or medium density fibre-board and then transport the carcasses into their final position before affixing the bench-top and cupboard doors.

A major problem with the above cupboards is the propensity of chipboard and MDF board to swell, warp and fail at high humidity levels and particularly if exposed to dampness from a water leak or water vapour from a dishwasher. A further problem is that of the dust produced when sawing, routing and drilling chipboard and MDF materials. Another problem is the time, and therefore cost, involved in having each panel accurately cut to size, machined, notched, drilled, etc. in order for it to fit correctly and to provide for all the door, drawer and shelf fittings required of it. There is also a substantial cost in transportation when cupboard carcasses are constructed before being carried by vehicle to their place of installation.

Many kit type cupboard systems have been proposed which rely upon one or two standard widths of carcass modules which are erected side by side. These suffer the severe limitation that most places where such cupboards are required are not exactly multiples of the modular widths and some potential cupboard space is lost. It would be desirable to have the benefits of a modular system without the limitations of fixed modular widths.

An aim of the present invention is to provide a system of cabinet construction which overcomes these difficulties.

Accordingly, in one aspect the invention provides a method of manufacturing a row of cupboards comprising: (i) moulding from plastics material a side panel having a non-constant cross section; (ii) moulding from plastics material a plurality of elongate spine members; and (iii) manually press-fitting said side panels to each of said spine members such that said side panels are prevented from sliding along the spine members.

In another aspect the invention provides a row of cupboards comprising three or more side panels moulded to have a non-constant cross section, and a plurality of elongate spine members moulded from plastics material, wherein each said spine member is press fitted onto each said side panel and is interlocked with said side panels such that said side panels are prevented from sliding along the spine members.

Preferably the elongate spine members have a cross-section which varies but repeats at less than 10mm intervals along its length. The spine members preferably extend across the top front and top rear of the cupboards.

One of the spine members may extend across the bottom front of the cupboards. One of the spine members may extend across the bottom rear of the cupboards. The bottoms of the side panels may be prevented from moving relative to each other by press fitting into engagement with them a bottom panel which extends between two adjacent side panels and forms the inside floor of the cupboard.

Brief Description of the Drawings In order that the invention may be more fully understood there will now be described, by way of example only, preferred embodiments and other elements of the invention with reference to the accompanying drawings where:

Figure 1 is an exploded view of parts of a cabinet carcass which would produce three cupboards manufactured in accordance with a first embodiment of the invention; Figure 2 is detail view showing parts of some components from Figure 1; Figure 3 is an exploded view of parts of a cabinet carcass manufactured in accordance with a second embodiment of the invention; Figure 4 is an end view of one of the components in Figure 3; Figure 5 is an exploded view of parts of a cabinet carcass manufactured in accordance with a third embodiment of the invention; Figure 6 is a detail showing the means of inter-engagement between the two components shown in Figure 5; Figure 7 is an exploded view of parts of a cabinet carcass manufactured in accordance with a fourth embodiment of the invention; Figure 8 is an exploded view of parts of a cabinet carcass manufactured in accordance with a fifth embodiment of the invention; Figure 9 is a detail showing an exploded view of part of the embodiment illustrated in Figure 8; Figure 10 is a view showing a manner by which shelves may be held in cupboards according to any of the above embodiments; Figure 11 is a diagrammatic view showing a manner by which the back of cupboards may be affixed; Figure 12 shows a manner in which a drawer runner may be moulded into the side walls of a cabinet according to the present invention; Figure 13 is a diagrammatic view illustrating manufacture of a cabinet carcass in accordance with a sixth embodiment of the invention; Figure 14 is a detail of part of Figure 13; Figure 15 is a detail showing an alternative to components shown in Figure 14; Figure 16 is an exploded view of parts of a cabinet carcass manufactured in accordance with a seventh embodiment of the invention; Figure 17 and 18 are further views of parts of the cabinet carcass in accordance with the seventh embodiment;

Figure 19 is an exploded view of parts of a carcass of a row of cabinets manufactured in accordance with an eighth embodiment of the invention; Figure 20 is a detail view of part of the carcass shown in Figure 19; Figure 21 is an exploded view showing further components of a cabinet manufactured in accordance with the eighth embodiment of the invention; and Figure 22 is a detail view of part of the carcass shown in Figure 21.

Detailed Description of the Invention For clarity of illustration, and in order to better emphasize the basic concepts of the invention, Figure 1 has been drawn omitting many of the features described in the following descriptions.

Referring to Figures 1 and 2, the carcass 2 of a cabinet having a row of three kitchen cupboards has four side panels 4 to 7, a top front rail 10, top rear rail 11 and a plinth 9. The rails 10 and 11 and the plinth 9 all have an elongate shape and are structural members of the carcass. The panels 4 to 7 each have a laterally extended foot portion 12 to 15. Panels 4 and 7 are end panels and their foot portions 12 and 15 extend to only one side of the panel. Panels 5 and 6 are intermediate side panels and their foot portions 13 and 14 extend from both sides.

Panels 4 to 7 are moulded complete with their foot portions 12 to 15 and detailing on its upper corner. Figure 2 shows a detail of the top front corner of side panel 4 and a cutaway view of the top front rail 10. The top front corner of the panel has a vertically extending channel 18 let into the top edge 19 of the panel 4 and has horizontally extending channel 20 let into the vertical edge 21. The horizontal channel 20 has an upturned groove 22 at its end. The channels 18 and 20 and groove 22 define on the panel a residual key portion 24 at the corner of the panel.

The rail 10 has the general form of an angle section with each flange of the angle itself carrying smaller, inwardly directed flanges 27 and 28 at its end. The backwardly directed flange 28 carries a lip 29 along its length.

The rail 10 is more flexible than the panel 4 and its flanges 27 and 28 may be bent to embrace the key 24, with the flanges clicking into channels 18 and 20 respectively.

The lip 29 engages with the groove 22 to help resist removal of the key from the hollow in the rail.

The vertical edge face 34 of the key 24 carries a vertically aligned V-shaped ridge 35 which engages with one of the mating V-shaped grooves 37 formed on the inside vertical face 38 of the rail 10. The inter-engagement of ridge 35 with grooves 37 prevents the key 24 sliding within the channel of the rail 10. The grooves 37 in the illustrated embodiment are spaced at about 4mm centres, but this could be reduced to 2mm or even down to 0.5mm centres to provide a fine adjustment for the width of each cupboard. Alternatively the grooves 37 could be spaced at up to 10mm centres if such fine adjustment was not required.

Figures 3 and 4 illustrate one means of joining the plinth member to the side panel.

Panel 52 has a foot portion 50 having a front vertical face 51 to which the plinth 55 attaches. The attachment is by means of two ridges 53, having enlarged heads, extending horizontally along the face 51 and two corresponding lipped channels 57 on the rear face of the plinth 55 into which the ridges 53 clip. The panel 49 is also provided with two feet 58 with adjustable height.

Figures 5 and 6 illustrate a preferred means of joining the plinth member when compared with that described above with reference to Figures 3 and 4. Panel 62 has a foot portion 60 having a front vertical face 61 on which the plinth 65 attaches. The attachment is by means of vertical beadings 63 vertically aligned along the face 61 and corresponding lipped channels 67 on the rear face of the plinth 65 into which the beadings clip.

A further alternative is shown in Figure 7 where the foot 70 of the side panel 72 has a downwardly directed tongue 71 which engages into a groove 77 in plinth 75. The face 78 of the tongue 71 carries a fine saw-tooth pattern 79, which engages with the

corresponding inner surface (not shown) of the groove 77. That inner surface may be grooved or smooth.

Referring to Figures 8 and 9, the foot 80 of a side panel 82 is positioned relative to the foot of an adjacent side panel (not shown) by means of a base panel 84 extending therebetween. Two locking inserts 83 nest into recesses on each side of each foot 80.

The inserts 83 are located by serrations 87 on the insert engaging with serrations 88 on the walls of the recesses. Two pins 85 on the upper side of each insert 83 engage into blind holes 86 let into the full length of the underside of the panel 84. Figure 8 shows (in phantom) only some of these holes for ease of illustration. The large centre to centre pitch of the holes 86 in combination with the fine pitch of the serrations 87 and 88 allows a fine adjustability of cupboard width while still retaining a fully pinned location.

Figure 10 shows the way in which a moulded shelf panel 94 may clip onto pins 96 moulded onto the side panel 92. The relatively tight tolerances possible by use of a moulding for the side panel 92 and a moulding or extrusion for the shelf panel 94 means that the shelf may be positively restrained against upward movement, by the pins 96 engaging behind the curled back edge 98 at the front and rear.

Figure 11 illustrates how a back panel 104 attaches to a side panel 102. The back panel 104 is a simple flat panel which slides down a slot 106 on the side panel on each side. The structure in the top corner is constructed so that the top rear rail (not shown) may be clipped into a vertical channel 108 and a horizontal channel 110 in the manner described with reference to Figure 2 and thereby preventing return movement of the back panel 104 up the slot 106. The back panels in each cupboard provide substantial rigidity to the cabinet structure.

Figure 12 illustrates a drawer runner moulded into a side panel 112. The drawer rolls on wheels fixed to the drawer and one such wheel 113 is shown in Figure 12. The runner comprises a channel 114 with a horizontal upper face 115. The lower face 116 has a main horizontal run 117 over most of its length, a hump 118 towards the front to

restrict the drawer from pulling fully out, and a ramped portion 119 at the rear to cause the drawer to pull itself shut from a near shut position.

Referring to Figures 13 and 14, the three components shown are fitted together in the directions indicated by the broad arrows. The base panel 126 is engaged with the foot 126 of the side panel 124 by way of three of the spade-like projections 130 on the underside of the base panel being pressed into three elongated slots 132 let into the upper surface of the foot 126. A slight tapering of the faces on both projections 130 and slots 132 ensures a firm fit. The foot 126 also carries leveling feet 134 with which to adjust the side panel on sloping or uneven flooring; such leveling arrangements will be known to the skilled addressee. A back panel 136 slides down with its edge in a slot 137 moulded in the side panel until it rests on the main upper face of the base panel 128. An upwardly directed lip 138 rises behind the bottom of the back panel.

In its assembled form, two rails across the top of the cabinet form elongate spine members joined to each of the side panels in the cabinet. Only one of these rails is shown in Figure 13; this is top front rail 140. An identical top rear rail is used at the back of the cabinet (similar to the equivalent rails 10 and 11 in Figure 1) but this is not shown in Figure 13. However the rails in the embodiment of Figure 13 are different to those in Figure 1. Rail 140 has a symmetrical C-shaped cross section with two internal serrated faces 146 and 147.

Side panel 124 has moulded onto its top front corner a generally diamond shaped key 142 protruding on a cylindrical neck 145 from a rebate in the vertical edge 143. The top and bottom of the key carry serrated sections 150 and 151 sized to engage with the serrated faces 146 and 147 inside the rail. The mating serrations of face 146 and section 150 are not necessarily of the same pitch, but one is preferably an integral multiple of the other in order to mesh most effectively. A similar key 141 is moulded at the top rear of the side panel to engage the top rear rail.

To attach the side panel 124 to the rail 140, the rail is slid over the key at 45° to the vertical edge 143 so that the lips 154 and 155 on the C-section rail slide behind the key, with the neck 145 of the key passing through the gap 148 in the C-section. When the appropriate position is reached and both front and rear rails are in place, the rail is rotated through 45° and the serrations are engaged so preventing movement of the side panel longitudinally of the rails. The top rear rail then also blocks movement of the back panel 136 in the slots 137.

Figure 15 shows an alternative configuration of the key portion 163 at the top of a side panel 161. In this configuration, the key has a single sharp ridge 165 and 166 on its top and bottom instead of an array of serrations. The ridges 165 and 166 are concave on one flank and flat on the other flank to better feed them into the serrations on the rail during installation.

Referring to Figures 16 and 17, keys 174 on each side panel 172 engage with a top front rail and top rear rail (not shown) generally as described with reference to Figure 2. The bottoms of the side panels 172 in a row of cupboards are located relative to each other by means of being locked to a base panel 180 which spans between the feet of adjacent side panels 172. Moulded into the upper surface of the foot 170 on each side of the side panel are a pair of channel-shaped recesses 176 at right angles to the plane of the panel 172. The channels 176 carry vertical serrations 178 on their side walls so that each serration extends at right angles to the spine members. The base panel 180 carries, on its underside, broad ribs 182 which carry serrations 184 on their sides. In use the lower shelf panel 180 is pressed down (as shown by arrows 204 and 205) onto the foot 170 of the side panel so that the ribs 182 press into the recesses 176 while the faces carrying serrations 178 and 184 neatly interengage to prevent the panel 180 slipping horizontally from its engagement with the foot 170. A pitch of about 1 to 2mm for the serrations 178 and 184 allows a fine adjustability of cupboard width while still retaining a fully pinned location.

It is not necessary to provide serrations on both vertical faces of each channel 176 and rib 182 in order to ensure positive location between the side panel 172 and base panel

180. The base panel 180 in the embodiment shown in Figures 16 and 17 has serrations on only the inboard vertical faces 183 and 185, while the outboard vertical faces 179 and 181 are smooth. The engaging faces in the channels 176 are correspondingly serrated on the inboard faces 177 and smooth on the outboard faces 175.

Engagement of the lower shelf panel 180 onto the feet of the side panels in this way means the lower shelf panel becomes a structural member and a continuous spine member is not required at the bottom of the cupboards for structural purposes.

However a plinth (not shown) may be affixed to the row of cupboards by attachment to the front face 210 of the foot.

It can be seen that the material for base panel 180 may be formed as a continuous length from which appropriate individual shelf lengths would be cut as required. The upper shelf panel 186 is identical to the base panel 180 and engages with a cleat 188 moulded onto the face of the side panel 172. This cleat carries a pair of channel- shaped recesses 190 which engage the upper shelf panel much as the recesses 176 engage the base panel. However the recesses 190 do not have the serrated side walls of recesses 176. Even so the shelf panels 186 engaged therewith cannot fall out because the tops and bottoms of adjacent side panels are solidly located relative to each other by the spine members at the top and the locked-in bottom panel.

In an alternative structure, the recesses 190 do have serrations on their side walls in the manner of the serrations 178 in recesses 176. This can add to the rigidity of the overall cabinet structure, but at the cost of greater complexity in the process for moulding or subsequent processing of side panel 172.

With reference to Figures 17 and 18, a back panel 192 slides down between adjacent side panels 172 with its side edge 194 at each end held in a vertical slot 196 until its bottom edge 193 rests on the main upper face of the base panel 180. The top edge 195 of the panel 192 then aligns with the lower face 201 of horizontal channel 200 so that when the top rear rail is engaged with the keys 174, the rail bears down upon the

top edge 195 of the back panel. This holds the panel firmly in place which, in turn, provides substantial lateral support for the row of cupboards.

As an alternative to the bottom edge 193 of the back panel 192 resting on the main upper face of the base panel, the edge 193 could be nested into a groove let into the upper face of the base panel 180. This would require a slightly taller back panel so that its top edge 195 would still bear against the channel 200. As a further alternative the base panel could be configured to have a raised lip like the lip 138 shown in Figure 13.

With reference to Figure 18 the key 174 at the top rear of the side panel carries a pair of in-turned grooves 198 which engage with corresponding lips (not shown) on the spine members in the same manner as the engagement of lip 29 with groove 22 as described with reference to Figure 2.

With reference to Figures 19 and 20, the embodiment shown is particularly adapted for use as a wall-mounted overhead kitchen cupboard. Four side panels 214 to 217 are retained at the desired spacing by four spine members in the form of rails 220 to 223 which engage keys 225 on the corners of the side panels in the same general manner as that described above with reference to Figures 1 and 2. However the means for preventing sliding of the panels along the rails in this embodiment comprises a v-shaped ridge 226 on the inboard wall of each channel 229 which engages with serrations 230 and 231 formed on the outer face of each rail each side of the gap in its c-section. Serrations 230 adopt a horizontal orientation, and serrations 231 adopt a vertical orientation when the rail is installed. It should be noted however that it is not necessary to have both arrays 230 and 231 of serrations on each rail; one array per rail is sufficient.

With reference to Figure 21, three horizontal panels locate into each cupboard of that particular embodiment. These are the base panel 232, top panel 233 and shelf panel 234. These three horizontal panels all have the same cross section which has a major flat face 236 and an opposite contoured face 238. The contoured face comprises an

edge flange 237 extending from each longitudinal edge 240 of the panel and a pair of broad longitudinal ribs 239, each rib spaced slightly inboard of a respective edge flange 237. A channel 242 lies between each flange 237 and its adjacent rib 239.

Within that channel, the wall on the rib side carries an array of serrations 244 running the full length of the channel.

The base panel 232 and shelf panel 234 are installed with their flat face 236 up, but the top panel 233 is installed with its flat face down. To assemble a row of cupboards, a person commences by connecting the side panels 214 to 217 to the two bottom rails 222 and 223. Each of the base panels 232 is then pressed into position against the bottom cleats 250 so that the ribs 239 rest astride the cleat. The serrations 244 are caused to mate with the vertical serrations 230 on the rails 222 and 223 as a flange of the rail engages into the channel 242. Then the shelf panel 234, top panel 233 and back panel 235 may be fitted in any order.

Upstanding tabs 255 on the middle cleats penetrate into the channels 242 on the shelf panel 234 and the serrations 244 on the shelf panel engage corresponding serrations on the inboard face of the tabs 255. The back panel 235 is slid into place along the vertical slots in the side panels. The top panel 233 is pressed down into place against top cleats 252 and the top rails 220 and 221 are engaged around the keys 225 at each corner of the side panels. The flanges 237 on each outside edge of the top panel is captured by respective rails when the rail is clipped around the keys 225. The serrations 244 are caused to mate with the vertical serrations 230 on the rails 220 and 221 as a flange of the rail engages into the channel 242. The rear panel 235 is also captured by the rear rails 221 and 223 as shown in Figure 22. The side edge 243 of the rear panel extends beyond the end of the rail to allow the edge 243 to slide into the adjacent side panel.

As for previously described embodiments, in-turned grooves 246 are formed extending off the channels 229 which define the keys 225 and these grooves engage with lips 247 on the rails. In this instance however each of the two channels 229

defining each key has such a groove 246 extending from it, whereas in the previously described embodiments only one of the two channels carried a groove.

The embodiments of the invention described earlier that are adapted to floor mounting are constructed in a different manner to those described with reference to Figures 19 to 22. For the floor mounted cupboards the top rails are connected to the side panels first.

The vertical panels forming the sides of the cupboards are preferably moulded as a thick panel being greater than 7mm thick and preferably greater than 10mm thick. More preferably they are about 16mm thick and may have a high proportion of recycled plastics material in their composition. The faces of the panels have a smooth gloss finish from the time they exit the mould in which they are formed. These panels are moulded in a batch process such as by injection moulding; they are not extruded, drawn or otherwise continuously cast because they have a widely varying cross section.

Although it is preferred that the side panels are moulded integrally with their laterally extending foot portions, it is also anticipated that the foot portion may be separately moulded and the main sheet of the side panel attached to it by, for example, press fitting pins or lugs on the bottom edge of the panel sheet into engagement with holes or slots on the top of the foot.

The elongate spine members have a uniform or substantially uniform cross section.

The only significant variation in the cross section is in the means for preventing sliding movement between the spine members and the side panels. The elongate spine members are accordingly preferably continuously formed, by way of extrusion for example. The serrations, indentations, bores or whatever other means is used for slide prevention are impressed into the elongate members by, for example, a rotary tool bearing onto the member as it exits, still soft, from the forming die, or by cutting the serrations into the material when it has cooled to a solid.

A significant advantage of the invention is the ability to transport the carcass of the multi-cupboard cabinet to the work-site as a"flat pack"of standard components for assembly. The shelves, back panels, base panels, and rails forming the spine members may simply be cut to length from a long length of the relevant extrusion or moulding. This provides the ability to allow on-site for a high degree of choice in the width of the cabinets and the cupboards within them. This means that detailed measurements of a site may not be required before a job is commenced as the size of the cabinets can be easily and accurately adjusted during construction on site. It also means the cost of a preliminary site visit for detailed measurements may not be required and the whole job can be done in one visit.

Although the invention is particularly adapted for use with cabinets installed in kitchens, it may be also used for cabinets in other locations such as laundries, bedrooms, offices, workshops and retail stores. The embodiments described with reference to Figures 1 to 18 are particularly adapted to floor standing cupboards whereas the embodiments described with reference to Figures 19 to 22 are applicable to wall-hung cabinets.

Assembly of the above described cabinets may take place without any screwing, nailing, tacking, stapling or gluing. Parts press fit or snap fit together using integrally formed connector details.

All components of the cabinet carcass may be made from the same colour homogeneous plastics material which provides a pleasing visual effect. Scratches, scuffs chips and dents are therefore not readily seen.

In the context of this specification, the carcass of a cabinet means the combination of the vertical support panels, horizontal structural members and optionally the back and the floor of the cabinet. The carcass does not include doors or an overlying bench- top.

Throughout this specification, unless the context requires otherwise, the word "comprise", and variations such as"comprises"and"comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Finally, it is to be understood that various alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the spirit or ambit of the invention.