FIELD OF THE INVENTION

[0001] The present invention relates to an easy to assemble cabinet unit and method of assembling same. The invention has been developed with particular regards to the DIY cabinet market. However, it will be appreciated that the invention is not limited to this particular application.

BACKGROUND OF THE INVENTION

[0002] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.

[0003] “Flat pack” cabinet kits for kitchens, bathrooms, storage units etc., comprising pre-cut panels and sets of different types of fasteners, are extremely popular. While they have the advantage of taking up minimal space for storage and transport, assembly can be tedious and time consuming when it comes to setting out the parts, following the step by step instructions in the right order and ensuring in the meantime that you don’t lose any of the many individual fasteners. Additionally, they often require an extra pair of hands to help set up and ensure, for example, that the corners are square, and no undue force is applied to the fasteners or panel edges due to misalignment. There is therefore a need for a simpler to assemble flat pack cabinet kit.

[0004] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

SUMMARY OF THE INVENTION

[0005] According to one aspect of the invention, there is provided a pre-fabricated cabinet frame structure including: two opposing side wall elements each having an inside surface, a front edge, a rear edge, a base portion, and a top portion; at least two spacer arms moveable between a folded configuration and an extended configuration, each spacer arm being hingedly connected by wall hinges at one end to an inside surface of one side wall element, and at the other end to an inside surface of the other opposing side wall element, whereby at least one spacer arm extends adjacent the front edge of each wall element and at least one spacer arm extends adjacent the rear edge of each wall element, wherein the at least one spacer arm adjacent the front edge is offset from the at least one spacer arm adjacent the rear edge such that they do not interfere with each other in the folded configuration.

[0006] In one embodiment, the at least one spacer arm adjacent the front edge is mounted vertically offset from the at least one spacer arm adjacent the rear edge.

[0007] The cabinet frame structure may comprise a simple storage box or could comprise a sub element such as a drawer within a storage cabinet that may or may not be constructed with a similar frame structure.

[0008] The spacer arms can take any suitable form, including, but not limited to, telescoping tube arrangements with rotatable locking elements, a “scissor jack” type structure lockable by clip means or similar, and folding hinged arms as discussed in more detail below. The wall elements may be solid panels or other more open structures.

[0009] In one embodiment, each spacer arm is a folding arm having an arm fold hinge connector permitting movement of each folding arm between the folded configuration, where the folding arms lie generally parallel to the side wall elements, and the extended configuration, where the folding arms extend generally transverse to the side wall elements. The arm fold hinge may be facilitated by any suitable means such as a flexible arm hinge or rigid arm hinge arrangement. Preferably, each of the folding arm includes two arm elements that are interconnected by the arm fold hinge connector. More preferably, each arm element is of equal length.

[0010] In the folded configuration, it is preferred that the two opposed wall elements are relatively closely spaced for packaging and transport, and in the extended configuration, it is preferred that the two opposing side walls are spaced away from each other a predetermined distance to define a storage space therebetween.

[0011] In one embodiment, the pre-fabricated cabinet frame structure includes at least two locking mechanisms to hold each folding arm in the folded configuration and/or the extended configuration. Each locking mechanism may be operatively associated with each wall hinge and/or each arm fold hinge connector. In one preferred form the locking mechanism may include an over centre mechanism that biases the arm from a partially extended position to either the folded configuration and/or the extended configuration.

[0012] In one embodiment, each wall hinge is a flat fold hinge.

[0013] In one embodiment, the pre-fabricated cabinet frame structure includes four folding arms. In a preferred embodiment, two arms are provided to connect either or both of the front or rear edges of the two opposed side elements. In one form, two arms are provided to connect the front edges of the side elements, the arms being positioned adjacent the top and rear portions of the side elements, and two arms are provided to connect the rear edges of the side elements which are both positioned between the front lower arm and the front top arm. While the folding arms can be made of any suitable material, there is an advantage in using the same material as the wall elements for consistency of appearance and minimising the variety of component materials to be procured and stocked.

[0014] Desirably, the cabinet frame structure also includes front top and or front base fascia panels or kick boards which ideally clip on to the assembled frame structure to hide the folding arms connected adjacent the front edges of the two side elements.

[0015] Reference throughout this specification to “one embodiment”, “some embodiments”, “an embodiment”, “one aspect”, (numbered) “aspect”, or “an aspect” or means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in some embodiments” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: [0017] Figure 1 is a perspective view of a first embodiment cabinet frame structure according to the invention illustrated in the collapsed transport configuration;

[0018] Figure 2 is an enlarged view of one of the hinged arm connectors illustrated in the collapsed configuration as shown in Figure 1 ;

[0019] Figure 3 is a perspective view of the frame structure of Figure 1 shown in a partially expanded orientation;

[0020] Figure 4 shows enlarged perspective views of the arm hinges in fully folded, partially opened and fully opened orientations;

[0021] Figure 5 is a perspective view of the frame structure of Figure 1 shown in a fully expanded orientation;

[0022] Figure 6 is an enlarged view of one of the hinged arm connectors illustrated in the fully extended configuration as shown in Figure 5;

[0023] Figure 7 is a perspective view of the frame structure of Figure 5 with means to attach a shelf and base;

[0024] Figure 8 is an enlarged perspective view of a shelf support as shown in Figure 7;

[0025] Figure 9 shows the partially assembled cabinet frame structure of Figure 7 with means to attach doors and a lower kick board;

[0026] Figure 10 is an enlarged perspective view of the door hinge arrangement shown in Figure 9;

[0027] Figure 11 is an enlarged perspective view of the kickboard connecting clip arrangement shown in Figure 9; and

[0028] Figure 12 is an enlarged perspective view of the cabinet of Figure 9 with doors fully assembled and means to attach the basin to the cabinet. PREFERRED EMBODIMENTS OF THE INVENTION

[0029] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings which should be considered in all respects as illustrative and non-restrictive. In the drawings, the same elements are denoted by the same reference numerals throughout. In the following description, detailed descriptions of known functions and configurations incorporated herein have been omitted for conciseness and clarity.

[0001] The embodiment illustrated in Figures 1 to 12 relates to a cabinet frame structure as shown in the final almost as fully assembled bathroom vanity cabinet in Figure 12.

[0002] T urning first to Figures 1 to 6 there is shown a first embodiment cabinet frame structure 1 according to the invention. The frame structure is illustrated in Figure 1 in the collapsed transport and packaging configuration and includes two opposing side wall elements, a left wall element 2 and right wall element 3. Each wall element respectively has an inside surface 4 and 4’, a front edge 5 and 5’, a rear edge 6 and 6’ a base portion 7 and 7’ and a top portion 8 and 8’.

[0003] The wall elements 2 and 3 are interconnected by at least two spacer arms. In the present embodiment, the at least two spacer arms are in the form of four separate folding arms, each folding arm being moveable between a folded configuration and an extended configuration. The first two 9 and 10 are connected adjacent front edges 5 and 5’, and the second two 11 and 12 connected adjacent the rear edges 6 and 6’.

[0004] As best seen in Figures 3 and 5, front arms 9 and 10 are located adjacent the top and base edges 8, 8’ and 7, T so as to maximise the front opening. The rear arms 11 and 12 are located vertically intermediate, or vertically spaced, the front arms 9 and 10 along an axis parallel to the wall elements. In this way when the arms are folded, they are all offset from each other, so they can fold and extend without interference.

[0005] Each of the folding arms are in the form of two preferably equal length elements that are interconnected at a mid-point by means of an arm fold hinge connector 14. This connector can be of any suitable form that ideally enables a neat butt joint in the fully extended configuration, while also facilitating a neat flat fold in the folded configuration as shown in Figure 1 . One example of a suitable hinge is shown in more detail in Figure 4.

[0006] The distal ends of each folding arm are connected to the inside surfaces 4, 4’ of the walls 2 and 3 by wall hinges in the form of flat fold hinges 15. As best seen in enlarged Figures 2 and 6, these hinges each have a rear flange 16 that secures to the inner surfaces of the side walls, and a front hinge 17 that connects to an inside surface of each end of each arm. In the folded configuration, the front and rear flanges 16 and 17 are generally parallel as shown in Figures 1 and 2, and in the extended configuration are at 90 degrees to each other as shown in Figures 5 and 6. Preferably, these hinges include either some form of over centre biasing mechanism to urge the hinge to the expanded 90 degree orientation, and/or some form of integral locking mechanism that helps to hold the hinge in the expanded 90 degree orientation. Optionally, other locking mechanisms may be provided which may form part of the wall hinges and/or the arm hinges or comprise independent elements. In the preferred form illustrated, the flat fold hinges 15 include an over centre spring mechanism that once moved from the folded configuration, biases the hinges toward a locked expanded 90 orientation and automatically locks. A release tab is provided which needs to be moved to a release position before the hinges can be returned to the collapsed position, should that be required.

[0007] As can be seen from Figures 1 to 6, assembly of the frame structure is incredibly simple. The frame structure is the collapsed transport and packaging configuration shown in Figure 1 , where each folded arm is in the folded configuration.

[0030] The two wall elements 2 and 3 are then pulled apart until fully expanded as shown in Figure 5. At this point the arrangement of hinges, and accurate pre-assembly of the components, contributes to a structurally stable and rigid assembly, which gains further strength and stability as the additional components are added which also provide further bracing.

[0031] In this particular embodiment, the next steps of adding in shelves, doors and basin or bench top are relatively simple as shown in Figures 8 to 12. For example, the shelves 18 can be installed by using conventional post mounts 19 as shown in Figures 7 and 8. These mounts 19 include a horizontal spigot 20 which is configured for an interference fit within pre-machined holes 21 formed in the inside surface of the sides walls as shown. The shelves are then provided with pre-machined blind holes in the underside of the shelves that are sized to snugly receive the post formations 22. When the shelves are inserted over the mounts, they can be pushed down over the post formations. This provides an accurate and rigid connection of the shelf to the assembled frame structure, again adding further bracing to the finished structure.

[0032] The doors 23 can be attached using any suitable door hinge 24 such as those shown in Figures 9 and 10. These two-part hinges are widely used. Each part could be pre-assembled or secured into pre-drilled or pre-marked locations. The doors are then connected by pushing the extending hinge arm 25 connected to each door, into the hinge gate 26 provided on the inside surface of the side walls.

[0033] Depending on the intended purpose and proposed location of the cabinet, it may be desirable to include some form of fascia board or kick board 27 such as the one shown in Figure 9. While these can be attached in any suitable manner, in most instances they have only aesthetic purpose and as such a simple clip in fastener system 28 such as that shown in more detail in Figure 11 is sufficient and fast to install.

[0034] T o complete the vanity unit of this particular embodiment, the final step is to attach the basin top 29. In the example shown, locating dowels 30 are used to accurately position the top and locate it laterally. Additional fixtures or adhesives may also be used.

[0035] While the illustrated embodiment uses spacer elements in the form of folding arms, it will be appreciated that the expandable and collapsible structure could be achieved by other means such as using telescoping arm elements, which may also be hingedly interconnected with the walls, or use some other form of linearly extendible connector structures such as a “scissor jack” type arm.

[0036] Additionally, while the embodiment illustrated uses a total of four folding arms to create the frame structure, it could be possible to use only two or three and provide additional stiffening bracing by other means such as further slide in or clip in spacers.

[0037] While the rear of the cabinet described is open to the rear, some form of rear panel could be provided if required which again could be secured by clips, cam fasteners, internal corner angles or again any suitable means.

[0038] It should also be noted that while the embodiment described illustrates use of the storage unit frame structure to create the carcass of a storage cabinet, that same storage unit frame structure principle could be used to create drawer units for cabinets that are made the same way or by other conventional means.

[0039] It should be appreciated that in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, Figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

[0040] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

[0041] While there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as falling within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.