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Publication numberUS3881794 A
Publication typeGrant
Publication dateMay 6, 1975
Filing dateOct 16, 1973
Priority dateOct 16, 1973
Publication numberUS 3881794 A, US 3881794A, US-A-3881794, US3881794 A, US3881794A
InventorsHenning Walter
Original AssigneeRegal Wood Products Inc
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Cabinet
US 3881794 A
Abstract
A cabinet is disclosed formed from a single sheet of board, laminated on at least one side with a finished material. The substrate may be so grooved that the laminate forms a living hinge which can be folded to form a cabinet with a bottom, two opposed sides, and a top from a single sheet. A framed front face plate comprises a pair of stiles at the vertical side edges, and a top rail and a bottom rail having mitered joints, all being joined to the cabinet members by living hinges. The cabinet is characterized by the absence of raw edges, and no necessity for further finishing. Optionally, a mullion may be positioned in the center. The mullion is secured to the top rail and bottom rail by means of dowels, and the rear face of the mullion can receive selectively locatable shelf supports along with and cooperating with selectively positioned shelf supports on the sidewalls. A back is framed into position when the side and top are folded into position and held in place by means of grooves in the rear portion of the sidewalls, top, and bottom.
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United States Patent 1 [111 3,881,794

Henning May 6, 1975 CABINET [75] Inventor: Walter Henning, Miami Lakes, Fla. Pnmary Examiner a FQ Attorney, Agent, or FzrmDommik, Knechtel, Godula [73] Assignee: Regal Wood Products, Inc., Miami, & Demeur Fla. 22 Filed: Oct. 16, 1973 [57] ABSTRACT A cabinet is disclosed formed from a single sheet of [21] Appl 406796 board, laminated on at least one side with a finished material. The substrate may be so grooved that the [52] US. Cl 312/259; 217/65; 312/257 R l minate forms a living hinge which can be folded to [51] Int. Cl A47b 47/04 form a c inet wi h a bottom, two opposed sides, and [58] Field of Search 312/257 R, 195, 330, 108, a top from a single sheet. A framed front face plate 312/263, 259; 29/477, 476; 217/65; 156/304; 229/D1G. 4, 31 R; 220/D1G. 14, 31 S, 46

References Cited UNITED STATES PATENTS comprises a pair of stiles at the vertical side edges, and a top rail and a bottom rail having mitered joints, all being joined to the cabinet members by living hinges. The cabinet is characterized by the absence of raw edges, and no necessity for further finishing. Optionally, a mullion may be positioned in the center. The mullion is secured to the top rail and bottom rail by means of dowels, and the rear face of the mullion can receive selectively locatable shelf supports along with and cooperating with selectively positioned shelf supports on the sidewalls. A back is framed into position when the side and top are folded into position and held in place by means of grooves in the rear portion of the sidewalls, top, and bottom.

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CABINET BACKGROUND OF INVENTION 1. Field of Invention The present invention related to cabinets, and more particularly that type of cabinet which may be formed from a single sheet of formed material folded into a rectangular housing. The cabinet is formed out of a laiminated material in which the exterior portion of the material, at least on one side, is a finished surface such as an imitation wood grained vinyl. In one embodiment the cabinet is laminated on both faces. The subject matter may be found in Class 312 sub 259 primarily.

2. Prior Art The prior art includes cabinets of the type which are fabricated by partial folding of scored and/or grooved laminated board. Exemplary of the prior art is U.S. Pat. No. 3,472,571. One of the problems with the prior art type cabinets, such as that exemplified in U.S. Pat. No. 3,472,571 is the retention of dead areas at both the top and the bottom of the cabinet beyond which the front rails and bottom rails extend. Another problem is the requirement for separate pieces for the bottom, top, and back. Additionally, the traditional cabinets, whether made of a laminated material or raw wood, often employ butt joints between the stiles and the rails, whereas a mitered joint is a more attractive and sturdy joint such as that employed in a picture frame. Furthermore, many of the production type cabinets are special purpose and not changeable into case goods, or interchangeable between wall and base cabinet without significant redesign.

SUMMARY The present invention stems from the usage of a single piece of grooved laminated board to fold and secure in such a fashion that the sides, bottom, and top of a cabinet are formed from a single piece of laminated material having living hinge type edges at the junctures of the separate members. The front portion is framed by stiles which are folded extensions of the sidewalls, and a top rail and bottom rail which are folded extensions from the top and bottom respectively. The stiles and rails are beveled at a preferred 45 angle at the point where they join each other, the base of the bevel being in axial alignment with the living hinge portion which adjoins the respective top and bottom with their adjacent sidewalls. A grooved construction may be provided in the rear portion of the opposed sidewalls to receive a back, which in turn is overlapped by a rear support which is an extension of the sidewalls and top and bottom. Thus, both the rear and the front have a framing periphery. The front portion including the rails and stiles may be double folded whereas the rear portion may be a single thickness member which abuts the back at its inner face. The front may be a single thickness where, as in motor and mobile homes, light weight and maximum interior space are needed. A groove is provided to receive the back in each of the sidewalls, top and bottom, thereby lockingly engaging the same, and when the unit is mounted to a wall, the mounting member penetrates both the back and the rear frame portion. Optionally, a mullion may be secured between the top rail and the bottom rail for a double door cabinet.

In view of the foregoing, it is one of the principal objects of the present invention to provide a cabinet the sides, top, front frame and rear frame portion of which are formed from a single sheet of material. This construction presents an uncluttered exterior, a strong selfcontained semi-monocoque unit, and economies which have heretofore not been achieved in wood simulated type cabinets.

Another object of the present invention is to provide a construction of a cabinet formed essentially of a single piece of material in which the back may be framed into position as the cabinet is assembled, and is used in conjunction with the back frame portion to secure the unit to a wall.

Still another object of the present invention is to provide a cabinet, which, in addition to achieving the above objectives, can do the same in a construction with laminations on both sides of the raw material, and when folded and glued or otherwise secured into shape, presents no raw edges and hence requires no painting or further finishing after shipped from the factory to the job site.

Yet another object of the present invention looks to the provision of a cabinet which can be essentially formed from a single sheet of material, and in which the size and proportion of the sides, top, and base can be varied and yet the essential unitization of the same be achieved by selecting the modules of the dimensions of the specific elements. A related advantage includes the ability to add legs to the subject cabinet to form a piece of furniture, or to add a toe rail support therebeneath to form a base cabinet, and the ability to secure the cabinet on a wall to become a wall cabinet.

Still another object of the present invention is to provide a cabinet in which the front face plate and rear frame turn inwardly thereby permitting installation into confined areas while maximizing internal capacity.

DESCRIPTION OF DRAWINGS Further objects and advantages of the present invention will become apparent as the following description of an illustrative embodiment proceeds, taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a typical cabinet illustrative of the present invention showing legs employed on the same in one embodiment.

FIG. 2 is a perspective view of a blank sheet of material from which the subject cabinet is formed.

FIG. 3 is a transverse sectional enlarged view of the blank shown in FIG. 2 taken along section line 33 of FIG. 2.

FIG. 4 is a longitudinal transverse sectional view of the blank shown in FIG. 2 in enlarged scale and broken in the middle of each of the four panels, and taken along section line 4-4 of FIG. 2.

FIG. 5 is a partially diagrammatic perspective view indicating how the blank of FIG. 2 is folded about itself in order to form the cabinet construction including the locking insertion of an optional back. In addition FIG. 5 shows an exploded relationship of a shelf and mullion which maybe optionally employed.

FIG. 6 is a longitudinal sectional view of the illustrative cabinet of FIG. 1 taken along section line 66 of FIG. 1.

FIG. 7 is a transverse sectional view of the illustrative cabinet shown in FIG. 1 taken along section lines 77 of FIG. 1.

FIG. 8 is a crosscut view of the cabinet shown in FIG. 1 taken above the center shelf and generally as illustrated in section line 88 of FIG. 1.

FIG. 9 is an enlarged sectional view of an optional single thickness stile construction taken in the general area referenced by the circled number 9 in FIG. 8.

FIG. 10 is an optional rear frame construction taken from FIG. 8 in the area generally designated by the circled numeral 10.

FIG. 11 shows the cutout for an optional front plate corner joint at the intersection of a rail and a stile in the blank unfolded form.

FIG. 12 is a view sequential from that shown in FIG. 11 when the blank of FIG. 11 is folded as illustrated generally in FIG. 5.

FIG. 13 is substantially a mirror of blank of that shown in FIG. 11.

FIG. 14 shows the reverse corner construction of that shown in FIG. 12 illustrating that in addition to a mitered joint at the intersection of the rails and the stiles, a simulated butt joint may also be prepared.

DESCRIPTION OF PREFERRED EMBODIMENT The cabinet 10 as illustrated in FIG. 1 includes a pair of doors 28 which are secured to the stiles 15 by means of a pair of hinges 29. An optionally provided mullion 40 separates the two doors 28. It will be appreciated that a wide variety of door constructions may be employed, including a single door covering the entire face of the cabinet, or a door in combination with drawers which may be at the other portion of the cabinet. The cabinet is generally framed in front by means of a face plate 11 which is made up of a pair of vertical opposed stiles 15, a top rail 16, and a bottom rail 18.

Before referring to the construction of the blank which is shown in perspective in FIG. 2, reference should be made to FIG. 5 where it will be seen how the cabinet 10 is folded into its final configuration. There it will be noted that the blank causes the formation of a cabinet 10 which includes a first sidewall 21 and opposed sidewall 22 which are joined by means of a bottom 24, and enclosed into a rectangular enclosure by means of a top 25. Optionally, depending upon the construction and ultimate location of the cabinet 10, a back 26 may be enclosed by means of a rear frame 12 which includes a hang rail 14, the latter being useful in the event the cabinet 10 is employed as a wall cabinet. In addition, as the csbinet 10 is folded into its final configuration as shown in FIG. 5, a shelf 50 may be positioned in a mid-position, and the mullion 40 positioned to divide the opening at the front portion of the cabinet.

As observed in FIG. 2, it will be seen that the blank 20 is provided with V-grooves in two different directions, the directions being mutually perpendicular. The material is preferably chip board, laminated on at least one surface. In the blank 20 shown in FIG. 3, it will be seen that the material is laminated on two surfaces. In some instances the lamination will be a simulated wood on both sides, whereas in other installations there may be a simulated painted surface such as a white laminate on the interior portion, and the wood simulation laminate on the exterior portion. In other applications, the interior laminate may be omitted. In all events, there must be at least one laminated surface susceptible of receiving a V-notch, the apex of which approximately contacts the laminate in order to define a living hinge at the base of a V-groove. In most instances, and in all instances described here, the V-groove has an included angle of 90 between the principal elements.

With reference to FIG. 3, it will be seen that the blank 20 defines a rear frame 12 at its left hand portion by means of a rear frame groove 34. In addition, a back groove 30, here being generally square in its cross section, is provided immediately adjacent the rear frame groove 34 in order to lockingly receive the back 26 as illustrated in FIG. 5. Over at the right hand portion of FIG. 3, it will be seen that the second sidewall 22 is adapted for a front plate portion including the stile portion 15, as well as the stile back 46. A front plate groove 35, with double plate grooves 36, permits the stile 15 to extend in a perpendicular relationship to the sidewall 22, and the stile back 46 to reversely fold upon itself to thereby define a double thickness stile (the same being illustrated in FIG. 8 in the area designated by the circled numeral 9). The rear frame 12 is folded in a single thickness with the second sidewall 22 as shown in FIG. 3, the ultimate rear frame configuration being shown by the circled numeral 10 in FIG. 8.

As illustrated in FIG. 4 taken in conjunction with FIG. 2, the various members including the first sidewall 21, second sidewall 22, bottom 24, and top 25 are all separated by V-grooves. The ends are provided with a first side bevel 38, and a second side bevel 39 for intersection when the unit is folded together as shown in FIG. 5. Thus FIG. 4 shows the first side bottom groove 31, a second side bottom groove 32, and a second side top groove 33. The other grooves are, as shown in FIGS. 2 and 3, the front plate groove 35 which runs the entire length of the blank 20, and the double plate double groove 36 which also runs the entire length of the blank shown in FIG. 2, and the just recited rear frame groove 34 and front plate groove 35.

In the embodiment shown, the rails 16, 18, and the stiles 15 have a double thickness. This is provided for in the blank 20 as shown in FIG. 2 by means of a stile back 46, and a bottom rail back 48 as well as a top rail back 49. Finally, a miter joint notch 45 is provided at three stations on the blank 20 as shown in FIG. 2 in order to define the forty-five degree angle miter joints on the front face plate 1 1, between ones of the stiles 15 and top rail 16 and bottom rail 18. The miter joint notch 45 is so proportioned, as shown in blank 20 of FIG. 2, that the stile back 46, bottom rail back 48, and top rail back 49 will overlap the mitered cut of its related front portion.

In some instances, preference may be made for a simulated butt joint around the face plate 11. Such a butt joint is shown in completed form in FIGS. 12 and 14; and in related blank form in FIGS. 11 and 13 respectively. In each instance, the stile 15 and top rail 16 include the butt joint V-notch 71, the butt 72, and the butt stringer 74. The butt stringer 74 is the thickness of the side, bottom or top therebehind and is required to finish the same.

When assembling the cabinet by folding into position as shown in FIG. 5, the back 26 is positioned into the back groove 30 (shown in the blank 20 in FIG. 2) so that its rearward portion is covered by the rear frame 12 and its hang rail 14 portion. The interlocking relationship is shown particularly at the upper and lower left portions of FIG. 7 as well as the upper left and upper right portions of FIG. 8. Once the construction is fully folded, the back 26 is locked in place interiorly of the cabinet 10. Similarly, the mullion 40 is provided with upper mullion pins 41 and lower mullion pins 42 which are received by the upper rail mullion pin holes 43 and the lower rail mullion pin holes 44. Additionally, if the shelf 50 is to be positively locked within the cabinet 10, the shelf 50 is provided with shelf pins 51 at its opposed ends, and shelf holes 52 are provided in the opposed sides 21, 22 to receive the same. Thus, when the unit is completely folded from the configuration shown in FIG. 5, the back 26, shelf 50, and mullion 40 are all locked into position by the nature of semimonocoque construction. The rectangular frame is closed at the opposed miter joints 38, 39 of the upper end of the first'sidewall 21 and the left hand end of the top 25.

It will be appreciated that in the alternative cabinet types the joint which closes the cabinet may be at an intersection of the bottom 24 and one of the sidewalls 21, 22. The upper closure is desirable when the cabinet 10 may be used as a wall cabinet, and thus the joint hidden. Alternatively, if legs 55 (such as shown in FIG. 1) are going to be employed so that the cabinet 10 will be on a floor, the joint is preferably between one of the sidewalls 21, 22 and the bottom 24. Similarly, if a toe rail box 56 such as shown in FIG. 7 is to be employed so that the cabinet 10 will be utilized as a base cabinet, the joint between the various top, bottom, and side members may be located to minimize its appearance.

As indicated above, it is entirely within the contemplation of the invention that the stiles and top rail 16, bottom rail 18 combination portion of the face plate 11 may be made of a single thickness. When this is done, as shown in FIG. 9, an end finish 60 is imparted to the raw end of the board. The end finish 60 is accomplished by means of a half out which defines a reverse member 61 and double V 62, the double V 62 flanking a V block 63, and a butt face 64, all as shown in FIG. 9. In addition, the regular V-groove 32 is applied adjacent the second sidewall 22 as shown in FIG. 9, and then, as shown in the lower portion of FIG. 9, the members are folded against themselves and glued to provide the completed end finish 60 of the stile l5, and folded to the groove 32 in order to define the perpendicular relationship between the stile 15 and the second sidewall 22.

A rounded end finish 65 is shown in FIG. 10 which can be optionally employed on the portion framing the back 26 in the area generally shown by the encircled numeral 10 at the upper right hand corner of FIG. 8. As will be noted in FIG. 10, the rounded end finish 65 is defined by a reverse member 66, and a triple V cut 67 defining a plurality of V blocks 69 and a cross plate 68. The back notch 30 is provided in the second sidewall 22 just as in the construction shown in FIG. 8, and then the back 26 is positioned in a butting relationship with the reverse member 66 as shown in the lower portion of FIG. 10.

Thus in review it will be seen that a cabinet 10 has been shown and described which can be made of a single piece of panel material 20, optionally provided with a back 26, mullion 40, and shelf 50. While the shelf 50 has been shown as fixed within the cabinet 10, other means for adjustably positioning the shelf 50 and removably securing the same inside the cabinet 10 are contemplated within the scope of the invention. The cabinet has an uncluttered exterior portion, and several cabinets may be stacked atop each other and secured together for wall cabinet storage. In addition, by optionally providing legs 55, the cabinet becomes a floor type storage cabinet, or by applying a toe rail box 56 (as shown in FIG. 7) it may become a base cabinet, or in the configuration as shown, with or without the back 26, the same may be employed as a wall cabinet. None of the back frame 12, face plate 11, or other members extend outwardly of the basic elements including the bottom 24, top 25, and opposed side members 21, 22 thereby minimizing and modularizing the space in which the cabinet may be positioned, and without sacrificing interior capacity of the cabinet 10.

Although particular embodiments of the invention have been shown and described in full here, there is no intention to thereby limit the invention to the details of such embodiments. On the contrary, the intention is to cover all modifications, alternatives, embodiments, usages and equivalents of a cabinet as fall within the spirit and scope of the invention, specification, and the appended claims.

What is claimed is:

l. A cabinet comprising, in combination, a single blank formed of a substrate and at least one laminated face by grooving the same to define a living hinge of laminate between ones of a first sidewall, a bottom adjoining the first said sidewall, a second sidewall adjoining said bottom, and a top joining said second sidewall for closing into rectangular enclosure,

a pair of stiles extending from the vertical front edge of each of said first sidewall and second sidewall and joined thereto by a living hinge,

a top rail extending downwardly from said top and joined thereto by a living hinge,

a bottom rail extending upwardly from said bottom adjoined thereto by a living hinge,

each of said top rail, bottom rail, and stiles having complementary ends proportioned for abutting relationship with the adjacent rails and stiles whereby the front portion of the cabinet is framed,

each of said top rail,'bottom rail, and stiles having a double groove and double plate to define a reversely folded back part abutting its adjacent sidewall and masking all 'raw edges.

2. In the cabinet of claim 1,

said blank being formed from a material which has been laminated on both faces with a finished material,

each of said elements being separated from the other by a V groove penetrating one of said lamination and terminating at approximately the back of the second laminate whereby the second laminate becomes a living hinge, I

each and every element being formed and proportioned so that when folded into a quadrilateral unit no raw portions of the blank appear and the interior is fully laminate finished as is the exterior thus requiring no further finishing upon installation.

3. In the cabinet of claim 1,

a rear frame defined by extensions from each of said top, first sidewall, bottom and second sidewall extending centrally and mitered at their end portions,

at least one of said members of said rear frame serving as a hang rail for securing the cabinet to the wall. I.

-4. In the cabinet of claim '1,v

a plurality of back retaining grooves defined in the rear edge portion of each of saidfirst sidewall, bottom, second sidewall, and top,

a back proportioned to be enveloped by the groove of said first sidewall, bottom, second sidewall, and said back,

and a rear frame defined by rearward extensions from each of said first sidewall, bottom, second sidewall, and top,

said frame extensions having complementary end portions to meet in framelike relationship at the rear of the cabinet,

and means for securing said frame to said back,

whereby any of the four members of the rear frame may serve as a hang rail and securing members may pass through the double thickness of the back and frame and then engage the surface in which the cabinet is mounted.

5. In the cabinet of claim 2,

a rear frame defined by extensions from each of said top, first sidewall, bottom, and second sidewall extending centrally and mitered at their end portions,

at least one of said members of said rear frame serving as a hang rail for securing the cabinet to the wall.

6. In the cabinet of claim 2,

a plurality of back retaining grooves defined in the rear edge portion of each of said first sidewall, bottom, second sidewall, and top,

a back proportioned to be enveloped by the groove of said first sidewall, bottom, second sidewall, and said back,

and a rear frame defined by rearward extensions from each of said first sidewall, bottom, second sidewall, and top,

said frame extensions having complementary end portions to meet in framelike relationship at the rear of the cabinet,

and means for securing said frame to said back,

whereby any of the four members of the rear frame may serve as a hang rail and securing members may pass through the double thickness of the back and frame and then engage the surface in which the cabinet is mounted.

7. In the cabinet of claim 3,

a plurality of back retaining grooves, defined in the rear edge portion of each of said first sidewall, bottom, second sidewall, and top,

a back proportioned to be enveloped by the groove of said first sidewall, bottom, second sidewall, and said back,

and a rear frame defined by rearward extensions from each of said first sidewall, bottom, second sidewall, and top,

said frame extensions having complementary end portions to meet in framelike relationship at the rear of the cabinet,

and means for securing said frame to said back,

whereby any of the four members of the rear frame may serve as a hang rail and securing members may pass through the double thickness of the back and frame and then engage the surface in which the cabinet is mounted.

8. In the cabinet of claim 1,

said complementary ends being 45 mitered ends,

thereby framing the front end portion of the cabinet in picture frame appearance.

9. In the cabinet of claim 2,

said complementary ends being 45 mitered ends, thereby framing the front end portion of the cabinet in picture frame appearance.

10. In the cabinet of claim 1,

said complementary ends being formed with a simulated butt joint having a butt joint V-notch, butt, and stringer elements,

whereby the framing of the front end has a simulated butt joint appearance.

11. A cabinet comprising, in combination,

a single blank formed of substrate and at least one laminated face by grooving the same to define a living hinge of laminate between ones of a first sidewall, a bottom adjoining the first sidewall, a second sidewall adjoining said bottom and a top joining said second sidewall for closing into a rectangular enclosure,

means defining a frame at the front portion of said enclosure, each of said means extending inwardly from the adjoining sidewall, bottom and top, and each having complementary ends for interfitting with the ends of adjacent such means,

back framing means extending inwardly and secured by a living hinge to each of said sidewalls, bottom and top,

a back for closing the rear of the cabinet,

and groove means adjoining the rear framing means living hinge,

whereby upon folding all of said sidewalls, bottom and top to form the rectangular enclosure, the back is locked in place in the grooves provided at the rear of the cabinet, and overlappingly secured by the back framing means, and the exterior of the cabinet is defined by the sidewalls and back frame thereby minimizing the space into which the cabinet may be fitted.

12. In the cabinet of claim 11,

said blank being formed from a material which has been laminated on both faces with a finished material,

each of said elements being separate from the other by a V groove penetrating one of said laminations and terminating at approximately the back fo the second laminate whereby the second laminate becomes a living hinge,

said rails and stiles having reversely folded back portions the raw ends of which abut the adjacent sidewalls and are masked thereby,

each and every element being formed and proportioned so that when folded into a quadrilateral unit no raw portions of the blank appear.

13. In the cabinet of claim 11,

said complementary ends being 45 mitered ends,

thereby framing the front end portion of the cabinet in picture frame appearance.

14. In the cabinet of claim 12,

said complementary ends being 45 mitered ends,

thereby framing the front end portion of the cabinet in picture frame appearance.

15. In the cabinet of claim 11,

said complementary ends being formed with a simulated butt joint having a butt joint V-notch, butt, and stringer elements,

whereby the framing of the front end has a simulated butt joint appearance.

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Classifications
U.S. Classification312/259, 312/257.1, 217/65
International ClassificationA47B96/20, A47B96/00
Cooperative ClassificationA47B96/202
European ClassificationA47B96/20B