US20170164734A1

US20170164734A1 - Modular Outdoor Cabinetry System

Info

Publication number: US20170164734A1
Application number: US15/378,835
Authority: US
Inventors: Richard Thomas Steele; John Rutkiewicz, JR.
Original assignee: Cardinal Systems Inc
Current assignee: Cardinal Systems Inc
Priority date: 2015-12-14
Filing date: 2016-12-14
Publication date: 2017-06-15
Also published as: WO2017106366A1

Abstract

A modular outdoor cabinetry system that can be easily assembled from standardized, prefabricated parts, and can be modified or disassembled with ease. The system consists of corner posts and panels that can be assembled into cabinets of various sizes. The cabinets may be configured as standard cabinets having one or more opening doors or may be configured as specialty cabinets with different kits. A bar kit enables a cabinet to include a raised bar, a sink kit enables a cabinet to house a sink, a grill kit enables a cabinet to house a grill, a drawer kit enables a cabinet to include drawers, a refrigerator kit enables a cabinet to house a refrigerator and a trash can kit enables a cabinet to house a trash can. The cabinets are configured to enable the exterior of the cabinets to be changed in an easy manner.

Description

PRIORITY

This application claims the priority under 35 USC §119 of Provisional Application 62/266,873 filed on Dec. 14, 2015, entitled “Outdoor Cabinetry System and Assembly” and having Richard Thomas Steele and John Rutkiewicz as inventors. Application 62/266,873 is herein incorporated by reference in its entirety.

BACKGROUND

Outdoor entertainment solidified itself as a premier form of social gathering with the invention of the charcoal grill in the 1950s. Driven by the grilling activity's increasing popularity, particularly in the United States where backyard space was plentiful, everyone began to move their parties outside the home during the warm spring and summer months. With more functions taking place outside, the public began to demand increased functionality from their outside space. By the 1990s, the concept of indoor/outdoor living had become ingrained in American culture, and the grill had become a ubiquitous presence on the patios of American families. Today, trends in design space consumption have moved many traditional aspects of the home to the backyard, where many people have demanded the same utility and comfort they enjoy inside. As such, many backyards now mimic the functionalities of modern living rooms, dining rooms, and kitchens.
Kitchen spaces in the backyard may range from a simple grill to a full-fledged, full-service system. Many people have decided their outdoor kitchens should be able to handle everything from set-up to clean-up, all without entering the house. To that end, outdoor kitchen systems began to be developed with cabinets for utensils, silverware, and china, as well as enclosures for grilling and refrigerator appliances. Such systems typically need to be custom-built to the unique specifications of the homeowner, which makes them quite expensive. Their expense is compounded because they necessitate extensive labor, as well as construction and masonry expertise to install. Moreover, typical systems are permanently installed, making them immovable and difficult to repair, replace, or reconfigure.
Some outdoor kitchen systems include prefabricated cabinets instead of custom designs, which claim to offer quicker and more cost-effective outdoor cabinetry to the homeowner. Despite their claims, however, most prefabricated cabinets still require the work of a skilled craftsman to install. For example, most require an installer to cutout openings to accommodate different features such as grills, refrigerators, sinks, doors, cabinets or the like. Also, they are typically covered with stone or brick to finish the exterior which requires masonry and/or construction expertise. Regardless of claims that such systems are able to be knocked down and relocated easily, they are difficult to disassemble and not displaceable after the exterior finish is applied.
There exists a need for an outdoor modular cabinetry system that provides the functionality of an outdoor kitchen outdoor space that can be tailored to the owner's needs and preferences. The system should provide the quality a custom designed outdoor kitchen system, with the added flexibility for the owner to be able to relocate, rearrange, disassemble, and reassemble the modular system with relative ease.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements and in which:

FIG. 1 illustrates a perspective view of an example corner post that is used for a modular outdoor cabinetry system, according to one embodiment.

FIG. 2 illustrates a perspective view of an example panel being secured to the example corner post of FIG. 1, according to one embodiment.

FIGS. 3A-F illustrate different views of an example standard cabinet, according to various embodiments.

FIG. 4 illustrates a perspective view of an example center post, according to one embodiment.

FIGS. 5A-D illustrate various views of an example bar kit and an example bar cabinet having a raised bar, according to one embodiment.

FIGS. 6A-E illustrate various views of an example grill insert and an example grill cabinet for housing a grill, according to various embodiments.

FIG. 7 illustrate an example sink cabinet, according to one embodiment.

FIGS. 8A-B illustrates an example refrigerator kit and a refrigerator cabinet for housing a refrigerator, according to one embodiment.

FIGS. 9A-C illustrates an example trashcan insert and an example trashcan cabinet to house and hide a trashcan therewithin, according to one embodiment.

FIGS. 10A-E illustrate several views of an example faceplate and an example drawer cabinet, according to one embodiment.

FIGS. 11A-B illustrate exploded and perspective views of an example 90 degree corner cabinet, according to one embodiment.

FIGS. 12A-B illustrate exploded and perspective views of an example 45 degree corner cabinet, according to one embodiment.

FIGS. 13A-B illustrate perspective views of an example bracket being utilized to secure corner posts of adjacent cabinets together, according to one embodiment.

FIGS. 14A-B illustrate exploded and perspective views of an example external designer (e.g., patterned) panel, according to one embodiment.

FIGS. 15A-B illustrate perspective views of an example tow kick system, according to one embodiment.

FIGS. 16A-C illustrate perspective views of several modular outdoor cabinetry systems, according to various embodiments.

DETAILED DESCRIPTION

The current invention is a modular outdoor cabinetry system that can be easily assembled from standardized, prefabricated parts, disassembled for relocation, and modified to suit the needs and design preferences of the owner, both in functionality and appearance. The system consists of corner posts and panels that can be assembled into cabinets of various sizes. The cabinets may be some standard dimensions for heights (e.g., 30 inches and 36 inches), depths (e.g., 24 and 30 inches) and lengths (e.g., 24, 30, 36, 42 and 48 inches in length). However, the modular cabinets are not limited to the noted dimensions as the standard dimensions or to standard dimensions.
The cabinets may be configured as standard cabinets having one or more opening doors or may be configured as specialty cabinets with different kits utilized with some of the standard components. For example, a bar kit enables a cabinet to include a raised portion to act as a bar, a sink kit enables a cabinet to house a sink, a grill kit enables a cabinet to house a grill, a drawer kit enables a cabinet to include drawers, a refrigerator kit enables a cabinet to house a refrigerator and a trash can kit enables a cabinet to house a trash can. The type of specialty cabinets is not limited to the above noted examples.
The cabinets are designed so that they can easily be assembled and connected together to enable a customer to build a modular outdoor cabinetry system in any number of configurations. The cabinets are configured to enable the exterior of the cabinets to be changed in an easy manner. The cabinets may easily be disconnected, rearranged and/or reconfigured. The modular cabinets of the current invention provide the customer with quality outdoor cabinets that can easily be assembled and configured in numerous fashions and also modified (e.g., added to, subtracted from, moved, reconfigured) as desired without the need for an installation company.
The cabinets are designed for use in various temperatures (high and low) and weather conditions (e.g., rain, snow, sun). The materials utilized in the cabinets are selected to maximize longevity and minimize rust and degradation. According to one embodiment, the various parts making up the cabinets are stainless steel. However, the current invention is not limited to stainless steel and may be other materials that can be used outdoors.
FIG. 1 illustrates a perspective view of an example corner post 100 that is used for modular outdoor cabinetry system, according to one embodiment. The corner post 100 includes a first flange 110 and a second flange 120 to secure to panels that are utilized as walls of the modular outdoor cabinets. The panels will be secured to the corner pieces 100 rather than being secured to each other in some fashion as is typical with cabinets. The flanges 110, 120 are configured to be perpendicular to each other in order to create a right angled corner as would be required for a typical square or rectangular cabinet. The flanges 110, 120 may include a plurality of holes 130 (a total of 5 illustrated on each flange 110, 120 with two on the top, one in the middle and two on the bottom—but in no way intended to be limited to that number or arrangement) for connecting to other components of the cabinets. For example, the holes 130 may be used for receiving a screw, rivet or the like in order to provide the connection to the other components (e.g., panels). Alternatively, the flanges 110, 120 may connect to the panels or other components using push tabs, hooks or other connection devices that do not require tools.
According to one embodiment, the corner piece 100 includes a body that supports the flanges 110, 120. As illustrated, the corner post 100 is configured as an open square post having two full sides 140, 150 and two partial sides 160, 170 that the flanges 110, 120 extend from. In this configuration, the flanges 110, 120 do not contact each other. The sides 140, 150 of at least some of the corner posts 100 may act as an exterior corner for the cabinets. For exterior walls of a cabinet, a panel may be mounted to an exterior of a flange 110, 120. The panel may be configured to extend from the flange 110, 120 or have a thickness that is approximately equal to depth of the side 160, 170 so as to be aligned with the side 140, 150.
FIG. 2 illustrates a perspective view of an example exterior wall panel 200 being secured to the example corner post 100, according to one embodiment. The panel 200 is secured to the flange 120 and has a thickness approximately equal to the depth of side 170 so that it is approximately in alignment with the side 150. As illustrated, the panel 200 may include holes (e.g., threaded holes) in alignment with the holes 130 in the flange 120 so that they can be connected using screws, rivets or the like. It should be noted that the screws, rivets or the like would be inserted from internal to the cabinet so they were not visible external to the cabinet. Alternatively, the panel 200 may connect to the flange 120 using push tabs, hooks or other connection devices that do not require tools. In such an embodiment, at least some of the holes in the panel 200 and the flange 110 may not be required.
The corner post 100 illustrated in FIGS. 1 and 2 is in no way intended to be limited to the illustrated embodiments. Rather, a corner post 100 capable of acting as a corner of a cabinet and receiving panels from two sides could have various different configurations without departing from the current scope. Furthermore, if the cabinets were not standard square or rectangle cabinets the corner post 100 would not be limited to providing a means for connecting the sides of the cabinet at a right angle as illustrated.
FIGS. 3A-F illustrate different views of an example standard (e.g., two door) cabinet 300, according to various embodiments. FIG. 3A illustrates a perspective view of a partially installed standard cabinet 300. The cabinet 300 includes a plurality of the corner posts 100 being secured to an example bottom 310 of the cabinet 300. A corner post 100 may be secured to each corner of the bottom 310 of the cabinet using screws, rivets, or the like 320. While not illustrated a nut, washer or the like may also be utilized to secure the corner posts 100 to the bottom 310. As one skilled in the art would understand the posts 100 and the bottom 310 could be secured to each other in various other manners without departing from the current scope.
FIG. 3B illustrates a perspective back view of the example cabinet 300 showing the addition of a center post 330 along the back of the cabinet 300 and a front upper support 340 and a back upper support 350. The post 330 and the supports 340, 350 may be secured using screw, rivets or the like or via other none means. The upper supports 340, 350 may be utilized to secure the upper ends of the corner posts 100 to other corner posts 100 to ensure the cabinet 300 is aligned, to provide a location for hinges, magnets or the like that may be required for cabinet doors, and to provide support for counter tops to be installed thereon. The center post 330 may be utilized for additional support along the back wall for cabinets 300 having a length greater than a defined amount (e.g., 24 inches). If the cabinet 300 has a length less than the defined amount, a single panel 200 may be secured between the two back corner posts 100. If the cabinet 300 has a length greater than the defined amount, the center post 330 may be utilized and a panel 200 may be installed between each corner post 100 and the center post 330. Alternatively, a single panel 200 may be used and secured in the middle to the center post 330. It should be noted that the use of the center post and the distances associated therewith are in no way intended to be limited to the illustrated embodiments.
FIG. 4 illustrates a perspective view of an example center post 330, according to one embodiment. The center post 330 is configured as an open rectangular post having a back 400, two sides 410, 420 and two flanges 430, 440 that extend outward from the sides 410, 420. The flanges 430, 440 may have a plurality of holes 450 formed therein for securing to the panel(s) 200 using screws, rivets or the like. Alternatively, the panels 200 and the center post 330 (flanges 430, 440) may be secured via other means, including for example, push tabs, hooks or other connection devices that do not require tools. The back 400 may act as an exterior center post for a cabinet. A panel 200 may be mounted to an exterior of a flange 430, 440. The panel 200 may be configured to extend from the flange 430, 440 or have a thickness that is approximately equal to depth of the side 410, 420 so as to be aligned with the back 400 (similar to how panel 200 had a thickness similar to the depth of side 170 and was approximately in alignment with the side 150 as illustrated in FIG. 2).
FIGS. 3C-D illustrate an exploded perspective view and a perspective view respectively of the example cabinet 300, according to one embodiment. The cabinet 300 includes corner posts 100 at the corners of the cabinet 300 and a center post 330 at a center of a back wall. Panels 200 are connected between front and back corner posts 100 on the sides of the cabinet 300 and between the back corner posts 100 and center post 330 at the back of the cabinet 300. It should be noted that depending on the size of the cabinet 300 that the side and rear panels may have the same or different dimensions. The cabinet 300 illustrates exterior panels 200 having a thickness that puts them in alignment with exterior walls of the corner posts 100 (as illustrated in FIG. 2) on each side of the cabinet 300. Such a configuration would be utilized if both ends of the cabinet were exterior walls in the modular outdoor cabinetry system designed. However, if one or more of the sides was an interior wall of the modular outdoor cabinetry system designed, the exterior panels 200 may be replaced with divider panels (to be discussed in more detail later).
The panels 200 may be configured to have holes 210 formed therein (a single hole is identified in FIG. 3C for ease of illustration) that are in alignment with the holes 130, 450 in the flanges 110, 120, 430, 440 of the posts 100, 330. The panels 200 may be attached to the posts 100, 330 with screws, rivets, or the like. Alternatively, the panels 200 and the posts 100, 330 may be secured via, for example, push tabs, hooks or other connection devices that do not require tools.
One or more doors 360 (two illustrated) are pivotally mounted to the cabinet 300 with hinges 364 or the like. It should be noted that the number of doors 360 utilized is configurable and may be based on the size of the cabinet 300 and the size of the doors 360 desired. The hinges 364 may be attached to the doors 360 and either the front corner posts 100, the bottom 310, the front support 340, or some combination thereof. The door(s) 360, the bottom 310, the front support 340 or some combination thereof may also include magnets or the like (not illustrated for ease) to assist in holding the door(s) 360 closed. The door(s) 360 include a handle(s) 362 for opening. The cabinet 300 may also include one or more shelfs 370 in the interior thereof.
The cabinet 300 may include legs 380 to lift the cabinet off the ground. The legs 380 may be located at the four corners of the cabinet 300. The legs 380 may include a screw that is received by threaded holes in the cabinet 300 to secure the legs 380 to the cabinet 300. The threaded holes may be formed in the bottom 310. Alternatively, the thread holes may be formed in the corner posts 100. The legs 380 may include an upper and lower portion where the lower portion may be received within the upper portion. The height of the legs 380 may be adjusted by turning the lower portion so that more or less of it is received by the upper portion. The configuration of the leg provides for leveling of the cabinet 300. As one skilled in the art would recognize the configuration of the adjustable leg is not limited to the described embodiment.
As previously noted, if one or more sides of the cabinet 300 are to be internal to the modular cabinetry system then they do not require external wall panels 200. Rather, a simple divider panel 390 may be utilized to separate the cabinets.
FIG. 3E illustrates a perspective view of an example divider panel 390 utilized between two corner posts 100. The divider panel 390 is thin compared to the corner post 100 (will not be aligned with exterior wall of the corner posts 100). The divider panel 390 may be connected to the corner posts 100 using for examples screws, rivets, or the like through aligned holes. Alternatively, the panels 390 and the posts 100 may be secured via, for example, push tabs, hooks or other connection devices that do not require tools.
FIG. 3F illustrates a perspective view of the example cabinet utilizing divider panels 390, according to one embodiment. As illustrated, the cabinet is identical to the cabinet of FIG. 3D with the exception that the external panels 200 on the sides of the cabinet have been replaced with the divider panels 390.
It should be noted that a standard cabinet is not limited to the embodiments illustrated and discussed with respect to FIGS. 3A-F. Rather, the illustrated embodiments simply illustrate and describe the modular concept of the cabinets with the use of standard parts such as corner posts and panels. The size of the standard cabinet and the specific configuration (e.g., number or doors, number of exterior panels, number of divider panels, use of center post) may vary based on the design of the modular outdoor cabinetry system.
A standard cabinet, such as the two-door cabinet illustrated in FIGS. 3A-F or other embodiments of a standard cabinet, may be modified to add a bar extending from the backside of the cabinets (provide support for the counter top extending past the end of the cabinet) or for a raised bar that includes a back splash extending up from the top of the top of the cabinet and the counter top extending backwards therefrom. It should be noted that for a cabinet to include a raised bar that the back corner posts 100, and if included the back center post 330, of such a cabinet may be longer than the front corner posts 100 by the height of the bar. The back upper support 350 may be mounted to the back corner posts 100 and center post at a height equal to height of front corner posts 100.
FIGS. 5A-D illustrate various views of an example bar kit 500 and a bar cabinet 505 equipped with a raised bar, according to one embodiment. FIG. 5A illustrates a front perspective view of the bar kit 500, according to one embodiment. The bar kit 500 is generally L-shaped with a first portion 510 and a second portion 520. The bar kit 500 is designed to secure to the back of the cabinet 505 in such a fashion that the first portion 510 extends upwards and the second portion 520 extends backwards therefrom. The first portion 510 may act as a back splash (e.g., may provide a stainless steel back splash). The second portion 520 may provide the support for a counter top to be secured thereto. The counter top may extend past the second portion 520 in either direction as desired (and feasible). According to one embodiment, if the second portion 520 is provided as a finished surface it may act as a stainless steel raised bar if that kind of look is desired. It should be noted that second portion 520 may include an indent 525 at the corner abutting the first portion 510 so that the corner post 100 can be received therein. The indent 525 may not be as thick as the rest of the second portion 520 or a side of the second portion may be cut out there.
FIG. 5B illustrates an exploded view of the bar kit 500 and the posts 100, 330 of the cabinet 505 it is mounted to. As previously noted, the back corner posts 100 and the center post 330 should be longer than the front corner posts by an amount approximately equal to the height of the first portion (backsplash) 510 of the bar kit 500. The bar kit 500 includes an external member 530, a support member 540, a pair of corner connectors 550 and a center connector 560. The external member 530 includes the first and second portions 510, 520 and is basically all that is visible in FIG. 5A. The support member 540 is attached to the connectors 550, 560 and supports the external member 530. The connectors 550, 560 are attached to the support member 540 and are to connect to the posts 100, 330. The corner connectors 550 are illustrated as a generally L-shaped bracket and the center bracket 560 is illustrated generally as two L-shaped brackets connected together separated by a distance approximately equal to width of the back 400 of the center post 330. The corner connectors 550 have a thickness approximately equal to the thickness of a flange of the corner post 100 and are secured to the flange with screws, rivets, or the like. Each L bracket of the center bracket 560 has a thickness approximately equal to the thickness of flanges of the center post 330 and is secured to the flanges of the center bracket 330 with screws, rivets, or the like.
FIG. 5C illustrates a back perspective view of the bar kit 500, according to one embodiment. The connectors 550, 560 are configured to be accessible along the back of the first portion (backsplash) 510 for connecting to the posts 100, 330.
FIG. 5D illustrates a perspective view of the bar cabinet 505 with a raised bar. The backsplash 510 extends upward from the back support 350 and then the second portion 520 extends backwards therefrom for supporting a countertop to act as a raised bar. It should be noted that the bar cabinet 505 illustrated in FIG. 5D includes external panels 200 on each side but is not limited thereto. As previously noted, the use of the panels 200 on the sides is based on the configuration of the modular outdoor cabinetry system the cabinet is utilized therein and whether either side will be an external end of the system. If the sides are internal, the external panel 200 may be replaced with the divider panel 390.
It should be noted that the bar kit 500 and bar cabinet 505 illustrated in FIGS. 5A-D are for use with a cabinet that includes the center post 330 along the back of the cabinet. The bar kit 500 and the bar cabinet 505 are in no way limited thereto. Rather, a bar kit 500 could be designed for cabinets that do not have the center post 330 or that have more than one center post. Furthermore, a bar kit could be designed for the side of a cabinet, or the back and side of the cabinet without departing from the current scope.
According to one embodiment, the bar kit may simply provide a bar that extends from the back of the cabinet 505 and not provide a raised portion. A non-raised bar kit would not include the first portion 510 to act as a backsplash and the back corner posts 100 and the center post 330 would not be raised. The bar assembly would connect to the cabinet and simply extend past the back of the cabinet.
A standard cabinet, such as the two-door cabinet illustrated in FIGS. 3A-F, may be modified to support a grill being housed therein. In order to do this the front support bar 340 may be lowered and smaller doors 360 may be used so that a portion of the front of the cabinet is available for the controls of the grill. A grill insert may then be installed on the top of the cabinet to secure the grill above the cabinet so that the grill does not sit directly on the countertop and the countertop can be cut to fit the grill kit.
FIGS. 6A-E illustrate various views of an example grill insert 600 for supporting a grill and a grill cabinet 605 for housing a grill, according to various embodiments. FIG. 6A illustrates a perspective view of the example grill insert 600, according to one embodiment. The grill insert 600 includes three sides 610, 620, 630 configured to attach to the sides and back of the cabinet 605. Each side 610, 620, 630 includes a flat portion 612, 622, 632 (622 not visible in FIG. 6A) and a raised portion 614, 624, 634. The raised portions 614, 624, 634 are for supporting the grill and the flat portions 612, 622, 632 are for supporting the counter top. The flat portions 612, 622, 632 are to mount to the cabinet (e.g., connect to appropriate flanges). The dimensions of the flat portions 612, 622, 632 may depend on the dimensions of the grill (be configured for specific parameters of the grill). The smaller the grill is in comparison to the cabinet 605 the greater the dimensions of the flat portions 612, 622, 632 as the flat portions will provide the appropriate size opening within the cabinet 605.
FIG. 6B illustrates an exploded view of a grill kit that includes the grill insert 600 and filler panels 650. The grill insert 600 includes a lower piece 660 and an upper piece 680 that each include three sides. The lower piece 660 provides the flat portions 612, 622, 632 while the upper piece 680 provides the raised portions 614, 624, 634. The size of the flat portions 612, 622, 632 provided by the lower piece 660 is configurable based on the parameters of the grill. The lower piece 660 includes flanges 662, 664, 666 extending upward at the end of each of the flat portions 612, 622, 632. The flanges 662, 664, 666 are used to secure to the upper piece 680. The upper piece 680 includes flanges 682, 684, 686 (only 684 and 686 visible in FIG. 6B) extending downward from each of the raised portions 624, 624, 634. The flanges 682, 684, 686 are used to secure to the lower piece 660.
The lower piece 660 also includes flanges 668 extending downward, which are used to secure it to the cabinet (flanges of the posts). The lower piece also includes flanges 670 extending downward along the front face which can be used to secure to the cabinet and also for securing the filler panels 650 thereto.
FIG. 6C illustrates a perspective view of the grill cabinet 605 for receiving a grill. As can be seen the doors 360 do not extend to the top of the cabinet 605 so that the control panels of the grill may be accessed. The filler panels 650 cover the front of the grill insert 600. It should be noted that the grill cabinet 605 illustrated includes external panels 200 on each side but is not limited thereto. As previously noted, the external panel 200 may be replaced with the divider panel 390 if the side will be internal in the modular outdoor cabinetry system.
The grill kit could also include a propane tank holder 690, shelves or other features that can be utilized with the cabinet 605.
FIGS. 6D-E illustrates a perspective view of a propane tank holder 690 (pull out drawer) and a grill cabinet 605 with a propane tank holder, according to one embodiment. The propane tank holder 690 may include brackets 692 mounted to the floor 310 and a drawer 696. The brackets 692 and the drawer 696 may include glide rails 694, 698 secured thereto. The glide rails 694, 698 are configured to interact with one another so that the drawer 696 can be slide in and out of the cabinet 605. It should be noted that the cabinet 605 does not include the grill insert 600 or the filler panels 650 for ease of illustration. It should have be noted the cabinet 605 includes a shelf 699.
It should be noted that the grill cabinet 605 illustrated includes external panels 200 on each side but is not limited thereto. As previously noted, the external panel 200 may be replaced with the divider panel 390 if the side will be internal in the modular outdoor cabinetry system. Furthermore, the pull out-drawer 690 is not limited to holding a propane tank or being located in a grill cabinet 605. Rather, the pull-our drawer 690 could house any number of devices, bins or the like and be utilized in any cabinet (including cabinets with pivoting doors).
FIG. 7 illustrate an example sink cabinet 700 for housing a sink therein, according to one embodiment. In order to support a sink the cabinet 700 may have the front support bar 340 lowered from the top of the cabinet to partially down the front of the cabinet 700 and smaller doors 360 may be used. This arrangement is so that the doors do not interfere with the sink that will drop below the top of the cabinet 700. A filler panel 710 may utilized to cover the front of the cabinet 700 above the doors. It should be noted that the sink cabinet 700 illustrated includes external panels 200 on each side but could utilize divider panels 390 on either side if the side will be internal in the modular outdoor cabinetry system.
A standard cabinet may be modified to house a refrigerator by leaving the doors off the cabinet and providing filler material for the front of the cabinet based on the refrigerator to be used therein. According to one embodiment, the cabinet may have a height higher than a typical cabinet as standard refrigerators may have a height higher than the typical cabinet.
FIGS. 8A-B illustrates an example refrigerator kit 800 and a refrigerator cabinet 805 for housing a refrigerator, according to one embodiment. The refrigerator kit 800 includes side panels 810 and an upper panel 820. The dimensions of the panels 810, 820 may be based on the dimensions of the refrigerator to be located therewithin. The side panels 810 are secured to the corner posts 100 on each side of the front face of the cabinet 805 to fill in any opening. The top panel 820 is secured to the corner posts 100 across the top of the front face of the cabinet 805 to fill in any opening. It should be noted that the refrigerator cabinet 805 illustrated has external panels 200 for each side but could utilize divider panels 390 for sides that will be internal in the modular outdoor cabinetry system. It should be noted that the refrigerator cabinet 905 is not limited to housing a refrigerator. Rather the cabinet 905 could be used to house any device that may be used in outdoor cabinetry that requires its own door (e.g., wine cooler, freezer, kegerator, humidor, smoker).
A standard cabinet may be configured to house a trashcan. The cabinet may include a door that pulls out rather than pivoting open as has been the case with the doors described with respect to the standard cabinets. A drawer capable of holding a trashcan may be attached to the door. Such a configuration, allows the trashcan to be stored within the cabinet hidden from view when not being used by closing the door.
FIGS. 9A-C illustrates an example trashcan insert 900 and a trashcan cabinet 905 to house and hide a trashcan therewithin. The trashcan insert 900 includes a door 910 that has a drawer 930 connected to a lower edge thereof with brackets 920. The drawer 930 can hold one or more trashcans (or a trashcan and recycling can) therewithin. It should be noted that the drawer 930 is not limited to holding trashcans (or recycling cans) but rather can hold any type of storage bin. The drawer 930 is designed to slide in and out of the cabinet 905. A glide rail system may be utilized to provide the movement of the drawer 930. An under mount glide rail system that is known to those skilled in the art is illustrated. The under mount glide rail system includes glide rail tracks 940 mounted to the bottom 310 of the cabinet 905, securing clips 950 mounted to a back of the drawer 930 and glide wheels 960 mounted to the bottom of the drawer 930. The securing clips 950 connect to the glide rail tracks 940 to secure the drawer 930 thereto and the glide wheels 960 slide within the glide rail tracks 940 to provide the movement. The trashcan insert 900 enables the trashcan to be hidden when not in use and be accessible when needed.
It should be noted that the cabinet 905 is not limited to the use of under mount glide rail systems. For example, the glide rail systems could include side mount glide rail systems that are known to those skilled in the art that include tracks on the side of the drawer 930 and the side of the cabinet 905 that slide within each other. Furthermore, the trashcan cabinet 905 is illustrated as a narrow cabinet that only includes a single back panel and no center post but is in no way intended to be limited thereto. Moreover, the trashcan cabinet 905 is illustrated as having external panels 200 for each side but could utilize divider panels 390 for one or more sides if they will be internal in the modular outdoor cabinetry system.
A cabinet may be configured to house a plurality of drawers rather than a door. The plurality of drawers provide for horizontal storage and access to each drawer individually. Like the trashcan cabinet discussed above, a glide rail system that is known to those skilled in the art may be utilized to provide the movement of each of the drawers. The glide rail system may be, for example, an under mount glide rail system or a side mount glide rail system. A faceplate must be utilized to cover the front of the cabinet and to provide openings for the drawers. As the cabinets will be used outside where they will be susceptible to the weather, the drawers will need to be weatherproofed in some fashion.
FIGS. 10A-E illustrate several views of an example drawer faceplate 1050 and an example drawer cabinet 1000, according to one embodiment. FIG. 10A illustrates a perspective view of the example drawer cabinet 1000 in a closed configuration. The cabinet 1000 includes one or more drawers 1010 (3 illustrated with only the top one being visible) for storing items. Each drawer 1000 includes a front panel 1020 having a handle 1030.
FIG. 10B illustrates a partial perspective view of the example faceplate 1050. The faceplate 1050 includes a plurality of holes 1060 (only one visible) for receiving the drawers 1010. Each of the holes 1060 has a gutter 1070 formed around an exterior thereof to prevent water from entering the drawer 1010. As illustrated, the top portion of the gutter 1070 is angled upward so as to create a trough for capturing any condensation (e.g., water) that is received to ensure it doesn't flow into the drawer 1010. The trough may be sloped toward one or both sides so that the water runs off to the side and does not stay within the trough. The sides of the gutter are illustrated as simply walls to prevent water from entering. The bottom is illustrated as a similar configuration to the top. It should be noted that the gutter 1070 configuration is not limited to the illustrated embodiment. Rather, any number of configurations could be utilized to prevent water from entering the drawer 1010.
FIG. 10C illustrates a partial perspective view of the example drawer cabinet 1000 in an open configuration. The front of the cabinet 1000 includes the faceplate 1050 with gutters 1070 mounted thereto. FIGS. 10D-E illustrate partial front and back perspective views of the drawer 1010 entering the hole 1060 in the faceplate 1050. As illustrated in FIG. 10E, the back of the front panel 1020 includes a frame 1022 and a recessed portion 1024. The frame 1022 abuts the face plate 1050 and the gutter 1070 is received with the recessed portion 1024. In this arrangement, the gutter 1070 is not visible in a closed configuration but will capture any water that gets between the faceplate 1050 and the front panel 1020 and ensure the water is not received in the drawer 1010 by routing it around the drawer 1010.
The drawer cabinet 1000 is illustrated as a narrow cabinet that only includes a single back panel and no center post but is in no way intended to be limited thereto. Moreover, the drawer cabinet 1000 is illustrated as having external panels 200 for each side but could utilize divider panels 390 for one or more sides if they will be internal in the modular outdoor cabinetry system.
The modular outdoor cabinets may be configured in various different ways based on the desires of the customers. For example, the customer may want various cabinets organized in a row. Alternatively, the customer may want the various cabinets organized in two different directions (e.g., L-shaped). In order for the cabinets to be organized in different directions, corner cabinets may be utilized to provide the change in direction. To create an L shape a cabinet providing a 90 degree turn would be required.
FIGS. 11A-B illustrate exploded and perspective views of an example 90 degree corner cabinet 1100, according to one embodiment. As illustrated, the cabinet 1100 has a substantially square perimeter with the exception of a square cut out from one corner. The square cut out provides a perimeter that has five corners and a corner post 100 may be secured to each of the corners. The cabinet 1110 includes a bottom 1110 that the corner posts 100 are mounted to. As illustrated, the back two adjacent sides include center posts 330 secured thereto and have panels 200 secured between corner posts 100 and center posts 330 to act as back walls. A face plate 1130 is installed between the front corner posts 100 to seal up the gap and provide a finished look. A top 1120 is mounted to the top of the posts 100, 330 to secure them in place and act as a support for a counter top to be located thereon.
As illustrated, the sides of the cabinet 1100 that would abut other cabinets are open and the back of the cabinets are closed. The sides are not required because the cabinet 1100 is used to rotate an arrangement of cabinets 90 degrees and would not be utilized as an end cabinet. Furthermore, the open ends would also provide access to the cabinet 1100 if the cabinet it was connected to had an open side as well. However, the side cabinet 1100 is not limited to the illustrated embodiment. The cabinet 1100 could include panels on the sides if desired. Moreover, the panels 200 forming one or more of the back walls could be replaced with one or more doors that would provide access to the cabinet 1100 from the rear of the cabinet arrangement.
Additionally, the 90 degree corner cabinet 1100 need not be squared shaped (where the associated back walls are parallel to back walls of cabinets the corner cabinet 1100 connects to). Rather, the cabinet 1100 could have a back wall that went diagonally from the two sides connecting to other cabinets. As one skilled in the art would recognize such an arrangement would not require the corner post opposite of the two adjacent front corner posts and the other two corner posts making up the back wall would need to be modified from the standard 90 degree corner posts (e.g., 45 degree corner posts).
The corner cabinets are in no way intended to be limited to 90 degrees. Rather, corner cabinets could be configured at various angles without departing from the current scope. The corner cabinets could change the direction of the cabinets by greater or less than 90 degrees depending on the type of configuration the costumer desires.
FIGS. 12A-B illustrate exploded and perspective views of an example 45 degree corner cabinet 1200, according to one embodiment. A 45 degree cabinet 1200 as discussed herein is a cabinet that changes the direction a first row of cabinets 1280 is traversing 45 degrees to the direction a second row of cabinets 1290 is traversing and vice versa (as shown in the simple direction map in the corner of FIG. 12A). As illustrated, the cabinet 1200 has a perimeter that includes a small front face that has a side extend from each end thereof at 135 degrees. The sides are a length associated with the depth of the cabinets that they will be connecting thereto. At the end of each side a back wall extends therefrom at 90 degrees and the back walls connect at a 135 degree angle. The cabinet 1200 includes a bottom 1210 and a top 1220 that have perimeters that have a shape defined above (front, two sides, and two backs). Corner posts 1230 having flanges angled at 135 degrees to each other are connected to the bottom 1210 at the two corners of the front and also the corner where the two back walls connect. Standard corner posts 100 are connected to the bottom 1210 at the other two corners. A face plate 1240 in installed between the front two corner posts 1230 to seal up the gap and provide a finished look. Panels 200 are secured between the corner posts 100 and the corner post 1230 along the back of the cabinet 1200 to create two back walls. The top 1220 is mounted to the top of the posts 100, 1230 to secure them in place and act as a support for a counter top to be located thereon. The use of standard posts 100 at the back corners that connect to other cabinets provides back walls that are parallel to back walls of cabinets the corner cabinet 1200 connects to.
As illustrated, the sides of the cabinet 1200 that would abut other cabinets are open and the back of the cabinets are closed. However, the side cabinet 1200 is not limited to the illustrated embodiment. The cabinet 1200 could include panels on the sides if desired. Moreover, the panels 200 forming one or more of the back walls could be replaced with one or more doors that would provide access to the cabinet 1200 from the rear of the cabinet arrangement. Additionally, the cabinet 1200 need not have two standard corner posts 100 that provide for two back walls that are parallel to back walls of cabinets being connected thereto. Rather, the cabinet 1200 could have a single back wall that went diagonally from the two sides connecting to other cabinets and was not parallel to the back walls of either of connecting cabinets. As one skilled in the art would recognize such an arrangement would require different corner posts in place of corner posts 100.
It should be noted that the cabinets and specialty kits described above are just a few examples of the types of cabinets that can be provided using the modular aspect of the current invention. Different types of cabinets may be provided by applying different kits or by combining two or more kits to a single cabinet. For example, a bar kit may be applied to a cabinet along with other kits to provide a specific purpose cabinet (e.g., grill, sink, refrigerator) that also includes a bar. In order to provide an outdoor cabinet system, multiple cabinets will be connected together in different configurations. Adjacent cabinets may include similar kits (e.g., bar kit) to provide a desired configuration (e.g., a bar extending for several cabinets).
Once the cabinets to be utilized in the modular outdoor cabinetry system have been assembled they can be located in the appropriate positions with respect to one another. The cabinets then must be secured to one another. In order to secure the cabinets together a bracket may be utilized to secure adjacent corner posts 100 together.
FIGS. 13A-B illustrate perspective views of an example bracket 1300 being utilized to secure two corner posts 100 to each other, according to one embodiment. The bracket 1300 may be secured to the flanges 110, 120 of the adjacent corner posts 100 (which should be parallel to each other). As illustrated, the bracket 1300 is generally U-shaped having a body and two flanges. The body of the bracket 1300 may rest on walls 160, 170 of the adjacent corner posts 100 and the flanges of the bracket 1300 may be aligned with the flanges 110, 120. The flanges of the bracket 1300 may have a hole formed therein in alignment with a hole in the flanges 110, 120 so they can be secured to one another using screws/nuts, rivets or the like. Alternatively, the bracket 1300 and the posts 100 may be secured via, for example, push tabs, hooks or other connection devices that do not require tools. The divider panels 390 may be configured to have a notch 395 cut out so that it does not interfere with the connection between the bracket 1300 and the posts 100.
The external panels 200 described above for use in the various cabinets were simply described as having a thickness to be aligned with the corner posts 100 and center posts 330. It was also described that the components of the modular outdoor cabinetry system would be stainless steel or a material providing similar characteristics. Some customers may not desire to have outdoor cabinetry that is stainless steel. Some customers may desire to have an outdoor cabinetry system that has a masonry (e.g., stone, brick) look. According to one embodiment, the exterior panels (e.g., stainless steel) may be replaced with receiving panels that are capable of receiving different faux panels therein. The faux panels may have different designs (e.g., brick, stone) than can be utilized. The receiving panels may be designed so that it is easy to install the faux panels and also easy to remove so that the design can be easily changed if desired.
FIGS. 14A-B illustrate exploded and perspective views of an example external designer (e.g., patterned) panel 1400, according to one embodiment. The designer panel 1400 includes a receiving panel 1400 and a faux panel 1450 that can be put together. The receiving panel 1410 is a thin panel (much like the divider panel 390) and includes a lip 1420 along a bottom, and a lip 1430 along the top that has a downward extending flange 1440. The bottom lip 1420 has a depth approximately equal to the thickness of the panel 200. The top lip 1430 has a depth less than the depth of the bottom lip 1420. The flange 1440 extends downward at the end of the top lip 1430. The faux panel 1450 has a thickness approximately equal to the thickness of the panel 200. The faux panel 1450 has a groove 1460 formed in an upper edge thereof in alignment with the flange 1430. The faux panel 1450 is secured to the receiving panel 1410 by sliding the faux panel 1450 onto the receiving panel 1410 such that the flange 1440 enters the groove 1460 and the lower edge of the faux panel 1450 is supported by the bottom lip 1420. According to one embodiment, the faux panel 1450 may be further secured in place by using some type of temporary securing means (e.g., screw, clip) to hold the faux panel 1450 on the lower lip 1420.
The external designer panel 1400 is to be secured to the cabinets in a similar fashion to the panels 200. The external designer panel 1400 is configured such that the faux panel 1450 can easily be installed and removed. This allows a customer to replace faux panels that may get damaged with ease. It also enables the customer to change the external look of outdoor cabinetry system if they desire without damaging the current faux panels 1400 or requiring major renovations.
Some customers may prefer not to see the legs or the underneath of the cabinets and may desire a toe kick for their modular outdoor cabinetry system. As the outdoor ground may not be level a toe tick needs to be able to adjust to the slope of the ground.
FIGS. 15A-B illustrate perspective views of an example tow kick system, according to one embodiment. The toe kicks system includes an upper 1500 frame and a lower frame 1510 that is configured for the configuration of the modular outdoor cabinetry system that has been designed. That is each cabinet will include upper and lower front toe kick pieces and upper and lower back toe kick pieces. For end cabinets there will also be upper and lower side toe kick pieces. The upper frame 1500 is created by connecting each upper toe kick piece to the appropriate cabinet and connecting upper toe kick pieces for adjacent cabinets together and also connecting side pieces to front and back pieces respectively. The lower frame 1510 is created by connecting to the appropriate lower toe kick pieces to the appropriate upper frame pieces and to each other. The lower frame 1510 is connected to the upper frame so that it can retract up to a certain distance (e.g., ½ inch) with the upper frame 1500. This configuration enables the toe kick to adjust itself based on the ground.
It should be noted that the adjustable toe kick is not limited to the embodiment illustrated and described.
FIGS. 16A-C illustrate perspective views of several modular outdoor cabinetry systems, according to various embodiments. The system illustrated in FIG. 16A is a straight line configuration that includes from left to right a grill cabinet 605, a two door standard cabinet 300, a sink cabinet 700 and a refrigerator cabinet 805. The system illustrated in FIG. 16B is an L-shaped configuration that includes from left to right a one door standard cabinet 300, a grill cabinet 605, a trashcan cabinet 900, a 90 degree corner cabinet 1100, a sink cabinet 700 and a refrigerator cabinet 805. The system illustrated in FIG. 16C is an L-shaped configuration that includes from left to right a trashcan cabinet 900, a grill cabinet 605, a 90 degree corner cabinet 1100, a two door standard cabinet 300, a sink cabinet 700 with a raised bar 500 and a refrigerator cabinet 805 with a non-raised bar 500. The raised bar 500 for the sink cabinet 700 along with the top of the refrigerator cabinet 805 (including the non-raised bar 500) create a large raised countertop surface.
It should be noted that the configurations illustrated in FIGS. 16A-C are simply a few examples of how a modular outdoor cabinetry system can be configured. The invention is in no way intended to be limited thereby. Rather, the configurations are only limited by the customer's imagination.
The description above and the accompanying drawings may reference and depict specific and relative dimensions and configurations of the invention, as well as referencing specific constituent materials and uses for the invention. The invention, however, is not limited to those dimensions, materials, or uses. The dimension and configuration choices made in the description and the accompanying drawings were merely descriptive and do not serve to limit the invention to those dimensions. Although the invention has been illustrated by reference to specific embodiments, it will be apparent that the disclosure is not limited thereto as various changes and modifications may be made thereto without departing from the scope. Reference to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described therein is included in at least one embodiment. Thus, the appearances of the phrase “in one embodiment” or “in an embodiment” appearing in various places throughout the specification are not necessarily all referring to the same embodiment.
The various embodiments are intended to be protected broadly within the spirit and scope of the appended claims.

Claims

What is claimed is:

1. A modular cabinet comprising:

a cabinet floor defining a shape of the cabinet;

a plurality of panels to provide walls of the cabinet;

a plurality of corner posts to be secured to corners of the cabinet floor, wherein each of the corner posts is configured to receive and secure two panels, wherein each panel secured to one of the corner posts provides at least a portion of at least one of the walls of the cabinet;

a first upper support to connect between a first set of the corner posts to provide support to an upper end of a first side of the cabinet;

a second upper support to connect between a second set of the corner posts to provide support to the upper end of a second side of the cabinet and to provide support for a counter top for the cabinet; and

an entry point along a side of the cabinet.

2. The modular cabinet of claim 1, wherein the corner posts include two flanges and the panels are secured to the flanges, wherein the panels have a thickness approximately equal to thickness of the corner posts so that the panels and the corner posts are in alignment.

3. The modular cabinet of claim 1, further comprising a center post secured to the cabinet floor and the second upper support, wherein a wall for the second side of the cabinet is formed by a panel between each corner post and the center post.

4. The modular cabinet of claim 1, wherein the entry point includes at least one pivoting door.

5. The modular cabinet of claim 1, wherein the entry point includes a frame having an opening provided therein for accessing a device housed within the cabinet.

6. The modular cabinet system of claim 1, further comprising a glide rail system mounted within the cabinet, wherein the entry point includes at least one pull out door, wherein the door has a drawer connected to a lower end thereof to house one or more bins, wherein the drawer is secured to the glide rail system, and wherein the door and the cabinet are capable of being pulled in and out of the cabinet.

7. The modular cabinet of claim 1, further comprising

a faceplate to be secured to the cabinet, wherein the faceplate has a plurality of drawer holes formed therein and wherein each of the drawer holes has a gutter formed therearound to route water away therefrom; and

a plurality of glide rail systems mounted within the cabinet, wherein a glide rail system is associated with each drawer hole;

wherein the entry point includes at a plurality of pull out drawers, wherein a pull out drawer is associated with each drawer hole and each glide rail system and is capable of being pulled in and out of the cabinet, wherein a front panel for each pull out drawer has a frame and a recessed portion, wherein the frame abuts the faceplate and the recessed portion receives the gutter.

8. The modular cabinet of claim 1, wherein the second upper support is U shaped and connects between the corner posts along the second side of the cabinet and two sides adjacent thereto, wherein the U shaped support includes a raised portion for securing a grill above a top of the cabinet.

9. The modular cabinet of claim 1, further comprising a bar kit having a back splash and a bar extending from the back splash, wherein the bar kit is to be mounted to a side of the cabinet so the backsplash extends upward from the top of the cabinet and the bar extends from the side of the cabinet.

10. The modular cabinet of claim 1, wherein at least a subset of the panels include a receiving panel and a faux designer panel to be secured to the receiving panel.

11. The modular cabinet of claim 1, further comprising a toe kick that includes an upper portion secured to the cabinet and a lower portion movably connected to the upper portion to provide for alignment on an uneven surface.

12. A modular cabinetry system comprising:

a plurality of modular cabinets connected together in an arrangement, wherein each cabinet comprises

a cabinet floor defining a shape of the cabinet;

one or more decorative panels to provide external walls for sides of the cabinet that will be external to the arrangement;

one or more divider panels to provide internal walls for sides of the cabinet that will be external to the arrangement;

a plurality of corner posts to be secured to corners of the cabinet floor, wherein each of the corner posts is configured to receive and secure some combination of decorative panels and divider panels from two sides;

a first upper support to connect between a first set of the corner posts to provide support to an upper end of a first side of the cabinet

an entry point along a side of the cabinet;

a plurality of mounting brackets to connect the plurality of modular cabinets together.

13. The modular cabinetry system of claim 12, wherein at least one of the plurality of modular cabinets includes the entry point having at least one pivoting door.

14. The modular cabinetry system of claim 12, wherein at least one of the plurality of modular cabinets includes the entry point having a frame providing an opening therein for accessing a device housed within the cabinet.

15. The modular cabinetry system of claim 12, wherein at least one of the plurality of modular cabinets includes a glide rail system mounted therewithin, wherein the entry point includes at least one pull out door having a drawer connected to a lower end thereof to house one or more bins, wherein the drawer is secured to the glide rail system.

16. The modular cabinetry system of claim 12, wherein at least one of the plurality of modular cabinets is a drawer cabinet, wherein the drawer cabinet includes

a faceplate to be secured to the cabinet, wherein the faceplate has a plurality of drawer holes formed therein and wherein each of the drawer holes has a gutter formed therearound to route water away; and

wherein the entry point includes at a plurality of pull out drawers, wherein a pull out drawer is associated with each drawer hole and each glide rail system, wherein a front panel for each pull out drawer has a frame and a recessed portion, wherein the frame abuts the faceplate and the recessed portion receives the gutter.

17. The modular cabinetry system of claim 12, wherein at least one of the plurality of modular cabinets is a grill cabinet, wherein

the second upper support is U shaped and connects between the corner posts along the second side of the cabinet and two sides adjacent thereto;

the U shaped support includes a raised portion for securing a grill above a top of the cabinet; and

the first upper support is lowered so that a portion of the first side of the cabinet is to receive a control panel for the grill.

18. The modular cabinetry system of claim 12, wherein at least one of the plurality of modular cabinets includes a bar kit having a back splash and a bar extending from the back splash, wherein the bar kit is to be mounted to the back of the cabinet so the backsplash extends upward from the top of the back of the cabinet and the bar extends from the back of the cabinet.

19. The modular cabinetry system of claim 12, wherein at least one of the plurality of modular cabinets includes a glide rail system mounted therewithin and a cabinet adapted to be received within the glide rail system, wherein the entry point includes at least one pivoting door.

20. The modular cabinetry system of claim 12, further comprising a corner cabinet to change direction of the plurality of modular cabinets in the arrangement.

21. The modular cabinetry system of claim 12, wherein at least a subset of the one or more decorative panels include a receiving panel and a faux designer panel to be secured to the receiving panel.

22. The modular cabinetry system of claim 12, further comprising a toe kick that includes an upper portion secured to the perimeter of the arrangement of the modular cabinetry system and a lower portion movably connected to the upper portion to provide for alignment on an uneven surface.