US20200332529A1

US20200332529A1 - Kitchen Kit

Info

Publication number: US20200332529A1
Application number: US16/855,334
Authority: US
Inventors: Robert Stanford; Stan Love; Darrin Griechen; James MEHLOS
Original assignee: Katerra Inc
Current assignee: VBC Tracy LLC
Priority date: 2019-04-22
Filing date: 2020-04-22
Publication date: 2020-10-22

Abstract

A kitchen kit is provided including a utility tower, infrastructure panels, and finishes. The kitchen kit allows each pre-fabricated component to provide a datum and alignment for the following component. The kitchen kit allows rapid installment of a kitchen with minimal to no measurement and alignment on site. A method of installing the kitchen kit is also provided.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/836,859 filed on Apr. 22, 2019, which is incorporated by reference as if fully set forth.

FIELD OF INVENTION

The present invention relates generally to the art of kitchen construction, and more specifically to packaging, shipping, and installing kitchen components, and a method of assembly thereof.

BACKGROUND

Kitchen construction and installation is a complicated, time-consuming task that can take months to complete. Installing the mechanical, electrical, and plumbing utilities takes time. Cabinets must be measured, ordered, and manually installed. After the cabinets are installed, the countertops are measured and ordered. There is a long wait period as countertop templating occurs. Moreover, backsplashes are time-consuming and labor intensive. Finally, assembly and tolerances are not well controlled, resulting in in-field adjustment, measuring, leveling, and rework. A kitchen kit that reduces cost and time of kitchen installation would be advantageous.

SUMMARY

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description will be better understood when read in conjunction with the appended drawings. For the purpose of illustration, there is shown in the drawings different embodiments. It should be understood, however, that the teachings are not limited to the precise kitchen kit shown.

FIG. 1A is a perspective view of a kitchen kit.

FIG. 1B is a perspective view of the infrastructure of the kitchen kit.

FIG. 1C is a perspective view of the finishes of the kitchen kit.

FIG. 2 is a perspective view of a packaged infrastructure kit.

FIG. 3 is a perspective view of a packaged finishes kit.

FIG. 4 is a perspective view of the packaged infrastructure kit placed on site.

FIG. 5 is a perspective view of the utility tower of the kitchen kit installed.

FIG. 6 is a perspective view of the infrastructure panels of the kitchen kit installed.

FIG. 7 is a perspective view of the packaged finishes kit placed on site.

FIG. 8 is a perspective view of the finishes of the kitchen kit installed.

FIG. 9 is a perspective view of the utility tower installed.

FIG. 10 is a view of a portion of the utility tower.

FIG. 11 is a perspective view of the utility tower with deployed articulating alignment arms.

FIG. 12 is a perspective view of the soffit components and end wall panels installed.

FIG. 13 is a perspective view of the rear panel and the sink base installed.

FIG. 14 is a perspective view of the base cabinets and backsplash installed.

FIG. 15 is a perspective view of the upper cabinets installed.

FIG. 16 is a section view of the soffit connection to the floor of the room above.

FIG. 17 is a perspective view of the alignment pins.

FIG. 18 is a perspective view of the backsplash installed.

FIG. 19 is a perspective view of a modular wiring system.

FIG. 20 is a front view of a second embodiment of a utility tower.

FIG. 21 is a front view of the second embodiment of a utility tower and a rear wall panel.

FIG. 22 is a front view of ledgers installed to the second embodiment of the utility tower and the rear wall panel.

FIG. 23 is a view of section 23 of FIG. 22.

FIG. 24 is a perspective view of a cabinet.

FIG. 25 is a perspective view of the finishes packaged.

FIG. 26 is a perspective view of the finishes placed on site.

FIG. 27 is a perspective view of the finishes rolled into place and installed.

DETAILED DESCRIPTION

A kitchen kit 100 is provided. The kitchen kit 100 incorporates prefabricated components that can quickly and easily be installed on site. The kitchen kit 100 includes features that allow the kitchen kit 100 components to be installed with little to no field alignment, measuring, or cutting. These features decrease the cost and labor of constructing a kitchen.
FIG. 1A is a perspective view of a kitchen kit 100. The kitchen kit 100 includes infrastructure components 200 and finishes 300. The infrastructure 200 provides the foundation or backbone to the kitchen kit 100. The infrastructure also provides datum points to align the finishes 300 when they are installed. The finishes 300 include essential kitchen components such as cabinets, sinks, appliances, etc. The finishes 300 may be selected by a user.
FIG. 1B is a perspective view of the infrastructure 200 of the kitchen kit 100. FIG. 1C is a perspective view of the finishes 300 of the kitchen kit 100. Each component of the kitchen kit 100 may be prefabricated. Once the kitchen kit 100 is transported to the site of the kitchen, the components may be quickly installed with little to no infield measuring, cutting, and aligning. Thus, the kitchen kit 100 also requires little to no tools to install. The first component of the kitchen kit 100 is installed and provides datum points and alignment for each component of the kitchen kit 100 installed thereafter. As the components of the kitchen kit 100 are sequentially installed, each component is installed according to the alignment and datum points provided by the previously installed component.
FIG. 2 is a perspective view of a packaged infrastructure kit 210. As shown in FIG. 2, the infrastructure 200 may be prefabricated in a factory and packed into an infrastructure kit 210 for easy transportation to the site of the kitchen. The infrastructure kit 210 is an efficient way to transport the infrastructure 200 to the site.
FIG. 3 is a perspective view of a packaged finishes kit 310. As shown in FIG. 3, the finishes 300 may be prefabricated in a factory and packed into a finishes kit 310 for easy transportation to the site of the kitchen. The finishes kit 310 is an efficient way to transport the finishes 300 to the site.
FIG. 4 is a perspective view the packaged infrastructure kit 210 placed on site. As shown in FIG. 4, the infrastructure kit 210 is transported to the site of the kitchen. The walls of the kitchen have already been built. The packaged infrastructure kit' 210 permits efficient shipping and handling. The infrastructure kit 210 may be craned onto the appropriate floor.
FIG. 5 is a perspective view of the utility tower 220 of the infrastructure kit 210 installed. As shown in FIG. 5, a utility tower 220, which is described in more detail herein, is a component of the infrastructure kit 210. The utility tower 220 is installed to the appropriate wall 400 of the kitchen.
FIG. 6 is a perspective view of the infrastructure panels 200 of the kitchen kit 100 installed. As shown in FIG. 6, the remaining infrastructure components 200 are installed according to the alignment and placement of the utility tower 220. The infrastructure 200 including the utility tower 220 are installed and secured to the wall 400.
FIG. 7 is a perspective view of the packaged finishes kit 310 placed on site. As shown in FIG. 7, the finishes kit 310 is transported to the site of the kitchen. The finishes kit 310 is packaged to allow efficient shipping and handling.
FIG. 8 is a perspective view of the finishes 300 of the kitchen kit installed. As shown in FIG. 8, the finishes 300 are secured to the installed infrastructure 200 shown in FIG. 6.
FIG. 9 is a perspective view of the utility tower 220 installed to the wall 400 of the kitchen. As shown in FIG. 9, the infrastructure components 200 include a utility tower 220, soffit components 230, end wall panels 240, and rear wall panels 250. The utility tower 220 includes pipes or conduit for the kitchen utilities. The utility tower 220 is installed and leveled. The utility tower 220 provides a datum for the remaining infrastructure components 200 and finishes 300. The utility tower 220 aligns the remaining infrastructure components 200 without the need for measurements or tools, thereby cutting the time of installation, labor and costs.
FIG. 10 is a view of a portion of the utility tower 220. As shown in FIG. 10, the utility tower 220 may include leveling feet 520. The utility tower 220 may also include a built-in level (not shown). The utility tower 220 may be leveled by inspecting the level and adjusting the leveling feet 520 accordingly. The utility tower 220 thus creates accurate datum points for the remaining kitchen kit 100 components, which are aligned and placed according to the utility tower 220. The utility tower 220 enables rapid, no measurement installation of all subsequent kitchen kit 100 components. The utility tower 220 may also include brackets 500 with alignment pins 510. The brackets 500 and alignment pins 510 may be used to install the finishes 300, such as a sink base, without measuring or aligning. The sink base may be installed on the brackets 500 and secured to the alignment pins 510.
FIG. 11 is a perspective view of the utility tower 220 with deployed articulating alignment arms 260 a-c. As shown in FIG. 11, the utility tower 220 may include at least one articulating alignment arm 260 a-c. The articulating alignment arms 260 a-c rotate out from the utility tower 220 after the utility tower 220 is installed to the wall of the kitchen 400. A first articulating arm 260 a may rotate up to create upper datum points and to receive the soffit components 230 without measuring. As shown in FIG. 11, a second and third articulating arm 260 b, 260 c may rotate up to create datum points and to receive soffit components 230 and end wall panels 240 without measuring. Alternatively, the second and third articulating arm 260 b, 260 c may rotate down from the utility tower 220 to create lower datum points and to receive and align lower finishes (not shown in FIG. 11) without measuring. The articulating alignment arms 260 b, 260 c may also include at least one alignment bracket 270 that may rotate out from the arm 260 b, 260 c via a hinge mechanism, as shown in FIG. 11. Alternatively, the articulating alignment arm 260 b, 260 c may include an alignment bracket 270 that attaches to the arm 260 b, 260 c post utility tower 220 and arm 260 b, 260 c installation.
FIG. 12 is a perspective view of the soffit components 230 and end wall panels 240 installed. As shown in FIG. 12, the soffit components 230 and the end wall panels 240 are installed according to the alignment and datum points of the articulating arms 260 a-c of the utility tower 220. The soffit components 230 are installed to the articulating arms 260 a-c. The end panels 240 are each installed to an alignment bracket 270 and or soffit components 230. Additionally, exhaust ductwork 275 for kitchen appliances is also installed.
FIG. 13 is a perspective view of the rear panels 250 and the sink base 320 installed. As shown in FIG. 13, the finishes kit 310 may include a sink base 320, lower cabinets 330, countertops 340, backsplash 350, and upper cabinets 360. Prior to installing the finishes 300 from the finishes kit 310, the rear wall panels 250 from the infrastructure kit 210 are installed to the wall of the kitchen 400. The rear wall panels 250 are placed and aligned according to the alignment and datum points of the utility tower 220 and/or soffit 230 and end wall panels 240 (shown in phantom for clarity). The sink base 320 is installed to the utility tower 220 per the brackets 500 and alignment pins 510 shown in FIG. 10. The sink base 320 creates datum points and alignment for the lower cabinets 330. The rear wall panels 250 and the sink base 320 may be installed before the soffit components 230 and end wall panels 240 are installed or after the soffit components 230 and end wall panels 240 are installed.
FIG. 14 is a perspective view of the base cabinets 330, backsplash 350 and countertops 340 installed. As shown in FIG. 14, the lower cabinets 330 are installed according to the alignment of the sink base 320. The lower cabinets 330 are installed to the rear wall panels 250 with alignment pins (not shown) in the rear wall panels 250. Although not shown, the alignment pins may be similar to the alignment pins 510 in the utility tower 220 as shown in FIG. 10. If the articulating arms 260 b, 260 c rotate down from the utility tower 220, the lower cabinets 330 may be installed to the rear wall panels 250 according to the alignment and datum points of the articulating arms 260 b, 260 c and alignment brackets 270. The countertops 340 are installed to the aligned lower cabinets 330. The backsplash 350 is pre-finished and installed to the rear wall panels 250 according to the alignment and datum points of the countertops 340. The backsplash 350 may snap in place to the rear wall panels 250.
FIG. 15 is a perspective view of the upper cabinets 360 installed. As shown in FIG. 15, the upper cabinets 360 are installed to the rear wall panels 250. The upper cabinets 360 are installed to the rear wall panels 250 with alignment pins (not shown) in the rear wall panels 250. Although not shown, the alignment pins may be similar to the alignment pins 510 in the utility tower 220 as shown in FIG. 10. The upper cabinets 360 are installed according to the alignment and datum points of the backsplash 350.
FIG. 16 is a section view of the soffit connection 230 to the floor of the room above. The soffit components 230 (not shown for clarity) must attach to the floor of the unit directly above. As shown in FIG. 16, slotted brackets 410 may be attached to the articulating arm 260 a or the floor joist 405. The slotted brackets 410 are used to attach the articulating arm 260 a and soffit components 230 to the floor joist 405. The slotted brackets 410 allow the articulating arm 260 a to remain level while accommodating variation in the floor joist 405.
FIG. 17 is a perspective view of the alignment pins 510. As shown in FIG. 17, the utility tower 220 and the rear wall panels 250 may include pre-installed alignment pins 510. The alignment pins 510 are screwed into or welded onto the utility tower 220 and rear wall panels 250 prior to being installed. If the alignment pins 510 are screwed in, once the utility tower 220 and rear wall panels 250 are installed, the alignment pins may be gradually unscrewed from the utility tower 220 and rear wall panels 250. After the alignment pins 510 are unscrewed an appropriate length, the finishes 300, for example the upper cabinets 360, may include pre-drilled holes which allow the finishes 300 to be slid onto and aligned with the alignment pins 510. A screw cap may then be installed on the alignment pin 510 to secure the finishes 300.
FIG. 18 is a perspective view of the backsplash 350 installed. The finishes 300 are standard panelized finishes. Because the finishes 300 are standard and pre-fabricated, no in-field measurement or piece work is required. As shown in FIG. 18, the backsplash 350 is also a pre-fabricated assembly. The countertop 340 may have a notched portion to accommodate and align the backsplash 350. Similarly, the backsplash 350 may include a notch on the top to accommodate and align the finishes 300 above the backsplash 350 including the upper cabinets 360.
FIG. 19 is a perspective view of a modular wiring system 600. As shown in FIG. 19, the kitchen kit 100 may also include a modular wiring system 600. The modular wiring system 600 is adapted to quickly connect the electrical system. The modular wiring system 600 may be pre-installed into one of the finishes 300 such as an upper cabinet 360. The modular wiring system 600 transforms the kitchen into an appliance. The modular wiring system 600 allows the kitchen to be pre-wired. Only one wire may be required to run from the junction box 610 to the kitchen. The junction box 610 allows for quick termination of the pre-wired and installed electrical components of the kitchen, such as outlets, switches, and lighting.
FIG. 20 is a front view of a second embodiment of a utility tower 220′. The kitchen kit 100 may include an alternative utility tower 220′ with vertical members 222 and horizontal members 224. As shown in FIG. 20, the utility tower 220′ includes horizontal members 224 that may extend past the vertical members 222. The length of the horizontal members 224 may vary according to the length of the kitchen wall 400. As shown in FIG. 20, a first end of the horizontal member 224 includes a ledger pin 226. The utility tower 220′ is installed to the kitchen wall 400 as previously described above. Although not shown, the utility tower 220′ may include leveling feet and a level.
FIG. 21 is a front view of the second embodiment of a utility tower 220′ and a rear wall panel 250′. As shown in FIG. 21, the rear wall panel 250′ is installed to the kitchen wall 400 adjacent to the utility tower 220′. The rear wall panel 250′ may be temporarily fastened to the utility tower 220′ until final alignment is completed. As previously discussed, the utility tower 220′ and rear wall panel 250′ are configured to receive and secure the finishes 300 of the kitchen kit 100.
FIG. 22 is a front view of ledgers 700 installed to the second embodiment of the utility tower 220′ and the rear wall panel 250′. The ledgers 700 are attached to the utility tower 220′ and the rear wall panel 250′. As shown in FIG. 22, the ledgers 700 may include alignment pins 510 to install the finishes 300. Each ledger 700 is pinned to the first end of the horizontal member 224 of the utility tower 220′ via the ledger pin 226. The ledger 700 is also pinned to the rear wall panel 250′. A level may be built into the ledger 700 to help level and install the ledger 700 substantially horizontal.
FIG. 23 is a view of section 23 of FIG. 22. As shown in FIG. 23, the ledger 700 may include a slot 710. The ledger 700 is pinned to the rear wall panel 250′ via the slot 710 and a pin 720. The slot 710 allows the ledger 700 to be slightly adjusted while remaining secured to the rear wall panel 250′. The slot 710 allows the pin 720 to move within the confines of the slot 710 without the ledger 700 coming unsecured from the rear wall panel 250′. Alternatively, the slotted end of the ledger 700 may be pinned to the utility tower 220′, while the non-slotted end is pinned to the rear wall panel 250′.
FIG. 24 is a perspective view of a cabinet 330. As shown in FIG. 24, the lower cabinets 330 and other applicable finishes 300 may include a platform 332. The platform 332 includes at least two rollers (not shown). These two rollers allow the cabinets 330 to be moved into place without equipment such as a moving dolly. The rollers may also include a leveling foot that may stabilize the cabinet 330 in place and may be used to level the cabinets 330 after or during installation.
FIG. 25 is a perspective view of the finishes 300 packaged. As shown in FIG. 25, the platforms 332 allows the cabinets 330 to be stacked and arranged on a crate 800 for easy and efficient shipping. The crate 800 and cabinets 330 are then wrapped and transported to the kitchen site.
FIG. 26 is a perspective view of the finishes 300 placed on site. As shown in FIG. 26, once on site, the crate 800 is removed and the lower finishes 300 may be rolled into their respective place in the kitchen via the rollers on the platforms 332.
FIG. 27 is a perspective view of the finishes 300 rolled into place and installed. As shown in FIG. 27, once in place, the lower finishes 300 are leveled and stabilized on the leveling feet. The finishes 300 may be installed as previously described.
The method of installing the kitchen kit 100 may be performed in a different order than the installation order described herein.
Having thus described in detail a preferred selection of embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made to the kitchen kit 100 without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.

Claims

What is claimed is:

1. A kitchen kit comprising:

a utility tower including at least one hook up for at least one kitchen appliance and including at least one articulating alignment arm, the utility tower including at least one mechanism to level the utility tower;

infrastructure panels including a rear wall panel including alignment pins, the rear wall panel aligned and installed according to the alignment and datum points of the utility tower; and

kitchen finishes including at least one of a sink base, a lower cabinet, an upper cabinet, a backsplash, a countertop and a kitchen appliance, the kitchen finishes aligned and secured to the rear wall panel via the alignment pins.

2. The kitchen kit of claim 1, wherein the at least one articulating alignment arm articulates down from a side of the utility tower.

3. The kitchen kit of claim 1, wherein the at least one articulating alignment arm articulates up from a side of the utility tower.

4. The kitchen kit of claim 1, further including at least one alignment bracket attached to the at least one articulating arm.

5. The kitchen kit of claim 1, wherein the infrastructure panels include at least one end wall panel, and a soffit.

6. The kitchen kit of claim 5, wherein the at least one end wall panel and the soffit are secured to the at least one articulating alignment arm.

7. The kitchen kit of claim 1, wherein the utility tower provides alignment and datum points for the infrastructure panels and the kitchen finishes.

8. A kitchen kit comprising:

a utility tower including at least one hook up for at least one kitchen appliance, the utility tower including at least one vertical member and at least one horizontal member connected to the at least one vertical member;

a rear panel configured to install adjacent to the utility tower, the rear panel including at least one vertical stud;

at least one ledger including alignment pins, a first end, and a second end, the first end configured to attach to the at least one horizontal member of the utility tower and the second end configured to attach to the at least one vertical stud of the rear panel; and

kitchen finishes including at least one of a sink base, a lower cabinet, an upper cabinet, a backsplash, a countertop and a kitchen appliance, the kitchen finishes aligned and secured to the alignment pins.

9. The kitchen kit of claim 8, wherein the at least one ledger includes a level.

10. The kitchen kit of claim 8, wherein the at least one ledger includes a slot in at least one of the first end and the second end.

11. The kitchen kit of claim 10, wherein the at least one ledger is configured to pin to at least one of the horizontal member and the vertical stud via the slot.

12. A method of installing a kitchen kit comprising:

receiving the kitchen kit, the kitchen kit including at least one end wall panel, a soffit, a rear panel, finishes, and a utility tower including at least one articulating alignment arm;

installing the utility tower to a kitchen wall;

leveling the utility tower;

deploying the at least one articulating alignment arm from the utility tower;

installing the at least one end wall panel to the at least one articulating alignment arm;

installing the soffit to the at least one articulating alignment arm;

installing the rear panel to the kitchen wall; and

installing the finishes to the rear panel.

13. The method of claim 12, wherein the finishes include at least one of a sink base, at least one cabinet, and a backsplash.

14. A method of installing a kitchen kit comprising:

receiving the kitchen kit including a utility tower, a rear panel, at least one ledger, and finishes, the at least one ledger including alignment pins;

installing the utility tower to a kitchen wall;

installing the rear panel to the kitchen wall adjacent to the utility tower;

attaching a first end of the at least one ledger to the utility tower;

attaching a second end of the at least one ledger to the rear panel; and

installing the finishes to the alignment pins in the at least one ledger.

15. The method of claim 14, wherein the finishes include at least one of a sink base, at least one cabinet, and a backsplash.

16. The method of claim 14, wherein at least one of the first end and second end of the at least one ledger includes a slot.

17. The method of claim 14, wherein the at least one ledger includes a leveling device.

18. An alignment apparatus for a kitchen comprising:

a plurality of kitchen components, a first kitchen component of the plurality of kitchen components is installed to a wall of the kitchen and provides alignment and datum points for each kitchen component of the plurality of kitchen components installed after the first kitchen component.

19. The alignment apparatus of claim 18, wherein the plurality of kitchen components includes at least one of a utility tower, a rear wall panel, a soffit, and an end wall panel.

20. A method of installing a kitchen comprising:

installing an alignment apparatus;

leveling the alignment apparatus; and

installing a plurality of kitchen components sequentially wherein a first of the plurality of kitchen components is installed and aligned according to alignment and datum points of the alignment apparatus and each kitchen component of the plurality of kitchen components installed thereafter is installed and aligned according to alignment and datum points of the previously installed kitchen component.