US20100270445A1

US20100270445A1 - Cabinet installation assembly

Info

Publication number: US20100270445A1
Application number: US12/754,764
Authority: US
Inventors: Paul L. Johnson
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-04-27
Filing date: 2010-04-06
Publication date: 2010-10-28

Abstract

A cabinet installation system is characterized by the use of adjustable brackets and rails used to align a wall or base cabinet for mounting the cabinets on a wall. The brackets include horizontal and vertical legs which are connected together at one end and by an adjustable device at the other end so that the brackets have a triangular configuration. The adjustable device varies the angle between the legs so that when the vertical leg of a bracket is mounted on a wall, the horizontal leg can be adjusted to a level position. Front and rear rails are adjustably connected with the brackets. With the brackets arranged in spaced relation on a wall and the horizontal legs adjusted to level, the rails are adjusted relative to each bracket, respectively, so that the rails are linear, parallel and spaced according to the depth of the cabinet. When a cabinet is aligned relative to the rails, it can be secured to the wall in a straight and level position.

Description

This application is a continuation-in-part of U.S. patent application Ser. No. 12/420,252 filed Apr. 27, 2009.

BACKGROUND OF THE INVENTION

The subject invention relates to built-in cabinets and more specifically to an assembly for the installation of wall and base cabinets.
There are two schools of thought as to where to start the installation of a set of wall and base cabinets. One procedure is to install the base cabinets first and the other is to install the wall cabinets first. Each procedure has its benefits. However, when the base cabinets are installed first, access to the wall cabinets is difficult because the base cabinets protrude from the face of the wall cabinets. Conversely, when wall cabinets are installed first there is nothing to hold them in place while they are leveled, plumbed and set to assure that the cabinet box is not racked or secured to an uneven wall leaving the box twisted. Two installers are generally needed to install wall cabinets so that one can hold the cabinet in place while the other fastens the cabinets to the wall.

BRIEF DESCRIPTION OF THE PRIOR ART

Various devices for supporting cabinets during mounting are known in the prior art as evidenced by the Goss U.S. Pat. No. 4,981,288 and the Cunningham US patent application publication No. 2009/0008849. These prior devices include brackets for supporting a wall cabinet while it is fastened to the wall, with the Goss device being adjustable. While these prior devices operate satisfactorily, they are rather cumbersome and do not provide both level and depth alignment of a cabinet relative to a wall that is not square or even.
The present invention was developed in order to overcome these and other drawbacks of the prior cabinet mounting assemblies by providing a mounting assembly that can support and align a cabinet and that allows a cabinet to be mounted with only one installer.

SUMMARY OF THE INVENTION

Accordingly, it is a primary object of the invention to provide a cabinet installation assembly including a plurality of brackets each of which includes horizontal and vertical legs which are connected at one end so that the angular relation of the legs can be adjusted relative to each other. An adjustment device is connected between the other ends of the legs, so that the brackets have a generally triangular configuration. The adjustment mechanism displaced the horizontal leg relative to the vertical leg to vary the angle between the legs. Front and rear rails are connected with the horizontal leg. More particularly, the horizontal leg contains a spaced pair of slots adjacent to the ends of the leg. Fasteners are provided which pass through the slots and engage threaded openings in the rails so that the rails can be arranged at fixed locations relative to a wall on which the vertical legs of the brackets are mounted. The adjustment mechanisms are operable to level the horizontal legs and the rails are adjusted to a linear configuration to accommodate variations in the wall. A cabinet to be connected with the wall is aligned relative to the front and rear rails and then shimmed and fastened to the wall.
According to a further object of the invention, the adjustment mechanism comprises a turnbuckle assembly and the rails have two portions defining an L-shaped configuration. The threaded openings are provided in one portion of each rail and the other portion of each rail defines a flange with which the front and rear edges of the cabinet are aligned.
The horizontal and vertical legs preferably include angled portions at the end where the legs are connected with the hinge. The angled portions define a region for accommodating the flange of the rear rail for alignment with the rear edge of the cabinet.
According to another object of the invention, the legs are integrally formed as an L-shaped bracket and a cam mechanism is used to adjust the horizontal leg relative to the vertical leg to level a cabinet prior to mounting on a wall.

BRIEF DESCRIPTION OF THE FIGURES

Other objects and advantages of the invention will become apparent from a study of the following description when viewed in the light of the accompanying drawing, in which:

FIG. 1 is a perspective view of a mounting bracket of the cabinet installation assembly according to the invention;

FIG. 2 is a side plan view of the mounting bracket of FIG. 1;

FIG. 3 is cut away view of the turnbuckle adjustment mechanism for the mounting bracket of FIG. 1;

FIGS. 4 and 5 are top and side plan views, respectively, of a front rail of the cabinet installation assembly according to the invention;

FIGS. 6 and 7 are top and side plan views, respectively, of a rear rail of the cabinet installation assembly according to the invention;

FIGS. 8 and 9 are front and top plan views, respectively, of a fastener of the cabinet installation assembly according to the invention;

FIG. 10 is a side view of the cabinet installation assembly according to the invention used for mounting a wall cabinet;

FIG. 11 is a side view of the cabinet installation assembly according to the invention used for mounting a base cabinet;

FIG. 12 is an exploded perspective view of a cabinet mounting bracket assembly according to an alternate embodiment of the invention;

FIGS. 13 and 14 are side and front plan views, respectively, of a lower adjustment bracket for the mounting bracket assembly of FIG. 12;

FIGS. 15 and 16 are side and front plan views, respectively, of an upper adjustment bracket for the mounting bracket assembly of FIG. 12; and

FIGS. 17, 18, and 19 are top, bottom, and front plan views of an adjustment handle for the mounting bracket assembly of FIG. 12.

DETAILED DESCRIPTION

The cabinet installation assembly according to one embodiment of the invention includes a plurality of adjustable brackets, one of which is shown in FIGS. 1-3. Each bracket 2 includes a horizontal leg 4 and a vertical leg 6 which are connected at one end via a hinge 8 so that the angle between the legs is adjustable. More particularly, an adjustment device 10 is connected between the other ends of the horizontal and vertical legs so that the bracket has a triangular configuration. The adjustment device 10 is preferably removably connected with the legs. Thus, the vertical leg includes a flange 12 containing an opening and the horizontal leg includes a flange 14 also containing an opening. A clevis pin 16 passes through openings in the ends of the adjustment device and the flanges to connect the ends of the adjustment device with the respective legs. A cotter pin 18 passes through the clevis pin to fasten it in place.
The vertical leg contains an upper slot 20 and a lower slot 22 for receiving a fastener such as a screw, not shown, to fasten the bracket to a wall by driving the screw into a stud of the wall. A plurality of brackets are mounted along the wall in spaced relation at the same height to assist with support and/or alignment of a cabinet or cabinets as will be developed in greater detail below.
Referring to FIGS. 2 and 3, the adjustment device contains a sleeve 24 having a turnbuckle 26 or other similar device allowing for left hand threads on one side and right hand threads on the other connected with an inner surface thereof. The turnbuckle or center of the adjustment arm is connected with an upper right hand threaded rod 28 secured to an upper portion 30 of the adjustment device and a lower left hand threaded rod 32 secured to a lower portion 34 of the adjustment device. Rotation of the sleeve by the user in one direction causes the turnbuckle to rotate which in turn displaces the threaded rods and the upper and lower portions of the adjustment device toward each other and rotation of the sleeve in the opposite direction displaces the threaded rods and the upper and lower portions of the adjustment device away from each other. Because the adjustment device is connected between the ends of the legs, the sleeve is operable to displace the ends of the legs toward and away from each other to vary the angle between the legs. With the vertical leg fastened to a wall, rotation of the sleeve 24 raises or lowers the end of the horizontal leg remote from the wall.
The cabinet installation system according to the invention further includes front and rear rails connected with the brackets. The front rail 36 is shown in FIGS. 4 and 5 and has an L-shaped configuration including a first portion 36 a which contains a plurality of spaced threaded openings 38 and a second flange portion 36 b. The flange portion is arranged generally normal to the first portion. The rear rail 40 is similar to the front rail in that it also has an L-shaped configuration with first and second portions 40 a and 40 b and threaded openings 42 in the first portion. The second or flange portion 40 b is preferably shorter than the flange portion of the front rail. The rails are provided in suitable lengths such as six feet to extend across a plurality of brackets mounted on a wall. The rails are connected with the brackets using fasteners 44 shown in FIGS. 8 and 9. Each fastener includes a knob 46 and a threaded stem 48.
Referring back to FIG. 1, the horizontal leg 4 includes a first slot 50 adjacent to the end where the adjustment device is connected with the horizontal leg and a second slot 52 adjacent to the hinge 8. In order to connect the rails with the brackets, the fasteners pass through the slots and into a selected threaded hole in the respective rails. The elongated slots allow the fasteners be positioned laterally relative to the horizontal leg of each bracket. In this manner, the fasteners and thus the rails can be positioned relative to each bracket so that the rails are arranged in a linear fashion and parallel to each other, even though the wall to which the brackets are fastened may not be perfectly flat or square. Moreover, the rails can be spaced according to the depth of the cabinet being installed. Other adjustable fastening devices may be used for connecting the rails with the horizontal legs of each bracket.
Use of the cabinet installation system for mounting cabinets will be described with reference to FIGS. 10 and 11. In FIG. 10, the cabinet installation system is shown for mounting a wall cabinet 50. A plurality of brackets 2 (of which one is shown in FIG. 10) are mounted in parallel spaced relation on a wall 52. The front rail 36 is connected with the bracket via a front fastener 44 with the flange 36 b extending downwardly. The rear rail 40 is connected with the bracket via a rear fastener 44 with the flange 40 b extending downwardly into the void defined by the angled portions of the horizontal and vertical legs adjacent to the hinge. The brackets are adjusted by turning their turnbuckles so that the front and rear rails are level. The rails are adjusted relative to the slots in the horizontal legs of each bracket so that the rails are parallel and linear and spaced according to the depth of the cabinet. The cabinet is rested on the front and rear rails with the front edge of the cabinet aligned with the flange of the front rail. Shims are inserted between the cabinet and the wall and the cabinet is then secured to the wall studs in a conventional manner. The mounted cabinet is not twisted or curved in any manner and is also then plumb and level.
FIG. 11 shows the cabinet installation system for a base cabinet 54. A plurality of brackets 2 are mounted upside down relative to the brackets of FIG. 10. The rails are connected with the brackets using fasteners 44 and the rail flanges are directed upwardly. The brackets are adjusted so that the rails are level and the rails are adjusted relative to the horizontal legs so that the rails are parallel and linear and spaced according to the depth of the cabinet. The cabinet is shimmed at the rear and bottom so that its front and rear edges are aligned with the rail flanges. Once properly positioned, the cabinet is fastened to the wall 52, and preferably the wall studs, in a conventional manner.
Referring now to FIGS. 12-19, an alternate and preferred embodiment of the invention will be described. In FIG. 12, a pair of mounting brackets 102 is shown. Each bracket includes a horizontal leg portion 104 and a vertical leg portion 106. The leg portions are integrally formed as a unitary member having an L-shaped configuration. Preferably, the member is formed of a lightweight metal such as aluminum which has a limited amount of flexure where the ends of the leg portions meet. The vertical leg portion includes upper 120 and lower 122 slots for mounting the vertical leg portion on a wall in a manner similar to that of the embodiment of FIGS. 1 and 2.
An adjustment mechanism 110 is removably connected between the free ends of the horizontal and vertical leg portions so that the bracket has a triangular configuration. The adjustment mechanism includes a lower adjustment bracket 124 connected at its lower end with the lower end of the vertical leg portion by a suitable fastener such as a bolt 126 and an upper adjustment bracket 128 connected at its upper end with the free end of the horizontal leg portion by a similar fastener 130. As shown in FIGS. 13 and 14, the lower adjustment bracket 124 contains a slot 124 a toward its upper end. As shown in FIGS. 15 and 17, the upper adjustment bracket 128 contains a plurality of spaced openings 128 a toward its upper end. Referring back to FIG. 12, the upper and lower adjustment brackets overlap and fasteners such as bolts 132 pass through the slot 124 a in the lower bracket 124 into the openings 128 a in the upper bracket 128 for connection with nuts 134. When the bolts 132 are loosened, the upper and lower brackets may be slidably displaced relative to one another to raise or lower the end of the horizontal leg portion relative to the vertical leg portion. When the horizontal leg portion is level, the fasteners 132 are tightened to secure the bracket assembly in a given position.
In order to assist with adjustment of the brackets 124, 128, an adjustment handle 136 is provided as shown in FIG. 12. The handle is shown in greater detail in FIGS. 17-19. The handle includes a circular base portion 136 a and a gripping portion 136 b which extends from the top of the base portion. The base portion includes an opening 136 c which is offset from the center of the base portion as shown in FIGS. 17 and 18. A fastener such as a bolt 138 is used to connect the handle with the uppermost opening 128 a in the upper adjustment bracket 128 and then secured with a nut 140. The connection affords rotational movement of the handle 136 relative to the bracket 128. The base portion 136 a of the handle abuts against the upper edge of the lower adjustment bracket 124 as shown in FIG. 12. Because the pivot point of the handle base portion 136 a is at the bolt 138 which is offset from the center of the base portion, the base portion acts as a cam against the upper edge of the bracket 124. Accordingly, rotation of the handle displaces the lower bracket relative to the upper bracket, effectively extending and retracting the adjustment mechanism to raise and lower the end of the horizontal leg portion 104 of the bracket relative to the vertical leg portion 106.
As in the embodiment of FIGS. 1-11, front rails 136 and rear rails 140 are connected with the horizontal leg portions of a series of spaced brackets via fasteners 144 as shown in FIG. 12 to provide a guide for mounting cabinets in a level and linear position on a wall. An extrusion 146 is provided to connect/align front rail sections.
The brackets and rails of the cabinet installation system can be formed of any rigid, durable material such as metal or synthetic plastic. In addition, when mounting a series of cabinets, spaces can be provided between cabinets to accommodate appliances, light fixtures, and the like.
While the preferred embodiment of the invention has been illustrated and described, it will be apparent to those of ordinary skill in the art that various changes and modifications may be made without deviating from the inventive concepts set forth above.

Claims

1. A cabinet installation bracket, comprising

(a) a generally vertical leg adapted for removable connection with a wall;

(b) a generally horizontal leg connected at one end with an upper end of said vertical leg;

(c) an adjustment mechanism connected with the other ends of said horizontal and vertical legs, said adjustment mechanism being operable to displace said horizontal leg relative to said vertical leg to level said horizontal leg, whereby when a cabinet is placed on said horizontal leg, said cabinet is arranged in a level position for connection with the wall.

2. A cabinet installation bracket as defined in claim 1, wherein said adjustment mechanism comprises a turnbuckle assembly.

3. A cabinet installation bracket as defined in claim 1, wherein said adjustment mechanism comprises a pair of brackets which are slidably connected for relative movement along their length.

4. A cabinet installation bracket as defined in claim 3, wherein said brackets include a first fastener for locking said brackets in a selected position relative to one another, thereby to secure said horizontal leg in a selected position relative to said vertical leg.

5. A cabinet installation bracket as defined in claim 4, wherein said first fastener comprises at least one bolt and nut assembly which passes through aligned openings and slots in said brackets, respectively.

6. A cabinet installation bracket as defined in claim 4, and further comprising a handle connected with said brackets for displacing one of said brackets relative to the other bracket.

7. A cabinet installation bracket as defined in claim 6, wherein said handle includes a cam mechanism abutting against one end of one of said brackets.

8. A cabinet installation bracket as defined in claim 1, wherein said horizontal and vertical legs are integrally connected.

9. A cabinet installation bracket as defined in claim 1, and further comprising a hinge for connecting said horizontal and vertical legs.

10. A cabinet installation assembly comprising a plurality of brackets as defined in claim 1 mounted in spaced parallel relation on the wall, and further comprising a first rail adjustably connected with the horizontal legs of said brackets and arranged transversely thereto, whereby said adjustment mechanism of each bracket may be operated to displace said horizontal leg of each bracket until said first rail is level and said first rail is adjusted relative to each horizontal leg until said first rail is linear, and further whereby a cabinet to be installed on the wall is aligned with an edge of said first rail to position the cabinet prior to fastening it to the wall.

11. A cabinet installation assembly as defined in claim 10, wherein said horizontal leg of each of said brackets contains a slot for receiving a second fastener for adjustably connecting said first rail to said horizontal leg.

12. A cabinet installation assembly as defined in claim 11, and further comprising a second rail adjustably connected with the horizontal legs of said brackets in spaced relation to said first rail, said first and second rails being arranged at opposite ends of said horizontal legs for supporting a cabinet whose front edge is aligned with said first rail.

13. A cabinet installation assembly as defined in claim 12, wherein said first and second rails contain a plurality of spaced parallel threaded openings for receiving said fastener.

14. A cabinet installation as defined in claim 13, wherein said first and second rails have two portions defining an L-shaped configuration, said threaded openings being arranged in one portion of said rails, the other portion defining a flange with which the edges of the cabinet are aligned.

15. A cabinet installation as defined in claim 14, wherein said one end of said horizontal and vertical legs includes end portions angled toward said hinge, thereby to define a region for accommodating a flange of said second rail for alignment with the rear edge of the cabinet.