FIELD OF THE INVENTION

The invention relates to a method of assembling a cabinet frame from a plurality of folded profiles, a cabinet frame and a cabinet frame assembly.

BACKGROUND OF THE INVENTION

Cabinets for electric components and control systems are used in many different sizes. Typically, cabinets are built of a heavy metal frame to which side panels are mounted which together forms a suitable enclosure for high power components, heavy cobber conductors, control systems, etc.

Due to the different use of cabinets and environment in which the cabinets are used a variety of different cabinet designs exists. In some technical fields such as cabinets for high power electric systems, cabinets are typically designed according to a specification describing e.g. IP classification, height, depth and width of the cabinet. Based on the specifications, the cabinet frame is produced and equipped with side panels and electric components.

Known methods of producing cabinet frames include prior art document WO2008124909. Here it is described how to make several “V” cuts in a cabinet profile allowing to bend the profile along a transversal fold line and thereby creating front and back frames. The front and back frames are then connected to each other via depth profiles mounted to the front and back frames by couplings.

Prior art cabinets including the one disclosed in WO2008124909 requires time consuming manual assembling. Further, the stability of prior art cabinets is not always sufficient before side panels are mounted.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a cabinet frame which is lightweight, stable and easy to assemble, therefore the invention relates to a method of assembling a cabinet frame, the method comprising the steps of: establishing a first folding area in a profile, the first folding area comprise a cutout part oriented in a first direction, establishing a second folding area in the profile, the second folding area comprise a cutout part oriented in a second direction different from the first direction, folding the profile at the first folding area in the first direction defined by the cutout part, folding the profile at the second folding area in the second direction defined by the cutout part, repeating steps a)-d) to establish four folded profiles, and connecting the four profiles to a cabinet frame.

The above method is advantageous in that the cabinet frame is created from four identical profiles which can be prepared and folded on site of assembling the cabinet frame.

Further, the effect of assembling a cabinet frame according to the above method is that the folding operations and assembly of the folded profiles requires no particular skills or strength from the person carrying out the method. Accordingly, the assembly of the cabinet frame can be made on the factory floor of the site where the cabinet frame is needed (i.e. for mounting with electric equipment). Thereby, transport and storage volume of cabinet frames are reduced significantly in that four non-folded profiles takes op significantly less volume/space than assembled cabinet frames.

According to an embodiment of the invention, the step of connecting the four profiles1a-1dto a cabinet frame includes the steps of: connecting profile1aand profile1b, thereby forming a first side and part of a second side and fourth side of the cabinet frame, connecting profile1cto profile1b, thereby forming the second side and part of a third side of the cabinet frame, and connecting profile1dto profile1cand profile1a, thereby forming the third and fourth sides of the cabinet frame.

In this way four (preferably) identical profiles are established which when connected forms a cabinet frame. Individually, the four profiles each constitute one horizontal and two vertical (or vice versa) elements of a cabinet frame (when each of the folding areas are folded 90° degrees).

According to an embodiment of the invention, the step of connecting the four profiles to a cabinet frame includes the steps of: connecting profile1aand profile1b, thereby forming a first cabinet part2a, connecting profile1cand profile1d, thereby forming a second cabinet part2b, and connecting the first and second cabinet parts2a,2b, thereby forming the cabinet frame.

This is advantageous in that it has the effect, that a cabinet frame can be assembled from connecting the first and second cabinet part in one direction. Accordingly, this eases automatization of the cabinet assembly process.

According to an embodiment of the invention, the orientation of the second folding area is established in the profile perpendicular to the orientation of the first folding area, and wherein the first and second folding areas further includes an additional cut-out part.

This is advantageous in that it has the effect, that the profiles when folded can be used to form a square formed cabinet frame.

According to an embodiment of the invention, step c and step d includes mounting a corner fitting in the profile at the first folding area and at the second folding area prior to folding, wherein a first part of the corner fitting is mounted inside the profile leaving a second part of the corner fitting extending outside the profile at the additional cut-out part when the profile is folded.

The corner fitting is advantageous in that has the effect, that it enables easy mounting of an end of one profile to a corner of another profile.

According to an embodiment of the invention, the profiles and/or cabinet parts are mounted by means of corner fittings.

This is advantageous in that it has the effect, that assembly can be made very fast and with identical corner fittings in each of the connections of profiles. This is furthermore advantageous in that this eases automatization of the cabinet assembly process.

According to an embodiment of the invention, the corner fitting comprises a nut, threaded part or a flexible protruding part by means of which the corner fitting is fastened to the profile. Advantageous in that it has the effect, that the corner fitting is then releasably fastened by the bolt or by friction.

Preferably the nut or threaded part is embedded e.g. by molding, pressed or 3D printed to the corner fitting which thereby holds the nut or threaded part when a bolt is inserted and tightened through a hole in the profile for fastening the corner fitting to the profile. The flexible protruding part is advantageous in that assemble of the cabinet can be made without use of bolts.

According to an embodiment of the invention, at least one of step a and step b further includes establishing a folding angle support part, and wherein at least one of step c and step d further includes folding the profile in an angle defined by the folding angle support part.

Moreover, the invention relates to a cabinet frame assembled by four folded profiles each having a first folding area (3a) and a second folding area (3b), wherein the first folding area comprise a cutout part oriented in a first direction and the second folding area comprises a cutout part oriented in a second direction, wherein the second direction is perpendicular to the first direction.

According to an embodiment of the invention, at least one of the first and second folding areas further comprises a folding angle support part, wherein the folding angle support part comprise a protruding part and a cave in part. The folding angle support part is advantageous in that it has the effect, that it has the effect of increasing precision of/defining the folding angle (angle in which the profile is folded at the folding areas) and stability of the “folded corner”.

The four profiles are preferably similar profiles forming the main supporting structure of the cabinet (also referred to as enclosure) i.e. the main frame of the cabinet is built from such profiles. Similar should here be understood as structural identical i.e. all having two folding areas. Accordingly, number of holes, notch, caving's, etc. may not be the same on each profile. The cabinet is preferably an electric cabinet, but could in principle be any kind of enclosure.

The cutout part is formed by completely removing part of the profile material from at least part of the folding area. The profile material is removed from both sides of the predetermined folding line on the opposite side of the profile relative to the folding line. Hence, the cutout part is advantageous in that it has the effect, that it allows the profile to be folded.

The folding angle support part is advantageous in that it has the effect that it ensures that the angle of which the profile is folded is precisely the intended angle. This is ensured when contact is obtained between the protruding part and the cave in part of the folding angle support part.

Further, the folding angle support part has the effect, that it can be easily determined if the profile is folded in the right plane. Hence an accurate fold of the profile will result in that the outer (and inner) side of the protruding part of the folding angle support part is in the same plane as the outer (and inner) side of the cave in part of the folding angle support part when the profile is folded.

Further, the folding angle support part has the effect, that when the profile is folded, the interaction of the protruding part in the cave in part maintains the profile in its folded position. This interaction between surface of the protruding and cave in part further has the effect, that the length of the interaction of surfaces is longer than known straight interactions and thereby the fold becomes more stable.

According to an embodiment of the invention, the folding area further comprise at least one folding recess located between the protruding part and cave in part of the folding angle support part.

The folding recess is advantageous in that it has the effect, that deformation of the profile material removed to create the folding recess is not required. This leads to less force needed to fold the profile and it eliminates the need for post-treatment of the deformed profiled material if a plane surface of the profile is desired.

Preferably, the folding area comprise two folding recesses positioned on opposed sides of the same plane/side or folding line about which the profile is folded.

Two folding recesses are advantageous in that there between a predetermined folding line is formed. The folding recesses and the folding line has the effect that it becomes possible with limited force (i.e. manually) to fold the profile precisely at the predetermined folding line without deformation of the profile material. Further, such folding line has the effect that the fold of the profile will naturally follow the folding line

According to an embodiment of the invention, the folding area comprise an additional cutout part.

The additional cutout part is advantageous in that it facilitates mounting a corner support element, having the effect of enabling mounting of a further profile (folded or un-folded) to the folded profile. Hence by the corner support element, it becomes possible to connect one profile to another profile thereby forming the resulting cabinet frame. Accordingly, the additional cutout part of the first folding area is “rotated” 90 degrees compared to the cutout part of the second folding area and therefore cut out in two adjacent sides of a square formed profile. In the embodiment where angle support parts are part of the folding areas, these are also rotated, but may in addition be mirrored depending which direction to folding area needs to be folded.

According to an embodiment of the invention, the folding area comprise one or more holes.

The one hole which is preferred has the effect, that it facilitates fastening the cabinet frame, when assembled, to a cabinet base/foundation or to another cabinet frame.

If a plurality of holes is provided, they are preferably provided asymmetric on both sides of the folding area.

Further, if a plurality of holes is provided in the profile these are advantageous in that they have the effect, that a corner support can be precisely fixed in a predetermined position to the profile thereby maintaining a desired angle of the folded profile.

Further, if a plurality of holes is provided in the profile these are advantageous in that they have the effect, that a corner fitting can be attached to both sides of the folding area when folded thereby increasing stability of the cabinet frame at least when side panels are not mounted on the cabinet frame e.g. during transportation or mounting of e.g. electric parts in the cabinet.

According to an embodiment of the invention, at least part of the one or more holes facilitates fastening a corner support to the profile.

This is advantageous in that it has the effect that stability of the folded profile is increased.

Using a corner support is advantageous in that it has the effect that by these corner supports two adjacent cabinets can be fastened together.

The corner support element is preferably made of a metal or similar material as the profile, a preferred material is aluminium.

One or more of the plurality of holes is preferably used for securing the assembled cabinet frame to a base or foundation.

According to an embodiment of the invention, a corner fitting comprises a first corner fitting part facilitating fastening the corner fitting to the profile, preferably by fastening the first corner fitting part inside the profile.

Preferably the corner fitting is an independent part which can be crated from a 3-dimensional (3D) printing process or molded.

According to an embodiment of the invention, one of the one or more holes facilitates fastening the first part of the corner fitting inside the profile by means of a bolt.

In an embodiment, the corner fitting comprises a nut by means of which the corner fitting can be fastened to the profile by means of a bolt. Preferably, the nut is molded or in another way fastened to the corner fitting which thereby holds the nut when a bolt is inserted and tightened through a hole in the profile for fastening the corner fitting to the profile.

In an embodiment, the corner fitting comprises a threated part which facilitates tightening/fastening a bolt directly to the threated part of the corner fitting. The threated part can be provided e.g. by 3D printing of the corner fitting.

According to an embodiment of the invention, the first part of the corner fitting comprises a flexible protruding part.

A flexible protruding part is advantageous in that it has the effect, that mounting the corner fitting inside the profile can be made without bolts and nuts. This is due to the friction or displacement of the flexible protruding part against the inside of the profile when the corner fitting is mounted inside the profile.

According to an embodiment of the invention, the corner fitting comprises a second corner fitting part which is perpendicular relative to the first part of the corner fitting and which extends outward in a direction perpendicular to the profile when mounted in the profile.

This is advantageous in that it has the effect, that when the corner fitting is mounted in the profile, via the perpendicular second corner fitting part, the profile can be mounted to another profile i.e. connection of two profiles is then facilitated.

The corner fitting is preferably made of a material different from the material of the profile. Preferably, the corner fitting is made of a plastic material strong enough to hold a nut or threated part, thereby facilitating fastening the corner fitting and the profile by means of a bolt.

According to an embodiment of the invention, the second folding area is rotated 90 degrees on the profile with respect to the first folding area. Having two folding areas is advantageous in that it has the effect, that it then becomes possible to form three sides of a cabinet frame from the same profile.

Accordingly, having a third folding area would lead to the possibility of forming four sides of a cabinet and so on.

Rotating a second folding area compared to a first folding area is advantageous in that it has the effect, that the three sides of a cabinet frame then is in three different planes. Accordingly, if the second folding area is folded 90° degrees with respect to the first folding area, part of a rectangular or quadratic cabinet frame is formed. Especially when folding e.g. a rectangular cabinet frame, it is advantegeous to form three sides i.e. high, depth and width from one profiled, because it has the effect that the resulting panel becomes more stable that cabinet profiles formed for folded profiled in only two planes.

According to an embodiment of the invention, the profile is a square formed profile.

A square formed profile is advantageous in that it has the effect, that the resulting cabinet frame has one side of the square formed profile to which it is possible to mount e.g. side panels, components, plates, drawers etc. the entire profile are plane.

According to an embodiment of the invention, the profile is circular.

A circular formed profiled adds flexibility to the dimensions in which a cabinet frame can be designed in that it has the effect, that in contrary to square formed profiles which can only be folded in four planes with 90° degrees between, a circular profile can be folded in any plane.

According to an embodiment of the invention, the profile is made of aluminium, steel or plastic.

Plastics is preferably coated with e.g. a glass fibre material to improve strength. Plastics is advantageous in that it has the effect, that it is possible to deform, lighter and cheaper than metal materials.

Aluminium is advantageous in that it is not attacked by corrosion and together with steel, it is advantageous in that it is a strong material leading to a solid and ridged resulting panel.

According to an embodiment of the invention, the outer dimensions of the profile are preferably between 10×10 mm and 50×50 mm. Standard dimensions are in steps of 5 mm and therefore steps of 5 mm are preferred sizes between the 10×10 mm and 50×50 mm. The thickness of the profiles is preferably between 1 and 2,5 mm.

If size and weight of the panel or material to be kept inside the panel requires so, the material of the profile can be even larger. It should be mentioned that the profile preferably is not massive i.e. a space is available inside the profile allowing mounting of corner fittings inside the profile.

According to an embodiment of the invention, each of the four profiles form part of one vertical part (vp) and two horizontal part (hp) of the cabinet frame when the cabinet frame is in its upright position.

This is advantageous in that it has the effect, that the cabinet frame is easy to assemble maintain sufficient stability.

According to an embodiment of the invention, each of the four profiles comprise two folded corners each having a corner support element facilitating fastening one of the corners of a first of the four profiles to the end of a second of the four profiles.

Moreover, the invention relates to a cabinet frame assembly including four profiles and eight identical corner fittings, wherein the four profiles are identical in that they are all having a first folding area and a second folding area, wherein the folding areas comprises a cutout part and an additional cutout part, wherein the cutout parts are turned 90 degrees on the profile with respect to the additional cutout part, wherein the corner fittings are having a first part perpendicular to a second part (9b), wherein the dimensions of the first and second parts are identical thereby facilitating mounting inside the profiles, and wherein the additional cutout part facilitates one of the first or second part to extend out from the profile when the opposite of the first or second part is mounted inside the profile.

According to an embodiment of the invention, the first and second areas further comprises a folding angle support part comprising a protruding part and a cave in part.

