Decorative panel system

Abstract

A panel system may be utilized in a variety of ways to protect or enhance the aesthetic features of an underlying object. The panel system may comprise a panel member, an insert and a base member. The insert is positioned between the panel member and the base member. Then the panel member may be attached to the base member. The panel member may include one or more openings and one or more recesses. The recesses may expose a second surface that results in a multi-tone appearance when a finish is applied to the unaltered first surface and the exposed second surface. The multi-tone appearance combines with the material or surface exposed by the openings in the panel member to create a unique appearance.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. provisional application Ser. No. 60/585,147, entitled “Decorative Stair Riser Screen,” filed 2 Jul. 2004.

BACKGROUND OF THE INVENTION

The present invention relates to a decorative panel and panel system. In particular, it relates to a decorative panel and system that can be used on a stair riser, among other applications.

SUMMARY OF THE INVENTION

The present invention is directed to a decorative panel and panel system that can be used on a stair riser, among other applications. A panel system having features of the present invention comprises a panel member, where the panel member has one or more recesses formed in it, which expose an inner surface. The panel member also has one or more openings formed in it. The present invention is also directed to a method of attaching a panel member to a stair riser using cove molding. The cove molding is attached to a strip of material called a build and an upper tread of a stair to secure the panel member to the existing riser. The present invention is also directed to a method for forming a panel member, where one provides a panel member and then forms one or more recesses or openings in that panel member. The present invention is also directed to a method of providing a panel system, where one provides one or more panel members that have one or more openings and one or more recesses that expose a second surface. Additionally, one also provides a staircase that contains stair risers and attaches at least one of the panel members to at least one of the risers.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a partial exploded perspective view of a panel system.

FIG. 2 is a perspective view of the panel member of FIG. 1.

FIG. 3 is an end view of the panel member of FIG. 1.

FIG. 4 is a top plan view of the panel member of FIG. 1.

FIG. 5 is a top plan view of the insert of FIG. 1.

FIG. 6 is a side view of the insert of FIG. 1.

FIG. 7 is a side view of a fastening component.

FIG. 8 is a top plan view of the fastening component of FIG. 7.

FIG. 9 is a perspective view of a staircase with panel members attached to existing stair risers.

FIG. 10 is a perspective view of an entryway with panel members attached to the walls to serve as a border and as a chair rail.

FIG. 11 is a perspective view of a light fixture with panel members attached to the light fixture to serve as molding.

FIG. 12A is a side view of a method of attaching a panel member to an existing stair riser utilizing cove molding.

FIG. 12B is an enlarged side view of the panel member, riser, build, cove molding and upper tread of FIG. 12A.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates one embodiment of a panel system 5, comprising a panel member 10, an insert 30 and a base member 40. The panel member 10 has a first surface 12 and an unfinished surface 20. The insert 30 has a front surface 32 and a rear surface 34. The base member has a front surface 42. In the embodiment pictured, the panel member 10 is positioned proximate to the insert 30, such that the unfinished surface 20 of the panel member 10 is adjacent to the front surface 32 of the insert 30. The insert 30 and panel member 10 are then positioned proximate to the base member 40, such that the rear surface 34 of the insert 30 is adjacent to the front surface 42 of the base member 40.

The panel member 10 as illustrated in FIGS. 1-4, includes an unmodified first surface 12, a second surface 18 formed by a plurality of recesses 14, and a plurality of openings 16, which expose the area or material beneath or behind the panel member 10. This embodiment of the panel member 10 also comprises an unfinished top surface 22 and an unfinished bottom surface 24. The combination of the unmodified first surface 12, the second surface 18 formed by the recesses 14, and the openings 16, may result in a multi-tone appearance when a finish is applied to the first surface 12 and the second surface 18 of the panel member 10. As used herein, the term “finish” refers to any stain, paint, lacquer, polyurethane, veneer, varnish, enamel, powder coating, acid wash, laminate, ink injection, or any similar coating known to one skilled in the art. Other finishes will be apparent to those of ordinary skill in the art. It will also be appreciated that any number of recesses 14 and/or openings 16 may be used.

In the present example, the recesses 14 are formed into the panel member 10 such that the depth of each recess 14 is less than the thickness of the panel member 10. This allows the recess 14 to expose the second surface 18, so that said second surface 18 may be seen and the finish may be applied to it. The depth of the one or more recesses 14 in relation to the depth of the panel member 10 is illustrated in FIGS. 1 and 3; however, it is not necessary that each second surface 18 be at the same depth. While the present drawings show circular recesses 14, it will be appreciated that a recess 14 may be any shape.

The openings 16 of the present example are formed into the panel member 10 so that they extend completely through the thickness of the panel member 10. Thus, when the panel member 10 is adjacent to another object, such as either the insert 30 or the base member 40, the openings 16 expose the material or area behind or beneath the panel member 10. The depth of the one or more openings 16 in relation to the thickness of the panel member 10 is illustrated in FIGS. 1 and 3. While the present drawings show circular openings 16, it will be appreciated that an opening 16 may be any shape.

While the present drawings show the recesses 14 and the openings 16 arranged in a diagonal line, it will be appreciated that the recesses 14 and the openings 16 may be arranged in any location or pattern in the individual panel member 10. In one embodiment, the recesses 14 and the openings 16 are arranged in a pattern or design in order to create an aesthetically pleasing appearance. Additionally, a panel system 5 may comprise a plurality of panel members 10, which may be attached to one or more base members, where the recesses 14 and the openings 16 are arranged on each individual panel member 10, such that, when the panel members 10 are positioned proximate to each other, the recesses 14 and the openings 16 may create a collective design.

The first surface 12 and second surface 18 of the panel member 10 of the present example are further illustrated in FIG. 4. The varying compositions of the first surface 12 and second surface 18 may result in the finish providing a first tone on said first surface 12 and a second tone on said second surface 18. The material or area behind or beneath the panel member 10 exposed by the openings 16 is also illustrated by FIG. 4. Once the finish is applied to the first surface 12 and the second surface 18, the combination of the varied appearances of the first tone on the first surface 12, the second tone on the second surface 18, and the area or material behind or beneath the panel member 10 may create a unique multi-tone appearance.

The panel member 10 may be constructed of any type of material. For instance, the panel member 10 may be constructed of a material whose original appearance can be changed by being carved entirely through, embossed, etched, scored, scratched, molded, grooved, routed, die cut or subject to any other process. As an illustrative version of the panel system 5, the panel member 10 may be constructed from medium density fiber core board, which may have a veneer or skin such as hardwood maple or oak attached, but this material is also available in an unfinished form. Other potential materials for the panel member 10 include, but are not limited to, synthetic or pre-fabricated wood material solid wood, exterior treated wood material, plastic, metal, marble, and any combination material. As discussed earlier in this specification, the finish applied to the first surface 12 and second surface 18 may be any stain, paint, lacquer, polyurethane, veneer, varnish, enamel, powder coating, acid wash, laminate, ink injection, or any other finish known to one skilled in the art. Alternatively, one could also apply one finish to the first surface 12 and an alternative finish to the second surface 18. As yet another illustrative alternative, one could apply a finish to either the first surface 12 or the second surface 18, creating a first tone on that surface, and leave the other surface unfinished to create a second tone. Still other variations will be apparent to those of ordinary skill in the art.

The general shape of the panel member 10, which may be but is not limited to being rectangular, and the recesses 14 and openings 16 may be formed by any appropriate process. For instance, the process may include carving entirely through, embossing, etching, scoring, scratching, molding, grooving, routing, die cutting or generally changing the appearance of the first surface 12 and exposing the second surface 18 of panel member 10. By way of example only, the manufacturing process may use a CNC router. Other possible alternatives include but are not limited to die cutting, laser cutting, plastic injection molding, plastic color-fill processing, or any combination of these or other manufacturing processes. Still other processes will be apparent to those of ordinary skill in the art.

The panel system 5 may include various parts to enable the other elements of the panel system 5, such as the panel member 10, to be utilized in a wide variety of manners. The following examples are intended to be illustrative and not limiting at all. As shown in FIG. 1 the panel system 5 may include an insert 30 and a base member 40. The base member 40 may comprise a variety of objects or materials. For instance, the base member 40 may comprise an existing stair riser. Alternatively, the base member 40 may be eliminated, and panel member 10 may be used as a riser in an existing staircase without stair risers. In some jurisdictions, building codes may require risers on new and existing staircases. Therefore, the panel system 5 may be utilized to satisfy this requirement. The panel member 10 may be used to retro-fit existing staircases that already contain risers in the manners just described, or the panel member 10 may be incorporated as a riser during the construction of a new staircase.

In another embodiment the base member 40 comprises a piece of cabinetry. Alternatively, the base member 40 may comprise a piece of furniture. In yet another embodiment the base member 40 comprises an outer surface of a structure, including but not limited to homes, sheds, and playhouses and the panel member 10 may be aligned with an existing window so as to serve as a window treatment or shutter. In yet another embodiment the base member 40 comprises an interior wall of a structure, and the panel member 10 may serve as wainscoting, trim molding, as part of a three-dimensional border, or in a frame or unframed to create a piece of art. In yet another embodiment, the base member 40 may comprise posts or rails, so that the panel member 10 may be utilized as a partition, including but not limited to being used to create a fence or a screen. FIGS. 9-11 illustrate various potential base members 40 and uses for the panel system 5. Different designs on the panel members 10 can be combined to create an overall pattern or design. FIG. 9 illustrates one embodiment where the panel members 10 are attached to existing stair risers. FIG. 10 illustrates yet another embodiment, where the panel members 10 are attached to a wall and utilized as a border and as a chair rail. FIG. 11 illustrates a third embodiment, where the panel members 10 are attached to a light fixture 120 and serve as molding around the light fixture 120. Still other objects that may serve as a base member 40 and other ways to utilize the panel member 10 without a base member 40 will be apparent to those of ordinary skill in the art.

As illustrated in FIG. 1, the panel system 5 comprises an insert 30. The insert 30 may comprise a thin sheet of any material or combination of materials of any color, texture or pattern. The insert 30 of the present example is positioned proximate to the panel member 10, so that the front surface 32 of the insert 30 is adjacent to the unfinished surface 20 of the panel member 10. The rear surface 34 of the insert 30 is positioned so that it is adjacent to the front surface 42 of the base member 40. This may allow the front surface 32 of the insert 30 to be viewed through the openings 16 in the panel member 10. The front surface 32 of the insert 30 may have a finish applied to it. One embodiment of insert 30 is illustrated in FIG. 5 and FIG. 6. The insert 30 may comprise a variety of materials, including but not limited to plastic, wood, or metal. The insert 30 may be solid or also have features such as the openings 16 of panel member 10.

In addition to the panel member 10, the insert 30 and the base member 40, the panel system 5 may also comprise a fastening component 50. One embodiment of the fastening component 50, referred to as a screw and post system, is illustrated by FIGS. 7 and 8. The fastening component 50 may be utilized to secure the panel member 10 to the base member 40. If the panel system 5 comprises an insert 30, the insert 30 may also be secured to the base member 40 with the fastening component 50. The present embodiment of the fastening component 50 comprises a base 58 comprising a front surface 62 and a rear surface 60, a plurality of bolts 52, a plurality of screw-head covers 53, and a plurality of material specific screws 54. The plurality of screw-head covers 53 may number the same as the plurality of bolts 52. The base 58 may also comprise a plurality of screw posts 56, numbering the same as the plurality of bolts 52, and a plurality of screw holes 64, numbering the same as the plurality of material specific screws 54. The screw holes 64 may be beveled to allow for a flush finish with the front surface 62 once the material specific screws 54 are inserted in the screw holes 64 to secure the base 58 to the base member 40. The material specific screws 54 may be selected based on the object serving as the base member 40 or based on other considerations. In one embodiment, the base member 40 may comprise a wooden object; therefore the material specific screws 54 may comprise wood screws. Still other fastening components 50 will be apparent to those of ordinary skill in the art.

In the embodiment illustrated in FIGS. 7 and 8, in order to secure the panel member 10 and the insert 30 to the base member 40, first the base 58 of the fastening component 50 may be positioned such that the rear surface 60 of the base 58 is adjacent to the front surface 42 of the base member 40. The base 58 may be secured to the base member 40 utilizing the material specific screws 54 by inserting the material specific screws 54 through the screw holes 64 and into the base member 40. The bolts 52 may then be inserted through the screw posts 56 and into the base member 40. The insert 30 and panel member 10 may then be positioned so that the front surface 32 of the insert 30 is adjacent to the unfinished surface 20 of the panel member 10 and the bolts 52 are inserted through openings 16 in the insert 30 and panel member 10. The screw head covers 53 may then be screwed onto the bolts 52 to secure the panel member 10 and the insert 30 to the base member 40.

Another embodiment of a fastening component 50 is illustrated by FIGS. 12A and 12B. In this embodiment, the panel member 10 is secured to an existing stair riser 80 utilizing cove molding 78 and a build 76. The cove molding 78 comprises a top surface 96 and a rear surface 98. The build 76 may comprise a piece of wood or other material cut to the same length as the panel member 10. The build 76 comprises a top surface 88, a bottom surface 94, a front surface 90 and a rear surface 92. The existing stair riser 80 is positioned between an upper tread 72 and a lower tread 74.

These surfaces are illustrated in FIG. 12B, an enlarged view of FIG. 12A. The build 76 is positioned such that the top surface 88 of the build 76 is adjacent to the bottom surface 84 of the upper tread 72, and the rear surface 92 of the build 76 is adjacent to the front surface 82 of the riser 80. The build 76 is then secured to the riser 80 and the upper tread 72 using nails or any other means of attachment apparent to one skilled in the art. The cove molding 78 is then positioned such that the rear surface 98 of the cove molding 78 is positioned adjacent to the front surface 90 of the build 76 and the top surface 96 of the cove molding 78 is positioned adjacent to the bottom surface 84 of the upper tread 72. The cove molding 78 is then secured to the build 76 and the upper tread 72 using nails or any other means of attachment apparent to one skilled in the art. The panel member 10 is inserted into the gap created by the riser 80, the build 76, and the cove molding 78, such that the unfinished surface 20 of the panel member 10 is adjacent to the front surface 82 of the existing stair riser 80 and the front surface 12 of the panel member 10 is adjacent to the rear surface 98 of the cove molding 78. The bottom surface 24 of the panel member 10 is positioned adjacent to the top surface 86 of the lower tread 74, and the top surface 22 of the panel member 10 is positioned adjacent to the bottom surface 94 of the build 76. Once the panel member 10 is positioned as described above, then it is secured to the riser 82.

Alternative methods of utilizing one or more elements of a panel system 5 will be apparent to those of ordinary skill in the art. These potential uses include but are not limited to a series of panel members 10 stacked, such that the unfinished surface 20 of one panel member 10 is adjacent to the front surface 12 of the second panel member 10. The size of the openings 16 in each successive panel member 10 may decrease, which may provide a matte effect. In another embodiment, the panel system 5 comprises a plurality of panel members 10 and one or more base members 40. The plurality of panel members 10 may be attached to the one or more base members 40 and positioned, so that when the panel members 10 are viewed together the panel members 10 create a unique, collective design and an overall aesthetically pleasing appearance.

Of course, the foregoing examples are merely illustrative, and are not intended to be limiting in any way. Having shown and described various embodiments and concepts of the invention, further adaptations of the methods and systems described herein can be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the invention. Several of such potential alternatives, modifications, and variations have been mentioned, and others will be apparent to those skilled in the art in light of the foregoing teachings. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as may fall within the spirit and scope of the appended claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.

Claims

1) A panel system, comprising:

a panel member, the panel member comprising:

i) a first surface having one or more recesses formed therein, wherein each of the one or more recesses provides a second surface, and

ii) one or more openings.

2) The panel system of claim 1, further comprising a base member, wherein the panel member is positioned proximate to the base member.

3) The panel system of claim 1, wherein one or more finishes are applied to the first surface and second surface of the panel member, wherein the one or more finishes provides a first tone on the first surface and a second tone on the second surface of the one or more recesses.

4) The panel system of claim 2, further comprising an insert positioned between the panel member and the base member.

5) The panel system of claim 2, wherein the base member comprises a stair riser, wherein the panel member is secured to the stair riser.

6) The panel system of claim 1, further comprising a staircase, wherein the panel member is secured to the staircase to be utilized as a stair riser.

7) The panel system of claim 2, wherein the base member comprises a piece of cabinetry.

8) The panel system of claim 2, wherein the base member comprises a wall, wherein the panel member is secured to the wall to be utilized as wainscoting.

9) The panel system of claim 9, wherein the panel member is secured to the wall to be utilized as trim molding.

10) The panel system of claim 2, wherein the base member comprises a piece of furniture.

11) The panel system of claim 2, wherein the base member comprises an outer surface of a structure and a window, wherein the panel member is secured to the outer surface of the structure near the window.

12) The panel system of claim 1, wherein the panel member is utilized to constitute a fence.

13) The panel system of claim 1, wherein the panel member is utilized to constitute a screen.

14) The panel system of claim 2, further comprising a plurality of panel members and at least one base member, wherein the plurality of panel members are attached to the one or more base members to provide a collective, aesthetically pleasing appearance.

15) The panel system of claim 1, further comprising one or more fastening components.

16) The panel system of claim 15, wherein the fastening component comprises a screw and post system.

17) The panel system of claim 15, wherein the fastening component comprises cove molding.

18) A method for attaching a panel member to a stair riser utilizing cove molding, the method comprising:

a) Installing the cove molding; and

b) Positioning the panel member between the cove molding and the stair riser.

19) The panel system of claim 1, wherein the panel member comprises at least one of a medium density fiber core board, a synthetic wood material, a pre-fabricated wood material, a solid wood material, exterior treated wood material, plastic, metal, or marble.

20) The panel system of claim 3, wherein the finish applied to the first surface is different from the finish applied to the second surface.

21) The panel system of claim 1, wherein at least one of the one or more recesses or at least one of the one or more openings are formed by a manufacturing process utilizing a CNC Router.

22) The panel system of claim 1, wherein at least one of the one or more recesses or at least one of the one or more openings are formed by a die cutting manufacturing process.

23) The panel system of claim 1, wherein at least one of the one or more recesses or at least one of the one or more openings are formed by a laser cutting manufacturing process.

24) The panel system of claim 1, wherein at least one of the one or more recesses or at least one of the one or more openings are formed by a plastic injection molding manufacturing process.

25) The panel system of claim 1, wherein at least one of the one or more recesses or at least one of the one or more openings are formed by a plastic color-fill manufacturing process.

26) A method for forming a panel member, the method comprising:

a) Providing a panel member;

b) Forming one or more openings in the panel member; and

c) Forming one or more recesses in the panel member.

27) The method of claim 26, wherein the act of forming at least one of the one or more openings or at least one of the one or more recesses comprises use of a CNC router.

28) The method of claim 26, further comprising die cutting at least one of the one or more openings or at least one of the one or more recesses.

29) The method of claim 26, further comprising laser cutting at least one of the one or more openings or at least one of the one or more recesses.

30) The method of claim 26, wherein the act of forming at least one of the one or more openings or at least one of the one or more comprises plastic injection molding.

31) The method of claim 26, wherein the act of forming at least one of the one or more openings or at least one of the one or more recesses in the panel member comprises plastic color-fill processing.

32) A method for providing a panel system, the method comprising:

(a) providing a plurality of panel members, each panel member comprising: i. a first surface having one or more recesses formed therein, wherein each of the one or more recesses provides a second surface, and ii. one or more openings;

(b) providing a staircase, wherein the staircase comprises a plurality of risers; and

(c) securing a panel member of the plurality of panel members to a riser of the plurality of risers.

33) The method of claim 32, further comprising applying one or more finishes to the panel member.