Abstract:
A decorative panel formed from at least a display panel secured to a frame. In some embodiments the panel comprises a transparent or translucent display panel and an interchangeable decorative insert disposed between the display panel and a supporting surface. In other embodiments an opaque display panel acts serves the function of both the display and decorative layers. A retaining frame is disposed about the periphery of the panels and retains the layers in generally abutting relation, the retaining frame being removable so as to permit replacement of the decorative insert or display panel. The retaining frame comprises a return flange disposed forwardly of the supporting surface at the position of the groove, such that the display panel is retained by the flange seated in the groove, generally concealing the retaining frame. The panel system of the invention provides a cost effective means of changing the look of cabinetry and other decorative fixtures that is easy to implement and results in little wastage of materials.

Description:
[0001]    FIELD OF INVENTION 
         [0002]    This invention relates to decorative panels for cabinetry and the like. 
       BACKGROUND OF THE INVENTION 
       [0003]    Interior cabinetry, for example kitchen cabinetry, utilizes “facings” including doors and drawers to close the cabinetry and conceal the cabinet or drawer interior. Such facing is often decorative, with myriad different styles and textures to choose from. The selected style and texture creates a ‘look’ intended to have aesthetic appeal. 
         [0004]    There are different types of panels used for this purpose. Solid panels can be made out of materials such as glass, plastic or wood. The main characteristic of this design is that the solid material supports the mounting and handle hardware as well as concealing the area that the panel is designed to cover. The panels are permanently finished in one of a variety of ways. A second type of panel is framed. This type of panel is characterized by a frame made of wood, metal or plastic, which supports the mounting and handle hardware, while the panel fills in the area inside the frame. Other types of panels include modern hybrids where a glass or translucent plastic panel are affixed to a frame or affixed to a solid panel by glues, fasteners or clasps. In all of these cases the frame and panel can be finished in different materials, colors and textures, but with the exception of wood panels, the surface finish of the assembled panel is permanent and unalterable. 
         [0005]    Even in the case of wood panels there are limitations on the ability to alter the surface aesthetics. It is unusual in today&#39;s age for wood facings to be hand painted. Typically they are pre-formed with a synthetic surface covering such as Masonite (Trademark), which cannot be covered over in any durable fashion; or factory-finished with a stain and/or varnish that is difficult to paint over, requiring extensive labour to remove the existing finish, with attendant costs. Moreover, even where the consumer or commercial user could change the facings using a paint or varnish, for example where the facings have a wood surface, it is virtually impossible to reproduce the surface finish with the same quality as a factory can. 
         [0006]    Accordingly, the conventional way of changing the “look” of a kitchen, bathroom, laundry room or other cabinetry-based room is to reface the cabinets. This involves removing the existing facings from cabinet boxes and drawers, and replacing them with new facings. This is relatively expensive, and results in a lot of wasted material because the removed facings (usually custom-fitted to the cabinetry) must typically be discarded. 
         [0007]    It would accordingly be advantageous to provide facings for cabinetry that can be aesthetically altered at low cost and with little wasted material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    In drawings which illustrate embodiments of the invention by way of example only: 
           [0009]      FIG. 1  is a front perspective view of a panel embodying the invention. 
           [0010]      FIG. 2  is an exploded perspective view of the panel of  FIG. 1  showing the arrangement of layers in the panel of  FIG. 1 . 
           [0011]      FIG. 3  is a side cross-section of the panel of  FIG. 1 . 
           [0012]      FIG. 4  is a plan view of an edge of the panel of  FIG. 1  showing one manner of closing the retaining band. 
           [0013]      FIG. 5  is a cross-section of a further embodiment of the retaining band. 
           [0014]      FIG. 6  is a front elevational view of a further embodiment of the invention utilizing frame components forming the supporting surface. 
           [0015]      FIG. 7  is a side elevational view of the embodiment of  FIG. 6 . 
           [0016]      FIG. 8  is an enlarged cross-sectional elevation of a corner of the frame in the embodiment of  FIG. 6 . 
           [0017]      FIG. 9  is a rear perspective view of the panel of  FIG. 6 . 
           [0018]      FIG. 10  is a rear perspective view of the panel of  FIG. 6  showing the manner of assembling or disassembling the frame to replace the interchangeable insert. 
           [0019]      FIG. 11  is an enlarged cross-sectional elevation of a corner of a further embodiment of the invention utilizing the frame of  FIG. 6 . 
           [0020]      FIG. 12  is an enlarged cross-sectional elevation of a corner of a still further embodiment of the invention utilizing a modification of the frame of  FIG. 6 . 
           [0021]      FIG. 13  is an enlarged cross-sectional elevation of a corner of a still further embodiment of the invention utilizing the frame of  FIG. 12 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    While the invention is described below in the environment of cabinetry, it also can be applied to appliance surfaces and other surfaces including partitions, dividers and wall panels. 
         [0023]    The dimensions of the panel can be made to meet standard or custom cabinet specifications, and can be manufactured with the cabinetry or supplied as a replacement for existing cabinetry in re-facing situations. Standard mounting and handle hardware can be installed using conventional methods and tools. 
         [0024]    In some embodiments the invention provides a decorative panel comprising a transparent or translucent display panel and a decorative insert, and a frame surrounding the periphery of the layers to retain the layers in generally abutting relation, the frame being capable of being removed or disassembled in order to permit replacement of the decorative insert. In some embodiments a supporting layer cooperates with a retaining band to from a frame retaining the decorative insert against the display panel. In other embodiments the decorative insert is supported by a self-contained frame comprising frame components. In these embodiments the invention provides a facing system for cabinetry that can be aesthetically altered at low cost and with little wasted material, requiring replacement solely of a aesthetic insert, which may be relatively thin and therefore of lower cost than replacing an entire door or drawer front. The design of the facing system makes it easy to disassemble and replace a colored or textured insert. The system of the invention is thus ideal for decorative cabinetry. The panel of the invention is particularly especially effective as a drawer front panel or cabinet door for kitchen, bathroom or other decorative cabinets. The invention also provides a method of forming the decorative panel. 
         [0025]    In some embodiments the invention provides a display panel combining both display and decorative functions. To change the look of a standard cabinet face, measurements need to be taken for all panel sizes, as well as hinge and handle locations, then a new panel needs to be manufactured complete with all hinge and handle holes. By changing only a single layer serving the function of both the display panel and the decorative insert, all that is required is to cut and profile new display panels and then install on site by disassembling the old panel and interchanging the display panels. The hinges can be left mounted to the back panel or frame (depending on the embodiment), and the handles need only be removed from the old display panel and re-mounted to the new display panel. These embodiments accommodate the use of materials that are naturally opaque rather than transparent or translucent, for example opaque plastics, wood, engineered wood, metal and stone, as the display panel. 
         [0026]    The invention thus provides a decorative panel, comprising a retaining frame, and a display panel transversely supported by a supporting surface of the retaining frame, the display panel comprising a groove at least partly surrounding the display panel along perimeter surfaces of the display panel, the retaining frame comprising an outer perimeter face forming a side edge of the frame supporting a return flange disposed substantially parallel with the groove and forwardly of the supporting surface at the position of the groove, the display panel being thereby fixed in position within the assembled frame and replaceable by disassembling at least a portion of the frame to allow the display panel to be inserted into the frame or removed from the frame. 
         [0027]    The invention further provides a method of forming a panel, comprising the steps of: a. providing a display panel comprising a groove at least partly surrounding the display panel along a perimeter face of the display panel, b. providing a frame having a supporting surface, the frame supporting a return flange disposed substantially parallel with the groove and forwardly of the supporting surface at the position of the groove, forming a channel, c. inserting the display panel into the channel, and d. affixing the frame around the display panel to retain said display panel, the retaining frame being removable so as to permit replacement of the display panel. 
         [0028]      FIGS. 1 to 5  illustrate a first embodiment of a decorative panel  10  according to the invention. The panel  10  comprises a front surface  12 , a top edge  14 , side edges  16 ,  18  and a bottom edge  20  defined by a retaining frame  40 , and a rear surface  22  opposite the front surface  12 . The panel  10  is suitable for mounting to cabinetry, appliances or any other structure in which a decorative surface is desired. 
         [0029]      FIG. 2  illustrates the layers of the panel  10  of  FIG. 1  in exploded view. The panel  10  comprises a transparent or translucent layer such as a display panel  30 , and an interchangeable layer such as decorative insert  32 . In this embodiment the panel further comprises a supporting layer such as back panel  34  which together with a retaining band  39  form a retaining frame  40 , for holding the display panel  30  and interchangeable decorative insert  32  together in surface-abutting relation as an integral unit (as shown in  FIG. 3 ). 
         [0030]    In the preferred embodiment the display panel  30  is transparent or translucent, being formed from glass or plastic, allowing light to pass through so that the interchangeable insert  32  is visible behind the display panel  30 . The back panel  34  is preferably rigid and strong enough to support the mounting and handle hardware, composed for example from medium density fibreboard (MDF) or another low cost material. The back panel can alternatively be made of a frame and panel combination. This would be used for either large panels where weight is a concern or for doors/drawers where a more elegant aesthetic is desired. The interchangeable insert  32 , which provides the decorative finish in the assembled panel  10 , is held in abutting relation between the front display panel  30  and the back panel  34 . 
         [0031]    In this embodiment these components are held together by a removable retaining band  39  forming a shallow channel  45  having a floor  40   a  and sides  40   b,    40   c,  which together with back panel  34  forms a retaining frame  40 . The retaining band  39  may be formed (for example stamped or extruded) from aluminum, sheet steel, plastic or any other suitable material. The retaining band  39  and the back panel  34  thus operate together to form a supporting frame  40  for supporting the interchangeable insert  32  in abutting relation with the front display panel  30 . 
         [0032]    The retaining band  39  is preferably formed as one piece, and can be opened and closed to allow for easy assembly and disassembly of the panel  10 . The ends of the retaining band  39  are butted up against one another and the retaining band  39  may thus be held in the closed position with a fastener affixing each end of the retaining band  39  to the back panel  34 , as shown in  FIG. 4 . In the case of larger panels, the retaining band  39  may be made of two or more portions (not shown), with a fastener at each end affixing the portion of the retaining band  39  to the back panel  34  in abutting relation such that the retaining frame  40  can be disassembled when it is desired to change the replaceable decorative insert  32 . The fasteners  42  are preferably positioned along the retaining frame  40  so as to be hidden from sight from a normal viewing position. For example, the fasteners may be wood screws that are countersunk and located along an edge of the panel that is difficult to see, such as the top edge of an upper cupboard door or the bottom edge of a drawer face. 
         [0033]    One side  40   a  of the channel  45  engages into a groove  30   a  surrounding (or partly surrounding) the perimeter edge faces  30   b  of the display panel  30 , i.e. the faces about the periphery of and orthogonal to the large faces of the panel  30 . In the preferred embodiment the portion of the display panel  30  which sits in the channel  45  is recessed, as shown at  46  in  FIG. 3 , so that the retaining band  39  (and thus the retaining frame  40 ) is flush with or slightly inset from the bottom edge of the display panel  30 . The retaining frame  40  is thus largely concealed from view when observed from the front of the panel  10 . The other side  40   c  of the channel  45  rests in a notch  34   b  surrounding (or partly surrounding) the back panel  34  near the perimeter of the back panel  34 , preferably (but not necessarily) along its rear surface. With the notch  34   b  disposed along the rear face  34   d  of the back panel  34 , the portion of the back panel  34  between the notch  34   b  and the perimeter edge face  34   c  is also preferably recessed from the rear face  34   d  of the back panel  34  such that the exterior face of the retaining frame  40  is flush with the rear face of the back panel  34 . Thus, in the embodiment illustrated the back panel  34  and interchangeable insert  32  are slightly smaller in dimension than the front surface of the display panel  30 . This generally conceals the side  40   b  of the channel  45 , for aesthetic purposes, but also avoids the collection of dirt and grime, or the seepage of liquids that may spill or spray onto the front surface of panel  10  into the channel  45  of the retaining frame  40 , which is particularly advantageous in a kitchen or bathroom. 
         [0034]    The visible exterior surfaces of the retaining band  39  are preferably decorative also, since at least some of these surfaces are visible when the panel  10  (for example a cabinet door or drawer face) is in the open position. The interchangeable insert  32  preferably (but not necessarily) fills the entire available area within the retaining band  39 , to thus overlay the entirety of the back panel  34 . 
         [0035]    The length of the side  40   c  of the retaining band  39 , which extends about the rear face of the back panel  34 , is formed as necessary so as to not interfere with door hinge hardware, but is large enough to securely grip the back panel  34  and may have a slight acute angle so that the flexible retaining band  39  can compensate for different thicknesses of insert or manufacturing tolerances. The side  40   b  the retaining band  39  is preferably made as small as possible so as not to interfere with direct visibility of the interchangeable insert  32 , while being large enough to hold the display panel  30  securely in position. The sides  40   b,    40   c  of the retaining band  39  may be mitered or rounded at the corners so as to allow the retaining band  39  to close around the panel  10 . 
         [0036]    To form the panel  10 , an interchangeable insert  32  of the appropriate size is positioned between a display panel  30  and a back panel  34 . The retaining band  39  is placed around the periphery of the composite panel arrangement, such that the side  40   b  sits in the groove  30   a  and the side  40   c  sits in the notch  34   a.  In the preferred embodiment a bead  40   d  formed along the rear side of the retaining band  39  seats in a complementary groove  34   b  formed at the end of the notch  34   a,  either continuously or intermittently around the periphery of the panel  10 . In the embodiment shown, when the retaining band  39  is disposed over the edge of the panel  10  the bead  40   d  is lodged in the groove  34   b  so as to prevent the retaining band  39  from dislodging along the direction of the plane containing the panel  10 , which is optional but provides a more secure attachment to the assembled panel  10 . 
         [0037]    The retaining frame  40  is fastened to the panel  10 , and simultaneously into the closed position, by fasteners  42  disposed through the projecting tongues  43  and into the side edge faces of the back panel  34 . The panel  10  assembled in this manner can be mounted to a drawer, cabinet box or other structure in conventional fashion, the hinges being affixed to the back panel  34 . 
         [0038]    To change the decor of the panel, the fasteners  42  are removed to open the retaining band  39 , removing the side  40   b  from the groove  30   a  around the perimeter of the display panel  30  and the side  40   c  from the notch  34   a  about the back panel  34 , and thus releasing the display panel  30  from the back panel  34 . The panel  10  can then be reassembled, as described above, with a different decorative insert  32  disposed between the display panel  30  and the back panel  34 . 
         [0039]    For a different effect to the decor, and to entirely hide side  40   b  from the front view of the panel, it is possible in this embodiment to combine the display panel  30  and decorative insert  32  into a single decorative opaque panel (not shown). For example, this avoids the need to take measurements for panel sizes, hinge and handle locations. By changing only a single layer serving the function of both the display panel and the decorative insert, all that is required is to cut and profile new display panels and then install on site by disassembling the old panel and interchanging the display panels. This saves considerable time in installation and manufacturing. 
         [0040]      FIG. 5  illustrates a further embodiment of the retaining band  39  having ribs  40   e  which aid in straight forming the retaining band  39  through an extrusion die. In this embodiment the back panel  34  comprises an overlay  48 , for example formed from transparent, translucent or opaque acrylic sheet. The overlay may be laminated to the wood portion of the back panel  34  as illustrated, or may be held in position against the wood portion of the back panel  34  by the retaining band  39 , which would allow a further decorative insert panel (not shown) to be mounted between the wood portion of the back panel  34  and the acrylic overlay  48 , for example to impart a decorative finish to the back of a cupboard door. In this embodiment the notch  34   a  and groove  34   b  are formed in the acrylic portion  48  of the back panel  34 . 
         [0041]    In a further embodiment of the invention illustrated in  FIGS. 6 to 10 , a decorative panel  50  is formed from a display panel  30  and an interchangeable decorative insert  32 . The display panel  30  and decorative insert  32  may be as described in the previous embodiment. In the embodiment of  FIGS. 6 to 10  the supporting frame holding the interchangeable insert  32  in abutting relation between the front display panel  30  the display panel  30  comprises a retaining frame  60 , which also holds the decorative insert  32  against the display panel  30 , so that a back panel ( 34  in the embodiment of  FIGS. 1 to 5 ) is not required. In a cupboard door utilizing this embodiment, the hinges (not shown) are mounted between the cabinet box (not shown) and the frame  60 . 
         [0042]    The retaining frame  60  in this embodiment may be composed of frame components  62  each having the length necessary to create a panel  50  of the required size. In the embodiment shown each frame component  62  is formed from an extrusion, for example of metal (such as aluminum), plastic or another suitable material. The frame components  62  may be affixed together in any suitable fashion, for example by corner key brackets  52  as shown, so that at least one component  62  can be removed from the frame for access to the interchangeable insert  32 . In the embodiment shown set screws  54  disposed through complementary threaded openings in the rear face  65  of the frame  50  are tightened to bear against the corner brackets  52  to maintain the frame  60  in an assembled condition. The set screws  54  at each end of a frame component  62  are loosened to release the respective corner brackets  52  and allow the frame component  62  to be removed from the assembled frame  60 , as shown in  FIG. 10 . 
         [0043]    Each frame component  62  comprises a front bearing wall  64  having a return flange  66  along (or partially along) its outer perimeter face  62   a,  best seen in  FIG. 8 . The return flange  66  is spaced from the bearing wall  64  to form a channel  68 . The return flange  66  engages into the groove  30   a  surrounding (or partly surrounding) the perimeter edge faces  30   b  of the display panel  30 . As in the previous embodiment, the portion of the display panel  30  that sits in the channel  68  may be recessed so that the frame  60  is flush with the bottom edge of the display panel  30  as shown(or slightly inset from the bottom edge of the display panel  30 , not shown). The frame  60  is thereby largely concealed from view when observed from the front of the panel  10 . As in the embodiment of 
         [0044]      FIGS. 1 to 5 , in the embodiment illustrated in  FIGS. 6 to 10  the interchangeable insert  32  is slightly smaller in dimension than the front surface of the display panel  30  and the perimeter edge of the interchangeable insert  32  thus sits in the channel  68  with the recessed portion of the display panel  30 . 
         [0045]    The bearing wall  64  may comprise a gasket  56 , for example adjacent to internal face  57  of the frame component  62 , against which the display panel  30  presses the interchangeable insert  32 , which both prevents rattling of the display panel  30  against the bearing wall  64  and helps to fix the insert  32  in position. 
         [0046]    To form the panel  50 , the display layer  30  is placed face down on surface. The decorative insert  32  is placed on top of the display layer  30  (if not already adhered to the display layer  30 ). The frame components  62  are positioned around the display layer  30 , such that the display panel  30  forms the front face of the panel  50  as shown in  FIG. 10 , inserting corner brackets  52  loosely into the frame components  62 . The frame components  62  are moved toward each other so that flanges  66  fit into grooves  30   a.  When the return flange  66  of the remaining frame component  62 ′ seats in the exposed groove  30   a,  the mitered corners of the remaining frame component  62 ′ abut the mitered corners of the assembled frame components  62 . The set screws  54  are then installed and tightened to secure the frame  60 . 
         [0047]    In the case of a door embodying the panel  50  of  FIGS. 6 to 10 , the hinges (not shown) may be conventional cabinet hinges and may be mounted to the rear surface of the frame  60  and the cabinet boxes in conventional fashion. The handle (not shown) can be removed from the panel  50  and re-attached to the panel  50  after the new decorative insert  32  has been mounted, or a new handle can be mounted through the new display panel  50 . 
         [0048]    A further embodiment of the invention, illustrated in  FIG. 11 ,provides a panel  70  comprising a single layer forming a display panel  72 , combining both display and decorative functions, along with the frame  60  of the embodiment of  FIGS. 6 to 10 . The embodiment of  FIG. 11  may be employed with rigid opaque materials such as (without limitation) plastic, wood, metal or stone as the display panel  72 . The groove  66  (and optionally the recessed portion of the perimeter edge surface) can be routed or milled into the perimeter surfaces of the display panel  72 . 
         [0049]    Thus, to replace the display panel  72  in a door with a display panel  72  of a different decor, the door is removed from the cabinet box (in many cases the hinges can be split by a quick-release) and the frame  60  is disassembled as previously described. The display panel  72  is removed by reversing the assembly procedure described above and the new display panel  72  is mounted by reassembling the frame  60  as described above. 
         [0050]    In the case of a door embodying the panel  70  of  FIG. 11 , the hinges (not shown) may be conventional cabinet hinges and may be mounted to the rear surface of the frame  60  and the cabinet boxes in conventional fashion. The handle (not shown) can be removed from the panel  70  and re-attached to the panel  70  after the new display panel  72  has been mounted, or a new handle can be mounted through the new display panel  72 . 
         [0051]      FIG. 12  illustrates a further embodiment in which the display panel  72  also forms the decorative insert. In this embodiment the frame components  62  are provided with an inner ridge  80  for retaining a rigid back panel  34  against the display panel  72 , to resist flexing and ‘billowing’ of the centre portion of the display panel  72 . In this embodiment the composition of the back panel  34  may be as described in the embodiment of  FIGS. 1 to 5  and is dimensioned to fit within the internal face  57  of the frame  60  and the ridge  80 . The ridge  80  at least partly surrounds the inner portion of the frame  60 , to retain the back panel  34  in snug abutting relation to the display panel  72 . If the frame components  62  are formed as extruded components the ridge  80  would circumscribe the internal faces  57  of the frame components  62 . 
         [0052]      FIG. 13  illustrates a further embodiment of the panel  70  having a transparent or translucent display panel  30 , as in the embodiment is  FIGS. 1 to 5 , and a decorative insert  32  is disposed between the display panel  30  and the back panel  34 , visible through the display panel  30  from the front of the panel  70 . The back panel  34  resists flexing and billowing of the centre portion of the decorative insert  32  and holds the decorative insert  32  in position. 
         [0053]    If the decorative insert  32  is particularly thin and unable to be self-supporting, for example a film, it may be removably laminated or otherwise adhered to the display panel  30  before the display panel  30  is inserted into the frame  40  or  60  to ensure that the decorative insert  32  remains in position without sagging or creasing. In this case the decorative insert  32  is replaced by removing the display panel  30  as described above and peeling the decorative insert off of the display panel  30 . If the new decorative insert  32  is similarly too thin to be self-supporting, it can be adhered to the display panel  30  in like fashion before the display panel is reinserted  30  into the frame  60 . If a thicker decorative insert  32  is used to replace the previous decorative insert  32 , a thinner display panel  30  can be used to accommodate the greater thickness of the decorative insert  32  within the channel  45  or  68 . 
         [0054]    Modifications of the invention may be made without departing from the scope of the invention described herein. For example, without limitation, the decorative insert may be adhered to the back panel or the display panel; other layers, partial layers and hybrid layers may be added or substituted for the layers illustrated (for example a decorative insert may be applied to or fixed within the frame overlaying the rear surface of the back panel); or the display panel may be provided with a colour and/or texture to complement or add design elements to the decorative insert layer. The invention includes all such modifications and adaptations as fall within the scope of the accompanying claims.