Decorative panel

A decorative panel is for a cabinet, cupboard or the like which includes a plurality of edge frames having mitered ends. A central panel element has a plurality of edges and each of the edge frames has an internal groove for respectively receiving one of the edges therein. Each of the edge frames has a laminated surface material secured to an outer surface thereof. The laminated surface material on each of the edge frames has a terminal portion which is located within the internal edge groove. The edge frames surround the center panel element as the edges are respectively located within the internal edge grooves of the edge frames. Each of the edges of the center panel element secures the terminal portions of the laminated surface material within the internal edge groove. The mitered ends of adjacent edge frames have aligned slots in aligned areas of the outer surfaces thereof which include the laminated surface material. A device for interlocking the mitered ends is disposed within the aligned slots for joining the adjacent edge frames. The device for interlocking the mitered ends includes a portion for overlying the aligned slots and the laminated surface material thereabout.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to a decorative panel for a cabinet, cupboard or the 
like and, more specifically, to such a panel which includes edge frame 
portions which are joined in a rigid and secure manner without detracting 
from the aesthetic appearance thereof. 
2. Description of the Prior Art: 
It is not uncommon for cabinets, cupboards, or the like to include doors, 
drawer faces, or other panels which are formed with mitered edge frames to 
provide overall strength and integrity to the panel. Although dowel pin 
and hole configurations can be used to join mitered ends of such frames, 
any system joining such frames which is simpler, less complicated, and 
more reliable would be an attractive alternative for the formation of such 
decorative panels, doors or drawer faces. 
For example, a basic mortise and tenon configuration has heretofore been 
used to join adjacent elements as an alternative to the basic dowel pin 
and hole configuration. Such mortise and tenons and other similar types of 
connectors are shown in U.S. Pat. No. 3,349,536, entitled "Frame Joint and 
Fastener Therefor"; U.S. Pat. No. 3,336,689, entitled "Picture Frame"; 
U.S. Pat. No. 4,050,211, entitled "Coupling Device for Joining Together 
Reinforced Concrete Elements, such as Concrete Piles or Pillars"; U.S. 
Pat. No. 4,632,589, entitled "Solder-Free Circuit Base Plate"; and U.S. 
Par. No. 2,378,562, entitled "Die". These patents are incorporated as if 
included in their entirety herein. 
Although such mortise and tenons as disclosed in these prior art patents 
can be configured to provide proper support for joining mitered frame 
elements, they would not be as aesthetically attractive as a dowel pin and 
hole configuration when used to form decorative panels or the like. 
Specifically, dowel pin and hole connectors are usually employed at the 
abutting surfaces of the mitered ends so that they are not visible when 
the door or panel is completely assembled. Although dowel pins and holes 
are more attractive, they are not easy to use because of the difficulty of 
aligning the dowel pins with the holes when assembling a door or panel. 
Further, a positive retention or coupling only occurs after the joints are 
properly glued and the glue has completely set. 
As a result, there remains a need for any configuration which properly 
joins mitered ends of door, drawer face or panel frames which will ensure 
their integrity while not detracting from the decorative appearance 
thereof. 
OBJECTS OF THE INVENTION 
It is therefore an object of the invention to provide a decorative panel 
for a cabinet, cupboard or the like which is simple to assemble with the 
elements thereof being reliably and securely joined. 
It is another object of the invention to provide such a decorative panel 
which is aesthetically pleasant and attractive throughout extended use. 
SUMMARY OF THE INVENTION 
It is therefore an object of the invention to provide a decorative panel 
for a cabinet, cupboard or the like which includes a plurality of edge 
frames having mitered ends. A central panel element has a plurality of 
edges and each of the edge frames has an internal groove for respectively 
receiving one of the edges therein. Each of the edge frames has a 
laminated surface material secured to an outer surface thereof. The 
laminated surface material on each of the edge frames has a terminal 
portion which is located within the internal edge groove. The edge frames 
surround the center panel element as the edges are respectively located 
within the internal edge grooves of the edge frames. Each of the edges of 
the center panel element secures the terminal portions of the laminated 
surface material within the internal edge groove. The mitered ends of 
adjacent edge frames have aligned slots in aligned areas of the outer 
surfaces thereof which include the laminated surface material. A device 
for interlocking the mitered ends is disposed within the aligned slots for 
joining the adjacent edge frames. The device for interlocking the mitered 
ends includes a portion for overlying the aligned slots and the laminated 
surface material thereabout. 
The preferred invention also includes a decorative structural element for a 
cabinet, cupboard or the like which has at least two edge frame portions 
having abutting ends. Each of the edge frame portions has at least one 
outer surface. The abutting ends of the edge frame portions have aligned 
slots in aligned areas of the outer surfaces. A device for interlocking 
the abutting ends is disposed within the aligned slots for joining the 
edge frame portions. The device for interlocking the abutting ends 
includes a portion for overlying the aligned slots and the outer surfaces 
thereabout.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
As seen in FIG. 1, a corner region 10 of the preferred decorative panel 
includes a pair of edge frames 12 and a center panel element 14. Each of 
the edge frames 12 includes mitered ends 16 so that adjacent edge frames 
12 can be joined at the corner region 10 of the preferred decorative panel 
as they surround and support the center panel element 14. Accordingly, the 
decorative panel can be used as a door, drawer front, or other form of 
structural element for a cabinet, cupboard, or other type of decorative 
furniture or the like. 
To properly secure the center panel element 14 within the interior of the 
edge frames 12, each of the edge frames 12 has an internal edge groove 18 
for respectively receiving one of the edges 20 of the center panel element 
14 therein. 
It should be noted, that the preferred panel of the invention includes the 
edge frames 12 and center panel element 14 which include exposed, outer 
surfaces thereof which are covered by a decorative laminated surface 
material 22. The laminated surface material 22 provides a durable, 
attractive exterior surface to protect the preferred decorative panels 
against damage resulting from age, wear or abuse. Additionally, the use of 
different laminated surface materials 22 for the cabinets, cupboards or 
the like having the preferred decorative panels means that numerous 
optional surface designs, colors and styles can be offered for selection 
by potential customers. 
However, although the laminated surface material is aesthetically 
attractive and quite durable, it is of primary concern that the laminated 
surface material 22 remains secured to the outer surfaces of the edge 
frames 12 and center panel element 14 during extensive use of the 
decorative panel. Accordingly, to prevent separation of the laminated 
surface material 22 from the region of the internal edge groove 18, the 
laminated surface material 22 on each of the edge frames 12 includes a 
terminal portion 24 which is located within the internal edge groove 18 at 
both, opposite sides thereof. As the preferred decorative panel is being 
assembled, the center panel element 14 is surrounded by the edge frames 12 
as the edges 20 thereof are respectively received within the internal edge 
grooves 18 of the edge frames 12. As a result, each of the edges 20 also 
serves to secure the terminal portions 24 of the laminated surface 
material 22 within the internal edge groove 18 to prevent its undesired 
movement or separation from the edge frame 12. Additionally, the 
entrapment of the edges 20 within the internal edge groove 18 will prevent 
separation of the laminated surface material 22 from the outer surface of 
the center panel element 14. 
As thus described, the preferred decorative panel could include the edge 
frames 12 being joined at their mitered ends 16 by dowel pin and hole 
configurations which are well known in the cabinet-making art. However, 
such joining of the mitered ends 16 is more complicated during assembly 
which must also include the positive retention of the center panel element 
14 in the edge grooves 18. Specifically, with such a dowel pin and hole 
configuration, the gluing and setting of the mitered ends may require the 
continuous application of pressure to the corners to insure a proper 
alignment of the mitered ends 16 and retention of the center panel element 
14 until the glue is fully set. 
Accordingly, the preferred decorative panel includes the mitered ends 16 of 
the edge frames 12 being joined by a preferred interlocking device or 
tenon 30 which is positioned in aligned slot means 32 of the mitered ends 
16. The slot means 32 preferably includes a dove-tail slot 34 at each of 
the mitered ends 16. The use of such an interlocking device 30 in the 
aligned slots 34 would tend to provide greater rigidity to the assembled 
structure but would appear to be aesthetically less attractive than the 
dowel pin and hole configuration located in the abutting surfaces of the 
mitered ends and thus hidden from view. However, the preferred 
interlocking device 30 is installed at the back side (the upper side as 
seen in FIG. 1) of the decorative panel so that it too would not normally 
be seen unless the door, drawer, or other portion of the cabinet, cupboard 
or the like is opened for access to the interior thereof. Nevertheless, 
because there is some exposure to the back side of the decorative panel 
during use, it is still important for the back side of the panel to have a 
durable and attractive appearance. 
If the edge frames 12 and center panel element 14 were made of the same 
material throughout, such a joining of the mitered ends 16 by a simplified 
form of a mortise and tenon might not detract from the aesthetic 
appearance of the decorative panel. However, because of the preferred 
laminated surface material 22, it is possible that the laminated surface 
material 22 around the slot means 32 of the mitered ends 16 would separate 
from the surface of the edge frames 12 after continued use. An examination 
of the entire structure of the decorative panel shows that the edges of 
the laminated surface material 22 are not exposed to normal wear and tear 
which could result in its separation from the remainder of the decorative 
panel except in the area surrounding the slots 34. Specifically, as 
mentioned above, the edges of the laminated surface material 22 at the 
terminal portions 24 and at the edges 20 of the center panel element 14 
are protected after the center panel element 14 is installed within the 
internal edge grooves 18. Additionally, the edges of the laminated surface 
material 22 at the abutting surface of each of the mitered ends 16 is so 
aligned with the edges of the laminated surface material 22 on the 
adjoining mitered end 16 that snagging, scratching or separation from the 
adjoining edge frames 12 is unlikely. However, as mentioned above, the 
particular region around the slots 34 would not normally be protected by 
the use of a simple trunion or interlocking device if it did not include 
some of the features included in the preferred interlocking device 30. 
In this regard, the preferred interlocking device 30 includes an upper 
portion 36 which extends beyond the lower, interlocking portion 38 to 
completely overlie and cover the aligned slot means 32. As a result, the 
upper portion 36 protects the edges of the laminated surface material 22 
which surrounds each of the slots 34 so that they are no longer exposed 
for possible inadvertent separation from the surface of the edge frames 
12. 
Before discussing additional features of the preferred decorative panel 
and, specifically, the locking device 30 thereof, it is appropriate to 
discuss the various preferred materials used to provide the decorative 
panel. Although the edge frames 12 and center panel element 14 could be 
formed of wood or other natural material, the preferred edge frames 12 and 
center panel element 14 are formed of a medium density fiberboard of the 
type which can be purchased by the Monsanno Corp., P.O. Box Drawer 369, 
Spring Hope, N.C. 27882. The preferred laminated surface material is sold 
under the trademark COREX by the Formica Corp., 10155 Reading Road, 
Cincinnati, Ohio 45241. Although COREX surface material, sold under the 
stock nos. 7153; 370; 371; and 7189, has been employed for such decorative 
panels, there are similar materials sold by other companies which could be 
alternatively employed. Finally, the preferred locking device 30 is made 
of a high-impact thermoplastic (ABS) of the type sold by Parker Plastics 
Corp., 3585 Valley Drive, Pittsburgh, Pa. 15234. 
There are additional features of the preferred locking device 30 and the 
manner in which it is installed within the slots 34 which both simplify 
installation and insure proper retention after being installed. As seen in 
FIG. 1, each of the preferred slots 34 includes a predetermined depth D of 
about 0.920 inches with a slot height S of about 0.340 inches. The depth D 
and the height S are not particularly critical as long as they are 
specifically larger than corresponding dimensions of the locking device 20 
installed therein. Additionally, the side walls of the preferred dove-tail 
slot 34 form an angle of about 40 degrees or about 20 degrees to either 
side of a center line thereof. 
As seen in FIGS. 2 through 6, the preferred interlocking device 30 includes 
the upper portion 36 thereof having a width W of about 0.625 inches and an 
overall length L1 of about 0.765 inches. The length L1 is clearly greater 
than twice the height S to insure complete coverage of the slots 34 and 
the edges of the laminated surface material 22 thereabout. 
An insertion height I of the interlocking portion 38 of the interlocking 
device 30 is about 0.812 inches to provide a general clearance of about 
0.06 inches to the base 40 (FIG. 1) of the slot 34 at the predetermined 
depth D. A thickness T of the upper portion 36 is about 0.046 inches and 
the edges are slightly rounded to lie as closely and smoothly as possible 
to the back side of the edge frames 12. Accordingly, an overall height H 
of the preferred interlocking device 30 is about 0.858 inches. 
The interlocking portion 38 of the interlocking device 30 is basically 
formed of two dove-tail portions 42 having an overall length L2 of about 
0.515 inches which is clearly less than the combined heights S of the two 
slots 34. As best seen in FIG. 6, the angle A at each side of the 
dove-tail portions 42 is about 20 degrees to match the angle of the slots 
34. However, each of the dove-tail portions 32 includes serrated 
interlocking surfaces with a plurality of serrations 44 thereon. The 
serrations 44 include a height h of about 0.038 inches and a depth d of 
about 0.014 inches. As mentioned above, the edge frames 12 are made of 
wood, fiberboard, or some other similarly deformable material. Therefore, 
upon insertion into the slots 34, the serrations deform the interior walls 
of the slots 34 to produce a frictional contact between the interlocking 
device 30 and the slots 34 to prevent any accidental withdrawal. Finally, 
a bottom 46 of the interlocking portion 38 is rounded to simplify 
alignment of the interlocking device 30 with the slots 34 as it is being 
inserted therein. 
As thus described, the preferred decorative panel can be simply and quickly 
assembled to provide a rigid, secure structure while insuring that the 
various components including the laminated surface material will remain 
intact after extensive use. Although not mentioned hereinabove, the 
preferred method of assembly would include a thorough application of glue 
or other bonding material in the internal edge grooves 18, at the abutting 
surfaces of the mitered ends 16, and within the slots 34. Although gluing 
and bonding in this manner is preferred, it should be noted that the 
preferred configuration provides sufficient rigidity and integrity to the 
entire assembly to allow subsequent handling and storing of the decorative 
panel before the glue is fully set. 
The invention as described hereinabove in the context of a preferred 
embodiment is not to be taken as limited to all of the provided details 
thereof, since modifications and variations thereof may be made without 
departing from the spirit and scope of the invention.