Patent Publication Number: US-2016222719-A1

Title: Decorative panel assemblies and associated methods

Description:
REFERENCE TO RELATED APPLICATION 
     The present application is a divisional of and claims priority under 35 U.S.C. §121, pre-AIA, to U.S. patent application Ser. No. 13/311,096, filed on Dec. 5, 2011, titled “Decorative Panel Assemblies and Associated Methods,” which claims priority to U.S. Provisional Patent Application No. 61/419,299, filed on Dec. 3, 2010, and titled “Decorative Panel Assemblies and Associated Methods,” the entire contents of each of which is hereby incorporated herein by reference for all purposes. 
    
    
     TECHNICAL FIELD 
     Embodiments described herein relate generally to decorative panels and associated methods for forming and installing decorative panels. 
     BACKGROUND 
     Paneling and other raised features are popular ornamentation to a home&#39;s doors and walls. Currently, in order to upgrade from non-paneled doors (or flat doors) to paneled doors, one must either replace the door itself or replace the whole door unit with a pre-hung door on an included door frame. Replacing the door itself typically requires specialty tools and skills to route the hinge locations and bore the door handle and latch holes, along with careful measuring and/or the use of a jig. Using a pre-bored door eliminates the routing and boring if the components happen to line up with the hardware locations on the existing frame. Often times, however, this is not the case. Replacing a door with pre-hung door assemblies is relatively messy and time consuming, as it requires demolition of the existing door, frame, and surrounding moldings, and then replacing the same. Materials cost as well as labor costs also impact a decision whether or not to upgrade an existing door. For example, a pre-hung hollow core door may cost approximately two times the amount of a hollow door. A raised panel door may be approximately four times the cost of a simple hollow door with a pre-hung version adding another substantial cost. In addition to the door and/or door and frame assemblies, handles, latches, moldings, finishing materials, and labor also incur substantial costs. 
     Likewise, wall paneling and the installation thereof can be relatively labor intensive. Wall paneling typically requires relatively significant amounts of measuring, calculating, aligning, re-aligning, and finishing. Each design, such as square or rectangular designs, typically require exact cutting of moldings for each side and exact perpendicular alignment of the four side pieces with one another, plus alignment and spacing of the assembled sections. Corner joints then need to be filled/caulked on each finished assembly. Given the finishing required on each assembled section, the moldings cannot be painted prior to installation, meaning that detailed painting has to be performed after installation. 
     Accordingly, there is an opportunity for improved decorative panel assemblies and associated systems and methods that minimize time, effort, labor, and costs associated with upgrading a home interior or exterior with paneling. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1C  illustrate example panel arrangements applied to doors, in accordance with example embodiments. 
         FIGS. 2A-2B  illustrate example panel arrangements applied to walls or other flat surfaces, in accordance with example embodiments. 
         FIG. 3A  illustrates a back view of a raised panel, in accordance with an example embodiment. 
         FIG. 3B  illustrates a cross-section view of a raised panel, in accordance with an example embodiment. 
         FIG. 4A  illustrates a back view of a framed panel, in accordance with an example embodiment. 
         FIG. 4B  illustrates a cross-section view of a framed panel, in accordance with an example embodiment. 
         FIG. 5  illustrates a side view of a panel, in accordance with an example embodiment. 
         FIGS. 6A-6E  illustrate example techniques for applying panels, in accordance with example embodiments. 
         FIGS. 7A-7C  illustrate example templates for use when applying panels, in accordance with example embodiments. 
         FIG. 8  is a flow chart of an example method for applying panels to a surface, according to an example embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     Embodiments of the disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. 
     Embodiments described herein provide decorative panel assemblies, and associated apparatus, systems, and methods. The decorative panel assemblies may be installed on any flat surface associated with a home or other structure, such as a door, wall, ceiling, or furniture, to simulate a raised decorative panel. For example, in one embodiment, one or more decorative panels may be affixed to a flat-faced door to simulate a door having raised panels. In another embodiment, one or more decorative panels may be affixed to a portion of a wall (e.g., lower portion) to simulate wall paneling type decor. In other embodiments, one or more decorative panels may be affixed to a ceiling, such as to simulate a ceiling tray or other ceiling molding. In yet other embodiments, one or more decorative panels may be affixed to a furniture surface to simulate decorative accents. According to various embodiments, multiple panels can be aligned vertically and/or horizontally, such as in a predetermined arrangement to achieve the desired effect of simulating more ornate and decorative items while minimizing cost and/or effort to replace existing items. 
     As mentioned above, specialty tools, demolition mess, door sizing, hinge location, handle/latch alignment with a strike plate, wall panel placement, finishing, and extended labor time are all significantly reduced or eliminated by these pre-manufactured panels. The panel assemblies described according to various embodiments herein can be installed in a matter of minutes and installed by an unskilled person. 
     These and other advantages will become apparent in light of the detailed example embodiments of the disclosure, which are described below with reference to the drawings. 
       FIGS. 1A-1C  illustrate example embodiments of panel assemblies arranged and affixed to a flat surface of a door  5 . According to the embodiment shown in  FIG. 1A , two panels  10 ,  12  are affixed to a surface of a door  5 , such as a front or back surface of the door  5 . In this embodiment, a lower panel  10  may be sized differently than an upper panel  12 . The lower panel  10  may be smaller or larger than the upper panel  12 . Moreover, the embodiment illustrated in  FIG. 1A  shows each of the two panels  10 ,  12  being a squared, raised panel. In certain embodiments, each squared, raised door panel (and wall panel, as described below with reference to  FIG. 2A ) can be formed as a single element having four sides, a front, and a back, and generally forming a rectangle. The panels  10 ,  12  may have various dimensions, which may be determined in part by the size and shape of the door  5  on which the panels  10 ,  12  are to be affixed, as described by example in more detail below. The panels may be affixed to a door  5  according to any number of suitable techniques, as described by example in more detail below. 
     The embodiment illustrated in  FIG. 1B  is similar to that described with reference to  FIG. 1A  except that at least one of the panels has an arched edge. According to this embodiment, two raised panels  20 ,  22  are affixed to a door  5 , with an upper panel  22  having an arched edge  24 . In other embodiments, more than one edge may have an arch. Moreover, in other embodiments, each panel may include at least one arched edge. 
     The embodiment illustrated in  FIG. 1C  includes six panels: two lower panels  30 , two middle panels  32 , and two upper panels  34 , arranged in two vertical rows of three. Each of the illustrated panels is a frame panel having a void defined between a raised frame of each panel, which would expose the surface of the door  5  therethrough. The differences between raised panels and framed panels are provided in more detail with reference to  FIGS. 3A-4B . Each of the panels  30 ,  32 ,  34  may have the same or different dimensions. For example, as shown, the upper panels  34  may be smaller in height than the middle panels  32  or the lower panels  30 . 
     According to one embodiment, each of the panels  10 ,  12 ,  20 ,  22  for the doors having two panel arrangements may be formed with relative dimensions ranging between approximately 15.5 inches and approximately 24 inches in width and approximately 24 inches and approximately 36 inches in height. In one embodiment, each of the panels  30 ,  32 ,  34  for the doors having six panel arrangements may be formed with relative dimensions ranging between approximately 6 inches and approximately 12 inches in width and approximately 4 inches and approximately 9 inches in height. It is appreciated, however, that the aforementioned dimensions are provided for illustrative purposes and are not intended to be limiting. The dimensions may therefore vary depending upon the number and arrangement of the panels, and size of the door on which they are intended to be affixed. 
     It is appreciated that the door panel embodiments shown in  FIGS. 1A-1C  are provided for illustrative purposes and that many variations may exist. For example, any combination and number of panels may be arranged on a door. Similarly, any size of panels may be arranged in any manner. In addition, while squared panels and arched panels are illustrated, in other embodiments, the panels may be formed according to any desired geometry. Similarly, panels shown in the above embodiments as raised may instead be open framed panels and panels shown as framed panels may instead be raised panels. 
       FIGS. 2A-2B  illustrate embodiments in which decorative panel assemblies are applied to a wall  7 . According to the embodiment illustrated in  FIG. 2A , a series of raised panels  40 , similar to those described with reference to  FIGS. 1A-1B , are affixed to a wall  7 . The panels  40  may be affixed along any portion of the wall, such as within a lower portion, along the middle (e.g., acting as a chair rail, etc.), along or near the bottom edge or top edge (e.g., enhancing the molding of the wall, etc.).  FIG. 2B  illustrates an embodiment in which the panels  42  are framed panels having an open interior or void defined therethrough. 
     According to one embodiment, the raised panels  40  and/or the framed panels  42  may be formed with relative dimensions ranging between approximately 12 inches and approximately 36 inches in width and approximately 20 inches and approximately 26 inches in height, such as if applied to the lower portion of the wall to simulate decorative paneling. It is appreciated, however, that the aforementioned dimensions are provided for illustrative purposes and are not intended to be limiting. The dimensions may therefore vary depending upon the number and arrangement of the panels, and size of the wall portion on which they are intended to be affixed. Moreover, any other panel configuration and shape may be provided for affixing to a wall surface, and are not limited to those illustrated by  FIGS. 2A-2B . 
       FIGS. 3A-3B  illustrate a back view and cross-section view of a raised panel, respectively, such as any of the panels  10 ,  12 ,  20 ,  22 ,  40  described above, according to one embodiment. A raised panel  300  may include a flat surface  302  and a recessed groove or valley  304  formed along at least a portion of the backside of the panel  300  near, but slightly distanced from, the periphery or edge of the panel  300 . The groove or valley  304  allows adhesive to be applied or included with the panel  300 , while still allowing the flat surface  302  to be flush with the flat surface of the door, wall, or other surface to which the panel is to be applied. With reference to  FIG. 3B , each panel can be constructed to form a raised center section  306  with tapered edges  308  and an integral thicker outer molding  310  with tapered inner edges  312 . The tapered edges  308 ,  312  meet to form a valley or concave section of the panel, providing a decorative and raised effect. It is appreciated that a raised panel  300  may be formed with any geometry as desired and is not limited to that shown in  FIGS. 3A-3B . Additionally, a groove or valley may or may not be provided. As desired, other attachment mechanisms may be utilized to affix a panel  300  to a door, wall, or other surface. 
     According to some embodiments, the panel  300  may be manufactured as a single pre-shaped molded piece. For example, the panel may be molded from materials including, but not limited to, plastic, urethane, wood composite, wood, rubber, any other suitable manufactured and/or moldable materials, and/or any combinations of materials as desired. Examples of techniques for manufacturing the panel, include, but are not limited to, a plastic or urethane molding process or a medium density fiberboard (“MDF”) or high density fiberboard (“HDF”) pressure forming process. In other embodiments, however, each panel  300  may not be molded but instead manufactured, such as through conventional shaping and planing techniques applied to woods or polymers, or other materials. 
       FIGS. 4A-4B  illustrate a back view and cross-section view of a framed panel, respectively, such as any of the panels  30 ,  32 ,  34 ,  42  described above. according to one embodiment. A framed panel  400  may similarly include an outer molding  406  having a groove or valley  404  formed along at least a portion of the backside of the panel  400  near, but at slightly distanced from, the periphery or edge of the panel  400 . However, the inner edges  408  may define a void or opening  402 , forming a picture frame effect. An opening  402  may be desired to show a surface of the door or wall underneath (or any other surface to which the framed panel  400  may be applied). It is appreciated that a framed panel  400  may be formed with any geometry as desired and is not limited to that shown in  FIGS. 4A-4B . Additionally, a groove or valley may or may not be provided. As desired, other attachment mechanisms may be utilized to affix a panel  300  to a door, wall, or other surface. 
       FIG. 5  illustrates an example side view of a panel, which may be a raised panel or a framed panel. With reference to  FIG. 5 , once a panel is applied to a door, wall, or other surface, at least a portion of the panel may extend outwardly from the surface, thereby forming a decorative feature. 
     As desired in various embodiments, each panel can be secured to a respective flat surface (e.g., door, wall, ceiling, furniture, etc.) using a variety of adhesive materials, such as, but not limited to, glue, construction glue, tape, hook and loop closures, or using hardware, such as, but not limited to, nails, staples, or screws. According to one embodiment, panels may be provided in a self-adhering configuration, which includes pre-installed or applied adhesive material. In some embodiments, the pre-installed or applied adhesive material may be provided within the groove or valley defined near the edge on the back surface of the panel, such as is described with reference to  FIGS. 3A-4B . In other embodiments, the pre-installed or applied adhesive material may be provided on one or more areas of the flat back surface, such as near the edges and/or near the center.  FIGS. 6A-6E  illustrate example techniques for applying one or more panels to a flat surface, using the panel arrangements shown in  FIGS. 1A-2B , respectively, as example arrangements. 
     According to various embodiments, for ease of installation and accuracy, panel assemblies may optionally include a self-adhering paper installation template. The template may include a pre-installed adhesive material on both sides to allow the template to be reversed for use on the front and back sides of a door or other surface. In some embodiments, the templates are specific to each door size and each panel style. For example, as illustrated in  FIG. 7A , a template  700  for a two panel arrangement includes two vertical sections—a first vertical section  702  oriented along the hinged side and a second vertical section  704  oriented along the latch side of the door  5 . The template  700  may further include three horizontal sections—a first horizontal section  706  along the top, a second horizontal section  708  along the middle, and a third horizontal section  710  along the bottom of the door  5 . These horizontal sections and vertical sections define an area  712  where a panel is to be applied, such as is illustrated by  FIG. 7A . In one embodiment, a template  700  may further include a cut-out  714  or other allowance for the door handle on the latch side of the template  700 . In certain embodiments, the cut-out  714  may be removed once the template  700  is affixed to a flat surface. For example, the cut-out  714  may not include adhesive material such that the cut-out  714  can be removed. 
       FIG. 7B  illustrates another template  750 , according to one embodiment for use with a six panel arrangement. Different than the template  700  for a two panel arrangement, this template  750  will include three vertical sections  752 ,  754 ,  756 , and four horizontal sections  758 ,  760 ,  762 ,  764 , defining six areas  768  where panels are to be applied. 
       FIG. 7C  illustrates another template  775  for a panel arrangement to be applied to a wall (or other flat surface), according to one embodiment. In this embodiment, the template  775  includes two vertical sections  777 ,  779  and two horizontal sections  781 ,  783 , defining an area  785  where a panel is to be placed. According to one embodiment, the vertical sections  777 ,  770  and the horizontal sections  781 ,  783  can be scaled in order to be cut the desired width and height, depending on the orientation of the panel, the length of the wall, and the height of the chair rail (or other desired placement). It is appreciated that, in some embodiments, a template may include multiple sections similar to the template  775  to allow precisely aligning and applying multiple panels to a flat surface (similar to that illustrated and described with reference to the door templates in  FIGS. 7A-7B ). 
     In use, a user would open a package, remove the panels and the template and apply the template to the door, wall, ceiling, furniture, or other flat surface. The user may then peel and remove paper covering a pre-installed adhesive material from the back of the panel (or attach with nails or other hardware if desired), and apply the panels to the door or wall surface in the areas identified by the template. The user could then caulk the edges of the panels (and fill nail or other hardware holes—if applicable), or paint the panels as-is. 
     It is appreciated that, in other embodiments, templates may be provided that are multi-purposed, such as having multiple outlines, perforations, or other scales that would allow applying to different doors or wall sizes and/or applying different panel arrangements. Thus, in embodiments including multi-purposed templates, a kit may be provided together or in parts that includes a single multi-purposed template (or a select few multi-purposed templates) and any number, shape, or size of templates, which may be selected individually, to allow varied applications. It is appreciated, however, that in other embodiments, different templates and panels may be provided for specific applications, such as, but not limited to, the above examples, which may increase the ease of installation and minimize any additional effort required by the installer. 
       FIG. 8  is a flow chart of an example method  800  for applying one or more panels to a surface, according to an example embodiment. The method  800  may begin at block  805 , and any number of decorative panels may be provided. As described above, each of the decorative panels may be formed from a wide variety of materials and include any number of suitable dimensions. At block  810 , at least one template may be provided. The template may assist in aligning the one or more decorative panels on the surface to which the panels will be applied or affixed. 
     At block  815 , the at least one template may be aligned to surface to which the panels will be applied. At block  820 , the at least one template may be affixed (e.g., temporarily affixed to the surface. As desired, one or more cut-out portions may be removed from the at least one template in order to define areas or section of the surface to which the panels will be affixed. At block  825 , the one or more decorative panels may be affixed to the surface utilizing any number of suitable attachment techniques, such as adhesive materials and/or attachment hardware. The at least one template may then be removed at block  830 , and the method  800  may end. As desired, the decorative panels may be caulked, stained, and/or painted either prior to removal of the at least one template or subsequent to removal of the at least one template. 
     Many modifications and other embodiments of the disclosure set forth herein will be apparent having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.