Patent Publication Number: US-2006010802-A1

Title: Decorative panel system

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.