GB2317145A

GB2317145A - Decorative part for door or wall-covering panels

Info

Publication number: GB2317145A
Application number: GB9716441A
Authority: GB
Inventors: John Victor Robert Beaumont
Original assignee: DOVE HOLDINGS PLC
Current assignee: DOVE HOLDINGS PLC
Priority date: 1996-08-06
Filing date: 1997-08-05
Publication date: 1998-03-18
Also published as: GB9716441D0; GB9616500D0

Abstract

A flat panel such as a door, is decorated using a decorative part to mount glass inserts 5 or form decorative profiles. Each decorative part comprises a pair of rectangular frames 8,9 located on opposite sides of the panel and having portions 11,12 engaging the surface of the panel and portions 13,14 that interlock through openings in the panel. The locking portions may comprise teeth 17 engaging a single barb 18, interengaging ratchet teeth (21,Fig 6) or snap connecting parts (22,23,Fig 7).

Description

DECORATING PANELS This invention relates to decorative parts for flat panels, in particular for doors or wall-covering panels.

Traditionally doors have been made of wood, and often include decorative panels or glass inserts. More recently, plastics materials have been used for doors, in order to reduce costs. Such doors usually have a wooden or metal surround, to which hinges and locks are attached and a central plastics panel, which carries any decoration. The panel is commonly formed by vacuum moulding two flat skins of PVCu to the required profile, and then bonding them to an insulating core.

There are two main problems with such panels. The first is that a large number of different profiles are needed, one for each of perhaps twenty different styles of door. Each profile needs its own vacuum mould, and the stock kept by a manufacturer will be large. As a result, the panels are expensive to make and to keep in stock. The second problem is in the insertion of any glass inserts, which can be done by either of two methods. Each method requires some steps to be completed before final assembly of the panel, and so is quite complex and expensive.

In the first method a hole is cut in one skin, and a larger hole in the other skin and the core. The glass insert is bonded to the inside of the skin surrounding the edge of the smaller hole, and a decorative trim is bonded to the outside of the other skin and the adjacent face of the glass insert. With this method the glass can be replaced if it is broken, by removing the trim and the glass. It may however not be attached to the panel very securely.

In the second method holes of the same size are cut in the two skins and a larger hole is cut in the core. The glass insert is bonded to the skin surrounding each hole at the same time as the skins are bonded to the core. This provides a secure attachment of the glass insert, but the glass cannot be replaced if it is broken.

According to the present invention, a decorative part for a flat panel comprises a pair of members adapted for location on opposite sides of a panel, each having an abutment portion for engagement with an adjacent surface of the panel, and at least one connecting portion adapted to co-operate with a connecting portion on the other member, each pair of connecting portions including locking means having an operative position in which the members are secured to one another, the arrangement being such that at least one of each pair of connecting portions is adapted to extend into an aperture in the panel, and with the locking means in the operative position the abutment portion of each member is retained in engagement with the adjacent panel surface.

Such a decorative part can be used to provide profiled panels without vacuum forming, and to mount glass inserts on a flat panel in a simple manner, and after assembly of the skins onto the core. The apertures for the decorative part can be made in the assembled flat panel.

This means that only flat panels need to be made and kept in stock, together with the appropriate number of decorative parts. The number of different decorative parts required to make all current panel profiles is quite small, at less than ten. The stock and the manufacturing costs are therefore reduced considerably. Further, the decorative part mounts a glass insert securely, but enables it to be replaced if broken, by removing the decorative part and replacing the insert and decorative part.

Conveniently, each member has a central aperture. The abutment portion projects beyond the connecting portion to form inner and outer peripheries of the members.

Preferably the connecting portions on each member extend into the aperture in the panel. The locking means act to secure the connecting portions together.

The locking means are preferably not releasable, to ensure that the decorative part is securely attached. The locking means may be of a ratchet type, or a snap lock. The locking means may have more than one operative position, to accommodate different thicknesses of panel.

The members are preferably of plastics material. They may be injection-moulded for precision.

For mounting a glass insert in a panel, an aperture large enough to accommodate the insert is made in an assembled flat panel. The glass insert is bonded to an internal surface of an inner abutment portion of one member which is'then applied to one side of the panel. The other member is applied to the opposite side of the panel, so that the connecting portions engage, and the locking means assume their operative position, to retain the members and the glass insert in the panel.

If the decorative part is to be used simply to create a profile, rather than to mount an insert, apertures are made in the panel corresponding to the connecting portions. The members are then applied to the panel with the connecting portions extending through the apertures, and the locking means engaged.

The use of decorative parts makes it easy to have profiles in a different colour from the rest of the panel.

Various embodiments of the invention are illustrated, by way of example, in the accompanying drawings, in which: Figure 1 is a front view of a door panel part cut away: Figure 2 is a perspective view of one member of a decorative part for a flat panel: Figure 3 is a similar view of the other member; Figure 4 shows a cross-section through the decorative part of Figures 2 and 3 in use; Figure 5 is similar to Figure 4, but shows a modified part; and Figures 6 and 7 show further modifications.

The door panel 1 shown in Figure 1 is made from a flat panel comprising two skins 2, 3 of PVCu bonded to an insulating core 4 which is of polystyrene foam. The door panel 1 includes a glass insert 5 and four decorative profiles 6. The insert 5 is mounted by a decorative part 7, and the profiles 6 are formed by similar decorative parts, such as are shown in Figures 2 to 4. The decorative parts 7 are mounted in apertures in the panel 1.

Figures 2 to 4 show a decorative part 7 mounting a glass insert 5.

Each part 7 comprises a pair of members 8, 9, one located on each side of the panel 1. The members 8, 9 are of similar outline, as shown being rectangular with a central aperture 10. It will be appreciated that the members 8, 9, could be of any desired shape, such as square, part-circular or the like. The members 8, 9 are injection-moulded from ABS or similar plastics material.

Each member 8, 9 has a flat abutment portion 11, 12 respectively adapted to engage the adjacent outer surface of a skin 2, 3 of the panel 1.

The abutment portions 11, 12 form the inner and outer peripheries of the members 8, 9. Each member 8, 9 also has respective spaced connecting portions 13, 14 projecting from a central part of the abutment portion 11, 12. The connecting portions 13, 14 are adapted to extend into an aperture 15 in the panel 1, as shown in Figure 4. The connecting portions 13, 14 form complementary pairs co-operating with each other, and each pair includes locking means 16 which engage in an operative position to secure the members 8, 9 together. The connecting portions 13 of the member 8 are tubular and each has a locking part in the form of ratchet-type teeth 17. The connecting portions 14 of the member 9 comprise cylindrical projections with a locking part in the form of barbs 18. The barbs 18 engage with the teeth 17 at different spacings of the member 8, 9 in order to accommodate different thicknesses of panel, such as 28mm and 24mm.

It will be appreciated that the locking means 16 is not readily releasable.

In order to make the door panel 1 of Figure 1, the flat panel is formed by sticking the two skins 2, 3 to the core 4. A rectangular aperture 15 is cut in the panel for the insert 5; the aperture 15 is large enough to accommodate the insert 5 and the connecting portions 13, 14.

One side of the insert 5 is then bonded to the inside of the abutment portion 11, round the inner periphery of the member 8, by double-sided adhesive tape 19 (see Figure 4). The member 8 is then inserted into the aperture 15 from one side of the panel, so that the connecting portions 13 extend into the aperture. The other side of the insert 5 is also provided with double-sided adhesive tape 20 round its periphery, and the other member 9 is inserted into the aperture 15 from the other side of the panel, so that the connecting portions 14 engage with the connecting portions 13. The member 9 is inserted until it reaches a point where the abutment portions 11, 12 on both members are firmly in engagement with the surfaces of the panel, and the locking means 16 is engaged. It will be appreciated that this may be at either of the spacings determined by the locking means 16. In this position the inner periphery of the inside of the abutment portion 12 engages the adhesive tape 20. The glass insert 5 and the members 8, 9 are then firmly secured to the panel.

The glass insert 5 is easy to mount by means of the members 8, 9 and cannot readily be removed without breaking it, because the locking means 16 are concealed and cannot be released once the insert is in place in the panel. However, if the glass breaks it can be removed, and the connecting portions 13, 14 are then exposed. The locking means 16 may then be released or the connecting portions 13, 14 severed in order to remove the members 8, 9. A new insert 5 can then be installed with new members 8, 9.

To complete the door panel 1 of Figure 1, four further parts 7 are mounted on the flat panel. Each is mounted in the same way. Instead of a large rectangular aperture 15, six smaller apertures are made, corresponding to the connecting portions 13, 14. A pair of members 8, 9 is then applied to the panel, one on each side, with the connecting portions 13, 14 inserted in the apertures, and are inserted until the abutment portions 11, 12 are firmly in engagement with the panel surfaces, and all the locking means 16 are engaged in their operative position.

The use of the decorative parts 7 for making door and other panels makes the panel very easy to manufacture, since a flat panel can be made, the apertures formed and the parts 7 applied. This is a considerable advantage over previous methods involving vacuum moulding of the skins 2, 3 and putting glass inserts in before final assembly of the skins 2, 3 and core 4. The decorative parts 7 reduce the stocks of panels that need to be kept, as well as the cost of manufacture. The method of making a panel with the decorative parts forms another aspect of the invention.

Figures 5 to 7 show modifications of the locking means 16. In Figure 5 the connecting portion 13 has a set of teeth 17, and the portion 14 a single barb 18.

In Figure 6 the connecting portions 13, 14 each have a set of ratchet-type teeth 21 which interengage. This has the advantage that the members 8, 9 can be identical in shape, and that it is easier to undo the locking means 16.

In Figure 7 the locking means 16 comprises a spherical projection 22 on the connection portion 14, engaging in part-spherical recesses 23 in the connecting portion 13. The projection 22 snaps into the recess 23, and is difficult to remove.

Claims

1. A decorative part for a flat panel, comprising a pair of members adapted for location on opposite sides of a panel, each having an abutment portion for engagement with an adjacent surface of the panel, and at least one connecting portion adapted to co-operate with a connecting portion on the other member, each pair of connecting portions including locking means having an operative position in which the members are secured to one another, the arrangement being such that at least one of each pair of connecting portions is adapted to extend into an aperture in the panel, and with the locking means in the operative position the abutment portion of each member is retained in engagement with the adjacent panel surface.

2. A decorative part as claimed in claim 1, in which each member has a central aperture.

3. A decorative part as claimed in claim 1 or claim 2, in which the abutment portion of each member projects beyond the connecting portion to form inner and outer peripheries of the member.

4. A decorative part as claimed in any preceding claim, in which the connecting portion on each member extend into the aperture in the panel.

5. A decorative part as claimed in any preceding claim, in which the locking means act to secure the connecting portions together.

6. A decorative part as claimed in any preceding claim, in which the locking means are not releasable.

7. A decorative part as claimed in claim 6, in which the locking means is of a ratchet type.

8. A decorative part as claimed in claim 6, in which the locking means is a snap lock.

9. A decorative part as claimed in any preceding claim, in which the locking means has more than one operative position.

10. A decorative part as claimed in any preceding claim, in which the members are of plastics material.

11. A decorative part for a flat panel substantially as described herein with reference to and as illustrated in Figures 1 to 4 of the accompanying drawings.

12. A decorative part for a flat panel substantially as described herein with reference to and as illustrated in Figure 5 of the accompanying drawings.

13. A decorative part for a flat panel substantially as described herein with reference to and as illustrated in Figure 6 of the accompanying drawings.

14. A decorative part for a flat panel substantially as described herein with reference to and as illustrated in Figures 7 of the accompanying drawings.