This invention relates to a decorative panel comprising rigid decorative sheets replaceably installed on a structural support. Such decorative sheets can be readily installed or replaced to exhibit a variety of designs by the use of fixing means such as screws. Moreover, a variety of decorative accessories such as a picture frame can be further set on the decorative surfaces. Such readily replaceable decorative panels are very useful, for example, for display rooms, etc.
Up until now, most tile panels have been produced by bonding tile pieces onto a substrate with wet mortar. Such wet installation of tiles demands professional skills and long working hours, sometimes the freshly bonded tiles slip down, and the mortar often needs a long aging time. Moreover, a very large scale operation is required to replace the tile pieces when the panel is remodelled.
Installation of decorative sheets such as tiles with strong organic adhesives also presents difficulties in partly stripping the sheets and cleaning the adhesive when the panel is remodelled.
Some decorative sheets can be nailed onto a substrate. Such a nailing installation, however, necessitates the grouting of the nail heads. The grout and nails have to be removed when the decorative sheets are replaced.
Considerable work is also required in these dry installation systems when the panel is remodelled.
Some sheets or plates to be installed with screws are also known. DE-A-2 149 129 corresponding with the preamble of claim 1 discloses ceramic tile to be assembled and installed having cut-outs at the corners thereof and no depression hole at the centre as shown in FIG.5 thereof. It is noted that the heads of the fixing screws at the corners of the tile are higher than the tile surfaces. DE-A-2 805 625 discloses large brick plates having lattice-like square holes and having neither cut-outs nor depressions at the corners thereof, wherein the hole can have a cone-like centre hole to fix the brick plate to a substrate by means of a screw and washer as shown in FIG. 7 thereof.
Thus, it is an object of the present invention to provide a decorative panel comprising rigid decorative sheets having cut-outs and depressions at the corners thereof which are replaceably installed on a structural support by the use of fixing means, such as screw.
Another object of an embodiment of the present invention is to provide the above mentioned decorative panel on which a variety of decorative accessories or articles are readily set by utilizing the heads of the fixing means.
According to the invention there is provided a decorative panel comprising right-angled tetragonal rigid decorative sheets replaceably installed on a structural support by the use of fixing means having flanges at the heads thereof; said decorative sheets having cut-outs at the corners thereof; each of the corners of four decorative sheets assembled together forming a cut-out hole; said structural support containing mating means for the fixing means; the cut-out holes of the assembled sheets being arranged on the mating means; the fixing means being fitted to the mating means through the cut-out holes:
characterised by said decorative sheets having depressions adjacent to the cut-outs; each depression being in the form of an inclined plane tapering down towards the cut-out; the inclined depressions of four assembled sheets forming an inclined depression plane around the cut-out hole, whereby the flanges at the heads of the fixing means are readily fitted in the inclined depressions to firmly support the decorative sheets; the heads of the fixing means recessed in the depressions being not higher than the level of the decorative surfaces of the decorative sheets; said structural support being a frame work consisting of substantially horizontal or vertical bars arranged at the spacing of the decorative sheets and at least two vertical or horizontal bars supporting the first-mentioned bars; and said mating means on the frame work being internal screw-thread holes or nut-containing holes set at the spacing of the decorative sheets.
Preferred embodiments of the invention are described in detail below, by example only, with reference to the accompanying drawings, wherein:
In Fig. 1 is shown a decorative panel 1 which comprises right-angled tetragonal rigid decorative sheets 2 replaceably installed on a structural support 9 such as frame works, substrate boards or walls by the use of removable fixing means such as screws 6; said decorative sheet 2 having cut-outs 3 at the corners thereof and depressions 4 adjacent to the cut-outs each of corners of four sheets 2 closely assembled together forming a cut-out hole 5 and a depression 4 around the hole; said structural support 9 containing mating fixing means such as internal screw-thread means 15; the cut-out holes 5 of the assembled sheets being arranged on the mating fixing means 15; the fixing means 6 being fitted to the mating means 15 through the cut-out holes 5; the flanges 7 at the heads of the fixing means being sunk in the depressions 4 around the holes 5; whereby the decorative sheets 2 are replaceably fixed onto the structural support 9.
The decorative sheets are normally assembled without substantial gaps. It is generally preferred in view of appearance that the heads of the fixing means recessed on the depressions 4 are not higher than the level of the decorative surface. Incidentally, a covering frame 12 can be applied onto an edge or edges of the decorative panel 1. In this case, it is not always needed to secure such covered parts of the decorative sheets by the fixing means. Moreover, other decorative articles can be set on the decorative panel 1 by means of accessories or magnetic force. In the latter case, either one of some fixing means and decorative sheet(s) or the decoration article contains magnet pieces, and the other contains magnetizable pieces.
Incidentally, the decorative sheets are generally assembled and installed from the bottom row of the decorative sheets. The decorative sheets can be readily installed or partly replaced to provide a variety of the decorative panels by those unskilled in the art, when the decorative sheets, structural supports and other accessories are supplied. Also, the decorative panel itself can be readily set or replaced to remodel the decorative designs.
The rigid decorative sheets to be used in the present decorative panel can be square or rectangular rigid sheets of plastics, plastic composites, glass, wood, ceramics, cement concrete, metal, mixtures thereof or the like. Heat-resistant sheets such as those of ceramics, concrete or metal can be glazed on the surfaces thereof. The dimensions of the decorative sheets are not especially restricted, but are normally in the range of about 10 cm to about 50 cm. The thickness of the sheet is such that sufficient strength is provided. The decorative sheet generally has cutouts 3 and depressions 4 at the four corners thereof. Thus, the cutouts and depression at the edges or corners of the panel 1 form semi- or quarter-circle configurations, where the fixing means can be inserted and recessed. As mentioned above, however, such cutouts and depressions are not always needed at the Corners or edges which are supported by the covering frame 12 of the decorative panel. The size of the cut-out 3 of the sheet is such that the shank of fixing means such as screws 6 can be passed through. The size of the depression 4 is such that the flange 7 at the head of the fixing means can be recessed thereon. Incidentally, the cut-outs 3 and depressions 4 are normally designed to comprise quarter-round corners.
The depression 4 at the corners of the decorative sheet 2 is in the form of an inclined plane tapering towards the cut-out 3 (although this is not immediately apparent from the drawings). It has been unexpectedly found that an inclined depression tapering down from the decorative surface to the cut-out 3 is advantageous to ceramic tile and the like, because the mechanical strength if the tapered corner is ensured owning to gradual change in the degree of compaction and also glaze is uniformly applied onto such tapering depressions.
The rigid decorative sheets 2 are replaceably installed on a structural support 9 such as a frame work containing mating fixing means by the use of removable fixing means such as screws 6 to provide the present decorative panel 1. The structural support 9 is exemplified by a frame work composed essentially of horizontal or vertical bars 10 arranged at an interval of the decorative sheet and at least two vertical or horizontal bars 11 are supporting the bars 10. The bars 10 have mating fixing means such as internal screw-thread holes 15 or holes 26 combined with nuts, at an interval of the decorative sheet to be installed thereon.
In a preferred embodiment, the bar 10 can be a metal bar 10 having U-shaped cross section. The U-shaped bars are composed to form a frame work or fixed onto a structural member with the openings thereof downward or upward or sideways. The U-shaped bars can have holes 26 at the both parallel sides thereof, as shown in FIG. 3. For example, nuts 13 having ring projections 14 at both ends thereof are set between pairs of the holes 26 of the U-shaped bar 10. Alternatively, the bars 10 can have internal screw-thread holes. The decorative sheets 2 can be readily screwed to the structural support 9 by means of bolts 6 and nuts 13 or screw-thread holes as illustrated in FIGS. 1 and 3, to provide a decorative panel such as decorative walls or self-standing screen walls (e.g. a screen with or without casters or a folding screen as shown in FIG. 2). By the use of U-shaped bars 10 and nuts 13 held thereby as shown in FIG. 3, the decorative sheets can be readily installed as necessary on both sides of the frame work 9; such structure is useful for screen walls.
The preferred combination of the bolt 6, nut 13 and other accessories is illustrated in FIG. 4. The fixing means such as a bolt 6 can have an inner hole (e.g. an inner screw-thread hole 16) for holding accessories and screwdriver grooves 17 at the head thereof. The inner hole 16 can hold a decorative head cap 18 or the like. As shown in FIG. 2, the head cap can be of relatively soft materials such as wood or rubber for pinning cards 19 or other displays thereon. Also, the inner holes 16 can be equipped with hooks or hangers 20, magnet pieces, rods for supporting shelf boards 21 or trays, or the like, by means of screws or adhesives, etc. The washer 8 is to protect the corners of decorative sheets, which is normally of relatively resilient materials such as rubber or plastics. The nut 13 normally has polygonal outward surfaces, whereby rotation of the nut is prevented by the bottom of the U-shaped bar as shown in FIG. 3. The length of the polygonal body 13 is as long as the distance between the parallel sides of the U-shaped bar 10, and the size of the ring projection 14 is as large as the diameter of the hole 26 at the sides of the bar 10. Incidentally, the decorative panel having inverted U-shaped horizontal bars can also be readily anchored onto a structural member such as walls by hooking means.
Other decoration articles e.g. picture frame 27 can be advantageously set on the surface of the present decorative panel 1 by means of magnetic force, as shown in FIG. 2.
When the decoration article such as decorative or displaying members are small and light, it can be set by a single magnet piece and a magnetizable piece. For example, the bolt 6 or cap 18 fixed to the bolt, as shown in FIGS. 1 and 4, can be a magnet piece and the decoration article can contain a magnetizable piece, and vice versa.
According to this embodiment, a picture frame containing magnetizable materials or magnet materials can be readily set and replaced without undecently exposed hanging means. When the picture frame is relatively light, it can be set on the decorative panel by means or plural magnet pieces. When the picture frame is relatively large and heavy, the frame 27 should have a hooking means 29 inside the upper portion thereof, as illustrated in FIG. 5. More specifically, the hook 29 (e.g. in the shape of inverted L or sideway U) at the upper portion of the frame 27 is anchored by the magnet cap 18 fixed to the decorative panel 1 to support the weight of the frame, and the magnetizable metal portions 28 of the frame are horizontally attracted by the magnet cap 18, whereby the picture frame 27 can be secured in both gravitational and horizontal directions. It is preferred that the magnetizable metal portion 28 with the hook 29 has some space 30 or allowance 30 with respect to the magnet cap 18 for easily mounting the frame 27.
Incidentally, the picture frame 27 can have optional configurations and may cover or contain thin articles 31 such as drawings, photographs, posters and documents. The frame 27 itself can also provide three dimensional decoration effects without such decorative articles. In other words, the picture frame is used in a fashion either to cover the decorative article 31 attached onto the decorative panel or to hold the decorative article therein.