WALL COVERING PANELS AND SYSTEM AND METHOD FOR INSTALLATION THEREOF

Abstract

An elongated panel for producing a wall covering, a kit for producing a wall covering, and a method of installing a wall covering are described. The elongated panel includes generally rectangular front surface and back surfaces, a first longitudinal edge, and a second longitudinal edge opposite the first longitudinal edge. A lateral cross-section of the first longitudinal edge can include a generally horizontal support portion proximate the back surface and a first beveled portion proximate the front surface, and a lateral cross-section of the second longitudinal edge can include a generally horizontal resting portion proximate the back surface and a second beveled portion proximate the front surface.

Claims

1. An elongated panel for producing a wall-covering, comprising: an elongated panel comprising generally rectangular front surface and back surfaces, a first longitudinal edge, and a second longitudinal edge opposite the first longitudinal edge, wherein a lateral cross-section of the first longitudinal edge comprises a generally horizontal support portion and a receiving portion, wherein a lateral cross-section of the second longitudinal edge comprises a generally horizontal resting portion and a lip, wherein the receiving portion is adapted to receive a lip of another elongated panel with a wall being covered serving as an opposing surface to a first surface of the receiving portion.

2. The elongated panel of claim 1, wherein the elongated panel is adapted so that, when the lip of one elongated panel is fully inserted into the receiving portion of an identical elongated panel, a gap is formed between the front surfaces of the two elongated panels.

3. The elongated panel of claim 1, wherein the elongated panel is adapted so that, when the lip of one elongated panel is fully inserted into the receiving portion of an identical elongated panel, the front surfaces of the two elongated panels contact one another or form only a crack.

4. The elongated panel of claim 1, wherein a depth of the receiving portion is less than a length of the lip by at least 1 mm.

5. The elongated panel of claim 1, wherein a thickness of the elongated panel is from 2 to 10 mm.

6. The elongate panel of claim 1, wherein a back surface of the elongated panel includes an adhesive.

7. The elongated panel of claim 1, wherein the receiving portion comprises the first surface and a second surface, wherein the elongated panel is adapted so that the first surface is generally parallel to a wall to which the elongated panel is attached and the second surface is generally perpendicular to the first surface.

8. The elongated panel of claim 1, wherein a longitudinal cross-section of a first lateral edge comprises a lateral receiving portion, wherein a longitudinal cross-section of a second longitudinal edge, opposite the first longitudinal edge, comprises a lateral lip, wherein the lateral receiving portion is adapted to receive a lateral lip of another elongated panel with a wall being covered serving as an opposing surface to a first surface of the lateral receiving portion.

9. The elongated panel of claim 8, wherein the elongated panel is adapted so that, when the lateral lip of one elongated panel is fully inserted into the lateral receiving portion of an identical elongated panel, a gap is formed between the front surfaces of the two elongated panels.

10. The elongated panel of claim 8, wherein the elongated panel is adapted so that, when the lateral lip of one elongated panel is fully inserted into the lateral receiving portion of an identical elongated panel, the front surfaces of the two elongated panels contact one another or form only a crack.

11. A kit for producing a wall-covering, comprising a plurality of elongated panels according to claim 1.

12. The kit of claim 11, wherein a back surface of the elongated panel includes an adhesive.

13. The kit of claim 11, wherein each of the plurality of elongated panels is adapted so that, when the lip of one elongated panel is fully inserted into the receiving portion of an identical elongated panel, a gap is formed between the front surfaces of the two elongated panels.

14. The kit of claim 11, wherein each of the plurality of elongated panels is adapted so that, when the lip of one elongated panel is fully inserted into the receiving portion of an identical elongated panel, the front surfaces of the two elongated panels contact one another or form only a crack.

15. The kit of claim 11, wherein a depth of the receiving portion is less than a length of the lip by at least 1 mm.

15. The kit of claim 11, wherein, when a lip of a first elongated panel is fully inserted into the receiving portion of a second elongate panel, a gap of at least 1 mm is formed between front faces of the first and second elongated panels.

16. The kit of claim 11, wherein a thickness of each of the plurality of elongated panel is from 2 to 10 mm.

17. The kit of claim 11, wherein the receiving portion comprises a first surface and a second surface, wherein the elongated panel is adapted so that the first surface is generally parallel to a wall to which the elongated panel is attached and the second surface is generally perpendicular to the first surface.

18. A method of installing a wall covering comprising: providing a plurality of elongated panels according to claim 1; attaching a back of a first elongated panel to a wall; and attaching a back of a second elongated panel to the wall above or below the first elongated panel, wherein a tab of the second panel is received within a receiving portion of the first panel with a wall being covered serving as an opposing surface to a first surface of the receiving portion.

19. The method of claim 18, wherein the attachment of the elongated panels to the wall is by adhesive.

20. The method of claim 18, wherein a depth of the receiving portion is less than a length of the lip.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The features and advantages of the present invention will be more fully disclosed in, or rendered obvious by the following detailed description of the preferred embodiments, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:

[0026] FIG. 1 is a front view of a panel as described herein.

[0027] FIG. 2 is a lateral cross-sectional view of the panel shown in FIG. 1 taken along cut line 2-2.

[0028] FIG. 3 shows a lateral cross-section of a plurality of panels of FIG. 1 abutting one another in order to achieve a desired effect.

[0029] FIG. 4 is a front view of another embodiment of a panel as described herein.

[0030] FIG. 5 is a lateral cross-section view of the panel shown in FIG. 4 taken along cut line 4-4.

[0031] FIG. 6 is a front view of another embodiment of a panel as described herein.

[0032] FIG. 7 is a lateral cross-sectional view of the panel shown in FIG. 6 taken along cut line 7-7.

[0033] FIG. 8 is a back view of the panel shown in FIG. 6.

[0034] FIG. 9 shows a lateral cross-section of a plurality of panels of FIG. 4 with the first longitudinal edge facing up abutting one another in order to achieve a desired effect.

[0035] FIG. 10 shows a lateral cross-section of a plurality of panels of FIG. 4 with the second longitudinal edge facing up abutting one another in order to achieve a desired effect.

[0036] FIG. 11 is a lateral cross-sectional view of a plurality of panels of FIG. 6 taken along cut line 7-7.

[0037] FIG. 12 is a front view of a panel as described herein.

[0038] FIG. 13 is a lateral cross-sectional view of the panel shown in FIG. 12 taken along cut line 13-13.

[0039] FIG. 14 shows a lateral cross-section of a plurality of panels of FIG. 12 abutting one another in order to achieve a desired effect.

[0040] FIG. 15 shows elements of a kit as described herein.

[0041] FIG. 16A is a lateral cross-sectional view of a two panels of FIG. 6 laid adjacent to one another.

[0042] FIG. 16B is a lateral cross-sectional view of a plurality of panels of FIG. 6 with the longitudinal lip inserted completely within the receiving portion, showing a gap between the support portion of a first panel and a resting portion of a second panel.

DETAILED DESCRIPTION

[0043] This description of sample embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as lower, upper, horizontal, vertical, above, below, up, down, top and bottom as well as derivatives thereof (e.g., horizontally, downwardly, upwardly, etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the product be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as connected, refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

[0044] As show in FIGS. 1-15, an elongated panel 2 for producing a wall-covering (e.g., a shiplap or nickel gap look, or a reclaimed wood look) is disclosed. The elongated panel 2 can have generally rectangular front 4 and back surfaces 6, as well as, a first longitudinal edge 8, and a second longitudinal edge 10 opposite the first longitudinal edge 8. In some embodiments, as shown in FIGS. 2, 3, 5, 7, 9-11, and 13, a lateral cross-section of the first longitudinal edge 8 comprises a generally horizontal support portion 12 proximate the back surface 6 and a first beveled portion 14 proximate the front surface 4. In some embodiments, a lateral cross-section of the second longitudinal edge 10 comprises a generally horizontal resting portion 16 proximate the back surface 6 and a second beveled portion 18 proximate the front surface 4.

[0045] In some embodiments, a thickness (t.sub.S) of the support portion 12 and a thickness (t.sub.R) of the resting portion 16 are approximately equal. In some embodiments, thicknesses of the support portion and the resting portion are independently 0.25 to 5 mm, or 0.5 to 4 mm, or 0.75 to 3 mm, or less than 2.5 mm, or less than 2 mm, or less than 1.5 mm, or less than 1mm, or any combination of these endpoints.

[0046] When multiple elongated panels 2 are being installed on a wall, this configuration allows the resting portion of the upper panel to rest on and/or slightly above the support portion 12 of a lower panel while adhesive bonding the elongated panel to the wall is curing. In some embodiments, the thickness of the resting portion and the thickness of the support portion are less than two-thirds of the thickness (t) of the panel, or 50% or less of the thickness (t) of the panel, or 40% or less of the thickness (t) of the panel, or 30% or less of the thickness (t) of the panel, or 25% or less of the thickness (t) of the panel 2.

[0047] As used herein, generally horizontal includes forming a right angle (90 degrees) relative to the back surface, as well as, minor variations therefrom (5 degrees, or 10 degrees, or 15 degrees). Generally horizontal can also include acute angles () with the back surface 6 ( is shown in FIG. 5). As used herein, approximately equal includes deviations of 1 mm or less.

[0048] In some embodiments, as shown in FIGS. 1-14, the first beveled portion 14 extends from an end of the support portion 12 to the front surface 4, and in some embodiments, as shown in FIGS. 5, 9-11 and 13, the second longitudinal edge comprises an intermediate portion 20 between the resting portion 16 and the second beveled portion 18. In some such embodiments, as shown in FIGS. 9, 10, and 14, an angle of the intermediate portion 20 is adapted to match an angle of the first beveled portion 14.

[0049] In some embodiments, as shown in FIG. 5, a lateral cross-section of the intermediate portion 20 and the second beveled portion 18 is convex 22 (e.g., in the shape of a triangle). In some embodiments, as shown in FIGS. 9 & 10, the intermediate portion 20 is adapted to overlap with (or abut against) the first beveled portion 14.

[0050] In some embodiments, as shows in FIGS. 1-3, the first beveled portion 14 extends from an end of the support portion 12 to the front surface 4 and the second beveled portion 18 extends from an end of the resting portion 16 to the front surface 4.

[0051] In some embodiments as shown in FIGS. 6 and 7, the panel features described above can form a front portion 25 of the elongated panel 2, and the panel 2 can also include a backing 30 attached to the back of the front portion 25. The backing 30 can have generally rectangular front and back surfaces. The backing 30 can cover a substantial portion, but not all, of the back surface of the front portion 25.

[0052] As shown in FIG. 11, a thickness (t.sub.b) of the backing 30 can be less than a thickness (t.sub.f) of the front portion 25 of the panel 2. In other embodiments, the thickness (t.sub.b) of the backing 30 can be approximately equal to the thickness (t.sub.f) of the front portion 25.

[0053] In some embodiments, a length and/or width of the backing 30 can be approximately equal to a respective length and/or width of the front portion 25. In other embodiments, the length and/or width of the backing 30 can be less than the respective length and/or width of the front portion 25.

[0054] The backing 30 can be positioned with a longitudinal edge extending past one of the longitudinal edges of the front portion 25, forming a longitudinal lip 34. The backing 30 can also be positioned with a lateral edge extending past one of the lateral edges of the front portion 25, forming a lateral lip 35. The longitudinal lip 34 and/or the lateral lip 35 can extend past the respective longitudinal and/or lateral edges of the front portion 25 by 25 mm or less, or 10 mm or less, or 8 mm or less, or 6 mm or less, or 5 mm or less, or 3 mm or less, or any combination of these endpoints (e.g. ranging from 5 mm to 10 mm, or from 3 mm to 5 mm).

[0055] In some embodiments, as shown in FIGS. 6-8, the first beveled portion 14 extends from an end of the support portion 12 to the front surface 4, and the lip 34 from the other end of the support portion 12. The second longitudinal edge can also comprises an intermediate portion 20 behind and/or along a back surface of the resting portion 16. In some such embodiments, a shape of the intermediate portion 20 is adapted to generally match a shape of the lip 34.

[0056] In some embodiments, the intermediate portion 20 can be formed by the backing 30. For example as shown in FIGS. 6-8, the other longitudinal edge of the front portion 25 can extend past the other longitudinal edge of the backing 30, forming a longitudinal receiving portion 38 along the back of the panel 2 as the intermediate portion 20. The other lateral edge of the front portion 25 can also extend past the other lateral edge of the backing 30, forming a lateral receiving portion 40. In some embodiments, the distance that the receiving portions (38 or 40) extend past the backing 30 can be approximately equal to the distance that the corresponding lips (34 or 35) extend past the front portion 25. In other embodiments, the distance that the receiving portions (38 or 40) extend past the backing 30 can be less than the distance that the corresponding lips (34 or 35) extend past the front portion 25, e.g. the lip 34 can be longer than the intermediate portion/receiving portion (20/38) creating a space 39 between the support portion 12 and the resting portion 16. Examples of such spaces 39 are shown in FIGS. 11 and 16B. As shown by the L, U and U, L designations in FIGS. 16A and 16B, the desired longitudinal or lateral interpanel space 39 can be achieved with the longitudinal or lateral lip 34, 35 extending down under the longitudinal or lateral receiving portion 38, 40 or the longitudinal or lateral lip 34, 35 extending up into the longitudinal or lateral receiving portion 38, 40, with the longitudinal or lateral lip 34, 35 being longer than the depth of the longitudinal or lateral receiving portion 38, 40 so that the support portion 12 and the resting portion 16 are separated when the lip 34, 35 is inserted fully into the receiving portion 38, 40.

[0057] A unique feature of this arrangement is that the lip 34, 35 is adjacent to the wall (W) rather than nested within a groove of an adjacent elongated panel 2. Another unique feature of the arrangement is that each receiving portion 38, 40 is one-sided, with the wall (W) serving as the second side for receiving the respective lip 34, 35. Thus, each lip 34, 35 is adapted to fit within the corresponding receiving portion 38 between the resting portion 16 and the wall (W). This facilitates a much thinner elongated panel 2, which need not be attached using fasteners, such as nails or staples. Rather, the elongated panels 2 can be attached via adhesive.

[0058] As shown in FIG. 11, the intermediate portion/receiving portion (20/38) is adapted to overlap with (or abut against) the longitudinal lip 34 of another panel 2. In some embodiments, the lateral receiving portion 40 is adapted to overlap with (or abut against) the lateral lip 35 of another panel 2. When the longitudinal or lateral receiving portion 38, 40 overlaps with (i.e., has fully received) the respective lip 34, 35 of another panel 2, the support portion and the resting portion (e.g., front surfaces) can (i) contact one another, (ii) have a crack therebetween, or (iii) have a gap 39 therebetween. As used herein, a crack is intended to refer to a space of less than 0.5 mm, while a gap is intended to refer to a space of at least 1 mm, or at least 1.25 mm, or at least 1.5 mm, or at least 1.75 mm, or at least 1.875 mm, or at least 2 mm.

[0059] As shown in FIGS. 11, 16A, and 16B, an elongated panel 2 for producing a wall-covering can include a generally rectangular front surface 4 and a generally rectangular back surface 6, a first longitudinal edge, and a second longitudinal edge opposite the first longitudinal edge, where a lateral cross-section of the first longitudinal edge comprises a generally horizontal support portion 12 and a receiving portion 38, and a lateral cross-section of the second longitudinal edge comprises a generally horizontal resting portion 16 and a lip 34, wherein the receiving portion 20, 38 is adapted to receiving a lip 34 of another elongated panel with a wall being covered serving as an opposing surface to the first surface 42 of the receiving portion 20, 38. This same configuration is repeated with respect to the lateral edges and the corresponding lateral lip 35 and lateral receiving portion 40. The desired gap is formed where the lip 34, 35 is longer than the depth of the corresponding receiving portion 38,40 by approximately the length of the desired gap. For example, the lip can be 4.5 mm and the receiving portion 2.7 mm in order to produce a gap of approximately 1.85 mm.

[0060] In some embodiments, the receiving portion 38, 40 is at least 1 mm deep, or at least 1.25 mm deep, or at least 1.5 mm deep, or at least 2 mm deep, or at least 2.25 mm deep.

[0061] As shown in FIGS. 11, 16A, and 16B, in some embodiments, a depth 50 of the receiving portion is less than a length 48 of the lip 34. As shown in FIGS. 11, 16A, and 16B, in some embodiments, a depth 50 of the receiving portion 38, 40 is less than a length 48 of the lip 34, 35 by at least 1 mm. In other words, the gap 39 formed between the front surfaces 4 of adjacent elongated panels 2 with the lip 3, 354 inserted fully into the receiving portion 38, 40 is at least 1 mm.

[0062] In some embodiments, the back surface 6 of the elongated panel 2 includes an adhesive layer 46 adhered to the back surface 6.

[0063] In some embodiments, the receiving portion 20, 38 comprises a first surface 42 and a second surface 44. In some embodiments, the elongated panel 2 is adapted so that the first surface 42 is generally parallel to a wall (W) to which the elongated panel 2 is attached and the second surface 44 is generally perpendicular to the first surface 42. As used herein, generally refers to a deviation of 10 or less, or 7.5 or less, or 5 or less, or 2.5 or less.

[0064] In some embodiments, a thickness (t.sub.b) of the lip 34 is less than 4 mm, or less than 4 mm, or less than 3 mm, or less than 2.5 mm, or less than 2 mm, or less than 1.5 mm. In some embodiments the height of the second surface is less than 1 mm larger than the thickness (t.sub.b) of the lip 34, or less than 0.8 mm, or less than 0.6 mm, or less than 0.5 mm.

[0065] As shown in FIGS. 8, 11, 16A and 16B, in some embodiments, the front surface 4 and the back surface 6 have different lengths. In this way, the front surface 4 and back surface 6 can be offset and form a lip 34 that is longer than the depth of the receiving portion 38. Similarly, the front surface 4 and back surface 6 can independently be offset and form a lip 35 that is longer than the depth of the receiving portion 39.

[0066] As shown in FIGS. 8, 11, 16A, and 16B in some embodiments, the front surface 4 and the back surface 6 have approximately the same widths, so that ends of the front surfaces of two elongated panels 2 placed end to end fit flush with the front surfaces abut or form a crack. For example, the front surface 4 and back surface 6 can be offset and form a lip 34 that is the same length or shorter than the depth of the receiving portion 38. Similarly, the front surface 4 and back surface 6 can be offset and form a lip 35 that is the same length or shorter than the depth of the receiving portion 40.

[0067] Any discussion or depiction of the longitudinal lip 34 and longitudinal receiving portion 38 applies equally to the lateral lip 35 and lateral receiving portion 40.

[0068] In some embodiments, the backing 30 can be a different material than the front portion (25) of the panel 2. For example, the front portion 25 can be reclaimed wood or real wood with various aesthetic finishes or composite wood with various aesthetic finishes, while the backing 30 can be plywood or other alternatives. In other embodiments, the materials can be the same.

[0069] In some embodiments, the color of the front portion 25 and the backing 30 can be substantially the same color. In other embodiments, the color of the backing 30 can be darker than the front portion 25. When installed, the lip (34 and/or 35) of the backing 30 can provide covering for portions of a wall between adjacent panels 2.

[0070] In some embodiments, as shown in FIGS. 1 & 5, a lateral distance (d.sub.b) across the back surface is longer than a lateral distance (d.sub.f) across the front surface. In some embodiments, as shown in FIG. 9, a lateral distance (d.sub.b) across the back surface is approximately equal to a lateral distance (d.sub.f) across the front surface.

[0071] In some embodiments, a thickness (t) of the panel 2 ranges from 2 mm to 25 mm. In some embodiments, a thickness (t) of the panel 2 ranges from 2.5 mm to 20 mm, or from 3 mm to 15 mm, or from 3.5 mm to 10 mm, or from 4 mm to 8 mm, or from 5 mm to 7 mm, or any combination of these end-points. In other embodiments, a thickness (t) of the elongated panel 2 ranges from 0.25 to 5 mm, or 0.5 to 5 mm, or 5 mm or less, or 4 mm or less, or 3 mm or less, or any combination of these endpoints.

[0072] In some embodiments, a length (l) of the elongated panel 2 ranges from 2 to 20. In some embodiments, a length (l) of the panel 2 an be any value ranging from 0.5 and 20, including 11, 1, 23, 2, 4, 8, 12, and 16.

[0073] In some embodiments, as evident from FIGS. 3, 9-11, and 14, if the first longitudinal edge 8 were abutting the second longitudinal edge 10, the second beveled portion 18 and the first beveled portion 14 produce a flute 24 (e.g., a V-shaped flute) along a front surface 4 of the panels 2.

[0074] In another embodiment, a kit 100 for producing a wall-covering is provided. The kit 100 can include a plurality of elongated panels 2 as disclosed herein. In some embodiments, the kit 100 also includes adhesive 26 (e.g., contact adhesive, construction adhesive, etc.), which may be provided in a caulking tube 26, and/or instructions 28 for installing the plurality of panels to achieve a desired appearance (e.g., shiplap effect or a rustic paneling effect).

[0075] In some embodiments, the kit 100 includes a plurality of elongated panels 2, each comprising generally rectangular front surface 4 and back surfaces 6, a first longitudinal edge 8, and a second longitudinal edge 10 opposite the first longitudinal edge 8. The lateral cross-section of the first and second longitudinal edges 8, 10 can be as described herein. As shown in FIGS. 3, 9-11, and 14, a lower longitudinal edge (8 or 10) of the upper panel (U) is adapted to abut with an upper longitudinal edge (10 or 8) of the lower panel (L) such that the lower longitudinal edge (8 or 10) of the upper panel (U) and the upper longitudinal edge (10 or 8) of the lower panel (L) produce a flute 24 along a front surface 4 of the upper and lower panel (U and L). As shown in FIG. 11, in some embodiments, the lower longitudinal edge 10 of the upper panel (U) is adapted to overlap with the lip 34 of the lower panel (L) and/or adapted to abut with a support portion 12 of the lower panel (L).

[0076] A method of installing elongated panels to produce a wall covering is also disclosed. Providing a plurality of elongated panels 2 as described herein. Adhering a first elongated panel 2 to a wall (W), then adhering a second elongated panel 2 to the wall (W) parallel to and immediately adjacent to the first panel 2, such that a first longitudinal edge 8 of one of the first and second elongated panels 2 abuts a second longitudinal edge 10 of the other of the first and second elongated panels 2. This process is then repeated with a third panel 2 so that the complementary longitudinal edges 8 and 10 abut one another across the entire wall.

[0077] In some embodiments, the method includes attaching each panel 2 to the wall (W) along the panel's back surface 6 without adhesive or other attachment applied between the longitudinal edges (8 or 10) or the resting support portions (12 or 16) of adjacent panels 2. As such, the system and method do not require that each panel is completely flush against the adjacent panel or that the edges of adjacent panels be entirely straight or otherwise have tightly matching configurations. In embodiments with panels 2 including a backing 30, references herein describing attaching the back 6 of an elongated panel 2 to a wall (W) include attaching the back surface 36 of the backing 30 to the wall (W).

[0078] It should be understood that, while the discussion refers to upper and lower elongated panels 2, the elongated panels 2 could be oriented vertically in order to create an effect where the flutes 24 run vertically.

[0079] The configurations of the complementary first and second longitudinal edges disclosed herein are selected provide a number of benefits. For example, the overlapping portions of FIGS. 4-14 prevent people from seeing through the space between panels to the underlying wall. In addition, the presence of the support and resting portions 12, 16 prevent a panel resting on another panel from sliding off the wall or behind the other panel while the adhesive is drying. Finally, the overlapping nature of the 20 intermediate portion and the first beveled portion 14 and/or the lip 34, helps prevent a panel from pivoting off the wall while the adhesive is drying. For example, in FIG. 9, the intermediate portion 20 of the upper panel (U) holds the upper edge of the lower panel (L) against the wall (W).

[0080] Although the subject matter has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art.