Wall Panel for Forming a Wall Covering With Multiple Panels

Abstract

Provided is a wall panel for forming a wall covering with multiple panels, including a centrally located core. The core includes a rear side, a decorative side opposite the rear side, and at least two sides including coupling parts for mutual coupling of several panels. The coupling parts are arranged to be coupled with an angling motion. A new panel is arranged to be angled into a panel already forming part of the wall covering. The coupling parts include at least one first coupling part and at least one second coupling part arranged on opposite sides of the core. The first coupling part includes a sideward tongue, an upper bridge portion for connecting the sideward tongue to the core and a downward groove, for accommodating at least a parts of an upward locking element. The second coupling part includes a groove.

Claims

1. A wall panel for forming a wall covering with multiple panels, comprising: a. a core, wherein the core comprises a rear side, a decorative side opposite the rear side, and at least two sides of said core comprising coupling parts for mutual coupling of several panels; b. wherein the coupling parts comprise at least one first coupling part and at least one second coupling part arranged on opposite sides of the core, wherein the at least one first coupling part and at least one second coupling parts are arranged to be coupled with an angling motion, c. wherein the first coupling part comprises a sideward tongue, an upper bridge portion for connecting the sideward tongue to the core and a downward groove, for accommodating at least a parts of an upward locking element; and d. wherein the second coupling part comprises a groove, for accommodating at least a part of a sideward tongue, defined by an upper lip and a lower lip extending from the core, wherein an end portion of the lower lip is provided with an upward locking element, which upward locking element has an inside facing the upper lip, an outside facing away from the upper lip and an upper side between the inside and the outside; e. wherein said upper side of the upward locking element is provided with a recess, extending at least partially through the upward locking element for receiving at least one fastening element, such as a screw, for fastening the wall panel to a wall.

2. The wall panel according to claim 1, wherein the inside of the upward locking element comprises a first locking surfaces, and the side of the sideward tongue facing towards the core comprises a second locking surface, which locking surfaces cooperate to provide locking of the panels in coupled condition.

3. The wall panel according to claim 1, wherein the side of the sideward tongue facing towards the decorative side comprises a third locking surface, and the side of the upper lip facing away from the decorative side comprises a fourth locking surface, which locking surfaces cooperate to provide locking of the panels in coupled condition.

4. The wall panel according to claim 1, wherein the recess is provided with bevelled edges, wherein preferably the recess has a substantially truncated cone shape in cross section, widest at the decorative side narrowing towards the rear side.

5. The wall panel according to claim 1, wherein the recess is centred in the upward locking element, in particular between the inside and the outside of the upward locking element.

6. The wall panel according to claim 1, wherein the recess extends maximally halfway the upward locking element.

7. The wall panel according to claim 1, wherein at least a part the side of the sideward tongue facing away from the upper bridge portion and/or at least a part of the groove between the upper and lower lip is partially rounded.

8. The wall panel according to claim 1, wherein in coupled condition a space is present between the side of the sideward tongue facing the rear side and the lower lip, wherein the space tapers from the upward locking element inwards.

9. The wall panel according to claim 1, wherein the width of upward locking element is less compared to the width of the upper bridge portion, such that preferably a space is present between the outside of the upward locking element and the core of another panel in coupled condition.

10. The wall panel according to claim 1, wherein the first coupling part comprises a first upper contact surface, between the decorative side and the sideward tongue and wherein the side of the upper lip facing away from the core comprises a second upper contact surface, wherein the first and second upper contact surfaces are arranged to be in contact at least partially in coupled condition.

11. The wall panel according to claim 10, wherein the first and/or second contact surfaces comprises an upper locking element, wherein preferably both contact comprise upper locking elements which are configured to co-operate in coupled state, to provide locking in one or more directions.

12. The wall panel according to claim 1, wherein the first and/or second coupling parts comprises a bevel or grout, arranged at the decorative side of the panel.

13. The wall panel according to claim 1, wherein the core comprises a thermoplastic material, in particular a foamed or non-foamed thermoplastic material or PVC, polypropylene, polyethylene or polyurethane and/or one or more fillers such as calcium carbonate, or a wooden material, for instance MDF, HDF or a wood-plastic-composite.

14. The wall panel according to claim 1, wherein the sideward tongue and groove are arranged to exert a clamping force in coupled condition, to force two coupled panels together.

15. The wall panel according to claim 1, wherein the groove comprises a channel, extending from the groove to the rear side of the wall panel.

16. The wall panel according to claim 1, wherein the panel is elongated, and is arranged to be placed horizontally to form part of the wall covering, wherein preferably the first and second coupling parts are arranged on the long sides of the panel and/or wherein two other opposing sides of the wall panel are provided with third and fourth coupling parts, preferably arranged to be coupled in the same angling motion as the first and second coupling parts.

17. The wall panel according to claim 1, wherein the panel is elongated, and is arranged to be placed vertically to form part of the wall covering, wherein preferably the first and second coupling parts are arranged on the long side of the panel and/or wherein the two other opposing sides of the wall panel are not provided with coupling parts.

18. The wall panel according to claim 1, wherein the panel is elongated, wherein the first and second coupling parts are arranged on the long side of the panel and wherein along the long side of the wall panel multiple recesses are present, preferably evenly spaced along the long side.

19. The wall panel according to claim 1, wherein the recess in the upward directed locking element forms a recessed groove, extending along one side of the wall panel, preferably the long side of an elongated panel.

20. The wall panel according to claim 1, wherein the lower lip extends beyond the upper lip along a distance which distance is at least 2 times, preferably at least 3 times, more preferably about 4 times, the thickness of the wall panel.

21. The wall panel according to claim 1, wherein the thickness of the upward locking element is about half the thickness of the wall panel.

22. The wall panel according to claim 1, wherein, in coupled condition of two panels, a space is present between the upper bridge portion of a first panel and the upward directed locking element of a second panel, at least over the complete width of the upward directed locking element, wherein the space preferably continues between the distal end of the upward directed locking element of the second panel and the core of the first panel.

23. The wall panel according to claim 1, wherein the upward directed locking element, at a rear side opposite the surface side, comprises an adhesive layer, such as a peel of adhesive, for temporarily attaching the wall panel to a supporting surface.

24. A method of installing a wall covering, preferably with wall panels according to claim 1, comprising the steps of: a. providing a first wall panel, with first and second coupling parts at least two opposite sides; b. attaching the first wall panel to a supporting surface, leaving a second coupling part of the first wall panel accessible; c. providing a second wall panel, with first and second coupling parts at least two opposite sides; d. placing a first coupling part of the second wall panel in the second coupling part of the first wall panel; e. angling in the second wall panel to be aligned with the first panel, leaving a second coupling part of the second wall panel accessible; f. optionally repeating steps c-e with a further panel.

25. The method according to claim 24, wherein before the first wall panel is provided, a base wall panel is provided with only the second coupling part; and/or wherein the final wall panel is a last wall panel with only the first coupling part.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0097] The invention will now be elucidated on the basis of non-limitative exemplary embodiments which are illustrated in the following figures. Corresponding elements are denoted in the figures by corresponding reference numbers. In the figures:

[0098] FIG. 1 schematically shows a detail of two wall panels in coupled condition, for forming a wall covering according to the present invention.

[0099] FIG. 2 shows the detail of FIG. 1, with an attachment;

[0100] FIG. 3 schematically shows a wall covering, with three wall panels, according to the present invention;

[0101] FIG. 4 schematically shows the wall covering of FIG. 3, in an inversed configuration;

[0102] FIG. 5 schematically shows a variation on FIG. 4;

[0103] FIG. 6 schematically shows a side view on three wall panels forming a wall covering according to the present invention;

[0104] FIG. 7 schematically shows variations on the covering of FIG. 6;

[0105] FIG. 8 schematically shows an example of the coupling parts on the other sides of the panel; and

[0106] FIG. 9 schematically shows a variation on FIG. 2.

DESCRIPTION OF THE INVENTION

[0107] FIG. 1 schematically shows a detail of two wall panels (1) in coupled condition, for forming a wall covering. Each panel (1) comprises a centrally located core (2), wherein the core comprises a rear side (2a), a decorative side (2b) opposite the rear side (2a), and at least two sides (3, 4) comprising coupling parts for mutual coupling of several panels. FIG. 1 shows the two sides (3, 4) in a coupled condition, in which the sides interact.

[0108] The coupling parts comprise at least one first coupling part (5) and at least one second coupling part (6) arranged on opposite sides of the core (2), wherein the first coupling part (5) comprises a sideward tongue (7) and an upper bridge portion (8) for connecting the sideward tongue (7) to the core (2), as well as a downward groove (9). The second coupling part (6) comprises a groove (10), defined by an upper lip (11) and a lower lip extending (12) from the core (2), wherein the lower lip (12) is provided with an upward locking element (13) arranged at a distance from the core (2), which upward locking element (13) has an inside (13a) facing the core (2), an outside (13b) facing away from the core (2) and a surface side (13c) between the inside (13a) and the outside (13b).

[0109] The upward locking element (13) is provided with a recess (14), extending partially through the upward locking element (13), which recess (14) is accessible from the surface side (13c) of the upward locking element (13) and extends towards an opposite side (13d) of the upward locking element (13). The recess (14) provides for a predetermined location for attaching the wall panel (1) to a supporting surface, such as a beam. For example, a nail, screw or cram can be used to attach the wall panel (1), wherein the nail head or screw head for example falls within the recessed space of the recess (14).

[0110] The inside (13a) of the upward locking element (13) comprises a first locking surface (18), and the side of the sideward tongue (7) facing towards the core (2) comprises a second locking surface (19), which locking surfaces cooperate to provide locking of the panels in coupled condition. The side of the sideward tongue (7) facing towards the decorative side (2b) comprises a third locking surface (20), and the side of the upper lip (11) facing away from the decorative side comprises a fourth locking surface (21), which locking surfaces cooperate to provide locking of the panels in coupled condition.

[0111] The recess (14) is provided with bevelled edges (22), with a substantially truncated cone shape in cross section, widest at the decorative side narrowing towards the rear side. The recess (14) is centred in the upward locking element (13), in between the inside (13a) and the outside (13b) of the upward locking element (13).

[0112] FIG. 2 shows the detail of FIG. 1, wherein a screw (15) is shown, with its head (16) arranged at least partially in the recess (14). FIG. 2 also shows that in coupled condition a space (23) is present between the side of the sideward tongue (7) facing the rear side (2a), or the bottom of the sideward tongue (7), and the lower lip (12), wherein the space tapers from the upward locking element (13) towards the core (2). The width of upward locking element (13) as shown is less compared to the width of the upper bridge portion (8), such that a space (24) is present between the outside (13b) of the upward locking element (13) and the core (2) of another panel in coupled condition, in the shown configuration the panel on the right.

[0113] The first coupling part comprises a first upper contact surface (25), between the decorative side (2b) and the sideward tongue (7) and the side of the upper lip (11) facing away from the core (2) comprises a second upper contact surface (26), wherein the first and second upper contact surfaces are in contact at least partially.

[0114] FIG. 3 schematically shows a wall covering (100), with three wall panels (1). FIG. 3 shows a view onto the decorative side, wherein at the top a sideward tongue (7) portion is shown, not connected to a next panel and at the bottom a lower lip (12) is shown transitioning into the inside (13a) of the upward locking element (13) as well as the surface side (13c). FIG. 3 shows an embodiment in which six recesses (14) are used, spread over the long side (4) of the panels (1).

[0115] FIG. 4 schematically shows the wall covering (100) of FIG. 3, in an inversed configuration, with the sideward tongue (7) at the bottom, and the lower lip (12) at the top.

[0116] FIG. 5 schematically shows a variation on FIG. 4. Instead of a number of recesses (14) in the upward locking element (13), the recess (14) is embodied as a continuous groove extending along the length of the panel (1).

[0117] FIG. 6 schematically shows a side view on three wall panels (1), of which panels (1) only the middle one is fully shown. In terms of installation, the bottom panel (1) is placed first and secured to a supporting structure (17) by means of a screw (15), connecting the bottom panel (1) to the supporting structure (17). Next the middle panel (1′) is angled into the bottom panel (1) by placing the sideward tongue (7) into the groove (10) and angling the tongue (7) into the groove (10). When the middle panel (1′) is aligned or in the same plane as the bottom panel (1), the middle panel (1′) is also secured to a supporting structure (17) by means of a screw (15). Now the groove (10) of the middle panel (1′) is available to accept the sideward tongue (7) of the top panel (1″) and the process can continue until the required height is reached. The same process can be applies, but turned 90 degrees, if the panels are placed vertically, instead of horizontally.

[0118] FIG. 7 shows a variation on the covering of FIG. 6. The variations can be applied to any panel in any configuration, and are not limited to the embodiment as shown, the principles are applicable wider. At the bottom connection between the lower panel (1) and the middle panel (1′) a first bevel (27) is shown. This bevel (27) is formed by a chamfering at the decorative surface (2b) of the first panel (1), while no chamfering is present at the second panel (1′). Liquid collecting on the decorative surface (2b), dripping down from the middle panel (1′) to the bottom panel (1) is thus prevented from seeping through the connection, but instead is guided towards the outside of the bottom panel (1).

[0119] At the middle connection between the middle panel (1′) and the top panel (1″) a second bevel (28) is shown. This bevel (28) is formed by a chamfering at the decorative surface (2b) of the middle panel (1′) and the top panel (1″). Such bevel (28) has a similar purpose, but has a different appearance.

[0120] At the middle connection the groove (10) of the middle panel (1′) comprises a channel (29), extending from the groove (10) to the rear side (2a) of the wall panel to pass potential liquid collecting in the groove (10) to the rear side (2a).

[0121] FIG. 8 schematically shows the coupling parts on the other sides of the panel, if such coupling parts are present. In the description references is made to the vertical and horizontal, which holds for the orientation the coupling parts are shown in FIG. 8. On wall panelling, the orientation may be flipped or reversed, wherein the same changes are to be applied to the terms used.

[0122] These coupling parts, as shown in FIG. 8, may be third (31) and fourth (32) coupling parts which are arranged to be coupled by means of a downward motion The third coupling part (31) comprises an upward tongue (33), at least one upward flank (34) lying at a distance from the upward tongue and an upward groove (35) formed in between the upward tongue and the upward flank, wherein the upward groove is adapted to receive at least a part of a downward tongue of the fourth coupling part of another panel. The side (33a) of the upward tongue (33) facing towards the upward flank (35) is the inside of the upward tongue and the side (33b) of the upward tongue facing away from the upward flank is the outside of the upward tongue.

[0123] The fourth coupling part (32) comprises a downward tongue (36), at least one downward flank lying (47) at a distance from the downward tongue, and a downward groove (48) formed in between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a part of the upward tongue of the first coupling part of another panel. The side (36a) of the downward tongue facing towards the downward flank is the inside of the downward tongue and the side (36b) of the downward tongue facing away from the downward flank is the outside of the downward tongue. The outside of the downward tongue and the upward flank both comprise an upper contact surface (37, 38) near, or at, or adjoining, or towards a top side of the panel, wherein said contact surfaces extend vertically at least partly, and preferably completely, and wherein the upper contact surface of the outside of the downward tongue of said panel is configured to engage the upper contact surface of the upward flank of an adjacent panel, in coupled condition of said panels.

[0124] Adjoining the upper contact surfaces (37, 38) both the downward tongue and the upward flank comprise an inclined contact surface (39, 40), wherein the inclined contact surface of the downward tongue of said panel is configured to engage the inclined contact surface of the upward flank of an adjacent panel, in coupled condition of said panels, wherein each vertical part of the upper contact surface and each adjoining inclining surface mutually enclose an angle (a) between 100 and 175 degrees. Adjoining the inclined contact surface (40) the downward tongue comprises an outer surface (41), situated below the inclined contact surface of the downward tongue, and adjoining the inclined contact surface (39) the upward flank comprises an inner surface (42), situated below the inclined contact surface of the upward flank, wherein the outer and inner surface run substantially parallel and extend at least partly in vertical direction. In coupled condition a space (43) is present between at least a part of the outer surface of said panel and at least a part the inner surface of an adjacent panel.

[0125] The upper contact surfaces (37, 38) may define a plane, in this shown configuration a vertical plane (44), wherein a portion (45) of the downward tongue (36) may thus protrude from this plane (44)

[0126] FIG. 9 schematically shows a variation on the coupling parts as shown in FIGS. 1-7. Reference signs indicating the same or similar features have the same reference numbers. Compared to the parts as shown in FIGS. 1-7 the recess (14) is provided with a second recess (46). The depth is this recess may be significantly less compared to the depth of the recess (14), and may be provided with similarly chamfered sides (47). The second recess (47) is shown in the centre of the recess (14). This second recess (47) may be incorporated in any of the embodiments shown in FIGS. 1-7, and aims to guide a connecting element like a nail or screw used to connect or attach the panels to a surface.

[0127] FIG. 9 also schematically shows the space (23) between the rear of the sideward tongue (7) and the lower lip (12), which is present between the locking surfaces (18, 19) and the outside or outermost side of the sideward tongue (7), wherein the rear side of the sideward tongue (7) and the lower lip (12) are thus not in contact with each other in coupled condition.

[0128] The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.

[0129] It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.

[0130] The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof.