US20200032524A1

US20200032524A1 - Wall covering panels and system and method for installation thereof

Info

Publication number: US20200032524A1
Application number: US16/523,629
Authority: US
Inventors: Ryan O'Leary
Original assignee: Project Wood LLC
Current assignee: Project Wood LLC
Priority date: 2018-07-27
Filing date: 2019-07-26
Publication date: 2020-01-30
Also published as: WO2020023896A1

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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Patent Application No. 62/711,053, filed on Jul. 27, 2018, the entirety of which is incorporated herein by reference for all purposes.

FIELD OF THE INVENTION

The present disclosure relates generally to wall coverings, and more specifically to wall covering panels and systems and methods for installation of wall coverings.

BACKGROUND

For aesthetic and other reasons, various wall coverings can be applied to interior or exterior walls. Wall coverings can be prefabricated, such as prefabricated panels, but still require installation by a user. Conventional wall panels often include time-consuming and complex installation procedures. More useful and efficiently installed wall coverings, methods and systems are needed.

SUMMARY

An elongated panel for producing a wall covering is 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.
In some embodiments, a length of the support portion and a length of the resting portion of the elongated panel can be approximately equal.
In some embodiments, the first beveled portion can extend from an end of the support portion to the front surface, and the second longitudinal edge can include an intermediate portion between the resting portion and the second beveled portion, with an angle of the intermediate portion is adapted to match an angle of the first beveled portion.
In some embodiments, a lateral cross-section of the intermediate portion and the second beveled portion is a convex triangle.
In some embodiments, the intermediate portion is adapted to overlap with the first beveled portion.
In some embodiments, the generally rectangular front surface and back surfaces, first longitudinal edge, and second longitudinal edge forms a front portion. The elongated panel can also include a generally rectangular backing attached to the back surface of the front portion and forming a longitudinal lip extending past one of the longitudinal edges of the front portion.
In some embodiments, the backing can also form a longitudinal receiving portion, opposite the longitudinal lip, adapted to overlap with the longitudinal lip of another panel.
In some embodiments, a thickness of the panel ranges from 2 to 25 mm.
In some embodiments, a thickness of the panel ranges from 2 to 10 mm.
In some embodiments, a thickness of the panel can be 5 mm or less.
A kit for producing a wall-covering is also described. The kit includes a plurality of elongated panels, each including 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. The plurality of elongated panels includes an upper panel and a lower panel, and a lower longitudinal edge of the upper panel can be adapted to abut with an upper longitudinal edge of the lower panel such that the lower longitudinal edge of the upper panel and the upper longitudinal edge of the lower panel produce a flute along a front surface of the upper and lower panel.
In some embodiments, a length of the support portion and a length of the resting portion, for each of the plurality of elongated panels, are approximately equal.
In some embodiments, for each of the plurality of elongated panels, the first beveled portion can extend from an end of the support portion to the front surface. The second longitudinal edge can include an intermediate portion between the resting portion and the second beveled portion, with an angle of the intermediate portion is adapted to match an angle of the first beveled portion.
In some embodiments, a lateral cross-section of the intermediate portion and the second beveled portion can be a convex triangle for each of the plurality of elongated panels.
In some embodiments, the intermediate portion can be adapted to overlap with the first beveled portion for each of the plurality of elongated panels.
In some embodiments, for each of the plurality of elongated panels, the first beveled portion can extend from an end of the support portion to the front surface and the second beveled portion can extend from an end of the resting portion to the front surface.
In some embodiments, for each of the plurality of elongated panels, the generally rectangular front surface and back surfaces and the first and second longitudinal edges forms a front portion, and each elongated panel further includes a generally rectangular backing. The backing can be attached to the back surface of the front portion and form a longitudinal lip extending past one of the longitudinal edges of the front portion.
In some embodiments, the kit also includes adhesive for adhering the plurality of elongated panels to a wall.
A method of installing a wall covering is also described. The method includes providing a plurality of elongated panels as described herein, attaching the back of a first elongated panel to a wall; and attaching the back of a second elongated panel to the wall. The second elongated panel can be attached above or below the first elongated panel, with a resting portion of the second panel positioned adjacent to the support portion of the first panel without adhesive in-between.
In some embodiments, the resting portion of the second panel can abut the support portion of the first panel.
In some embodiments, the method can include attachment of the elongated panels to the wall by adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

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

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

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.

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

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

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

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

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

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.

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.

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

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

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

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.

FIG. 15 shows elements of a kit as described herein.

DETAILED DESCRIPTION

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.
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.
In some embodiments, a thickness (t_S) of the support portion 12 and a thickness (t_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 1 mm, or any combination of these endpoints.
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.
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 (θ) with the back surface 6 (θ is shown in FIG. 5). As used herein, “approximately equal” includes deviations of ±1 mm or less.
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.
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.
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.
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.
As shown in FIG. 11, a thickness (t_b) of the backing 30 can be less than a thickness (t_f) of the front portion 25 of the panel 2. In other embodiments, the thickness (t_b) of the backing 30 can be approximately equal to the thickness (t_f) of the front portion 25.
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.
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).
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.
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).
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.
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.
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.
In some embodiments, as shown in FIGS. 1 & 5, a lateral distance (d_b) across the back surface is longer than a lateral distance (d_f) across the front surface. In some embodiments, as shown in FIG. 9, a lateral distance (d_b) across the back surface is approximately equal to a lateral distance (d_f) across the front surface.
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.
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′.
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.
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).
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).
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.
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).
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.
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).
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.

Claims

What is claimed is:

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 proximate the back surface and a first beveled portion proximate the front surface,

wherein a lateral cross-section of the second longitudinal edge comprises a generally horizontal resting portion proximate the back surface and a second beveled portion proximate the front surface.

2. The elongated panel of claim 1, wherein a length of the support portion and a length of the resting portion are approximately equal.

3. The elongated panel of claim 2, wherein the first beveled portion extends from an end of the support portion to the front surface, and wherein the second longitudinal edge comprises an intermediate portion between the resting portion and the second beveled portion, wherein an angle of the intermediate portion is adapted to match an angle of the first beveled portion.

4. The elongated panel of claim 3, wherein a lateral cross-section of the intermediate portion and the second beveled portion is a convex triangle.

5. The elongated panel of claim 3, wherein the intermediate portion is adapted to overlap with the first beveled portion.

6. The elongated panel of claim 1, wherein the generally rectangular front surface and back surfaces, first longitudinal edge, and second longitudinal edge forms a front portion, and

the elongated panel further comprises a generally rectangular backing attached to the back surface of the front portion and forming a longitudinal lip extending past one of the longitudinal edges of the front portion.

7. The elongated panel of claim 6, wherein the backing forms a longitudinal receiving portion, opposite the longitudinal lip, adapted to overlap with the longitudinal lip of another panel.

8. The elongated panel of claim 1, wherein a thickness of the panel ranges from 2 to 25 mm.

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

10. A kit for producing a wall-covering, comprising:

a plurality of elongated panels, each 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 second longitudinal edge comprises a generally horizontal resting portion proximate the back surface and a second beveled portion proximate the front surface;

wherein the plurality of elongated panels comprise an upper panel and a lower panel, and

wherein a lower longitudinal edge of the upper panel is adapted to abut with an upper longitudinal edge of the lower panel such that the lower longitudinal edge of the upper panel and the upper longitudinal edge of the lower panel produce a flute along a front surface of the upper and lower panel.

11. The kit of claim 10, wherein, for each of the plurality of elongated panels, a length of the support portion and a length of the resting portion are approximately equal.

12. The kit of claim 11, wherein, for each of the plurality of elongated panels, the first beveled portion extends from an end of the support portion to the front surface, and wherein the second longitudinal edge comprises an intermediate portion between the resting portion and the second beveled portion, wherein an angle of the intermediate portion is adapted to match an angle of the first beveled portion.

13. The kit of claim 12, wherein, for each of the plurality of elongated panels, a lateral cross-section of the intermediate portion and the second beveled portion is a convex triangle.

14. The kit of claim 12, wherein, for each of the plurality of elongated panels, the intermediate portion is adapted to overlap with the first beveled portion.

15. The kit of claim 11, wherein, for each of the plurality of elongated panels, the first beveled portion extends from an end of the support portion to the front surface and the second beveled portion extends from an end of the resting portion to the front surface.

16. The kit of claim 10, wherein, for each of the plurality of elongated panels, the generally rectangular front surface and back surfaces and the first and second longitudinal edges forms a front portion, and

each elongated panel further comprises a generally rectangular backing attached to the back surface of the front portion and forming a longitudinal lip extending past one of the longitudinal edges of the front portion.

17. The kit of claim 10, further comprising adhesive for adhering the plurality of elongated panels to a wall.

18. A method of installing a wall covering comprising:

providing a plurality of elongated panels, each comprising generally rectangular front surface and back surfaces, a first longitudinal edge, and a second longitudinal edge opposite the first longitudinal edge;

attaching the back of a first elongated panel to a wall; and

attaching the back of a second elongated panel to the wall above or below the first elongated panel, wherein a resting portion of the second panel is positioned adjacent to the support portion of the first panel without adhesive.

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 the resting portion of the second panel abuts the support portion of the first panel.