Corner Assembly and a Method for Manufacturing Same

The technical field relates to polymeric-based wall covering panels and corner assemblies for covering walls and other building support surfaces. It also relates to a method for manufacturing a corner assembly from wall covering panels and a kit for covering a building wall surface.

Siding covering panels, made of plastic materials and designed for facing exterior building walls, are known. For example, such coverings can have the appearance of natural materials, such as wooden clapboards, cedar shakes, masonry (stones, bricks, etc.) and the like. The coverings include a plurality of elongated panels which are individually affixed to bearing substrates such as building walls. The elongated panels are secured to the bearing substrates, in horizontal courses. When the panels are installed on the building walls, the joints between the panels can be substantially imperceptible, creating a realistic aspect to the wall assembly.

At corners of the bearing substrate surfaces of the building or structure to which the panels are mounted, joints are formed between the elongated panels affixed thereon. In order to hide these joints, it is known to cover the corner sections with vertical elongated corner moldings (or corner trims). The corner moldings can have the appearance of natural material, like the panels. Known corner moldings however tend to pose aesthetic issues, as they are often unaesthetic and can lessen the natural appearance of the coverings.

In view of the above, there is a need for corner assemblies and a method to manufacture same which would be able to overcome or at least minimize some of the above-discussed prior art concerns.

It is therefore an aim of the present invention to address the above mentioned issues.

According to a general aspect, there is provided a method for forming a corner assembly from at least one polymeric-based wall covering panel having 3D simulated building elements on a front surface thereof. The method comprises: determining a cut location along the at least one polymeric-based wall covering panel; cutting the at least one polymeric-based wall covering panel at the cut location with a bevel cut to form two panel sections, at least one of the two panel sections having a beveled edge; forming the corner assembly by abutting the beveled edges of two of the panel sections against one another with both sections, wherein a pattern of the simulated building elements of the two of the panel sections form a continuity at their junction; and securing the two of the panel sections forming the corner assembly together.

In an embodiment, each one of the at least one polymeric-based wall covering panel has two longitudinal edges and two lateral edges, at least one of the lateral edges is a nonrectilinear lateral edge, and the corner assembly comprises the at least one nonrectilinear lateral edge. The cut location can extend through some of the 3D simulated building elements and perpendicular to the two longitudinal edges.

In an embodiment, the cutting of the at least one polymeric-based wall covering panel at the cut location defines two panel sections, each one including a respective one of the beveled edges and wherein forming the corner assembly by abutting the beveled edges of two of the panel sections against one another comprises abutting the beveled edges of the two of the panel sections from a same of the at least one polymeric-based wall covering panel.

In an embodiment, each one of the 3D simulated building elements comprises a protruding surface, each one of the at least one polymeric-based wall covering panel includes a plurality of rows of the 3D simulated building elements and each one of the rows includes a plurality of horizontally adjacent ones of the 3D simulated building elements.

In an embodiment, securing the two of the panel sections together includes welding the two of the panel sections.

According to another general aspect, there is provided a corner assembly comprising: a first panel section having 3D simulated building elements on a front surface thereof and a rectilinear beveled edge on a first lateral side and a second nonrectilinear lateral edge, opposed to the first lateral edge; and a second panel section having 3D simulated building elements on a front surface thereof and a rectilinear beveled edge on a first lateral side abutted against and secured to the rectilinear beveled edge of the first panel section in a corner configuration defining a non-zero degree angle. A pattern of the 3D simulated building elements of the first and the second panel sections is continuous over the corner assembly.

In an embodiment, the first panel section and the second panel section are welded together along the rectilinear beveled edges.

In an embodiment, the first panel section and the second panel section are obtained by cutting a polymeric-based wall covering panel at a cut location with a bevel cut and abutting beveled edges of the first panel section and the second panel section against one another.

In an embodiment, each one of the 3D simulated building elements comprises a protruding surface, each one of the first panel section and the second panel section includes a plurality of rows of the 3D simulated building elements and each one of the rows includes a plurality of horizontally adjacent ones of the 3D simulated building elements.

According to still another general aspect, there is provided a corner assembly comprising: a first panel section having 3D simulated building elements on a front surface thereof and a rectilinear beveled edge on a first lateral side and an underlying section, free of 3D simulated building elements, in a lateral edge region adjacent to a second lateral edge; and a second panel section having 3D simulated building elements on a front surface thereof and a rectilinear beveled edge on a first lateral side abutted against and secured to the rectilinear beveled edge of the first panel section in a corner configuration defining a non-zero degree angle, the second panel section having an overlying section, including a portion of the 3D simulated building elements, in a lateral edge region adjacent to a second lateral edge. A pattern of the 3D simulated building elements of the first and the second panel sections is continuous over the corner assembly.

In an embodiment, the first panel section and the second panel section are welded together along the rectilinear beveled edges.

In an embodiment, the first panel section and the second panel section are obtained by cutting a polymeric-based wall covering panel at a cut location with a bevel cut and abutting beveled edges of the first panel section and the second panel section against one another.

In an embodiment, each one of the 3D simulated building elements comprises a protruding surface, each one of the first panel section and the second panel section includes a plurality of rows of the 3D simulated building elements and each one of the rows includes a plurality of horizontally adjacent ones of the 3D simulated building elements.

In an embodiment, the overlying section of the second panel section is superposable to the underlying section of the first panel section with a corresponding profile.

According to a further general aspect, there is provided a kit for covering a support surface. The kit comprises the wall covering corner assembly as described above, the wall covering corner assembly having a rear surface, opposed to the front surface; at least two polymeric-based wall covering panels having a 3D simulated building elements on a front surface thereof, each one of the at least two polymeric-based wall covering panels having opposed lateral edges and a rear surface, opposed to the front surface; and at least one elongated bracket engageable with horizontally adjacent ones of the at least two polymeric-based wall covering panels and the corner assembly from the rear surfaces thereof. At least two of the lateral edges of the at least two polymeric-based wall covering panels and the second lateral edges of the corner assembly are rectilinear and juxtaposable against one another in a horizontally-adjacent configuration and the at least one elongated bracket being engageable with the rear surfaces thereof to maintain the abutted and horizontally-adjacent configuration.

In an embodiment, in the horizontally-adjacent configuration, the 3D simulated building elements of the at least two polymeric-based wall covering panels forms a continuous pattern.

In an embodiment, the 3D simulated building elements form elongated ribs on the rear surfaces, the at least two of the lateral edges of the polymeric-based wall covering panels and the second lateral edges of the corner assembly have aligned elongated ribs at a junction thereof and the at least one elongated bracket is crimpable over the aligned elongated ribs.

In an embodiment, the at least one elongated bracket comprises longitudinal edges and teeth protruding from at least one of the longitudinal edges, the teeth being insertable in the elongated ribs when the at least one elongated bracket is crimped to the aligned elongated ribs.

In an embodiment, the kit further comprises thermoplastic sealant applicable at a junction of the rectilinear lateral edges to fill gaps inbetween.

It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

Moreover, although the embodiments of a corner assembly for covering a wall corner or any other corner at the junction of building support surfaces, a wall covering panel, and corresponding parts thereof consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations, may be used for the corner assembly and the wall covering panel, as will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art. Moreover, it will be appreciated that positional descriptions such as “above”, “below”, “left”, “right” and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.

In the following description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional, and are given for exemplification purposes only.

Moreover, it will be appreciated that positional descriptions such as “above”, “below”, “forward”, “rearward” “left”, “right” and the like should, unless otherwise indicated, be taken in the context of the figures and correspond to the position and orientation of the corner assembly and the wall covering panel and corresponding parts when being mounted to a wall (or another building bearing substrates), with the “front” corresponding to an exposed position of the panel, the corner or the panel assembly and the “rear”/“back” corresponding to a position adjacent/superposed to the wall (or the support surface of a bearing substrate). Positional descriptions should not be considered limiting.

In the following description, the term “about” means within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e. the limitations of the measurement system. It is commonly accepted that a 10% precision measure is acceptable and encompasses the term “about”.

In the above description, an embodiment is an example or implementation of the inventions. The various appearances of “one embodiment,” “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiments. Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the inventions.

Although various features of the invention may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, the invention may also be implemented in a single embodiment.

If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element. It is to be understood that where the claims or specification refer to “a” or “an” element, such reference is not to be construed that there is only one of that element.

It is to be understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only. Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belongs, unless otherwise defined.

The principles and uses of the teachings of the present invention may be better understood with reference to the accompanying description, figures and examples.

Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can be implemented in embodiments other than the ones outlined in the description above.

It is to be understood that the terms “including”, “comprising”, “consisting” and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers.

It is to be understood that where the specification states that a component, feature, structure, or characteristic “may”, “might”, “can” or “could” be included, that particular component, feature, structure, or characteristic is not required to be included.

Referring to, a first embodiment of a polymeric-based wall covering panel, which can be mounted to a wall (or another support surface of a bearing substrate) to cover a portion thereof, is shown. In the non-limitative embodiments shown herein, the polymeric-based wall covering panelsand alternative embodiments thereof are mounted to vertical walls. However, it is appreciated that they can be mounted to other support surfaces, such as an inclined roof. In some implementations, the inclined roof has an inclination of at least 30/12 and is some implementations, at least 45/12. The polymeric-based wall covering panelhas 3D simulated building elementson a front surfacethereof and a rear surface. The 3D simulated building elementsprotrudes forwardly. Each one of the panels includes a plurality of rows of 3D simulated building elementsand each one of the rows includes a plurality of horizontally adjacent 3D simulated building elements. The polymeric-based wall covering panelextends between two lateral edgesand two longitudinal edges.

More particularly, the polymeric-based wall covering panelhas an upper longitudinal edgeand a lower longitudinal edge, vertically spaced apart from the upper longitudinal edge. Hereinafter, the term “upper” refers to the highest longitudinal edge when the panelis mounted to an inclined support surface. Extending inwardly from the upper longitudinal edge, the polymeric-based wall covering panelhas an upper marginal edge regionthat is superposable to the support surface and securable thereto using, for instance, mechanical fasteners such as screws or nails. In the non-limitative embodiment shown, the upper marginal edge regionis free from 3D simulated building elements. Similarly, extending inwardly from the lower longitudinal edge, the polymeric-based wall covering panelhas a lower marginal edge regionthat is superposable over the underlying upper marginal edge regionof a vertically-adjacent and lower mounted polymeric-based wall covering panelto cover/hide its upper marginal edge region. In the lower marginal edge region, the front surfaceof the polymeric-based wall covering panelincludes 3D simulated building elements(at least in a portion thereof). Therefore, when two polymeric-based wall covering panelsare vertically mounted to a support surface with the lower marginal edge regionof an upper one of the panelscovering the upper marginal edge regionof a lower one of the panels, the pattern of the 3D simulated building elementsis continuous over a horizontally-extending junction of the two polymeric-based wall covering panels. Therefore, the horizontally-extending junction (or seam) between the two vertically adjacent polymeric-based wall covering panelsinstalled on the support surface is substantially imperceptible.

Each one of the simulated building elementshas a protruding surface, protruding forwardly with respect to the upper marginal edge region.

In addition, in the non-limitative embodiment shown, the polymeric-based wall covering panelhas two non-rectilinear and, more particularly, stair shaped lateral edges, complementary in shape. Extending inwardly from one of the two lateral edges(the left-one in the non-limitative embodiment shown), the polymeric-based wall covering panelhas overlapping sections when the panelsare mounted in horizontal courses to a bearing substrate such as a wall. More particularly, the polymeric-based wall covering panelhas a stair shaped underlying section. Similarly, extending inwardly from the other lateral edge(the right-one in the non-limitative embodiment shown), the polymeric-based wall covering panelhas a combination of underlying sections,and overlying sections,,

In the non-limitative embodiment shown in, a left lateral edge regionincludes the underlying section, which in the non-limitative embodiment shown, is slightly spaced-apart from the support surface when the panelis mounted thereto. The purpose will be described in more details below. In the non-limitative embodiment shown, a right lateral edge regionincludes two underlying sections,which contact the support surface when the panelis mounted thereto. An elongated receiving groove, being stair shaped is defined between the underlying sections,and overlying sections,, including simulated building elements. The elongated receiving grooveis configured to receive respective vertical and horizontal segments of the underlying sectionof a horizontally-adjacent polymeric-based wall covering panel. A third overlying sectionis also provided in a lower portion of the panel. Once inserted in the elongated receiving grooves, the underlying sectionis hidden by the overlying sectionsand the wall covering elements of the two horizontally-adjacent polymeric-based wall covering panelsform a continuous pattern over a vertically and stair shaped junction of the two polymeric-based wall covering panels. Therefore, the vertically and stair shaped junction between the two horizontally-adjacent polymeric-based wall covering panelsmounted to the support surface is substantially imperceptible.

Referring to, there is shown that the rear surfaceof the wall covering panelcomprises a plurality of elongated ribsextending substantially parallel to the longitudinal edges,. The elongated ribscorrespond to the simulated building elementsdefined on the front surface.

Referring now to, there is shown an alternative embodiment of the wall covering panelwherein the features are numbered with reference numerals in theseries which correspond to the reference numerals of the previous embodiment.

It is appreciated that the shape of the simulated building elementsand the non-rectilinear lateral edgesdiffer from the embodiment shown in. However, as the polymeric-based wall covering panel, the polymeric-based wall covering panelhas overlapping sections when the panelsare mounted in horizontal courses to a bearing substrate such as a wall.

In the embodiment shown in, a right lateral edge regionincludes the underlying sections,,. A left lateral edge regionincludes the overlying sections(one for each row of simulated building elements), which in the non-limitative embodiment shown, is slightly spaced-apart from the support surface when the panelis mounted thereto. The underlying sections,,contact the support surface when the panelis secured thereto and are covered by the overlying sectionof the horizontally-adjacent polymeric-based wall covering panelto form a continuous pattern over a vertically and stair shaped junction of the two polymeric-based wall covering panels.

Referring now to, there is shown another alternative embodiment of the wall covering panel,wherein the features are numbered with reference numerals in theseries which correspond to the reference numerals of the previous embodiment.

Ss the polymeric-based wall covering panels,, the polymeric-based wall covering panelhas overlapping sections when the panelsare mounted in horizontal courses to a bearing substrate such as a wall. In the embodiment of, the left lateral edgeof the polymeric-based wall covering panelfollows the pattern of the 3D simulated building elements. On the right lateral side, the building elements are recessed from the right lateral edge, defining the underlying sectiontherebetween. The left and right lateral edges and the underlying sectionare nonrectilinear. The underlying sectionis superposable to and contact the support surface when the panelis secured thereto. In the non-limitative embodiment shown, the underlying sectionis free from 3D simulated building elements. Similarly, extending inwardly from the left nonrectilinear lateral edge, the polymeric-based wall covering panelincludes an overlying sectionthat is superposable over and covers the underlying sectionof a horizontally-adjacent polymeric-based wall covering panelto cover/hide the underlying section. Therefore, the underlying sectionand the overlying sectionhave a corresponding profile. As for the above-described embodiments, when two polymeric-based wall covering panelsare mounted to the support surface in a horizontally adjacent configuration, the pattern of the 3D simulated building elementsis continuous over a vertically and nonrectilinear junction of the two polymeric-based wall covering panels.

In the embodiments shown in, the lateral edges,andare non-rectilinear edges. However, it is appreciated that, in still an alternative embodiment (not shown), the lateral edges can be rectilinear. Furthermore, it is understood that the left and the right-side features can be reversed in alternative embodiments.

The panels,,are polymeric-based and, more particularly, plastic-based panels. The expression “polymeric-based” is intended to include composite materials such a combination of a polymer, such as a plastic, and inorganic and/or organic fillers. In the non-limitative embodiment shown, the panels are made of polypropylene. However, it is appreciated that they could be made of other injection moldable or extrudable thermoplastic polymers, such as and without being limitative, polyethylene.