Corner Assembly and a Method for Manufacturing Same

Description

TECHNICAL FIELD OF THE INVENTION

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.

BACKGROUND

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.

BRIEF SUMMARY OF THE INVENTION

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.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a polymeric-based wall covering panel in accordance with a first embodiment, including stones as simulated building elements.

FIG. 2 is a front elevation view of the polymeric-based wall covering panel shown in FIG. 1.

FIG. 3 is a rear elevation view of the polymeric-based wall covering panel shown in FIG. 1.

FIG. 4 is a perspective view of an assembly of four of the polymeric-based wall covering panels shown in FIG. 1, assembled in two vertical rows of two horizontally-adjacent panels.

FIG. 5. is a front elevation view of a polymeric-based wall covering panel in accordance with a second embodiment including shingles as simulated building elements.

FIG. 6 is a front elevation view of a polymeric-based wall covering panel in accordance with including rows of stones as simulated building elements.

FIG. 7 is a perspective view of a corner assembly in accordance with an embodiment, made of the polymeric-based wall covering panels shown in FIG. 6, wherein the corner assembly includes two rows of vertically-adjacent panels.

FIG. 8 is a front elevation view of the polymeric-based wall covering panel shown in FIG. 6 showing a cut location to create panel sections for the corner assembly of FIG. 7.

FIG. 9 is a rear perspective view of two panel sections formed by cutting the polymeric-based wall covering panel at the cut location as shown in FIG. 8, wherein each one of the panel sections includes a beveled edge.

FIG. 10 is rear perspective view of the two panel sections of FIG. 9 secured together along their beveled edges to define the corner assembly.

FIG. 11 is front elevation view of a polymeric-based wall covering panel assembly covering a section of a wall in accordance with an embodiment, wherein the panel assembly includes an entire lower row of polymeric-based wall covering panels mounted to the wall and an incomplete second row, extending above the lower row.

FIG. 12 is a front elevation view of the polymeric-based wall covering panel assembly covering the section of the wall of FIG. 11, wherein the second row is completed with two panel sections having abutting rectilinear edges.

FIG. 13 is a rear perspective view of two panel sections having juxtaposed rectilinear edges and ready to be assembled together with elongated brackets to create a variable-length panel.

FIG. 14 is another rear perspective view of two panel sections having juxtaposed rectilinear edges and assembled together with elongated brackets and a thermoplastic sealant.

FIG. 15 is a perspective view of an elongated bracket in accordance with an embodiment.

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

DETAILED DESCRIPTION

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 FIGS. 1 to 4, a first embodiment of a polymeric-based wall covering panel 20, 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 panels 20 and 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 panel 20 has 3D simulated building elements 22 on a front surface 24 thereof and a rear surface 34. The 3D simulated building elements 22 protrudes forwardly. Each one of the panels includes a plurality of rows of 3D simulated building elements 22 and each one of the rows includes a plurality of horizontally adjacent 3D simulated building elements 22. The polymeric-based wall covering panel 20 extends between two lateral edges 26 and two longitudinal edges 28.

More particularly, the polymeric-based wall covering panel 20 has an upper longitudinal edge 28a and a lower longitudinal edge 28b, vertically spaced apart from the upper longitudinal edge 28a. Hereinafter, the term “upper” refers to the highest longitudinal edge when the panel 20 is mounted to an inclined support surface. Extending inwardly from the upper longitudinal edge 28a, the polymeric-based wall covering panel 20 has an upper marginal edge region 30 that 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 region 30 is free from 3D simulated building elements 22. Similarly, extending inwardly from the lower longitudinal edge 28b, the polymeric-based wall covering panel 20 has a lower marginal edge region 32 that is superposable over the underlying upper marginal edge region 30 of a vertically-adjacent and lower mounted polymeric-based wall covering panel 20 to cover/hide its upper marginal edge region 30. In the lower marginal edge region 32, the front surface 24 of the polymeric-based wall covering panel 20 includes 3D simulated building elements 22 (at least in a portion thereof). Therefore, when two polymeric-based wall covering panels 20 are vertically mounted to a support surface with the lower marginal edge region 32 of an upper one of the panels 20 covering the upper marginal edge region 30 of a lower one of the panels 20, the pattern of the 3D simulated building elements 22 is continuous over a horizontally-extending junction of the two polymeric-based wall covering panels 20. Therefore, the horizontally-extending junction (or seam) between the two vertically adjacent polymeric-based wall covering panels 20 installed on the support surface is substantially imperceptible.

Each one of the simulated building elements 22 has a protruding surface, protruding forwardly with respect to the upper marginal edge region 30.

In addition, in the non-limitative embodiment shown, the polymeric-based wall covering panel 20 has two non-rectilinear and, more particularly, stair shaped lateral edges 26, complementary in shape. Extending inwardly from one of the two lateral edges 26 (the left-one in the non-limitative embodiment shown), the polymeric-based wall covering panel 20 has overlapping sections when the panels 20 are mounted in horizontal courses to a bearing substrate such as a wall. More particularly, the polymeric-based wall covering panel 20 has a stair shaped underlying section 36. Similarly, extending inwardly from the other lateral edge 26 (the right-one in the non-limitative embodiment shown), the polymeric-based wall covering panel 20 has a combination of underlying sections 38a, 38b and overlying sections 39a, 39b, 39c.

In the non-limitative embodiment shown in FIGS. 1 and 2, a left lateral edge region 26a includes the underlying section 36, which in the non-limitative embodiment shown, is slightly spaced-apart from the support surface when the panel 20 is mounted thereto. The purpose will be described in more details below. In the non-limitative embodiment shown, a right lateral edge region 26b includes two underlying sections 38a, 38b which contact the support surface when the panel 20 is mounted thereto. An elongated receiving groove 40, being stair shaped is defined between the underlying sections 38a, 38b and overlying sections 39a, 39b, including simulated building elements 22. The elongated receiving groove 40 is configured to receive respective vertical and horizontal segments of the underlying section 36 of a horizontally-adjacent polymeric-based wall covering panel 20. A third overlying section 39c is also provided in a lower portion of the panel 20. Once inserted in the elongated receiving grooves 40, the underlying section 36 is hidden by the overlying sections 38 and the wall covering elements of the two horizontally-adjacent polymeric-based wall covering panels 20 form a continuous pattern over a vertically and stair shaped junction of the two polymeric-based wall covering panels 20. Therefore, the vertically and stair shaped junction between the two horizontally-adjacent polymeric-based wall covering panels 20 mounted to the support surface is substantially imperceptible.

Referring to FIG. 3, there is shown that the rear surface 34 of the wall covering panel 20 comprises a plurality of elongated ribs 252 extending substantially parallel to the longitudinal edges 28a, 28b. The elongated ribs 252 correspond to the simulated building elements 22 defined on the front surface 24.

Referring now to FIG. 5, there is shown an alternative embodiment of the wall covering panel 20 wherein the features are numbered with reference numerals in the 100 series which correspond to the reference numerals of the previous embodiment.

It is appreciated that the shape of the simulated building elements 122 and the non-rectilinear lateral edges 126 differ from the embodiment shown in FIGS. 1 to 4. However, as the polymeric-based wall covering panel 20, the polymeric-based wall covering panel 120 has overlapping sections when the panels 120 are mounted in horizontal courses to a bearing substrate such as a wall.

In the embodiment shown in FIG. 5, a right lateral edge region 126b includes the underlying sections 138a, 138b, 138c. A left lateral edge region 126a includes the overlying sections 139 (one for each row of simulated building elements 122), which in the non-limitative embodiment shown, is slightly spaced-apart from the support surface when the panel 120 is mounted thereto. The underlying sections 138a, 138b, 138c contact the support surface when the panel 120 is secured thereto and are covered by the overlying section 139 of the horizontally-adjacent polymeric-based wall covering panel 120 to form a continuous pattern over a vertically and stair shaped junction of the two polymeric-based wall covering panels 120.

Referring now to FIG. 6, there is shown another alternative embodiment of the wall covering panel 20, 120 wherein the features are numbered with reference numerals in the 200 series which correspond to the reference numerals of the previous embodiment.

Ss the polymeric-based wall covering panels 20, 120, the polymeric-based wall covering panel 220 has overlapping sections when the panels 220 are mounted in horizontal courses to a bearing substrate such as a wall. In the embodiment of FIG. 6, the left lateral edge 226a of the polymeric-based wall covering panel 220 follows the pattern of the 3D simulated building elements 222. On the right lateral side, the building elements are recessed from the right lateral edge 226b, defining the underlying section 236 therebetween. The left and right lateral edges and the underlying section 236 are nonrectilinear. The underlying section 236 is superposable to and contact the support surface when the panel 220 is secured thereto. In the non-limitative embodiment shown, the underlying section 236 is free from 3D simulated building elements 222. Similarly, extending inwardly from the left nonrectilinear lateral edge 226a, the polymeric-based wall covering panel 220 includes an overlying section 238 that is superposable over and covers the underlying section 236 of a horizontally-adjacent polymeric-based wall covering panel 220 to cover/hide the underlying section 236. Therefore, the underlying section 236 and the overlying section 238 have a corresponding profile. As for the above-described embodiments, when two polymeric-based wall covering panels 220 are mounted to the support surface in a horizontally adjacent configuration, the pattern of the 3D simulated building elements 222 is continuous over a vertically and nonrectilinear junction of the two polymeric-based wall covering panels 220.

In the embodiments shown in FIGS. 1 to 6, the lateral edges 26, 126 and 226 are 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 20, 120, 220 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.

Referring now to FIGS. 7 to 12, the polymeric-based wall covering panels 20, 120 and 220 described previously (or alternatives thereof) can be assembled in a corner assembly 242, which can be mounted to two adjacent walls to cover a corner 254 thereof. In the following paragraphs, reference to elements of the embodiment of FIG. 6 will be made. However, it is appreciated that the description also applies to the embodiments of the wall covering panels 20, 120 of FIGS. 1 to 5, and alternatives thereof.

Referring to FIG. 7, there is shown that the wall covering corner assembly 242 comprises sections 220a, 220b of polymeric-based wall covering panels 220 mounted in an adjacent and abutting configuration and defining a non-zero degree angle inbetween, i.e. either a right angle or an oblique angle. In the non-limitative embodiment shown, the wall covering corner assembly 242 comprises two rows of vertically-superposed panels 220. However, it is appreciated that, in alternative embodiments, the wall covering corner assembly 242 can include a single row of wall covering panels 220 or more than two rows.

Each one of the sections 220a, 220b of polymeric-based wall covering panels 220 has a rectilinear beveled edge 250 (FIG. 9) extending therealong. The rectilinear beveled edges of two panel sections 220a, 220b in the same rows are abutted against one another to define at least a portion of the corner assembly 242. In the embodiment shown, the corner assembly 242 is configured to cover an outside corner, i.e. wherein the front surfaces of the two adjacent and abutted panel sections 220a, 220b define an angle ranging from 181 degrees to 359 degrees (i.e. by measuring the angle defined between the front surfaces 224 of the two panel sections 220a, 220b). However, it is appreciated that, in an alternative embodiment, the corner assembly 242 can be configured to cover an inside corner, i.e. wherein the front surfaces of the two adjacent and abutted panel sections 220a, 220b define an angle ranging from 1 degree to 179 degrees.

Referring now to FIGS. 8 to 10, a method to assemble the corner assembly 242 will be described. As shown in FIG. 8, the polymeric-based wall covering panel 20 is first miter cut at a cut location 244, shown in dark grey, along a straight line extending between the upper edge 228a and the lower edge 228b to form two panel sections 220a, 220b. In FIG. 8, two miter cuts are made across the panel 220 to form the two panel sections 220a, 220b that can be joined together to create the corner assembly 242. Therefore, in some embodiments, at least some of the 3D simulated building elements 222 are split in two sections, with a first section being located on the first panel section 220a and a second section being located on the second panel section 220b. The polymeric-based wall covering panel 220 is cut to define two beveled edges 250, one on each panel section 220a, 220b. In the embodiment shown in FIG. 9, the beveled edge 250 is a 45 degrees beveled edge. However, its appreciated that, in alternative embodiments, the angulation of the beveled edge 250 can vary.

In a non-limitative embodiment, the panel cutting can be performed using a waterjet. For instance, the panels 220 can be cut sequentially in a water cutting cell. It is appreciated that other cutting methods can be used.

In the embodiment shown, the beveled edges 250 of the panel sections 220a, 220b are rearwardly extending to abut one another in the corner assembly 242 configured to cover an outside corner, i.e. the panel sections 220a, 220b are longer adjacent to their front surface 224 than at their rear surface 234. In another embodiment (not shown) where the corner assembly 242 is configured to cover an inside corner, the beveled edges 250 would be forwardly extending, i.e. the panel sections 220a, 220b are shorter adjacent to their front surface 224 and longer adjacent to their rear surface 234.

Turning now to FIG. 10, the two panel sections 220a, 220b are secured in a corner configuration defining the corner assembly 242 by welding the two panel sections 220a, 220b together along their beveled edges 250. The weld was performed at the rear surfaces 234 of the panel sections 220a, 220b, at the seam/junction 256. As shown in FIG. 7, the panel section joint 256 is substantially imperceptible at the junction of the front surfaces 224 of the panel sections 220a, 220b. In the embodiment shown, the two panel sections 220a, 220b were bound together using an extrusion welder fed with the same material and color than the panel. As mentioned above, in the non-limitative embodiment shown, the panel sections 220a, 220b are made of polypropylene. Therefore, the two panel sections 220a, 220b were bound together using polypropylene.

Referring now to FIGS. 11 to 14, a kit to cover a length of a bearing substrate including at least one corner and, more particularly, the wall 248 (only a section thereof is shown in FIGS. 11 and 12), for instance extending between two corner assemblies 242, will be described. It is understood that the length of the support surface of the wall 248, for instance between two corner assemblies 242, may not be coverable by a perfect multiple of wall covering panels 220. Therefore, at least one panel may need to be cut to remove a section thereof. Therefore, the kit to cover the wall 248 along its entire length includes at least one corner assembly 242 (in some implementations, it will include two corner assemblies 242, i.e. one for each one of the corners), at least one wall covering panel 220, and at least one elongated bracket 246 to secure two panel sections together. In some embodiments, the kit further includes a thermoplastic sealant, such as and without being limitative caulk.

At least one of the wall covering panel(s) 220 of the kit is used a variable-length panel 258, which is required to cover the wall 248 extending between two covering corner assemblies 242 or between a finish panel and one covering corner assembly 242.

The length of the variable-length panel 258 required to fill the wall between two spaced-apart wall covering panels, having non-rectilinear lateral edges can be determined knowing a distance between the two corners delimiting a selected wall 248, a length of the wall covering panels 220, and the number of full-length covering panels 220 which can be mounted to the wall 248.

The variable-length panel 258 is configured to be mounted between two horizontally spaced-apart wall covering panels 220 having non-rectilinear edges delimiting a spacing to receive the variable-length panel 258. The length of the variable-length panel 258 can be either shorter or longer than a length of one of the wall covering panel 220.

The variable-length panel 258 can be obtained by cutting one of the wall covering panels 220 of the kit into three sections: two sections having a non-rectilinear lateral edge and a rectilinear lateral edge and one middle section having two rectilinear lateral edges, which will be discarded. It can also be obtained by cutting two of the wall covering panels 220 to obtain to panel sections 220c, 220d, each one having a non-rectilinear lateral edge and a rectilinear lateral edge. More particularly, a first one of the panel sections 220c, 220d has its non-rectilinear lateral edge and its rectilinear edge respectively on a left side and a right side thereof. A second one of the panel sections 220c, 220d has its non-rectilinear lateral edge and its rectilinear edge respectively on a right side and a left side thereof, i.e. opposed to the first one of the panel sections 220c, 220d. The two rectilinear edges of the panel sections 220c, 220d are juxtaposable and the panel sections 220c, 220d are securable together to define the variable-length panel 258, as will be described in more details below, insertable in the spacing between the two horizontally spaced-apart wall covering panels 220.

In both cases, the wall covering panel(s) 220 cut to define the panel sections 220c, 220d, which will be assembled to form the variable-length panel 258, are cut to form straight and linear edges, i.e. 90 degrees edges extending between the front and the rear surfaces 224, 234 and the upper and the lower longitudinal edges 228a, 228b, perpendicular thereto. The straight cuts can be performed in a manufacturing plant or on-site. For instance, if they are cut on-site, they can be cut using a regular saw. If they are cut in the manufacturing plant, they can be cut using a water jet, as for the corner assembly 242.

In some implementations, each one of the panel sections 220c, 220d forming the variable-length panel 258 has substantially the same length. However, it is appreciated that, in alternative implementations, each one of the panel sections 220c, 220d forming the variable-length panel 258 can have a different length, depending on a desired location of a seam/junction 260 of the two panel sections 220c, 220d along the wall 248.

In an embodiment, the length of the panel sections 220c, 220d are measured based on a forwardly-exposed portion of the panel sections 220c, 220d, i.e. excluding the underlying sections 236, which are covered by the overlying sections 238 of a horizontally-adjacent one of the panels 220.

Referring to FIG. 11, there is shown a polymeric-based wall covering panel assembly 262 including a first and lower row of polymeric-based wall covering panels 220 mounted to the wall 248. In FIG. 11, only a right section of the wall 248 is shown including the corner 254 but it is appreciated that the polymeric-based wall covering panel assembly 262 can extend between two corners 254 delimiting the wall 248 or between a corner 254 and another feature, such as a window or a door, provided in the bearing substrate. The right section of the lower row includes a variable-length panel, which is almost imperceptible, and one of the corner assembly 242.

The second row, vertically-adjacent to the lower row and extending above, includes at least one of the polymeric-based wall covering panels 220 mounted to the wall 248 (only one is shown) with the underlying section 236 thereof being exposed, ready to be cover by the overlying section 238 of a horizontally-adjacent one of the polymeric-based wall covering panel 220 or the variable-length panel 258. In the embodiment shown in FIG. 12, the horizontally-adjacent panel is the variable-panel 258, which length has been determined knowing the distance between the corner assembly 242, which will be mounted to the right side to cover the corner 254 and the polymeric-based wall covering panel 220 mounted to the wall 248 on the left side.

Thus, in FIG. 12, the variable-length panel 258 is mounted between one of the polymeric-based wall covering panels 220, on the left side, and the corner assembly 242, on the right side. It includes the two panel sections 220c, 220d with the almost imperceptible seam 260 extending inbetween.

Referring now to FIGS. 13 and 14, there is shown that the two panel sections 220c, 220d are assembled together prior to mounting the variable-length panel 258 to the wall 248. In an embodiment, the kit includes one or more of the elongated brackets 246 and a rigid thermoplastic sealant 264, such as caulk. In an embodiment, the colour of the thermoplastic sealant 264 corresponds substantially to the colour of the polymeric-based wall covering panels 220. Referring now to FIG. 15, in the non limitative embodiment shown, the elongated brackets 246 are substantially V-shaped and crimpable. In the non-limitative embodiment shown, the elongated brackets 246 have teeth 266 protruding from one of the longitudinal edges thereof. It is appreciated that, in alternative embodiment (not shown), the elongated brackets 246 have teeth 266 on both longitudinal edges or be free of teeth. In an embodiment, the elongated bracket 246 has a length ranging between about 3 inches and about 8 inches and, in a particular embodiment, between about 4 and about 6 inches.

Referring back to FIGS. 13 and 14, the two panel sections 220c, 220d are assembled together from the rear surface 234 using the elongated brackets 246. When the rectilinear edges of the panel sections 220c, 220d are juxtaposed and the longitudinal edges 228a, 228b are colinear, at least some of the elongated ribs 252 of two panel sections 220c, 220d are aligned. As mentioned above, the elongated ribs 252 are defined on the rear surface 234 and can correspond to the simulated building elements 222. The elongated ribs 252 extend substantially perpendicular to the lateral rectilinear edges. The elongated brackets 246 can be mounted to the two juxtaposed panel sections 220c, 220d by being crimped on aligned ones of the elongated ribs 252 on the rear surface 234. If present, the teeth 266 protruding from the longitudinal edges of the elongated bracket 246 are inserted in the respective one of the elongated ribs 252. Then, the sealant 264 is applied along the junction 260 of the panel sections 220c, 220d to fill all remaining gaps therebetween. From the front surface, the junction of the panel sections 220c, 220d is substantially imperceptible.

It is appreciated that the number and the position of the elongated brackets 246 can vary from the embodiment shown. The two panel sections 220c, 220d assembled by the combination of the elongated brackets 246 and the sealant 264 provides the variable-length panel 258, which can be mounted to the wall 248.

Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.