Corner Assembly and a Method for Manufacturing Same

Abstract

There is provided a corner assembly, which comprises a first panel section and a second panel section, each 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. The rectilinear beveled edges are abutted against one another and secured together in a corner configuration defining a non-zero degree angle. There is also provided a method for forming a corner assembly from at least one polymeric-based wall covering panel and a kit for covering a support surface.

1 . 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 comprising:
 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.   
     
     
         2 . The method of  claim 1 , wherein 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. 
     
     
         3 . The method of  claim 2 , wherein the cut location extends through some of the 3D simulated building elements and perpendicular to the two longitudinal edges. 
     
     
         4 . The method of  claim 1 , wherein 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. 
     
     
         5 . The method of  claim 1 , wherein 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. 
     
     
         6 . The method of  claim 1 , wherein securing the two of the panel sections together includes welding the two of the panel sections. 
     
     
         7 . 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;   wherein a pattern of the 3D simulated building elements of the first and the second panel sections is continuous over the corner assembly.   
     
     
         8 . The corner assembly of  claim 7 , wherein the first panel section and the second panel section are welded together along the rectilinear beveled edges. 
     
     
         9 . The corner assembly of  claim 7 , wherein 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. 
     
     
         10 . The corner assembly of  claim 7 , wherein 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. 
     
     
         11 . 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;   wherein a pattern of the 3D simulated building elements of the first and the second panel sections is continuous over the corner assembly.   
     
     
         12 . The corner assembly of  claim 11 , wherein the first panel section and the second panel section are welded together along the rectilinear beveled edges. 
     
     
         13 . The corner assembly of  claim 11 , wherein 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. 
     
     
         14 . The corner assembly of  claim 11 , wherein 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. 
     
     
         15 . The corner assembly of  claim 11 , wherein the overlying section of the second panel section is superposable to the underlying section of the first panel section with a corresponding profile. 
     
     
         16 . A kit for covering a support surface, the kit comprising:
 the wall covering corner assembly as claimed of  claim 7 , 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;   wherein 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.   
     
     
         17 . The kit of  claim 16 , wherein, in the horizontally-adjacent configuration, the 3D simulated building elements of the at least two polymeric-based wall covering panels forms a continuous pattern. 
     
     
         18 . The kit of  claim 16 , wherein 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. 
     
     
         19 . The kit of  claim 16 , wherein 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. 
     
     
         20 . The kit of  claim 16 , wherein the kit further comprises thermoplastic sealant applicable at a junction of the rectilinear lateral edges to fill gaps inbetween.