Wall panelling boards and wall panelling arrangements

Abstract

A wall panelling board comprising a substrate and an outermost surface, the board being rectangular and having two oppositely disposed relatively long sides each incorporating an outermost tongue form

Description

Field of the Invention The invention relates to wall panelling boards and related arrangements. In particular, wall panelling boards include cladding and siding planks or the like which are primarily configured to cover the upwardly extending surfaces of buildings and other structures requiring to be covered as appropriate. Background to the Invention and prior art known to the applicant(s) Cladding or siding boards / planks often have two long sides which are configured to interlock with one another or overlap one another. In order to minimize water ingress, an upper plank is configured to overlap with a lower plank. In particular, the side portion of the upper plank often overhangs the upper portion of the lower plank. Conventional thinking in the art has therefore developed boards which are asymmetrical about their longitudinal central axis in order to facilitate the interlock and overhang. This limits the versatility of the board as it can only be used in one orientation. These boards also tends to detach from one another when exposed to high winds and suffer from relatively poor thermal properties in the connection area between adjacent boards. The present invention sets out a number of improvements in wall panelling boards. In particular, certain embodiments of the invention seek one or more of the following: • Allowing the board to be placed in any orientation whilst, in certain embodiments, still forming an overlap; this is particularly significant in composite boards that have limited patterns and configurations; • To improve the weather resistance and in particular to further limit the passage of water through an arrangement of weather boards of the kind in question; • Improving the versatility of the board to lend itself to horizontal and vertical mounting whilst also allowing a number of overlapping configurations and also having the capacity of being mounted level with one another if so desired; • Improve how the boards are secured with respect to one another for further improved resistance to wind damage; • Improve the thermal properties of the resulting arrangement by improving the joint between neighbouring boards. One or more of these technical objectives will be addressed in the following aspects. Summary of the Invention In a first broad independent aspect, the invention provides a wall panelling board suitable for cladding and / or siding a wall comprising: a substrate; an outermost surface; wherein the board is substantially rectangular in plan view, the board having two oppositely disposed relatively long sides and two oppositely disposed relatively short sides; the long sides each incorporating an outermost tongue formed with the perimeter region of the outermost covering layer and a perimeter region of the substrate; the long sides each further incorporating a groove adjacent to the outermost tongue; the groove being sized and shaped to receive the outermost tongue of a further wall panelling board when, mounted side by side; wherein the long sides each further incorporate an innermost tongue formed preferably entirely in the substrate and against which the outermost tongue of a further wall panelling board abuts, when, mounted side by side; wherein the board has one or any combination of the following: • wherein the groove incorporates a further recessed portion located at an innermost location of the groove and which is smaller than the outermost tongue; wherein the further recessed portion remains unoccupied by an outermost tongue of the further board when it is inserted into the board; and / or • wherein the outermost tongue is thicker than the innermost tongue; and / or • wherein the innermost tongue is recessed relative to the outermost tongue. This configuration is particularly advantageous as the board may be secured to an adjacent board with either of its long sides. Thus, allowing the board to form a variety of configurations. Furthermore, in certain embodiments the board configured in this manner improves the thermal properties of the junction, to prevent or minimise any form of water ingress and provide the basis for an arrangement of boards which is less prone to damage in high winds. In a subsidiary aspect, the substrate is at least in part metallic. In a further subsidiary aspect, the substrate is at least in part of wood. In a further subsidiary aspect, the substrate comprises both polymeric material and either metal or wood. In a further subsidiary aspect, the substrate comprising a filler dispersed in a polymeric foam matrix; wherein the outermost tongue comprises both a portion of the outermost covering layer and a portion of the substrate. This provides in certain embodiments an outermost tongue with great mechanical toughness whilst at the same time minimizing the overall weight of the board due to the part porous nature of the substrate. In a further subsidiary aspect, the outermost tongue is thicker than the innermost tongue. This configuration is particularly advantageous as minimising the weight of the structure whilst at the same time providing a more robust structure to withstand wind damage and other weather effects such as high impact or extreme temperature variations. In a further subsidiary aspect, the innermost tongue is recessed relative to the outermost tongue. This is particularly advantageous as it allows the angle between neighbouring planks to be adjusted. There is thus great tolerance and flexibility of use when mounting adjacent planks together. In a further subsidiary aspect, a lateral direction extends at least in part between the longitudinal sides of the board, the outermost tongue incorporates troughs which extend in the perimeter region principally in the lateral direction. This is particularly advantageous in terms of break the surface tension in any liquid which could be otherwise drawn up between adjacent planks. This also causes the liquid to remain in the outermost surface of the boards and drip back down naturally under gravity without reaching the inner portion of the boards. In a further subsidiary aspect, a longitudinal direction extends at least in part between the short sides of the board, the outermost tongue incorporates troughs which extend in the perimeter region principally in the longitudinal direction. In this configuration, the drainage is improved when the board is secured vertically instead of horizontally. In a further subsidiary aspect, the groove incorporates a further recessed portion located at an innermost location of the groove and which is smaller than the outermost tongue; wherein the further recessed portion remains unoccupied by an outermost tongue of the further board when it is inserted into the board. This configuration provide a break on the inside of the groove to prevent liquid entering and remaining behind the board. Instead, any droplets are channelled away or preferably drip down the front face of the cladding or siding arrangement. In a further subsidiary aspect, the portion of the outermost layer of the outermost tongue is more flexible than the portion of the substrate of the outermost tongue. As an optional configuration, this may provide a tighter friction fit between adjacent boards. In a further broad independent aspect, the wall panelling arrangement comprises at least three boards in accordance with any of the preceding aspects, wherein the arrangement comprises a succession of at least a first board, a second board and a third board; the first board being disposed at a lower most portion, the second board engaging the first board by inserting the innermost tongue of the second board into at least part of the groove of the upper portion of the first board; the third board engaging the second board by inserting the innermost tongue of the lower portion of the third board into at least part of the groove of the upper portion of the second board. This configuration provides a series of overlapping portions which minimize any water ingress, improve the thermal properties of the connection area between adjacent boards and allow the boards to attached to one another in a versatile manner. In a further subsidiary aspect, the wall panelling arrangement comprises at least three boards in accordance with any of the preceding aspects, wherein the arrangement comprises a succession of at least a first board, a second board and a third board; the first board being disposed adjacent to a second board, the second board engaging the first board by inserting the outermost tongue of a first board into the first groove of the second board; the third board engaging the second board by inserting an outermost tongue of the third board into a second groove of the second board. This configuration is particularly advantageous to allow the board in a particular embodiment to be secure vertically and in a configuration where the entirety of one board protrudes further than two neighbouring boards whilst still benefiting from the weather improvements and the thermal advantages described with respect to other aspects. In a further subsidiary aspect, the wall panelling arrangement comprises at least three boards in accordance with any of preceding claims, wherein the arrangement comprises a succession of at least a first board, a second board and a third board; the first board being disposed on a first side of the second board; the first and second boards being attached together by virtue of a first connector; the third board being attached to the second board by virtue of a second connector; the connectors having respectively first and second tongues which fit into the grooves of the respective boards. This configuration allows adjacent boards to be level with respect to one another if so desired for certain mounting projects. Brief description of the figures Figure 1 shows a perspective view of a comer portion of a wall panelling board in accordance with a first embodiment of the invention. Figure 2 shows a cross-sectional view of a board or plank suitable for cladding or siding with an outermost layer with a relief in accordance with a further embodiment of the invention. Figure 3 shows a cross-sectional view of a board or plank suitable for cladding or siding in accordance with a further embodiment of the invention. Figure 4 shows a perspective view of a wall panelling arrangement with the panels or boards extending in the X direction and being stacked or mounted vertically on top of one another in the Y direction. Figure 5 shows a side view of a wall panelling arrangement with the panels or boards extending in the X direction and being stacked vertically on top of one another in the Y direction. Figure 6 shows a perspective top view of a wall panelling arrangement with the panels or boards extending in the Y direction and being fitted side by side along the X direction. Figure 7 shows a top view of a wall panelling arrangement with the panels or boards extending in the Y direction and being fitted side by side along the X direction. Figure 8 shows a side view of a wall panelling arrangement with neighbouring panels secured to one another by connectors. Detailed description of the figures Figure 1 shows a comer region 1 of wall panelling board suitable for cladding and / or siding a wall (not shown). The board has a first short side 2 which is only partially visible in the figure in order to provide further details of the long sides such as long side 3 which is likewise only partially visible. The board is preferably symmetrical about the central longitudinal axis of the board so that long side 3’s shape and configuration is mirrored on the opposite long side of the board. Both long sides of the board incorporate an outermost tongue 4 formed with the perimeter region 5 of the outermost covering layer 6 and a perimeter region 7 of the substrate 8. The perimeter region may be defined as a side region located in preferred embodiments within the dashed line 9. As can be seen in figure 1, the outermost tongue 4 is integral with the substrate. The outermost tongue may thus be of the same material as the rest of the board. The board may be of polymeric material including boards formed in a mould and boards formed through an extrusion process. In alternative embodiments, the boards may be fully or partially formed of wood. In further embodiments, the boards may be fully or partially formed of metal such as aluminium or steel. Optionally, the boards may be a composite of several materials with an outermost covering layer 6 of polymeric material which adheres to a portion of the substrate. Optionally, the boards may be a composite of several materials with an outermost covering layer of painted aluminium and a substrate of polymeric material. In certain embodiments in accordance with any of the configurations of the boards envisaged in this description, In certain embodiments, the outermost tongue has an outermost surface with a relief of peak and troughs. In alternative embodiments, the outermost tongue has a relatively smooth surface. For simplicity of presentation, the troughs 10 are represented by an irregular line. In alternative embodiments, the troughs may be formed between two square edges defining any appropriate regular geometric shape. The troughs 10 may serve to break the surface tension in liquid and encourage liquid to drain down from the plank rather than being drawn up between the planks. This provision is particularly advantageous to minimise and prevent water ingress from an outside environment through to the building on which the cladding or siding may be provided. Furthermore, the properties of the outermost layer may advantageously differ from the properties of the substrate. In one embodiment, the outermost layer may be harder than the substrate. In a preferred embodiment, the perimeter region is more flexible than the substrate in order to improve the fit between adjacent boards. In certain embodiments, the outermost layer may be formed primarily as an elastomer. The long sides each further incorporate a groove 11 adjacent to the outermost tongue 4 which is sized and shaped to receive the outermost tongue of a further wall panelling board when, mounted side by side. The long sides each further incorporate an innermost tongue 12 formed entirely in the substrate and against which the outermost tongue of a further wall panelling board abuts, when, mounted side by side. In a preferred embodiment, the thickness of the outermost tongue 4 is at least twice the thickness of the innermost tongue. In a further subsidiary aspect, the thickness of the outermost tongue 4 is at least three times the thickness of the innermost tongue. The innermost tongue may also be recessed relative to the outermost tongue in the lateral direction of the board. The length of the outermost tongue may therefore be greater than the length of the innermost tongue in the lateral direction. The groove 11 incorporates a further recessed portion 13 located at an innermost location of the groove and which is smaller than the outermost tongue 4 allowing it to remain unoccupied by an outermost tongue of a further board when it is inserted into the board. This recessed portion 13 forms a longitudinal channel which may run the entire length of the long sides of the board allowing unwanted water to drain away as it contributes to breaking the surface tension and any such pressure which can, otherwise, cause water to travel up the junction between adjacent boards. In preferred embodiments, the entirety of the outermost surface of the board has a relief which may resemble natural wood grains. However, in addition, the outermost surface may be further shaped for improved sealing between adjacent boards. Furthermore, the perimeter region, for example, the region located between dashed line 9 and the lateral edge of the board may not only have troughs in the lateral direction but also in the longitudinal direction of the board. Dependent upon the orientation of the installation of the boards, one orientation will be preferred to the other in terms of breaking up surface tension in water and in facilitating the flow of water to avoid and minimize undesirable water ingress. These troughs may be angled to provide break lines in any direction in order to encourage any droplets to be in effect subjected to gravity and drip off the outside surface of the boards. In a further embodiment, only the region located between the dashed line 9 and the lateral edge of the board incorporates a strip of polymeric material whereas the rest of the outermost face of the board presents a metallic or wooden surface and / or substrate. In a further embodiment, both the region located between the dashed line 9 and the lateral edge of the board and the exposed outermost surface of the board is of either metal or wood. The board may be shaped from wood or extruded in metal or plastics material. In alternative embodiments, the boards may incorporate a combination of plastics and wood or plastics and metal as appropriate. In a further embodiment, the board or a part thereof may be moulded as one piece with the substrate comprising a filler dispersed in a polymeric foam matrix. The polymeric matrix may be formed from monomers, wherein at least one of the monomers is a polyol. The polymeric foam matrix may be blown polyurethane with appropriate filler including fire retardants. Figures 2 and 3 show respectively the two opposite side configurations as symmetrical. For ease of reference, the following features and numerical references are provided: • Outermost tongue 4; • Outermost covering layer 6; • Perimeter region 7; • Substrate 8; • Trough 10; • Groove 11; • Innermost tongue 12; • Further recessed portion 13 (or longitudinal channel 13); • Peak 14. Figure 2 shows an outermost covering layer with a pronounced relief. Figure 3 shows an embodiment where the board is formed primarily from a single piece of wood or metal without any peaks and troughs in the uppermost surface. In other embodiments, peaks and troughs may form a relief in wood based or metal based boards of this kind. Figures 4 and 5 show a wall panelling arrangement comprising three boards in accordance with any of the preceding aspects. The arrangement comprises a succession of at least a first board 15, a second board 16 and a third board 17. The first board 15 is disposed at a lower most portion, the second board 16 engaging the first board by inserting the innermost tongue 19 of the lower portion of the second board into at least part of the groove 20 of the upper portion of the first board; the third board 17 engaging the second board by inserting the innermost tongue 18 of the lower portion of the third board into at least part of the groove 33 of the upper portion of the second board. The upper portion of the first board 15 also comprises an outermost tongue 34 which is located in the groove of the lower portion of the second board whilst the upper portion of the second board 16 also has an outermost tongue 35 which is located in the groove of the lower portion of the third board 17. In this configuration, the grooves 20 and 33 (see figure 5) of the upper portions of the boards are occupied only by the innermost tongue of a neighbouring board whilst the grooves of the lower portions of the second and third boards are fully occupied by the outermost tongues 34 and 35. This configuration is particularly advantageous to allow small adjustments of the angle between adjacent boards which increases the versatility of the board as it may be suited for covering surfaces with geometric variations whilst at the same time providing an advantageous barrier against water ingress through the arrangement. The unoccupied channels also serve to direct any droplets of water which may be present therein. Furthermore, at the junction regions between neighbouring boards, the outermost tongues overlap one another and provide a region of considerable thickness of solid material which improves the thermal properties of this region. Figures 6 and 7 show a wall panelling arrangement comprising at least three boards in accordance with any of the preceding aspects, wherein the arrangement comprises a succession of at least a first board 21, a second board 22 and a third board 23; the first board 21 being disposed adjacent to a second board 22, the second board engaging the first board by inserting the outermost tongue 24 of a first board into the first groove of the second board; the third board engaging the second board 22 by inserting an outermost tongue 25 of the third board 23 into a second groove of the second board. This configuration is particularly advantageous for mounting the boards in the vertical direction with the boards located adjacent to one another in the X direction. This also provides particularly robust junction regions which have advantageous thermal properties. Figure 8 shows a wall panelling arrangement comprising at least three boards in accordance with any of the preceding aspects, wherein the arrangement comprises a succession of at least a first board 26, a second board 27 and a third board 28; the first board 26 being disposed on a first side of the second board 27; the first 26 and second boards 27 being attached together by virtue of a first connector 29; the third board 28 being attached to the second board 27 by virtue of a second connector 30; the connectors having respectively first and second tongues 31 and 32 which fit into the grooves of the respective boards. The connectors may take the form of a T-shaped body with two tongues 31 and 32 which are sized and shaped to fit into correspondingly shaped grooves in adjacent boards.

Claims

1. A wall panelling board suitable for cladding and / or siding a wall comprising:a substrate;an outermost surface;wherein the board is substantially rectangular in plan view, the board having two oppositely disposed relatively long sides and two oppositely disposed relatively short sides; the long sides each incorporating an outermost tongue formed with the perimeter region of the outermost covering layer and a perimeter region of the substrate; the long sides each further incorporating a groove adjacent to the outermost tongue; the groove being sized and shaped to receive the outermost tongue of a further wall panelling board when, mounted side by side; wherein the groove comprises a main groove portion and a further recessed portion located at an innermost location of the main groove portion, wherein the further recessed portion is narrower than the outermost tongue; whereby, when the outermost tongue of a further wall panelling board is inserted into the groove, the outermost tongue abuts a shoulder formed at a transition between the main groove portion and the further recessed portion and straddles the further recessed portion, leaving it unoccupied.

2. The wall panelling board of claim 1, wherein the substrate is at least in part metallic.

3. The wall panelling board of either claim 1 or claim 2, wherein the substrate is at least in part of wood.

4. The wall panelling board of either claim 2 or claim 3, wherein the substrate comprises both polymeric material and either metal or wood.

5. The wall panelling board of any one of the preceding claims, where the substrate comprising a filler dispersed in a polymeric foam matrix; wherein the outermost tongue comprises both a portion of the outermost covering layer and a portion of the substrate.

6. The wall panelling board of any one of the preceding claims, wherein a lateral direction extends at least in part between the longitudinal sides of the board, the outermost19 03 26tongue incorporates troughs which extend in the perimeter region principally in the lateral direction.

7. The wall panelling of any one of claims 1 to 4, wherein a longitudinal direction extends at least in part between the short sides of the board, the outermost tongue incorporates troughs which extend in the perimeter region principally in the longitudinal direction.

8. The wall panelling board in accordance with any of the preceding claims, wherein a portion of the outermost layer of the outermost tongue is more flexible than a portion of the substrate of the outermost tongue.

9. A wall panelling arrangement comprising at least three boards in accordance with any of the preceding claims, wherein the arrangement comprises a succession of at least a first board, a second board and a third board; the first board being disposed at a lower most portion, the second board engaging the first board by inserting the innermost tongue of the lower portion of the second board into at least part of the groove of the upper portion of the first board; the third board engaging the second board by inserting the innermost tongue of the lower portion of the third board into at least part of the groove of the upper portion of the second board.

10. A wall panelling arrangement comprising at least three boards in accordance with any of claims 1 to 8, wherein the arrangement comprises a succession of at least a first board, a second board and a third board; the first board being disposed adjacent to a second board, the second board engaging the first board by inserting the outermost tongue of a first board into the first groove of the second board; the third board engaging the second board by inserting an outermost tongue of the third board into a second groove of the second board.

11. A wall panelling arrangement comprising at least three boards in accordance with any of claims 1 to 8, wherein the arrangement comprises a succession of at least a first board, a second board and a third board; the first board being disposed on a first side of the second board; the first and second boards being attached together by virtue of a first connector; the third board being attached to the second board by virtue of a secondconnector; the connectors having respectively first and second tongues which fit into the grooves of the respective boards.19 03 26

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