GB2561908B

GB2561908B - Method for mounting wall panels & wall panel system

Info

Publication number: GB2561908B
Application number: GB1706840.4A
Authority: GB
Inventors: Coulson Gordon; Fleet Robert
Original assignee: RECO SURFACES Ltd
Current assignee: RECO SURFACES Ltd
Priority date: 2017-04-28
Filing date: 2017-04-28
Publication date: 2019-09-25
Anticipated expiration: 2037-04-28
Also published as: GB2561908A; GB201706840D0

Description

METHOD FOR MOUNTING WALL PANELS & WALL PANEL SYSTEM

The present invention relates to a method for mounting wall panels and a wall panel system. For example, the invention has particular utility in the context of wet environments such as bathrooms and kitchens.

Achieving a watertight seal is very important for wet environments such as bathrooms and kitchens, however it can be difficult to mount wall panels on to a surface in a manner that produces a high quality watertight seal at the edges of panels. Furthermore, it is necessary to maintain the seal for a long period of time. As time goes by sealant often becomes separated from wall panels due to flexing of wall panels, for example with building movement/settlement, when a user leans on them, or when panels bow in the vicinity of the seal. Another problem is that sealant applied into a gap between wall panels is easily removed by cleaning e.g. rubbing. Especially if excess sealant is not removed immediately after sealing. Sometimes people pick at the sealant. Once a small amount of sealant protrudes, it is easily stripped out of its seating, leaving the wall exposed to moisture. This is highly undesirable.

Wall panels can comprise flat sheets, for example of a plastics material, or can have a pattern of tiles formed therein. Typically a plurality of such sheets is required to cover a section of wall. However a problem with conventional wall panels is that when a pair of panels is located side by side such that their edges abut one another, a distinct joining line is clearly visible. This is particularly true if all or part of an edge protrudes above the adjacent edge. This may be due to more adhesive or sealant behind the panel edge or to a variation in the wall surface. If the difference in height is greater than the thickness of print design or colour on a white or other coloured substrate, that substrate colour becomes visible and highlights the join. Traditional solutions to hide or disguise this joining line include using a separate joining profile such as a slotted elongate connector member. The connector member successfully hides the joining line however it is much more clearly visible than the joining line itself and therefore it is clear where the separate panels are located. Accordingly it is desirable to have a wall panel system that provides a substantially seamless appearance to a casual observer.

The present invention seeks to mitigate at least one of the problems mentioned above, or at least to provide an alternative method for mounting wall panels and a wall panel system from known methods and systems.

According to one aspect of the invention there is provided a method for mounting plastics wall panels to a surface, such as a wall, including providing a first plastics wall panel having a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the profiled first edge; mounting the first plastics wall panel to the surface such that the recessed surface presents an undercut void on an inner side of the first plastics wall panel; and applying settable sealant to the profiled first edge such that some of the sealant bonds to the recessed surface.

The inner side of the first plastics wall panel faces generally towards the wall, when mounted thereon. The sealant substantially fills the undercut void. The invention enables wall panels to be sealed together in a manner that makes it very difficult for the set sealant to be removed from the joint. This is because the undercut void ensures that the width of the set sealant is wider than a minimum gap between adjacent wall panels. Also the surface area of the undercut edge is greater than a conventional square edge, which provides a strong bond between the sealant and the panel. Thus it is very difficult for a person to prise the sealant through the joint. The invention provides a very simple and effective solution to the sealant removal problem.

The method can include providing a second plastics wall panel having a first edge, and mounting the second plastics wall panel to the wall. The second plastics wall panel is mounted on to the wall such that first edge of the second plastics wall panel is arranged substantially parallel to the first edge of the first plastics wall panel. The profiled first edge of the first plastics wall panel is spaced apart from the first edge of the second plastics wall panel. A gap between the first edge of the first plastics wall panel and the first edge of the second plastics wall panel is typically greater than or equal to 0.5mm, preferably greater than or equal to 0.6mm, more preferably greater than or equal to 0.8mm, and more preferably still greater than or equal to 1mm. The gap is typically less than or equal to 4mm, preferably less than or equal to 3.5mm, more preferably less than or equal to 3mm, and more preferably still less than or equal to 2.5mm.

In preferred methods the first edge of the second plastics wall panel is a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the profiled first edge; and mounting the second plastics wall panel to the wall such that the recessed surface presents an undercut void on an inner side of the second plastics wall panel; and applying settable sealant to the profiled first edge of the second plastics wall panel such that some of the sealant bonds to the recessed surface. Advantageously the recessed surfaces of the first and second plastics wall panels face generally towards one another.

The or each recessed surface can comprise a chamfered surface or a bevelled surface. In embodiments wherein the recessed surface of each of the first and second panels is chamfered or bevelled, the recessed surfaces together present a substantially trapezoidal undercut void, which is substantially filled with sealant. This shape of recess is easy to manufacture and provides an effective grip on the sealant.

In preferred methods the or each chamfered or bevelled surface subtends an angle of around 10 to 50 degrees with respect to a reference line that is arranged substantially parallel with an inner major surface of the wall panel, preferably subtends an angle of around 20 to 40 degrees with the reference line, and more preferably subtends an angle of around 25 to 35 degrees with the reference line.

In preferred methods the profiled first edge of at least one of the first and second plastics wall panels can include a second recessed surface extending along at least a part of the length of the profiled first edge. The method can include mounting the first plastics wall panel to the surface such that the second recessed surface presents an undercut void on an outer side of the first plastics wall panel. The second recessed surface can comprise a chamfered or bevelled surface. The chamfered or bevelled surface subtends an angle of around 10 to 50 degrees with respect to a reference line that is arranged substantially parallel with an outer major surface of the wall panel, preferably subtends an angle of around 20 to 40 degrees with the reference line, and more preferably subtends an angle of around 25 to 35 degrees with the reference line.

In some methods the or each recessed surface comprises a concave or a convex surface.

In preferred methods the or each profiled first edge is a longitudinal edge of the wall panel.

In preferred methods the recessed surface extends along substantially the full length of the profiled first edge.

In preferred methods the first panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the first plastics wall panel. The method can include applying settable sealant to the profiled second edge of the first plastics wall panel such that some of the sealant bonds to the recessed surface.

In preferred methods the profiled second edge is arranged opposite to the profiled first edge. This enables a third wall panel to be mounted adjacent to the first plastics wall panel, on a side of the first plastics wall panel opposite to that which is adjacent the second plastics wall panel. Preferably the profiled second edge is a longitudinal edge. Alternatively, the profiled second edge can be arranged substantially perpendicularly to the profiled first edge. In some embodiments the profiled second edge is a transverse edge. Preferably the recessed surface extends along substantially the full length of the profiled second edge.

In preferred methods the second plastics wall panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the second plastics wall panel. The method can include applying settable sealant to the profiled second edge of the first plastics wall panel such that some of the sealant bonds to the recessed surface. The second profiled edge can include a second recessed surface. The second recessed surface can be arranged similarly to the second recessed surface of the profiled first edge.

In preferred methods the profiled second edge is arranged opposite to the profiled first edge. This enables a fourth wall panel to be mounted adjacent to the second plastics wall panel, on a side of the second plastics wall panel opposite to that which is adjacent the first plastics wall panel. Preferably the profiled second edge is a longitudinal edge.

Alternatively, the profiled second edge can be arranged substantially perpendicularly to the profiled first edge. In some embodiments the profiled second edge is a transverse edge. Preferably the recessed surface extends along substantially the full length of the profiled second edge.

In preferred methods at least one further edge of at least one of the first and second plastics wall panels comprises a profiled edge having a recessed surface extending along at least a part of the length of the profiled edge; wherein the recessed surface of the profiled edge presents an undercut void on an inner side of the wall panel. For example, the at least one further edge can comprise a transverse edge or a longitudinal edge. Preferably each wall panel includes first and second profiled transverse edges. Preferably each of the first and second profiled transverse edges is profiled similarly to the first and/or profiled second edges. The at least one additional profiled edge can include a second recessed surface. The second recessed surface can be arranged similarly to the second recessed surface of the profiled first edge.

In preferred methods at least one of the first and second plastics wall panels comprises a moulded plastics wall panel. Preferably at least one of the first and second plastics wall panels is manufactured by way of a vacuum forming process.

In preferred methods at least one of the first and second plastics wall panels comprises a tile effect wall panel. Preferably at least one of the first and second plastics wall panels has a first major surface having a pattern of channels formed therein, said pattern of channels defining an arrangement of tile-like areas in the first major surface.

In preferred methods at least one of the first and second plastics wall panels comprises a substantially planar wall panel.

In preferred methods as least one of the first and second plastics wall panels is substantially rectangular in plan. That is, at least one, and preferably each, of the first and second panels has substantially rectangular major outer surface.

The method can include attaching at least one of the first and second plastics wall panels to the wall by means of plurality of vertical or horizontal beads of adhesive. In preferred embodiments the beads of adhesive are spaced around 80mm apart. In preferred embodiments a first bead is arranged around 40mm from the profiled first edge. In preferred embodiments each bead of adhesive is around 6 to 8mm wide.

The method can include attaching at least one portion of double sided adhesive tape or film onto the surface; mounting the first plastics wall panel onto the surface such that the profiled first edge overlies the double sided adhesive tape or film; applying sealant to at least one of the double sided adhesive tape or film and the profiled first edge of the first plastics wall panel; mounting the second plastics wall panel onto the surface such that the profiled first edge overlies the double sided adhesive tape or film, the arrangement being such that the profiled first edge of the second plastics wall panel is located adjacent to, and substantially parallel with, the profiled first edge of the first plastics wall panel. This mounting arrangement helps to provide a watertight seal since the tape helps to ensure that edge portions of the first and second plastics wall panels are bonded tightly to the wall, and therefore do not warp over time.

In some methods at least one, and preferably each, of first and second plastics wall panels, has a first major surface having a pattern of channels formed therein, said pattern of channels defining an arrangement of tile-like areas in the first major surface, a second major surface located substantially opposite to the first major surface. The method can include mounting the first plastics wall panel onto the surface; applying sealant to the profiled first edge; mounting the second plastics wall panel onto the surface, the arrangement being such that an edge of the second plastics wall panel is located adjacent to, and substantially parallel with, the profiled first edge of the first plastics wall panel. The arrangement is such that a peripheral portion of the first major surface for the first plastics wall panel and a peripheral portion of the first major surface of the second plastics wall panel are each arranged such that when the first and second plastics wall panels are positioned side by side said peripheral portions define a channel that is substantially similar to at least one of the other channels.

The or each peripheral portion of the first major surface includes a partial channel formation, which can include at least one longitudinal side wall of a channel. Having a partial channel formation at a peripheral portion of the first major surface enables first and second plastics wall panels to be abutted together so that their partial channel formations form a shape that is similar to at least one of the channels in the major surface. This provides a visual impression to a casual viewer of a substantially continuous surface where the two wall panels join.

Advantageously the longitudinal side wall of the partial channel formation can include a curved profile. Advantageously the curved profile can include a substantially convex portion. For example, the longitudinal side wall can include a curved bevelled portion.

Advantageously the or each partial channel formation can comprise substantially one half of a channel. Having one half of a channel ensures that no special matching of sides is required when mounting wall panels. However it will be appreciated by the skilled person that the partial channels can be formed complementary by having different proportions of a channel. That is, the partial channel formation can be formed using a non-central longitudinal channel axis such that greater, or less than, 50% of the channel is included in the formation. For example, in pairs of complementary formations, one of the formations can have approximately 40% of the channel and the other formation can have approximately 60%, or any other suitable combination such as 45% and 55%, 30% and 70%.

Each of the channels can include first and second longitudinal side walls. Advantageously at least one of the first and second side walls, and preferably both of the side walls, can include a curved profile. This is particularly evident when viewed in transverse crosssection. Advantageously the curved profile can include a substantially convex portion. This provides the tile-like areas with rounded edges, which helps to provide an easy to clean surface, thereby reducing the build-up of dirt and bacteria on the panel. For example, the longitudinal side walls can include curved bevelled portions.

Advantageously at least some of the side walls blend into an adjacent tile-like area.

At least some of the channels can include a base. Advantageously the base can be substantially concave. This is particularly evident when viewed in transverse cross-section.

Advantageously the width of the or each channel can be greater in the vicinity of a longitudinal channel opening than at the channel base. This helps to visually hide the seams between two panels. In particular, arranging each of the channels in the following manner provides very good results for hiding seams: each channel includes a base, longitudinal side walls, and a longitudinal opening defined by the longitudinal side walls, wherein the longitudinal side walls include substantially convex curved portions, the arrangement being such that the base is narrower than longitudinal opening.

Advantageously the wall panel can include sheet material. The wall panel can be made from a single sheet of material. The wall panel is moulded, and is preferably moulded by a vacuum forming process. Other techniques such as hot or cold forming can be used. Since the panel is moulded the channels formed comprise a continuous smooth surface, which is good for hygiene purposes since it is easier to clean and reduces the ability of dirt and bacteria from gripping the surface. This feature is particularly effective when used in conjunction with channels having curved side walls and/or a curved base. For many prior art tile effect boards, the channels are formed by routing a parallel groove. This leaves vertical sides and can also leave a rough surface in the groove, which causes dirt to accumulate and makes the board more difficult to clean. The tile edges produced by routing tend to be sharper, and the channel walls flat, which also makes it more difficult to remove dirt.

Advantageously wall panel is made from, or includes, a water impervious material. Typically the sheet material can include a plastics material such as ABS, acrylic, acryliccapped ABS (sanitary grade), High Impact Styrene (HPS), Polypropylene (PP), Polyethylene (PE), Polyvinylchloride (PVC), polycarbonate, or any other vacuum formable plastics material. These materials are easy to cut, for example to fit into comers of a room.

The method can include providing at least one further wall panel. The at least one further wall panel can be arranged similarly to at least one of the first and second plastics wall panels.

According to another aspect of the invention there is provided a wall panel system, including a first plastics wall panel for covering at least part of a wall surface, said first plastics wall panel having a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the profiled first edge, said recessed surface arranged to present an undercut void on an inner side of the first plastics wall panel in a mounted condition, wherein the profiled first edge includes a second recessed surface extending along at least a part of the length of the profiled first edge, wherein the second recessed surface presents an undercut void on an outer side of the first plastics wall panel in a mounted condition..

The system can include a second plastics wall panel having a first edge.

In preferred embodiments the first edge of the second plastics wall panel is a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the profiled first edge; said recessed surface is arranged to present an undercut void on an inner side of the second plastics wall panel, said inner side facing generally towards a wall in a mounted condition.

In preferred embodiments the or each recessed surface comprises a chamfered surface or a bevelled surface.

In preferred embodiments the or each chamfered or bevelled surface subtends an angle of around 10 to 50 degrees with respect to a reference line that is arranged substantially parallel with an inner major surface of the wall panel, preferably subtends an angle of around 20 to 40 degrees with the reference line, and more preferably subtends an angle of around 25 to 35 degrees with the reference line.

In preferred embodiments the profiled first edge in the second plastics wall panel can include a second recessed surface extending along at least a part of the length of the profiled first edge. The second recessed surface is arranged opposite to the first recessed surface. When the wall panel is in a mounted condition, the second recessed surface presents an undercut void on an outer side of the first plastics wall panel. The second recessed surface can comprise a chamfered or bevelled surface. The chamfered or bevelled surface subtends an angle of around 10 to 50 degrees with respect to a reference line that is arranged substantially parallel with an outer major surface of the wall panel, preferably subtends an angle of around 20 to 40 degrees with the reference line, and more preferably subtends an angle of around 25 to 35 degrees with the reference line.

For thinner sheets, say having a thickness less than 2 mm, the chamfered or bevelled angle is typically towards the lower end of the range in order to preserve the thickness of the planar surface and avoid the risk of one edge riding up over the other, when positioning the panels.

In preferred embodiments the or each recessed surface comprises a concave or a convex surface.

In preferred embodiments the or each profiled first edge is a longitudinal edge of the wall panel.

In preferred embodiments the recessed surface extends along substantially the full length of the profiled first edge.

In preferred embodiments the first panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the first plastics wall panel.

In preferred embodiments the profiled second edge is arranged opposite to the profiled first edge.

In preferred embodiments the second panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the second plastics wall panel. The second profiled edge can include a second recessed surface. The second recessed surface can be arranged similarly to the second recessed surface of the profiled first edge.

In preferred embodiments at least one further edge of at least one of the first and second plastics wall panels comprises a profiled edge having a recessed surface extending along at least a part of the length of the profiled edge; wherein the recessed surface of the profiled edge presents an undercut void on an inner side of the wall panel. The at least one further profiled edge can include a second recessed surface. The second recessed surface can be arranged similarly to the second recessed surface of the profiled first edge.

In preferred embodiments at least one of the first and second plastics wall panels comprises a moulded plastics wall panel.

In preferred embodiments at least one of the first and second plastics wall panels comprises a tile effect wall panel.

In preferred embodiments wherein at least one of the first and second plastics wall panels comprises a substantially planar wall panel.

In preferred embodiments as least one of the first and second plastics wall panels is substantially rectangular in plan. That is, at least one, and preferably each, of the first and second panels has substantially rectangular major outer surface.

The system preferably includes a settable sealant is for applying to at least one of the recessed surfaces. The settable sealant preferably comprises a silicone or acrylic sealant, however alternatives such as MS modified polyether and one or two part polyurethane may be used.

The recessed surface assists the accuracy of positioning a nozzle of the sealant gun. This also assists the flow of sealant onto on to other parts of the profiled edge, particularly the surface facing directly towards an adjacent wall panel and into the undercut.

The system preferably includes at least one portion of double-sided adhesive tape or film. Typically this is used to provide water resistant joints.

In preferred embodiments the double-sided tape or film has a static shear adhesion at 23°C lkg/625mm2 of at least 4000 minutes, preferably at least 4500 minutes and more preferably still of at least 5000 minutes.

In preferred embodiments the double-sided tape or film has a static shear adhesion at 70°C 0.5kg/625mm2 of at least 500 minutes, preferably at least 550 minutes, and more preferably still at least 600 minutes.

In preferred embodiments the double-sided tape or film has a tack AFERA 4015 characteristic of at least 3.0N/25mm, preferably at least 3.5N/25mm and more preferably still at least 4.0N/25mm.

In preferred embodiments the system includes at least one further wall panel. The at least one further wall panel can be arranged similarly to at least one of the first and second plastics wall panels.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is an enlarged cross-sectional view of a of part of a first wall panel in accordance with a first embodiment of the invention;

Figure 2 is a cross-sectional view of a part of the wall panel of Figure 1;

Figure 3 is a cross-sectional view similar to Figure 2 with sealant applied to an edge of the first wall panel;

Figure 4 is a transverse cross-sectional view similar to Figure 3 with a second wall panel located adjacent the first wall panel;

Figure 5 is an enlarged cross-sectional view of a sealed joint of the first and second wall panels;

Figures 6 is a diagrammatic plan view of four tiled wall panels mounted on to a wall;

Figure 7 is an enlarged cross-sectional view of a of part of a first wall panel in accordance with a second embodiment of the invention;

Figure 8 is a cross-sectional view of a part of the wall panel of Figure 7;

Figure 9 is a cross-sectional view similar to Figure 8 with sealant applied to an edge of the first wall panel;

Figure 10 is a transverse cross-sectional view similar to Figure 9 with a second wall panel located adjacent the first wall panel; and

Figure 11 is an enlarged transverse cross-sectional view of a sealed joint of the first and second wall panels.

Figure 1 shows a cross-section of part of a wall panel 1 in accordance with the invention.

The wall panel 1 comprises a sheet of a plastics material that has been vacuum formed to provide the sheet with a tile-like 5 formations on a major outer surface 7, which faces outwardly when the panel is mounted on a wall 23. This is best seen in Figure 6, which shows an array of four wall panels 1 mounted on to a wall. Typically the sheet comprises ABS, acrylic or other similar plastics material, such as acrylic-capped ABS (sanitary grade), High Impact Styrene (HPS), Polypropylene (PP), Polyethylene (PE), Polyvinylchloride (PVC), polycarbonate, or any other vacuum formable plastics material, and has a substantially uniform thickness PT of at least 0.5mm, and preferably in the range 1mm to 4mm. In the example shown in Figure 1, the panel has a thickness PT of 1.5 mm. plastics material such as ABS, acrylic, acrylic-capped ABS (sanitary grade), High Impact Styrene (HPS), Polypropylene (PP), Polyethylene (PE), Polyvinylchloride (PVC), polycarbonate, or any other vacuum formable plastics material.

Using moulded plastics panels is very hygienic since it is easy to wipe the surface clean, for example dirt does not accumulate in grooves 9a,9b.

Typically the wall panel 1 is substantially rectangular in plan, however other shapes, such as triangles, hexagons, and pentagons are possible. The wall panel 1 has two longitudinal side edges 15,17 and two transverse edges 19,21. Each edge 15,17,19,21 is profiled in the manner illustrated in Figure 1. The edge has an outer planar surface 30 and a recessed surface 32. The recessed surface 32 is formed on an inner side of the wall panel, which faces generally towards the wall in use. The recessed surface 32 runs along substantially the full length of the edge 15,17,19,21. The recessed surface 32 is in the form of a chamfer. The recessed surface 32 subtends an angle a with respect to a reference line 34 that is arranged substantially parallel with a major surface of the wall panel 1 (see Figure 1), this is generally parallel to the surface of the wall, wherein a is typically in the range 10° to 50°, and is preferably around 20-30°. The panel edge thickness (PET?) is preferably around 1mm.

When the panel 1 is mounted on to the wall, each recessed surface 32 provides an undercut void along the edge.

The vacuum forming process forms an arrangement of grooves 9a,9b in the sheet. The grooves 9a,9b are formed such that they indent the major outer surface 7 and form ribs 11 in a major inner surface 13, with recesses 14 therebetween. The major inner surface 13 faces towards the wall 23 when the panel is mounted on the wall. The depth of the indentation can be selected according to the thickness of the sheet and to provide the overall desired visual effect wall panel 1. For a sheet having a thickness of around 2mm it is preferred to form grooves 9 having a depth of around 1mm. This provides an overall wall panel depth of around 3mm, measured from the major outer surface 5 to tips of the ribs 11.

Typically the width of each groove 9a,9b towards its base is around 1mm. The width of each groove 9 a,9b towards its opening is around 2mm.

Typically the arrangement of grooves 9a,9b, and hence ribs 11, define substantially rectangular tile-like formations 5. The tile-like formations 5 are preferably arranged in an array. For example, the wall panel 1 in Figure 6 has a 4 x 4 array of rectangular tile-like formations 5 in each wall panel 1. It will be apparent to the skilled person that the array can have any practicable arrangement. Typically the array will include n columns of tilelike formations 5, where n is in the range 1 to 10, and m rows where m is in the range 1 to 10. However the wall panel 1 may include significantly more tile-like formations 5 than this, for example when providing a mosaic tile-like effect.

The grooves 9a,9b are arranged to include a first set of grooves 9a, wherein each groove 9a in the set is arranged substantially parallel to one another, and a second set of grooves 9b, wherein each groove 9b is arranged substantially perpendicularly to the first set of grooves 9a. That is, the first and second sets of grooves 9a,9b are arranged in the form of a grid.

The first set of grooves 9a is arranged substantially parallel to longitudinal edges 15,17 of the wall panel 1. The second set of grooves 9b is arranged substantially parallel to transverse edges 19,21 of the wall panel 1.

The sides of each groove 9a,9b are defined by convex curvatures 7 that curve downwards from the tile-like formations 5 towards the base of the groove 9a,9b. The base of the groove 9a,9b is defined by a concave curvature 10, which joins the convex curvatures 7 together. The upper ends of the convex curvatures 7 blend into adjacent tile-like formations 5. The lower ends of the convex curvatures 7 blend into the concave base 10.

The maximum width of the grooves 9a,9b in the example shown in Figure 1 is around 4mm. The minimum width is around 1mm. Preferably the width to depth ratio of the grooves 9a,9b is around 1:4. Preferably each convex curvature 7 has a cross-sectional radius of around 1mm.

Portions of the panel 1 adjacent each of the edges 15,17,19,21 is formed by the vacuum forming process to be shaped similar to half a groove 9a,9b, when truncated along a longitudinal axis. Thus portions of the panel adjacent each edge 15,17,19,21 comprises one convex side wall 7 and part of the concave base. The effect of this is that when two wall panels 1 are placed side by side so that their sides abut, the two complementary sides 15,17,19,21 form a shape that is approximately the same as a groove 9a,9b (see Figure 5). This provides a visual impression along the joint that approximates to one of the grooves 9a,9b formed across the sheets 3. This makes it difficult for the joint to be detected on a casual inspection thus provides the illusion that two adjacent wall panels are part of a continuous wall panel. Also, the shape of the grooves 9a,9b, in particular having convex side walls helps to hide the location of the joint. This is because the base of the groove 9a,9b, where the joint is located, is narrower than the longitudinal opening. This contributes to the optical effect of making it difficult to see joint. The overall appearance provided by the arrangement of the side walls is that of having curved bevelled edges, which blend into the groove base and the planar part of the tiled area, thereby avoiding sharp edges in the upper surface. A wall panel system in accordance with the invention includes a plurality of wall panels 1, means for attaching the wall panels 1 to the wall, such as double-sided adhesive tape 25 and/or an adhesive 27, and a settable gap filling sealant 29.

The double-sided adhesive tape 25, is typically used when waterproof joints are required. The double-sided adhesive tape 25 is a high-tack, high strength, tape which has been designed to provide a watertight joint, by strongly gripping onto the wall 23 and the panel 1. This is important, since along the edges of the panel 1, where the tape 25 grips the panel 1, only approximately half the width of a rib 11 fully contacts the tape 25. Therefore it is necessary for the tape 25 to have a strong adhesive in order to retain the panel 1 to the wall 23.

The tape 25 includes a carrier layer that is water resistant, which helps to ensure that the joint is watertight. For example, the carrier layer can comprise a plastics material, and is preferably made from Polyester. The adhesive is a high performance solvent acrylic adhesive suitable for demanding applications, giving very good low and elevated temperatures. It has good resistance to chemicals and UV light.

Typical characteristics of the tape are as follows:

Tape thickness APERA 4006: 0.07mm

Colour: Clear

Carrier material: 12 Micron Polyester 180° Peel Adhesion AFERA 4001 10 Min: 10.7 N/25mm 180° Peel adhesion AFERA 4001 24 hrs: 14.2 N/25mm

Dynamic shear adhesion ASTM D-1200 10 mins: 108 N/625mm2

Static shear adhesion 23°C lkg/625mm2: 5500 Minutes

Static shear adhesion 70°C 0.5kg/625mm2: 700 Minutes

Tack AFERA 4015: 4.60N/25mm

Temperature resistance: -30°C to 160°C

The colour of the sealant 29 is selected to substantially match the colour of the wall panels 1. The sealant 29 is typically a silicone or acrylic type sealant, however alternatives such as MS modified polyether and one or two part polyurethane may be used. A method for mounting wall panels 1 to a wall will now be described with reference to Figures 2 to 6. As a preliminary point, some walls 23 require water proof joints, such as bathroom or kitchen walls 23. Other walls 23 do not. The mounting method used is at least in part determined by the type of joint (water proof / non-water proof) required.

In the case of a waterproof joint, the wall panels 1 are typically arranged to provide a substantially waterproof barrier between a water source and the wall 23. In such arrangements, the wall panels 1 are made from a water impervious material and when at least two panels are joined together an appropriate waterproof seal is applied to prevent water ingress into the joint.

When installing wall panels 1 a centreline is marked onto one of the walls 23. The centreline is used as a datum to determine the locations for double sided adhesive tape, according to the wall panel 1 size.

Strips of double-sided adhesive tape 25 are applied to the wall 23 at each site of a waterproof joint between two adjacent wall panels 1. Typically each strip of tape 25 is attached to the wall 23 in a substantially vertical or horizontal orientation.

Vertical beads of adhesive 27 are applied to the inner face of a first wall panel 1. A first bead of adhesive 27, which is typically 3 to 4 mm wide, typically spaced from an adjacent edge AS-E by around 40mm. Successive beads of adhesive 27 are typically spaced AS around 80mm apart. Each successive bead of adhesive 27 has a width or around 6 to 8mm. The first wall panel 1 is mounted on to the wall such that edge portions requiring a waterproof joint are mounted on to respective strips of tape 25. In particular, a partial rib 11 on the major inner surface 13 bonds to the adhesive tape 25. A bead of sealant 29 is placed along each tape 25 and/or along each edge 15,17,19,21 mounted thereon (see Figure 3). The sealant 29 extends along the full length of the edge 15,17,19,21. Sufficient sealant is applied to each edge 15,17,19,21 to bond to the planar surface 30 and the recessed surface 32, thereby substantially filling the undercut void. A second wall panel 1 is prepared for mounting on the wall 23 by applying beads of adhesive 27 in a similar manner to the first wall panel. The second wall panel 1 is mounted on the wall 23 such that one of its edge portions is mounted on the strip of tape 25 (see Figure 4) adjacent an edge 15,17,19,21 of the first wall panel. The second wall panel edge 15,17,19,21 mounted on to the tape 25, causes the bead of sealant 29 to be forced upwards towards the major outer surfaces 7 of the wall panels 1, and downwards into the undercut voids, thereby filling any gaps between the panels. The panels are pressed flat to ensure they are level. The sealant 29 is smoothed off to improve the outer appearance. The adjacent edges are substantially parallel with one another. Typically the adjacent edges are spaced apart PS (panel spacing) by around 0.5mm to 3mm. The spacing is of course filled by the sealant.

When the sealant 29 sets, it prevents the ingress of water into the joint. This together with the tape 25 firmly bonding the side edges 15,17,19,21 to wall, provides a water tight joint.

The process is repeated for each additional wall panel 1 that is required.

If no waterproof joints are required, then it is not necessary to use tape 25. The wall panels can be mounted to the wall 23 using only the beads of adhesive. 27. Sealant may still be applied to fill the gaps between adjacent panels.

The overall effect of the wall panel system can be to provide wall panels where the joins between panels are substantially undetectable by the casual viewer.

Another advantage of the system is that if the installer needs to cut a wall panel 1 to size, provided that he cuts the panel 1 along one of the channels 9a,9b, the overall visual effect is similar to that when placing two preformed panel wall sides together. The size of wall panels used in any installation can be selected from the most appropriate standard sizes available, or where necessary bespoke panels can be formed.

It will be appreciated by the skilled person that the vacuum forming process can form the sides 15,17,19,21 so that some of the sides have a different proportion of the groove from others. For example, some of the sides 15,17,19,21 can have around 60% of the groove when truncated along the longitudinal axis and others can have around 40%. The sides having 40% will be complementary to the sides having 60% such that when complementary sides are abutted together, a whole groove 9a,9b is formed thus giving substantially the same overall impression as when two sides having 50% of a groove are abutted together. A wall panel for use in a domestic bathroom has a length 1, where 1 is typically in the range 500mm to 2500mm, and is preferably around 1250mm, and a width w, where w is typically in the range 500mm to 2500mm, and is preferably around 900mm. A second embodiment is shown in Figures 7 to 11. The second embodiment is similar to the first embodiment, except that instead of the wall panels 1 having a tile effect, the wall panels 101 comprises a substantially planar sheet, having a major outer surface 107, a major inner surface 113 and profiled edges 115,117,119,121. Typically the wall panel 101 is substantially rectangular in plan, however other shapes, such as triangles, hexagons, and pentagons are possible. The wall panel 101 has two longitudinal side edges 115,117 and two transverse edges 119,121. Each edge 115,117,119,121 is profiled in the manner illustrated in Figure 7. The edge has an outer planar surface 130 and an inner recessed surface 132. The inner recessed surface 132 is formed on an inner side of the wall panel, which faces generally towards the wall. The inner recessed surface 132 runs along substantially the full length of the edge 115,117,119,121. The inner recessed surface 132 is in the form of a chamfer. The inner recessed surface 132 subtends an angle a with respect to a reference line 134 that is arranged substantially parallel with a major surface of the wall panel 101 (see Figure 1), this is generally parallel to the surface of the wall 123, wherein a is typically in the range 10° to 50°, and is preferably around 30°. For the example shown in Figure 7, wherein the panel thickness is 2.0mm and a is 30°, the inner chamfer width ICW and inner chamfer depth ICD are approximately 0.9mm and 0.5mm respectively.

For thinner sheets, say having a thickness less than 2 mm, the chamfered angles a and β are typically towards the lower end of the range in order to preserve the thickness of the planar surface 130 and to avoid the risk of one edge riding up over the other, when positioning the panels.

Each profiled edge also includes an outer recessed surface 136. The outer recessed surface 136 extends along a full length of each edge 115,117,119,121, and typically comprises a chamfer. The inner recessed surface 136 subtends an angle β with respect to a reference line 136 that is arranged substantially parallel with the outer major surface 113 of the wall panel (see Figure 1), this is generally parallel to the surface of the wall 123, wherein β is typically in the range 10° to 30°, and is preferably around 20°. For the example shown in Figure 7, wherein the panel thickness is 2.0mm and β is 20°, the outer chamfer width OCW and inner chamfer depth OCD are approximately 1.4mm and 0.5mm respectively. Accordingly, for the example shown in Figure 7, the panel edge thickness PES is approximately 1mm.

Planar wall panels 101 are mounted to the wall 123 in a similar fashion to the tiled wall panels of the first embodiment. Due consideration is given to whether any particular joint needs to be waterproof.

It will be appreciated by the skilled person that the invention is not limited to the described embodiments and includes variations which are within the scope of the appended claims. For example, techniques other than vacuum forming can be used to form the tile-like appearance of the wall panel.

In the embodiment shown, the tile-like formations 5 have a substantially rectangular shape when viewed in plan. Other shapes, and combinations of shapes are possible. For example, the tile-like formations can have a triangular, pentagonal, hexagonal or other similar shape. Similarly the wall panel shown also has a substantially rectangular shape when viewed in plan. The wall panel can have a triangular, pentagonal, hexagonal or other similar shape.

Other shapes of recessed surfaces can be used, for example a bevelled recessed surface or a concave surface.

Claims

1. Method for mounting wall panels to a surface, including providing a first plastics wall panel having a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the profiled first edge; mounting the first plastics wall panel to the surface such that the recessed surface presents an undercut void on an inner side of the first plastics wall panel; and applying settable sealant to the profiled first edge such that some of the sealant bonds to the recessed surface.

2. The method according to claim 1, including providing a second plastics wall panel having a first edge, and mounting the second plastics wall panel to the surface.

3. The method according to claim 2, wherein a first edge of the second plastics wall panel is a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the first edge; and mounting the second plastics wall panel to the wall such that the recessed surface presents an undercut void on an inner side of the second plastics wall panel; and applying settable sealant to the first edge of the second plastics wall panel such that some of the sealant bonds to the recessed surface.

4. The method according to any one of the preceding claims, wherein the or each recessed surface comprises a chamfered surface or a bevelled surface.

5. The method according to claim 4, wherein the or each chamfered or bevelled surface subtends an angle of around 10 to 50 degrees with respect to a reference line that is arranged substantially parallel with an inner major surface of the plastics wall panel.

6. The method of claim 5, wherein the or each chamfered or bevelled surface subtends an angle of around 20 to 40 degrees with the reference line.

7. The method according to any one of claims 1 to 3, wherein the or each recessed surface comprises a concave or a convex surface.

8. The method according to any one of the preceding claims, wherein the profiled first edge of at least one of the first and second plastics wall panels includes a second recessed surface extending along at least a part of the length of the profiled first edge, wherein the second recessed surface presents an undercut void on an outer side of at least one of the first and second plastics wall panels, when the panel is mounted to the surface.

9. The method according to any one of the preceding claims, wherein the or each profiled first edge is a longitudinal edge of the plastics wall panel.

10. The method according to any one of the preceding claims, wherein the recessed surface extends along substantially the full length of the profiled first edge.

11. The method according to any one of the preceding claims, wherein the first plastics wall panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the first plastics wall panel.

12. The method according to claim 11, wherein the profiled second edge is arranged opposite to the profiled first edge.

13. The method according to any one of claims 3 to 12 when dependent on claim 2, wherein the second plastics wall panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the second plastics wall panel.

14. The method according to claim 13, wherein the profiled second edge is arranged opposite to the profiled first edge.

15. The method according to any one of the preceding claims, wherein at least one further edge of at least one of the first and second plastics wall panels comprises a profiled edge having a recessed surface extending along at least a part of the length of the profiled edge; wherein the recessed surface of the profiled edge presents an undercut void on an inner side of the plastics wall panel.

16. The method according to any one of the preceding claims, wherein at least one of the first and second plastics wall panels comprises a moulded plastics wall panel.

17. The method according to any one of the preceding claims, wherein at least one of the first and second plastics wall panels comprises a tile effect wall panel.

18. The method according to any one of the preceding claims, wherein at least one of the first and second plastics wall panels comprises a substantially planar wall panel.

19. The method according to any one of the preceding claims, wherein as least one of the first and second plastics wall plastics panels is substantially rectangular in plan.

20. The method according to any one of the preceding claims, including attaching at least one of the first and second plastics wall panels to the wall by means of plurality of vertical or horizontal beads of adhesive.

21. The method according to any one of claims 4 to 21 when dependent on claim 3, including attaching at least one portion of double sided adhesive tape or film onto the surface; mounting the first plastics wall panel onto the surface such that the profiled first edge overlies the double sided adhesive tape or film; applying sealant to at least one of the double sided adhesive tape or film and the profiled first edge of the first plastics wall panel; mounting the second plastics wall panel onto the surface such that the profiled first edge overlies the double sided adhesive tape or film, the arrangement being such that the profiled first edge of the second plastics wall panel is located adjacent to, and substantially parallel with, the profiled first edge of the first plastics wall panel.

22. A wall panel system, including a first plastics wall panel for covering at least part of a wall surface, said first plastics wall panel having a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the profiled first edge, said recessed surface arranged to present an undercut void on an inner side of the first plastics wall panel in a mounted condition, wherein the profiled first edge includes a second recessed surface extending along at least a part of the length of the profiled first edge, wherein the second recessed surface presents an undercut void on an outer side of the first plastics wall panel in a mounted condition.

23. The system according to claim 22, including a second plastics wall panel having a first edge.

24. The system according to claim 23, wherein the first edge of the second plastics wall panel is a profiled first edge, said profiled first edge including a recessed surface extending along at least a part of the length of the profiled first edge; said recessed surface is arranged to present an undercut void on an inner side of the second plastics wall panel, said inner side facing generally towards a wall in a mounted condition.

25. The system according to any one of claims 22 to 24, wherein the or each recessed surface comprises a chamfered surface or a bevelled surface.

26. The system according to claim 25, wherein the or each chamfered or bevelled surface subtends an angle of around 10 to 50 degrees with respect to a reference line that is arranged substantially parallel with an inner major surface of the wall panel.

27. The system according to claim 26, wherein the or each chamfered or bevelled surface subtends an angle of around 20 to 40 degrees with the reference line.

28. The system according to any one of claims 22 to 27, wherein the or each recessed surface comprises a concave or a convex surface.

29. The system according to any one of claims 25 to 28 when dependent on claim 24, wherein the profiled first edge of the second plastics wall panel includes a second recessed surface extending along at least a part of the length of the profiled first edge, wherein the second recessed surface presents an undercut void on an outer side of the second plastics wall panel in a mounted condition.

30. The system according to any one of claims 22 to 29, wherein the or each profiled first edge is a longitudinal edge of the wall panel.

31. The system according to any one of claims 22 to 30, wherein the recessed surface extends along substantially the full length of the profiled first edge.

32. The system according to any one of claims 22 to 31, wherein the first plastics wall panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the first plastics wall panel.

33. The system according to claim 32, wherein the profiled second edge is arranged opposite to the profiled first edge.

34. The system according to any one of claims 25 to 33 when dependent on claim 24, wherein the second plastics panel includes a profiled second edge, said profiled second edge including a recessed surface extending along at least a part of the length of the profiled second edge; wherein the recessed surface of the profiled second edge presents an undercut void on an inner side of the second plastics wall panel.

35. The system according to claim 34, wherein the profiled second edge is arranged opposite to the profiled first edge.

36. The system according to any one of claims 22 to 35, wherein at least one further edge of at least one of the first and second plastics wall plastics panels comprises a profiled edge having a recessed surface extending along at least a part of the length of the profiled edge; wherein the recessed surface of the profiled edge presents an undercut void on an inner side of the respective plastics wall panel.

37. The system according to any one of claims 22 to 36, wherein at least one of the first and second plastics wall panels comprises a moulded plastics wall panel.

38. The system according to any one of claims 22 to 37, wherein at least one of the first and second plastics wall panels comprises a tile effect wall panel.

39. The system according to any one of claims 22 to 38, wherein at least one of the first and second plastics wall panels comprises a substantially planar wall panel.

40. The system according to any one of claims 22 to 39, wherein as least one of the first and second plastics wall panels is substantially rectangular in plan.

41. The system according to any one of claims 22 to 40, including a settable sealant for applying to at least one of the recessed surfaces.

42. The system according to any one of claims 22 to 41, including at least one portion of double-sided adhesive tape or film.

43. The system according to claim 42, wherein the double-sided tape or film has a static shear adhesion at 23°C lkg/625mm2 of at least 4000 minutes, preferably at least 4500 minutes and more preferably still of at least 5000 minutes.

44. The system according to claim 42 or 43, wherein the double-sided tape (25) or film has a static shear adhesion at 70°C 0.5kg/625mm2 of at least 500 minutes, preferably at least 550 minutes, and more preferably still at least 600 minutes.

45. The system according to any one of claims 42 to 44, wherein the double-sided tape (25) or film has a tack AFERA 4015 characteristic of at least 3.0N/25mm, preferably at least 3.5N/25mm and more preferably still at least 4.0N/25mm.