FIELD OF THE INVENTION The present invention generally relates to construction materials. More particularly, the invention relates to a panel installation kit.

BACKGROUND OF THE INVENTION Installation of panelling for indoor and outdoor applications is typically a very complicated operation for an average consumer. The prior art has established several ways to simplify this process:

-US 3529393 describes a wall to floor connector beam where a composite floor unit comprised of a series of panels that are joined together and where elongate sills surround the unit. The sill is of shell like construction to which a corresponding upright wall is secured. The sill is secured to the floor and to the upright wall structure by an embedded mating portion and by a fastening means respectively. -US 4051641 describes a panelized structural system that employs pre-constructed exterior wall panels that are parallelogram shaped and that permit interchangeable insertion with out any intervening studding to form flat sidewalls.

-US 4021983 discloses a honeycomb building wall construction where a building wall structure is comprised of several paperboard honeycomb layers that are secured with adhesive to each other in a vertical arrangement, where each honeycomb layer has a central core of paperboard honeycomb also having vertical honeycombs, and a closure sheet comprised of paperboard, essentially covering the top and the bottom of the core. The opposite long sides of the central core are open on each side and the top of the honeycomb layer is secured adhesively to an adjacent honeycomb layer by top and bottom closure sheets. The invention also relates to prefabricated walls and wall sections.

-US 2004/0096624 describes synthetic building materials and methods for production of synthetic redwood material that is made from a silicone mould imprisoned with genuine redwood and containing an outward layer of a polyester gel coat and a rearward facing layer. An intermediate layer of matting material is used as well as a third intermediate layer of honeycomb material. -US 4602466 describes foam building panels and a method to make the same, where upper and lower rigid sheets of material are positioned, like paper pulp, in a spaced relation so that a foamable type of material can be disposed between the and grip with both sheets as it expands and solidifies. Consequently, there is presently a need for a panel or panel installation kit that can be used and installed easily, rapidly and safely.

SUMMARY OF THE INVENTION An object of the present invention is to propose a panel that satisfies at least one of the above-mentioned needs.

According to the invention, that object is accomplished with a panel installation kit for installing at least one panel on a surface, the kit comprising:

- at least one base panel comprising:

- a cardboard honeycomb substrate covered on at least one of each opposite side with flat cardboard;

- and

- a covering structure to be affixed to the substrate with a linking adhesive. Another aspect of the present invention relates to a panel comprising a cardboard honeycomb substrate covered on at least one of each opposite side with flat cardboard.

As well, the present invention relates to a method for installing a panel on a surface comprising the steps of:

(a) providing a panel installation kit comprising:

- at least one base panel comprising:

- a cardboard honeycomb substrate covered on at least one of each opposite side with flat cardboard; and

- a covering structure affixed to the substrate with a linking adhesive;

and

- an installation adhesive to bond the at least one base panel to the surface; and

(b) bonding the at least one base panel to the surface with the installation adhesive. Installation of the base panel can be made through an installation guide and installation adhesive means provided with the product at purchase. No additional tools or fasteners such as hammers or nails will be necessary, although fasteners can be used if desired for even more support. A non-restrictive description of a preferred embodiment of the invention will now be given with reference to the appended drawings. BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a perspective view of a panel according to a preferred embodiment of the present invention;

Figure 2 is another perspective view of the panel shown in Figure 1 ; and

Figure 3 is another perspective view of the panel shown in Figure 1. Figure 4 is a perspective view of a preferred embodiment of the panel in accordance with another embodiment of the present invention where the covering structure comprises staggered wood panels.

Figure 5 is another perspective view of the panel of Figure 4, adjoining with an adjacent panel.

Figure 6 is another perspective view of the panel of Figure 4, with an adjacent panel being separated therefrom. Figures 7A and 7B are top and side views respectively of a panel having a covering structure with staggered wood panels in accordance with another preferred embodiment of the present invention.

Figures 8A, 8B and 8C are rear, side and bottom views respectively of a panel in accordance with another preferred embodiment of the present invention.

Figure 9 is a perspective view of mouldings installed on a panel in accordance with another preferred embodiment of the present invention. Figure 10 is a perspective view of mouldings installed on a panel in accordance with another preferred embodiment of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

The panel and assembly kit according to the present invention gives consumers the opportunity of installing panels themselves to a chosen surface through easy, quick and safe installation. This is accomplished through an installation guide and an installation adhesive provided with the base panel at the moment of purchase for bonding the base panel to the surface. No other tooling or fasteners such as hammers or nails are necessary but can be used if desired. For example, while an adhesive is provided, it might be desired for certain applications to nail the panel at four corners thereof in order to ensure that the installed panel remains properly in place once installed. Various finishes for these panels are also offered to the consumer including natural, with primer, painted, varnished, sealed, clear coated, stained or others that are listed below.

As shown in Figures 1 to 3, the present invention provides a panel installation kit comprising at least one base panel 10 comprising a cardboard honeycomb substrate 12 covered on each opposite side with flat cardboard 14, and a covering structure 6 to be affixed to the substrate 12 with a linking adhesive.

Typically, an assembled panel will include four components:

- the substrate;

- the covering structure;

- the adhesive; and

- the finishing surface. Preferably, the substrate 12 is a honeycomb cardboard with two sheets of flat cardboard 14 on each side but could also be with one sheet of cardboard 14 on only one side or no sheet at all thereof, in order to form a total thickness of substrate 12 between less than one-sixty-forth of an inch and more than five inches. It is to be understood by a person versed in the art that these measurements can be customized to meet any specification required.

Preferably, the covering structure 16 is made of wood of different thicknesses between less than 1/64" to more than 5". The length of the covering structure 16 can vary between less than 1" to more than 245" with a width of less than 1" to more than 192". The panels can overlap one over the other or abut each other and be glued together when assembled.

Preferably, on the base panel 10, various items can be added to the substrate 12 and replace any wood of the covering structure, covering totally or in part, and include aluminum, stainless steel, ceramic, ceramic composite, stone, brick, stone composite, brick composite, tiles or tile composites, bamboo or any other material. More particularly, the covering structure can be made of a material comprising at least one of wood, wood composite, aluminum, stainless steel, ceramic, ceramic composite, stone, brick, stone composite, brick composite, tiles, tile composites bamboo, glass, polymethyl methacrylate or any other materials. Preferably, as seen in Figures 2 and 3, the kit includes a "shiplap" system 20 to overlap finished panels one within the other upon installation onto the surface.

As shown in Figures 9 and 10, mouldings 22 can be provided in the kit in order to cover 90 degree exterior and interior angles or 45 degree exterior or interior angles or any other angles. Moreover, other mouldings 22 above the wall, on the side of the wall, or flooring can be assembled on the panel or sold separately. Care must be taken when assembling adjacent panels when wood covering structures are used. Indeed, any wood structure will change in size when submitted to changes in levels of humidity in cold or hot weather or during seasonal transitions. Adjacent panels should have appropriate spacing between each other in order to avoid any subsequent swelling of the structure. In other applications, structures may be provided such that the kit according to the present invention may be used to build a suspended ceiling structure or, in the alternative, a floor structure. The linking adhesive used in the kit is preferably a white PVA type glue, hot melt glue, eurethane type glue, water based glue, thermal adhesives, two-part adhesives, moisture cure adhesives, UV cure adhesives, cyanocrylate adhesives, anaerobic adhesives and film adhesives, or any other known adhesive with similar bonding properties. The adhesive will be chosen with respect to its adhesive and resistance properties. For consumer applications, optimal glue, adhesive or adhesive strips or any other solutions can be selected for the installation adhesive based on the application according to the required drying time.

Depending on the conditions present where the panel is to be installed, care must be taken when applying glue between the covering structure and the substrate. Under certain conditions, glue or adhesive may be applied to the contact surface in discrete places to allow for play between the substrate and covering structure (when a wood covering structure is used), depending on the humidity conditions where the panel is to be installed, as the panel may swell as the wood absorbs humidity in summer, for example, or during seasonal transitions that cause contraction of the wood (e.g. low humidity in winter conditions). Under certain other installation conditions, applying glue on the complete contact surface may be possible.

Preferably, specific installation and application of adhesive materials will have to be tailored to the conditions where the panel is to be installed. For example, the adhesive can be hydrophobic to account for differing climate conditions and to maintain the adhesive's integrity even in high humidity situations.

Preferably, according to a preferred embodiment of the present invention, the base panel is adapted such that it is hydrophobic.

Any type of finishing can be applied to the panel. For example, a vacuum coater can be used; as well as a spray applicator or a brush applicator or even a roller or any other known option. The finishing coat can be dried using any system known to a person skilled in the art, including convection ovens or UV or forced-air or air-dried or infrared drying systems or any other methods.

Different finishing services include natural, with primer, painted, varnished or stained or sealed or clear coated or any other finish.

The finish can also comprise clear finish, organic coating, shellac, polyurethane, lacquer, wax, drying oils, water based finishes, hot and cold rolling mechanically applied finishes, textured coating, luster coating, sandblast coating, flamed coating, brushed coating, polished coating, honed coating, tumbled coating, textured coating, bush hammered coating, cleft or split face, cleft slates, stones, tiles, hardcoat, sulphuric anodized coating, chromic anodized coating, alodine, or any other finish.

Preferably, the finishing can also include certain insect repellents and treatments against certain parasites, for example, termites.

Furthermore, in a preferred embodiment of the present invention, the base panel is treated or adapted such that it repels insects and other parasites such as termites.

As well, according to a preferred embodiment of the present invention, the base panel is adapted to be fire retardant. In general, the panelling according to the present invention offers the following advantages:

- Light weight, therefore easy to transport.

- Greatly improved installation time.

- Ecological, as the substrate is made from at least 50%, preferably 100%, recycled cardboard and can be FSC while the wood used with the panelling is a renewable material.

- Less costly as the panel costs more at purchase than equivalent wood individual panelling but costs less in terms of labour since installation time is decreased.

- Reduced transportation costs.

- More than 50% less use of wood in panel structures.

- Can be built according to various specifications, including:

Length: up to 245"

Cardboard thickness: less than 1/64" to more than 5"

Wood thickness: less than 1/64" to more than 5"

Combination of different materials.

- Offered with different finishing surfaces. Can also be pre-finished offsite and include primer, paint, varnish, stain, sealed, clear coated surfaces or any other type of finish.

- Contributes to the overall decorative effect of a room and increases the possibilities for decorative goals given the several different combinations of kit models.

Preferably, the honeycomb cardboard of the substrate is at least a 50% recycled honeycomb cardboard designed, among multiple applications, for a lightweight panel with a hybrid wood and cardboard frame. The density for the honeycomb cardboard, measured in psi, reaches at least 20 psi and up to 110 psi in a controlled environment with 23°C at 50% relative humidity.

Preferably, the substrate is specifically designed for a board on frame "hybrid" light panel assembly applications, the top and bottom liners feature a virgin paper recipe, over a very small cell size honeycomb shape core made of at least 50%, preferably 100%, recycled fibers for a high surface contact. The combination offers a higher bonding properties needed when gluing a finishing coat (veneer, stratified and/or laminated wood compressed such as high density MDF, etc.).

Preferably, the panel cardboard substrate has the following specifications:

Furthermore, as shown in Figures 4 to 7B, the present invention discloses a covering structure wherein the covering structure is comprised of a plurality of panels 30 that are affixed to the substrate by a fixing means, such as an adhesive or even nails and screws, thereby giving the impression of panelling on walls to which the plurality of panels of the present invention are mounted to. Preferably, these panels 30 can be affixed to the substrate of the base panel either vertically or horizontally. The panels forming the covering structure can further be arranged in a staggered manner, minimizing the appearance of having a joint line between two adjoining base panels.

As shown in Figures 4 to 7B, the staggered plurality of panels 30 that are affixed to the substrate of the base panel are spaced in such a manner so that they meet with respective and corresponding staggered wood panels that are affixed onto the substrate of an adjacent base panel, when both base panels are placed next to each other in order to form a continuous piece. Preferably, the plurality of panels comprise a lengthwise interlocking shiplap system adaptable with the shiplap system of an adjacent panel that is affixed to the substrate of an adjacent base panel.

Preferably, the abovementioned panel can be made of wood; however, it is to be understood that this panel can be made of any other type of material. For example: plastic, aluminium, etc.

Preferably, as shown in Figures 8A to 8C, for certain applications, adhesive strips 60 are used as the installation adhesive for installing the panel on a surface.

Alternatively, the present invention relates to a panel to be installed onto a surface where panelling is desired.

Preferably, this panel comprises a base panel further comprised of a cardboard honeycomb substrate covered on at least one of each opposite side with flat cardboard.

Preferably, the panel of the present invention further comprises a covering structure that can be adhered to the substrate of the base panel, forming the panel system of the present invention. Preferably, the present invention also relates to the use of the panels and the panel kits discussed herein. As well, the present invention relates as well to a method of installing the panels discussed above. This method involves at least one of the following steps:

-Identifying and preparing the mouldings to be used with the panels. This preparation can involve painting or varnishing the mouldings.

-Preparing the wall on which the panel will be installed by ensuring the surface is clean and by tracing the locations of where the mouldings will be placed once the panel is installed. -Removing all electrical outlet plates, breakers and electrical baseboards.

-Installing the baseboard by placing it on the perimeter to be covered and cutting the panel at the location where the baseboard will be installed. -Preparing the panel for installation by inserting it into the baseboard, positioning it and ensuring that it is properly levelled. Then, identifying and making the cuts that will be needed to account for the mouldings, electrical outlets, and the like. -Placing the base panel to the chosen surface and using an adhesive to adhere the base panel to said chosen surface.

-Repeating this process for the entire surface to be covered.

-Installing the mouldings once the wall panels are in fixed to the wall space. More specifically however, the present invention relates to a method for installing a panel involving the step of taking at least one base panel, the base panel comprising a cardboard honeycomb substrate covered on at least one of each opposite side with flat cardboard, then affixing a covering structure to the substrate; and finally, adhering the panel to a surface on which it is desired to have such a panel.

Although preferred embodiments of the present invention have been described in detail herein and illustrated in the accompanying drawings, it is to be understood that the invention is not limited to these precise embodiments and that various changes and modifications may be effected therein without departing from the scope or spirit of the present invention.