US20110036037A1 - System for providing a decorative covering on a support surface using panels with interlocks - Google Patents
System for providing a decorative covering on a support surface using panels with interlocks Download PDFInfo
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- US20110036037A1 US20110036037A1 US12/858,260 US85826010A US2011036037A1 US 20110036037 A1 US20110036037 A1 US 20110036037A1 US 85826010 A US85826010 A US 85826010A US 2011036037 A1 US2011036037 A1 US 2011036037A1
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- panel
- set forth
- panels
- riser
- overlap portion
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0864—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/29—Means for connecting or fastening adjacent roofing elements
- E04D1/2907—Means for connecting or fastening adjacent roofing elements by interfitted sections
- E04D1/2914—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements
- E04D1/2918—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements the fastening means taking hold directly on adjacent elements of succeeding rows
Definitions
- the present invention relates to a system for providing a decorative covering on a support surface such as on a wall of a building. More specifically, the present invention relates to the system having a plurality of panels with interlocks for securing adjacent panels together on the support surface.
- each of the panels includes a top, a bottom, and first and second ends.
- a mounting flange is adjacent to the top for securing the panels to a support surface.
- Each of the panels also includes upper and lower rows of decorative portions.
- the lower row of decorative portions has a lower edge adjacent to the bottom of the panel.
- a plurality of pockets are defined in the lower edge.
- the upper row of decorative portions has an upper edge adjacent to the mounting flange.
- a plurality of protruding elements are disposed on the upper edge and extend upwardly from the upper edge for mating with the pockets defined in the lower edge of a vertically adjacent panel.
- each of the panels includes a top, a bottom, and first and second ends.
- a first overlap portion is adjacent to the first end and a second overlap portion is adjacent to the second end.
- the first overlap portion overlaps the second overlap portion of a horizontally adjacent panel.
- the first overlap portion includes a plurality of upwardly extending hooks.
- the second overlap portion defines a plurality of corresponding slots.
- interlocks are often difficult to manufacture into the panel and may result in installation problems because they include elements that protrude from the panel. These types of interlocks are also subject to damage during manufacturing and transportation due to their protruding nature. Therefore, it would be advantageous to provide an interlock in the overlapping end regions that overcomes such problems to secure horizontally adjacent panels to one another.
- the present invention provides a system for decoratively covering a support surface using a plurality of panels.
- Each of the panels has a top, a bottom, and first and second ends.
- a mounting flange is adjacent to the top to facilitate mounting of the panel to the support surface.
- a first row of decorative portions is disposed between the top and bottom to define a first front face and a second row of decorative portions is disposed between the top and bottom to define a second front face.
- a riser connects the first and second rows such that the first row is in a stepped relationship with the second row.
- a first overlap portion is adjacent to the first end and a second overlap portion is adjacent to the second end. The first overlap portion overlaps the second overlap portion of a horizontally adjacent panel mounted to the support surface.
- a first interlock having an inner surface, extends from the riser at the first end.
- a second interlock having an outer surface, extends from the riser at the second end.
- the inner and outer surfaces are defined as abutting surfaces sloped upwardly toward the top at an acute angle relative to at least one of the first and second front faces wherein the inner surface overlies and abuts the outer surface of the horizontally adjacent panel at the acute angle. This connection reduces relative movement between the panels when mounted on the support surface.
- the first interlock includes a flap and the second interlock is further defined as a catch.
- the present invention provides an interlock between overlapping ends of adjacent panels that overcomes the problems that characterize the prior art. Specifically, the first and second interlocks of the present invention are unobtrusive and are easily formed into the panels when the panels are manufactured. Further, since the first and second interlocks do not protrude from the panel, there is little or no chance of the interlocks being damaged during manufacturing and transportation.
- FIG. 1 is a perspective view of a building with a system of the present invention providing a decorative covering for exterior walls of the building;
- FIG. 2 is a front perspective view of a panel of the system forming the decorative covering
- FIG. 3 is a rear perspective view of the panel forming the decorative covering
- FIG. 4 is a front perspective view of the first end of a first panel spaced from a second end of a second, horizontally adjacent panel prior to engagement with the second end having a second interlock with an outer surface;
- FIG. 5 is a front perspective view of the first panel fully engaging the second panel shown in FIG. 4 ;
- FIGS. 6A and 6B are cross-sectional views taken generally along line 6 - 6 in FIG. 5 illustrating the overlap of the horizontally adjacent panels and, more specifically, illustrating overlying and abutment of the inner and outer surfaces of the first and second interlocks;
- FIG. 7 is a front perspective view of the panels integrated in a continuous strip of material formed from a vacuum-forming method.
- a system for providing a decorative covering on a support surface 11 is generally shown at 10 in FIG. 1 .
- the system 10 comprises a plurality of interlocking panels 14 for mounting to the support surface 11 .
- the panels 14 are positioned adjacent to one another to cover the support surface 11 .
- the system 10 preferably covers exterior support surfaces, such as those on exterior walls of buildings (see building 12 illustrated in FIG. 1 ). In this instance, the panels are referred to as “siding” panels. In alternative embodiments, the system 10 may cover other surfaces or structures.
- the panels 14 are placed on the support surface 11 in a number of courses using methods well known to those skilled in the art. The dimensions of the panels 14 , such as length, may vary depending on the desired course layout of the panels 14 .
- each of the panels 14 is substantially similar such that each of the panels 14 can interlock with any other panel 14 .
- Each of the panels 14 is preferably formed from a unitary sheet of material and has a top 16 , a bottom 18 , and first 20 and second 22 ends.
- the sheet of material is preferably a rigid thermoplastic, such as polyvinylchloride or “vinyl.”
- Each panel 14 defines a mounting flange 24 adjacent to the top 16 .
- the mounting flange 24 is used to mount the panel 14 to the support surface.
- the mounting flange 24 is also referred to as a nailing hem 24 .
- the nailing hem 24 is generally flat and has apertures 28 for receiving fasteners to secure the panel 14 to the support surface 11 .
- the nailing hem 24 is preferably folded onto itself as is well known to those in the siding art to increase strength and stability of the panel 14 .
- a butt flange 26 is disposed adjacent to the bottom 18 , opposite the nailing hem 24 .
- the butt flange 26 generally has a height that is greater than the nailing hem 24 .
- the butt flange 26 has a generally hook-shaped clamping portion adjacent the bottom 18 comprising a flexible lip 27 for insertion under the folded over nailing hem 24 .
- the folded over nailing hem 24 cooperates with the flexible lip 27 of vertically adjacent panels 14 to secure the panels 14 to one another in a manner well known to those skilled in the art.
- the panel 14 defines a first row 30 of decorative portions 32 and a second row 34 of decorative portions 32 .
- the first 30 and second 34 rows are disposed, one above the other, between the top 16 and bottom 18 . More specifically, the first 30 and second 34 rows are disposed between the nailing hem 24 and the butt flange 26 and the rows 30 , 34 extend between the first 20 and second 22 ends.
- These types of panels 14 are generally known as double panels 14 , e.g., double-4, double-5 panels.
- the first row 30 of decorative portions 32 defines a first front face 35 of the panel 14 and the second row 34 of decorative portions 32 defines a second front face 37 that is generally parallel to the first front face.
- Each of the front faces preferably has a width of from about 3 to about 6 inches, more preferably from about 4 to about 5 inches.
- Each row 30 , 34 is formed from a series of generally rectangular molds, each having a different and distinct appearance to create the decorative portions 32 .
- the decorative portions 32 are impressions of real, authentic wood shake siding such that the panels 14 , when collectively mounted to the support surface 11 , resembles real wood shake siding.
- the panels 14 could also be formed to simulate other building materials.
- a plurality of grooves 36 are defined in the front faces 35 , 37 of the rows 30 , 34 between adjacent decorative portions 32 to divide the decorative portions 32 .
- the grooves 36 are substantially flat and recessed from the decorative portions 32 to further create the appearance of real, authentic wood shake siding.
- each of the grooves 36 is disposed transversely across the front faces 35 , 37 .
- the grooves 36 in the first front face 35 are horizontally offset from the grooves 36 in the second front face 37 when viewing the panels 14 from the top 16 to the bottom 18 .
- a riser 38 is disposed longitudinally between the first 30 and second 34 rows to connect the first row 30 to the second row 34 such that the first row 30 is in a stepped relationship with the second row 34 .
- the riser 38 extends between the first 20 and second 22 ends.
- the riser 38 further enhances the appearance of the separate decorative portions 32 and further creates the appearance of separate rows 30 , 34 .
- the riser 38 has a shadow face 39 generally perpendicularly connecting the first 35 and second 37 front faces of the first 30 and second 34 rows.
- a first overlap portion 40 of the panel 14 is disposed adjacent to the first end 20 and a second overlap portion 50 is disposed adjacent to the second end 22 .
- the first overlap portion 40 overlaps the second overlap portion 50 of a second, horizontally adjacent panel (See FIG. 5 ) that has been previously mounted to the support surface 11 .
- the second overlap portion 50 of the horizontally adjacent panel is hidden by the first overlap portion 40 of the panel 14 .
- the second overlap portion 50 is recessed relative to the first 35 and second 37 front faces to define an abutment for the first overlap portion 40 and regulate an amount of overlap between adjacent panels 14 and guide mating of the panels 14 .
- a first interlock 42 extends from the riser 38 at the first end 20 and a second interlock 51 extends from the riser 38 at the second end 22 .
- the first interlock 42 is configured for interlocking with the second interlock 51 of the horizontally adjacent panel to secure the panels 14 together on the support surface 11 .
- the first interlock 42 is preferably formed as part of the first overlap portion 40 .
- the first interlock 42 includes a bent flap 43 extending from the riser 38 at the first end 20 . Referring specifically to FIG. 3 , the flap 43 has an inner surface or first abutting surface 44 that is inclined or sloped upwardly toward the top 16 .
- the flap 43 also has an outer surface that is exposed when mounted to the support surface 11 .
- the outer surface preferably has a stylized portion thereon.
- the stylized portion may be omitted, as in FIG. 2 .
- the second interlock 51 is further defined as a catch 52 for receiving the flap 43 .
- the catch 52 includes a recessed portion for receiving the flap 43 .
- the catch 52 has an outer surface or a second abutting surface 54 sloped upwardly toward the top 16 .
- FIG. 4 illustrates the panel 14 having the first end 20 aligned to engage the second end 22 of a second, horizontally adjacent panel 15 .
- the first overlap portion 40 of the panel 14 overlaps the second overlap portion 50 of the second panel 15 such that the first 42 and second 52 interlocks of the panels 14 , 15 contact one another and the first 44 and second 54 abutting surfaces create a mating fit therebetween.
- FIG. 5 illustrates the panel 14 fully engaging the second panel 15 .
- the flexible lip 27 of the clamping portion that is disposed in the first overlap portion 40 flexes over the second overlap portion 50 at the bottom 18 of the second panel 15 to secure the panels 14 , 15 together at the bottom 18 .
- the first overlap portion 40 of the panel 14 includes a first overlapping section (see numeral 40 near the top 16 ) at one end of the first row 30 and a second overlapping section (see numeral 40 near the bottom 18 ) at one end of the second row 34 . These sections are offset from one another.
- the second overlap portion 50 of the second panel 15 includes a first overlapping section (see numeral 50 near the top 16 ) extending from one end of the first row 30 and a second overlapping section (see numeral 50 near the bottom 18 ) extending from one end of the second row 34 . These sections are also offset from one another.
- the first overlapping sections and the second overlapping sections of the overlap portions 40 , 50 are complementary to one another to fit together as shown.
- a gap between the decorative portions 32 in the first row 30 is offset from a gap between the decorative portions 32 in the second row 34 . This further provides the authentic cedar shake appearance.
- a contact wall 56 interconnects the riser 38 and the catch 52 such that the riser 38 rises above the catch 52 to define an abutment.
- the contact wall 56 extends substantially perpendicular to the riser 38 to guide the flap 43 of the panel 14 into mating engagement with the catch 52 .
- FIG. 5 when the panels 14 , 15 are assembled together, the flap 43 is fitted into the catch 52 such that a gap is maintained between the flap 43 and the contact wall 56 .
- FIGS. 6A and 6B cross-sectional views taken generally along line 6 - 6 in FIG. 5 are shown.
- FIG. 6A shows the first panel 14 as it is installed horizontally next to the second panel 15 , which is already mounted to the support surface 11 . More specifically, FIG. 6A illustrates the first interlock 42 of the first panel 14 engaging the second interlock 51 of the second panel 15 . As can be seen, the first abutting surface 44 abuts the second abutting surface 54 .
- This fit provides for improved stability of the panels 14 , 15 when mounted to the support surface 11 , e.g., the exterior surface of the building 12 , and limits the vertical movement of such panels 14 , 15 .
- FIG. 6A shows the first panel 14 as it is installed horizontally next to the second panel 15 , which is already mounted to the support surface 11 . More specifically, FIG. 6A illustrates the first interlock 42 of the first panel 14 engaging the second interlock 51 of the second panel 15 . As can be seen, the first abut
- FIG. 6B illustrates the first panel 14 interlocked and installed with the second panel 15 on the support surface 11 .
- FIG. 6B also illustrates additional courses of the panels 14 installed above the first 14 and second 15 panels to illustrate the fit between the nail hem 24 and the flexible lip 27 of vertically adjacent panels.
- the first abutting surface 44 is inclined or sloped upwardly toward the top 16 at a first acute angle ⁇ relative to the generally parallel first 35 and second 37 front faces.
- the first abutting surface 44 forms a second acute angle ⁇ with the shadow face 39 .
- the first acute angle ⁇ is preferably less than 90 degrees, more preferably from about 25 degrees to about 85 degrees, and most preferably from about 65 degrees to about 80 degrees.
- the second acute angle ⁇ is preferably greater than 0 degrees, more preferably from about 5 degrees to about 65 degrees, and most preferably from about 10 degrees to about 25 degrees.
- the second abutting surface 54 slopes upwardly toward the top 16 at the same first acute angle ⁇ relative to the first 35 and second 37 front faces.
- the second abutting surface 54 forms the same second acute angle ⁇ with the shadow face 39 .
- the first abutting surface 44 overlies the second abutting surface 54 of the horizontally adjacent panel 15 to reduce relative movement between the panels 14 , 15 .
- FIG. 7 illustrates a single continuous strip 62 of thermoplastic material that can be cut into individual panels 14 .
- the first and the second ends 20 , 22 when formed from such a method, are initially integrally formed together and then cut.
- the continuous strip 62 is sectioned into the individual panels 14 , the first and second ends 20 , 22 are separated to create the appearance shown in FIGS. 4 and 5 .
Abstract
A system for decoratively covering a support surface is provided. The system comprises a plurality of panels. Each panel includes a top, a bottom, and first and second ends. Each panel includes a nailing hem for mounting the panel to the support surface. Each panel also includes first and second rows of decorative portions simulating building materials. A riser interconnects the first and second rows. Each panel further includes a flap extending from the riser at the first end and a catch extending from the riser at the second end. The flap and catch mate with a corresponding catch and flap of horizontally adjacent panels. The flap and catch are both sloped upwardly toward the top at an acute angle to provide a mating fit between corresponding flaps and catches.
Description
- This application claims the benefit of U.S. patent application Ser. No. 11/613,470, filed Dec. 20, 2010, now U.S. Pat. No. 7,775,009, which claims the benefit of U.S. Provisional Patent Application No. 60/753,199, filed on Dec. 22, 2005, the advantages and disclosure of both of which are hereby incorporated by reference.
- The present invention relates to a system for providing a decorative covering on a support surface such as on a wall of a building. More specifically, the present invention relates to the system having a plurality of panels with interlocks for securing adjacent panels together on the support surface.
- Prior art systems that utilize panels to provide a decorative covering on a support surface are well known in the art. For decades, vinyl siding panels have been mounted on exterior walls of buildings to cover, protect, and decorate the exterior walls. Generally, these panels are positioned adjacent to one another for covering the exterior wall of the building and, often, the panels include interlocks for securing adjacent panels to one another. U.S. Pat. No. 4,598,522 to Hoofe III illustrates one such system.
- In Hoofe III, each of the panels includes a top, a bottom, and first and second ends. A mounting flange is adjacent to the top for securing the panels to a support surface. Each of the panels also includes upper and lower rows of decorative portions. The lower row of decorative portions has a lower edge adjacent to the bottom of the panel. A plurality of pockets are defined in the lower edge. The upper row of decorative portions has an upper edge adjacent to the mounting flange. A plurality of protruding elements are disposed on the upper edge and extend upwardly from the upper edge for mating with the pockets defined in the lower edge of a vertically adjacent panel. As a result, the cooperating pockets and protruding elements act as interlocks for vertically adjacent panels to prevent horizontal shifting of the panels.
- Other prior art systems utilize interlocks that are located on the ends of overlapping panels. In U.S. Patent Application Publication No. 2004/0159062 to Donlin et al., each of the panels includes a top, a bottom, and first and second ends. A first overlap portion is adjacent to the first end and a second overlap portion is adjacent to the second end. The first overlap portion overlaps the second overlap portion of a horizontally adjacent panel. The first overlap portion includes a plurality of upwardly extending hooks. The second overlap portion defines a plurality of corresponding slots. As a result, the hooks are inserted into the slots defined in the horizontally adjacent panel to secure the panels to one another when mounting the panels on a support surface.
- One draw back to the prior art interlocks is that the interlocks are often difficult to manufacture into the panel and may result in installation problems because they include elements that protrude from the panel. These types of interlocks are also subject to damage during manufacturing and transportation due to their protruding nature. Therefore, it would be advantageous to provide an interlock in the overlapping end regions that overcomes such problems to secure horizontally adjacent panels to one another.
- The present invention provides a system for decoratively covering a support surface using a plurality of panels. Each of the panels has a top, a bottom, and first and second ends. A mounting flange is adjacent to the top to facilitate mounting of the panel to the support surface. A first row of decorative portions is disposed between the top and bottom to define a first front face and a second row of decorative portions is disposed between the top and bottom to define a second front face. A riser connects the first and second rows such that the first row is in a stepped relationship with the second row. A first overlap portion is adjacent to the first end and a second overlap portion is adjacent to the second end. The first overlap portion overlaps the second overlap portion of a horizontally adjacent panel mounted to the support surface. A first interlock, having an inner surface, extends from the riser at the first end. A second interlock, having an outer surface, extends from the riser at the second end. The inner and outer surfaces are defined as abutting surfaces sloped upwardly toward the top at an acute angle relative to at least one of the first and second front faces wherein the inner surface overlies and abuts the outer surface of the horizontally adjacent panel at the acute angle. This connection reduces relative movement between the panels when mounted on the support surface.
- In another aspect of the present invention, the first interlock includes a flap and the second interlock is further defined as a catch.
- The present invention provides an interlock between overlapping ends of adjacent panels that overcomes the problems that characterize the prior art. Specifically, the first and second interlocks of the present invention are unobtrusive and are easily formed into the panels when the panels are manufactured. Further, since the first and second interlocks do not protrude from the panel, there is little or no chance of the interlocks being damaged during manufacturing and transportation.
- Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
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FIG. 1 is a perspective view of a building with a system of the present invention providing a decorative covering for exterior walls of the building; -
FIG. 2 is a front perspective view of a panel of the system forming the decorative covering; -
FIG. 3 is a rear perspective view of the panel forming the decorative covering; -
FIG. 4 is a front perspective view of the first end of a first panel spaced from a second end of a second, horizontally adjacent panel prior to engagement with the second end having a second interlock with an outer surface; -
FIG. 5 is a front perspective view of the first panel fully engaging the second panel shown inFIG. 4 ; -
FIGS. 6A and 6B are cross-sectional views taken generally along line 6-6 inFIG. 5 illustrating the overlap of the horizontally adjacent panels and, more specifically, illustrating overlying and abutment of the inner and outer surfaces of the first and second interlocks; and -
FIG. 7 is a front perspective view of the panels integrated in a continuous strip of material formed from a vacuum-forming method. - Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a system for providing a decorative covering on a
support surface 11 is generally shown at 10 inFIG. 1 . Thesystem 10 comprises a plurality ofinterlocking panels 14 for mounting to thesupport surface 11. Thepanels 14 are positioned adjacent to one another to cover thesupport surface 11. Thesystem 10 preferably covers exterior support surfaces, such as those on exterior walls of buildings (seebuilding 12 illustrated inFIG. 1 ). In this instance, the panels are referred to as “siding” panels. In alternative embodiments, thesystem 10 may cover other surfaces or structures. Thepanels 14 are placed on thesupport surface 11 in a number of courses using methods well known to those skilled in the art. The dimensions of thepanels 14, such as length, may vary depending on the desired course layout of thepanels 14. - Referring to
FIGS. 2 and 3 , front and rear perspective views of one embodiment of thepanel 14 used in thesystem 10 is shown. In the preferred embodiment, each of thepanels 14 is substantially similar such that each of thepanels 14 can interlock with anyother panel 14. Each of thepanels 14 is preferably formed from a unitary sheet of material and has a top 16, a bottom 18, and first 20 and second 22 ends. The sheet of material is preferably a rigid thermoplastic, such as polyvinylchloride or “vinyl.” Eachpanel 14 defines a mountingflange 24 adjacent to the top 16. The mountingflange 24 is used to mount thepanel 14 to the support surface. The mountingflange 24 is also referred to as a nailinghem 24. The nailinghem 24 is generally flat and hasapertures 28 for receiving fasteners to secure thepanel 14 to thesupport surface 11. The nailinghem 24 is preferably folded onto itself as is well known to those in the siding art to increase strength and stability of thepanel 14. - A
butt flange 26 is disposed adjacent to the bottom 18, opposite the nailinghem 24. The butt flange 26 generally has a height that is greater than the nailinghem 24. Preferably, thebutt flange 26 has a generally hook-shaped clamping portion adjacent the bottom 18 comprising aflexible lip 27 for insertion under the folded over nailinghem 24. The folded over nailinghem 24 cooperates with theflexible lip 27 of verticallyadjacent panels 14 to secure thepanels 14 to one another in a manner well known to those skilled in the art. - The
panel 14 defines afirst row 30 ofdecorative portions 32 and asecond row 34 ofdecorative portions 32. The first 30 and second 34 rows are disposed, one above the other, between the top 16 and bottom 18. More specifically, the first 30 and second 34 rows are disposed between the nailinghem 24 and thebutt flange 26 and therows panels 14 are generally known asdouble panels 14, e.g., double-4, double-5 panels. Thefirst row 30 ofdecorative portions 32 defines a firstfront face 35 of thepanel 14 and thesecond row 34 ofdecorative portions 32 defines a secondfront face 37 that is generally parallel to the first front face. Each of the front faces preferably has a width of from about 3 to about 6 inches, more preferably from about 4 to about 5 inches. - Each
row decorative portions 32. Preferably, thedecorative portions 32 are impressions of real, authentic wood shake siding such that thepanels 14, when collectively mounted to thesupport surface 11, resembles real wood shake siding. Of course, thepanels 14 could also be formed to simulate other building materials. - A plurality of
grooves 36 are defined in the front faces 35, 37 of therows decorative portions 32 to divide thedecorative portions 32. Thegrooves 36 are substantially flat and recessed from thedecorative portions 32 to further create the appearance of real, authentic wood shake siding. Preferably, each of thegrooves 36 is disposed transversely across the front faces 35, 37. Thegrooves 36 in the firstfront face 35 are horizontally offset from thegrooves 36 in the secondfront face 37 when viewing thepanels 14 from the top 16 to the bottom 18. - A
riser 38 is disposed longitudinally between the first 30 and second 34 rows to connect thefirst row 30 to thesecond row 34 such that thefirst row 30 is in a stepped relationship with thesecond row 34. Theriser 38 extends between the first 20 and second 22 ends. Theriser 38 further enhances the appearance of the separatedecorative portions 32 and further creates the appearance ofseparate rows riser 38 has ashadow face 39 generally perpendicularly connecting the first 35 and second 37 front faces of the first 30 and second 34 rows. - A
first overlap portion 40 of thepanel 14 is disposed adjacent to thefirst end 20 and asecond overlap portion 50 is disposed adjacent to thesecond end 22. Thefirst overlap portion 40 overlaps thesecond overlap portion 50 of a second, horizontally adjacent panel (SeeFIG. 5 ) that has been previously mounted to thesupport surface 11. As a result, thesecond overlap portion 50 of the horizontally adjacent panel is hidden by thefirst overlap portion 40 of thepanel 14. Thesecond overlap portion 50 is recessed relative to the first 35 and second 37 front faces to define an abutment for thefirst overlap portion 40 and regulate an amount of overlap betweenadjacent panels 14 and guide mating of thepanels 14. - A
first interlock 42 extends from theriser 38 at thefirst end 20 and a second interlock 51 extends from theriser 38 at thesecond end 22. Thefirst interlock 42 is configured for interlocking with the second interlock 51 of the horizontally adjacent panel to secure thepanels 14 together on thesupport surface 11. Thefirst interlock 42 is preferably formed as part of thefirst overlap portion 40. Thefirst interlock 42 includes abent flap 43 extending from theriser 38 at thefirst end 20. Referring specifically toFIG. 3 , theflap 43 has an inner surface or first abuttingsurface 44 that is inclined or sloped upwardly toward the top 16. Theflap 43 also has an outer surface that is exposed when mounted to thesupport surface 11. As a result, the outer surface preferably has a stylized portion thereon. However, the stylized portion may be omitted, as inFIG. 2 . Referring specifically toFIG. 2 , the second interlock 51 is further defined as a catch 52 for receiving theflap 43. The catch 52 includes a recessed portion for receiving theflap 43. The catch 52 has an outer surface or a second abuttingsurface 54 sloped upwardly toward the top 16. -
FIG. 4 illustrates thepanel 14 having thefirst end 20 aligned to engage thesecond end 22 of a second, horizontallyadjacent panel 15. Thefirst overlap portion 40 of thepanel 14 overlaps thesecond overlap portion 50 of thesecond panel 15 such that the first 42 and second 52 interlocks of thepanels FIG. 5 illustrates thepanel 14 fully engaging thesecond panel 15. Theflexible lip 27 of the clamping portion that is disposed in thefirst overlap portion 40 flexes over thesecond overlap portion 50 at the bottom 18 of thesecond panel 15 to secure thepanels - As shown in
FIG. 4 , thefirst overlap portion 40 of thepanel 14 includes a first overlapping section (see numeral 40 near the top 16) at one end of thefirst row 30 and a second overlapping section (see numeral 40 near the bottom 18) at one end of thesecond row 34. These sections are offset from one another. Likewise, thesecond overlap portion 50 of thesecond panel 15 includes a first overlapping section (see numeral 50 near the top 16) extending from one end of thefirst row 30 and a second overlapping section (see numeral 50 near the bottom 18) extending from one end of thesecond row 34. These sections are also offset from one another. As a result, the first overlapping sections and the second overlapping sections of theoverlap portions overlap portions FIG. 5 , a gap between thedecorative portions 32 in thefirst row 30 is offset from a gap between thedecorative portions 32 in thesecond row 34. This further provides the authentic cedar shake appearance. - Referring again to
FIGS. 4 and 5 , acontact wall 56 interconnects theriser 38 and the catch 52 such that theriser 38 rises above the catch 52 to define an abutment. Thecontact wall 56 extends substantially perpendicular to theriser 38 to guide theflap 43 of thepanel 14 into mating engagement with the catch 52. As shown inFIG. 5 , when thepanels flap 43 is fitted into the catch 52 such that a gap is maintained between theflap 43 and thecontact wall 56. - Referring to
FIGS. 6A and 6B cross-sectional views taken generally along line 6-6 inFIG. 5 are shown.FIG. 6A shows thefirst panel 14 as it is installed horizontally next to thesecond panel 15, which is already mounted to thesupport surface 11. More specifically,FIG. 6A illustrates thefirst interlock 42 of thefirst panel 14 engaging the second interlock 51 of thesecond panel 15. As can be seen, the first abuttingsurface 44 abuts the second abuttingsurface 54. This fit provides for improved stability of thepanels support surface 11, e.g., the exterior surface of thebuilding 12, and limits the vertical movement ofsuch panels FIG. 6B illustrates thefirst panel 14 interlocked and installed with thesecond panel 15 on thesupport surface 11.FIG. 6B also illustrates additional courses of thepanels 14 installed above the first 14 and second 15 panels to illustrate the fit between thenail hem 24 and theflexible lip 27 of vertically adjacent panels. - As shown in
FIG. 6B , the first abuttingsurface 44 is inclined or sloped upwardly toward the top 16 at a first acute angle α relative to the generally parallel first 35 and second 37 front faces. The first abuttingsurface 44 forms a second acute angle β with theshadow face 39. The first acute angle α is preferably less than 90 degrees, more preferably from about 25 degrees to about 85 degrees, and most preferably from about 65 degrees to about 80 degrees. The second acute angle β is preferably greater than 0 degrees, more preferably from about 5 degrees to about 65 degrees, and most preferably from about 10 degrees to about 25 degrees. The secondabutting surface 54 slopes upwardly toward the top 16 at the same first acute angle α relative to the first 35 and second 37 front faces. The secondabutting surface 54 forms the same second acute angle β with theshadow face 39. The first abuttingsurface 44 overlies the second abuttingsurface 54 of the horizontallyadjacent panel 15 to reduce relative movement between thepanels - Various methods may be used to form the
panels 14 of the present invention. One especially useful method is disclosed in U.S. Pat. No. 6,635,218 to King entitled “Continuous Production of Plastic Siding Panels with Separate Shingle Appearance”, which is hereby incorporated by reference.FIG. 7 illustrates a singlecontinuous strip 62 of thermoplastic material that can be cut intoindividual panels 14. The first and the second ends 20, 22, when formed from such a method, are initially integrally formed together and then cut. When thecontinuous strip 62 is sectioned into theindividual panels 14, the first and second ends 20, 22 are separated to create the appearance shown inFIGS. 4 and 5 . - While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (26)
1. A system for providing a decorative covering on a support surface, said system comprising:
a plurality of panels, each of said panels having a top and a bottom and first and second ends and including:
a first row of decorative portions disposed between said top and bottom to define a first front face and a second row of decorative portions disposed between said top and bottom to define a second front face,
a riser connecting said first and second rows such that said first row is in a stepped relationship with said second row, and
a first interlock having an inner surface extending from said riser at said first end and a second interlock having an outer surface extending from said riser at said second end,
said inner surface overlying said outer surface and being sloped upwardly toward said top at an acute angle relative to at least one of said first and second front faces to secure said interlocks together and reduce relative movement between said panels when mounted to the support surface.
2. The system as set forth in claim 1 wherein said riser defines a shadow face generally perpendicular to said first and second front faces and each of said inner and outer surfaces slope upwardly from said riser toward said top at a second acute angle relative to said shadow face.
3. The system as set forth in claim 1 wherein said first interlock includes a flap extending from said riser at said first end and said second interlock is further defined as a catch extending from said riser at said second end for mating engagement with said flap of a second horizontally adjacent panel.
4. The system as set forth in claim 24 wherein said second overlap portion is recessed relative to said first and second front faces to define an abutment for said first overlap portion of a second horizontally adjacent panel to regulate an amount of overlap between adjacent panels and guide mating of said abutting surfaces.
5. The system as set forth in claim 24 including a clamping portion adjacent said bottom having a flexible lip for flexing over said second overlap portion at said bottom of said horizontally adjacent panel to secure said panels together at said bottom.
6. The system as set forth in claim 23 wherein said mounting flange is further defined as a nailing hem.
7. The system as set forth in claim 1 wherein said decorative portions include a plurality of grooves defined in said first and second front faces and extending transversely across said front faces with said grooves being offset between said first front face and said second front face to simulate shake shingles.
8. The system as set forth in claim 1 wherein each of said panels is formed in a unitary sheet of material.
9. The system as set forth in claim 8 wherein each of said panels is cut from a continuous strip of said material.
10. The system as set forth in claim 1 wherein each of said front faces has a width of from about 3 to about 6 inches.
11. The system as set forth in claim 10 wherein each of said front faces has a width of from about 4 to about 5 inches.
12. The system as set forth in claim 24 wherein each of said first and second overlap portions include a first overlapping section and a second overlapping section offset from said first overlapping section to define offset gaps between said panels when interconnected.
13. A panel for decoratively covering a support surface, said panel comprising:
a top and a bottom and first and second ends,
a first row of decorative portions disposed between said top and bottom to define a first front face and a second row of decorative portions disposed between said top and bottom to define a second front face,
a riser connecting said first and second rows such that said first row is in a stepped relationship with said second row, and
a first interlock having an inner surface extending from said riser at said first end and a second interlock having an outer surface extending from said riser at said second end,
said inner surface overlying said outer surface and being sloped upwardly toward said top at an acute angle relative to at least one of said first and second front faces to secure said interlocks together and reduce relative movement between the panels when mounted to the support surface.
14. The panel as set forth in claim 13 wherein said riser defines a shadow face generally perpendicular to said first and second front faces and each of said inner and outer surfaces slope upwardly from said riser toward said top at a second acute angle relative to said shadow face.
15. The panel as set forth in claim 13 wherein said first interlock includes a flap extending from said riser at said first end and said second interlock is further defined as a catch extending from said riser at said second end for mating engagement with said flap of a second horizontally adjacent panel.
16. The panel as set forth in claim 15 including a contact wall interconnecting said riser and said catch such that said riser is raised above said catch to define an abutment for said flap of said second horizontally adjacent panel.
17. The panel as set forth in claim 26 wherein said second overlap portion is recessed relative to said first and second front faces to define an abutment for said first overlap portion of a second horizontally adjacent panel to regulate an amount of overlap between adjacent panels and guide mating of said abutting surfaces.
18. The panel as set forth in claim 26 including a clamping portion adjacent said bottom having a flexible lip for flexing over said second overlap portion at said bottom of the horizontally adjacent panel to secure the panels together at said bottom.
19. The panel as set forth in claim 25 wherein said mounting flange is further defined as a nailing hem.
20. The panel as set forth in claim 13 wherein said decorative portions include a plurality of grooves defined in said first and second front faces and extending transversely across said front faces with said grooves being offset between said first front face and said second front face to simulate shake shingles.
21. The panel as set forth in claim 13 wherein each of said front faces has a width of from about 3 to about 6 inches.
22. The panel as set forth in claim 21 wherein each of said front faces has a width of from about 4 to about 5 inches.
23. The system as set forth in claim 1 including a mounting flange adjacent said top.
24. The system as set forth in claim 1 including a first overlap portion adjacent said first end and a second overlap portion adjacent said second end wherein said first overlap portion is configured for overlapping said second overlap portion of a horizontally adjacent panel mounted to the support surface.
25. The panel as set forth in claim 13 including a mounting flange adjacent said top.
26. The panel as set forth in claim 13 including a first overlap portion adjacent said first end and a second overlap portion adjacent said second end wherein said first overlap portion is configured for overlapping said second overlap portion of a horizontally adjacent panel mounted to the support surface.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US12/858,260 US20110036037A1 (en) | 2005-12-22 | 2010-08-17 | System for providing a decorative covering on a support surface using panels with interlocks |
Applications Claiming Priority (3)
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US75319905P | 2005-12-22 | 2005-12-22 | |
US11/613,470 US7775009B2 (en) | 2005-12-22 | 2006-12-20 | System for providing a decorative covering on a support surface using panels with interlocks |
US12/858,260 US20110036037A1 (en) | 2005-12-22 | 2010-08-17 | System for providing a decorative covering on a support surface using panels with interlocks |
Related Parent Applications (1)
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US11/613,470 Continuation US7775009B2 (en) | 2005-12-22 | 2006-12-20 | System for providing a decorative covering on a support surface using panels with interlocks |
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US20110036037A1 true US20110036037A1 (en) | 2011-02-17 |
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US12/858,260 Abandoned US20110036037A1 (en) | 2005-12-22 | 2010-08-17 | System for providing a decorative covering on a support surface using panels with interlocks |
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US11/613,470 Active 2028-10-04 US7775009B2 (en) | 2005-12-22 | 2006-12-20 | System for providing a decorative covering on a support surface using panels with interlocks |
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US (2) | US7775009B2 (en) |
CA (1) | CA2572000C (en) |
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US8863461B2 (en) * | 2013-01-21 | 2014-10-21 | Tapco International Corporation | Siding panel system |
USD754885S1 (en) | 2013-10-14 | 2016-04-26 | Quality Edge, Inc. | Shake metal roof panel |
USD747500S1 (en) | 2013-11-13 | 2016-01-12 | Quality Edge, Inc. | Slate metal roof panel |
US9097019B1 (en) | 2014-01-31 | 2015-08-04 | Quality Edge, Inc. | Modular roof panel with integrated drainage system |
US9181702B2 (en) | 2014-01-31 | 2015-11-10 | Quality Edge, Inc. | Modular roof panel with integrated drainage system |
US9181703B2 (en) | 2014-01-31 | 2015-11-10 | Quality Edge, Inc. | Modular roof panel with integrated drainage system |
US9181704B2 (en) | 2014-01-31 | 2015-11-10 | Quality Edge, Inc. | Modular roof panel with integrated drainage system |
US9593488B2 (en) | 2014-01-31 | 2017-03-14 | Certainteed Corporation | Modular roof panel with integrated drainage system |
US9689164B2 (en) | 2014-01-31 | 2017-06-27 | Certainteed Corporation | Modular roof panel with integrated drainage system |
WO2015195290A1 (en) * | 2014-06-17 | 2015-12-23 | Ply Gem Industries, Inc. | Siding panel with interlock |
USD776833S1 (en) | 2014-06-27 | 2017-01-17 | Certainteed Corporation | Metal roofing |
US20180016793A1 (en) * | 2016-07-14 | 2018-01-18 | Tapco International Corporation | Elongated utility receiver |
Also Published As
Publication number | Publication date |
---|---|
CA2572000C (en) | 2013-02-12 |
US20070144095A1 (en) | 2007-06-28 |
US7775009B2 (en) | 2010-08-17 |
CA2572000A1 (en) | 2007-06-22 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: TAPCO INTERNATIONAL CORPORATION, MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KING, DANIEL W.;REEL/FRAME:024848/0702 Effective date: 20061206 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |