U.S. patent application number 10/723660 was filed with the patent office on 2005-05-26 for clapboard siding panel with built in fastener support.
Invention is credited to Morse, Rick James.
Application Number | 20050108965 10/723660 |
Document ID | / |
Family ID | 34592333 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050108965 |
Kind Code |
A1 |
Morse, Rick James |
May 26, 2005 |
Clapboard siding panel with built in fastener support
Abstract
A generally rectangular siding panel is provided having a front
and rear faces, The rear face has a first area proximate to a top
end of the rear face and shaped such that at least a portion of the
area sits substantially flush with a portion of a vertical wall
when the siding panel is secured to the vertical wall and angled to
overlap at least a portion of a second siding panel secured to the
vertical wall.
Inventors: |
Morse, Rick James; (Grass
Lake, MI) |
Correspondence
Address: |
DUANE MORRIS, LLP
IP DEPARTMENT
ONE LIBERTY PLACE
PHILADELPHIA
PA
19103-7396
US
|
Family ID: |
34592333 |
Appl. No.: |
10/723660 |
Filed: |
November 26, 2003 |
Current U.S.
Class: |
52/518 |
Current CPC
Class: |
E04F 13/0864
20130101 |
Class at
Publication: |
052/518 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A generally rectangular siding panel having a front and rear
faces, said rear face having a first area proximate to a top end of
said rear face shaped such that at least a portion of said area
sits substantially flush with a portion of a vertical wall when
said siding panel is secured to said vertical wall and angled to
overlap at least a portion of a second siding panel secured to said
vertical wall.
2. The siding panel of claim 1, wherein said siding panel is a
clapboard siding panel.
3. The siding panel of claim 1, wherein said siding panel is a
fiber cement or wood clapboard siding panel.
4. The siding panel of claim 1, wherein said first area comprises a
reinforced area
5. The siding panel of claim 4, wherein said reinforced area
comprises a protruding area that extends substantially along the
entire length of said rear face.
6. The siding panel of claim 4, wherein said reinforced area
includes a planar first face that is disposed to contact said
portion of said vertical wall, said planar first face having a
height of about at least one inch.
7. The siding panel of claim 4, wherein said reinforced area
includes a planar face a planar face that is disposed to sit
substantially flush with said portion of said vertical wall when
said rear face overlaps said second siding panel such that a major
portion of said rear face forms an angle with said vertical wall
between about 1-10 degrees.
8. The assembly of claim 4, wherein said reinforced area comprises:
a thickened portion, a resinous, fibrous or particulate
reinforcement, a fabric, scrim or panel.
9. A siding panel assembly, comprising: at least a first and a
second siding panels attached to a vertical wall of a structure,
each of said siding panels being a generally rectangular shaped
panel having a front and rear faces, said first siding panel angled
to overlap at least a portion of said second siding panel, said
rear face of at least said first siding panel having a reinforced
area proximate to a top end of said rear face shaped such that at
least a portion of said area sits substantially flush with a
portion of said vertical wall.
10. The assembly of claim 9, wherein said reinforced area extends
substantially along the entire length of said rear face.
11. The assembly of claim 9, wherein said siding panels are fiber
cement clapboard siding panels.
12. The assembly of claim 9, wherein said siding panels are
installed using a blind nail method using a plurality of nails and
at least some of said nails are disposed through said reinforced
area.
13. The assembly of claim 9, wherein said siding panels are
installed using a face nail method using a plurality of nails and
at least some of said nails are disposed through said reinforced
area.
14. The assembly of claim 9, wherein said siding panels are secured
to said vertical wall at least in part by a series of fasteners
extending through said respective siding panels and into said
vertical wall, wherein at least some of said fasteners are disposed
through said reinforced area.
15. The assembly of claim 9, wherein said reinforced area includes
a planar first face that contacts said portion of said vertical
wall, said planar first face having a height of at least about one
inch.
16. The assembly of claim 9, wherein said reinforced area includes
a planar face that contacts said portion of said vertical wall,
said planar face extending from a top edge of said first siding
panel at an angle that substantially matches an angle between said
rear face of said first panel and said wall created by said
overlap.
17. A method of installing a siding panel assembly on a structure,
comprising the following steps: providing at least a first and
second siding panels, each of said siding panels being a generally
rectangular shaped panel having a front and rear faces, said rear
face of at least said first siding panel having a first area
proximate to a top end of said rear face shaped such that at least
a portion of said area sits substantially flush with a portion of
said vertical wall when said first siding panel is secured to said
wall and angled to overlap at least a portion of said second siding
panel; and attaching said first and second siding panels to said
structure such that a rear face of said first siding panel
partially overlaps a front face of said second siding panel.
18. The method of claim 17, wherein said first area is a reinforced
area.
19. The method of claim 18, wherein: said attaching step utilizes a
blind nail attachment method comprising driving a series of nails
through said first siding panel, through said reinforced area and
into said vertical wall.
20. The method of claim 18, wherein: said attaching step utilizes a
face nail attachment method comprising driving a series of nails
through said first siding panel, through said reinforced area and
into said vertical wall.
21. The method of claim 17, wherein said attaching step includes
the step of driving a series of nails fasteners through said first
area of said first siding panel.
22. The method of claim 17, wherein said siding panels are
clapboard siding panels.
23. The method of claim 17, wherein said siding panels are fiber
cement clapboard siding panels.
24. The method of claim 17, wherein said first area includes a
planar face that contacts said portion of said vertical wall and a
major portion of said rear face forms an angle with said vertical
wall between about 1-10 degrees.
25. A generally rectangular shaped clapboard siding panel having a
front and rear faces, said rear face having a protruding area
proximate to a top end of said rear face shaped such that at least
a portion of said area sits substantially flush with a portion of a
vertical wall when said siding panel is secured to said vertical
wall and angled to overlap at least a portion of a second siding
panel secured to said vertical wall, such that said vertical wall
provides support for said rear face when fasteners are driven
through said clapboard siding panel and into said vertical wall
through said protruding area.
26. The siding panel of claim 25, wherein said protruding area
includes a planar face that is disposed to sit substantially flush
with said portion of said vertical wall when said rear face
overlaps said second siding panel such that a major portion of said
rear face forms an angle with said vertical wall between about 1-10
degrees.
27. A siding panel having front and rear faces and a longitudinal
length, said rear surface having a first portion forming and
oblique angle with respect to a vertical wall to which said siding
panel is affixed, said rear surface of said siding panel also
including a second portion which is disposed in substantially flush
contact with said vertical wall when said siding panel is affixed
to said vertical wall.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to siding products and methods
of installing siding products, and more particularly to clapboard
siding products and methods of installing the same.
BACKGROUND OF THE INVENTION
[0002] Typically, clapboard siding panels, such as fiber cement
clapboard siding panels, are installed on a wall of a structure,
generally on a sheathing product, in one of two ways--either in a
so called "blind nail" method or a so called "face nail" method. In
the blind nail method, illustrated by siding panel assembly 20 of
FIG. 2, a first siding panel 16a is aligned on the face of a wall
12 and a series of horizontally spaced nails (not shown) is driven
through the panel 16a, generally through an upper region of the
exterior face of the panel 16a, into the wall 12. A second panel
16b is then secured to the wall 12 in the same manner using a
series of nails 18. The second panel 16b overlaps a portion of the
exterior face of the first panel 16a and covers the nails or
fasteners driven through the first panel 16a. Another panel (not
shown) is then installed overlapping panel 16b and covering nails
18.
[0003] In the face nailing method shown by panel assembly 10 of
FIG. 1, the first siding panel 14a is properly aligned on the wall
12. A second siding panel 14b is then aligned overlapping the first
siding panel 14a, as described above, and nails 18a are driven
through both siding panels 14a, 14b, exposing the head of the nail
18a at the exterior surface of the second siding panel 14b. This
process is repeated with subsequent siding courses, such as panels
14c and 14d shown in FIG. 1, using nails 18b and 18c.
[0004] FIG. 3 is a side cross-sectional view of the panel assembly
20 of FIG. 2. As can be seen from the cross-sectional view, the
panels 16a and 16b of this assembly do not sit flush with the wall
12, i.e., a gap, illustrated generally by reference 22, exists
between the siding panels and the wall 20 proximate to where nails
18 are driven through the panels. As explained above, fasteners 18
secure the panels to the wall 20. Because of the gap between the
wall 20 and the siding panels, the fasteners apply a bending force
to the panel, both when being driven through the panels and after
being secured to wall 20. This bending force stresses the panels
and can lead to cracking. Further, the nails tend to fracture the
rear surface of the panels as they puncture the rear surface and
enter the gap area 22 between the rear surface of the panels and
the wall, like a bullet exiting an object into free space. The
stress cracks and fractures, in turn, can expose the panels to
water, weaken the holding strength of the fasteners and generally
reduce the product life of the panels. Similar problems are
encountered with the assembly 10 of FIG. 1.
[0005] In light of the above, there is a need for a new siding
panel system and panel configuration that reduce or eliminate
stresses and fractures placed on the siding panel both during and
after installation.
SUMMARY OF THE INVENTION
[0006] A generally rectangular siding panel is provided having a
front and rear faces. The rear face has a first area proximate to a
top end of the rear face and shaped such that at least a portion of
the area sits substantially flush with a portion of a vertical wall
when the siding panel is secured to the vertical wall and angled to
overlap at least a portion of a second siding panel secured to the
vertical wall.
[0007] Because at least a portion of the rear face, i.e., a first
or protruding portion of the rear face, sits flush with the
vertical wall, a gap proximate to the nail puncture and between the
rear face and the wall is substantially eliminated and the wall
provides support for the rear face during the nailing step. This
support helps to reduce the fracturing or splintering of the rear
face local to the nail puncture and helps to minimize bending of
the siding panel as the nail is driven into the wall, thereby
further reducing stresses that can lead to fractures in the siding
panel. The reduction of fractures in the siding panel can reduce
exposure of the siding panel to water damage and improve the
strength of the connection between the siding panel and the wall,
thereby improving the panel's wind load resistance.
[0008] In one embodiment, a generally rectangular shaped clapboard
siding panel is provided having a front and rear faces, the rear
face having a first area proximate to a top end of the rear face
shaped such that at least a portion of the area sits substantially
flush with a portion of a vertical wall when the siding panel is
secured to the vertical wall and angled to overlap at least a
portion of a second siding panel secured to the vertical wall, such
that the vertical wall provides support for the rear face when
fasteners are driven through the clapboard siding panel and into
the vertical wall through the first area. The first area can be
reinforced, such as by thickening, fibrous, particle or resin
reinforcement or by the addition of a reinforcing member, such as a
metal mesh, scrim, fabric, or panel, for example, made of glass,
graphite, plastic or metal, such as galvanized steel mesh or sheet
metal. These reinforcements are preferably embedded or laminated to
the panel at least on or in the first area.
[0009] A siding panel assembly is also provided including a first
and a second siding panels attached to a vertical wall of a
structure. Each of the siding panels has a generally rectangular
shaped panel having a front and rear faces. The first siding panel
is angled to overlap at least a portion of the second siding panel.
The rear face of at least the first siding panel has a first area
proximate to a top end of the rear face shaped such that at least a
portion of the area sits substantially flush with a portion of the
vertical wall.
[0010] A method of installing a siding panel assembly on a
structure is also provided. A first and second siding panels are
provided. Each of the siding panels has a generally rectangular
shaped panel having a front and rear faces. The rear face of at
least the first siding panel has a protruding area proximate to a
top end of the rear face shaped such that at least a portion of the
area sits substantially flush with a portion of the vertical wall
when the first siding panel is secured to the wall and angled to
overlap at least a portion of the second siding panel.
[0011] The above and other features of the present invention will
be better understood from the following detailed description of the
preferred embodiments of the invention that is provided in
connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings illustrate preferred embodiments
of the invention, as well as other information pertinent to the
disclosure, in which:
[0013] FIG. 1 is a partial perspective view of a prior art face
nail clapboard panel assembly;
[0014] FIG. 2 is a partial perspective view of a prior art blind
nail clapboard panel assembly;
[0015] FIG. 3 is a side cross-sectional view of the assembly of
FIG. 2;
[0016] FIG. 4 is a side elevational view of a clapboard siding
panel according to the present invention;
[0017] FIG. 5 is a side cross-sectional view of a clapboard siding
panel assembly utilizing the clapboard siding panel of FIG. 4;
[0018] FIG. 6 is a side elevational view of an alternative
embodiment of a clapboard siding panel according to the present
invention;
[0019] FIG. 6A is an enlarged view of a portion of the panel of
FIG. 6; and
[0020] FIG. 7 is a side cross-sectional view of a clapboard siding
panel assembly utilizing the clapboard siding panel of FIG. 6.
DETAILED DESCRIPTION
[0021] Referring first to FIG. 4, a side elevational view of a
siding panel 100 is shown. Siding panel 100 has a generally
rectangular shape, like the siding panels shown in the perspective
views of FIGS. 1 and 2, and, in an exemplary embodiment, is a
clapboard siding panel, preferably a fiber cement clapboard siding
panel. "Fiber Cement" refers to a cementitious composition
including Portland cement, cellulose fibers and aggregate
(typically, sand). Siding panel 100 has front and rear faces 102
and 104, respectively. In one embodiment, the siding panel may be
between about 12'-16' in length, as is conventional, with faces
between about 5" to 16" in height. The siding panel has a thickness
typically between about 1/8 to 1/2", and preferably around
{fraction (3/16)}".
[0022] The panel 100 includes a first area 106 located proximate to
the top edge 108 of the panel and preferably extending along the
length of the rear face 104. The first area 106 is shaped such that
a face of the area sits flush against a vertical wall 110 when a
first siding panel 100a is secured to a wall 110 and angled to at
least partially overlap a second siding panel 100b, as shown in the
assembly 200 of FIG. 5. In one embodiment, the first area has a
first planar face 106a that contacts the wall 110 during and after
installation and a second face 106b that connects the first face to
the remainder of the rear face 104. The first planar face 106a
extends from the top edge 108 and forms an angle ".alpha." with the
major portion of the rear face 104 of the siding panel. Angle
.alpha. is selected such that the sum of angle .alpha. and angle
".beta." are preferably between about 170-190.degree., and more
preferably about 180.degree., at installation where angle .beta. is
the angle between the major surface of rear face 104 and the wall
110 created when the panel is installed (as described below in
connection with FIG. 5) to overlap another siding panel. Angle
.beta. is typically between about 1-10.degree., so angle .alpha. is
preferably between about 170-179.degree. so that the face 106a is
substantially flush with the wall 110.
[0023] During installation of a panel 100, nails are driven through
a siding panel to secure the panel to the wall after the panel is
correctly positioned on a wall. In a conventional assembly, each
nail is typically positioned within about an inch from the top edge
108. With respect to siding panel 100, it is preferred that the
nails are driven through the first area 106 of the siding panel
100, and preferably through face 106a that sits flush with the
vertical wall after the panel 100 is correctly positioned. For this
reason, face 106a should have a height along rear face 104 of at
least one inch.
[0024] During installation, a siding panel 100 is positioned on a
wall 110 so that at least a portion of the first area 106 is flush
with a portion of the wall 110, as shown in FIG. 5. A series of
horizontally spaced nails 112 are then driven through the siding
panel 100 and through the first portion 106 (specifically, through
the face 106a that lies flush with the wall 110), and into the wall
110. Because the face 106a sits flush with the wall 110, the gap 22
proximate to the nail puncture is eliminated and the wall 110
provides support for the face 106a during the nailing step. This
support prevents the fracturing or splintering of the rear face 104
local to the nail puncture and prevents bending of the siding panel
as the nail 112 is driven into the wall 110. The reduction of
fractures and other stresses in the siding panel can reduce
exposure of the siding panel to water damage and improve the
strength of the connection between the siding panel and the wall,
thereby improving the panel's wind load resistance and product
life.
[0025] Although FIG. 5 illustrates a siding panel assembly 200
having only two overlapping siding panels 100a, 100b, it should be
understood that this is for purposes of illustration only. Also,
although siding panel assembly 200 is shown assembled via the so
called "blind nail" method, an assembly may also be formed using
panels 100 via the "face nail" assembly method described above in
the "Background of the Invention" section. Similar panels are
preferably, but not necessarily, used to form the assembly, i.e.,
each panel preferably has a respective first area 106 located on
the rear face 104.
[0026] Although the siding panels illustrated herein are described
as clapboard fiber cement siding panels, this is by no means a
requirement. One of ordinary skill will realize that siding panels
may be fabricated from a variety of materials other than fiber
cement, such as wood or plastic, such as PVC, or composites
thereof. It should also be apparent that, although not illustrated,
the siding panel assembly described herein may include other
products typically included in panel assemblies, such as sheathing,
air and water barriers and insulation.
[0027] Fabrication of the panels 100 having first portion 106
described above may be accomplished using known fabrication
techniques for manufacturing fiber cement or other clapboard siding
panels. For example, first area shapes can simply be incorporated
into the press or mold contour used to fabricate fiber cement
clapboard siding panels. This manufacturing process is often
referred to as "Post Press." Alternatively, an accumulator roll
process, for example, may be utilized.
[0028] A method of installing a siding panel assembly on a
structure is also provided herein. A first and second siding panels
are provided. At least a first one of the siding panels is
configured like a siding panel 100 described above, i.e., it has a
first area 106 on a rear face thereof. First and second siding
panels are attached to the structure such that the first area of
the first siding panel sits substantially flush with the vertical
wall of the structure when the first siding panel is angled to
overlap at least a portion of the second siding panel. Nails are
driven through the panels to secure the panels to the wall as
described above in either the face or blind nail manner.
Preferably, this process is repeated until the structure is covered
with siding panels. As noted, the nails are preferably positioned
so that they are driven through the portion of the first area that
is flush with the wall of the structure, thereby providing a secure
nailing surface and reducing or eliminating stress induced
fracturing of the rear face of the siding panel.
[0029] FIG. 6 illustrates a siding panel 308 having first area 306
without a protruding area, described in connection with the panel
100 of FIG. 4, but angled to provide the flush seating with wall
110, as shown in the assembly 300 of FIG. 7. Panels 308a and 308b
are installed in the manner described above for panels 100 in the
assembly 200. Like panel 100, siding panel 308 has front and rear
faces 302, 304 respectively and a longitudinal length. The rear
surface 304 has a first portion of the rear face 304 forming an
oblique angle .beta. with respect to the exterior surface of
vertical wall 110 to which the siding panels 308 are affixed. The
rear surface 304 of the siding panels 308 also include a second
portion in area 306 that is disposed in substantially flush contact
with the vertical wall 110 when the siding panel 308 is affixed to
the vertical wall 110. The portion of rear face that sits flush
with wall 110 forms an angle .alpha. with the first portion of rear
surface 304. The sum of angles .alpha. and .beta. preferably total
180.degree., but may be in the range of about 170-190.degree. so
that the second portion is substantially flush with the wall 110.
The second portion of the rear face in contact with the wall 110
preferably has a height of at least 1" so that nails or other
fasteners may be driven through the same and into wall 110, thereby
providing a secure nailing surface and reducing or eliminating
stress induced fracturing of the rear face of the siding panel.
[0030] In one embodiment, the first area 306 (FIG. 6) (or 106 for
panel 100) can be reinforced, such as by thickening, fibrous,
particle or resin reinforcement or by the addition of a reinforcing
member, such as a metal mesh, scrim, fabric, or panel, for example,
made of glass, graphite, plastic or metal, such as galvanized steel
mesh or sheet metal. These reinforcements are preferably embedded
or laminated to the panel on or in the first area as taught in, for
example, U.S. patent application Ser. No. 10/288,189 to William P.
Bezubic Jr., filed Nov. 5, 2002, entitled "Cementitious External
Sheathing Member with Rigid Support Member" commonly assigned to
the assignee of the present application, the entirety of which is
hereby incorporated by reference herein.
[0031] Bezubic Jr. teaches that a rigid support member 400 may be
bonded with a fiber cement material, as shown in the enlarged
partial side view of the panel 308 (FIG. 6A). The enlarged view of
FIG. 6A illustrates fiber cement panel 308 as including plurality
of laminated layers with a support member 400 bonded to the rear
surface 304 at last along a portion of rear surface 304 at the
first area 306. Bezubic Jr. provides that the support member 400
may includes a rigid polymer resin, such as, rigid polyvinyl
chloride ("PVC"), fiberglass-reinforced epoxy or polyester, or a
metal plate, sheet or lath. Suitable metallic materials include
anodized or polymer-coated aluminum or copper, brass, bronze,
stainless steel, or galvanized steel, in plate, sheet or lath form.
If aluminum is selected, it should be coated wherever it comes in
contact with the cementitious material, since it is prone to attack
by alkali compositions. Similarly, carbon steel selections should
be coated or galvanized in order to prevent rusting. The metal
plate or lath can be roll formed and punched in order to provide
through-holes for fasteners. If a lath, scrim, or mesh construction
is used, separate holes may not be necessary since the open
construction of a lath, scrim, or mesh is ideal for mechanically
locking with the cementitious layer of the panel 308 and is easily
penetrated by fasteners such as nails and screws. With lath or
scrim constructions, embedding the support member within the
cementitious layer of the panel 308 is an option, in which case,
the rigid support member may contain corrugations, grooves
perforations or ridges to assist in mechanically locking with the
cementitious layer of the panel.
[0032] As noted, Bezubic Jr. also teaches the use of reinforcing
additives within the fiber cement structure. These additives are
shown as fibers 402 in FIG. 6A. These fibers may be added to the
cementitious layers of the panel 308 in order to increase the
interlaminar bond strength, compressive, tensile, flexural, and
cohesive strengths of the unhardened wet material as well as the
hardened panels made therefrom. Fibers should preferably have high
tear and burst strengths (i.e., high tensile strength), examples of
which include waste paper pulp, abaca, southern pine, hardwood,
flax, bagasse (sugar cane fiber), cotton, and hemp. Fibers with a
high aspect ratio of about 10 or greater work best in imparting
strength and toughness to the moldable material.
[0033] In U.S. patent application Ser. No. 10/342,529 to William P.
Bezubic Jr. and Claude Brown Jr., filed Jan. 15, 2003, entitled
"Cementitious External Sheathing Member Having Improved
Interlaminar Board Strength" (Bezubic II), commonly assigned to the
assignee of the present application, the entirety of which is
hereby incorporated by reference herein, the Applicants teach the
introduction of a resinous bond promoter, such as acrylic, starch,
polyvinyl alcohol, or polyvinyl acetate, a Theological agent, or
the use of mechanical means described below to improve the strength
between individual layers of cementitious material. Sufficient
resinous additions, manipulation of the fiber, or both, can result
in improvements to ILB (inter-laminate board) strength. In addition
to resinous bond promoters and Theological agents, Bezubic II
proposes the use of mechanical manipulation of the wood fiber so
that the individual fibers can be oriented in a "z" direction
between layers to improve ILB strength. In addition to using the
suggested additives, or apart therefrom, Bezubic II proposes the
use of a series of pins, partially or fully disposed within the
layer or layers of the fiber cement product to pierce the sheet and
displace the fibers perpendicular to the direction of the forming
machine, thus allowing the fibers to join the sheets together.
Bezubic II also teaches employing further, or alternatively, a
piercing wheel, punching die, vibration table, needling equipment,
or a smoother surface such as a roll or plate that can be used to
upset the fiber location on each, or selective ones, of the layers
of the fiber cement product.
[0034] Although the invention has been described in terms of
exemplary embodiments, it is not limited thereto. Rather, the
appended claims should be construed broadly to include other
variants and embodiments of the invention that may be made by those
skilled in the art without departing from the scope and range of
equivalents of the invention.
* * * * *