U.S. patent application number 10/838813 was filed with the patent office on 2005-11-10 for interlocking self-aligning cladding panel for floors, walls, ceilings, or the like.
Invention is credited to Zhu, Sai Yu.
Application Number | 20050247000 10/838813 |
Document ID | / |
Family ID | 35238170 |
Filed Date | 2005-11-10 |
United States Patent
Application |
20050247000 |
Kind Code |
A1 |
Zhu, Sai Yu |
November 10, 2005 |
Interlocking self-aligning cladding panel for floors, walls,
ceilings, or the like
Abstract
Interlocking cladding panels for floors, walls, ceilings, or the
like, having a top surface and a bottom surface and terminating
with at least a receiving edge and an engaging edge. The receiving
edge has a head tooth, a leveling tooth recess, an intermediate
tooth, a locking tooth recess, and a foot tooth. The engaging edge
has a head tooth recess to cooperate with the head tooth, a
leveling tooth to cooperate with the leveling tooth recess, an
intermediate tooth recess to cooperate with the intermediate tooth,
a locking tooth to cooperate with the locking tooth recess, and a
foot tooth recess to cooperate with the. foot tooth. The receiving
edge is complementary in shape to the engaging edge so that when
the engaging edge is placed on the foot tooth of an adjacent panel
it is guided into position permitting the installer to snap the
panels into a locked position.
Inventors: |
Zhu, Sai Yu; (Changzhou
City, CN) |
Correspondence
Address: |
GALLAGHER & DAWSEY CO., L.P.A.
P.O. BOX 785
COLUMBUS
OH
43216
US
|
Family ID: |
35238170 |
Appl. No.: |
10/838813 |
Filed: |
May 4, 2004 |
Current U.S.
Class: |
52/588.1 |
Current CPC
Class: |
E04F 2201/023 20130101;
E04F 15/04 20130101; E04F 2201/025 20130101; E04F 13/08 20130101;
E04F 15/02 20130101; E04F 2201/0153 20130101 |
Class at
Publication: |
052/588.1 |
International
Class: |
E02F 009/28 |
Claims
I claim:
1. An interlocking self-aligning cladding panel (100) for floors,
walls, ceilings, or the like, comprising: a top surface (110) and a
bottom surface (120) that are substantially parallel and terminate
with at least four edges including a receiving edge (200) and an
engaging edge (300); the receiving edge (200) having a head tooth
(210), a leveling tooth recess (220), an intermediate tooth (230),
a locking tooth recess (240), and a foot tooth (250); the engaging
edge (300) having a head tooth recess (310) to cooperate with the
head tooth (210), a leveling tooth (320) to cooperate with the
leveling tooth recess (220), an intermediate tooth recess (330) to
cooperate with the intermediate tooth (230), a locking tooth (340)
to cooperate with the locking tooth recess (240), and a foot tooth
recess (350) to cooperate with the foot tooth (250); and the
receiving edge (200) being substantially complementary in shape to
the engaging edge (300) so that when the engaging edge (300) of one
panel (100) is placed on the foot tooth (250) of the receiving edge
(200) of an adjacent panel (100) and is rotated toward the bottom
surface (120) the panels (100) snap together so as to oppose
withdrawal of the receiving edge (200) from the engaging edge (300)
in a direction substantially parallel to the top surface (110) and
bottom surface (120) of the panels (100).
2. The interlocking cladding panel of claim 1, wherein the head
tooth (210) is defined by the top surface (110) of the panel (100),
a primary surface (212), and a lower surface (214), the
intermediate tooth (230) is defined by an upper surface (232), a
primary surface (234), and a lower surface (236), the leveling
tooth recess (220) is defined by the lower surface (214) of the
head tooth (210), a rear surface (222), and the upper surface (232)
of the intermediate tooth (230), the foot tooth (250) is defined by
an upper surface (252), a primary surface (254), and the bottom
surface (120) of the panel (100), and the locking tooth recess
(240) is defined by the lower surface (236) of the intermediate
tooth (230), a rear surface (242), and the upper surface (252) of
the foot tooth (250), and wherein the leveling tooth (320) is
defined by an upper surface (322), a primary surface (324), and a
lower surface (326), the head tooth recess (310) is defined by a
rear surface (312) and the upper surface (322) of the leveling
tooth (320), the locking tooth (340) is defined by an upper surface
(342), a primary surface (344), and a lower surface (346), the
intermediate tooth recess (330) is defined by the lower surface
(326) of the leveling tooth (320), a rear surface (332), and the
upper surface (342) of the locking tooth (340), and the foot tooth
recess (350) is defined by the lower surface (346) of the locking
tooth (340) and a rear surface (352).
3. The interlocking cladding panel of claim 2, wherein the foot
tooth (250) extends beyond both the intermediate tooth (230) and
the head tooth (210) by a projection distance (256) parallel to the
top surface (110) from the distal most point on the foot tooth
(250) to the distal most point of the head tooth (210), or the
intermediate tooth (230), that is greater than, or equal to, the
height (258) of the foot tooth (250).
4. The interlocking cladding panel of claim 2, wherein the foot
tooth (250) extends beyond both the intermediate tooth (230) and
the head tooth (210) by a projection distance (256) parallel to the
top surface (110) from the distal most point on the foot tooth
(250) to the distal most point of the head tooth (210), or the
intermediate tooth (230), that is greater than, or equal to,
twenty-five percent of the thickness (130) of the panel (100).
5. The interlocking cladding panel of claim 2, wherein the foot
tooth (250) extends beyond both the intermediate tooth (230) and
the head tooth (210) by a projection distance (256) parallel to the
top surface (110) from the distal most point on the foot tooth
(250) to the distal most point of the head tooth (210), or the
intermediate tooth (230), that is greater than, or equal to,
thirty-five percent of the thickness (130) of the panel (100).
6. The interlocking cladding panel of claim 2, wherein the lower
surface (346) of the locking tooth (340) is formed with at least
one heel (347) projection extending toward the bottom surface (120)
of the panel (100) that cooperates with at least one heel recess
(253) formed in the upper surface (252) of the foot tooth
(250).
7. The interlocking cladding panel of claim 6, having two heel
(347) projections and two heel recesses (253).
8. The interlocking cladding panel of claim 2, wherein when
adjacent panels (100) are engaged at least a portion of the
leveling tooth (320) upper surface (322) is coincident with a
portion of the head tooth (210) lower surface (214), a portion of
the leveling tooth (320) lower surface (326) is coincident with a
portion of the intermediate tooth (230) upper surface (232), a
portion of locking tooth (340) upper surface (342) is coincident
with a portion of the intermediate tooth (230) lower surface (236),
and a portion of the foot tooth (250) upper surface (252) is
coincident with a portion of the locking tooth (340) lower surface
(346).
9. The interlocking cladding panel of claim 2, wherein when
adjacent panels (100) are engaged the foot tooth (250) primary
surface (254) does not contact the rear surface (352) of the foot
tooth recess (350).
10. The interlocking cladding panel of claim 2, wherein when
adjacent panels (100) are engaged the leveling tooth (320) primary
surface (324) does not contact the rear surface (222) of the
leveling tooth recess (220).
11. The interlocking cladding panel of claim 2, wherein when
adjacent panels (100) are engaged the locking tooth (340) primary
surface (344) does not contact the rear surface (242) of the
locking tooth recess (240).
12. The interlocking cladding panel of claim 3, wherein the head
tooth (210) has a head tooth length (216), the intermediate tooth
(230) has an intermediate tooth length (238), the leveling tooth
(320) has a leveling tooth length (328), and the locking tooth
(340) has a locking tooth length (348), wherein the head tooth
length (216), the intermediate tooth length (238), and the leveling
tooth length (328) are less than fifty percent of the panel
thickness (130) and the locking tooth length (348) is less than
seventy-five percent of the panel thickness (130).
13. The interlocking cladding panel of claim 12, wherein the head
tooth lower surface (214), the leveling tooth upper surface (322),
the intermediate tooth lower surface (236), and the locking tooth
upper surface (342) are substantially parallel to the top surface
(110) and the bottom surface (120) of the panel (100).
14. The interlocking cladding panel of claim 12, wherein the head
tooth primary surface (212), the leveling tooth recess rear surface
(222), the intermediate tooth primary surface (234), the locking
tooth recess rear surface (242), the foot tooth primary surface
(254), the head tooth recess rear surface (312), the leveling tooth
primary surface (324), the intermediate tooth recess rear surface
(332), the locking tooth primary surface (344), and the foot tooth
recess rear surface (352) are substantially orthogonal to the top
surface (110) and the bottom surface (120) of the panel (100).
15. An interlocking self-aligning cladding panel (100) for floors,
walls, ceilings, or the like, comprising: a top surface (110) and a
bottom surface (120) that are substantially parallel and terminate
with at least four edges including a receiving edge (200) and an
engaging edge (300); the receiving edge (200) having a head tooth
(210), a leveling tooth recess (220), an intermediate tooth (230),
a locking tooth recess (240), and a foot tooth (250); the engaging
edge (300) having a head tooth recess (310) to cooperate with the
head tooth (210), a leveling tooth (320) to cooperate with the
leveling tooth recess (220), an intermediate tooth recess (330) to
cooperate with the intermediate tooth (230), a locking tooth (340)
to cooperate with the locking tooth recess (240), and a foot tooth
recess (350) to cooperate with the foot tooth (250); the receiving
edge (200) being substantially complementary in shape to the
engaging edge (300) so that when the engaging edge (300) of one
panel (100) is placed on the foot tooth (250) of the receiving edge
(200) of an adjacent panel (100) and is rotated toward the bottom
surface (120) the panels (100) snap together so as to oppose
withdrawal of the receiving edge (200) from the engaging edge (300)
in a direction substantially parallel to the top surface (110) and
bottom surface (120) of the panels (100); the head tooth (210) is
defined by the top surface (110) of the panel (100), a primary
surface (212), and a lower surface (214), the intermediate tooth
(230) is defined by an upper surface (232), a primary surface
(234), and a lower surface (236), the leveling tooth recess (220)
is defined by the lower surface (214) of the head tooth (210), a
rear surface (222), and the upper surface (232) of the intermediate
tooth (230), the foot tooth (250) is defined by an upper surface
(252), a primary surface (254), and the bottom surface (120) of the
panel (100), and the locking tooth recess (240) is defined by the
lower surface (236) of the intermediate tooth (230), a rear surface
(242), and the upper surface (252) of the foot tooth (250), and
wherein the leveling tooth (320) is defined by an upper surface
(322), a primary surface (324), and a lower surface (326), the head
tooth recess (310) is defined by a rear surface (312) and the upper
surface (322) of the leveling tooth (320), the locking tooth (340)
is defined by an upper surface (342), a primary surface (344), and
a lower surface (346), the intermediate tooth recess (330) is
defined by the lower surface (326) of the leveling tooth (320), a
rear surface (332), and the upper surface (342) of the locking
tooth (340), and the foot tooth recess (350) is defined by the
lower surface (346) of the locking tooth (340) and a rear surface
(352); the foot tooth (250) extends beyond both the intermediate
tooth (230) and the head tooth (210) by a projection distance (256)
parallel to the top surface (110) from the distal most point on the
foot tooth (250) to the distal most point of the head tooth (210),
or the intermediate tooth (230), that is greater than, or equal to,
the height (258) of the foot tooth (250); and the lower surface
(346) of the locking tooth (340) is formed with at least one heel
(347) projection extending toward the bottom surface (120) of the
panel (100) that cooperates with at least one heel recess (253)
formed in the upper surface (252) of the foot tooth (250).
16. The interlocking cladding panel of claim 15, wherein the foot
tooth (250) extends beyond both the intermediate tooth (230) and
the head tooth (210) by a projection distance (256) parallel to the
top surface (110) from the distal most point on the foot tooth
(250) to the distal most point of the head tooth (210), or the
intermediate tooth (230), that is greater than, or equal to,
twenty-five percent of the thickness (130) of the panel (100).
16. The interlocking cladding panel of claim 15, wherein the foot
tooth (250) extends beyond both the intermediate tooth (230) and
the head tooth (210) by a projection distance (256) parallel to the
top surface (110) from the distal most point on the foot tooth
(250) to the distal most point of the head tooth (210), or the
intermediate tooth (230), that is greater than, or equal to,
thirty-five percent of the thickness (130) of the panel (100).
17. The interlocking cladding panel of claim 16, having two heel
(347) projections and two heel recesses (253).
18. The interlocking cladding panel of claim 15, wherein when
adjacent panels (100) are engaged at least a portion of the
leveling tooth (320) upper surface (322) is coincident with a
portion of the head tooth (210) lower surface (214), a portion of
the leveling tooth (320) lower surface (326) is coincident with a
portion of the intermediate tooth (230) upper surface (232), a
portion of locking tooth (340) upper surface (342) is coincident
with a portion of the intermediate tooth (230) lower surface (236),
and a portion of the foot tooth (250) upper surface (252) is
coincident with a portion of the locking tooth (340) lower surface
(346).
19. The interlocking cladding panel of claim 15, wherein when
adjacent panels (100) are engaged the foot tooth (250) primary
surface (254) does not contact the rear surface (352) of the foot
tooth recess (350).
20. The interlocking cladding panel of claim 15, wherein when
adjacent panels (100) are engaged the leveling tooth (320) primary
surface (324) does not contact the rear surface (222) of the
leveling tooth recess (220).
21. The interlocking cladding panel of claim 15, wherein when
adjacent panels (100) are engaged the locking tooth (340) primary
surface (344) does not contact the rear surface (242) of the
locking tooth recess (240).
22. The interlocking cladding panel of claim 15, wherein the head
tooth (210) has a head tooth length (216), the intermediate tooth
(230) has an intermediate tooth length (238), the leveling tooth
(320) has a leveling tooth length (328), and the locking tooth
(340) has a locking tooth length (348), wherein the head tooth
length (216), the intermediate tooth length (238), and the leveling
tooth length (328) are less than fifty percent of the panel
thickness (130) and the locking tooth length (348) is less than
seventy-five percent of the panel thickness (130).
23. The interlocking cladding panel of claim 22, wherein the head
tooth lower surface (214), the leveling tooth upper surface (322),
the intermediate tooth lower surface (236), and the locking tooth
upper surface (342) are substantially parallel to the top surface
(110) and the bottom surface (120) of the panel (100).
24. The interlocking cladding panel of claim 22, wherein the head
tooth primary surface (212), the leveling tooth recess rear surface
(222), the intermediate tooth primary surface (234), the locking
tooth recess rear surface (242), the foot tooth primary surface
(254), the head tooth recess rear surface (312), the leveling tooth
primary surface (324), the intermediate tooth recess rear surface
(332), the locking tooth primary surface (344), and the foot tooth
recess rear surface (352) are substantially orthogonal to the top
surface (110) and the bottom surface (120) of the panel (100).
25. An interlocking self-aligning cladding panel (100) for floors,
walls, ceilings, or the like, comprising: a top surface (110) and a
bottom surface (120) that are substantially parallel and terminate
with at least four edges including a receiving edge (200) and an
engaging edge (300); the receiving edge (200) having a head tooth
(210), a leveling tooth recess (220), an intermediate tooth (230),
a locking tooth recess (240), and a foot tooth (250); the engaging
edge (300) having a head tooth recess (310) to cooperate with the
head tooth (210), a leveling tooth (320) to cooperate with the
leveling tooth recess (220), an intermediate tooth recess (330) to
cooperate with the intermediate tooth (230), a locking tooth (340)
to cooperate with the locking tooth recess (240), and a foot tooth
recess (350) to cooperate with the foot tooth (250); the receiving
edge (200) being substantially complementary in shape to the
engaging edge (300) so that when the engaging edge (300) of one
panel (100) is placed on the foot tooth (250) of the receiving edge
(200) of an adjacent panel (100) and is rotated toward the bottom
surface (120) the panels (100) snap together so as to oppose
withdrawal of the receiving edge (200) from the engaging edge (300)
in a direction substantially parallel to the top surface (110) and
bottom surface (120) of the panels (100); the head tooth (210) is
defined by the top surface (110) of the panel (100), a primary
surface (212), and a lower surface (214), the intermediate tooth
(230) is defined by an upper surface (232), a primary surface
(234), and a lower surface (236), the leveling tooth recess (220)
is defined by the lower surface (214) of the head tooth (210), a
rear surface (222), and the upper surface (232) of the intermediate
tooth (230), the foot tooth (250) is defined by an upper surface
(252), a primary surface (254), and the bottom surface (120) of the
panel (100), and the locking tooth recess (240) is defined by the
lower surface (236) of the intermediate tooth (230), a rear surface
(242), and the upper surface (252) of the foot tooth (250), and
wherein the leveling tooth (320) is defined by an upper surface
(322), a primary surface (324), and a lower surface (326), the head
tooth recess (310) is defined by a rear surface (312) and the upper
surface (322) of the leveling tooth (320), the locking tooth (340)
is defined by an upper surface (342), a primary surface (344), and
a lower surface (346), the intermediate tooth recess (330) is
defined by the lower surface (326) of the leveling tooth (320), a
rear surface (332), and the upper surface (342) of the locking
tooth (340), and the foot tooth recess (350) is defined by the
lower surface (346) of the locking tooth (340) and a rear surface
(352); the foot tooth (250) extends beyond both the intermediate
tooth (230) and the head tooth (210) by a projection distance (256)
parallel to the top surface (110) from the distal most point on the
foot tooth (250) to the distal most point of the head tooth (210),
or the intermediate tooth (230), that is greater than, or equal to,
the height (258) of the foot tooth (250); the lower surface (346)
of the locking tooth (340) is formed with two heel (347)
projections extending toward the bottom surface (120) of the panel
(100) that cooperates with two heel recess (253) formed in the
upper surface (252) of the foot tooth (250); the foot tooth (250)
extends beyond both the intermediate tooth (230) and the head tooth
(210) by a projection distance (256) parallel to the top surface
(110) from the distal most point on the foot tooth (250) to the
distal most point of the head tooth (210), or the intermediate
tooth (230), that is greater than, or equal to, thirty-five percent
of the thickness (130) of the panel (100); the head tooth (210) has
a head tooth length (216), the intermediate tooth (230) has an
intermediate tooth length (238), the leveling tooth (320) has a
leveling tooth length (328), and the locking tooth (340) has a
locking tooth length (348), wherein the head tooth length (216),
the intermediate tooth length (238), and the leveling tooth length
(328) are less than fifty percent of the panel thickness (130) and
the locking tooth length (348) is less than seventy-five percent of
the panel thickness (130); the head tooth lower surface (214), the
leveling tooth upper surface (322), the intermediate tooth lower
surface (236), and the locking tooth upper surface (342) are
substantially parallel to the top surface (110) and the bottom
surface (120) of the panel (100); the head tooth primary surface
(212), the leveling tooth recess rear surface (222), the
intermediate tooth primary surface (234), the locking tooth recess
rear surface (242), the foot tooth primary surface (254), the head
tooth recess rear surface (312), the leveling tooth primary surface
(324), the intermediate tooth recess rear surface (332), the
locking tooth primary surface (344), and the foot tooth recess rear
surface (352) are substantially orthogonal to the top surface (110)
and the bottom surface (120) of the panel (100); wherein when
adjacent panels (100) are engaged the foot tooth (250) primary
surface (254) does not contact the rear surface (352) of the foot
tooth recess (350), the leveling tooth (320) primary surface (324)
does not contact the rear surface (222) of the leveling tooth
recess (220), and the locking tooth (340) primary surface (344)
does not contact the rear surface (242) of the locking tooth recess
(240).
Description
TECHNICAL FIELD
[0001] The present invention relates to the field of cladding
panels used in the construction of floors, walls, ceilings, and the
like, in particular, to a edge joining profile that securely locks
adjacent panels together.
BACKGROUND OF THE INVENTION
[0002] During the past few years laminated floors have achieved an
increase in popularity. Generally, in the production of laminated
floors, a decorative thermosetting laminate is first produced. The
decorative laminate typically consists of a base layer of paper
sheets impregnated with resin and a decorative surface layer. The
finished laminate is produced by pressing the different layers
together at high pressure and elevated temperature. The laminate is
then glued to a carrier, often particle board. This panel is then
sawn into floor boards and distinct edge profiles are added.
[0003] In the past the edge profiles simply mated together and
required some form of mechanical fastener or adhesive to secure the
boards to one another. Such fastening techniques made it difficult,
if not impossible, to change damaged boards or remove the boards
for reinstallation in another location. In an effort to avoid these
fastening techniques many manufacturers have developed panels with
interlocking edge profiles. While these prior art interlocking edge
profiles have eliminated the use of glue, they rarely provide a
rigid joint and are therefore often easily distinguishable from
solid wood floors. Additionally, such prior art interlocking edges
are prone to weak joints, or those that tend to loosen over time
and develop gaps between adjacent panels. Gaps are also produced
during installation due to poor workmanship or adjacent panels that
are not perfectly aligned. Dirt and water can penetrate into these
gaps. Moisture in such gaps will cause the core of the laminate to
expand in cases where it is made of wood, fiber board, or particle
board. Such expansion causes the surface layer to rise closest to
the edges of the joint where surface wear is then concentrated,
which radically reduces the useful life of the floor.
[0004] In the past numerous single tongue and groove joining
systems have been patented. Patents in this category include U.S.
Pat. No. 935,402, U.S. Pat. No. 5,797,237, U.S. Pat. No. 6,216,409,
U.S. Pat. No. 6,591,568, and U.S. Pat. No. 6,601,359. Flooring
manufacturers have since realized that do-it-yourselfers need
flooring that is essentially fool-proof and aligns itself so as not
to have gaps. As such, numerous joining systems that claim to be
self-aligning have been patented. One such system is found in U.S.
Pat. No. 6,591,568. Unfortunately, to date most self-aligning
systems have been plagued by weak joints and installation
difficulties.
[0005] What has been needed in the industry is a multi-tongue, or
multi-toothed, self-aligning edge profile that is simple enough for
do-it-yourself installers. While some prior art multi-tongue
systems do exist they have not yet achieved the appropriate balance
between self-alignment, joint rigidity, and ease of
installation.
SUMMARY OF INVENTION
[0006] In its most general configuration, the present invention
advances the state of the art with a variety of new capabilities
and overcomes many of the shortcomings of prior devices in new and
novel ways. In its most general sense, the present invention
overcomes the shortcomings and limitations of the prior art in any
of a number of generally effective configurations. The instant
invention demonstrates such capabilities and overcomes many of the
shortcomings of prior methods in new and novel ways.
[0007] The interlocking cladding panels for floors, walls,
ceilings, or the like, of the present invention, have a top surface
and a bottom surface that are substantially parallel and terminate
with at least four edges, including a receiving edge and an
engaging edge. The receiving edge has a head tooth, a leveling
tooth recess, an intermediate tooth, a locking tooth recess, and a
foot tooth. The engaging edge has a head tooth recess to cooperate
with the head tooth, a leveling tooth to cooperate with the
leveling tooth recess, an intermediate tooth recess to cooperate
with the intermediate tooth, a locking tooth to cooperate with the
locking tooth recess, and a foot tooth recess to cooperate with the
foot tooth.
[0008] The receiving edge is substantially complementary in shape
to the engaging edge so that when the engaging edge of one panel is
placed on the foot tooth of the receiving edge of an adjacent panel
and is rotated toward the bottom surface the panels snap together.
The foot tooth acts to guide the locking tooth into position so
that it may be easily snapped into its locked position. The guiding
nature of the foot tooth makes installation virtually impossible to
do incorrectly even by the most novice installer. When adjacent
panels are joined together they interlock so as to oppose
withdrawal of the receiving edge from the engaging edge.
[0009] The foot tooth extends beyond both the intermediate tooth
and the head tooth by a projection distance. The projection
distance is parallel to the top surface from the distal most point
on the foot tooth to the distal most point of the head tooth, or
the intermediate tooth. The projection distance is generally
greater than, or equal to, the height of the foot tooth. In one
particular embodiment, the projection distance is greater than, or
equal to, twenty-five percent of the thickness of the panel. In yet
a further embodiment, the projection distance is greater than, or
equal to, thirty-five percent of the thickness of the panel.
Experimentation has shown that a projection distance of
approximately forty percent of the thickness of the panel produces
a secure and rigid joint. In one particular embodiment the locking
tooth may be formed with at least one heel projection extending
toward the bottom surface of the panel that cooperates with at
least one heel recess formed in the foot tooth to impart enhanced
resistance to separation of the panels.
[0010] These variations, modifications, alternatives, and
alterations of the various preferred embodiments may be used alone
or in combination with one another as will become more readily
apparent to those with skill in the art with reference to the
following detailed description of the preferred embodiments and the
accompanying figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Without limiting the scope of the present invention as
claimed below and referring now to the drawings and figures:
[0012] FIG. 1 shows a side elevation view of the interlocking
cladding panel, not to scale;
[0013] FIG. 2 shows a side elevation view of the interlocking
cladding panel, not to scale;
[0014] FIG. 3 shows a side elevation view of the interlocking
cladding panel, not to scale;
[0015] FIG. 4 shows a side elevation view of the interlocking
cladding panel, not to scale;
[0016] FIG. 5 shows a side elevation view of the interlocking
cladding panel, not to scale;
[0017] FIG. 6 shows a side elevation view of the interlocking
cladding panel, not to scale; and
[0018] FIG. 7 shows a side elevation view of the interlocking
cladding panel, not to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The interlocking cladding panel of the instant invention
enables a significant advance in the state of the art. The
preferred embodiments of the apparatus accomplish this by new and
novel arrangements of elements and methods that are configured in
unique and novel ways and which demonstrate previously unavailable
but preferred and desirable capabilities. The detailed description
set forth below in connection with the drawings is intended merely
as a description of the presently preferred embodiments of the
invention, and is not intended to represent the only form in which
the present invention may be constructed or utilized. The
description sets forth the designs, functions, means, and methods
of implementing the invention in connection with the illustrated
embodiments. It is to be understood, however, that the same or
equivalent functions and features may be accomplished by different
embodiments that are also intended to be encompassed within the
spirit and scope of the invention. Referring to FIG. 1, the
interlocking cladding panels (100) for floors, walls, ceilings, or
the like, of the present invention have a top surface (110) and a
bottom surface (120) that are substantially parallel and terminate
with at least four edges including a receiving edge (200) and an
engaging edge (300). The receiving edge (200) has a head tooth
(210), a leveling tooth recess (220), an intermediate tooth (230),
a locking tooth recess (240), and a foot tooth (250). The engaging
edge (300) has a head tooth recess (310) to cooperate with the head
tooth (210), a leveling tooth (320) to cooperate with the leveling
tooth recess (220), an intermediate tooth recess (330) to cooperate
with the intermediate tooth (230), a locking tooth (340) to
cooperate with the locking tooth recess (240), and a foot tooth
recess (350) to cooperate with the foot tooth (250).
[0020] The receiving edge (200) is substantially complementary in
shape to the engaging edge (300) so that when the engaging edge
(300) of one panel (100) is placed on the foot tooth (250) of the
receiving edge (200) of an adjacent panel (100) and is rotated
toward the bottom surface (120) the panels (100) snap together, as
seen in FIGS. 5, 6, and 7. The foot tooth (250) acts to guide the
locking tooth (340) into position so that it may be easily snapped
into its locked position. The guiding nature of the foot tooth
(250) makes installation virtually impossible to do incorrectly
even by the most novice installer. An angle of entry of the
engaging edge (300) of between approximately five degrees to
approximately seventy-five degrees has been found to be effective
with the embodiment illustrated in FIGS. 1 through 7. When adjacent
panels (100) are joined together, as shown in FIG. 7, they
interlock so as to oppose withdrawal of the receiving edge (200)
from the engaging edge (300) in a direction substantially parallel
to the top surface (110) and bottom surface (120) of the panels
(100).
[0021] With reference now to FIG. 2, the head tooth (210) is
defined by the top surface (110) of the panel (100), a primary
surface (212), and a lower surface (214). The intermediate tooth
(230) is defined by an upper surface (232), a primary surface
(234), and a lower surface (236). The leveling tooth recess (220)
is defined by the lower surface (214) of the head tooth (210), a
rear surface (222), and the upper surface (232) of the intermediate
tooth (230). The foot tooth (250) is defined by an upper surface
(252), a primary surface (254), and the bottom surface (120) of the
panel (100). The locking tooth recess (240) is defined by the lower
surface (236) of the intermediate tooth (230), a rear surface
(242), and the upper surface (252) of the foot tooth (250). The
leveling tooth (320) is defined by an upper surface (322), a
primary surface (324), and a lower surface (326). The head tooth
recess (310) is defined by a rear surface (312) and the upper
surface (322) of the leveling tooth (320). The locking tooth (340)
is defined by an upper surface (342), a primary surface (344), and
a lower surface (346). The intermediate tooth recess (330) is
defined by the lower surface (326) of the leveling tooth (320), a
rear surface (332), and the upper surface (342) of the locking
tooth (340). The foot tooth recess (350) is defined by the lower
surface (346) of the locking tooth (340) and a rear surface
(352).
[0022] The foot tooth (250) extends beyond both the intermediate
tooth (230) and the head tooth (210) by a projection distance
(256), as seen in FIG. 3. The projection distance (256) is parallel
to the top surface (110) from the distal most point on the foot
tooth (250) to the distal most point of the head tooth (210), or
the intermediate tooth (230). The projection distance (256) is
generally greater than, or equal to, the height (258) of the foot
tooth (250). In one particular embodiment, the projection distance
(256) is greater than, or equal to, twenty-five percent of the
thickness (130) of the panel (100). In yet a further embodiment,
the projection distance (256) is greater than, or equal to,
thirty-five percent of the thickness (130) of the panel (100).
[0023] Experimentation has shown that a projection distance (256)
of approximately forty percent of the thickness (130) of the panel
(100) produces a secure and rigid joint.
[0024] With reference now to FIG. 4, in one particular embodiment
the lower surface (346) of the locking tooth (340) is formed with
at least one heel (347) projection extending toward the bottom
surface (120) of the panel (100) that cooperates with at least one
heel recess (253) formed in the upper surface (252) of the foot
tooth (250). The embodiment of FIG. 4 illustrates two heel (347)
projections and two heel recesses (253). Such a dual heel (347)
embodiment imparts enhanced resistance to separation of the panels
(100).
[0025] In the embodiments illustrated in FIGS. 1 through 7, at
least a portion of the leveling tooth (320) upper surface (322) is
coincident with a portion of the head tooth (210) lower surface
(214) when adjacent panels (100) are engaged, however such
coincidence is not required. Similarly, a portion of the leveling
tooth (320) lower surface (326) may be coincident with a portion of
the intermediate tooth (230) upper surface (232), a portion of
locking tooth (340) upper surface (342) may be coincident with a
portion of the intermediate tooth (230) lower surface (236), and a
portion of the foot tooth (250) upper surface (252) may be
coincident with a portion of the locking tooth (340) lower surface
(346).
[0026] Additionally, in some embodiments the foot tooth (250)
primary surface (254) may not contact the rear surface (352) of the
foot tooth recess (350) wherein when adjacent panels (100) are
engaged. Similarly, the leveling tooth (320) primary surface (324)
may not contact the rear surface (222) of the leveling tooth recess
(220), and the locking tooth (340) primary surface (344) may not
contact the rear surface (242) of the locking tooth recess (240).
The lack of contact between the various teeth and their associated
recesses is only present in one embodiment and one skilled in the
art will appreciate that such contact is permissible, and perhaps
desirable in some embodiments.
[0027] Referring again to FIG. 3, the head tooth (210) may be
further characterized as having a head tooth length (216).
Similarly, the intermediate tooth (230) has an intermediate tooth
length (238), the leveling tooth (320) has a leveling tooth length
(328), and the locking tooth (340) has a locking tooth length
(348). In one particular embodiment the head tooth length (216),
the intermediate tooth length (238), and the leveling tooth length
(328) are less than fifty percent of the panel thickness (130) and
the locking tooth length (348) is less than seventy-five percent of
the panel thickness (130). The ratios of this embodiment have been
found to produce a particularly secure and rigid connection between
adjacent panels (100).
[0028] In further embodiments, illustrated in FIGS. 1 through 7,
the head tooth lower surface (214), the leveling tooth upper
surface (322), the intermediate tooth lower surface (236), and the
locking tooth upper surface (342) are substantially parallel to the
top surface (110) and the bottom surface (120) of the panel (100).
Similarly, additional embodiments may have the head tooth primary
surface (212), the leveling tooth recess rear surface (222), the
intermediate tooth primary surface (234), the locking tooth recess
rear surface (242), the foot tooth primary surface (254), the head
tooth recess rear surface (312), the leveling tooth primary surface
(324), the intermediate tooth recess rear surface (332), the
locking tooth primary surface (344), and the foot tooth recess rear
surface (352) substantially orthogonal to the top surface (110) and
the bottom surface (120) of the panel (100).
[0029] Numerous alterations, modifications, and variations of the
preferred embodiments disclosed herein will be apparent to those
skilled in the art and they are all anticipated and contemplated to
be within the spirit and scope of the instant invention. For
example, although specific embodiments have been described in
detail, those with skill in the art will understand that the
preceding embodiments and variations can be modified to incorporate
various types of substitute and or additional or alternative
materials, relative arrangement of elements, and dimensional
configurations. Accordingly, even though only few variations of the
present invention are described herein, it is to be understood that
the practice of such additional modifications and variations and
the equivalents thereof, are within the spirit and scope of the
invention as defined in the following claims. The corresponding
structures, materials, acts, and equivalents of all means or step
plus function elements in the claims below are intended to include
any structure, material, or acts for performing the functions in
combination with other claimed elements as specifically
claimed.
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