U.S. patent application number 11/263743 was filed with the patent office on 2007-05-17 for staggered look shake siding panel with improved locking mechanism.
This patent application is currently assigned to CertainTeed Corporation. Invention is credited to Andrew Clyde Brandt, Robert David Shaw, Stephen William Steffes.
Application Number | 20070107356 11/263743 |
Document ID | / |
Family ID | 38039312 |
Filed Date | 2007-05-17 |
United States Patent
Application |
20070107356 |
Kind Code |
A1 |
Steffes; Stephen William ;
et al. |
May 17, 2007 |
Staggered look shake siding panel with improved locking
mechanism
Abstract
A simulated shake siding panel having the random appearance of
individual shakes is provided. The siding panel comprises a siding
panel board, the siding panel board comprising front and rear
faces, the front face including at least a bottommost course of a
plurality of simulated side-by-side shakes forming an uneven butt
line. A nailing strip is disposed proximate to a top edge of the
siding panel board. A downwardly open hook is provided on the front
face proximate to a top edge of the siding panel for interfitting
with an upwardly open hook of a second like siding panel, the
siding panel and second siding panel interfitted top to bottom. An
upwardly open hook is disposed on the rear face of the siding
panel, a top edge of the upwardly open hook being uniformly spaced
from the top edge of the siding panel and non-uniformly spaced from
the uneven butt line.
Inventors: |
Steffes; Stephen William;
(McPherson, KS) ; Shaw; Robert David; (Parma,
MI) ; Brandt; Andrew Clyde; (Spring City,
PA) |
Correspondence
Address: |
DUANE MORRIS, LLP;IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Assignee: |
CertainTeed Corporation
|
Family ID: |
38039312 |
Appl. No.: |
11/263743 |
Filed: |
November 1, 2005 |
Current U.S.
Class: |
52/518 |
Current CPC
Class: |
E04F 13/0864
20130101 |
Class at
Publication: |
052/518 |
International
Class: |
E04D 1/00 20060101
E04D001/00 |
Claims
1. A simulated shake siding panel having the random appearance of
individual shakes comprising: a siding panel board, said siding
panel board comprising front and rear faces, said front face
including at least a bottommost course of a plurality of simulated
side-by-side shakes forming an uneven butt line; a downwardly open
hook disposed on said front face adjacent to a top edge of said
siding panel for interfitting with an upwardly open hook of a
second like siding panel, said siding panel and second siding panel
interfitted top to bottom; and an upwardly open hook disposed on
said rear face of said siding panel, a top edge of said upwardly
open hook being uniformly spaced from the top edge of said siding
panel and non-uniformly spaced from said uneven butt line.
2. The simulated shake siding panel of claim 1, wherein said siding
panel comprises polypropylene or blend thereof.
3. The simulated shake siding panel of claim 1, wherein points
along said uneven butt line corresponding to two different shakes
from said bottommost course differ at least 0.25 inch in distance
from said upwardly open hook top edge.
4. The simulated shake siding panel of claim 1, wherein points
along said uneven butt line corresponding to two different shakes
from said bottommost course differ between about 0.25 to 1.0 inch
in distance from said upwardly open hook top edge.
5. The simulated shake siding panel of claim 1, wherein at least
some of said plurality of shakes from said bottommost course have
different widths.
6. The simulated shake siding panel of claim 1, wherein said shakes
are simulated cedar shakes.
7. The simulated shake siding panel of claim 1, further comprising
a nailing strip disposed proximate to a top edge of said siding
panel board, said nailing strip comprising preformed nailing
apertures.
8. The simulated shake siding panel of claim 1, wherein the
upwardly open hook and the downwardly open hook engage with a
frictional interference fit.
9. A simulated shake siding panel having the random appearance of
individual shakes comprising: a siding panel board, said siding
panel board comprising front and rear faces, said front face
including at least two course of simulated shakes disposed in top
and bottom overlapping and underlapping relation, each course
comprising a plurality of simulated side-by-side shakes, at least a
bottommost course of said at least two courses forming an uneven
butt line; a nailing strip disposed proximate to a top edge of said
siding panel board; a downwardly open hook disposed on said front
face adjacent to a top edge of said siding panel for interfitting
with an upwardly open hook of a second like siding panel, said
siding panel and second siding panel interfitted top to bottom; and
an upwardly open hook disposed on said rear face of said siding
panel, a top edge of said upwardly open hook being uniformly spaced
from the top edge of said siding panel and non-uniformly spaced
from said uneven butt line.
10. The simulated shake siding panel of claim 9, wherein said
siding panel comprises polypropylene or blend thereof.
11. The simulated shake siding panel of claim 9, wherein points
along said uneven butt line corresponding to two different shakes
from said bottommost course differ at least 0.25 inch in distance
from said upwardly open hook top edge.
12. The simulated shake siding panel of claim 9, wherein points
along said uneven butt line corresponding to two different shakes
from said bottommost course differ between about 0.25 to 1.0 inch
in distance from said upwardly open hook top edge.
13. The simulated shake siding panel of claim 9, wherein at least
some of said shakes from each of said first and second courses have
different widths.
14. The simulated shake siding panel of claim 9, wherein said
shakes are simulated cedar shakes.
15. The simulated shake siding panel of claim 9, wherein said
nailing strip comprises preformed nailing apertures.
16. The simulated shake siding panel of claim 9, wherein a topmost
course of said first and second courses forms an uneven butt
line.
17. An injection molded simulated shake siding panel having the
random appearance of individual shakes comprising: a siding panel
board, said siding panel board comprising front and rear faces,
said front face including at least two courses of simulated cedar
shakes disposed in top and bottom overlapping and underlapping
relation, each course comprising a plurality of simulated
side-by-side shakes, each course having an uneven butt line and
non-uniformly shaped shakes; a nailing strip disposed proximate to
a top edge of said siding panel board and comprising preformed
nailing apertures; a downwardly open hook disposed on said front
face adjacent to a top edge of said siding panel for interfitting
with an upwardly open hook of a second like siding panel, said
siding panel and second siding panel interfitted top to bottom; and
an upwardly open hook disposed on said rear face of said siding
panel, a top edge of said upwardly open hook being uniformly spaced
from the top edge of said siding panel and non-uniformly spaced
from the uneven butt line of a bottommost course of said first and
second courses, wherein the upwardly open hook and the downwardly
open hook engage with a frictional interference fit.
18. The simulated shake siding panel of claim 17, wherein said
siding panel comprises polypropylene or blend thereof.
19. The simulated shake siding panel of claim 17, wherein points
along said bottommost course butt line corresponding to two
different shakes from said bottommost course differ at least 0.25
inch in distance from said upwardly open hook top edge.
20. The simulated shake siding panel of claim 17, wherein at least
one of said upwardly and downwardly open hooks comprises a flange
spaced from a plane of the panel body, and wherein the flange is at
least partially flared in a direction away from the plane of the
panel body, thereby providing a lead-in for engagement of said
hooks.
21. A method of installing a siding panel assembly, comprising the
steps of: providing first and second simulated shake siding panels
having the random appearance of individual shakes, each panel
comprising: a siding panel board, said siding panel board
comprising front and rear faces, said front face including at least
a bottommost course of a plurality of simulated side-by-side shakes
forming an uneven butt line; a downwardly open hook disposed on
said front face adjacent to a top edge of said siding panel for
interfitting with an upwardly open hook of a second like siding
panel, said siding panel and second siding panel interfitted top to
bottom; and an upwardly open hook disposed on said rear face of
said siding panel, a top edge of said upwardly open hook being
uniformly spaced from the top edge of said siding panel and
non-uniformly spaced from said uneven butt line; attaching said
first siding panel to a vertical wall of a structure; and engaging
the upwardly open hook member of the second siding panel with the
downwardly open hook member of the first siding panel such that
said first and second siding panels are interfitted top to bottom;
and attaching said second siding panel to said vertical wall of
said structure.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application relates to commonly assigned U.S. Design
Pat. Application No. 90/______ entitled "Double Rough Split Shake
Siding Panel," filed on the same date hereas, the entirety of which
is hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to siding panels,
and more particularly to simulated wood shake siding panels and
still more particularly to simulated cedar shake siding panels.
BACKGROUND OF THE INVENTION
[0003] Siding products for facing exterior building walls can
resemble traditional wooden clapboards, cedar shakes and the like
and are available in durable low-maintenance materials such as
aluminum and various polymers. Simulative modern siding panels
often are made to resemble traditional wood siding materials. A
traditional wooden siding material might be installed in overlapped
tiers or courses, for example single horizontally elongated
clapboards or single rows of discrete single shingles, placed
adjacent to one another and individually nailed. Modern siding
materials also are installed in overlapping courses, but each
course of the siding panel material can simulate two or more
overlapped courses of traditional materials such as clapboards or
shingles.
[0004] In the case of simulated shingles or cedar shakes, each
integral siding panel simulates at least one row of laterally
adjacent shingles, and usually simulates two or more courses that
appear to overlap vertically. The siding panel is supplied in
convenient lengths for handling and installation, for example four
or eight or twelve feet.
[0005] With specific reference to FIGS. 7A to 7E thereof, U.S. Pat.
No. 6,737,008 to Gilbert et al. discloses a siding panel having a
single course containing a plurality of simulated cedar shake
impressions formed therein. In order to give the appearance that
individual shakes have different lengths, the bottom edge of some
of the shake impressions are beveled, though the individual cedar
shake impressions each have the same length.
[0006] The siding panel of Gilbert et al. has a continuous bottom
edge which forms into a J-channel having a continuous lip for
mating with a downwardly facing U-channel of a second siding panel
attached below it on a wall. The lip is uniformly spaced along its
length from the bottom edge, as the J-channel is formed by bending
a portion of the precursor polymeric sheet, which has a continuous
lateral edge. This continuous lip ensures that all siding panels in
an upper row of panels are equally spaced from a lower row of
siding panels to which they are coupled, as the mating J-channel
and U-channel are sized to provide the desired spacing, i.e., the
upper siding panels are correctly located when the continuous
J-channel lip, once inserted into the U-channel of a siding panel
from the lower row, meets the top wall of the U-channel.
[0007] U.S. Pat. No. 4,015,391 to Epstein et al. discloses a two
course siding panel where the shakes of the lower course do not
each have the same length. Perhaps for this reason, Epstein et al.
employ a locking mechanism comprising a downwardly depending flange
24 and an upwardly open channel 22 for receiving the flange. (See,
e.g., Epstein et al., FIG. 4). This mechanism is not preferred
though, as it is believed to significantly limit the amount by
which the shingle impressions of the lower course can differ in
length while still providing an aesthetically pleasing panel where
the flange 24 is not readily visible.
[0008] Therefore, there remains a need for an improved siding panel
having a simulated shake appearance where individual shakes have
different lengths. Still further, there remains a need for a mating
mechanism for mating overlapping panels having shakes of different
lengths.
SUMMARY OF THE INVENTION
[0009] A simulated shake siding panel having the random appearance
of individual shakes is provided. The siding panel comprises a
siding panel board, the siding panel board comprising front and
rear faces, the front face including at least a bottommost course
of a plurality of simulated side-by-side shakes forming an uneven
butt line. A nailing strip is disposed proximate to a top edge of
the siding panel board. A downwardly open hook is provided on the
front face adjacent to a top edge of the siding panel for
interfitting with an upwardly open hook of a second like siding
panel, the siding panel and second siding panel interfitted top to
bottom. An upwardly open hook is disposed on the rear face of the
siding panel, a top edge of the upwardly open hook being uniformly
spaced from the top edge of the siding panel and non-uniformly
spaced from the uneven butt line.
[0010] From the foregoing, a siding panel is provided having a
realistic, simulated shake appearance. Random butt lines in the
shake courses provide the appearance of shakes having different
lengths, while still allowing for mating hook members to be used as
connection members for overlapping panels. Further, by varying the
length, width and/or intermediate shake gap depth and/or width, the
appearance of randomly selected shakes is provided. By providing
sufficient numbers of such shakes in a panel, it becomes difficult
to visually discern a shake pattern when multiple panels are
installed to cover a vertical wall of a structure.
[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 front perspective view of the a double rough
split siding panel showing our new design;
[0014] FIG. 2 is a front elevational view of the siding panel of
FIG. 1;
[0015] FIG. 3 is a rear elevational view of the siding panel of
FIG. 1;
[0016] FIG. 4 is a right side elevational view of the siding panel
of FIG. 1;
[0017] FIG. 5 is a left side elevational view of the siding panel
of FIG. 1; and
[0018] FIG. 6 is a section view showing an inventive joint for
overlap engagement, shown in several stages of engagement.
DETAILED DESCRIPTION
[0019] FIG. 1 is a front perspective view of a simulated shake
siding panel 10. FIGS. 2 and 3 are front and rear elevational views
of the siding panel 10 of FIG. 1, respectively. FIGS. 4 and 5 are
right and left side elevational views of the siding panel of FIG.
1, respectively.
[0020] In embodiments, the siding panel may be formed by
beltmolding/extrusion, blow molding, compression molding, vacuum
forming and other processes. In an exemplary embodiment, the siding
panel is integrally formed in an injection molding process from a
polymeric material, such as vinyl, polyethylene, nylon,
polyurethane, wood composite resin, etc. . . . and more preferably,
polypropylene or a polypropylene blend or mixture, such as
polypropylene mixed with 15-25%, and preferably about 20%,
CaCO.sub.3 and with a UV stabilizer. The mix preferably has a melt
flow rate of 30-40 g/10 min.
[0021] The panel has a front face 12, a rear face 14 and a top edge
16. The front face 12 of the illustrated panel 10 includes two
courses 18, 20 of simulated side-by-side shakes 22, with course 18
being the bottommost course. Although illustrated as having two
courses, the panel 10 may include only a single course or more than
two courses. The courses 18, 20 are oriented, at least in
appearance, in overlapping and underlapping relation, with the
bottoms of shakes of the upper course 20 appearing to overlap the
tops of the shakes of bottommost course 18.
[0022] In an exemplary embodiment, the shakes of each course are
molded to have a simulated shake appearance, with realistic
vertical grooves simulating hand-split rough cedar shakes. In
furtherance of this simulated appearance, individual shakes in the
panel have seemingly random widths as well as lengths. In exemplary
embodiments the widths vary between about 4.25 to 7.0 inches, and
preferably between about 4.35 to 6.95 inches. Each shingle is
separated from an adjacent shingle by an inter-shingle gap 24 that
preferably is a variation in surface height as opposed to
through-gaps between portions of the integral panel material
(although actual through-gaps would also be possible). In
embodiments, the gaps 24 between adjacent shakes can vary in width,
such as between about 0.2 to 0.5 inches, and preferably between
about 0.24 to 0.44 inches.
[0023] In exemplary embodiments, each course includes shingle
shakes nominally having a length of about 9 inches. As shown, each
course 18, 20 preferably has an uneven butt line 26, 28. Individual
shakes have exposed faces ranging from about 8.25 to 10.0 inches,
and preferably between about 8.5 to 9.8 inches. Of course,
individual shakes in the bottommost course 18 can have different
exposed lengths across their width depending upon the respective
lengths of the shakes from the upper course 20 that overlap the
individual shakes of the bottommost course 18.
[0024] In one embodiment, the panel 10 has a length between about 4
to 12 feet, and ideally about 5 feet. Each course 18, 20 may have
between about 7 to 24 shingles, and preferably about 9 in a 5 foot
embodiment. In an exemplary embodiment, no two shakes in a panel
are identical.
[0025] Adjacent to the top edge 16, the siding panel 10 includes a
planar nailing strip 34 having preformed elongated nailing
apertures 36 therein located to receive nails or other fasteners
for attaching the panel 10 to the vertical wall of a structure. The
nailing strip and fasteners are covered by and overlapping siding
panel in an installed siding panel assembly.
[0026] The front face 12 also includes a downwardly open hook
member 30 disposed adjacent to the top edge 16 of the siding panel
10, such as between the nailing apertures 36 of the nailing strip
34 and the upper shingle course 20. This hook member 30
frictionally engages the return leg of complimentary upwardly open
hook member 32 disposed on the rear face 14 of a like siding panel
10 and shown in the rear elevational view of FIG. 3.
[0027] Importantly, upwardly open hook member 32 has a top edge 33
that is equally spaced from a fixed, continuous reference point,
such as the top edge 16 of the siding panel 10, is but unevenly
spaced from the butt line 26 of the bottommost course 18 of shakes.
The continuous (or semi-continuous) and straight edge 33 can be
formed by use of appropriately shaped mold inserts, such as in the
case of injection molding, for example, or by post formation trim
operations. The straight edge 33 ensures consistent, accurate
placement of overlapping and underlapping panels 10 with respect to
one another as well as with respect to adjacent panels, as the edge
33 makes continuous engagement with the downwardly open hook member
30 as described in more detail below notwithstanding the uneven
butt line 26 of the bottommost course 18.
[0028] FIG. 6 is a section view showing the overlap coupling of two
siding panels together in various stages using hook members 30, 32.
As can be seen from the view of FIG. 6, the butt line 26 of the
bottommost course 18 of shakes is uneven. FIG. 6 shows the cross
section being taken through first shake 22a, with second shake 22b
shown extending beyond the bottom edge of the shake 22a.
[0029] The return leg of upwardly open hook member 32 is preferably
tapered. This taper or ramp feature allows the joint to mate easily
by guiding the tab into the slot, and reduces the incidence of
partial engagement.
[0030] In the embodiment shown in FIG. 6, the downward hook 30 has
a curved shape wherein the ramp at the leading edge leads to a
pinch point of minimum slot width, at which an interference fit is
obtained with the return leg of the upward hook 32, which is also
tapered on the leading edge. This structure has particular
advantages because the interference fit at the point of minimum
slot width provides a tactile indication to the installer, when the
hooks 30, 32 are engaged up to a particular point. The tactile
indication of resistance is not unlike the resistance of a detent,
but unlike a detent does not produce a snap or positive obstruction
at a particular insertion distance. The tapered parts and the
interference fit at the cusp along hook 30 as shown in FIG. 6 have
the advantages of a detent without the disadvantage of fixing a
specific position or insertion distance that can instead depend on
the ambient temperature versus nominal temperature expectations if
desired.
[0031] The interference fit in FIG. 6 enables a course that is
being installed to be held temporarily by an already-installed
course due to the frictional engagement of hooks 30, 32. The
temporary engagement, without fixing relative positions as would be
the case with a detent or a hook with a positive barb, allows the
installer to make fine adjustments in the position of the panel
while it is held frictionally close to a final position. At the
same time, the frictional support permits the installer to release
his or her grip on the panel, for example to reach for a nail. The
frictional support also can wholly or partly support the panel
while the installer's attention is directed to making the
attachments to adjacent panels as described below. When installed,
the friction fit preferably does not prevent lateral expansion and
contraction of the panel due to temperature changes.
[0032] The frictional engagement can be a bend or rounded bump in
the female-side hook 30 versus a taper in the male-side hook 32, or
another form of frictional engagement that operates without
positively fixing a supporting position.
[0033] The lap joint as described, namely with an interference fit
made along the vertically overlapped upper and lower edges of panel
courses, is especially apt when provided together with the butt
joint structure described below. The butt joint structure makes it
possible to assemble the butt joint, between panels along the same
course (typically in the same line of horizontal elongation), by
moving the panel being installed in a substantially vertical
direction relative to the last previously installed panel in the
same course. Alternatively, the motion is inwardly and normal to
the plane of the wall, followed by an upward movement.
[0034] To facilitate installation notwithstanding the frictionally
tight arrangement of hooks 30, 32, at least one of the upwardly and
downwardly opening hooks, namely the downwardly opening hook 30 in
the embodiment shown in FIG. 6, comprises a flange 31 spaced from a
plane of the panel body, wherein the flange 31 is at least partly
flared in a direction away from the plane of the panel body,
thereby providing a lead-in for engagement of the hooks 30, 32.
This embodiment also shows that hook 30 can be buttressed by one or
more ridges 38 disposed outside and against the hook opening, thus
contributing to the strength of hook 30 and to the extent to which
hook 30 can exert a pinching pressure on the flange of hook 32 to
hold the lower panel in place, temporarily during installation, by
the frictional interference fit of hooks 30, 32.
[0035] In an assembly, the siding panels are hung in overlapping
courses. Proceeding from a point of low elevation, for example, a
first panel is positioned and nailed to the building by passing
fasteners (e.g., nails or screws) through the top edge of the
panel, i.e., through holes 36 of the nailing strip 34. The next
upper course overlaps and conceals the nailing strip along the top
edge of the next lower course. As the panels are installed, each
section of paneling is joined to the next adjacent panel(s) on the
same level or course. The hook members 30, 32 are sized to affix
the bottom edge of the upper course correctly relative to the
overlapped lower course, and side butt joint structures can affix
panels 10 end-to-end in the direction of their elongation. In an
exemplary embodiment, the butt joints comprise interlocking
underlap edges 40 and tabs 42 as described fully in copending,
commonly assigned U.S. patent application Ser. No. 10/697,479
entitled "Siding Panel Tab and Slot Joint" to Stucky et al., the
entirety of which is hereby incorporated by reference herein. Other
complementary joint structures for joining adjacent panels in
end-to-end abutment described in Stucky et al. may also be
employed.
[0036] There should be clearance for the panels to expand without
interference, and sufficient overlap or depth of joint engagement
so that when the panels contract, they remain adequately attached.
To that end, a temperature scale/indicator can be employed, and
appropriate installation methodology, as described in, for example,
U.S. Pat. No. 6,939,036 entitled "Temperature-Expansion Indicator
for Siding Panels" to Beck et al., the entirety of which is hereby
incorporated by reference herein.
[0037] From the foregoing, a siding panel is provided having a
realistic, simulated shake appearance. Random butt lines in the
shake courses provide the appearance of shakes having different
lengths, while still allowing for mating hook members to be used as
connection members for overlapping panels. Further, by varying the
length, width and/or intermediate shake gap depth and/or width, the
appearance of randomly selected shakes is provided. By providing
sufficient numbers of such shakes in a panel, it becomes difficult
to visually discern a shake pattern when multiple panels are
installed to cover a vertical wall of a structure.
[0038] 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
* * * * *