U.S. patent application number 11/633188 was filed with the patent office on 2007-06-21 for wall covering with stone appearance.
Invention is credited to Alexandre Golberg, William Patrick Lincoln.
Application Number | 20070137127 11/633188 |
Document ID | / |
Family ID | 38171784 |
Filed Date | 2007-06-21 |
United States Patent
Application |
20070137127 |
Kind Code |
A1 |
Lincoln; William Patrick ;
et al. |
June 21, 2007 |
Wall covering with stone appearance
Abstract
A wall covering having a plurality of panels. The panels are
molded to disguise the panel's individuality after installation.
The panel's outline is jagged to terminate horizontal and vertical
partition lines of the panel's front surface. The partition of the
panel's front surface is not aligned with the horizontal and
vertical edges of the front surface's outline. The panels are
attached to a wall to create a substantially random appearance.
This invention is especially suited to create wall covering with
the appearance of random ashlar stone layout. Multiple molded
panels having different front face partitions may be used to
increase the random appearance. Molding the panels is simplified by
molding parts of the panel interlock mechanism separately.
Inventors: |
Lincoln; William Patrick;
(Bell Canyon, CA) ; Golberg; Alexandre; (Bell
Canyon, CA) |
Correspondence
Address: |
William Lincoln
101 Dapplegray Road
Bell Canyon
CA
91307
US
|
Family ID: |
38171784 |
Appl. No.: |
11/633188 |
Filed: |
December 4, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60742088 |
Dec 5, 2005 |
|
|
|
Current U.S.
Class: |
52/384 |
Current CPC
Class: |
B44F 11/06 20130101;
B44F 9/04 20130101; F16B 5/0635 20130101; E04F 13/0801 20130101;
E04F 13/185 20130101; B44C 5/0453 20130101 |
Class at
Publication: |
052/384 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Claims
1. A wall covering comprising: (a) a plurality of panels, and (b)
an appearance means for substantially disguising said panels'
individuality after installation, and (c) a partition of the front
surface of said panels whereby said panels will be attached to a
wall to create a substantially random appearance.
2. The panels in claim 1 wherein said panels are not identically
molded.
3. The panels of claim 1 wherein said partition is not aligned with
the horizontal and vertical edges of the outline of said panel's
front surface.
4. The panels of claim 1 wherein said panels have ajagged outline
thereby terminating lines formed by said partition of the front
surface of said panels.
5. The panels of claim 1 wherein said partition is a plurality of
stones.
6. The panels of claim 1 wherein said panels interlock with
neighboring said panels.
7. The panels of claim 6 wherein brackets used in said interlock
are made separately from said panels thereby simplifying the
manufacture of said panels.
8. The panels of claim 1 wherein said panels have different
appearance from each other to substantially increase the random
appearance when installed.
9. The panels of claim 1 wherein said panels are made from vinyl,
said panels have a jagged outline, said panel's front surface has
the appearance of a partition of building elements, said front
surface consists of a number of building elements separated by
gaps, said gaps can vary in width to create a pleasing appearance,
said panels has an attachment means located at said panel edges to
the left and above the long axis of said panel, said nail hem has
holes for fasteners to the wall, said nail hem has pockets that
brackets from neighboring said panels fit into to secure said
panels to its neighbors, some areas of said nail hem are thinner on
the front so when the said panels are assembled the overlapping
nail hems do not become too thick, said nail hems overlap to insure
proper water shedding, said panels have a spacing means to separate
the assembled said panels from each other, said spacing means are
sized to be similar to the width of the gap between the stones on
the face of the panel, said partition of said panel into individual
stones is the means used to disguise the individuality of the
panels after installation, said panels have sockets on the back of
said panel, said sockets accept brackets used to secure the
neighboring said panels to each other, said brackets fitted into
pockets provide tension to maintain spacing between panels.
10. A method for covering a wall with a plurality of panels,
comprising the steps of: (a) providing said panels that have a
partition of the front surface and, (b) attaching them to a surface
in sequence thereby creating a wall covering where the panel's
identity is substantially hidden whereby said method creates
appearance of a random ashlar stone wall covering.
11. The method of claim 10 wherein said panels overlap previous
installed neighboring said panel's attachment means, and interlock
with neighboring said panels.
12. The method of claim 10 wherein said panels are installed using
alternating different said panels.
13. The method of claim 10 wherein said panels are installed in a
diagonal manner.
14. The panels of claim 10 wherein said panels are manufactured
with an injection molding process.
15. The panels of claim 10 wherein said panels are made separately
from the brackets thereby making the manufacture of said panels
easier.
16. The panels of claim 10 wherein said panels are made from vinyl,
said panels have a jagged outline, said panel's front surface has
the appearance of a partition of building elements, said front
surface consists of a number of building elements separated by
gaps, said gaps can vary in width to create a pleasing appearance,
said panels has an attachment means located at said panel edges to
the left and above the long axis of said panel, said nail hem has
holes for fasteners to the wall, said nail hem has pockets that
brackets from neighboring said panels fit into to secure said
panels to its neighbors, some areas of said nail hem are thinner on
the front so when the said panels are assembled the overlapping
nail hems do not become too thick, said nail hems overlap to insure
proper water shedding, said panels have a spacing means to separate
the assembled said panels from each other, said spacing means are
sized to be similar to the width of the gap between the stones on
the face of the panel, said partition of said panel into individual
stones is the means used to disguise the individuality of the
panels after installation, said panels have sockets on the back of
said panel, said sockets accept brackets used to secure the
neighboring said panels to each other, said brackets fitted into
pockets provide tension to maintain spacing between panels.
17. A wall covering comprising: (a) a plurality of panels, and (b)
a set of at least two differently molded said panels (b) an
appearance means for substantially disguising said panels
panel-to-panel identity after installation, and (c) a jagged
outline of said panels, and (d) a partition of the front surface of
said panels whereby said panels will be attached to a wall to
create a substantially random stone appearance.
18. The panels in claim 17 wherein said panels are not identically
molded.
19. The panels of claim 17 wherein said partition is not aligned
with the horizontal and vertical edges of the outline of said
panel's front surface, and said panel's have a jagged outline
thereby terminating lines formed by said partition of the front
surface of said panels, and said partition is a plurality of
stones.
20. The panels of claim 17 wherein said panels are made from vinyl,
said panels have a jagged outline, said panel's front surface has
the appearance of a partition of building elements, said front
surface consists of a number of building elements separated by
gaps, said gaps can vary in width to create a pleasing appearance,
said panels has an attachment means located at said panel edges to
the left and above the long axis of said panel, said nail hem has
holes for fasteners to the wall, said nail hem has pockets that
brackets from neighboring said panels fit into to secure said
panels to its neighbors, some areas of said nail hem are thinner on
the front so when the said panels are assembled the overlapping
nail hems do not become too thick, said nail hems overlap to insure
proper water shedding, said panels have a spacing means to separate
the assembled said panels from each other, said spacing means are
sized to be similar to the width of the gap between the stones on
the face of the panel, said partition of said panel into individual
stones is the means used to disguise the individuality of the
panels after installation, said panels have sockets on the back of
said panel, said sockets accept brackets used to secure the
neighboring said panels to each other, said brackets fitted into
pockets provide tension to maintain spacing between panels.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Provisional patent application.
[0002] U.S. Application No. 60/742,088
[0003] Filing date: Dec. 5, 2006
[0004] Name of Applicants: Alex Golberg, Bell Canyon, Calif. [0005]
William Lincoln, Bell Canyon, Calif.
FEDERALLY SPONSORED RESEARCH
[0006] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0007] Not Applicable
BACKGROUND OF INVENTION
[0008] The field of the present invention relates to wall
coverings. In particular, the present invention relates to
injection molded siding panels that have improved random
appearance.
BACKGROUND OF THE INVENTION--PRIOR ART
[0009] Various types of exterior wall panels are currently known
and used in the construction and improvement of buildings. Such
panels are usually formed from a plastic resin. Extrusion,
injection molding or thermoforming manufactures them. The panels
may be formed in various shapes. Prior known designs used long
elongated sections or single panels having one of more rows of
individual decorative elements. Prior designs having one of more
rows have a limitation on the layout of the decorative elements.
They cannot, for example, produce random ashlar patterns in the
installed panels.
[0010] Prior known panel designs incorporate one or more rows of
decorative elements such as shake shingles. A problem with these
designs is that when installed there are long horizontal lines
formed by these decorative elements. The nature of the wall
covering using repeated panels is visually obvious.
[0011] Prior known panel designs use identically molded panels.
Because panels are identically molded, a panel-to-panel identity
can be easily noticed. Using a single molded panel in prior panel
designs produces a relatively unattractive repetitive pattern when
installed.
[0012] When installing such panels it is known to interlock the
panels to each other. Prior designs use apertures in the panels
that accept tabs from neighboring panels. These apertures create
openings where moisture can enter behind the installed panels.
[0013] The panels are often connected to other previously installed
panels. The panels usually overlap portions of the previously
installed panels. Prior known panel designs use vertical side and
horizontal bottom connections that are molded as part of the panel.
These attachment mechanisms complicate the mold design since the
attachment mechanism used to secure one panel to another also
hinders the removal of the panel from the mold. Previously molds
have been constructed with sliders that released the panel from the
mold, but these sliders complicate the mold construction and the
panel manufacture.
[0014] U.S. Pat. No. 6,336,303 B1 by Vandeman et al. discloses an
exterior siding panel that simulated cedar shake shingles. The
panel shape is a stair step. The panel's partition into shingles is
made so there is a long line of shingles when the panels are
installed. There is not a substantially random appearance after
installation. Using only a single panel design also reduces the
random appearance of the installed panels. Cedar shingles are not
as desirable as stone siding. The panel is made from polypropylene.
Polypropylene is not as durable for outside use. The tab and
apertures complicate the manufacture of their panels.
[0015] U.S. Pat. No. 6,955,019 B2 by Donlin et al. discloses a wall
covering comprising a plurality of plastic panels. Each of their
panels contains rows of building elements. Because the panels
contain rows of building elements the panels will not create a
random appearance when installed. The building elements are cedar
shake shingles.
[0016] Prior know panel designs have a stair step outline but with
grout lines within each panel coincided with the horizontal edge of
the step. When installed there are long horizontal lines. Use of
these prior designs can only produce a coursed stone
arrangement.
[0017] Other materials besides vinyl are often used by prior
designs. Panels made from other plastics may auto-ignite at high
temperatures. Many prior designs use other plastics that are not
very durable for outdoor use and have not been uniformly approved
for building siding applications.
[0018] Prior designs often use panels that are rectangular shaped.
They do not have a jagged outline so that after installation the
panels have long straight horizontal and vertical lines
corresponding to the panel outlines. This visual pop-out of the
individual panels is more obvious since the interior of these
panels are partitioned into stones that do not break horizontal and
vertical lines within the panel. The human visual system is very
good at performed texture segmentation. The panel-to-panel identity
is obvious in these prior designs.
BACKGROUND OF THE INVENTION--OBJECTS AND ADVANTAGES
[0019] A primary object of the present invention is to provide a
system of siding that will overcome the shortcomings of the prior
art methods.
[0020] An object of the present invention is to provide a system of
siding for dramatically reducing the time and cost to install
siding with a stone, rock, or masonry appearance compared to
existing systems.
[0021] Another object is to speed the time of construction by
having a panel system consists of multiple stones per panel.
[0022] Another object is to provide a system of siding that
develops the building industry to serve a larger number of homes by
providing a stone, rock, or masonry appearance for less cost.
[0023] Another object is to provide a system of vinyl siding giving
the appearance of stone, rock, or masonry but with a much lower
weight. This reduces the requirements on the structure, and thus
lowering costs of construction.
[0024] Another object is to provide a system of vinyl siding with a
stone, rock, or masonry look that insulates the structure from heat
and cold.
[0025] Another object is to provide a system of siding that ensures
that the individual panels are not obvious. The vertical and
horizontal seams should not be obvious. The panels should blend
together to form a continuous surface. After installation the
identity of the individual panels should be disguised.
[0026] Another objective is to provide a wall covering that gives a
pleasing layout of individual stones. To insure the wall covering
is attractive the stones should be laid out in a pattern obeying
certain placement rules. The horizontal and vertical joints should
not be too long. The vertical joint should not be more than the
maximum height of the stones. The horizontal joint should not be
more than three stones wide. No stones of the same height should be
placed end-to-end. All stones should be placed so that their height
is no more than their width. Using these rules will create a random
ashlar stone layout. Our invention has multiple panels consisting
of multiple stones on the panel's surface. When the panels are
interlocked next to each other the resulting surface should have a
pleasing appearance and look as if it was made of individual stones
and not panels consisting of multiple stones. The resulting surface
should obey as many of the individual stone placement rules as
possible. The stone surface panel shape, using multiple molded
panels, and the panel's surface partition into individual stones
achieve many of the individual stone placement guidelines.
[0027] Another object is to provide a panel-to-panel interlock
system that is easier to manufacture. Injection mold are easiest to
make and use when they open and the panel can be pulled from the
mold with no internal moving parts in the mold.
[0028] Another object is to provide a system of siding that is an
alternative to painting with its associated costs, maintenance and
hazards. The stone, rock, or masonry appearance gives the building
a more substantial and impressive appearance.
[0029] Another objective of this invention is to provide a rain
screen. A rain screen is a vapor barrier, allows airflow behind,
and has a protective surface.
[0030] Another objective is to provide panels made from vinyl.
Vinyl is self-extinguishing, more durable that other plastics.
Vinyl has been used in the building industry for many years and is
part of the Uniform Building Code.
[0031] Other objects and advantages of the present invention will
become obvious to the reader and it is intended that these objects
and advantages be within the scope of the present invention.
[0032] There has thus been outlined, rather broadly, the more
important features of the invention in order that the detailed
description thereof may be better understood, and in order that the
present contribution to the art may be better appreciated. There
are additional features of the invention that will be described
hereinafter.
[0033] In this respect, before explaining at least one embodiment
of the invention in detail, it is to be understood that the
invention is not limited in its application to the details of
method and to the arrangements of the components set forth in the
following description or illustrated in the drawings. The invention
is capable of other embodiments and of being practiced and carried
out in various ways. Also, it is to be understood that the
phraseology and terminology employed herein are for the purpose of
the description and should not be regarded as limiting.
[0034] To the accomplishment of the above and related objects, this
invention may be embodied in the form illustrated in the
accompanying drawings, attention being called to the fact, however,
that the drawings are illustrative only, and that changes may be
made in the specific construction illustrated.
SUMMARY
[0035] The general purpose of the present invention is to provide a
new wall covering that has many more advantages than wall covering
mentioned heretofore and many novel features that result in a new
wall covering which is not anticipated, rendered obvious,
suggested, or even implied by any of the prior art wall covering,
either alone or in any combination thereof.
[0036] A set of prototiles for siding is a set of different panel
shapes, and the set of shapes is sufficient to cover a surface by
packing the prototiles. The wall covering consists of jagged
prototiles and an appearance means for disguising the prototile's
individuality after assembly. The front surface is partitioned into
stones. When assembled the panels cover the surface and the front
surface disguises the identity of the individual panels. Multiple
molded panels help disguise the panel-to-panel identity.
[0037] The panel shapes have a jagged outline. The purpose of this
jagged outline is to avoid large vertical or horizontal joints in
the siding surface. Large joints give the appearance of siding made
out of panels and not the desired appearance of stone siding.
[0038] There is a method of attaching each panel to the wall. The
surface panels have a nail hem at the top and left edges of the
panel where nailing slots are located. The molding panels have a
nail hem. Depending on variations on the orientation of the jagged
outline of the stone surface panel, the nail hem may be at the top
and right edges.
[0039] The surface appearance of the stone surface panel is
partitioned into individual stone shapes. The panel partition is
not disposed of in rows since this would cause long horizontal rows
to form during installation of the panels. The stones shapes can
have different sizes, colors, and textures. The partition is made
in such a way that when the panels are fit next to each other large
vertical and horizontal joints are avoided. The surface of the
stone surface panel has the appearance of a random stone pattern.
The face of each stone surface panel has the appearance of many
stones. The panel surface appearance is subdivided into areas
looking like individual stones. The panels are used to construct a
wall surface having a random stone appearance. The dry-stack look
is especially suitable to molded plastic panels. By using stone
partitions and more than one panel our panel's give a more pleasing
random appearance.
[0040] The panels have sockets on their back that does not
interfere with the removal of the part from the injection mold. A
bracket fits into the socket and is secured by a pocket in the
neighboring panel. The pocket is designed in a way that is does not
interfere with the removal of the part from the injection mold.
Molding our brackets separately from the panel makes our panel
easier to manufacture.
[0041] The panels are made from vinyl that is accepted by the
building industry for outside use.
DRAWINGS--FIGURES
[0042] Various other objects, features and attendant advantages of
the present invention will become fully appreciated as the same
becomes better understood when considered in conjunction with the
accompanying drawings, in which like reference characters designate
the same or similar parts throughout the several views, and
wherein:
[0043] FIG. 1 illustrates the front of panel 1 (shown without stone
texture).
[0044] FIG. 2 illustrates the rear of panel 1.
[0045] FIG. 3 illustrates the stone texture on the front of panel
1.
[0046] FIG. 4 illustrates the front of panel 2 (shown without stone
texture).
[0047] FIG. 5 illustrates the rear of panel 2.
[0048] FIG. 6 illustrates the stone texture on the front of panel
2.
[0049] FIG. 7 illustrates the front of an assembly of panels 1 and
2 (shown without stone texture).
[0050] FIG. 8 illustrates the rear of an assembly of panels 1 and
2.
[0051] FIG. 9 illustrates the stone texture of the front of an
assembly of panels 1 and 2.
[0052] FIG. 10 illustrates the preferred assembly of panels 1 and
2.
[0053] FIG. 11 illustrates the bracket connection to a socket.
[0054] FIG. 12 illustrates the assembled bracket into socket.
[0055] FIG. 13 illustrates the trim or quoin panel.
[0056] FIG. 14 illustrates the long trim or quoin panel.
[0057] FIG. 15 illustrates the assembled corner.
[0058] FIG. 16 illustrates the wall corner moulding.
DRAWINGS--REFERENCE NUMERALS
[0059] 1 panel 1 [0060] 4 panel 2 [0061] 11 bracket
DETAILED DESCRIPTION--PREFERRED EMBODIMENT
[0062] Description--FIGS. 1-16.
[0063] Turning now descriptively to the drawings, in which similar
reference characters denote similar elements throughout the several
views, the attached figures illustrate a system of vinyl siding,
which comprises multiple siding panels, trim and quoin panels, and
other architectural panels and components.
[0064] Description of the front of panel 1 (shown without stone
texture) (FIG. 1). The panel has a jagged outline. The stone
surface panel's outside front surface has the appearance of a
partition of stones, rocks, or masonry building materials. The
front surface consists of a number of stones separated by gaps
(102). The gaps can vary in width to create a pleasing appearance.
The nail hem (103) is located at the panel edges to the left and
above the long axis of the panel. The nail hem has holes (104) for
fasteners to the wall or fence. The nail hem has pockets (105, 106,
and 107) that brackets from neighboring panels fit into to secure
on panel to its neighbor. Some areas (108, 109, and 110) of the
nail hem are thinner on the front so when the panels are assembled
the overlapping nail hems do not become too thick. The nail hems
should overlap to insure proper water shedding. The edge of the
panel has a number of small tabs (111) to separate the assembled
panels from each other. The tabs are sized to be similar to the
width of the gap between the stones on the face of the panel. When
assembled the gaps between the panels are similar to the gap sizes
between the stones.
[0065] The partition of the panel into individual stones is the
appearance means used to disguise the individuality of the panels
after installation.
[0066] Description of the rear of panel 1 (FIG. 2). The rear of the
panel is hollow. The nail hem (201) is flush with the back of the
panel. The pockets (202, 203, and 204) extend forward from the back
of the panel. Some areas (205 and 206) of the nail hem are thinner
on the back so when the panels are assembled the overlapping nail
hems do not become too thick. The overlapping nail hems increase
the water resistance of the assembled panels. The gaps between the
stones form channels (210) between the stones. The rib (211)
separating the upper half from the lower half is there so when the
panel is cut parallel and below this rib a half panel is created.
This half panel is used during installation. The sockets (207, 208,
and 209) on the back of the panel are used with brackets to secure
the neighboring panels to each other. The brackets fitted into
pockets also provide tension to maintain spacing between
panels.
[0067] The outline of the panels is made jagged, ragged, broken,
cleft, craggy, indented, irregular, notched, pointed, ridged,
rough, rugged, serrated, snaggy, spiked, toothed, uneven, unlevel,
unsmooth, cornered, crooked, crotched, staggered, zigzag, uneven,
bumpy, craggy, fluctuating, irregular, jerky, notched, odd,
off-balance, rugged, scraggy, serrate, or unsmooth. The purpose of
the jagged outline is to disrupt the continuous straight vertical
and horizontal lines when installing multiple panels.
[0068] The partition of the panel's surface is made so that when
multiple panels are interconnected the resulting combined surface
appears to be made from arranged individual stones. It is made
jagged so that the vertical and horizontal joints are not too long.
The center stone shown in FIG. 1 (101) breaks the horizontal joint
line in the assembled panels.
[0069] Description of the stone texture on the front of panel 1.
(FIG. 3). The front surface (301) of panel 1 is a stone, rock, or
masonry texture. FIG. 3 shows one example of the texture. Other
textures can be used. The nail hem (302) is shown here not
extending to the end on the upper right or the lower left. We
prefer it extended to the ends since this gives better water
resistance to the panel assembly. We prefer the texture and gaps to
give the appearance of stones that are installed dry stacked
without mortar joints. A design with dry stacked joints does not
require reproducing mortar joints in thermoplastic.
[0070] Description of the front of panel 2 (shown without stone
texture) (FIG. 4). The second panel has a front surface with a
different internal stone partition. This different partition is
useful to add variation to assembled panels, and to avoid the same
rocks repeating with a recognizable periodicity. This helps
disguise the nature of the assembly of panels, and makes it look
more like an arrangement of individual stones.
[0071] The other features of panel 2 are the same as panel 1. The
stones on the front surface (401) are separated by gaps (402). The
nail hem (403) has holes for fasteners (404) and pockets (405, 406,
and 407), and thin areas (408, 409, and 410). The panel has spacers
(411).
[0072] Description of the rear of panel 2 (FIG. 5). The rear of
panel 2 has the same features as panel 1. Panel 2 has a nail hem
(501) with pockets (502, 503, and 504) and thin areas (505 and
506). It has sockets (507, 508, and 509) in the same positions as
panel 1. This allows panel 1 and panel 2 to be used next to each
other. The channels (510) extend into the back of the panel to give
the gaps between the stones a deep groove. The rib (511) in this
panel serves the same purpose as in panel 1.
[0073] Description of the stone texture on the front of panel 2
(FIG. 6). The front surface (601) of panel 2 is a stone, rock, or
masonry texture. FIG. 6 shows one example of the texture. Other
textures can be used. The nail hem (602) is shown here not
extending to the end on the upper right or the lower left. We
prefer it extended to the ends since this gives better water
resistance to the panel assembly. Panel 2 has a stone face where
the individual stones are created to look like dry stacked stones
without mortar joints between the stones.
[0074] Description of the front of an assembly of panels 1 and 2
(shown without stone texture) (FIG. 7). During installation on a
wall or fence the panel assembly is formed. Panels (701, 702, 703,
704, 705, and 706) are installed to create the illusion of
individually installed stones.
[0075] Description of the rear of an assembly of panels 1 and 2
(FIG. 8). During installation brackets (801-808) fit into pockets
in the neighboring panels to help secure the bottom edge of the
panel to the previously secured panel. The previously secured panel
is fastened to the surface with nail, screws, or other method. In
this way each panel is secured by the nail hem on some edges and by
brackets on other edges. Brackets can also be placed on the
vertical edges for extra support.
[0076] Description of the stone texture of the front of an assembly
of panels 1 and 2 (FIG. 9). After installation the panels form a
pleasing arrangement of individual stones. The identity of
individual panels is hidden. The installed panels look like
dry-stacked stones. This dry-stacked look avoids grout mortar lines
and helps disguise the panel seems since the separation between
panels is the same as the channel between stones in the panel
face.
[0077] Description of the preferred assembly of panels 1 and 2
(FIG. 10). There are many ways to install the panels. Different
methods give different effects. The preferred method to begin
installation at the lower right with Panel 2 (1001). Then the upper
half of panel 2 (1002) is installed to the left. This upper half
panel is used to create a shift in the panels by one half-panel
height. This breaks up the continuous horizontal lines that would
be formed in an assembly of panels without the half panel shift.
Some installations may prefer the continuous horizontal lines, but
our preferred installation breaks up the continuous horizontal
line. The order of installation (1001-1020) is such that each panel
overlaps its neighboring panels' nail hems. This assembly
alternates the panels in a way that the same area of panel 1 is not
adjacent to the same area of panel 1. This also holds for panel 2's
areas. This helps to avoid a repetitious pattern during
installation.
[0078] Description of the bracket connection to a socket (FIG. 11).
The sockets (1101) on the back of each panel (1102) accept a
bracket (1103). In the preferred embodiment the bracket is secured
by a ring (1104). Other methods can be used to secure the bracket
including glue, or friction from the tight fit of the bracket into
the socket. The bracket fits into the pocket (1106) on the nail hem
(1107) of the neighboring panel. The pocket is wider at the top to
help slide the bracket into the pocket, and to wedge it into place
in the pocket.
[0079] Description of the assembled bracket into socket (FIG. 12).
After the bracket (1205) is secured in the socket (1201) by the
ring (1202), the neighboring panel (1203) is installed by
overlapping the nail hem (1204) of the neighboring panel. The
bracket fits into the pocket (1206) of the nail hem. This secures
panels to their neighbors.
[0080] Making the bracket a separate part from the socket makes the
injection molding process easier. Injection molding uses a mold
with two halves that come together to form a cavity. The cavity is
filled with heated plastic resin. After the resin cools the mold
opens and the panel is taken out of the mold. It is possible to
make molds that have sliders and other internal moving parts that
move after the resin cools to allow the parts with complicated
geometries to come out of the mold, but these internal moving parts
increase the complexity of the mold and the manufacturing process,
and increase the cost of the panel as a result. Our panel does not
require any of these moving parts since the orientation of the
socket's walls is the same as the panel edges and channels. The
panels are molded with a simple mold with not sliders. The bracket
is also molded separately in a simple mold with no sliders. When
the bracket is inserted into the socket it creates a mechanism to
secure the panel to the neighboring panel's pocket. If the bracket
were created as part of the panel the mechanism that secures the
bracket to the pocket would be exactly the reason why the panel
would not be able to be taken out of a mold without moving
sliders.
[0081] Description of the trim or quoin panel (FIG. 13). Other
panels are used during the installation. This panel is used at
corners and for trim around doors and windows. For the trim or
quoin panel we prefer the face (1301) of the panel have a masonry
texture. A stone or rock texture can also be used. The panel has a
nail hem (1302) with holes (1303) for fasteners. The nail hem has
pockets (1307, 1308). Some areas (1304) of the nail hem are thinner
on the front. Some areas (1305 and 1306) of the nail hem are
thinner on the back. These areas are where the nail hems overlap
each other. The thin areas are so the overlapping nail hems do not
combine to become too thick. There are sockets (1309 and 1310) in
the back of the panel. The socket, bracket, and pocket mechanism is
the same as for panels 1 and 2. There are two sockets and pockets
so the panel can be installed in two different orientations rotated
90 degrees from each other. This is useful for the left and right
side of corners, windows, or doors.
[0082] Description of the long trim or quoin panel (FIG. 14). At
the corners of walls or fences it is sometimes desired to have a
larger quoin alternating with a smaller quoin. The long trim or
quoin panel has a masonry, rock, or stone face (1401). The nail hem
(1402) with holes for fasteners (1403) is used to secure the panel
to the wall or fence. The nail hem has thinner areas (1404, 1405,
1406, 1407). These areas are where the nail hems of either the
smaller or larger trim or quoin panels overlap. The nail hem has
pockets (1408, 1409) in the locations needed during assembly and
installation. There are sockets (1410 and 1411) in the back of the
panel. The socket, bracket, and pocket mechanism is the same as for
panels 1 and 2. The left or right part of the nail hem may be
trimmed depending on the installed orientation or position of the
long trim or quoin.
[0083] Description of the assembled corner (FIG. 15). The quoin
panels (1501 and 1502) are used together with a corner moulding
(1503) to create an assembled quoin during installation.
[0084] Description of the wall corner moulding (FIG. 16). The
corner moulding is attached to the wall with adhesive and/or
fasteners at nail hems (1601, and 1602). The nail hem of the
exterior corner moulding (1601 and 1602) gives water resistance to
the seam between the moulding and the other siding material
installed after the moulding. Other siding material butts up
against the surface (1603 and 1604).
[0085] FIGS. 16A and 16B show alternative views of a section of the
extruded part. FIG. 16C shows the profile of the extruded part.
[0086] The front surface (1605, 1606, and 1607) of the corner
moulding has an attractive profile. Other profiles that give
different front surface appearance can be used.
[0087] The stone surface panel and all the other siding components
may also be made in the mirror image.
[0088] Applying moisture barrier tape to cover the fasteners
increases the water resistance.
[0089] Pegs, pins, knobs, rods, spikes, studs, balls, or u-joints
can be used to connect each panel to its neighboring panel. The
preferred embodiment is brackets.
[0090] Pegs may fit into slots, holes, channels, sockets, grooves,
or slits. The preferred embodiment is pockets.
[0091] Other architectural components can be used. Architectural
components come in various shapes and sizes. Architectural
components include arches and panels for light and electrical
outlets, security wires, and other low voltage wiring. The
architectural components have a nail hem located at the panel edges
to the left and above the one axis.
[0092] In the preferred embodiment, the panels are made of
vinyl.
[0093] Panels may be colored. Coating can be applied to the whole
panel and to individual stones within the panel. The panels may be
coated differently from each other. A solvent-based paint is
preferred. Aggregate can also be added to further enhance the
surface appearance.
[0094] As to a further discussion of the manner of usage and
operation of the present invention, the same should be apparent
from the above description. Accordingly, no further discussion
relating to the manner of usage and operation will be provided.
[0095] With respect to the above description then, it is to be
realized that the optimum dimensional relationships for the parts
of the invention, to include variations in size, materials, shape,
form, function and manner of operation, assembly and use, are
deemed readily apparent and obvious to one skilled in the art, and
all equivalent relationships to those illustrated in the drawings
and described in the specification are intended to be encompassed
by the present invention.
[0096] Therefore, the foregoing is considered as illustrative only
of the principles of the invention. Further, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and operation shown and described, and accordingly,
all suitable modifications and equivalents may be resorted to,
falling within the scope of the invention.
[0097] The preferred embodiments herein disclosed are not intended
to be exhaustive or to unnecessarily limit the scope of the
invention. The preferred embodiments were chosen and described in
order to explain the principles of the present invention so that
others skilled in the art may practice the invention. Having shown
and described preferred embodiments of the present invention, those
skilled in the art will realize that many variations and
modifications may be made to affect the described invention. Many
of those variations and modifications will provide the same result
and fall within the spirit of the claimed invention. It is the
intention, therefore, to limit the invention only as indicated by
the scope of the claims.
Operation of Invention
[0098] Many stones arrangements are possible. FIG. 8 is
illustrative. Many other designs are readily apparent.
[0099] Installation of the panels may be executed in the following
order: [0100] Install moldings around doors and windows. [0101]
Install corner assembly at corners. Corner mouldings can also be
used. [0102] Install architectural components as desired. [0103] At
concave corners install mouldings. The panels can also be mitered
at a concave corner to form the concave corner joint. Caulk the
seam. [0104] Install surface panels starting from the lower right
next to the previously installed molding. The panels are installed
to allow for expansion and contraction. The panel can be cut during
installation. The panels are installed so that they lap the nail
hem. [0105] When another door, window, or corner is reached, cut
surface panels to fit. [0106] The panels are cut to closely butt up
against the trim panels and mouldings, thus hiding the cut. The
seam is caulked. [0107] Removing the damaged panel and replacing
with a panel of the same type and shape may execute maintenance of
the panels.
Description and Operation of Alternative Embodiments
[0108] Description--FIGS. 17-33.
[0109] FIG. 17 illustrates an alternate texture of the front of
panel 1.
[0110] FIG. 18 illustrates alternate internal face partitions for
the panels.
[0111] FIG. 19 illustrates alternate embodiment of socket and
bracket.
[0112] FIG. 20 illustrates alternate panel shapes and internal
stone partitions.
[0113] FIG. 21 shows an alternate embodiment: One Layer Ashlar
Panel
[0114] FIG. 22 shows an alternate embodiment: One Layer Ashlar
Assembly
[0115] FIG. 23 shows an alternate embodiment: Two Layer Ashlar
Panel
[0116] FIG. 24 shows an alternate embodiment: Two Layer Ashlar
Assembly
[0117] FIG. 25 shows an alternate embodiment: Alternate Two Layer
Ashlar Panel (nail hem not shown)
[0118] FIG. 26 shows an alternate embodiment: Alternate Two Layer
Ashlar Assembly (nail hem not shown)
[0119] FIG. 27 shows an alternate embodiment: Three Layer Ashlar
Panel (nail hem not shown)
[0120] FIG. 28 shows an alternate embodiment: Three Layer Ashlar
Assembly (nail hem not shown)
[0121] FIG. 29 shows an alternate embodiment: Random Layer Ashlar
Panel (nail hem not shown)
[0122] FIG. 30 shows an alternate embodiment: Random Layer Ashlar
Assembly (nail hem not shown)
[0123] FIG. 31 shows an alternate embodiment: Alternate Random
Layer Ashlar Assembly (nail hem not shown)
[0124] FIG. 32 shows an alternate embodiment: Alternate Random
Layer Ashlar Assembly (nail hem not shown)
[0125] FIG. 33 shows an alternate embodiment: Alternate
Assemblies
[0126] All panels can be made in mirror image. In particular, the
orientation of the jagged outline of the stone surface panel can be
reversed. The nail hems may be placed at the right and top instead
of the left and top.
[0127] Pockets may be placed on the vertical edges of the nail hem.
Sockets may also be placed near the vertical edge so that brackets
can be inserted and locked into the pocket on the vertical edge in
the neighboring panel's nail hem.
[0128] The surface appearance of the panels can be varied. Possible
surface appearance is stone shapes, marble looking pieces, river
rock, granite rocks, metal-looking panels, any masonry looking
surface finish.
[0129] The corner panel's surface can be made to look like stones.
The corner panel's outline can be jagged to match the stone surface
panel's shape.
[0130] Instead of using a corner panel at convex corner, the
surface panels can be mitered to form a corner joint and the seam
caulked.
[0131] Various connectors can be used instead of pegs and dowels. A
system of u-joints could be used to interlock the adjacent
panels.
[0132] Description of an alternate texture of the front of panel 1
(FIG. 17). The front surface (1701) of panel 1 is a stone, rock, or
masonry texture. FIG. 17 shows another example of the texture.
Other textures can be used.
[0133] Description of alternate internal face partitions for the
panels (FIG. 18). Other internal stone partitions are possible.
Increasing the number of different internal partitions will
increase the variation in the final installation. FIG. 18 shows
three more examples of internal stone partitions. The panels have
nail hems (1801, 1803, 1805). The internal faces (1802, 1804, 1806)
differ.
[0134] Description of alternate embodiment of socket and bracket
(FIG. 19). The sockets (1903) on the back of each panel (1901)
accept a bracket (1906). Teeth (1907) secure the bracket in the
socket. The bracket is made from spring metal to give the assembled
bracket in the pocket spring tension to hold it into place. Other
methods can be used to secure the bracket. The bracket fits into
the pocket (1905) on the nail hem (1904) of the neighboring panel
(1902). The pocket is wider at the top to help slide the bracket
into the pocket, and to wedge it into place in the pocket. The
assembled bracket fits into the socket. After the bracket (1906) is
secured in the socket (1903) then the panel (1901) is installed by
overlapping the nail hem (1904) of the neighboring panel. The
bracket (1906) fits into the pocket of the nail hem (1904). This
secures panels to their neighbors.
[0135] Additional sockets and corresponding pockets may be added.
The sockets may be added at vertical orientations. Corresponding
pockets may be added on the vertical portions of the nail hem. A
continuous socket may be added that follows the edge of the panel.
Together with a continuous pocket on the entire nail, this would
allow brackets to be placed at any locations to interlock the
panels. The brackets may also provide inter-panel spacing instead
of the spacing tabs on the outside edge.
[0136] Description of alternate panel shapes and internal stone
partitions (FIG. 20). Different panel shapes and panel face
partitioning are possible and give different visual effects when
the panels are assembled.
[0137] Description of alternate embodiment: One Layer Ashlar Panel
(FIG. 21). Different panel shapes and panel face partitioning are
possible and give different visual effects when the panels are
assembled. Nail hem (2101) is shown.
[0138] Description of alternate embodiment: One Layer Ashlar
Assembly (FIG. 22). Different panel shapes and panel face
partitioning are possible and give different visual effects when
the panels are assembled.
[0139] Description of alternate embodiment: Two Layer Ashlar Panel
(FIG. 23). Different panel shapes and panel face partitioning are
possible and give different visual effects when the panels are
assembled. Nail hem (2301) is shown.
[0140] Description of alternate embodiment: Two Layer Ashlar
Assembly (FIG. 24). Different panel shapes and panel face
partitioning are possible and give different visual effects when
the panels are assembled.
[0141] Description of alternate embodiment: Alternate Two Layer
Ashlar Panel (nail hem not shown) (FIG. 25). Different panel shapes
and panel face partitioning are possible and give different visual
effects when the panels are assembled.
[0142] Description of alternate embodiment: Alternate Two Layer
Ashlar Assembly (nail hem not shown) (FIG. 26). Different panel
shapes and panel face partitioning are possible and give different
visual effects when the panels are assembled.
[0143] Description of alternate embodiment: Three Layer Ashlar
Panel (nail hem not shown) (FIG. 27). Different panel shapes and
panel face partitioning are possible and give different visual
effects when the panels are assembled.
[0144] Description of alternate embodiment: Three Layer Ashlar
Assembly (nail hem not shown) (FIG. 28). Different panel shapes and
panel face partitioning are possible and give different visual
effects when the panels are assembled.
[0145] Description of alternate embodiment: Random Layer Ashlar
Panel (nail hem not shown) (FIG. 29). Different panel shapes and
panel face partitioning are possible and give different visual
effects when the panels are assembled.
[0146] Description of alternate embodiment: Random Layer Ashlar
Assembly (nail hem not shown) (FIG. 30). Different panel shapes and
panel face partitioning are possible and give different visual
effects when the panels are assembled.
[0147] Description of alternate embodiment: Alternate Random Layer
Ashlar Assembly (nail hem not shown) (FIG. 31). Different panel
shapes and panel face partitioning are possible and give different
visual effects when the panels are assembled.
[0148] Description of alternate embodiment: Alternate Random Layer
Ashlar Assembly (nail hem not shown) (FIG. 32). Different panel
shapes and panel face partitioning are possible and give different
visual effects when the panels are assembled.
[0149] Description of alternate embodiment: Alternate Assemblies
(FIG. 33). The panels can be assembled in parallel and offset ways
(FIGS. 33A and 33B), or the mixture of both. The panels can be
randomly or orderly selected for various rock layouts (FIG. 33C).
These layouts will produce different visual affects.
[0150] There are many possibilities for the outline of the stone
surface panel. In general any prototile that forms a tessellation
of the wall can be used.
[0151] Alternate materials can be used to make the panels in the
system. Materials used to make the product include vinyl, plastic,
plastic resin, plaster, cement, wood, metal, or any other building
material.
[0152] A buttlock may be used to overlap a nail hem of an adjacent
panel. A buttlock is a notch cut out from the backside of the panel
that matches the size and shape of the nail hem.
[0153] A corner panel that is a single component with two wings can
also be used. The nail hem is located on the left side of the left
wing and on the top of the left and right wings.
Conclusion, Ramification, Scope
[0154] Thus the reader will see that the wall covering invention
provides a durable, easy to install and maintain, attractive, yet
economical method of having a wall covering with a beautiful stone
appearance. While my above descriptions contain many specificities,
these should not be construed as limitations on the scope of the
invention, but rather as an exemplification of one preferred
embodiment thereof. Many other variations are possible. For
example, many possible panel partitions are possible. Other panel
shapes are possible. The panel installation order may be varied.
Many stone textures can be used. Colors may be varied. Dry-stacked
or stones with simulated grout can be used. The panels can be used
without the brackets. The panels can be changed in size. The panels
can be made of different material. The panels can be interlocked in
a different manner. The panels can be made separately and assembled
or made integrally.
[0155] Additional sockets and corresponding pockets may be added.
The sockets may be added at vertical orientations. Corresponding
pockets may be added on the vertical portions of the nail hem. A
continuous socket may be added that follows the edge of the panel.
Together with a continuous pocket on the entire nail, this would
allow brackets to be placed at any locations to interlock the
panels. The brackets may also provide inter-panel spacing instead
of the spacing tabs on the outside edge.
[0156] Accordingly, the scope of the invention should be determined
not by the embodiments illustrated, but by the appended claims and
their legal equivalents.
* * * * *