U.S. patent application number 12/056360 was filed with the patent office on 2009-10-01 for composite siding system.
Invention is credited to Bob Bryan.
Application Number | 20090241459 12/056360 |
Document ID | / |
Family ID | 41115036 |
Filed Date | 2009-10-01 |
United States Patent
Application |
20090241459 |
Kind Code |
A1 |
Bryan; Bob |
October 1, 2009 |
Composite Siding System
Abstract
The present invention is an improved system of wall siding which
provides a aesthetically appealing, weather resistant and
maintenance free house cladding which has the appearance of wood
siding. The system includes a plurality of elongated composite
siding boards for mounting to the wall studs, each composite siding
board having a length, opposite outer and inner sides and opposite
upper and lower edges. The upper edge of each board has a tongue
formed thereon which extends along the entire length of the siding
board. The opposite lower edge has a groove formed thereon which
also extends the entire length of the siding board. Each board has
a shoulder portion extending from the inner side of the siding
board adjacent the lower edge. The groove is formed on the shoulder
adjacent the lower edge. The lower edge has a lower lip extending
below the groove, the tongue and the groove being dimensioned and
configured such that the tongue of one siding board can be snugly
received within the groove of the siding board mounted immediately
above. The board are mounted to the wall studs by a plurality of
mounting clips, the mounting clips each having a flat portion and a
sinusoidal portion, the sinusoidal portion being dimensioned and
configured to fit in the groove between the groove of one siding
board and the tongue of the adjacent siding board, the flat portion
having an aperture for receiving a mounting element for mounting
the clip to the wall stud.
Inventors: |
Bryan; Bob; (Belton,
CA) |
Correspondence
Address: |
Elias Borges
Suite 406, 555 Burnhamthorpe Road
Toronto
ON
M9C 2Y3
CA
|
Family ID: |
41115036 |
Appl. No.: |
12/056360 |
Filed: |
March 27, 2008 |
Current U.S.
Class: |
52/539 ; 52/518;
52/543 |
Current CPC
Class: |
E04F 13/0864
20130101 |
Class at
Publication: |
52/539 ; 52/543;
52/518 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Claims
1. A siding system for mounting to a plurality of wall studs to
form wall siding, the system comprising: a plurality of elongated
siding boards for mounting to the wall studs in a parallel and
abutting side to side orientation, each siding board having a
length, opposite outer and inner sides and opposite upper and lower
edges, the upper edge having a tongue formed thereon extending
substantially the entire length of the siding board and the
opposite lower edge having a groove formed thereon extending
substantially the entire length of the siding board; the tongue and
the groove being dimensioned and configured such that the tongue of
one siding board can be received within the groove of the siding
board mounted immediately above; a plurality of mounting clips for
mounting the siding boards to the wall studs, the mounting clips
each having a sinusoidal portion contoured and dimensioned to fit
in the groove between the groove of one siding board and the tongue
of the siding board immediately below, the clip having an aperture
for receiving a mounting element for mounting the clip to the wall
stud.
2. The system of claim 1 wherein each siding board has a shoulder
projecting from the inner side, the shoulder positioned adjacent
the lower edge and extending substantially the entire length of the
board, the groove being formed on the shoulder, the lower edge of
each board having a lip projecting below the shoulder, the lip
being dimensioned and configured such that the lip overlaps a
portion of the tongue of the board immediately beneath when said
tongue is fully inserted in the groove.
3. The system of claim 1 wherein the sinusoidal portion of the clip
is provided with at least one resilient dimple, the dimple being
positioned on the sinusoidal portion and dimensioned such that when
two siding boards are mounted together the tongue of one siding
board is separated from the groove of the other siding board by a
gap.
4. The system of claim 2 wherein the shoulder has a toe portion
formed on one side of the groove and the inner side of the board
adjacent the groove forms a side wall, the groove having a top wall
positioned between the toe and the side wall.
5. The system of claim 4 wherein the sinusoidal portion of the clip
is provided with at least one resilient dimple, the dimple being
positioned on the sinusoidal portion and dimensioned such that when
two siding boards are mounted together the tongue of one siding
board is separated from the groove of the other siding board by a
gap.
6. The system of claim 5 wherein the dimple of the clip is
positioned on the sinusoidal portion such that the dimple bears
against the top wall.
7. The system of claim 2 wherein the lip is further dimensioned and
configured such that when the tongue portion of one siding board is
fully inserted into the groove portion of another siding board, the
lip contacts a contact surface on the outer side of the siding
board adjacent the tongue portion.
8. The system of claim 7 wherein the lip is dovetailed.
9. The system of claim 6 wherein the lip is dovetailed such that
when the tongue portion of one siding board is fully inserted into
the groove portion of another siding board, the lip contacts a
contact surface on the outer side of the siding board adjacent the
tongue portion.
10. A siding system for mounting to a plurality of wall studs to
form wall siding, the system comprising: a plurality of elongated
siding boards for mounting to the wall studs in a parallel and
overlapping side to side orientation, each siding board having a
length, opposite outer and inner sides and opposite upper and lower
edges, the upper edge having a tongue formed thereon extending
substantially the entire length of the siding board and the
opposite lower edge having a groove formed thereon extending
substantially the entire length of the siding board; a shoulder
portion extending from the inner side of the siding boards adjacent
the lower edge, the groove being formed on the shoulder adjacent
the lower edge, the lower edge having a lower lip extending below
the groove, the tongue and the groove being dimensioned and
configured such that the tongue of one siding board can be snugly
received within the groove of the siding board mounted immediately
above; a plurality of mounting clips for mounting the siding boards
to the wall studs, the mounting clips each having a flat portion
and a sinusoidal portion, the sinusoidal portion being dimensioned
and configured to fit in the groove between the groove of one
siding board and the tongue of the adjacent siding board, the flat
portion having an aperture for receiving a mounting element for
mounting the clip to the wall stud.
11. The system of claim 10 wherein the sinusoidal portion of the
clip is provided with at least one resilient dimple, the dimple
being positioned on the sinusoidal portion and dimensioned such
that when two siding boards are mounted together the tongue of one
siding board is separated from the groove of the other siding board
by a gap.
12. The system of claim 11 wherein the board further comprises an
elongated spine projecting from the inner side, the spine extending
substantially along the entire length of the board, the board
further comprising a first flat surface formed on the shoulder and
a second flat surface formed on upper edge adjacent the tongue and
a third flat surface formed on the spine, said first, second and
third flat surfaces all being coplanar.
13. The system of claim 12 wherein each siding board has a shoulder
projecting from the inner side, the shoulder positioned adjacent
the lower edge and extending substantially the entire length of the
board, the groove being formed on the shoulder, the lower edge of
each board having a lip projecting below the shoulder, the lip
being dimensioned and configured such that the lip overlaps a
portion of the tongue of the board immediately beneath when said
tongue is fully inserted in the groove.
14. The system of claim 13 wherein the lip is dovetailed such that
when the tongue portion of one siding board is fully inserted into
the groove portion of another siding board, the lip contacts a
contact surface on the outer side of the siding board adjacent the
tongue portion.
15. A siding system for mounting to a plurality of wall studs to
form wall siding, the system comprising: a plurality of elongated
siding boards for mounting to the wall studs in a parallel and
abutting side to side orientation, each siding board having a
length, opposite outer and inner sides and opposite upper and lower
edges, the upper edge having a tongue formed thereon extending
substantially the entire length of the siding board and the
opposite lower edge having a groove formed thereon extending
substantially the entire length of the siding board; the tongue and
the groove being dimensioned and configured such that the tongue of
one siding board can be received within the groove of the siding
board mounted immediately above; a plurality of mounting clips for
mounting the siding boards to the wall studs by suspending the
siding boards, the clips being dimensioned and configured to permit
the boards to move slightly relative to the mounting clips.
16. The siding system of claim 15 wherein the mounting clips each
have a sinusoidal portion contoured and dimensioned to fit in the
groove between the groove of one siding board and the tongue of the
siding board immediately below, the clip having an aperture for
receiving a mounting element for mounting the clip to the wall
stud.
17. The siding system of claim 16 wherein each siding board has a
shoulder projecting from the inner side, the shoulder positioned
adjacent the lower edge and extending substantially the entire
length of the board, the groove being formed on the shoulder, the
lower edge of each board having a lip projecting below the
shoulder, the lip being dimensioned and configured such that the
lip overlaps a portion of the tongue of the board immediately
beneath when said tongue is fully inserted in the groove.
18. The siding system of claim 17 wherein the shoulder has a toe
portion formed on one side of the groove and the inner side of the
board adjacent the groove forms a side wall, the groove having a
top wall positioned between the toe and the side wall.
19. The siding system of claim 18 wherein the sinusoidal portion of
the clip is provided with at least one resilient dimple, the dimple
being positioned on the sinusoidal portion and dimensioned such
that when two siding boards are mounted together the tongue of one
siding board is separated from the groove of the other siding board
by a gap.
20. The siding system of claim 19 wherein the dimple of the clip is
positioned on the sinusoidal portion such that the dimple bears
against the top wall.
Description
FIELD OF THE INVENTION
[0001] The invention relates generally to composite siding for
mounting to wall studs to form a wall.
BACKGROUND OF THE INVENTION
[0002] Wooden siding has been a very popular way of cladding a
house against the elements. Generally speaking, wooden siding is
simply nailed (or screwed) to the wall studs in overlapping
parallel horizontal rows to form a weather resistant cladding.
Wooden siding can be a very effective form of cladding,
particularly if premium weather resistant woods such as treated
cedar are used and maintained. Unfortunately, genuine cedar is
relatively expensive. Furthermore, periodic maintenance is required
to maintain the weather resistant nature of the wood siding.
Periodically treating wooden siding is a labor intensive operation
involving the use of messy chemical sealants. As a result,
alternative forms of siding have been attempted.
[0003] Aluminum siding has been used in place of wooden siding with
adequate results. The resulting cladding is often inexpensive and
effective, but is not as aesthetically pleasing as genuine wooden
siding. In an attempt to create a more authentic looking
appearance, composite siding boards have been used. These composite
boards generally consist of an extruded polymeric material of resin
and filler. Various formulations exist for the composition of the
composite board, but the key ingredients are generally a polymer
resin and a fibrous filler material such as wood fiber. The
finished siding board is often quite similar to wood in texture and
appearance, and in some cases, can even be sawed and nailed just
like genuine wood siding. While lacking some of the structural
strength and rigidity of genuine wooden siding, the composite
siding is generally impervious to weather and never needs
maintenance after installation.
[0004] While composite siding has become quite popular as a result
of its relative cost and maintenance free characteristics, it has a
few drawbacks. Firstly, the composite boards tend to lack the
structural strength and rigidity of genuine wood. This makes
composite siding more difficult to mount to the wall studs. In hot
sunny weather, the composite siding boards have a tendency to
soften and expand, causing the boards to buckle. Buckling of the
boards causes minute gaps and fissures to open up between the
boards, resulting in a less effective cladding as well as an
aesthetically displeasing appearance. An improved siding system
which overcomes the limitations of composite siding is therefore
desirable.
SUMMARY OF THE INVENTION
[0005] In accordance with one aspect of the present invention,
there is provided an improved system of wall siding which overcomes
the disadvantages of the prior art. The system includes a plurality
of elongated composite siding boards for mounting to the wall studs
in a parallel and abutting side to side orientation. Each composite
siding board has a length, opposite outer and inner sides and
opposite upper and lower edges. The upper edge has a tongue formed
thereon extending substantially the entire length of the siding
board and the opposite lower edge has a groove formed thereon
extending substantially the entire length of the siding board. The
tongue and the groove are dimensioned and configured such that the
tongue of one siding board can be received within the groove of the
siding board mounted immediately above. The siding boards are
mounted to the wall studs by a plurality of mounting clips. The
mounting clips each have a sinusoidal portion contoured and
dimensioned to fit in the groove between the groove of one siding
board and the tongue of the siding board immediately below. Each
clip has an aperture for receiving a mounting element for mounting
the clip to the wall stud.
[0006] In accordance with another aspect of the present invention,
there is provided an improved system of wall siding which provides
a weather resistant and maintenance free house cladding which will
not buckle after installation. The system includes a plurality of
elongated composite siding boards for mounting to the wall studs in
a parallel and abutting side to side orientation, each composite
siding board having a length, opposite outer and inner sides and
opposite upper and lower edges. The upper edge has a tongue formed
thereon extending substantially the entire length of the siding
board and the opposite lower edge has a groove formed thereon
extending substantially the entire length of the siding board. The
tongue and the groove are dimensioned and configured such that the
tongue of one siding board can be received within the groove of the
siding board mounted immediately above. The system further includes
a plurality of mounting clips for mounting the siding boards to the
wall studs by suspending the siding boards, the clips being
dimensioned and configured to permit the boards to move slightly
relative to the mounting clips.
[0007] In accordance with another aspect of the present invention,
there is provided an improved system of wall siding which provides
a aesthetically appealing, weather resistant and maintenance free
house cladding which has the appearance of wood siding and which
overcomes the drawbacks of the prior art. The system includes a
plurality of elongated composite siding boards for mounting to the
wall studs in a parallel and overlapping side to side orientation,
each composite siding board having a length, opposite outer and
inner sides and opposite upper and lower edges. The upper edge of
each board has a tongue formed thereon which extends along the
entire length of the siding board. The opposite lower edge has a
groove formed thereon which also extends the entire length of the
siding board. Each board has a shoulder portion extending from the
inner side of the siding board adjacent the lower edge. The groove
is formed on the shoulder adjacent the lower edge. The lower edge
has a lower lip extending below the groove, the tongue and the
groove being dimensioned and configured such that the tongue of one
siding board can be snugly received within the groove of the siding
board mounted immediately above. The board are mounted to the wall
studs by a plurality of mounting clips, the mounting clips each
having a flat portion and a sinusoidal portion, the sinusoidal
portion being dimensioned and configured to fit in the groove
between the groove of one siding board and the tongue of the
adjacent siding board, the flat portion having an aperture for
receiving a mounting element for mounting the clip to the wall
stud.
[0008] With the foregoing in view, and other advantages as will
become apparent to those skilled in the art to which this invention
relates as this specification proceeds, the invention is herein
described by reference to the accompanying drawings forming a part
hereof, which includes a description of the preferred typical
embodiment of the principles of the present invention.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1. is side view of a siding board made in accordance
with the present invention.
[0010] FIG. 2 is a side view of the siding board shown in FIG. 1
with a mounting clip made in accordance with the present invention
attached thereto.
[0011] FIG. 3 is a side view of two siding boards made in
accordance with the present invention being mounted by a mounting
clip made in accordance with the present invention.
[0012] FIG. 4 is an isometric view taken from the bottom showing a
mounting clip made in accordance with the present invention.
[0013] FIG. 5 is a perspective view of a mounting clip made in
accordance with the present invention.
[0014] FIG. 6 is a side view of three siding boards made in
accordance with the present invention being mounted by mounting
clips.
[0015] FIG. 7 is a side view of three siding boards made in
accordance with an alternate embodiment of the present invention
being mounted by mounting clips
[0016] In the drawings like characters of reference indicate
corresponding parts in the different figures.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring firstly to FIGS. 1 and 2, a siding board made in
accordance with the present invention is shown generally as item 10
and comprises a an elongated board 12 having upper edge 16 and
lower edge 14, inner side 28 and outer side 26. Board 12 may be
made of solid wood, particle board or, preferably, a composite
board made of an extruded polymer/filler mix, the composition of
which is designed to balance cost, appearance and strength. Several
suitable formulations of polymer resin and filler are readily
available in the marketplace for use in manufacturing board 12. For
example, a mixture of approximately 50% wood fiber and
approximately 50% polymer is useful for many applications. Of
course, the exact formulation of polymer resin and filler will be a
function of raw material cost, desired appearance and the weather
conditions the boards are destined to be used in.
[0018] Board 12 has tongue 18 formed on upper edge 16 and groove 20
formed on lower edge 14. Board 12 has flat surface 59 on end 16.
Groove 20 is formed on shoulder 24 which projects from inner side
28 adjacent edge 14. Shoulder 24 has toe portion 30, top wall 32
and flat surface 61. Side wall 34 is formed on edge 14 adjacent
groove 20. Lip 22 is formed on edge 14. Outer side 26 may have a
pattern formed thereon to simulate the appearance of natural wood.
Upper edge 16 may have scallop 50 formed thereon.
[0019] Tongue 18 and groove 20 are dimensioned and configured such
that tongue 18 of one siding board can fit within groove 20 of an
identical siding board. Spine 56 projects from inner side 28 and
extends along the entire length of the board. Spine 56 adds
structural rigidity to board 12. Spine 56 has flat surface 63
formed thereon. Flat surface 63 is coplanar with flat surfaces 61
and 59.
[0020] Referring now to FIGS. 3, 4 and 5, mounting clips 36 are
used to mount boards 12 to the wall studs 100 forming the wall (see
FIG. 6). Siding boards 12a and 12b are mounted to the wall studs in
horizontal abutting parallel arrangement with the tongue of one
board retained in the groove of the board immediately above. To
mount the siding boards to the wall studs clips 36 are first
mounted to the wall studs by means of fastener 44 (either a nail or
screw). Aperture 42 is provided on flat portion 40 of clip 36 to
provide a quick and simple means to mount the clips to the wall
studs. Clips 36 each have a sinusoidal portion 38 which is
contoured to fit closely within groove 20. Sinusoidal portion 38 is
profiled to closely fit over toe portion 30 and to fit snugly
between top wall 32 and tongue 18. Sinusoidal portion 38 has
dimples 46 formed thereon which act as spacers separating the tip
of tongue 18 from top wall 38 such that the tongue and groove are
separated by a small predefined gap 58. The dimensions of dimples
46 define the size of gap 58, which is preferably about 1 mm.
[0021] Lip 22 of edge 14 is dovetailed such that when tongue 18 is
inserted into groove 20, a portion 52 of lip 22 contacts surface 54
of board 12a adjacent tongue 18. The close contact between lip 22
and surface 54 of tongue 18 adds to the weather resistant nature of
the cladding.
End
[0022] Clip 36 is preferably made from resilient steel. Preferably,
clip 36 is formed by stamping an elongated strip of steel with the
profile of clip 36 in a suitable stamping machine. Dimples 46 can
then be formed by stamping. Since dimples 46 are formed on stamped
steel clip 36, the dimples are resilient and can be deformed in the
event boards 12a and 12b heat and expand. The board are thereby
permitted to move relative to the clips to prevent the boards from
buckling in the heat.
[0023] Referring now to FIG. 6, a plurality of siding boards 12 can
be attached to wall stud 100 to form a wall 101. As mentioned
above, siding boards 12 are mounted to the wall studs in horizontal
abutting parallel arrangement with inner side 28 facing wall stud
100 and with the tongue 18 of one board retained in the groove 20
of the board immediately above. Clips 36 are fastened to wall stud
100 by fasteners 44 and the clips securely mount siding boards 12
to the wall stud at both upper edge 16 and lower edge 14,
preventing the siding boards from buckling. Preferably reinforcing
spine 56 is dimensioned to lay flush against board 100 to ensure
that there is an air gap 57 between board 12 and stud 100.
Preferably, spine 56 is dimensioned such that surface 63 is
co-planar with surfaces 59 of end 16 and surface 61 of shoulder 24
of each board so that when the boards are positioned against stud
100, the boards will lay flat against the stud and substantially
parallel to the studs. Since clips 36 secure boards 12 to studs 100
at both ends 14 and 16 and since surfaces 63, 59 and 61 are
coplanar, siding boards 12 are more likely not to buckle or
warp.
[0024] An alternate embodiment of the present invention is shown in
FIG. 7 and consists of a plurality of siding boards 102 which are
mounted to wall stud 110 by clips 136. Clips 136 are identical in
every way to clips 36. Boards 102 consist of flat elongated boards
having upper edge 116 and lower edge 114, inner side 128 and outer
side 126. As with boards 12, boards 102 may be made of solid wood,
particle board or, preferably, a composite material made of an
extruded polymer/filler mix, the composition of which is designed
to balance cost, appearance and strength. Boards 102 have tongue
118 formed on end 116 and groove 120 formed on end 114. Groove 120
and tongue 118 are identical to groove 20 and tongue 18 formed on
board 12 of the previous embodiment and function in the same way.
Board 102 lacks scallop 50 and reinforcing spine 56 found in board
12 of the previous embodiment. If board 102 is made of a very rigid
material such as wood or a rigid polymer/filler combination, then
board 102 may have sufficient rigidity without the need of a
reinforcing spine. Furthermore, since boards 102 are being
supported from below by clips 136 and since the upper ends 116 of
each board is held to stud 110 by clips 136, the boards will have
less tendency to warp and buckle even without a reinforcing
spine.
[0025] The present invention has many advantages over the prior
art. Firstly, mounting the siding boards is quite quick because of
the use of the mounting clips. The user simply has to measure out
the placement of the clips and then nail a plurality of clips to
the wall studs in a horizontal row. The boards are then suspended
to the row of clips by attachment of the sinusoidal portion of the
clips to the grooved edge of the boards. The top edge of the boards
are then secured by attaching another row of clips. The next row of
siding boards are then suspended to the last row of clips and
process is repeated. Since the boards "float" on the stud wall via
the clips, making minute adjustments to the positioning of the
siding boards is possible. Also, the floating boards are less prone
to buckling as a result of sun exposure or as a result of settling.
Finally, since the boards are not directly mounted to the studs but
are rather supported by the clips, to boards do not require as much
structural strength.
[0026] A specific embodiment of the present invention has been
disclosed; however, several variations of the disclosed embodiment
could be envisioned as within the scope of this invention. It is to
be understood that the present invention is not limited to the
embodiments described above, but encompasses any and all
embodiments within the scope of the following claims.
* * * * *