U.S. patent application number 13/898539 was filed with the patent office on 2013-10-03 for siding joinery.
This patent application is currently assigned to Royal Mouldings, Limited. The applicant listed for this patent is Royal Mouldings, Limited. Invention is credited to Michel BOULANGER, Steven A. MITCHELL, Brandon NADLER, Brian L. STAFFORD.
Application Number | 20130255174 13/898539 |
Document ID | / |
Family ID | 49232991 |
Filed Date | 2013-10-03 |
United States Patent
Application |
20130255174 |
Kind Code |
A1 |
STAFFORD; Brian L. ; et
al. |
October 3, 2013 |
SIDING JOINERY
Abstract
A panel system includes elongated panels coupled together at a
seam portion with respective interlocking portions at corresponding
vertical ends to provide a substantially planar surface. In siding
panel systems, joined siding panels are provided in vertically
arranged rows that further couple together along adjacent
horizontal edges of the respective rows of siding panels.
Inventors: |
STAFFORD; Brian L.;
(Bristol, VA) ; MITCHELL; Steven A.; (Chilhowie,
VA) ; NADLER; Brandon; (Abingdon, VA) ;
BOULANGER; Michel; (St. Bruno, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Royal Mouldings, Limited |
Marion |
VA |
US |
|
|
Assignee: |
Royal Mouldings, Limited
Marion
VA
|
Family ID: |
49232991 |
Appl. No.: |
13/898539 |
Filed: |
May 21, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13847087 |
Mar 19, 2013 |
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13898539 |
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12750065 |
Mar 30, 2010 |
8402707 |
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13847087 |
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61650102 |
May 22, 2012 |
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61299383 |
Jan 29, 2010 |
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Current U.S.
Class: |
52/539 ;
52/519 |
Current CPC
Class: |
E04F 2201/0138 20130101;
E04F 2201/0517 20130101; E04F 2201/0505 20130101; E04F 2201/026
20130101; E04F 15/02038 20130101; E04F 2201/0115 20130101; E04F
13/0894 20130101; E04F 2201/07 20130101 |
Class at
Publication: |
52/539 ;
52/519 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Claims
1. A panel system comprising a pair of panels coupled by a coupling
means at adjacent vertical ends of a first panel of the pair of
panels and a second panel of the pair of panels, wherein an outer
surface of the first panel and an outer surface of the second panel
together provide a substantially planar row outer surface, wherein
the coupling means interlocks the panels as a single composite
panel, wherein the composite panel moves horizontally as a single
unit during shifting, contraction or expansion.
2. The panel system of claim 1, wherein the coupling means is a
first rectangular projection adjacent a first rectangular receiving
groove on the vertical end of the first panel coupled to a
complimentary first rectangular projection adjacent a first
rectangular receiving groove on the vertical end of the second
panel.
3. The panel system of claim 1, wherein the coupling means is a
first non-perpendicular parallelogram projection adjacent a first
non-perpendicular parallelogram receiving groove on the vertical
end of the first panel coupled to a complimentary first
non-perpendicular parallelogram projection adjacent a first
non-perpendicular parallelogram receiving groove on the vertical
end of the second panel.
4. The panel system of claim 1, wherein the coupling means is a
first rectangular projection adjacent a first rectangular receiving
groove on the vertical end of the first panel coupled to a
complimentary first retractable projection adjacent a first
receiving groove on the vertical end of the second panel.
5. The panel system of claim 1, wherein the coupling means is a
saw-tooth flange projection on the vertical end of the first panel
coupled by an adhesive to a complimentary saw-tooth flange
projection on the vertical end of the second panel.
6. The panel system of claim 1, wherein the coupling means is an
arrow-head shaped projection on the vertical end of the first panel
coupled to a complimentary receiving recess on the vertical end of
the second panel.
7. The panel system of claim 1, wherein the coupling means is an
ratcheted tongue-shaped projection on the vertical end of the first
panel coupled to a complimentary ratcheted tongue-shaped recess on
the vertical end of the second panel.
8. The panel system of claim 1, wherein the coupling means is a
tongue projection on the vertical end of the first panel coupled by
an adhesive to a complimentary groove recess on the vertical end of
the second panel.
9. The panel system of claim 1, wherein the coupling means is a
first lap flange projection on the vertical end of the first panel
coupled by an adhesive to a complimentary first lap flange
projection on the vertical end of the second panel.
10. The panel system of claim 1, wherein the coupling means is a
first lap flange projection on the vertical end of the first panel
coupled by a mechanical cleat including barbs to a complimentary
first lap flange projection on the vertical end of the second
panel, wherein the barbs of the mechanical cleat deform adjacent
surfaces of the first lap flange projection of the first panel and
first lap flange projection of the second panel.
11. The panel system of claim 1, wherein the coupling means is a
mechanical cleat coupled to parallel outer surfaces of both a first
panel and a second panel of the pair of panels, wherein the barbs
of the mechanical cleat deform the outer surfaces of the first
panel and the second panel.
12. The panel system of claim 1, wherein the coupling means is
selected from the group consisting of adhesives, welds, mechanical
fasteners, melt-bonds, and magnets.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority of
U.S. Provisional Application No. 61/650,102 filed on May 22, 2012,
and is a Continuation-in-part of U.S. patent application Ser. No.
13/847,087 filed on Mar. 19, 2013, which is a Continuation of U.S.
patent app. Ser. No. 12/750,065 filed on Mar. 30, 2010, now U.S.
Pat. No. 8,402,707, which claims the benefit of U.S. Provisional
Application No. 61/299,383 filed on Jan. 29, 2010, all of which are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to panel systems, such as
generally flat sections used in building, construction and other
applications, including in walls, siding, flooring, tiling,
shelving, furniture and like. In non-limiting embodiments the
present invention provides a system of interlocking siding panels
and a method of making interlocking siding panels.
[0004] 2. Description of Related Art
[0005] Vinyl and metal siding panels, such as those used to cover
the exterior of a building, generally are formed as single lap
panels that extend horizontally across the building. In cases where
a single panel is not long enough to extend across an entire
surface of a building, multiple panels may be positioned
horizontally adjacent to one another. Horizontally adjacent siding
panels may overlap one another, such as when the siding panels are
thin or hollow, or may be fastened with their ends in an abutting
arrangement such as with a bracket or shim.
[0006] Once installed, the siding panels may tend to expand or
contract horizontally as the ambient temperature changes. This
expansion and contraction may cause irregularities in the seam
section between two adjacent panels. For example, if adjacent
abutting panels expand, the ends of the adjacent panels may expand
toward each other, causing them to deflect away from the building
at the seam section. If adjacent abutting panels contract, the ends
of the panels may draw away from each other, resulting in a gap at
the seam section. The gapping created by expansion or contraction
of the siding panels may leave openings that can be unsightly, and
leave the siding and building surface susceptible to damage from
the elements.
[0007] In siding panel assemblies having overlapping end portions,
the overlapping portion typically is left unfastened, so that the
individual panels may expand and contract without causing bulging
or gapping. However, the overlapping region leaves an undesirable
visible seam. In addition, the gap between the two overlapping
sections allows water, air, and insects to pass which may cause
damage to the siding panels or the underlying building surface.
Furthermore, where the overlapping region is unfastened, the ends
of the siding panels can separate, further exacerbating these
issues.
[0008] In siding panel assemblies having abutting siding panels,
additional connectors and similar devices have been used to prevent
movement and separation of the ends of the siding panels. However,
the use of separate connector pieces complicates the installation
and assembly of the siding panels.
[0009] The description herein of certain advantages and
disadvantages of known methods and devices is not intended to limit
the scope of the present invention. Indeed, the present embodiments
may include some or all of the features described above without
suffering from the same disadvantages.
SUMMARY OF THE INVENTION
[0010] In view of the foregoing, it is a feature of the embodiments
described herein to provide a system of panels that provides an
improved end-to-end seam section with the outer surfaces of the
joined panels providing a generally planar surface. In various
embodiments, adjacent panels in a siding system may overlap and
interlock at a seam section in a secure fashion. Once interlocked,
the siding panels may expand and contract without causing a bulge
or gap at the seam section. One benefit of siding panel assembly
may be that the expansion and contraction associated with the
individual siding panels is transferred to the ends of the
assembly, rather than the end of each individual siding panel.
Another benefit of the siding panel assembly of the embodiments is
that it allows for a smoother seam between individual panels, so
that it is less apparent from all viewing angles, unlike vinyl
siding where the pieces are overlapped, to allow for expansion and
contraction.
[0011] In embodiments of the invention, a variety of geometries may
be provided at the respective ends of adjacent panels (i.e.
joints), including without limitation interlocking laps or
overlapped ends, tongue and groove ends and butt joints.
[0012] In some embodiments adjacent siding ends may by locked by
friction fit and/or shape-driven mechanical fit. In various other
embodiments the joints may include, without limitation, one or more
of frictional fits, shaped mechanical fits, adhesives, mechanical
fasteners, welds, melt-bonds and magnets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a top plan view of two panels interlocked in a
manner, according to exemplary embodiments of the invention;
[0014] FIG. 2 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing an interlocking lap joint disclosed in
U.S. Pat. No. 8,402,707, according to an exemplary embodiment of
the invention;
[0015] FIG. 3 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing an angled interlocking lap joint,
according to an exemplary embodiment of the invention;
[0016] FIG. 4 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing an interlocking lap joint with punch tap,
according to an exemplary embodiment of the invention;
[0017] FIG. 5 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing an interlocking lap joint with saw-tooth
geometry, according to an exemplary embodiment of the
invention;
[0018] FIG. 6A-6C are cross-section views A-A of the two
interlocked panels of FIG. 1 showing an arrow-head snap joint
depicting a snap head pointing outward toward both opposite outer
surfaces of a panel to interlock within a complementary recess FIG.
6A, a snap head pointing outward toward a single outer surface of a
panel to interlock within a complementary recess FIG. 6B), and a
snap head pointing outward toward another (opposite direction from
FIG. 6B) single outer surface of a panel to interlock within a
complementary recess FIG. 6C, according to exemplary embodiments of
the invention;
[0019] FIG. 7 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing a ratcheted tongue and groove joint,
according to an exemplary embodiment of the invention;
[0020] FIG. 8 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing a standard tongue and groove joint with
glue, according to an exemplary embodiment of the invention;
[0021] FIG. 9 is a is a cross-section view A-A of the two
interlocked panels of FIG. 1 showing a lap joint with glue,
according to an exemplary embodiment of the invention;
[0022] FIG. 10 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing a lap joint with an inner mechanical
cleat, according to an exemplary embodiment of the invention;
and
[0023] FIG. 11 is a cross-section view A-A of the two interlocked
panels of FIG. 1 showing of a butt joint with an outer surface
mechanical cleat, according to an exemplary embodiment of the
invention.
[0024] These and other exemplary embodiments and advantages will
become apparent from the following detailed description, taken in
conjunction with the accompanying drawings, illustrating by way of
example the principles of the various exemplary embodiments.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] The following description is intended to convey a thorough
understanding of the embodiments by providing a number of specific
embodiments and details involving a siding panel assembly. It is
understood, however, that the invention is not limited to these
specific embodiments and details, which are exemplary only. It is
further understood that one possessing ordinary skill in the art,
in light of known devices, systems and methods, would appreciate
the use of the invention for its intended purposes and benefits in
any number of alternative embodiments.
[0026] Generally speaking, as shown in FIG. 1, panel systems 100 of
the present invention are generally flat sections used in building,
construction and other applications, including in walls, siding,
flooring, tiling, shelving, furniture and like. In one described
but non-limiting embodiment, a panel system 100 of the invention
includes siding panels 110 that have a plurality of horizontally
adjacent siding panels 120 that are interlocked on their vertical
ends 115 and 125 to provide a composite siding panel 200. The
siding panels 110 and 120 are joined together so that the composite
siding panel 200 forms a single unit, such as in a row with
outer-facing surfaces 117 and 127 of the siding panels providing an
exterior siding surface of building in which a row of siding panels
forms a substantially planar surface. Any horizontal expansion or
contraction of the individual siding panels 110 or 120 is
transferred to the end of the composite panel 200, rather than
causing gapping or buckling at the junction between two adjacent
panels 110 and 120. In some embodiments several composite siding
panels 200 may be assembled in horizontal rows, adjacent other
composite siding panels 200 along respective horizontal edges of
the adjacent rows, to form a siding panel assembly (not shown) that
covers a surface, such as the wall of a building.
[0027] As used herein, the terms "horizontal" and "vertical" are
not intended to be limited to a specific orientation and reflect
generally perpendicular sides, edges or ends with respect to one
another. The references of "horizontal" and "vertical" as
describing one embodiment of the invention are intended to continue
to reference the respective edge, side or end in other embodiments
where a panel 110 or panel system 100 is provided in another
orientation relative to the ground or horizon.
[0028] In the various exemplary embodiments, the siding panel
systems 100 and their components may be made from solid or foamed
polymers, such as vinyl or cellular PVC. However, the embodiments
are not so limited. The siding panel systems 100 and their
components may be made from any known or later developed material
used for siding panels including, but not limited to, wood,
aluminum, steel and other metals, polymer materials, plastics,
masonry, stone, brick, concrete, composites and combinations
thereof. Panels of various materials may be shaped by extrusion,
milling, molding, and the like. One having ordinary skill in the
art would understand how to apply the teachings of various
materials and panel manufacturing methods to various embodiments of
the invention.
[0029] Referring to FIG. 2, a cross section view A-A of one
embodiment of the invention an interlocking lap joint for adjacent
siding panels 110A and 120A in siding panel system 100A is shown as
described in U.S. Pat. No. 8,402,707, which is included herein by
reference. Siding panel 110A has an integrally formed interlock
including a rectangular receiving groove 113A and a rectangular
projection 114A at a vertical end. Siding panel 120A has a mating
integrally formed interlock including a rectangular receiving
groove 123A and a rectangular projection 124A at a vertical end
adjacent to the vertical end of siding panel 110A. Siding panels
110A and 120A may be joined the their corresponding interlocks to
form a composite siding panel 200.
[0030] Referring to FIG. 3, a cross section view A-A of one
embodiment of the invention an interlocking lap joint for adjacent
siding panels 1108 and 120B in siding panel system 1008 is shown.
Siding panel 1108 has an integrally formed interlock including a
non-perpendicular parallelogram-shaped receiving groove 113B and a
non-perpendicular parallelogram-shaped projection 114B at a
vertical end. Siding panel 120B has a mating integrally formed
interlock including a non-perpendicular parallelogram-shaped
receiving groove 1238 and a non-perpendicular parallelogram-shaped
projection 124B at a vertical end adjacent to the vertical end of
siding panel 1108. Siding panels 1108 and 120B may be joined the
their corresponding interlocks to form a composite siding panel
200. The angled geometry of the interlock may provide a positive
interlock between siding panels 1108 and 120B.
[0031] Referring to FIG. 4, a cross section view A-A of one
embodiment of the invention an interlocking lap joint for adjacent
siding panels 110C and 120C in siding panel system 100C is shown.
Siding panel 120C has an integrally formed interlock including a
receiving groove 123C and a punched interlock tab 420 at a vertical
end. Siding panel 110C has a mating integrally formed interlock
including a receiving groove 113C and a rectangular projection 114C
at a vertical end adjacent to the vertical end of siding panel
120C. Siding panels 110C and 120C may be joined the their
corresponding interlocks to form a composite siding panel 200. The
punched interlock tab 420 of siding panel 110C may retract into a
recess in receiving groove 113C during assembly of a composite
siding panel 200 to allow for a more forgiving field installation
and fitment between siding panels 110C and 120C.
[0032] Referring to FIG. 5, a cross section view A-A of one
embodiment of the invention an interlocking saw-tooth lap joint for
adjacent siding panels 110D and 120D in siding panel system 100D is
shown. Siding panel 110D has an intergally formed interlock
including a flange 512 with a saw-tooth geometry surface 513.
Siding panel 120D has a mating integrally formed interlock
including a flange 522 with a saw-tooth geometry surface 523 at a
vertical end adjacent to the vertical end of siding panel 110D.
Siding panels 110D and 120D may be joined the their corresponding
interlocks with an adhesive to form a composite siding panel. The
saw tooth geometry 512 and 522 of the flange surfaces may provide
mechanical interlocking as well as greater surface area for
adhesive bonding.
[0033] Referring to FIGS. 6A-6C, in another exemplary embodiment
the invention siding panel system 100E may include siding panels
110E-G and 120E-G which include an arrow-head snap fit geometry for
interlocking joint attachment. Siding panel 110E-G may include an
arrow-head snap 612E-G that may be inserted in a complementary
recess 622E-G in siding panel 120E-G. The snap head 612E-G and
complementary recess 622E-G may be shaped to secure a head pointing
outward in multiple directions 612E as shown in FIG. 6A or pointing
in one of opposite directions 612F and 612G as shown in FIG. 6B and
FIG. 6C resepctively. The snap fit geometry may provide a strong
mechanical joint which may not require a bonding adhesive.
[0034] Referring to FIG. 7, a cross section view A-A of one
embodiment of the invention an interlocking ratcheted tongue and
groove joint for adjacent siding panels 110H and 120H in siding
panel system 100H is shown. Siding panel 110H has an integrally
formed interlock including a ratcheted tongue 713 at a vertical end
adjacent to the vertical end of siding panel 120H. Siding panel
120H has a mating integrally formed interlock including a receiving
groove 723 at a vertical end. Receiving groove 723 may include a
mating ratchet surface to ratcheted tongue 713. Siding panels 110H
and 120H may be joined the their corresponding interlocks to form a
composite siding panel 200. The interlock between receiving groove
723 and ratcheted tongue 713 may provide a tight mechanical fit
which may not require adhesive or other bonding means.
[0035] Referring to FIG. 8, a cross section view A-A of one
embodiment of the invention an interlocking standard tongue and
groove for adjacent siding panels 110J and 120J in siding panel
system 100J is shown. Siding panel 110J has an integrally formed
interlock including tongue 813 at a vertical end adjacent to the
vertical end of siding panel 120J. Siding panel 120J has a mating
integrally formed interlock including a receiving groove 823 at a
vertical end. Siding panels 110J and 120J may be joined the their
corresponding interlocks to form a composite siding panel 200. The
interlock between receiving slot 823 and tab 813 may be secured at
the joint by an adhesive. The tongue and groove interlock may
simplify fabrication of the siding panels 110J and 120J. The
adhesive bond between siding panels 110J and 120J may also provide
added strength to the interlock.
[0036] Referring to FIG. 9, a cross section view A-A of one
embodiment of the invention a lap joint for adjacent siding panels
110K and 120K in siding panel system 100K is shown. Siding panel
110K has an intergally formed flange 912. Siding panel 120K has a
mating integrally formed flange 922 at a vertical end adjacent to
the vertical end of siding panel 110K. Siding panels 110K and 120K
may be joined the their corresponding interlocks with an adhesive
to form a composite siding panel 200. The simple geometry of the
flanges may simplify fabrication of the siding panels 110K and
120K. The adhesive bond between siding panels 110K and 120K may
also provide added strength to the siding panel system 100K.
[0037] Referring to FIG. 10, a cross section view A-A of one
embodiment of the invention a lap joint for adjacent siding panels
110L and 120L in siding panel system 100L is shown. Siding panel
110L has an integrally formed flange 1012. Siding panel 120L has a
mating integrally formed flange 1022 at a vertical end adjacent to
the vertical end of siding panel 110L. Siding panels 110L and 120L
may be joined the their corresponding interlocks with a mechanical
cleat 1030 to form a composite siding panel 200. The mechanical
cleat 1030 may include barbs or other protrusions that may pierce
or otherwise deform the mating surfaces of flanges 1012 and 1022 to
grip and interlock siding panels 110L and 120L to form a composite
siding panel 200. The mechanical cleat 1030 may be made of metals,
plastics or the like. Flanges 1012 and 1022 may provide a relief
space for the mechanical cleat 1030 so the mechanical cleat 1030
may be inserted while allowing the outer surfaces of siding panels
110L and 120L to remain substantially parallel.
[0038] Referring to FIG. 11, in another embodiment siding panel
110M and 120M ends may be joined as a butt joint 1110 with one or
more mechanical fasteners 1130, such as a cleat across a seam of
one or both outer surfaces of created by the adjacent siding panel
110M and 120M. The mechanical fastener 1130 may include barbs or
other protrusions that may pierce or otherwise deform the outer
surfaces of flanges siding panels 110M and 120M to form a composite
siding panel 200. The mechanical fastener 1130 may be made of
metals, plastics or the like. In other embodiments, fastening
components may include, without limitation, one or more of
adhesives, welds, mechanical fasteners, melt-bonds and magnets.
[0039] Referring to FIGS. 2-11, in other exemplary embodiments,
various other interlocking lap geometries may be provided to secure
ends of adjacent siding panels. Such geometries may be secured at
the joint by, without limitation, by one or more of frictional
fits, shaped mechanical fits, adhesives, mechanical fasteners,
welds, melt-bonds and magnets.
[0040] In the preceding specification, various preferred exemplary
embodiments have been described with reference to the accompanying
drawings. It will, however, be evident that various modifications
and changes may be made thereto, and additional exemplary
embodiments may be implemented, without departing from the broader
scope of the invention as may be set forth in such patent claims as
may be based on this application and specification. The
specification and drawings are accordingly to be regarded in an
illustrative rather than restrictive sense.
* * * * *