Note: Descriptions are shown in the official language in which they were submitted.
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SIDING JOINERY
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] 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.
Description of Related Art
[0002] 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.
[0003] 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.
[0004] 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
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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.
[0005]
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.
[0006] 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
' [0007]
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.
[0008]
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.
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[0009] 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
[0010] FIG. 1 is a top plan view of two panels interlocked in a manner,
according
to exemplary embodiments of the invention;
[0011] 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. Patent 8,402,707,
according to an
exemplary embodiment of the invention;
[0012] 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;
[0013] 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;
[0014] 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;
[0015] 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;
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[0016] 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;
[0017] 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;
[0018] 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;
[0019] 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
[0020] 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.
[0021] 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
[0022] 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.
[0023] Generally speaking, as shown in FIG. 1, panel systems 100 of the
present
invention are generally flat sections used in building, construction and other
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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.
[0024] 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.
[0025] 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.
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[0026]
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. Patent 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.
[0027] Referring to FIG. 3, a cross section view A-A of one embodiment of the
invention an interlocking lap joint for adjacent siding panels 110B and 120B
in siding
panel system 100B is shown. Siding panel 110B 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 123B and a non-perpendicular
parallelogram-shaped projection 124B at a vertical end adjacent to the
vertical end
of siding panel 110B. Siding panels 110B 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 110B
and
120B.
[0028] 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
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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.
[0029] 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.
[0030] 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.
[0031] 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
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ratcheted tongue 713 may provide a tight mechanical fit which may not require
adhesive or other bonding means.
[0032] 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.
[0033]
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.
[0034] 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.
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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.
[0035] 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.
[0036] 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.
[0037] 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.
,
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