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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional patent application.

U.S. Application No. 60/742,088

Filing date: Dec. 5, 2006

Name of Applicants: Alex Golberg, Bell Canyon, Calif.

• • William Lincoln, Bell Canyon, Calif.

FEDERALLY SPONSORED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

BACKGROUND OF INVENTION

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

A primary object of the present invention is to provide a system of siding that will overcome the shortcomings of the prior art methods.

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.

Another object is to speed the time of construction by having a panel system consists of multiple stones per panel.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

The panels are made from vinyl that is accepted by the building industry for outside use.

DRAWINGS—FIGURES

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:

FIG. 1 illustrates the front of panel 1 (shown without stone texture).

FIG. 2 illustrates the rear of panel 1.

FIG. 3 illustrates the stone texture on the front of panel 1.

FIG. 4 illustrates the front of panel 2 (shown without stone texture).

FIG. 5 illustrates the rear of panel 2.

FIG. 6 illustrates the stone texture on the front of panel 2.

FIG. 7 illustrates the front of an assembly of panels 1 and 2 (shown without stone texture).

FIG. 8 illustrates the rear of an assembly of panels 1 and 2.

FIG. 9 illustrates the stone texture of the front of an assembly of panels 1 and 2.

FIG. 10 illustrates the preferred assembly of panels 1 and 2.

FIG. 11 illustrates the bracket connection to a socket.

FIG. 12 illustrates the assembled bracket into socket.

FIG. 13 illustrates the trim or quoin panel.

FIG. 14 illustrates the long trim or quoin panel.

FIG. 15 illustrates the assembled corner.

FIG. 16 illustrates the wall corner moulding.

DRAWINGS—REFERENCE NUMERALS

• 1 panel 1
• 4 panel 2
• 11 bracket

DETAILED DESCRIPTION—PREFERRED EMBODIMENT

Description—FIGS. 1-16.

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.

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.

The partition of the panel into individual stones is the appearance means used to disguise the individuality of the panels after installation.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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).

FIGS. 16A and 16B show alternative views of a section of the extruded part. FIG. 16C shows the profile of the extruded part.

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.

The stone surface panel and all the other siding components may also be made in the mirror image.

Applying moisture barrier tape to cover the fasteners increases the water resistance.

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.

Pegs may fit into slots, holes, channels, sockets, grooves, or slits. The preferred embodiment is pockets.

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.

In the preferred embodiment, the panels are made of vinyl.

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.

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.

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.

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.

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

Many stones arrangements are possible. FIG. 8 is illustrative. Many other designs are readily apparent.

Installation of the panels may be executed in the following order:

• • Install moldings around doors and windows.
  • Install corner assembly at corners. Corner mouldings can also be used.
  • Install architectural components as desired.
  • At concave corners install mouldings. The panels can also be mitered at a concave corner to form the concave corner joint. Caulk the seam.
  • 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.
  • When another door, window, or corner is reached, cut surface panels to fit.
  • The panels are cut to closely butt up against the trim panels and mouldings, thus hiding the cut. The seam is caulked.
  • 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

Description—FIGS. 17-33.

FIG. 17 illustrates an alternate texture of the front of panel 1.

FIG. 18 illustrates alternate internal face partitions for the panels.

FIG. 19 illustrates alternate embodiment of socket and bracket.

FIG. 20 illustrates alternate panel shapes and internal stone partitions.

FIG. 21 shows an alternate embodiment: One Layer Ashlar Panel

FIG. 22 shows an alternate embodiment: One Layer Ashlar Assembly

FIG. 23 shows an alternate embodiment: Two Layer Ashlar Panel

FIG. 24 shows an alternate embodiment: Two Layer Ashlar Assembly

FIG. 25 shows an alternate embodiment: Alternate Two Layer Ashlar Panel (nail hem not shown)

FIG. 26 shows an alternate embodiment: Alternate Two Layer Ashlar Assembly (nail hem not shown)

FIG. 27 shows an alternate embodiment: Three Layer Ashlar Panel (nail hem not shown)

FIG. 28 shows an alternate embodiment: Three Layer Ashlar Assembly (nail hem not shown)

FIG. 29 shows an alternate embodiment: Random Layer Ashlar Panel (nail hem not shown)

FIG. 30 shows an alternate embodiment: Random Layer Ashlar Assembly (nail hem not shown)

FIG. 31 shows an alternate embodiment: Alternate Random Layer Ashlar Assembly (nail hem not shown)

FIG. 32 shows an alternate embodiment: Alternate Random Layer Ashlar Assembly (nail hem not shown)

FIG. 33 shows an alternate embodiment: Alternate Assemblies

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.

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.

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.

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.

Instead of using a corner panel at convex corner, the surface panels can be mitered to form a corner joint and the seam caulked.

Various connectors can be used instead of pegs and dowels. A system of u-joints could be used to interlock the adjacent panels.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.

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.