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.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

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

1. Field of the Invention

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.

2. Description of Related Art

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.

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.

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.

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.

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

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.

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.

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

FIG. 1 is a top plan view of two panels interlocked in a manner, according to exemplary embodiments of the invention;

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;

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;

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;

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;

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;

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;

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;

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;

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

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.