CA2332671A1

CA2332671A1 - Interlocking panels with infinitely variable relative positioning

Info

Publication number: CA2332671A1
Application number: CA002332671A
Authority: CA
Inventors: William J. Hoofe, Iii
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-01-29
Filing date: 2001-01-29
Publication date: 2002-07-29

Abstract

Interlocking panels with infinitely variable relative positioning for use as siding and roofing panels. The panels are of relatively uniform thickness having raised decorative elements, such as by way of example, shake, tile, brick, stone and slate, to name a few, with a rear and side nailing flange thereon. The rear of the decorative elements include a rearward extending protrusion, with the front of the decorative elements having a continuous slot extending under the front edge of the decorative elements and effectively extending uninterrupted along the length of the panel. This allows the protrusions on the rear of the decorative elements of one course to engage the slot in the lower part of the next course in any relative position, so as to allow the breaking up of what would otherwise be a recognizable, limited pattern. The continuous slot weakens the front edge of individual panels sa that the same should not be walked on. However, by properly proportioning the projections at the rear of the panel and the slot and structure therearound, support is provided for the slot in installed panels, making it safe to walk thereon as if the slot had been formed in a discontinuous manner. Fabrication of the panel may be by various techniques, though injection molding is preferred.

Description

JAN-24-2001 WED 04.14 PM BST&Z-LA FAX N0, 310 820 5988 P, 05 BACKGRC)L1N~ OF TIir'' TNVEN'1~T(~l~
1. Field of trze ~nve'nt:ion The present invention xelates to the field of roofing and siding, and more particularly to interlocking decorative roofing and siding pc3nels.

2. Prior ArY
Roofing and siding panels of various kinds are well known in the p.r.ior art. Such panels are generally fabricated with raised decorative elements sizriulatirlg classic roofing and siding materials, such as by way of example, shake, tile, brick, stone and slate, to name a f,ew. Such panels may be fabr~.cated from thermoplastic sheets, by injection molded plastic, fiberglass molding and formed aluminum, among other materials. in comparison to reel. wood shake, such panels are generally easier to i,izstall, requa.xe less care, and provide a reduced fire hazard and greater life. Of course, with respect to real tile, simulated tile panels f~rrthPr have the advantage of far less weight, reducing the structural. requirement for the building itself, and of course ~0 being much safer in earthquake prone areas.
In U.S, Patent No. 4,598<52~, interlocking panels are disclosed wherein each panel comprises a background sheet of relatiwaly thin material in which are integrally formed one or more r<-lised decorative elements such as simulated tile or s~i3kc _, _ CA 02332671 2001-O1-29 .~.-..... "._.... ._.......__"

JAN-24-2001 WED 04.14 PM BST&Z-LA FAX N0, 310 820 5988 P, 06 elements. At the front or lower edge of each panel, at least same of the decorative elements have a sunken or indented area integrally formed in the face thereof, and in the rear or upper poxtion of each decorative element, there are cooperatively disposed integrally formed proi~xuding elements. During i.nstall~.tion, after a sl:arter course is installed, each panel of.
each successive course is retained in position at the front thereof by the interlocking of the sunken regions on the front of at least some of the decorative elements thereon with the 7.0 protruding regions on i~he rear of the next 7.ower course, and at the rear thereof by nails or staples passed through a nailing fl~.~nga provided for that purpose. The fasteners are covexed by the lower poxtion of the next higher course to pxovide an interlocking weatherproof system with h~.dden fasteners, The sunken regions and the protruding regions on the decorata_ve elements are specificaJ.ly lim~.ted in lateral. extent. to significantly less than the width of the front and back of the decorative elements to avoid any intersections between the edges of the decorative elements and the interlockers. 'this design was ZO particular.ly suited to fabrication by vacuum forming, as i~he preferab7.e implementations thereof specifically avoided three sided coxners wherever poss~.ble, particularly where generous rounding of the corner could not reasonably be affected.
Sub~~equent to the issuaricc~ of the foregoing patent, the concept of the patent was extended to an injection molded panel.
wherein the formation of three sided comers did not in itself _2_ CA 02332671 2001-O1-29 ~~~'°m"~'~°.._.~ ......m,""»

,IAN-24-2001 WED 04:15 PM BST&Z-LA FAX N0, 310 820 5988 p, 07 present any particular problem_ However, such panels simulated a typical cedar shake and were characterized by a nailing flange at the: rear amd at one side of the panels. The side nailing flange was configured to go under a decorative member on the adjacent and oL the next adjacent panel in a manner so as to provide a water weal wa.th the rear nailing flange providing a means for fastening the pznel down _ The proj ecti.ons on the back of the decorati~re elements on each panel were evenly spaced across the panel. and extended over only a fraction of the width of each oL the decorative elements.
'file depression in the front of the decorati~re elements took the fore of a slot under the deGOrat~.ve elements, though the slot wa:
interrupted periodically by webs under the decoxativa elements, providing direct coupling and support between the decorative elements and the underlying portion of the panel so that the panels could be walked on during and after installation without fear of cracking the panels because of the oOherwise relatively un:~upported channel opening.
These panels proved to be strong, durable, readily capable of being walked on, easily installed and long last~~.ng. However, they had the disadvantage that the webs in the slot at the front of the decorative membors for reinforcing purposes limited the range of positioning of the next course of panels relative to i~he prior course oL panels, pre~renting an installer from fully randomly positioning one course with respect to the immediately lower course.

JAN-24-2001 WED 04.15 PM BST&Z-LA FAX N0, 310 820 5988 P, 08 ~~rn~2A~Y hr~ ~1~HF INVENTION
Interlocking panels with infinitely variable relative positioning for use as siding and roofing panels. The pane7.s are of relatively uniform thickness having raised decorative e.~ements, such as shake ox tile-liko elements, with a reax' and side nailing flange thereon. The rear of the decorative elements include rearward extending protrusion, with the front of the decorative e7.ements having a continuous slot extending under the front edge of tile decorative elements and eftecti~re~y extending uninterrupted along the length of the panel. This allows the protrusions on the rear oL the decox~:~tive elemEnts of one course to engage the slot in the lower part, of the next course in any relative position, so as to allow the breaking up of what would otherwise be a reGOgnizable, l~.mited pattern. The continuous slot weakens the front edge of individual panels so that the same should not be walked on. However, by properly proportioning the projP_Ct10T1~ cat the rear of. the panel and the slot and structure therearound, suppoit is provided for the slot in installed panels, making it safe to walk thereon as if the slot had been formed iiz a discontinuous manner. Fabrication of the panel rnay be by ~rarious tec~~nic~res, though infection molding is preferred.
_q_ JRN-24-2001 WED 04.16 PM BST&Z-LA FAX N0, 310 820 5988 p, Og PRTFF DESCRIP'I'TON nF 'fHF FICURRS
Figure 1 is a perspective view of a preferred embodiment of the present invention.
Figure 2 is a perspective view taken on an expandEd scale illustrating the fitting of tabs on one Course into the slots in the front of panels in the next higher course.
Figures 3 and 3a is a front view and a partial side view of z prior ar. t panel. .
Figure 4 is a front view of a panel in accordance with Ghe t~resent invention.
Figure S is a partial side view of a panel in accordance with the presc:n~ invention.
Figure 6 is a top view of a pair of panels il~.ustrating how they fit together.
7.5 r'igures 7a and 7b are side views illustrating two exemplary ways Lor panels of two adjacent COUrses to tit together.
Figure 8 is a perspective bottam view of a panel in accordance with the preferred embodiment of the present invention.
Figure 9 is a top view of an alternate em't~odiment of the invention.
Figure 10 is a perspective view of a still further Prr~hodiment .

JRN-24-2001 WED 04:16 PM BST&Z-LR FRX N0, 310 820 5988 P. 10 Figure J.1 is a perspective vie~nr illustrating the side moisture barrier interlock between adjacent panels.
Figure 12 is a cross section taken along llnPS 12-7.? of Figure 11. , ~HN-24-2001 W~:D 04.17 PM BST&Z-LA FAX N0. 310 820 5988 P. 11 DF,T.~1TLED T~FSCkTPTIt~N OF TF3~ PRES~;NT INVF,NTInN
First ~eferrincd to Figure 1, a preferred embodiment of the prc~ent invention nay be seen. Tn accordance with this embodiment, individual injection molded panels 20 are provided, characterized by a single row of decorative elements 22, specifically simulated cedar shake members integrally formed with upper and lower regions and left and r9_ght and regions. The entire panel .is configured, as shall subsequently he described, so as to interfit with and interlock with respect to adjacent panels in a manner 'Lo form the required moisture barrier to provide aesthetic continuity across and up an area covered by the panels, whether the same are used for siding or xoofing_ Of particular importance to the present invention is the faeC
that Lhe panels will interlock and form the required moisture barriers with any lateral relative orientation of the panels, course to course. This provides unlimited flexibility in the positioning of each course relative to the other courses, allowing the breakup of what otherwise would be a somewhat repetitive pattern going up a building side or roof. In this regard, the:
individual simulated cedar decorative members zormod on individual p~~nels are purposely given different widths, which together with the ability for any relative positioning oL panels course to course, avoids the monotonous repetition in pattern that. would glOSJly detract from an otherwise aesthetically pleasing appearance of the building side or x'oof. In addition, the ability to interlock the panels at any relative lateral position, course JAN-24-2001 WED 04.18 PM BST&Z-LA FAX N0. 310 820 5988 P. 12 Lo course, is achieved in manner to be described so as t:o be fully capable of being walked on or being subjected to other.
extraordinary loads, either at the time of installation or as may purposely or accidentally occur during ordinary use.
Now .referring to F~.gures 2 and 5, the nature of the slots 24 extending across the front of each panel may be seen. ~s s~lown in Figure 5 particularly, the slot 24 extends across the full w~.dth of, the panel so as to tae uninterrupted across an entire: course of panels. This allows the tabs 26 (see particular7.y Fig~_~res 1, 2, 6 and 7a and 7b) to extend into the slot at any lateral location along the entire course. This is to be compared with the prior art shown in Figures 3 and 3a wherein integral slot support memhe.r, s 28 were molded-in adj acent: the edge of each simulated cec7~~r paile7_ to provide support for the slot structure when the ~_5 panel is subjected to unusual loads. These support structures support each decorative element adjacent the edges thereof to prevent excessive stres~i,ng and cracking of the slot structure a.n regions 30 due to extraordinary loads. In particu7.ar, the suhst=antially flat orthogonal front face member 32 of each decorative p~-~nel helps distribute a load imposed near the center o~ trial decorative element across the width of the slot to provide a reasonable load bearing capability. However, extraordinary load: near an. edge o~ a decorative element or spanning the edges of two decor_ati.ve elements will cause much higher_ stresses in region 30 if the support structures 28 were not used.
_g_ JAN-24-2001 WED 04:18 PM BST&Z-LA FAX N0. 310 820 5988 P, 13 In the present invention, thc~ support structux'es 28 in the prior aLt of Figures 3 and 3a hare been eliminated, as shown i.n Figure 5. This has the effect of creating an unsupported slot extending entirely across a panel, and for that matter, entirely across a17. panels of a particular course. Thus, region 34'of the s7.ot structure is subject to high stresses and possible cracking or fracture wizen someone walks on the panel ox the panel is otherwise subjected to high loads, particularly in cold weather.
Tn accordance with the present invention, it has been recognized that an installer can easily abstain f.rnm walking on au unin~talled panel and can othe=°wise avoid excessive loads and other amuse of the panels before installation. Aftex installation, the equivalent of the support structure 28 of the prior art of Figures 3 and 3a may be provided by a tabs 26 in the rear structure of the decorative element of the next lower course, alone oar in conjunction with the vertical rear portion of the decorative elements in the next lower course. This may be seen in the side cross sectional views of installed panels of Figures 7z and '7b, In Figure 7a, front wall section 36 togetriez' with the lower. wall of the slot 24 fill the separation between the tab 26 and the rear nai7.ing f7.ange 40. 'this results in the positive loc)cing, pcinel to panel, to prevent rattling of installed panel in windy conditions. Note that in this cmbodirnent, the slot 24 is carefully controlled by dosic~n to be larger than the tab 26, or at least the portion thereof extending into the slot, but to only be slig~il:l.y larger, so that in the case of the parlol being subjected to extraordinary loads in the region of the slot:, the slot JHN-~4-~UU 1 W~:U U4 . 1 U t'f~ UST&C-LH h HX NU. 31 U 8~U SUUU f. I 4 :structure will. flex well within its elastic xanc~c, even when cold, to pinch the tnb 26 and be supported thereby and to be supported by the back wall 42 of the decorative elements on the next lower course of panels. 'this is to be compared to the prior art wherein the slot 24 was supported by the support members 28 (showri in Figure 3a) so that the slot didn't close on the tabs 26.
Consequently C~:e sire of the slot wasn't that important, and in fact created a shadow line by being somewhat open. The same shadow line may be created in the embodiment of Figure "la by the chamfer 38 if desired.
Figure '7b illustrates an alternate embodiment wherein the tab 26 fills slot 2~. This prevents rattla.ng of installed panels, and directly transfers any extraordinary load on that region of the panel directly to region ~2 of the next lower course of panels.
Again the shadow line may be created in the embodiment of Figure '7b by the chamfer 38 if dosired.
In both the P-mbodiments of rigure 7a and T'iguxP 7b, the chamfer 33 may facilitate the assembly of panels during inst,a7.lation. Of course, while the tabs 26 are shown as being 2U tapered on the bottom surface, the upper surface or both surfaces may be tapered, or the slot itse7.f may be tapered, alone or in conjunction with tapered tabs. In that regard, tapering both surfaces of_ tho tab, together with close control of tolerances, would allow the tab to Spring the slot open somewhat until the ?.5 member 36 and the lower structure of the slot filled the distance -10-.

JAN-24-2001 WED 04:19 PM BST&Z-LA FAX N0. 310 820 5988 P, 15 between the tab and the nailing flange, combining the features of Figure,; 7a and 7b.
Now referring to Figure 8, an underside perspective of a part of. a panel in accordance with the previous embodiment may be seen.
The panel 20 is injection molded with a substantially uniform trri.ckness generally throughout the panel so that the decorati~re elemr_nCs 22 are formed as members raised from a flat base plane 50, defined by the nailing flanges along the top and one side of each panel. The front face of each panel has indentations 52,, also v~i.siblo in Figures 1, 2 and 4, which in some instances such as the starter course for rooting, will be visible and which simulate individual shake members of an underlying starter course.
N'ow referring to Figure 9, a top view of an alternate embodiment of the presEnt invention may be seen. Tn this embodiment, the panels consist of two courses of decorative elements 56 and 58, the courses being staggered with respect to eac~n ocher. The panel is provided with a nailing flange GO at i~he upper or rear thereof, and side nailing flanges 62 and 64. Each such panel in such embodiment would be provided with a continuous slot along the front edge of the lower course of decorative members 56, as described by way of example with reference to Figure 5 for a s~.ngle course of panels, and preferably would further have region 66 slotted to receive the tab of an adjacent panel. The slot on region 66, however, while preferably continuous across the portion of decorative element 58 extending beyond the edge of lower decorative element 56, could be -il-JHN-C4-CUU 1 Wh.U U4 . CU t'1'1 fj~ ! t~L-LH h Ht( NU. ~ 1 U tfCU SUtSti Y. 1 ti discontinuous, provided it is ~lottcd in the proper position for receipt of tab 62 on an adjacent panel, as obviously the relative literal positions of the decorative elements 56 and 58 for the two courses integral to the panels themselves is predefined by the panel design. The slot across the front of decorative members 56, however, should definitely be continuous to allow any relative positioning of any two courses of such panels relative to the adjacent two courses of such panels.
A further alternate embodiment i> illustrated in Figure 10, 1.0 namely an embodiment comprising a single decorative element 70, again having a slot 72 extending all the way acxoss the decorative element and of course with rear and side nailing flanges 74 and 76, respocti~rcly, and a rear tab 78 for positioning anywhere in the slot in, the front of a similar member in the next higher couxse, or alterrZatively spanning two adjacent simi7.ar members in the next higher course.
Figure ~.1 illustrates the side interlocking of a single course panels, whether having a single decorative element 70 in accordance with Fa.gure 10, or multiple decorati~re elements in a ?,0 single course such as the embodiments hexeinbefore deJcribed with xespeci: to Fa.gures 1 through 8. In particular, the side nailing flange 76 has a vertically raised water baxxier 78 adjacent side 80 to define the slot for recei~ring the edge of an adjacent panel.
This .i.s illustrated in Figure 12, wherein the side of an adjacent panol F30 i a sho~,rn fitting within the slot defined by moisture barrier 78 and the side of the raised area of an adjacent panel.

JAN-24-2001 WED 04:20 PM BST&Z-LA FAX N0, 310 820 5988 P, 17 This, together with the surface tension of water, prevents any sic~ni.ficant moisture from getting into this area. Also, any moisture which does in fact get into this area will be directed downward onto the top of the nailing flange of the course there below, whereby it may flow over. the panel there below around the side of a decorative element thereon and over the rest of the lower. panels to flow off the roof..
The same side interlocks are used on the embodiment of. ~'iguro 1 through 8, the raised moisture barrier 78 being visible by way of example in Figures 1 and 6. In the case of the embodiment of Figure 9, each course has a similar moisture barrier 78, any moisture getting into this region beside decorative element 58 bea.ng di.r:ected downward and around decorative element 56 on the r_ext lower course of the panel, to be deposited upon the top of the next lower cou.xse.
The preferred embodiment has been disclosed herein with reference to a cedar shake s~.mulation panel. Obviously the proSCr~L invont;ion my be incox'porated into panels of other decorative designs, such as, by way of example, tile, brick, stone and slake, to name a few.
GJhile preferred embodiments of the present invention have been disclosed and described in detail herein, it will be obvious to those skilled in the art that various changes in form and detail ma3y he made therein without departinra from the spirit and scope thereof.
-13~

Claims

1. A panel, having front and rear edges and first and second side edges and adapted to interfit with similar panels when installed, comprising:
an injection molded panel having:
a nailing flange adjacent the rear edge of the panel;
at least one raised simulated decorative element between the nailing flange and the front edge of the panel;
a water barrier adjacent the first side edge of the panel and adapted to fit under a simulated decorative element of an identical panel adjacent the second side edge of the identical panel to form a water barrier between the sides of two adjacent panels;
the at least one raised simulated decorative element having a slot extending across and below the entire simulated decorative clement adjacent to front of the panel so as to have a slot opening unobstructed across the entire front of the panel;
the at least one raised simulated decorative element further having a projection extending from the rear thereof over a part of the rear nailing flange;
the projection having an elevation on the panel to fit within the slot of an adjacent panel in a next higher course of panels at any relative position along the width of the panel;

the projection having a width and thickness to adequately locally fill the slot of a similar adjacent panel in a next higher course of panels to provide support for the slot opening within the elastic range of the panel to resist damaging a panel when walking on or applying unusual loads on installed panels.

2. The panel of claim 1 wherein the at least one raised simulated decorative element consists of one raised decorative element.

3. The panel of claim 1 wherein the at least one raised simulated decorative element comprises a plurality of raised decorative elements forming a part of a single course of decorative elements, and the projection comprises a plurality of projections on the rear of the decorative elements of a number and spacing to provide support for the slot opening within the elastic range of the panel to resist damaging a panel when walking on or applying unusual loads anywhere along the front edge of installed panels.

4. The panel of claim 1 wherein the at least one raised simulated decorative element comprises a plurality of raised decorative elements forming a part of two courses of decorative elements, and wherein the decorative elements in the two courses are staggered with respect to each other.

5. The panel of claim 4 wherein the first and second side edges of the panel adjacent one of the two courses are staggered with respect to the first and second side edges of the panel adjacent the other of the two courses, the second side edge of the panel for the decorative elements foaming the course of decorative elements adjacent the nailing flange extends further to the side of the panel than the second side edge of the panel for the decorative elements for the course of decorative elements adjacent the front edge of the panel.

6. The panel of claim 1 wherein the decorative element is a simulated cedar shake decorative element.

7. A panel having front and rear edges and first and second side edges and adapted to interfit with similar panels when installed, comprising:
an injection molded panel having:
a nailing flange adjacent the rear edge of the panel;
at least one raised simulated decorative element between the nailing flange and the front edge of the panel;

a water barrier adjacent the first side edge of the panel and adapted to fit under a simulated decorative element of an identical panel adjacent the second side edge of the identical panel to form a water barrier between the sides of two adjacent panels;
the at least one raised simulated decorative element having a slot extending across and below the entire simulated decorative clement adjacent to the front of the panel so as to have a slot opening unobstructed across the entire front of the panel;
the at least one raised simulated decorative element further having a projection extending from the rear thereof over a part of the rear nailing flange;
the projection having an elevation on the panel to fit within the slot of an adjacent panel in a next higher course of panels at and relative position along the width of the panel;
the projection having a width and thickness to locally span the vertical height of the slot of a similar adjacent panel in a next higher course of panels to retain the front of one panel in a course with respect to the rear of the adjacent panel in a next lower course of panels, and to transfer the load from the front of a simulated element adjacent the front edge of the panel to the rear of a decorative element adjacent a rear edge of the panel in a next lower course of panels when walking on or applying unusual loads on installed panels.

8. The panel of claim 7 wherein the at least one raised simulated decorative element consists of one raised decorative element.

9. The panel of claim 7 wherein the at least one raised simulated decorative element comprises a plurality of raised decorative elements forming a part of a single course of decorative elements, and the projection comprises a plurality of projections on the rear of the decorative elements of a number and spacing to provide support for the slot opening within the elastic range of the panel to resist damaging a panel when walking on or applying unusual loads anywhere along the front edge of installed panels.

10. The panel of claim 7 wherein the at least one raised simulated decorative element comprises a plurality of raised decorative elements forming a part of two courses of decorative elements, and wherein the decorative elements in the two courses are staggered with respect to each other.

11. The panel of claim 10 wherein the first and second side edges of the panel adjacent one of the two courses are staggered with respect to the first and second side edges of the panel adjacent the other of the two courses, the second side edge of the panel for the decorative elements forming the course of decorative elements adjacent the nailing flange extends further to the side of tree panel than the second side edge of the panel for the decorative elements for the course of decorative elements adjacent the front edge of the panel.

12. The panel of claim 7 wherein the decorative element is a simulated cedar shake decorative element.

13. A panel having front and rear edges and first and second side edges and adapted to interfit with similar panels when installed, comprising:
an injection molded panel having:
a nailing flange adjacent the rear edge of the panel;
at least one raised simulated decorative element between the nailing flange and the front edge of the panel;
a water barrier adjacent the first side edge of the panel and adapted to fit under a simulated decorative element of an identical panel adjacent the second side edge of the identical.
panel to form a water barrier between the sides of two adjacent panels;
the at least one raised simulated decorative element having a slot extending across and below the entire simulated decorative element adjacent the front of the panel so as to have a slot opening unobstructed across the entire front of the panel;

the at least one raised simulated decorative element further having a projection extending from the rear thereof over a part of the rear nailing flange;
the projection having an elevation on the panel to fit within the slot of an adjacent panel in a next higher course of panels at any relative position along the width of the panel.

14. The panel of claim 13 wherein the at least one raised simulated decorative element consists of one raised decorative element.

15. The panel of claim 13 wherein the at least one raised simulated decorative element comprises a plurality of raised decorative elements forming a part of a single course of decorative elements, and the projection comprises a plurality of projections on the rear of the decorative elements of a number and spacing to provide support for the slot opening within the elastic range of the panel to resist damaging a panel when walking on or applying unusual loads anywhere along the front edge of installed panels.

16. The panel of claim 13 wherein the at least one raised simulated decorative element comprises a plurality of raised decorative elements forming a part of two courses of decorative elements, and wherein the decorative elements in the two courses are staggered with respect to each other.

17. The panel of claim 16 wherein the first and second side edges of the panel adjacent one of the two courses are staggered with respect to the first and second side edges of tree panel adjacent the other of the two courses, the second side edge of the panel for the decorative elements forming the course of decorative elements adjacent the nailing flange extends further to the side of the panel than the second side edge of the panel for the decorative elements for the course of decorative elements adjacent the front edge of the panel.

18. The panel of claim 13 wherein the decorative element is a simulated cedar shake decorative element.