Decorative wall covering with improved interlock and corner construction

A wall covering comprising a plurality of plastic molded panels each having a relatively thin body portion formed with rows of simulated building elements. The panels are mounted on a support surface in a plurality of horizontal courses with a side marginal edge region of one panel overlapping and sealingly engaging an underlying side marginal edge region of the adjacent panel. The underlying side marginal edge region of each panel is formed with a plurality of laterally extending interlock flanges each having a nailing aperture, and the overlapping side marginal edge region of the adjacent panel has a plurality of integrally formed hooks for engaging an upper peripheral edge of a respective one of the interlock flanges for positively interlocking the overlapping sides and for maintaining sealing engagement therebetween. A corner molding is provided for receiving respective ends of the panels at a corner in a manner which enhances the aesthetic appearance of the finished installation.

FIELD OF THE INVENTION 
The present invention relates generally to roof and wall coverings 
primarily intended for outdoor usage, and more particularly, to roof and 
wall coverings comprised of relatively large panels which each are molded 
or otherwise formed with decorative patterns characteristic of 
conventional roofing and siding materials such as shake, tile, brick or 
the like. 
BACKGROUND OF THE INVENTION 
Various synthetic roof and wall coverings are known today, such as those 
formed of elongated thermoplastic panels that are nailed to the wall or 
roof support surface in horizontal courses or rows in partially 
overlapping relation to each other so as to provide a substantially water 
resistant, protective layer over the support surface. Such panels, which 
usually are identically molded, commonly are formed with a plurality of 
rows of simulated building elements, such as shake shingles. Because the 
panels are identically molded, a panel-to-panel identity can be easily 
noticed if the panels are not carefully installed. Leakage problems 
between adjoining panels also can occur. 
To facilitate installation, such panels typically are nailed to the wall or 
support surface along an upper horizontal nailing flange with the lower 
marginal edge region overlapping the panel in the course immediately below 
and with one side marginal edge region overlapping the laterally adjacent 
panel. While various means have been proposed for interlocking the 
overlapping portions of adjacent panels to provide a water seal 
therebetween and to minimize the noticeability of the junctions between 
panels, such interlocks often have been cumbersome to engage during 
installation and frequently are ineffective in establishing and 
maintaining sealed engagement of the panels, particularly when the panels 
are mounted on irregular surfaces or are exposed to extreme weather 
conditions. 
Because such panels are made of plastic and are relatively large in size, 
usually having a length of 48 inches or more, the panels tend to easily 
bend and deform during handling and upon mounting on even slightly 
irregular or rough mounting surfaces, which often occurs when the panels 
are being used as a replacement covering on an existing wall or roof. 
Deformation and bending of the panels, either as a result of mounting or 
because of exposure to the outside elements, can destroy peripheral seals 
between the panels and detract from the appearance of the covering. Such 
irregularities are especially noticeable in panels formed with simulated 
"perfection" shake, which have a relatively uniform appearance. Because of 
the uniformity in such perfection shake panels, difficulties also have 
been incurred in forming corners with the wall covering without detracting 
from the realistic and aesthetic appearance of the installation. 
OBJECTS AND SUMMARY OF THE INVENTION 
It is an object of the present invention to provide a wall and roof panel 
that is adapted for more reliable interlocking engagement along its 
peripheral sides for maintaining a sealed condition between overlapping 
marginal edge portions of the panels and for enhancing the realistic and 
aesthetic appearance of the assembled wall covering, even when mounted on 
slightly irregular support surfaces. 
Another object is to provide a synthetic wall and roof panel which permits 
more secure mounting of the panel on the support surface and easier and 
more effective interlocking of overlapping side marginal edge regions. A 
related object is to provide such a panel which enables nailing of the 
panel to the support surface along top and side marginal edge regions for 
more secure installation, while not encumbering the interlocking 
engagement of subsequently installed panels. 
A further object is to provide a wall and roof panel of the foregoing type 
which is relatively simple in construction and which lends itself to 
economical manufacture and ease of installation. 
Yet another object is to provide a more aesthetic and naturally appearing 
corner construction for synthetic wall and roof panels formed with 
relatively uniform building elements, such as perfection shake.

While the invention is susceptible of various modifications and alternative 
constructions, a certain illustrated embodiment thereof has been shown in 
the drawings and will be described below in detail. It should be 
understood, however, that there is no intention to limit the invention to 
the specific form disclosed, but on the contrary, the intention is to 
cover all modifications, alternative constructions and equivalents falling 
within the spirit and scope of the invention. 
DETAILED DESCRIPTION OF THE INVENTION 
Referring now more particularly to the drawings, there is shown an 
illustrative wall covering 10 comprising a plurality of panels 11 each 
embodying the present invention. The panels 11, which preferably are 
molded out of relatively thin rigid plastic material, each are formed with 
simulated building elements. In this instance, the panels 11 are formed 
with simulated cedar shake 12 of irregular width which are disposed in a 
plurality of parallel rows 12a, 12b and 12c, with adjacent shake 12 in 
each row being separated by a small gap 13. The illustrated simulated 
shake pattern is of a type known in the industry as "perfection" shake, 
wherein the lower edges 14a, 14b, 14c of the rows 12a, 12b, 12c are in 
substantially straight line, and except for their width, the individual 
shake elements are substantially similar in appearance. It will be 
understood that the panels 11 could be formed with other forms of 
simulated shake shingles, or other types of building materials, such as 
tile, brick and the like. 
Each panel 11 has an upper horizontal marginal edge region 15 having a 
substantially uniform width w extending across the top of the panel 
immediately above the top row 12a of shake 12, a lower marginal edge 
region 16 which defines a lower peripheral edge of the panel, a side 
marginal edge region 18 located to the right-hand side of the last 
simulated shake 12 in each row 12a, 12b, and 12c, and a marginal edge 
region 19 on the opposite side of the panel 11 which defines a left-side 
peripheral edge immediately adjacent the first simulated shake of each row 
12a, 12b, 12c. The panels 11 are mounted on a support surface 25, which 
may be a wall or roof of a house or other building structure, in 
horizontal courses with the right-side marginal edge region 18 in 
underlying relation to the left-side marginal edge region 19 of the panel 
immediately to the right thereof and with the lower marginal edge region 
16 of the panels in each course overlying the upper marginal edge region 
15 of the panel in the course immediately below. 
To enable mounting of the panels 11 in side-by-side relation with the 
junctures between adjacent panels less noticeable to the eye, the rows 
12a, 12b, 12c of shake 12 of each panel 11 extend in offset relation to 
each other so as to define stepped left and right-hand sides of the panel. 
In the illustrated embodiment, the middle row 12b of shake extends farther 
to the right than the first row 12a a distance corresponding to about 
one-quarter to one-half the width of one shake 12, and the bottom row 12c 
extends farther to the right than the middle row 12b about a similar 
distance. 
For rigidifying the panels 11 and for providing stable mounting of the 
panels on the support surface 25, each panel 11 has an integrally formed 
rectangular grid 26 of reinforcing and support ribs on the underside 
thereof (FIG. 9). The grid 26 includes a plurality of horizontally 
extending ribs 28 formed on the underside of the panel 11 adjacent the top 
and bottom of each row of shake, the lowermost horizontal rib of which 
defines a bottom sealing flange 30. To complete the grid 26, a plurality 
of vertically oriented, laterally spaced ribs 29 are formed on the 
underside of each panel at locations adjacent the sides of some of the 
shake 12, in this instance, extending rearwardly from ridges 31 defined by 
the separating gaps 13 between the shake 12. The substantially rectangular 
grid 26 defined by the horizontal and vertical ribs 28, 29 has been found 
to enhance the rigidity of the panels 11 so as to resist bending and 
deformation during handling and upon mounting, thereby facilitating the 
establishment of reliable seals about the overlapping marginal edge 
regions of the panels upon mounting. 
The panels 11 preferably are mounted beginning with the left-hand panel of 
the lowermost course to be installed on the wall or roof, as is known in 
the art. The first panel in each course typically is cut at a different 
location along a left-hand side thereof in order that the simulated shake 
12 of each course are offset with respect to the simulated shake of the 
panel in the course below so as to enhance the natural appearance of the 
wall covering. The panels 11 in this instance each have two predetermined 
cutting lines A, B (FIG. 2) along which the panels alternatively may be 
cut to start alternate courses as disclosed in U.S. Pat. No. 5,076,037, 
assigned to the same assignee as the present application. 
For securing the panels 11 to the support surface 25, the upper marginal 
edge region 15 of each panel is formed with a row of elongated laterally 
spaced nailing apertures 32. In order to provide firm support for the 
panel on the wall during nailing and for establishing a seal between the 
rear side of the panel 11 and the support surface 25, the upper marginal 
edge region 15 is formed with a pair of rearwardly extending horizontal 
sealing flanges 34 which extend substantially the length of the upper 
marginal edge region 15 on top and bottom sides of the nailing apertures 
32 (FIGS. 6 and 9). Once the upper marginal edge region 15 is nailed to 
the support surface, the horizontal sealing flanges 34 are maintained 
firmly against the support surface 25 and cannot be lifted from the 
support surface even during severe weather conditions. 
In accordance with the invention, a side marginal edge region of each panel 
defines a plurality of mounting and interlock flanges, each of which is 
formed with a respective nailing aperture, for enabling secure and easy 
interlocking engagement of overlapping side marginal edge regions of the 
panels during installation. To this end, in the illustrated embodiment, 
the right-side marginal edge region 18 of each panel 11 has a plurality of 
mounting and interlock flanges 40a, 40b, 40c which each are formed with a 
respective nailing aperture 41a, 41b, 41c. One mounting and interlock 
flange 40a in this case is nearly centrally located at the right side of 
the panel and is formed with a nailing aperture 41a at the upper end 
thereof, a second mounting and interlock flange 40b is disposed in 
laterally stepped relation below and to the right of the first flange 40a 
and is formed with a nailing aperture 41b adjacent an upper end thereof, 
and a third relatively smaller sized mounting and interlock flange 40c 
extends laterally from the bottom of the panel and has a nailing aperture 
41c. For maximizing the lateral width of the second and third flanges 40b, 
40c, a side edge 42 of the second flange 40b is tapered downwardly and 
laterally to the left, as viewed in FIG. 4. 
The nailing apertures 41a, 41b, 41c each have a horizontally-oriented 
elongated configuration for permitting lateral thermal expansion and 
contraction of the mounted panel, and the mounting and interlock flanges 
40a, 40b, 40c each have an elongated boss 44 integrally formed on the 
underside thereof in surrounding relation to the respective nailing 
aperture for supporting the panel during mounting. For providing further 
stability for the mounting and interlocking flanges 40a, 40b, 40c on the 
support surface 25, an elongated foot or rib 45a, 45b is integrally formed 
on the underside of the flanges 40a, 40b laterally to the right of the 
nailing aperture bosses 44. It will be appreciated by one skilled in the 
art that by nailing the panel 11 to the support surface 25 through the 
nailing apertures 32, 41a, 41b, 41c along both upper and right-side 
marginal edge regions 15, 18, the panel 11 may be securely retained on the 
support surface. 
In keeping with the invention, the mounting and interlock flanges 40a, 40b, 
40c each are supported in predetermined spaced relation to the support 
surface 25 by the nail aperture bosses 44 for easy and secure interlocking 
engagement by hooks 50a, 50b, 50c (see FIGS. 2 and 9) integrally formed on 
the underside of the overlapping side marginal edge region 19 of the 
adjacent panel. The hooks 50a, 50b, 50c are formed in downwardly directed 
fashion on the underside of the left-side marginal edge region 19 of each 
panel for positive interlocking engagement under the respective upper edge 
portions of the mounting and interlock flanges 40a, 40b, 40c of the 
underlying panel. The hooks 50a, 50b, 50c in this case each is formed with 
a downwardly and rearwardly tapered engagement or ramp surface 51 (FIG. 
10) which facilitates positioning of the hook under the mounting and 
interlock flange of the underlying panel and drawing together of the hooks 
50a, 50b, 50c and mounting and interlock flanges 40a, 40b, 40c, and thus 
the overlapping side marginal edge regions 18, 19 of the panels as the 
panel in the upper course is moved downwardly into mounted position. It 
will be appreciated that since the nailing apertures 41a, 41b, 41c and 
associated support bosses 44 are disposed in close relation to the upper 
peripheral edges of the mounting and interlock flanges 40a, 40b, 40c, the 
mounting and interlock flanges define a relatively rigid anchor or 
retention means for engagement by the hooks 50a, 50b, 50c of the overlying 
panel. 
To assist in positioning of the panels 11 of each course in horizontally 
aligned relation to each other, the tapered ramp surface 51 of each hook 
50a, 50b, 50c is formed with a small horizontal locating ledge 52 which 
serves as a stop or abutment for the upper peripheral edges of the 
mounting and interlock flanges 40a, 40b, 40c of the underlying panel (FIG. 
8). As a result, as the left-hand marginal edge region 19 of a panel is 
lowered onto the right-side marginal edge region of the previously mounted 
panel, the tapered ramp surfaces 51 of the hooks 50a, 50b, 50c draw the 
left-side marginal edge 19 into secure overlapping relation with the 
right-side marginal edge region 18 of the previously mounted panel until 
the upper edges of the mounting and interlock flanges 40a, 40b, 40c engage 
the locating ledges 52 of the tapered ramp surfaces 51 of the hooks. 
The hooks 50a, 50b, 50c in this case each define a groove 54 with the 
underside of the left-side marginal edge region 19 which extends upwardly 
beyond the locating ledge 52 for permitting vertical thermal expansion and 
contraction between the overlapping side marginal edge regions 18, 19 of 
the panels following installation. In this regard, the locating ledges 52 
have a relatively small height sufficient to provide a positive indication 
of when proper seating is established between the hooks 50a, 50b, 50c and 
the respective mounting and interlock flanges 40a, 40b, 40c, but yet which 
permits the upper edges of the mounting and interlock flanges 40a, 40b, 
40c to move past the locating ledges 52 and further into the grooves 54 
during relative expansion between the panels. 
For forming a seal between the overlapping side marginal edge regions 18, 
19 of adjacent panels 11, the left-side peripheral edge of each panel is 
formed with a vertically and laterally stepped rearwardly directed sealing 
flange 58 adapted for bearing engagement with the right-hand marginal edge 
region 18 of the previously mounted panel. In this instance, a platform 
59a extending laterally to the right of the last shake 12 in the first row 
12a defines a first sealing surface 60a, and a platform 59b adjacent the 
last shake in the second row 12b defines a second side sealing surface 
60b. The second and third mounting and interlock flanges 40b, 40c are 
coplanar and define a third side platform 59c and sealing surface 60c 
adjacent the end of the lower row 12c of simulated shake as shown in FIG. 
4. The rearwardly directed sealing flange 58 of the overlapping side 
marginal edge region 19 is positionable onto the sealing surfaces 60a, 
60b, 60c and is maintained thereon by positive interlocking engagement 
between the hooks 50a, 50b, 50c and the mounting and interlocking flanges 
40a, 40b, 40c. 
To facilitate positioning of the sealing flange 58 onto the surfaces 60a, 
60b, a plurality of tapered rib-like ramps 65 (FIG. 4) extend between the 
respective platforms 59a, 59b and the adjacent lower level surfaces of the 
right-hand marginal edge region 18. In the unlikely event that the side 
sealing flange 58 should move off of the sealing surfaces 60a, 60b defined 
by the platforms 59a, 59b during extreme contraction, the ramps 65 serve 
to guide movement back onto the platform when normal conditions return. To 
prevent an unsightly gap between the stepped side sealing flange 58 and 
the side of the last shake in the second and third rows 12b, 12c during 
lateral contraction of the panels, small lateral flanges 66a, 66b extend 
outwardly from the last shake 12 of the second and third rows 12b, 12c, 
respectively, in substantially aligned relation to the lower peripheral 
edge of the first and second rows 12a, 12b of shake. 
To assist in positioning the first shake of each panel in proper laterally 
spaced relation to the last shake of the previously mounted panel, the 
flanges 66a, 66b are formed with locating notches 68 for receiving similar 
locating ledges 69 at the stepped corners of the side sealing flange 58. 
The bottom sealing flange 30 is formed with a similar locating notch 70 
for engagement with a locating ledge 71 formed on the bottom periphery of 
the lower mounting and interlock flange 40c (FIGS. 4, 9, and 12). A 
spacing or gap 72 between the shake of adjacent panels 11 preferably 
should correspond substantially to that of the fixed gaps 13 between shake 
12 formed in the panels (FIGS. 5 and 11). Preferably the fixed gaps 13 
between shake 12 are of various widths, such as in the range of between 
1/4 inch and 5/16 inch, in order that the variance in the gap 72 between 
the last shake of each panel and the first shake of the adjacent panel 
caused by thermal expansion is substantially undetectable. 
Upon completing installation of one course of panels across the support 
surface 25, as indicated above, a second course is similarly nailed to the 
support surface, with the lower marginal edge regions 16 of the panels of 
that course overlying the upper marginal edge regions 15 of the panels in 
the course immediately below. For interlocking the lower marginal edge 
region 16 of each panel to the upper marginal edge region 15 of the 
previously mounted panel, the underside of each panel has a plurality of 
laterally spaced, downwardly directed hooks 75, similar to the hooks 50a, 
50b, 50c, for engaging the upper peripheral edge of the panel in the 
course below. The hooks 75 in this instance extend rearwardly from the 
ridges 31 defined on the underside of the panel by the gaps 13 between the 
shake 12. Like the hooks 50a, 50b, 50c the hooks 75 have a downwardly and 
rearwardly tapered ramp surface 76 to facilitate engagement with the upper 
peripheral edge of the underlying panel, and the ramp surface 76 of each 
hook 75 is formed with a locating ledge 78 that facilitates predetermined 
positioning of the panel during mounting, while permitting relative 
movement between the upper edge of the panel and the hooks 75 during 
thermal expansion and contraction (FIG. 6). 
For establishing seals between the overlapping bottom marginal edge region 
16 of one panel and the upper marginal edge region 15 of the panel 
immediately below, the bottom downwardly-turned sealing-lip 30 of the 
overlapping panel bears against the face of the upper marginal edge region 
15 of the underlying panel. The bottom sealing lip 30 in this instance is 
positioned over a water barrier ledge 80 formed on the face of the upper 
marginal edge region 15 of the underlying panel adjacent the upper edges 
of the top row 12a of simulated shake 12. The overlying panel preferably 
is mounted with the bottom sealing lip 30 positioned with a small space 
separating the sealing lip 30 from the ledge 80 to accommodate thermal 
expansion and contraction of the mounted panels. To prevent the downwardly 
turned peripheral lip 30 of the upper panel from catching on the ledge 80 
of the underlying panel during mounting, the upper side of the locating 
ledge 80 is in the form of an inclined ramp 81 which tends to guide the 
bottom peripheral lip 30 over the ledge 80 into proper position during 
installation. The interlocking engagement between the hooks 75 of the 
overlying panel and the upper edge of the underlying panel retains the 
sealing lip 30 in engagement with the underlying panel. 
For further retaining sealed engagement between the overlapping upper and 
lower marginal edge regions 15, 16 of the panels, each panel 11 is formed 
with a pair of auxiliary nailing apertures 85a, 85b in close proximity to 
the left side of the upper marginal edge region 15 immediately below the 
nailing apertures 32. Upon positioning of the lower marginal edge region 
16 of one panel onto the underlying panel, the lowermost side nailing 
aperture 41c is positioned into coincident relation with either the 
auxiliary nailing aperture 85a or the auxiliary nailing aperture 85b, 
depending upon whether the course is started along cutting line A or B. 
Upon nailing the side marginal edge region 18 of the panel to the support 
surface, the lowermost mounting and interlock flange 40c is directly 
secured to the underlying upper marginal edge region 15 with the nail 
passing through the lowermost nailing aperture 41c and the coincident 
auxiliary nailing aperture 85a or 85b. 
In carrying out a further aspect of the invention, a corner molding 90 is 
provided which preserves the natural and aesthetic appearance of the 
simulated building elements at corners of a wall or building structure. 
The corner molding 90 in this case includes a pair of mounting flanges 91 
extending outwardly of the molding at a right angle to each other (FIGS. 2 
and 3). The mounting flanges 91 each are formed with vertically spaced 
nailing apertures 92 to facilitate nailing of the molding to right angle 
walls or support surfaces. Each corner molding 90 further is formed with 
three tiers 94a, 94b, 94c of simulated building elements, in this case 
"perfection" shake, also formed at a right angle juncture. Each tier 94a, 
94b, 94c has an outer surface extending in downward and outwardly tapered 
fashion, similar to the shake in corresponding first, second and third 
rows 12a, 12b, 12c of each panel. 
For creating a relatively uninterrupted and unnoticeable juncture between 
the simulated building elements of the corner molding 90 and those of 
adjacent panels 11, the building element tiers 94a, 94b, 94c of the corner 
molding 90 and the mounting flanges 91 define an outwardly opening pocket 
95 on each side of the molding 90 for receiving an end of a respective 
panel 11. The end of the panel 11 is appropriately cut along a straight 
line and positioned within the pocket 95 such that the shake at the end of 
the first, second and third rows 12a, 12b, 12c of the panel are positioned 
in close underlying relation to the shake of the first, second and third 
tiers 94a, 94b, 94c of the corner molding 90. Since the walls of the 
simulated shake of the corner molding, like the walls of the panel 11, are 
relatively thin, such as about 3/16 inch, the step between the exposed 
tapered surfaces of the corner molding and the exposed surface of the 
underlying simulated shake 12 of the adjoining panel 11 is small and 
barely noticeable in the finished installation. 
In order to encompass the corner of the building structure in a 
substantially sealed enclosure, each corner molding pocket 95 in the 
illustrated embodiment is defined by the underside of building element 
tiers 94a, 94b, 94,c, the mounting flange 91, and an end wall 96, which 
together define a sealed chamber 98 about the corner (FIG. 3). 
To permit the corner moldings 90 to be mounted in partially overlapping 
relation to each other, consistent with the panels 11, the end walls 96 
are formed with a respective upwardly extending notches 99 (FIG. 2) at the 
lower end thereof which permit positioning of the lower end of one corner 
molding 90 over the previously mounted corner molding. The mounting 
flanges 91 are formed with small horizontal locating ledges 100 at their 
upper ends to facilitate proper positioning of the notches 99 of the 
corner molding 90 onto the previously mounted corner element. 
From the foregoing, it can be seen that the wall covering of the present 
invention is adapted for secure mounting utilizing nailing apertures along 
both upper and side marginal edge regions, while still enabling easy and 
effective interlocking engagement between overlapping marginal edge 
regions for enhancing a realistic and aesthetic appearance of the wall 
covering, even when installed on slightly irregular support surfaces. The 
panels furthermore have a relatively simple construction which lends 
itself to economical manufacture and ease of installation. The corner 
moldings further enhance the aesthetic appearance of the finished 
installation.