Polymer building products

In polymer building products, such as polymer siding, polymer roofing, j-blocks, gable vents, etc., characterized by fastener apertures each comprising an elongate slot bounded by a peripheral wall defining the slot, the peripheral wall having a height, a fastener centering-guide comprising a layer of material extending into the elongate slot from the peripheral wall thereof, the layer of material having defined therein (a) an elongate opening that is generally parallel to, but of smaller transverse dimensions than, the elongate slot, and (b) a predetermined location, defined intermediate the length of the elongate opening, for receiving a fastener therethrough, and wherein further the layer of material is characterized by a thickness that is less than the height of the peripheral wall and sufficiently thin so as to permit relative movement between a fastener extending through the centering guide and the polymer building product.

FIELD OF THE INVENTION

The present invention pertains to the field of polymer building products, such as, for example, siding, roofing, J-blocks, gable vents, siding joints, etc., and more particularly to an improved, polymer siding-joint for concealing the opposing lateral edges of horizontally adjacent pieces of polymer siding, improved means for ensuring the accurate and facile installation of siding and roofing panels, as well as a fastener centering-guide and a hammer stop for incorporation into polymer building products.

BACKGROUND

While the advent of polymer building products has greatly eased the installation of roofing, siding and trim components, drawbacks remain.

To facilitate their installation, polymer building products, such as, for example, siding, roofing, J-blocks, gable vents, etc., are usually characterized by a plurality of fastener apertures each comprising an elongate slot of constant width bounded by a peripheral wall defining the slot. In these regards, the disclosure of the applicant's own prior-published application, US Pub. No. 20080083186, the disclosure of which is incorporated herein by reference in its entirety, is exemplary. In installation, a fastener, such as a nail, for instance, is driven through each slot and into a substrate to thus secure the building product in place. The slots are elongate so that once a fastener is positioned therein and secured to the underlying substrate, the building products can slide relative to the fasteners as the polymer material expands and contracts due to changing ambient temperatures.

Necessarily, the fasteners must be positioned approximately in the middle of each slot in order to permit the unfettered relative movement of the building products in either direction so as to accommodate both contraction and expansion of the building products. Unfortunately, hasty installation can lead to the misplacement of fasteners too close to one or the other end of these slots. When this occurs, the slot end confronts the fastener prematurely during its relative movement, leading to unwanted buckling of the building product.

Another common occurrence during installation of polymer building products is for fasteners to be driven too deeply into the substrate, such that the building product is effectively fixed in position and unable to move relative to the fastener in response to changes in the ambient temperature. As with misplacement of the fastener within the slot, this installation error can lead to unwanted buckling of the building product.

Still a further problem in the installation of polymer siding and roofing panels is the need to ensure proper alignment of vertically adjacent rows of siding or roofing panels as they are “stacked” one on top of the other. With conventional polymer roofing and siding panels, it is possible to misalign vertically successive panels relative to the preceding, vertically lower one, unless due care is taken by the installer. However, such due care can slow the installation process.

A further drawback of polymer siding is that the necessity, in some installation methods, of leaving a slight gap between horizontally adjacent panels (to ensure sufficient room for the panels to expand and contract due to changes in ambient temperature) creates an unsightly aesthetic to the thus-finished building. While siding-joints are known as a satisfactory means for concealing such gaps, the conventional forms of these joints are difficult to install.

SUMMARY OF THE DISCLOSURE

The present invention addresses the foregoing problems of the prior art in the provision of improvements to polymer building products, such as polymer siding, polymer roofing, j-blocks, gable vents, etc.

According to a first aspect of the invention, there is provided a fastener centering-guide comprising a layer of material extending into the elongate slot from the peripheral wall thereof, the layer of material having defined therein (a) an elongate opening that is generally parallel to, but of smaller transverse dimensions than, the elongate slot, and (b) a predetermined location, defined intermediate the length of the elongate opening, for receiving a fastener therethrough, and wherein further the layer of material is characterized by a thickness that is less than the height of the peripheral wall and sufficiently thin so as to permit relative movement between a fastener extending through the centering guide and the polymer building product.

According to one feature, the predetermined location for receiving a fastener through the layer of material comprises an opening of a first size, and the elongate opening comprises a pair of slots extending oppositely from the opening, each slot being characterized by smaller transverse dimensions than the opening.

The layer of material may be formed of polymer, for example, and may be formed integrally with the peripheral wall or as a separate element that is fixedly secured to the peripheral wall.

In another aspect thereof the invention comprises a siding joint for concealing the gap between opposing lateral edges of horizontally adjacent pieces of siding, the siding joint having a bottom portion adapted to be secured to a substrate beneath, and proximate the opposite lateral edges of, horizontally adjacent pieces of siding; and a top portion connectable to the bottom portion so as to capture therebetween horizontally adjacent pieces of siding, the top portion concealing the opposing lateral edges of horizontally adjacent pieces of siding.

Per one feature, the top portion comprises an outwardly-facing surface simulating the appearance of a natural siding material.

Per another feature, the top and bottom portions comprise interlocking elements by means of which the top portion is connectable to the bottom portion.

Per another feature, the bottom portion is a generally wedge-shaped element that tapers in thickness along a longitudinal axis thereof.

According to a still further feature, the bottom portion comprises a plurality of spaced openings therein. At least one locking tab extends into each said opening. Further according to this feature, the top portion comprises a plurality of rigid supports corresponding in number to the number of the plurality of openings in the bottom portion, each said rigid support terminating in a foot engageable by the at least one tab in the corresponding opening.

According to yet another feature, the bottom portion comprises a plurality of laterally spaced-apart deformable or frangible projections dimensioned to abut the opposing lateral edges of horizontally adjacent pieces of siding. The projections are adapted to be deformable or frangible in response to the force of a siding panel's lateral edge acting against the projections during expansion of the panel as occasioned by changes in ambient temperature.

Per still another feature, the bottom portion further comprises a plurality of laterally extending ribs dimensioned to be able to support overlying siding.

According to a further aspect thereof, the invention comprehends a hammer stop for limiting the depth to which a fastener may be driven into each elongate slot comprising the fastener apertures of a polymer building product. The hammer stop comprises vertically elevated, rigid stop surfaces, the stop surfaces positioned about each elongate slot so as to confront the face of a hammer having a head diameter greater than the distance between the stop surfaces, and the stop surfaces being vertically elevated above each elongate slot by a distance sufficient to prevent a fastener from being driven into the slot to a depth at which the building product is prevented from moving relative to the fastener during expansion and contraction of the building product.

Per one feature thereof, the hammer stop comprises a pair of elongate ribs disposed oppositely of the elongate slot and longitudinally extending in a direction generally parallel to the longitudinal axis of the elongate slot.

Per still another feature, the fastener apertures are disposed serially along a length of the building product, and wherein the improvement further comprises the pair of elongate ribs extending continuously and generally coextensively with the fastener apertures.

In another aspect thereof, the invention comprehends a polymer roofing or siding panel, comprising a front, outwardly-facing decorative surface and an opposite, rearwardly facing surface, a top edge and a vertically spaced-apart bottom edge; a first stand-off positioned proximate the top edge of the roofing or siding panel, the stand-off projecting rearwardly from the rearwardly facing surface, and the stand-off engageable with a substrate to define a gap between the siding or roofing panel and a substrate in the area immediately above the stand-off; and a hook positioned proximate the bottom edge of the roofing or siding panel and projecting from the rearwardly facing surface thereof, the hook opening toward the bottom edge of the roofing or siding panel so as to be slidingly receivable in the said gap defined in a like, vertically adjacent roofing or siding panel.

Per one feature of the invention, the first stand-off is a continuous element extending generally coextensively with the length of the roofing or siding panel.

Per another feature, the hook is defined by a rearwardly projecting element that terminates in a portion extending downwardly toward the bottom edge of the roofing or siding panel.

According to still another feature, the hook is a continuous element extending generally coextensively with the length of the roofing or siding panel.

According to yet another feature, the hook is a discrete element disposed along the length of the roofing or siding panel.

Per a still further feature, a plurality of discrete hooks are disposed along the length of the roofing or siding panel.

DETAILED DESCRIPTION

Referring now to the drawings, wherein like numerals refer to like or corresponding parts, the present invention will be seen to most generally comprise improvements to polymer building products, such as polymer siding, polymer roofing, j-blocks, gable vents, etc. According to a first such improvement, shown inFIGS. 1 through 4, there is provided a fastener centering-guide for facilitating the proper positioning of fasteners (e.g., nails) within each fastener slot so that subsequent relative movement of the building product in response to changes in ambient temperature is possible. More particularly according to the illustrated embodiment, there is provided a polymer siding panel1having a rear surface2(FIG. 1) facing inwardly toward a substrate (not shown) and a front, outwardly-facing decorative surface3(FIG. 4). To facilitate securement of the panel1to the substrate, there are provided a plurality of fastener apertures (indicated generally at4). Viewed from the rear surface2(FIGS. 1 and 2) as well as in cross-section (FIG. 3), each such aperture4will be seen to comprise, according to convention, an elongate slot bounded and defined by a peripheral wall5.

Referring more particularly toFIGS. 2 and 3, a fastener centering-guide is further provided within the area of each slot defined by the wall5, the centering-guide generally comprising a layer of material6extending or protruding into the elongate slot from the peripheral wall5. The layer of material6has defined therein an elongate opening8that is generally parallel to, but of smaller transverse dimensions than, the elongate slot defined by the wall5. Elongate opening8may be defined by a slit in the layer of material or, as desired, by a slot of transverse dimensions.

Further defined in the layer of material intermediate the length of the elongate opening8is a predetermined location7for receiving a fastener, such as, for instance, a nail (not shown), therethrough. In the illustrated embodiment, this predetermined location7is depicted as an opening the dimensions of which are sufficient to permit the shank of a fastener such as a nail to pass freely therethrough. According to this embodiment, the elongate opening8is a slot characterized by smaller transverse dimensions than the opening of location7so as to thereby distinguish the preferred approximate location for positioning a fastener.

It will be appreciated that the dimensions of the location7may be smaller or larger than as shown, subject only to the need for the location7to clearly identify for an installer the preferred approximate location for positioning a fastener within the slot defined by the wall5. Thus, for instance, it is contemplated that the location7may simply comprise indicia, such as an “X,” positioned along the length of the elongate opening8for identifying the preferred position for the fastener to be driven into the layer of material.

Referring specifically toFIG. 3, the layer of material6will be seen to be characterized by a thickness that is less than the height of the peripheral wall5. This thickness of the layer of material6is sufficiently thin so as to permit relative movement between the fastener (not shown) extending through the centering guide and the polymer building product, as occasioned by changes in ambient temperature which cause expansion and contraction of the polymer material of the building product.

Further to the illustrated embodiment, the layer of material6is a polymer which may be formed with the siding panel1or other building product so as to be integral therewith. Alternatively, the layer of material6may be formed separately and subsequently fixed in place, such as with adhesives, over the elongated slots. It will also be appreciated that the layer of material need not be formed of polymer, being formed instead, for example, from fabric, cellulose, etc.

According to a second improvement to building products encompassed by the present disclosure, also shown inFIGS. 3 and 4, there is provided a hammer stop for limiting the depth to which a fastener may be driven into each elongate slot defined by the peripheral wall5, thereby preventing the building product from being fixed immovably in place against the substrate. Generally, the hammer stop comprises vertically elevated, rigid stop surfaces9,10positioned about each elongate slot (defined by the peripheral wall5) so as to confront the face of a hammer having a head diameter greater than the distance between the stop surfaces9,10.

According to the illustrated embodiment ofFIGS. 3 and 4, in which the hammer stop is shown in conjunction with siding panel1, the rigid stop surfaces9,10of the hammer stop define a pair of elongate ribs disposed oppositely of the fastener apertures4and longitudinally extending in a direction generally parallel to the longitudinal axis of each elongate slot (defined by the peripheral wall5).

Each stop surface9,10is further defined in cross-section (FIG. 3) as a raised shoulder extending the length of the panel1generally coextensive with the series of fastener apertures4. The vertical distance between each stop surface9,10and the elongate slot defined by peripheral wall5is such as to ensure that, during installation of the building product (e.g., the siding panel1) with a hammer having a head diameter greater than the distance between the opposing stop surfaces9,10, a fastener can be driven through the slot and into the underlying substrate only so far as to a depth which leaves sufficient space for the building product to move relative to the fastener during expansion and contraction.

Referring next toFIGS. 5 through 12, a further improved building product according to the present disclosure comprises a polymer siding joint for concealing the gap between opposing lateral edges of horizontally adjacent pieces of siding, the siding joint comprising a bottom portion20adapted to be secured to a substrate beneath, and proximate the opposite lateral edges of, horizontally adjacent pieces of siding (1and1′ inFIGS. 11 and 12), and a top portion30connectable to the bottom portion20so as to capture therebetween horizontally adjacent pieces of the siding1,1′, the top portion30concealing the opposing lateral edges of horizontally adjacent pieces of siding.

Referring more specifically toFIGS. 5 through 8, the top portion30comprises a generally planar member having a front, outwardly-facing decorative surface31which may be fashioned to match the appearance of the outwardly-facing decorative surfaces of the siding panels. For instance, the outwardly-facing surface31may simulate the appearance of a natural siding material, such as wood. This generally planar member of the top portion is, as indicated, at least of sufficient dimensions in both width and length so that, in use (described hereafter), it substantially conceals the opposing lateral edges of horizontally adjacent pieces of siding and the gap which must of necessity be left therebetween during installation so as to permit expansion of the siding due to changes in ambient temperature.

From the rear, inwardly facing surface32there project a plurality of rigid supports33interconnected at their bases by a rib34. The end of each support33terminates in a generally planar foot35oriented substantially normal to the support. As depicted best inFIG. 5, each foot35is characterized on either side of the support33by a forward edge36which slopes upwardly toward the rear surface32, then terminating abruptly in a surface37disposed generally perpendicular to the plane of the foot35.

Referring next toFIGS. 5,6,9and10, the bottom portion20is, in profile (FIGS. 5 and 6), a generally wedge-shaped member the taper of which corresponds to the taper of the polymer siding installed thereover. One or more recessed or counter-bored openings21are provided through the bottom portion20, each opening21dimensioned to receive therethrough a fastener (e.g., a nail) whereby the bottom portion may be fixed to a substrate. As shown in the exemplary embodiment, openings21are offset relative to the longitudinal centerline of the bottom portion20, being disposed, more particularly, proximate the right hand side of the bottom portion as shown.

Extending laterally from the bottom portion20are a plurality of ribs22dimensioned to support the rear surface of siding lying thereover.

Openings23corresponding approximately in shape to each of the feet35are also provided through the bottom portion20. Extending into each such opening23at the forward portion thereof are a pair of locking tabs24separated by an elongated opening25. Two of the three openings23are further characterized by the presence of a stop surface26as best shown inFIGS. 6 and 9.

Referring specifically toFIGS. 5 and 9, the upper surface of the bottom portion20further includes several projections27. As shown, the projections27are disposed in laterally spaced-apart pairs. Each such projection27extends upwardly a sufficient distance so as to abut the opposing lateral edges of horizontally adjacent pieces of siding panel during installation thereof, as explained further below. Each such projection27is preferably fabricated so as to be either frangible or deformable in response to the force of a siding panel's lateral edge acting against the projection27during expansion of the panel as occasioned by changes in ambient temperatures.

Turning now toFIGS. 11 and 12, the manner of employment and operation of the inventive siding joint will be better understood.

According to convention, rows of siding panels (e.g.,1,1′) are installed on a substrate (not shown) in horizontally-adjacent fashion, with a sufficient distance left between the opposing edges of horizontally-adjacent panels so as to accommodate thermal expansion of these panels following securement thereof to the substrate. Following placement and installation of a first siding panel1, the bottom portion20is positioned and installed on the substrate proximate the lateral edge of the siding panel1. To facilitate such installation, the installer positions the bottom portion20against the substrate (not shown) and partially beneath the siding panel1so that the lateral edge of the siding panel abuts the nearest of the pairs of projections27. To further facilitate precise placement of the bottom portion20, there may, as shown inFIG. 12, be provided one or more stops11, stand-offs or the like on the rear surface2of each siding panel which are adapted to contact the top edge of the bottom portion20, as depicted.

Following placement, fasteners are driven through the off-set openings21to fix the bottom portion20to the substrate. Thereafter, the next horizontally adjacent siding panel1′ is positioned and installed. Positioning relative to the bottom portion20is again facilitated using the projections27, with the lateral edge of the siding panel1′ being arranged so as to abut the nearest of the pairs of such projections27.

After the siding panel1′ is fixed in place on the substrate, the top portion30(not depicted inFIGS. 11 and 12) is mated to the bottom portion20. This is accomplished by positioning the top portion proximate the bottom edges of the siding panels1,1′ such that the front, outwardly-facing decorative surface31is disposed above the front surface3,3′ of each siding panel1,1′, the supports33are aligned with the gap G defined between the adjacent, installed siding panels1,1′, and the feet35are positioned beneath the rear surface (not shown) of each siding panel1,1′. Thereafter, the top portion30is slid upwardly toward the bottom portion20until each of the feet35is positioned above a corresponding one of the openings23. The top portion30is then urged downwardly until the feet35confront stop surfaces26, whereupon the top portion20is urged upwardly once more to force tabs24over the forward edge36of each foot35and into locking engagement against the surface37.

Referring next toFIGS. 3,13and14, a further improved building product according to the present disclosure comprises the provision of a unique profile for siding panels (1,1″), as depicted, or roofing panels, which permits such panels to be easily and accurately positioned vertically-adjacent each other. As shown best inFIGS. 3 and 14, there is provided proximate the top edge of each siding panel1, positioned above the elongate slot defined by peripheral wall5, a rearwardly projecting stand-off12which serves to contact the substrate upon installation of the siding and so maintain between the siding panel1and the substrate a gap13defined in the area immediately above the stand off12. Along the length of the siding panel1the gap13defines, upon installation of the siding panel, an upwardly-opening channel. But while the stand-off12is shown as a continuous element extending generally coextensively with the length of the siding panel, it will be understood that a plurality of discrete ones of such stand-offs may instead be provided, each positioned along the length of the panel.

Referring particularly toFIG. 14, there is provided proximate the bottom of each siding panel1,1″ a rearwardly projecting element14which terminates in a downwardly extending portion15to define, in cross-section, a substantially “L”-shaped hook. This element14may extend continuously across the length of the siding panel1,1″ or, alternatively, may be formed as one of a plurality of discrete ones of such elements positioned along the length of the panel.

In operation, which may be best understood with reference toFIG. 14, a first siding panel1is installed against a substrate S, with the stand-off12defining the gap13in the area above the stand-off12and between the top edge of the siding panel and the substrate. In placing the next vertically-adjacent siding panel1″, an installer simply slides the panel1″ downwardly towards the previously installed panel1until the downwardly extending portion15of element14is received in the gap13and abuts against the stand-off12, thus indicating accurate placement of the panel1′ relative to the panel1. The panel1′ may then be fixed in place against the substrate and the siding panel installation process repeated.

It will be appreciated from the foregoing disclosure that the present invention provides polymer building products which facilitate the accurate and rapid installment thereof.

Of course, the preceding specification is merely illustrative of the present invention, and those of ordinary skill in the art will appreciate that many additions and modifications to the present invention, as set out in this disclosure, are possible without departing from the spirit and broader aspects of this invention as defined in the appended claims.