Abstract:
A system is provided having a number of interlocking panels for constructing a building. Each of the panels has a linear concave member protruding from a first surface and a linear convex member protruding from a second surface. The convex member is configured to slide linearly into the concave member and become locked therein against separation in a direction perpendicular to the line of sliding. The convex member is positioned adjacent to a first edge of each panel and the concave member is positioned adjacent to a second edge of each panel in a manner that when assembled, a first assembled panel is offset from a second assembled panel, creating a lapped series. The panels additionally have holes for being fastened to a building frame.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to the field of building materials, and more particularly to a system of exterior building panels for roofing and siding. 
       BACKGROUND OF THE INVENTION 
       [0002]    Traditionally, exterior roofing and siding building materials have mainly been designed and applied in a manner intended to shed rainwater and keep the building interior dry. The building frame is typically first clad with a sheathing material, e.g. plywood. A barrier layer, e.g. tarpaper or Tyvek® plastic sheeting, is then applied to seal the building against wind and water. Last, a layer of shingles for the roof and lapped siding, e.g. wood planks or vinyl strips, is applied. The outer layer of roofing or siding is applied by starting from the bottom, attaching a first row, and then mounting a second row in a manner for the lower portion of the second row to overlap the upper portion of the first row. With this configuration of lapped exterior panels covering the building frame, rain that falls on the panels runs down to the ground and does not enter the building interior. 
         [0003]    While this traditional building panel system is effective in protecting the building interior from rain and other precipitation, weather systems often involve significant wind. Wind usually blows horizontally and occasionally at various angles, including vertically. In many areas of the world, and especially in recent years, “nor&#39;easters,” hurricanes, cyclones, and tornadoes occur. These storms include high velocity wind driven in odd directions. With the changes that have been occurring to the global climate, these storms are more violent and more frequent than in the past. When high velocity wind and water hit a building in a horizontal direction, the lower edge of roof shingles may be lifted and rain is driven into the building. If the wind velocity is high enough, the roof shingles are torn off the building. In extreme cases, wind can remove siding planks from the building frame. The end result is often serious damage to the building and its contents that is upsetting to the inhabitants and costly to repair. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention provides an interlocking panel system for buildings that overcomes the drawbacks of the known roofing and siding materials. The invention system includes a series of panels having a tongue along first edge on a first surface and a mating groove along a second edge on a second surface, the second edge being parallel to the first edge. The tongue and groove are configured to engage and disengage by sliding in a direction parallel to the first and second surfaces only, preventing disengagement by lifting in a direction perpendicular to the surface. A series of mounting holes are formed along a line near the second edge to affix the panel to the building frame members, preferably without the need for plywood sheathing. The various configuration of panels of the present invention include an edge panel, a plate panel and a ridge panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    The present invention is best understood in conjunction with the accompanying drawing figures in which like elements are identified by similar reference numerals and wherein: 
           [0006]      FIG. 1  is a side elevation schematic view of a building frame with a roof formed of panels according to the present invention. 
           [0007]      FIG. 2  is a perspective view of a plate panel of the invention positioned for being engaged with an edge panel of the invention. 
           [0008]      FIG. 3  is a perspective view of a pair of ridge panels of the invention. 
           [0009]      FIG. 4  is a partial end view of an upper panel and a lower panel showing the interlocking tongue and groove of the invention in juxtaposed positions. 
           [0010]      FIG. 5  is a plan view of a building portion with interlocking panels of the invention mounted thereto in staggered configuration. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0011]    Referring now to  FIG. 1 , a building frame  10  is illustrated in side elevation view without sheathing sheets, and with the roof enclosed according to the invention. Rafters  12  are mounted at an exemplary angle S. The process of applying the interlocking panel system of the present invention begins by placing an edge panel  18  in contact with the lower end of each rafter set  12  with the downwardly directed flap of each edge panel  18  resting against the angular exposed end of rafters  12 . A series of fasteners F are inserted through holes formed along a line adjacent to the upper edge of each edge panel  18 . A tier of plate panels  20  are interlocked with edge panels  18  as will be described below. A series of fasteners F are inserted through holes formed along a line adjacent to the upper edge of plate panel  20 . Fasteners F are preferably screw fasteners to securely hold edge panel  18  to rafters  12 . Fasteners F may alternatively be adhesive coated nails. As illustrated, plate panels  20  are substantially planar; if the slope S of rafters  12  is relatively steep in comparison to the run R of each plate panel  20 , the upper edge of plate panel  20  may be formed at an upward angle to better accommodate fasteners F. Run R is typically in the range of 6 to 10 inches. Whereas there is no sheathing applied to rafters  12 , workers assembling the panel system of the invention to a building frame are able to install sequential tiers of plate panels  20  while standing on horizontal joists  14 , avoiding the danger of standing on sheathing assembled to sloping rafters  12 . As additional tiers of plate panels  20  are mounted to rafters  12  approaching the peak of the roof, the final tiers must be mounted by roofers positioned on the roof. Finally, ridge panels  22  and ridge flashing  24  are mounted to close the roof surface. As seen, the completed panel system creates a lapped surface covering. 
         [0012]    Referring now to  FIG. 2 , an edge panel  18  and a plate panel  20  are depicted in position for being assembled to one another. Edge panel  18  is formed by extrusion with a rectangular planar portion  38  and a rectangular lip portion  40  in angular relation to one another, a concave linear interlocking member such as groove  42  and a series of mounting holes  44 . As noted above, edge panel  18  is mounted to the building rafters  12  (see  FIG. 1 ) with lip portion  40  in intimate contact with the exposed angular end of each rafter  12  and a series of fasteners inserted through holes  44 . Additional edge panels  18  are mounted to rafters  12  to cover the entire edge of building frame  10  ( FIG. 1 ). Referring further to  FIG. 2 , plate panel  20  is formed with a rectangular planar portion  28 , a convex linear interlocking member such as tongue  30 , a concave linear interlocking member such as groove  32 , and a series of mounting holes  34 . Holes  34  of plate panel  20  and holes  44  of edge panel  18  are preferably separated from one another by a distance to match conventional building methods, e.g. a spacing between adjacent holes of 8 inches will match commonly used building frame component spacing of 16 or 24 inches. Tongue  30  is positioned adjacent to one edge of plate panel  20  on a lower surface, and groove  32  is positioned adjacent to an opposed edge of plate, panel  20  on an upper surface. As shown, the edge portion of plate panel  20  that is adjacent to tongue  30  extends a minimal distance beyond tongue  30  to reduce the potential lifting effect of a high velocity wind. Tongue  30  of each plate panel  20  is configured to engage and lock into a groove  32  of an adjacent edge panel  18  or sequential plate panel  20 . Therefore, to cover higher sections of rafters  12  ( FIG. 1 ), a first plate panel  20  is moved laterally in the direction indicated by arrow A to slide tongue  30  of plate panel  20  into engagement with groove  42  of previously mounted mating edge panel  18 , and fasteners are inserted through mounting holes  34 . Whereas tongue  30  is formed on the lower surface and groove  32  is formed on the upper surface of plate panel  20 , plate panel  20  cannot be incorrectly mounted, and mounting holes  34  are always positioned toward the top of the building. Holes  34  are preferably positioned along a line parallel to groove  32 , between groove  32  and the adjacent edge of plate panel  20 . According to known building practice, it is preferred to stagger the edges of successive rows of panels to minimize the chance of water infiltration as will be seen in  FIG. 5 . The length L of edge panel  18  is substantially equal to length L of plate panel  20 . Length L is typically in the range of 3 to 6 feet. Depending on the intent of the manufacturer, the panels comprising the present invention may be formed with a uniform thickness throughout or with thinner portions and intermediate longitudinal ribs for rigidity. 
         [0013]    Referring now to  FIG. 3 , a pair of ridge panels  22  are illustrated as positioned juxtaposed to one another in substantially the orientation shown in  FIG. 1  as they are mounted to a typical roof structure. Ridge panels  22  are made to length L of 3 to 6 feet. Ridge panels  22  are formed with a tongue  50  on lower surfaces and adjacent to an edge thereof. Ridge panels  22  have a channel  26  formed along an opposite edge. Channel  26  is configured for the insertion of a bent or rounded ridge flashing component  24  (see  FIG. 1 ) or, alternatively a ridge vent, by sliding the component laterally into channels  26 . After a ridge flashing or a ridge vent is put in place, the roof covering is basically complete. To further secure the panels and reduce the chance of water infiltration, the lines of juncture between each adjacent panel may be sealed with caulking compound or similar weather-resistant material. 
         [0014]    Referring now to  FIG. 4 , an enlarged partial side elevation of an upper plate panel  20   a  having tongue  30  depending downwardly therefrom and a lower plate panel  20   b  having groove  32  extending upwardly therefrom are illustrated opposed to one another. As depicted, the opening within groove  32  is sized and shaped to snugly and slidingly receive tongue  30 . Tongue  30  and groove  32  are each preferably formed as an equilateral trapezoid in cross sectional view. Alternate shapes for tongue  30  and groove  32 , e.g. circular or “T” shaped, are considered within the scope of the present invention. According to the preferred embodiment of the invention, all panel components described are formed by the process of extrusion. The preferred material for forming the panels described herein is aluminum, although other materials susceptible to extrusion, including other metals and plastic resins, are deemed to be included in the principles of the present invention. With tongue  30  inserted in groove  32  by sliding along their respective lengths, and fastened to the building frame, the assembly is substantially permanent. Removal of any intermediate panel of the present invention involves dismantling the panels from the top of the building surface to the level of the problem panel. 
         [0015]    Referring now to  FIG. 5 , a plan view of a portion of a building is shown as covered with the interlocking panel system of the invention. As seen, a first row of edge panels  18  is followed by a number of rows of plate panels  20 . At the upper end, a row of ridge panels  22  is assembled and the covering is completed with a ridge flashing or ridge vent  24 . The common practice of staggering each succeeding row of panels has been employed to avoid continuous aligned joints from the top to the bottom and thus minimize the chance of water infiltration. Whereas the illustrated and described example relates to a roof covering system, the major features of the invention are readily adaptable to exterior vertical wall coverage. 
         [0016]    As described above, the interlocking panel system of the invention provides a series of building exterior panels that are easy to install and is more secure and protective than currently known shingles, planking or extruded vinyl siding. 
         [0017]    While the description above discloses preferred embodiments of the present invention, it is contemplated that numerous variations and modifications of the invention are possible and are considered to be within the scope of the claims that follow.