Patent Publication Number: US-2011061323-A1

Title: Simulated Masonry Wall Panel with Improved Seam Integration

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to wall and roof coverings primarily intended for outdoor usage, and more particularly, to wall coverings comprised of relatively large panels where each are molded or otherwise formed with simulated building elements, and particularly building elements in the form of simulated hand laid masonry, such as stone. 
     BACKGROUND OF THE INVENTION 
     Various synthetic roof and wall coverings are known, such as those formed of elongated thermoplastic wall panels that are nailed or screwed to a wall or support surface in horizontal courses or rows in partially overlapping relation to each other so as to provide a substantially water repellant, protective layer over the support surface. Such panels, which usually are identically molded, commonly are formed with a plurality of horizontal rows of simulated building elements. Since the panels are identically molded, a panel-to-panel identity can be easily noticed if the panels are not carefully installed, which can be tedious and time consuming. 
     Concealing the panel-to-panel identity of panels formed with simulated hand laid stone or brick patterns has been particularly difficult. In an effort to conceal the juncture between rows of simulated masonry of adjacently mounted panels, it is known to stagger the length of the rows of the simulated masonry of each panel, and to interlock the rows of adjacent panels by forming a small slot in the underside of the masonry element of one row which receives a side flange of an adjacently mounted panel. Because of the small depth of the flange receiving slot, particularly with the shorter height simulated stone or brick, the tooling required during injection molding of the panel must be so thin that it can be subjected to warpage or breakage, causing variances in formation of the slot that can impede the precision by which the panels can be inter-engaged, resulting in unslightly and unnatural gaps between the simulated masonry of the adjacent panels. Moreover, because the simulated hand-laid stone or brick are separated by simulated mortar lines, irregular or inconsistent gaps between the stone or brick at adjoining ends of the panels that are not consistent with the mortar lines throughout the panel can be particularly noticeable. 
     A further problem with panels formed with such simulated masonry is that the seam between adjacent panels can become visible due to molding inconsistencies and thermal expansion. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a wall covering comprised of panels formed with rows of simulated masonry that can be installed with a more aesthetic and natural appearance. 
     Another object is to provide a wall covering as characterized above in which the gaps between stone or brick masonry of adjacently mounted panels can be more tightly and precisely controlled for a more natural appearance and that an overlap between adjacent panels can be introduced to minimize seam visibility during thermal expansion and to more properly simulate stone panels. 
     Still another object is to provide a wall covering of the above kind in which the gaps between the masonry of adjacently mounted panels is defined by naturally appearing mortar lines consistent with the mortar lines separating the stone or brick masonry throughout the panels. 
     Yet another object is to provide a wall covering of the foregoing type in which the mortar lines between masonry of adjacently mounted panels enhances the aesthetic appearance of the juncture between the rows of simulated masonry of adjacent panels, as well as the mating engagement of the adjacent panels. 
     Another object is to provide a wall covering having panels of the above type which are adapted for easier installation and which enable a more robust interlocking of overlapping side marginal regions of adjacent panels. 
     A further object is to provide such a wall panel which facilitates precise alignment of the rows of simulated building elements of adjacent panels as an incident to installation. 
     Still a further object is to provide a plastic wall panel of the foregoing type which can be economically molded with more reliable and easier to use tooling. 
     Yet another object is to provide a plastic injection molded panel that is painted with a finishing process that gives the panel a textured surface more characteristic of natural stone or brick. 
     Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective of an illustrative wall panel in accordance with the present invention; 
         FIG. 2  is a rear plan view of the wall panel shown in  FIG. 1 ; 
         FIG. 3  is a plan view of a wall covering comprised of a plurality of wall panels shown in  FIG. 1 ; 
         FIG. 4  is an enlarged right end view of the illustrated wall panel, taken in the plane of line  4 - 4  in  FIG. 1 ; 
         FIG. 5  is an enlarged fragmentary section of the engagement of a lowermost panel of the wall covering with a bottom starter strip, taken in the plane of line  5 - 5  in  FIG. 3 ; 
         FIG. 6  is an exploded fragmentary section of upper and lower marginal edge regions of panels in adjacent courses, taken in the plane of line  6 - 6  in  FIG. 3 ; 
         FIG. 6A  is a fragmentary section similar to  FIG. 6 , showing the lower and upper marginal edge regions of the panels in engaged relation with each other; 
         FIG. 7  is an enlarged fragmentary section of overlying side marginal edge regions of the wall cover, taken in the plane of line  7 - 7  in  FIG. 3 ; 
         FIG. 8  is an enlarged exploded view of adjacent wall panels showing the side marginal edge regions of the panels in separated relation to each other; 
         FIG. 8A  is an enlarged plan view, similar to  FIG. 8 , showing the side marginal edge regions of the adjacent panels in engaged relation with each other. 
         FIG. 9  is an enlarged fragmentary section taken in the plane of line  9 - 9  in  FIG. 8 ; 
         FIG. 9A  is an enlarged fragmentary section, similar to  FIG. 9 , showing the side marginal edge regions in interengaged relation with each other; 
         FIG. 10  is a fragmentary underside perspective of the interengaged side marginal edge regions of the illustrated wall covering; 
         FIGS. 11 and 11A  are enlarged fragmentary sections taken in the planes of  11 - 11  and  11 - 11 A, respectively, in  FIG. 8 ; 
         FIG. 12  is a plan view of a wall covering comprised of a plurality of wall panels showing an improved seam integration feature according to one aspect of the invention; 
         FIG. 13  is an enlarged right end view of one wall panel of the embodiment depicted in  FIG. 12 ; 
         FIG. 14  is an exploded fragmentary section of upper and lower marginal edge regions of panels in adjacent courses, taken in the plane of line  14 - 14  in  FIG. 12 ; and 
         FIG. 14A  is a fragmentary section similar to  FIG. 14 , showing the lower and upper marginal edge regions of the panels in engaged relation with each other at a seam integration location. 
         FIG. 14B  is an enlarged view of  FIG. 14A , showing a non-planar projection of the lower marginal edge portion of the overlying panel so as to partially obscure a mortar line formed between panels. 
         FIG. 14C  is an another enlarged view of the panel similar to  FIG. 14B , but illustrating the non-planar projection of the lower marginal edge portion of the overlying panel located closer to the tapered seat. 
         FIG. 15  is an enlarged view of a portion of the panel of  FIG. 12  showing an embodiment where the second lower marginal portion is located laterally to the side of the first lower marginal portion. 
     
    
    
     While the invention is susceptible of various modifications and alternative constructions, a certain illustrative 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 PREFERRED EMBODIMENT 
     Referring now more particularly to the drawings, there is shown an illustrative wall covering  10  comprising a plurality of panels  11  in accordance with the invention. The panels  11 , which preferably are molded of thermoplastic material, are formed with a simulated stone and mortar design, typical of hand-laid stone masonry. The simulated stone  12  in this case is generally disposed in a plurality of parallel horizontal rows with the stones  12  being isolated from each other by simulated lines of mortar  14 . The stones  12  protrude outwardly of the mortar lines  14 , typical of hand-laid stone, and some of the simulated stones  12  in this instance have a width (i.e. a vertical dimension as viewed in  FIG. 1 ), greater than other of the stones in the row. The simulated stone  12  has irregular outer surfaces consistent with natural stone, and the mortar lines  14  also have a waving, or undulating, non-planar naturally appearing outer surface configuration. While the invention has particular utility in panels formed with simulated masonry, such as hand laid stone or brick, it will be understood that the panels could be made with other forms of simulated building elements, such as shake shingles, tile, or the like. 
     Each illustrated panel  11  has an upper horizontal marginal edge region  18  having a substantially uniform width extending across the top of the panel immediately above the top row of stone  12 , a lower marginal edge region  19  which defines a lower peripheral edge of the simulated pattern, a side marginal edge region  20  located to the right-hand side of the last simulated stone  12  in each row, and a left side marginal edge region  21  on the opposite side of the panel  11 . The left side marginal edge region  21  in this case is defined by the left hand edges of the stone in the respective rows, and the right marginal edge region  20  is defined by an irregular configured flange  27  that extends outwardly from the base of the stone at the right hand ends of the rows. The panels  11  are mounted on a support surface  22 , which may be a wall of a house or other building structure, in horizontal courses with the right-side marginal edge region  20  in underlying relation to the left-side marginal edge region  21  of the panel immediately to the right thereof and with the lower marginal edge regions  19  of the panels in each course overlying the upper marginal edge regions  18  of the panels in a previously installed course immediately below. The panels  11  typically are mounted beginning with the left-hand panel of the lowermost course to be installed on the wall or roof, utilizing a bottom starter strip  31 , as is known in the art ( FIGS. 3 and 5 ). Upon completion of the first course, the second course is installed, immediately above the first course, again starting from the left-hand side. 
     For securing the panels  11  to the support surface  22 , the upper marginal edge region  18  of each panel  11  has a mounting flange  23  parallel to the support surface  22  formed with a row of elongated laterally spaced nail or screw apertures  25 . In order to provide firm support for the mounting flange  23  on the wall surface during fastening, the upper marginal edge region  18  in this instance is formed with a pair of rearwardly extending horizontal sealing flanges  26  which extend substantially the length of the upper marginal edge region  18  on top and bottom sides of the nailing apertures  25  ( FIG. 2 ). For rigidifying the sealing flanges  26 , circular posts  27  interconnect the parallel flanges  26  at spaced intervals along the upper marginal edge region  18  at locations between the nailing apertures  25 . 
     In order to positively interlock the overlapping lower marginal edge region  19  of a panel  11  with an upper marginal edge region  18  of a previously mounted panel  11  when installing the next course of panels, each panel  11  is formed with a plurality of laterally spaced rearwardly and downwardly directed interlock flanges  30  on the underside of the lower marginal edge region  19  of the panel  11  ( FIGS. 2-4 ), which are engageable with the upper marginal edge region mounting flange  23  of the previously mounted panel  11   a  supported in elevated parallel relation to the wall surface  22  by the sealing flanges  26  ( FIGS. 6 and 6A ). For locating the upper panel in predetermined overlying relation to the previously mounted panel  11   a , while permitting thermal expansion and contraction of the panels in a vertical direction, frangible locating pins  33  extend rearwardly from the lower marginal edge region  19  which are positionable into abutting relation to the upper perimeter of the upper marginal edge region mounting flange  23  ( FIGS. 2 and 6 ). 
     In order for the mortar lines  14  of adjacent top and bottom panels  11  to adjoin each other in coplanar closely adjacent relation such that the simulated stone  12  of each of the panels has a substantially uniform depth for a more natural and aesthetic appearance, the lower marginal edge region  19  of the overlying panel  11  is formed with a tapered seating surface  35  ( FIGS. 6-6A ) adapted for mating engagement with a tapered seating surface  36  of the upper marginal edge region  18  of the underlying panel  11 , as disclosed in U.S. Pat. No. 7,587,871, the disclosure of which is incorporated herein by reference. In the illustrated embodiment, the mounting flange  23  of the upper marginal edge region  18  is disposed in recessed relation to the plane of the mortar lines  14 , being supported by a tapered wall  34  that defines the tapered seating surface  36  and the mortar line  14  adjacent to top row of simulated stone has a width substantially corresponding to the width of the mortar lines  14  throughout the panel. The tapered seating surface  35  of the overlying lower marginal edge region  19  intersects the sides of the stone  12  such that upon mating with the tapered seating surface  36  of the underlying panel, the depth of the simulated stone corresponds substantially to the depth of the simulated stone throughout the panels. 
     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 of stone  12  of each panel  11  extend in offset relation to each other so as to define staggered left and right-hand sides of the panel. Nevertheless, as indicated above, heretofore it has been difficult to mold such panels in a manner that enabled reliable inter-engagement of the overlying side marginal edge regions without unsightly or unnatural gaps between the simulated masonry of the adjacently mounted panels. 
     In accordance with an important aspect of the invention, the side marginal edge regions of adjacently mounted panels have an interlock arrangement which simultaneously aligns the panels during installation and which draws the side marginal edge regions into precise tight fitting relation that conceals the juncture between the adjoining panels and defines a naturally appearing mortar line between the simulated stone of the adjacent panels. To this end, the overlying left marginal edge region of each panel is formed with one or more depending hooks or standoffs that are engageable with respective outwardly opening slots in the underlying previously mounted panel which cooperate to align the overlying side marginal edge regions into precise relation to each other while simultaneously drawing the marginal edge regions into secure overlying engagement with each other. In the illustrated embodiment, the overlying left side marginal edge region  21  is formed with a pair of outwardly facing hooks  40   a ,  40   b  depending from an underside thereof, and the right side marginal edge region  20  is formed with a corresponding pair of outwardly opening hook receiving slots  41   a ,  41   b . The hooks  40   a ,  40   b  are disposed at predetermined lateral distances from the left marginal edge  21  of the simulated stone  12 , and the hook receiving slots  41   a ,  41   b  are correspondingly located and formed in the right marginal edge flange. The hook receiving slot  41   a  in this case is formed in the edge of the flange  27 , and the hook receiving slot  41   b  is formed in a larger recess  44  of the flange laterally inwardly up the slot  41   a.    
     The hooks  40   a ,  40   b  have a rigid construction, comprising a support section  45  fixed in depending relation to the underside of the left side marginal edge region  21  and a pair of wings  46  extending outwardly from opposite sides of the support section  45 . The support sections  45  in this instance each have an end wall  48  facing the outer perimeter of the side marginal edge region  21  and a pair of support legs  49  extending rearwardly of the end wall  48 , with the wings  46  each extending outwardly from a respective leg  49  of the support section  45 . For added rigidity, the legs  49  extend in rearwardly of the wings  46  and a vertical reinforcing plate  50  interconnects each wing  46  to the respective support leg  49 . 
     For supporting the right side marginal edge region flange  27  in elevated relation to the support surface  22  on which the panels  10  are mounted and for rigidifying the interengagement between the panels  10 , the right side marginal edge region  20  is formed with pairs of parallel depending flanges  54  on opposite sides of the hook receiving slots  41   a ,  41   b  which in this case extend horizontally. For maintaining the support flanges  54  in secure engaged relation to the support surface prior to installation of the next panel, the right side marginal edge region panel  20  is formed with one or more nailing apertures  53 . The nailing apertures  55  in this case have an elongated configuration oriented at an acute angle to the horizontal for facilitating multidirectional temperature expansion or contraction. 
     For aligning the rows of simulated stone  12  of one panel  10  with the rows of simulated stone on a previously mounted panel as an incident to engagement of the hooks  40   a ,  40   b  with the hook receiving slots  41   a ,  41   b  during installation, the hook receiving slots  41   a ,  41   b  have a V-shaped configuration that narrows in a direction inwardly toward the edge of the panel  10 . For ease of installation, the hooks  40   a ,  40   b  may be positioned into the wide mouths of the slots  41   a ,  41   b , and lateral advancement of the hooks  40   a ,  40   b  into the slots  41   a ,  41   b  will simultaneously move the panel into aligned relation to the previously mounted panel. To facilitate such interengagement and alignment, the depending legs  49  of the hook support section  45  in this case also are angled with respect to each other in a general V configuration. 
     For drawing the side marginal edge regions  20 ,  21  firmly together as the overlying left marginal edge region  21  is moved into mating engagement with the previously mounted panel  10 , the wings  46  are inclined at an acute angle to the substantially horizontal plane of the panel with a trailing end of each wing  46  being disposed more closely to the underside of the panel. It can be seen, therefore, that as the hooks  40   a ,  40   b  enter the respective slots  41   a ,  41   b  the leading edges of the wings  46  move under the right marginal edge region flange  27  with the taper of wings  46  drawing the side marginal edge regions into tight close-fitting relation with each other, as the sides of the V-shaped openings  41   a ,  41   b  simultaneously guide the hooks  40   a ,  40   b  into lateral aligned relation with the previously mounted panel such that the rows of simulated masonry of the adjacent panel, are directed into properly aligned relation to each other. For locating the left side marginal edge region  21  in predetermined overlying relation to the previously mounted panel, while permitting thermal expansion and contraction of the panels  20  in a horizontal direction, frangible locating pins  52  depend from the underside of the left side marginal edge region  21  which are engageable by the right side marginal edge region flange  27 . 
     By virtue of the foregoing side interlock arrangement of the panels  10 , it can be seen that the rows of simulated stone  12  of adjacent panels can be securely and precisely located with a gap corresponding in size to that of the mortar lines  14  throughout the panels. It will be appreciated by one skilled in the art that the side alignment and locking feature may be efficiently and reliably produced by plastic injection molding. Since the side interlocks do not require a small slot or groove under the masonry building element, typical of the prior art, they may be produced without thin plate tooling that can be susceptible to warpage or breakage. 
     In keeping with a further aspect of the invention, the gaps between rows of simulated masonry of adjacent panels is defined by a non-planar or undulating mortar line  55  consistent with the mortar lines  14  throughout the panels, which further conceals the juncture between the panels  12  and which facilitates the interengagement of the panels at that juncture. In the illustrated embodiment, the right side marginal edge region flange  27  is formed with a slightly raised pad  56  adjacent to the periphery of the right hand ends of the simulated stone of each row, which has a non-planar undulating surface corresponding to that of the mortar lines  14  throughout the panel. The overlying left side marginal edge region  21  of each panel  10  further is formed with an undulating surface  58  complementing the surface of the pad  56 . Mating of such corresponding and conforming undulating surfaces  56 ,  58  enable tight interfitting of the engagement panels without unsightly gaps between the mating side marginal edge regions. Instead, the mortar lines defined by the pad  56  closely follows the edges of the simulated stone  12  defined by the left side marginal edge  21  of the overlying panel and further enhance the interengagement of the overlying side marginal edge regions. 
     In keeping with the invention, the simulated masonry has a textured outer surface more characteristic of natural stone or brick. To this end, following molding of the plastic panels, the panels are coated with a paint mixed with suspended sand-like particles. The particles may be made of natural or man-made materials, preferably sized between 0.020 and 0.200 inches. The paint and particle mixture, which may be mixed with a suitable solvent as necessary, may be sprayed by conventional spray guns. As is known in the art, the outer faces of the stone and the separating mortar lines may be separately painted with different colors for the particular application. It will be appreciated by one skilled in the art that the resulting roughened textured surface of the simulated masonry will more closely resemble, both in appearance and feel, natural hand laid masonry. 
     Referring now to  FIGS. 12-14 , another embodiment of the invention is illustrated. Similar reference numbers are used to indicate common elements described above. In this embodiment, the panels  11 , include a lower marginal edge  19  that includes a first lower marginal edge portion  19   a  and a second marginal edge portion  19   b . The first lower marginal edge portion  19   a  defines a non-planar contour for portions  100  of the lower marginal edge with respect to a plane  200  that extends substantially along the lover marginal edge  19 . More particularly, as shown in  FIG. 12 , the lower marginal edge  19  when the panel is viewed on its forward face includes portions  100  that protrude downward beyond other portions  102  which lie substantially along the plane  200  (thereby defining planar contour portions). These non-planar portions provides a visual appearance of a rough stone edge. This has the tendency to break up the visual perception of a distinct seam between upper and lower panels and provides a more natural appearance. 
     As shown in  FIG. 13 , in the area of the non-planar contour portions  100 , the first lower marginal edge portion  19   a  protrudes downward from the second lower marginal edge portion  19   b , which lies substantially along plane  200 . In the areas of the planar contour portions  102 , the first lower marginal edge portion  19   a  lies substantially along plane  200  and in lie with the second lower marginal edge portion. 
       FIGS. 14 ,  14 A and  14 B show the assembly of the panels  11  in this embodiment and how the projection of the first lower marginal edge portion  19   a  obscures the location of the seam  150 . Specifically, the first lower marginal edge  19   a  in the non-planar region  100  preferably protrudes downward a distance D 1  from the second lower marginal edge portion  19   b . In order to prevent interference between panels, the projection D 1  is less than the defined mortar spacing M that forms between the panels thus leaving a gap D 2 . Preferably the distance D 1  is greater than 0.020 inches and less than 0.250 inches, and more preferably between 0.50 inches and 0.200 inches. 
     While  FIGS. 14 ,  14 A and  14 B illustrate the non-planar first lower marginal edge portion  19   a  located forward of the second lower marginal edge portion  19   b , it is also contemplated that the first lower marginal edge portion  19   a  may extend the entire width of the cross-section or be located immediately adjacent to the tapered seating surface  35 , as shown in  FIG. 14C , and the second lower marginal edge portion  19   b  may be located in the planar portions  102  on the lateral sides of the first lower marginal edge portion  19   a , as shown in  FIG. 15 . 
     From the foregoing, it can be seen that a wall covering is provided that comprises plastic injection molded panels formed with rows of simulated masonry that can be efficiently installed with a more aesthetic and natural appearance. The spacing and alignment of simulated stone or brick of adjacently mounted panels can be more tightly and precisely controlled for a more natural appearance. The gaps between masonry of adjacently mounted panels, furthermore, is defined by mortar lines consistent with the mortar lines separating the stone or brick masonry throughout the panels. The simulated masonry further has a textured surface appearance more characteristic of natural stone or brick. Yet, the wall panels further are adapted for economical manufacture and more robust interlocking of overlapping side marginal edge regions of the panel.