Patent Publication Number: US-9890538-B2

Title: Siding panel system with full depth keyways

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of application Ser. No. 14/252,869, filed Apr. 15, 2014, which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to siding or roofing panel systems for attachment to mounting surfaces. 
     BACKGROUND 
     Exterior siding or roofing systems may include a plurality of panels, with each of the panels formed to simulate a plurality of individual decorative units. For example, each panel may emulate a plurality of wooden shakes or shingles. As such, each decorative unit is formed to simulate a single shake or shingle. Furthermore, the decorative units may be formed to simulate other siding materials, including stone, tile, et cetera. 
     SUMMARY 
     A panel or panel system configured for attachment to a mounting surface is provided. The panel includes a plurality of raised faces formed, and extending substantially continuously between, an upper edge and a lower edge of the panel. The raised faces define a face plane. 
     A shoulder is defined on the raised faces adjacent the upper edge. The shoulder is configured to be spaced from the mounting surface by a shoulder offset, such that the face plane is also spaced from the mounting surface by the shoulder offset at the shoulder of the raised faces. 
     A plurality of keyways are defined between each of the raised faces. The keyways are recessed from the face plane of the raised faces. The keyways are configured to be spaced from the mounting surface by a bottom keyway offset adjacent to the lower edge. 
     The bottom keyway offset is substantially equal to the shoulder offset. Therefore, the face plane of the raised faces at the upper edge of the panel is spaced from the mounting surface by substantially the same distance as the keyways are spaced from the mounting surface at the lower edge of the panel. 
     The above features and advantages, and other features and advantages, of the present invention are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the invention, which is defined solely by the appended claims, when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic plan view of a siding system having a plurality of panels; 
         FIG. 2  is a schematic cross-sectional view taken generally along line  2 - 2  of  FIG. 1 ; 
         FIG. 3A  is a schematic detail view from area A of  FIG. 2 , illustrating a keyway-lap intersection between the panels; 
         FIG. 3B  is a schematic detail view from area B of  FIG. 2 , illustrating an intersection without the keyway-lap between the panels; and 
         FIG. 4  is a schematic plan view of a panel for a siding system, illustrating locations of elements and features of the panel. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, like reference numbers correspond to like or similar components wherever possible throughout the several figures. There is shown in  FIG. 1  a siding system  10  for attachment to a mounting surface  12 . The siding system  10  may alternatively be attached to roofs or angled walls, such that the mounting surface  12  may be an angled wall or a roof surface. 
     The siding system  10  includes at least a first panel  14  and a second panel  16 , and likely includes a third panel  18 . The second panel  16  and the third panel  18  have similar features to the first panel  14 , such that they may be referred to collectively or generically as panels  19 . Each of the panels  19  is formed from a substrate material having substantially-constant thickness. The rearward side of the panels  19  define a mounting plane, particularly when assembled to each other, which may be substantially coincident with the mounting surface  12 . 
     While the present invention may be described with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the invention. Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” et cetera, are used descriptively of the figures, and do not represent limitations on the scope of the invention, as defined by the appended claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the invention in any way. 
     Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Furthermore, no features, elements, or limitations are absolutely required for operation. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting of the claims or the description. 
     Referring also to  FIG. 2 , and with continued reference to  FIG. 1 , there is shown a schematic side view of portions of the siding system  10 .  FIG. 2  shows a cross-sectional view of the first panel  14 , the second panel  16 , and the third panel  18 . 
     Features of the first panel  14 , the second panel  16 , and the third panel  18  will be described with reference to  FIG. 1  and  FIG. 2 . The described features of the panels  19  may refer to any of the first panel  14 , the second panel  16 , or the third panel  18 . Note that manufacturing variance may lead to natural differences between panels  19  that are, otherwise, intended to be identical. 
     The panels  19  may be formed from different types of plastic or composite materials. For example, and without limitation, the panels  19  may be formed from vinyl, polypropylene, et cetera. Furthermore, the panels  19  may be formed as unitary, one-piece components, such that each of the first panel  14 , the second panel  16 , and the third panel  18  is a single component formed from a single piece of material (a single substrate), without subsequent attachment of pieces formed separately to complete each of first panel  14 , the second panel  16 , and the third panel  18 . 
     The panels  19  include a fastener edge or lock edge  20  defined along one edge, and is shown on a top or upper edge in  FIGS. 1 and 2 . A lap edge or butt edge  22  is defined opposite the lock edge  20 , and is shown on a bottom or lower edge in  FIGS. 1 and 2 . As viewed in the figures, the lock edge  20  is toward the top of each panel  19  and the butt edge  22  is toward the bottom of each panel  19 . References to upper and lower directions, regions, or portions are defined relative to gravity and, therefore, to the general flow direction of water or moisture over the panels  19  and the structures to which they are mounted (although wind may cause water to move opposite gravity). 
     The lock edge  20  contacts the mounting surface  12  and has a plurality of fastener holes  24  defined there through. The fastener holes  24  are configured to mount the panels  19  to the mounting surface  12  with a plurality of fasteners  25 , which may include nails, screws, staples, et cetera. The fastener holes  24 , fasteners  25 , and mounting surface  12  are shown schematically in  FIG. 2  to illustrate attachment. In some embodiments, the fastener holes  24  may not be fully defined through the lock edge  20  but may instead be areas designated or identified for piercing by the fasteners  25 , such that the fasteners at least partially pierce the material forming the panels  19 . 
     A plurality of raised faces  26  are formed between the lock edge  20  and the butt edge  22 . The raised faces  26  shown generally simulate wooden shingles, and have variable widths, as shown in  FIG. 1 . The raised faces  26  generally define a plane or face plane  27 , as illustrated by dashed lines extending from the raised face  26  of the first panel  14  in  FIGS. 2 and 3A  and the third panel  18  in  FIG. 2 , and as viewable in other figures and on other panels. Leftward of the face plane  27 , as viewed in the figures, is a side of the raised faces  26  that is opposite, or facing away, from the mounting surface  12 ; this side may be referred to as an outside  27   a  of the panels  19 . Similarly, rightward of the face plane  27 , as viewed in the figures, is a side of the raised faces  26  that is nearer to, or facing toward, the mounting surface  12 ; this side may be referred to as an inside  27   b  of the panels  19 . The raised faces  26  may be designed to represent other decorative units, including shakes, tiles, et cetera. 
     A plurality of recessed keyways  28  are formed between each of the raised faces  26 . The keyways  28  define grooves or channels and link each of the raised faces  26 . The keyways  28  are formed from the same substrate material as the raised faces  26  and are recessed from the raised faces  26  toward the mounting surface  12  or the mounting plane that represents the mounting surface  12  to which the panels  19  may subsequently be attached. The keyways  28  may simulate the empty horizontal gap between individual wooden shingles in traditional shingle siding. 
     Note that the second panel  16  may have raised faces  26  of different size, number, or both, relative to the first panel  14 . Such that the keyways  28  may be spaced at different intervals on each of the panels  19 . Furthermore, even on panels intended to be identical, such as multiple copies of the first panel  14 , manufacturing differences may exist. 
     The keyways  28  are staggered such that they appear to be randomly located, in order to better approximate the aesthetics of natural wooden shingles. The patterns of the keyways  28  vary across a pre-set number of panels  19 , which are then assembled onto the mounting surface to approximate wooden shingles. Ideally, the keyways  28  of vertically-adjacent panels  19  never align, irrespective of the order in which the first panel  14 , the second panel  16 , and the third panel  18  are assembled, and irrespective of staggering or cut-off lines on the panels  19 . 
     The keyways  28  are located on the various panels  19  based upon a formula or algorithm. Illustrative formulas or algorithms for locating the keyways  28  may be found in U.S. patent application Ser. No. 13/746,133, filed Jan. 21, 2013, the entirety of which is hereby incorporated by reference. 
     A side lap  30  is formed on the edge of the panels  19 . The side lap  30  facilitates horizontal assembly or mating of the panels  19 . For example, another panel  19  may be placed to the right of the first panel  14  and would cover the side lap  30  on the first panel  14 . 
     Referring also to  FIG. 3A  and  FIG. 3B , and with continued reference to  FIGS. 1-2 , there are shown detail views of junctions or mating regions between adjacent panels  19 .  FIG. 3A  shows a zoomed or detail view of the intersection between the lock edge  20  of the first panel  14  and the butt edge  22  of the second panel  16 , and illustrates the interaction between keyways  28  and the lock edges  20 . The view of  FIG. 3A  is taken generally from area  3 A in  FIG. 2 .  FIG. 3B  shows a zoomed or detail view of the intersection between the lock edge  20  of the second panel  16  and the butt edge  22  of the third panel  18 , and illustrates intersections without keyways  28 . The view of  FIG. 3B  is taken generally from area  3 B in  FIG. 2 . 
     The raised faces  26  define a shoulder  32  adjacent to the lock edge  20 . The shoulder  32  is spaced from the mounting surface  12  by a shoulder offset  34 . A plurality of face walls  35  provide structures spacing the raised faces  26  from the mounting surface  12 , as shown adjacent the shoulder  32  in  FIG. 3A . As shown in the figures, the shoulder offset  34  is measured on the raised faces  26 , at the face plane  27 , as opposed to nearer the mounting surface  12  or elsewhere along the face walls  35 . Alternatively stated, and as viewed in the figures, the shoulder offset  34  is defined on the side of the raised faces  26  that is opposite the mounting surface  12 . Furthermore, the shoulder  32  provides an abutment face or surface for interface between the lock edge  20  of one of the panels  19  and the butt edge  22  of another of the panels  19 . 
     The keyways  28  are spaced from the mounting surface  12  by a top keyway offset  36  adjacent to the lock edge  20  and by a bottom keyway offset  38  adjacent to the butt edge  22 . A plurality of wall or keyway walls  39  provide structures spacing the keyways  28  from the mounting surface  12 , as shown adjacent bottom keyway offset  38  in  FIG. 3A . As shown in the figures, both the top keyway offset  36  and the bottom keyway offset  38  are measured from the side of the keyways  28  that is opposite the mounting surface  12 , which is to the left in the figures, as opposed to the side of the keyways  28  nearer the mounting surface  12 . In the configuration of the panels  19  shown, the bottom keyway offset  38  is substantially equal to the shoulder offset  34 . Note that, as shown in the figures, both the bottom keyway offset  38  and the shoulder offset  34  are measured from the mounting surface  12  or mounting plane formed by the rearward side of the panels  19 . 
     Alignment of the bottom keyway offset  38  and the shoulder offset  34  also applies to panels  19  having the lock edge  20  and the butt edge  22  reversed, such that the panels  19  are fastened at the bottom. Furthermore, configurations of panels  19  that do not include the lock edge  20 —such as head-lap configurations where there is no direct locking between vertically-adjacent panels—may still have the bottom keyway offset  38  substantially equal to the shoulder offset  34 . 
     Alternatively, the bottom keyway offset  38  may be measured from the back side of the panels  19 , such that the shoulder offset  34  is substantially equal to the bottom keyway offset  38  plus the thickness of the substrate forming the panels  19 . Therefore, the bottom of the keyway  28  on the second panel  16  is substantially aligned with the shoulder  32  of the first panel  14 , which simulates the look of two wooden shingles partially covering and overlapping a lower wooden shingle. 
     As used herein, substantially equal refers to quantities, values, or dimensions that are within manufacturing variance or tolerance ranges of being perfectly equal. Substantially equal dimensions, for example, may be planned as ideally equal but normal manufacturing tolerances may cause the resulting dimensions to vary by 10-20% for different pieces. 
     Depending on the materials and the surface textures of the panels  19 , the bottom keyway offset  38  may differ from the shoulder offset  34  by up to 10% in many configurations. In systems with surface textures having very aggressive wood grains, the bottom keyway offset  38  may differ from the shoulder offset  34  by up to 15% and still be considered as substantially equal because the visual appearance will still show that the bottom of the keyway  28  on the second panel  16  is substantially aligned with the shoulder  32  of the first panel  14  to simulate natural wooden shingles. 
     A lock flange  40  is formed on the lock edge  20  and extends away from the mounting surface  12 . Although not generally needed to hold the first panel  14  to the mounting surface  12  with the fastener  25 , the lock flange  40  creates depth or thickness from the mounting surface  12  at the lock edge  20 . 
     A lock slot  42 , or overlap portion, is formed on the lock edge  20  and at least partially defined by the lock flange  40 . The lock slot  42  opens toward the butt edge  22 . As shown in the figures, the butt edge  22  of the second panel  16  mates with the lock flange  40  of the first panel  14 . 
     A lock tab  44  is also formed on the lock flange  40  and extends at an angle to the mounting surface  12 . The lock tab  44  is spaced from the mounting surface  12  by a lock flange offset  46 , which is determined at the furthest edge of the lock tab  44 , as shown in  FIG. 2 . 
     Assembly of the illustrated siding system  10  may involve a bottom-up process. For example, the first panel  14  may be aligned on the mounting surface  12  and then attached by driving fasteners  25  through the fastener holes  24 . Additional panels may then be placed to the right or left, as viewed in  FIG. 1 , of the first panel  14  and attached to the mounting surface  12 . Therefore, the first panel  14  may be part of a first course or first row, which extends horizontally from the first panel  14 . 
     A second course of panels may then be placed on the mounting surface  12  above the first course. The second panel  16  is aligned above the first panel  14 , as viewed in  FIG. 1  and  FIG. 2 . The lock tab  44  of the second panel  16  is inserted into the lock slot  42  of the first panel  14 . The butt edge  22  of the second panel  16  is aligned to generally abut the top of the raised faces  26  of the first panel  14 . This gives the appearance that the second panel  16  is formed from individual wood shingles laid partially over the top of wood shingles below, on the first panel  14 . 
     The butt edge  22  shown includes a lap portion  48 , which is used to interface the second panel  16  with the first panel  14 . The lap portion  48  slides into the lock slot  42 . During installation, the lap portion  48  of the second panel  16  is inserted into the lock slot  42  of the first panel  14 , and fasteners  25  are then inserted though the fastener holes  24  to affix the second panel  16  to the mounting surface  12 . 
     The lock flange offset  46  of the lock tab  44  is greater than the bottom keyway offset  38 . Therefore, the panels  19  are configured such that the keyways  28  of the second panel  16  cannot be coincident with the lock tab  44  of the first panel  14 . Otherwise, the installer may not be able to assemble the second panel  16  to the first panel  14 . 
     The panels  19  include a plurality of flange cutouts  50  defined in the lock edge  20 . The flange cutouts  50  on the first panel  14  and the second panel  16  are hidden from view in  FIG. 1 , but are viewable on the upper portion of the third panel  18  in  FIG. 1 . Portions of the flange cutouts  50  are also viewable in the cross-sectional views. 
     The flange cutouts  50  are portions of the lock edge  20  that do not include at least the lock tab  44  of the lock flange  40 . Therefore, the flange cutouts  50  provide space for the keyways  28  of adjacent, upper panels  19  to be assembled or mated to the lock flange  40 , as illustrated by the intersection between the first panel  14  and the second panel  16  shown in  FIG. 3A . The back side of the keyways  28  of the third panel  18  are shown in solid lines in  FIG. 3B , with the front side shown in phantom. As illustrated in  FIG. 3B , the lock tab  44  extends further from the mounting surface  12 —and into the space behind the raised faces  26 —than the keyways  28 . 
     The flange cutouts  50  formed on the first panel  14  provide space for the keyways  28  of the second panel  16 . Otherwise, the backside of the keyways  28  of the second panel  16  would contact the lock tab  44  of the first panel  14 . The flange cutouts  50  shown in the figures are generally arch-shaped. However, the flange cutouts may be rectangular, trapezoidal, or other suitable shapes defining space for the keyways  28  of adjacent panels  19 . 
     As best viewed in the  FIG. 3B  on the second panel  16 , the fastener holes  24  pass through two layers of the material forming the panels  19 , such that each fastener  25  passes through two fastener holes  24 . In many configurations, the panels  19  will be manufactured by folding the lock flange  40  to formed the lock slot  42  during forming of the panel  19 , and the fastener holes  24  may be formed prior to the folding operation. Therefore, an interior portion (to the right, as viewed in  FIG. 3B ) of the fastener hole  24  may be formed with a larger diameter than an exterior portion (to the left, as viewed in  FIG. 3B ). 
     The escalating-diameter configuration of the fastener holes  24  shown in  FIG. 3B  improves installation when manufacturing variability alters the location of one, or both, of the fastener holes  24 . The smaller hole is more likely to be coincident with the larger hole if either is offset, but the smaller hole still provides surface contact for the head of the fastener  25 . 
     Additionally, as best viewed on the third panel  18  in  FIG. 1 , the fastener holes  24  may not be formed in areas where adjacent keyways  28  will intersect the third panel  18 . Location of the fastener holes  24  is also illustrated through a comparison of the portion of the lock edge  20  of the first panel  14  shown in  FIG. 3A  with the portion of the lock edge  20  of the second panel  16  shown in  FIG. 3B . 
     The fasteners  25  will often not be driven tightly against the lock flange  40 . Leaving the fasteners  25  extended slightly may allow for slight movement, expansion, and contraction of the panels  19 . However, the fasteners  25  may then come into contact with keyways  28  from subsequently-added panels  19 . Therefore, in areas where an adjacent keyway  28  will intersect the first panel  14 , as shown in  FIG. 3A , there are no fastener holes  24 , such that an installer will not insert the fastener  25  in those areas. However, where there is no keyway  28  adjacent to the second panel  16 , as shown in  FIG. 3B , there is sufficient room for the fastener  25  to extend away from the mounting surface  12 . The fastener  25  viewable in  FIG. 3A  is in the background from the plane of the cross section. 
     As best viewed in  FIG. 1  (and also in  FIG. 4 ) the panels  19  may be configured such that there are no fastener holes  24  formed through the lock edge  20  above the flange cutouts  50 . Both the flange cutouts  50  and the portions of the lock flange  40  formed without the fastener holes  24  are located at areas in which adjacent keyways  28  of the subsequent panel  19  will intersect. Therefore, the flange cutouts  50  and fastener holes  24  (or lack thereof) are located based upon the formula or algorithm used to located the keyways  28  on the various panels  19 . 
     Referring now to  FIG. 4 , and with continued reference to  FIGS. 1-3B , there is shown a schematic view of a panel  119 , which may be used with the siding system  10 . The panel  119  is similar to the panels  19  and identical or similar features to those described with respect to the panels  19  may not be separately described. 
     The panel  119  includes a lock edge  120  defined along one edge, and is shown on the upper edge in  FIG. 4 . A butt edge  122  is defined opposite the lock edge  120 , and is shown on the lower edge in  FIG. 4 . The lock edge  120  has a plurality of fastener holes configured to mount the panels  119  to a mounting surface (not shown or numbered) with a plurality of fasteners (not shown), which may include nails, screws, staples, et cetera. 
     A plurality of raised faces  126  are formed between the lock edge  120  and the butt edge  122 . The raised faces  126  shown generally simulate wooden shingles, and have variable widths, as shown in  FIG. 4 . The raised faces  126  may be designed to represent other decorative units, including shakes, tiles, et cetera. A plurality of keyways  128  are recessed between each of the raised faces  126  and link or form connections between each of the raised faces  126 . The keyways  128  extend from the raised faces  126  toward the mounting surface  112 , and may simulate the empty space between conventional shingles. 
     A side lap  130  is formed on the edge of the panel  119 . The side lap  130  facilitates horizontal assembly or mating of multiple panels  119 . A lock flange  140  is formed on the lock edge  120  and extends away from the mounting surface  112 . The lock flange  140  creates depth or thickness from the mounting surface at the lock edge  120  and includes a lock tab  144 . The lock flange  140  mates with the butt edge  122  of adjacent panels  119 . 
     A plurality of flange cutouts  150  are defined in the lock edge  120  of the panel  119 . The flange cutouts  150  are portions of the lock edge  120  that do not include at least a portion of the lock flange  140 , particularly the lock tab  144 . Therefore, the flange cutouts  150  provide space for the keyways  128  of adjacent, upper panels  119  to be assembled or mated to the lock flange  140 . 
     The keyways  128  are located based upon an algorithm or formula and vary in relative location across the panel  119 . Therefore, unless subsequent panels  119  will be assembled in a very specific pattern, which may be cumbersome on installers, the exact location of the keyways  128  for the subsequent panel that will be assembled above the panel  119  are unknown. A plurality of subsequent keyways  128 ′ are illustrated in phantom above a portion of the panel  119  in  FIG. 4 . 
     As shown in  FIG. 4 , the panel  119  defines a panel length (PL)  152 , which is the sum of widths of the raised faces  126  and the keyways  128 . The number of the raised faces  126 , and also of the keyways  128 , defines a number (n) of shingles represented on the panel  119 . As shown in  FIG. 4 , there are nine shingles on the panel  119 , such that n=9. Dividing the number of shingles by the panel length  152  yields an average shingle distance (ASD)  154 , such that ASD=PL/n. 
     The keyways  128  are not spaced from each other by the ASD, such that the distance between keyways  128  varies. However, a few of the keyways  128  nearly coincide with the actual average shingle distances, as shown in  FIG. 4 . Several of the keyways  128  are spaced by greater margins than the ASD and several are spaced by smaller margins. 
     An average center  156  is located at the center of each ASD  154 , and represents the average location of the center of each of the shingles. The flange cutouts  150  are located at the average centers  156 . The flange cutouts  150  are located to ensure that the subsequent keyways  128 ′ do not intersect the lock tab  144  of the lock flange  140 . Contact between the lock tab  144  and the subsequent keyways  128 ′ may prevent the next panel  119  from being properly installed. 
     As illustrated with the panel system  10  shown in  FIG. 1 , multiple—although not identical—panels  119  are layered upon each other. Subsequent courses of panels may be offset by any multiple of ½ ASD, which will result in the subsequent keyways  128 ′ of the subsequent (upper) panels  119  coinciding with some portion of the flange cutouts  150 . 
     Additionally, a cutout width (CW) of the flange cutouts  150  is sized to account for the variability of the subsequent keyways  128 ′. Large (wide) flange cutouts  150  allow for greater flexibility of location for the subsequent keyways  128 ′. However, large flange cutouts  150  also reduce the rigidity of the panel  119  by removing portions of the lock flange  140  and the lock tab  144 . Furthermore, in configurations where the fastener holes  124  are removed, large flange cutouts  150  also reduce the availability of attachment points by reducing the number of fastener holes  124  for the panels  119  to the mounting surface. 
     Numerical examples of the panels  119  are given herein, for illustrative purposes only, to demonstrate location and sizing of the flange cutouts  150 . The panel length  152  of the panel  119  shown in  FIG. 4  may be PL=60 inches. Therefore, because ASD=PL/n, the ASD is approximately 6.67 inches, such that the flange cutouts  150  are spaced apart by 6.67 inches. 
     The keyways  128  and subsequent keyways  128 ′ may be located based upon an algorithm that limits the width of the shingles to between a shingle minimum (S_min) and a shingle maximum (S_max). For example, S_min may be approximately 5 inches and S_max may be approximately 8 inches. 
     Within the same panel  119 , the flange cutouts  150  do not intersect or overlap with the keyways  128 . Therefore, one scheme for sizing the flange cutouts  150  would be to extend them over substantially the entire width of the raised faces  126 , such that each flange cutout  150  spanned from the edge of one keyway  128  to the edge of another. However, this would result in flange cutouts  150  having variable widths, which may increase manufacturing difficulty, and would severely limit the number of fastener holes  124 . 
     The width of the flange cutouts  150  may also be determined as a percentage or ratio of either the maximum shingle width or the minimum shingle width. For example, the cutout width (CW) may be less than 60% of the minimum shingle width, such that CW=0.6*S_min, which is approximately 3 inches. CW may also be determined as less than 40% of the maximum shingle width, such that CW=0.4*S_max, which is approximately 3.2 inches. 
     Alternatively, the cutout width (CW) may be based upon the allowable overlap or stacking differential for the keyways  128 . An allowable keyway offset (KO) of the keyways  128  is the minimum distance at which vertically-adjacent keyways  128  will be considered as “stacked.” If the KO is 1 inch, no subsequent keyway  128 ′ may be with 1 inch of any of the keyways  128 . Otherwise, the subsequent keyway  128 ′ would be considered as stacked (i.e., vertically-aligned) with the keyway  128 , which would not occur with properly-assembled natural wooden shingles. Therefore, the width of the flange cutouts  150  may be determined as: CW=S_min−(2*KO), which is 3 inches in the above illustration. 
     The detailed description and the drawings or figures are supportive and descriptive of the invention, but the scope of the invention is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed invention have been described in detail, various alternative designs, configurations, and embodiments exist for practicing the invention defined in the appended claims.