Patent Publication Number: US-6336303-B1

Title: Injection molded exterior siding panel with positioning relief and method of installation

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The field of the present invention relates to decorative exterior wall coverings. In particular, the present invention relates to injection molded siding panels that have improved, integrally formed attachment elements that facilitate easier installation. 
     2. Background Art 
     Many types of exterior wall panels are currently known and used in the construction and improvement of residential, commercial, industrial, and other buildings. Typically, such panels are formed from a lightweight composite plastic material and are manufactured using conventional extrusion molding, injection molding, impression molding, and thermotorminy processes. Such panels may be formed in various shapes, such as individual elongated sections similar to standard aluminum siding, or single panels incorporating one or more rows of individual decorative elements. These single panels are often connected to other previously installed, identical panels through a vertical attachment and a horizontal attachment by which portions of the panel to be installed overlap portions of previously installed panels. 
     Prior known panel designs employ vertical side and horizontal bottom connections that must both be viewed and fitted simultaneously by the installer during installation. A problem with these designs is that the installation of such panels is difficult because the installer can only view one connection at a time. Often the installer will attempt to circumvent this problem by first connecting only the vertical side or the horizontal bottom, only to discover that the remaining connection either cannot then be attached, or will cause the initial connection to slip out of place. 
     In addition, prior known panel designs have both side and bottom connections that require a precise fit. Installation of these panels with such precise connections is difficult for several reasons. For example, often an entire row of connections must be attached along the vertical side or horizontal bottom of a panel, necessitating frequent checking and adjusting as the panel is maneuvered into its installed position. Also, this problem is exacerbated by the need for such panels to overlap in order to conceal their attachment points because such connections are hidden from the installer as they are attached during installation. The installer is often forced either to position his head in an awkward viewing position near the wall surface when fitting the panel into position, or even to blindly “feel” the panel into position with his hands by fitting each connection without actually viewing the connections as they are attached. In addition, this difficulty is further exacerbated when the vertical side and horizontal bottom connections have to be viewed simultaneously when attached, as described above. 
     Further, prior panels have employed fastener attachments located on the rear of the panel that have no logical relation to reference elements on the front side of the panel. For example, one prior design comprises a series of tabs spaced at intervals on the rear side of the panel that do not correspond to the arrangement of any elements or reference points on the front side. This problem hampers installation because, as described above, those elements are hidden from the installer during installation, and the installer cannot, by simply looking at the front of the panel, identify the locations of the attachment elements on the rear of the panel. 
     Prior known panel designs have also employed connections that lock firmly into place upon attachment. A problem with such connections is that they are rigid, and cannot accommodate the inevitable movement associated with thermal expansion or the settling of the underlying wall surface after the panels are installed. 
     Finally, prior panel designs have been difficult to cut, trim, or otherwise adjust to fit into tight areas along a wall surface, such as within the gable of a roof line, or the area surrounding windows and other surface irregularities. Some existing panels may only be cut in certain structurally designated locations without compromising their overall structural integrity. Other panels are made of materials that are difficult to cut, occasionally requiring certain types of saws and saw blades. 
     SUMMARY OF THE INVENTION 
     The present invention provides an exterior siding panel with positioning relief comprised of external rows of decorative elements that may be used in conjunction with other panels to form a continuous sided surface along a wall. Along the top of each panel relatively wide rectangular apertures are spaced at intervals to receive relatively narrow complimentary tabs spaced on the lower rear portions of an overlapping panel to provide positioning relief. The sides of the panels are also connected by a discontinuous, tongue-and-groove apparatus where one connection is made on the side edge of the lower row of elements and a second connection is made on the side edge of the upper row of elements. These two side connections connections fit over an area of overlap, with one side of the panel underlying an overlapping portion on an adjacent complimentary panel. 
     The relatively wider receiving apertures on an installed panel provide a free lateral pace, allowing a wider margin for the insertion of the relatively narrower tabs on the lower rear portion of the panel being installed, as the installer cannot directly view these connections as they are effected. These relatively wide receiving apertures are disposed through the panel at an angle that slopes downward from the front side of the panel to the rear side. This angle allows the tabs of an overlapping panel to pass horizontally through the apertures while simultaneously accommodating the vertical downward movement of the tabs behind the rear panel surface. This aids installation by eliminating the two step process that would be necessitated by a horizontally level aperture, comprising a first step of pushing the tabs horizontally through the apertures, followed by a second vertical downward shifting of the panel to move the tabs downward behind the rear surface of an underlying panel. 
     The tongue-and-groove apparatus, although partially hidden from the installer during installation, allows for the easier side attachment of horizontally adjacent panels because it consists of only two complimentary connections. The tongue-and-groove apparatus further provides for easier installation because the tongues on the sides of the panels are longer than the complimentary grooves on adjacent connecting panels. This eliminates the need to fit the tongues into the grooves along the entire length of the tongues. 
     The relatively narrow tabs on the rear of the panel are each located directly behind the center of a decorative element. Therefore, although these tabs are necessarily hidden from the installer during installation, the installer, by simply viewing the decorative elements on the front side, can identify precisely where each tab on the rear side is located. 
     The horizontal tab and aperture connections and the vertical tongue-and-groove connections are not firmly or rigidly attached, and can accommodate shifting and other movement of the panels along the attachment points, while still maintaining the overall connections of the panels on the wall surface. These attachment methods provide a wall covering comprised of a plurality of panels that is more resistant to the shifting of the panels after installation due to thermal expansion or the settling of the underlying wall surface. 
     The panels may be installed by either of two methods. The first method eliminates the need to make simultaneous horizontal and vertical connections. Using this method, first the relatively narrow tabs on the bottom rear of a panel are inserted vertically directly downward into the relatively wider rectangular apertures in a second previously installed lower panel, bringing the panel to rest on top of the previously installed lower panel. The grooves of the panel are automatically aligned with the tongues of a horizontally adjacent, previously installed third panel when the panel is resting on the previously installed lower panel. The panel is then shifted directly horizontally, engaging the tongue-and-groove connections with the horizontally adjacent third panel. 
     The second installation method allows the panels to be mounted onto previously installed panels from a variety of approach angles without requiring the installer to view two simultaneous connections. The panel is installed by first initially inserting the tongues of the panel into the corresponding side grooves of a previously installed, horizontally adjacent panel. The installer then rocks the panel into position by rotating the panel in a clockwise direction, and inserting the relatively narrow tabs on the lower rear of the panel into the relatively wider apertures along the upper front of a vertically adjacent panel while completing the insertion of the tongue of the panel into the groove of the horizontally adjacent panel. The installer need only view the side tongue-and-groove connection because the free lateral space provided by the relatively wider receiving apertures in the vertically adjacent lower panel accommodate the wider range of motion of the tab. 
     Finally, the panels can be easily manufactured using known injection molding processes and comprise a single piece of injection molded material. The panels are composed of a rigid, firm composition that is resistant to impacts on the front side of the panel after installation, yet is capable of being easily cut during installation using most standard saw blades along horizontal, vertical, or diagonal directions without cracking, shattering or otherwise damaging the panel. This ability to be cut in any location allows the panels to be custom fit to cover awkward or cramped areas of a wall surface such as the gable of a roof line, or around and between windows, doors, and other surface irregularities. The synthetic composition of the panel is weather-resistant, does not require painting, and the synthetic composition further prevents the panel from acting as a host for termites, carpenter ants, or other pests. 
     In one form, the present invention is a siding panel comprising decorative elements, apertures, and tabs. The decorative elements are formed with the panel and disposed in at least one row, defining a front face of the siding panel. A top edge is disposed above a row of decorative elements. The apertures are formed in said panel and disposed below the top edge and on a rear side of said siding panel. The tabs are each narrower than the apertures to provide positioning relief, with the tabs formed with the panel depending downward from the rear side and spaced in intervals corresponding to the apertures. 
     In another form, the present invention is a plurality of siding panels forming siding for a building. Each panel comprises horizontal upper and lower edges, and vertical first and second lateral side edges offset such that the side edges are discontinuous. Apertures are disposed beneath the upper edges spaced at intervals, and tabs which are narrower than the apertures depend downward and are disposed above the lower edges being spaced at intervals complimentary to the apertures. Also, side tabs are disposed on a side edge, the side tabs defining discontinuous groove spaces. Tongues extend from the other side edge to engage the side tabs. 
     In another form, the present invention relates to a method of installing a wall covering formed of plurality of horizontal courses of siding panels. This method involves first installing first and second panels relatively diagonally so the first panel is lower and laterally offset from the second panel. Next, a third panel is installed by a series of steps: (A) inserting tabs on the rear the front face of the third panel into apertures of the first lower panel then shifting the third panel horizontally, engaging grooves of the third panel with tongues of the second laterally adjacent panel; or (B) initiating engagement of grooves of the third panel with tongues of the second laterally adjacent panel and concurrently inserting tabs on the rear of the third panel into apertures of the first lower panel, while concurrently completing engagement of grooves of the third panel with tongues of the second laterally adjacent panel. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of an exemplary embodiment of the invention taken in conjunction with the accompanying drawings, wherein: 
     FIG. 1 is a front elevation of a panel illustrating the relatively wide rectangular apertures and the tongues along the right edge, and also showing in dashed lines both the relatively narrow tabs near the lower edge, and the tabs on the rear of the panel near the left side that define the grooves along the left edge. 
     FIG. 2 is a rear elevation of a panel illustrating the relatively wide rectangular apertures, the tongues along the left edge, the relatively narrow tabs near the lower edge, and the groove connections along the right edge. 
     FIG. 3 is a sectional drawing taken through the line  3 — 3  of FIG.  1  and viewed in the direction of the arrows. 
     FIG. 4 is a perspective rear view of a plurality of panels installed in an interfitting manner, illustrating the side tongue-and-groove attachments. 
     FIG. 5 is a plan view of a plurality of panels installed on a wall surface, with one panel shown separated from the others in a position illustrating a first method of installation. 
     FIG. 6 is a plan view of a plurality of panels installed on a wall surface, with one panel shown separated from the others in a position illustrating a second method of installation. 
     Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent an exemplary embodiment of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplification set out herein illustrates an exemplary embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The exemplary embodiment disclosed below is not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the exemplary embodiment is chosen and described so that others skilled in the art may utilize its teachings. 
     The present invention provides injection molded exterior siding panels that facilitate easier installation by incorporating relatively wide rectangular apertures along the top of each panel to receive relatively narrow complimentary tabs spaced on the lower rear of an overlapping second panel, as well as a side attachment comprising a discontinuous tongue-and groove-apparatus. 
     The structure of the inventive panels is depicted in FIGS. 1 and 2, showing front and rear elevations of such a panel. Panel  10  comprises top portion  12 , bottom portion  14 , right side portion  16 , and left side portion  18 . Along front side  20  of panel  10 , decorative elements  24  are arranged in upper row  26  and lower row  28 . However, further embodiments in the form of panels comprising only a single row of decorative elements  24  or three or more rows of decorative elements  24  may be designed in accordance with the present invention as hereinafter described. Returning to the exemplary embodiment, upper row  26  and lower row  28  of decorative elements  24  are offset, resulting in a discontinuous left edge portions  30  and a discontinuous right edge portions  32  of panel  10 . Decorative elements  24  which are depicted in FIGS. 1 and 2 show an un-ornamental smooth facing; however, decorative elements  24  may also comprise simulated cedar shake shingles or other types of shingles with simulated wood grain finish. Between adjacent decorative elements  24  are gaps  34  of uniform thickness. Decorative elements  24  are disposed such that the bottom portion  36  of each decorative element  24  is spaced further away from the wall surface (not shown) than the top portion  38  of each decorative element  24  when panel  10  is installed. This results in the appearance of overlap of each successive upper row  26  of decorative elements  24  over an adjacent lower row  28  of decorative elements  24 . As may be seen in FIG. 2, support ridges  40  between each decorative element  24  on the upper row  26  fit against the wall surface (not shown) and support panel  10  against the wall surface. 
     Panel  10  is manufactured using a customary injection molding process, and comprises a single piece of injection molded material, for example polypropylene or polyvinyl chloride (PVC). Generally, panel  10  is formed of a composition that will provide a firm, rigid panel resistant to impacts on front side  20 , yet is able to accommodate flexing, such as bending or bowing. Panel  10  is also formed of a non-brittle composition that is resistant to cracking or fracturing, and therefore able to withstand cutting along horizontal, vertical, or diagonal directions during installation. For example, one suitable material includes polypropylene, a blend of copolymer and homopolymer resins, filled with calcium carbonate and ultraviolet (UV) stabilizer. 
     Referring again to FIGS. 1 and 2, top portion  12  of panel  10  comprises mounting strip  42 , which is disposed between top edge  44  and aperture ledge/edge  46 . Spaced at intervals along the mounting strip  42  are nailing apertures  48 . Nailing apertures  48  are herein illustrated in an elongated oval shape. However, nailing apertures  48  may take any shape, and need only be wider in the horizontal direction than the width of a nail (not shown) in order to accommodate the horizontal shifting movement of installed panels  10  that is generally associated with thermal expansion or the settling of the underlying wall surface. Nailing apertures  48  are bordered on the rear side  22  of panel  10  by rings  50  which are integrally formed with panel  10  and abut the wall surface. Rings  50  prevent the heads of the nails from directly pinning mounting strip  42  to the wall surface along its entire length in a flush manner when nailed into place during installation. Such pinning of mounting strip  42  to the wall surface may result in panel  10  tearing from the underlying wall surface around the head of the nail. 
     Also spaced along the top portion  12  of panel  10  are rectangular apertures  52 . Rectangular apertures  52  are disposed below nail apertures  48  and intersect aperture edge  46  such that rectangular apertures  52  are partially disposed both within mounting strip  42  and upper row  26  decorative elements  24 . Rectangular apertures  52  are spaced along top portion  12  of panel  10  such that rectangular apertures  52  are centered with respect to gaps  34  between decorative elements  24 . 
     Referring to FIG. 2, lateral ridge  54  is disposed along the bottom portion  14  of panel  10 , and is integrally formed with panel  10 . Tabs  56  are spaced along lateral ridge  54  at the center of each decorative element  24  in lower row  28 . Tabs  56  are integrally formed with lateral ridge  54  in a horizontal row and depend downward from lateral ridge  54 . Tab supports  58  are integrally formed with tabs  56  and lateral ridge  54  and prevent tabs  56  from bending around the pivot of lateral ridge  54  toward the rear side  22  of panel  10 . Tabs  56  are tapered slightly toward their ends  58  and are narrower than rectangular apertures  52 . More specifically, tabs  56  are usually about one half the width of rectangular apertures  52 . The difference in width between tabs  56  and rectangular apertures  52  provide a free lateral space in either horizontal direction. Therefore, when tabs  56  of a first panel are inserted into rectangular apertures  52  of a second panel, the free lateral space provides positioning relief for the mounting of panel  10  onto previously installed panels. 
     Referring again to FIGS. 1 and 2, vertical ridges  60  are disposed along the rear side  22  of panel  10  proximal to left edge  30 . The area between vertical ridges  60  and left edge  30  defines left overlap portion  62 . Integrally formed with vertical ridges  60  are tabs  64  which extend horizontally from vertical ridges  60  toward left edge  30 . Tabs  64 , together with left overlap portion  62  define grooves  68  with open ends facing left edge  30 . 
     Tongues  70  extend from the discontinuous right edge  32 . Tongues  70  contain tongue channels  72  which open facing the front side  20  of panel  10 . Tongues  70  also contain tongue support ridges  74  which abut the wall surface (not shown) and support tongues  70  against the wall surface. Tongues  70  are longer than the corresponding tabs  64 , which, together with left overlap portion  62  define grooves  68 . 
     Referring to FIG. 3, it may be seen that rectangular apertures  52  are disposed through panel  10  at a generally downward angle toward the wall surface (not shown). This downward angle allows tabs  56  to be inserted both through and downward into rectangular apertures  52  in a single motion, as opposed to first inserting tabs  56  through rectangular apertures  52  followed by a second motion of tabs  56  downward behind the rear side  22  of panel  10 . Nailing apertures  48  surrounded by rings  50  which abut the wall surface are also shown, disposed above rectangular apertures  52 . Support ridges  40  are disposed between the decorative elements  24  of upper row  26  and support panel  10  against wall the surface (not shown). Tabs  56  are integrally formed with lateral ridge  54  and depend downward from the center of each decorative element  24  on the lower row  28 . 
     Referring to FIG. 4, an adjoining pair of panels is shown as they would be attached in accordance with the present invention. Tabs  56  are inserted through rectangular apertures  52  and are disposed against the rear side  22  of panel  10 . On either side of tabs  56  a free lateral space  75  may be seen, which allows tabs  56  to move horizontally within rectangular apertures  52  to provide positioning relief for the installation of panel  10 . Tongues  70  are inserted within grooves  68 . Similar to the connections of tabs  56  through rectangular apertures  52 , the connections between tongues  70  and grooves  68  can accommodate horizontal movement while still maintaining an interlocking connection. Tongue support ridges  74  abut the wall surface (not shown) and support tongues  70  against the wall surface (not shown). Support ridges  40  also abut the wall surface and support panel  10  against the wall surface. End portions  76  of mounting strips  42  are offset on opposite ends of each mounting strip  42  in order to facilitate an overlapping relation. End portions  76  of mounting strips  42  also contain nailing apertures  48  which may be overlapped to receive a mounting nail driven through both nailing apertures  48 . 
     Although both the horizontal connections comprising tabs  56  fitted within rectangular apertures  52  and the vertical connections comprising tongues  70  fitting within grooves  68  of panel  10  have been described as above, such horizontal and vertical connections may be structurally reversed. In such an embodiment, each panel (not shown) may comprise horizontal connections of tongues similar to tongues  70  mounted to and extending from the mounting strip  42  fitting within grooves similar to grooves  68  defined by tabs similar to tabs  64  mounted on the rear of lower row  28  of decorative elements  24 . Such a panel may further comprise vertical connections of relatively narrow tabs similar to tabs  64  mounted on the rear of the panel proximal to the sides of both the upper row  26  and lower row  28  of decorative elements  24 , fitting within rectangular apertures similar to rectangular apertures  52  disposed at intervals through left overlap portion  62 , the aforementioned embodiment not departing from the scope of the present invention. 
     Returning to the example embodiment and referring to FIGS. 5 and 6, two alternative methods of installing panel  10  are illustrated. In either method, first a starter strip (essentially comprising the structure of mounting strip  42 ), is nailed into place along the bottom of wall surface  78 . The starter strip is comprised of an upper portion, similar to mounting strip  42  and a lower portion accommodating rectangular apertures similar to rectangular apertures  52 . Beginning, for example, at the lower left comer of the wall surface  78 , an initial panel  80 , identical to panel  10  as illustrated in FIGS. 1,  2 ,  3 , and  4 , is cut vertically to fit flush against the left edge of the wall surface. The location on initial panel  80  at which that panel is cut vertically is determined by the discretion of the installer, as initial panel  80  may be cut at any location. Initial panel  80  is mounted on the starter strip by inserting the tabs on the rear of initial panel  80  through the rectangular apertures within the starter strip, then nailing initial panel  80  into place by driving a plurality of nails through nailing apertures of initial panel  80 . Additional panels are then installed along the starter strip to effect a first course  90  of installed panels. 
     Referring to FIGS. 5 and 6, it will be seen that once the starter strip and initial panel  80  are installed, additional panels are installed by connecting them to previously installed panels. It will also be seen that previously installed panels  82  and  84  are disposed in a diagonal orientation, more specifically, panel  82  is disposed diagonally from panel  84 , and lower and to the right of panel  84 . This diagonal can be seen by reference to the rectangularly shaped wall covering comprised of panels  80 ,  82 , and  84  where panels  82  and  84  are disposed diagonally from each other. Two alternative methods of installing new panel  86  are outlined below. 
     Referring to FIG. 5, a first method of installation of panel  86  is illustrated. First, the relatively narrow tabs  56  on the rear of the bottom portion  14  of panel  10  are inserted vertically downward through rectangular apertures  52  of vertically adjacent, previously installed panel  82  (and also panel  80 ). The positioning relief provided by the difference in width between tabs  56  and rectangular apertures  52  aids this first step of installation. In this position, panel  86  may rest upon panel  82  in a partially overlapped position, and it may be seen that side grooves  68  of panel  86  are aligned horizontally with the corresponding tongues  70  of horizontally adjacent, previously installed panel  84 . Panel  86  is then shifted directly horizontally in the direction of arrow A, thereby engaging grooves  68  of panel  86  around tongues  70  of panel  84 . Panel  86  is then permanently secured by driving nails through nailing apertures  48  disposed within mounting strip  42  of panel  86 . 
     Referring to FIG. 6, a second method of installation of panel  86 ′ is illustrated. First, grooves  68  of panel  10  are initially partially engaged around the corresponding tongues of a horizontally adjacent, previously installed panel  84 . It will be seen that the tongue-and-groove attachment between panels  86 ′ and  84  allow panel  86 ′ to be initially installed from a variety of approach angles. Panel  86 ′ is then rotated in a clockwise direction in the direction of arrow B, simultaneously inserting the relatively narrow tabs  56  of panel  86 ′ through the rectangular apertures  52  of vertically adjacent, previously installed panel  82 , while simultaneously completing the engagement of grooves  68  of panel  68 ′ around the tongues  70  of panel  82 . The positioning relief provided by the difference in width between the relatively wide rectangular apertures  52  and the relatively narrow tabs  56  allows panel  86 ′ to be rotated such that the tabs  56  of panel  86 ′ may be inserted through the rectangular apertures  52  of panel  82  without the installer being required to view such insertion. The installer therefore need only focus his attention on the engagement of grooves  68  of panel  86 ′ around the tongues  70  of panel  84 . Panel  86 ′ is then permanently secured by driving nails through nailing apertures  48  disposed within mounting strip  42  of panel  86 ′. 
     In the exemplary embodiment of the invention tabs  56  are about one inch (1″) wide and apertures  52  are about three inches (3″) wide. The material of panels  10  is: polypropylene, which may include one or more of the following additives: calcium carbonate and UV stabilizer. The panel size, in the exemplary embodiment, has dimensions of approximately thirty-five and one half inches (35 ½″) breath by approximately sixteen and one half inches (16 ½″) height by approximately seven sixty-fourths inches ({fraction (7/64)}″) wall thickness. 
     While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.