Decorative wall covering with upward movement panel interlock system

[0001] The present invention relates generally to roof and wall coverings which are primarily intended for outdoor usage, and more particularly, to roof and wall coverings comprised of relatively large panels which each are molded or otherwise formed with decorative patterns characteristic of conventional roofing and siding materials, such as shake shingles, tile, brick or the like.

[0002] Various synthetic roof and wall coverings are known today which are formed of elongated thermoplastic panels that are nailed to a wall or roof support surface in horizontal courses or rows in partially overlapping relation to each other so as to provide a substantially water resistant, protective layer over the support surface. Such panels, which usually are identically molded, commonly are formed with a plurality of rows of simulated building elements, such as shake shingles. Because the panels are identically molded, a panel-to-panel identity can be easily noticed if the panels are not carefully installed and maintained in secure relation to the support surface. Leakage problems between adjoining panels also can occur.

[0003] To facilitate installation, such panels commonly are nailed to the wall or support surface along an upper horizontal nailing flange with the lower marginal edge region overlapping a panel in the course immediately below and with one side marginal edge region overlapping the laterally spaced adjacent panel. It is known to interlock the overlapping lower marginal edge region to the upper marginal edge region of the underlying panel in order maintain the panels in secure relation to each other and the support surface upon which they are mounted. It also is know to interlock the overlying side marginal edge regions in order to prevent bowing of the panels in a vertical direction, and preferably, to interlock the overlying side marginal edge regions adjacent each row of simulated building elements.

[0004] Heretofore the provision and use of side interlocks in such simulated building panels has created installation problems. Typically the side interlocks require lateral movement of the panel onto a previously installed panel. On the other hand, to lock the upper and lower marginal edge regions, it is necessary to move the panel vertically upwardly relative to the previously installed panel. Hence, engaging of both the upper, lower, and side interlocks has required cumbersome manipulation of the panel. Moreover, when installing the panels along the bottom of framed windows, dormers, or the like, it is not possible to move the panel both upwardly and laterally during installation. Heretofore, the panel often had to be pried or bent in order to engage the various interlocks, which is difficult and time consuming.

[0005] It is an object of the present invention to provide a plastic wall or roof panel having an interlock system adapted for easier and more reliable panel installation.

[0006] Another object is to provide a panel as characterized above which has upper, lower, and side marginal edge interlocks that all are engageable as an incident to upward movement of a panel being installed relative to a previously mounted panel.

[0007] A further object is to provide a panel of the above kind which includes side interlocks adjacent each row of simulated building elements formed on the panel so as to effect reliable interengagement and prevent bowing along the entire length of the overlapping side marginal edge region.

[0008] Still another object is to provide a panel of the foregoing type with interlocks that can be easily engaged even when the panel is installed about window frames, dormers, or the like. A related object is to provide such a panel which has side interlocks that permit, or which are easily adaptable, for interengagement as an incident to either vertical or lateral movement of the panel relative to a previously installed panel.

[0009] Yet another object is to provide a panel of the foregoing type which is relatively simple in construction and which lends itself to economical manufacture.

[0010] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which:

[0022] While the invention is susceptible of various modification and alternative constructions, certain illustrated embodiments thereof have 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 forms 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.

[0023] Referring now more particularly to FIG. 1 of the drawings, there is shown an illustrative wall covering 10 comprising a plurality of panels 11 in accordance with the present invention. The general type of panel employed in the instant invention is described in commonly assigned U.S. Pat. Nos. 5,347,784 and 5,537,792, the disclosures of which are incorporated herein by reference. As shown in FIG. 1, the panels 11 each are formed with simulated building elements. In this instance, the panels 11 are formed with simulated cedar shake 12 of irregular width which are disposed in three parallel rows 12a, 12b, 12c with adjacent shake 12 in each row being separated by a small gap 13. The illustrated simulated shake pattern is of a type known in the industry as “perfection” shake, wherein the lower edges 14a, 14b, 14c of the rows 12a, 12b, 12c are in a substantially straight line, and except for their width, the individual shake elements are substantially similar in appearance.

[0024] The simulated shake 12 in this case each have a front face 15 (FIG. 2) extending downwarldy and outwardly at a slight taper to a wall or support surface 17 upon which the panel is mounted and a downwardly directed end face 16 perpendicular to the front face 15. The front face 15 is molded with grooves which simulate the grain of the simulated shake 12, and the end face 16 has the appearance of being in overlapping relation to the upper perimeter of the shake 12 in the underlying row. It will be understood that the panels 11 could be formed with other forms of simulated shake shingles, or other types of building materials, such as tile, brick and the like.

[0025] Each panel 11 has an upper horizontal marginal edge region 18 having a substantially uniform width “w” extending across the top of the panel immediately above the top row 12a of shake 12, a lower marginal edge region 19 which defines a lower peripheral edge of the panel, a side marginal edge region 20 located to the right-hand side of the last simulated shake 12 in each row 12a, 12b, 12c, and a marginal edge region 21 on the opposite side of the panel 11 defined by a left-side peripheral edge immediately adjacent the first simulated shake of each row 12a, 12b, 12c. The panels 11 are mounted on a support surface 17, which may be a wall or roof 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 region 19 of the panels in each course overlying the upper marginal edge region 18 of the panel in the previously installed course immediately below.

[0026] 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 12a, 12b, 12c of shake 12 of each panel 11 extend in offset relation to each other so as to define stepped left and right-hand sides of the panel. In the illustrated embodiment, the second row 12b of shake extends farther to the right than the first row 12a a distance corresponding to about one-quarter to one-half width of one shake 12 and the last shake of third row 12c extends a similar distance beyond the last shake of the second row 12b.

[0027] The panels 11 typically are mounted beginning with the left-hand panel of the lowermost course to be installed on the wall or roof, as is known in the art. Upon completion of the first course, the second course is installed, immediately above the first course, again starting from the left-hand side. As is known in the art, the left-hand marginal edge region of the first panel of each row is appropriately cut square with the left side starting edge of the support surface. In the following description, when discussing the interaction of panels disposed in vertically displaced courses, the upper panel will be designated with the reference “11b” and the lower or previously mounted panel will be designated with the reference “11a” (FIG. 4). This convention is employed in order to clarify the relative positions and order of installation of the subject panels. It will be understood, of course, that despite this nomenclature, the individual panels are substantially identical, and the distinguishing nomenclature is used only to designate positional, not structural, differences.

[0028] For securing the panels 11 to the support surface 17, the upper marginal edge region 18 of each panel 11 is formed with a row of elongated laterally spaced nailing apertures 25. In order to provide firm support for the panel 11 on the wall during nailing and for establishing a seal between the rear side of the panel 11 and the support surface 17, 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. 3). Once the upper marginal edge region 18 is nailed to the support surface, the horizontal sealing flanges 26 are maintained against the support surface 17 subject to relative thermal expansion and contraction.

[0029] In order to positively interlock the overlapping lower marginal edge region 19 of a panel 11b with an upper marginal edge region 18 of a previously mounted panel 11a, each panel 11 is formed with a plurality of laterally spaced forwardly and downwardly directed interlock flanges 28 disposed on the upper marginal edge region 18 between the nailing apertures 25 and the first row 12a of building elements. The illustrated interlock flanges 28 have an upper base portion 29 extending outwardly from the upper marginal edge region 18 and a relatively flat locking portion 30 extending downwardly from the upper base portion 29. The relatively flat locking portion 30 is disposed a distance from the forward surface of the upper marginal edge region 18 such that the locking flange 28 and the face of the upper marginal edge region 18 form a slot 30a.

[0030] The lower marginal edge region 19 of each panel 11 in turn is formed with An upturned interlock flange or lip 31, running substantially the length of the panel 11 and having a thickness corresponding substantially to the width of the slots 30a defined by the locking portions 30 of the upper interlock flange 28. The lower interlock lip 31 thus can be positioned under the interlock flanges 28 on the upper marginal region 18 and be moved upwardly into engaged relation with the interlock flange 28. For locating the interlock lip 31 at a predetermined installed position that will accommodate thermal expansion and contraction of the panels in a vertical direction, frangible locating pins 32 extend outwardly of the upper marginal edge region 18 of the underlying panel. It can be seen that the lower interlock lip 31 and upper interlock flanges 28, therefore, can be positioned in predetermined interlocking relation to each other as an incident to vertical movement of a panel 11b relative to the previously mounted panel 11a.

[0031] In accordance with the invention, the side marginal edge regions of the panels are provided with side interlocks which also are adapted for easy and reliable interengagement as an incident to upward vertical movement of the panel relative to a previously mounted underlying panel. To this end, in the illustrated embodiment, the right side marginal edge region 20 of each panel 11 is defined by three laterally offset transverse flange-like segments 20a, 20b, 20c which each is adjacent a respective row 12a, 12b, 12c of the simulated shake. The upper segment 20a includes a mounting flange portion 35, formed with a nailing aperture 36, extending parallel, but in recessed relation, to the upper marginal edge region 18, a tapered flange portion 38 having a front face generally parallel, but again in recessed relation, to the front face 15 of the adjacent shake 12a, and an end portion 39 which defines a downwardly directed end face generally perpendicular to the tapered front face in recessed relation to the end face 16 of the adjacent shake 12a. The middle segment 20b has a tapered flange portion 40 with a front face in recessed, parallel relation to the tapered front face 16 of the adjacent shake 12b and a downwardly directed end portion 41 parallel to, and in recessed relation, to the end face 16 of the adjacent shake 12b. The middle segment 20b in this case has a nailing aperture 42 adjacent an upper end thereof. The lower segment 20c is in the form of a laterally extending transverse flange 43 having a front face parallel, but again in recessed relation, with respect to the adjacent shake 12c, and a lower end 44 recessed from the lower end face 16 of the adjacent shake 12c. The flange 43 in this case extends laterally in spaced relation above the support surface 17 upon which the panel 11 is mounted.

[0032] In carrying out the invention, the left-side marginal edge region of each panel is provided with interlocks that are engageable with the right-side marginal edge region segments of a previously mounted panel as an incident of vertical movement of the panel relative to the previously mounted underlying panel. In the illustrated embodiment, the underside of the left side marginal edge region 21 of each panel 11 includes a first interlock flange 50 (FIG. 3) extending upwardly from the end face 16 of the first shake 12 of the top row 12a for engaging an aperture 51 (FIG. 2) formed in the end portion 39 of the first right-side marginal edge region segment 20a It can be seen that as an incident of upward movement of the panel 11 relative to a previously mounted underlying panel, the interlock flange 50 can be inserted into the aperture 51 in underlying relation to the tapered flange portion 38 for positively interlocking the side marginal edge regions adjacent the first row 12a of shake. The interlock-receiving aperture 51 preferably has an elongated configuration of a width slightly greater than the width of the interlock flange 50 for allowing horizontal thermal expansion and contraction of the interlocked panels.

[0033] In order to provide further interlocking stability between the overlapping side marginal edge regions 20, 21, a second similar interlock flange 54 extends upwardly from the end face 16 of the first shake of the second row 12b for engaging a similar elongated aperture 55 formed in the end portion 41 of the second side marginal edge region segment 20b for interlocking the side marginal edge regions at a location adjacent the second row 12a of shake. For interlocking the side marginal edge regions 20, 21 at a location adjacent the third row 12c of shake, a right-hand end portion 31a (FIG. 3) of the lower marginal edge region interlock flange or lip 31 is positionable into interlocking relation under a lower peripheral portion 44 of the flange 43 that defines the third side marginal edge region segment 20c. It will be understood by one skilled in the art that in lieu of utilizing an end of the lower marginal edge region interlock lip 31, a separate side interlock flange could be provided at the lower marginal edge region of the panel for engaging an aperture in an end face of the third side marginal edge region segment 20c, similar to the interlocking arrangement of the first and second side marginal edge region segments.

[0034] It can be seen from the foregoing that as an incident to upward movement of one panel relative to previously mounted panels the upper and lower marginal edge interlocks, as well as the side marginal edge interlocks, can be brought into engagement with previously mounted underlying panels. Such interlocking can be easily effected, nearly simultaneously, with simple upward movement of the panel relative to the underlying previously mounted panels. Since the panels are interlocked both along the upper and lower marginal edge regions 18, 19, and at a location adjacent each row of simulated building elements 12a, 12b, 12c, the panels will be securely maintained in engagement with each other and the wall or roof support surface upon which they are mounted.

[0035] In accordance with a further aspect of the invention, the panels may have side interlocks which permit, or which are easily adaptable, for enabling interengagement of the side interlocks as an incident to either vertical or lateral movement of the panel relative to a previously installed panel. With reference to FIGS. 7-8, there is a shown a panel 11, similar to that described above, but in which interlock-receiving openings adjacent the ends of the first and second rows 12a, 12b of simulated shake are defined by side opening slots 51a, 55a, rather than enclosed apertures. In this embodiment, it will be seen that the side interlock flanges 50, 54 may be inserted into and engage the slots 51a, 55a as an incident to either vertical movement of a panel relatively to the previously installed panel, in a manner similar to that depicted in FIGS. 5A and 5B, with the interlock flange moving upwardly into the slots 51a, 55a, or alternatively, the side interlock flanges 50, 54 may be inserted into and engage the slots 51a, 55a as an incident to lateral movement of a panel relative to a previously mounted panel with the interlock flanges 50, 54 moving laterally into the side opening slots 51a, 55a from the open right-hand side thereof, as depicted in FIGS. 8A and 8B. The lower lip portion 31A similarly may be brought into interlocking relation with the flange 43 of lower side marginal edge segment 20c as an incident to either vertical or lateral movement. It will be appreciated by one skilled in the art that such modified panel design is particularly adaptable for mounting around window frames, dormers, and other corner areas, in which movement of the panel may be restricted or impeded during mounting. The side interlocks in this case can be easily engaged in such case by either lateral or vertical movement of the panel being installed without prying or cumbersome manipulation of the panel typical of the prior art.

[0036] In keeping with the invention, the side opening interlock slots 51a, 55a may be formed during original molding of the panel 11, or alternatively, a small segment of the side marginal edge region end portions 39, 41, designated 39a, 41a in FIG. 2, may be cut away or otherwise removed from the panel in the field, such as by use of a utility knife, to open the end of the slot for enabling the side interlock flanges to enter as an incident to lateral panel movement. During normal mounting, i.e., as an incident to vertical panel movement, the apertures 51, 55 would remain intact.

[0037] From the foregoing, it can be seen that a plastic wall or roof panel of the present invention has a marginal edge region interlock system adapted for easier and more reliable panel installation. Specifically, the panels have upper, lower, and side marginal edge interlocks that all are engageable as an incident to upper movement of a panel being installed relative to a previously mounted underlying panel. The panels further may have side interlocks that permit, or are easily adaptable, for interengagement as an incident to either vertical or lateral movement of the panel relative to a previously installed panel. Yet, the panels have a relatively simple construction which lends itself to economical manufacture.