Unitary modular shake-siding panels, and methods for making and using such shake-siding panels

• US 6,276,107 B1
• Filed: 05/07/1998
• Issued: 08/21/2001
• Est. Priority Date: 05/07/1998
• Status: Expired due to Term

• Current Assignee: General Tools & Instruments LLC (Kellogg Company)
• Original Assignee: Pacific International Tool & Shear, Ltd.
• Inventors: Waggoner, Kurt, Fladgard, Scott, Fladgard, Lloyd
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): DORSEY, DENNIS
• Application Number:
  US09/074,809
• Time in Patent Office: 1,202 Days
• Field of Search: 523/13, 523/14, 523/16, 525/54, 525/55, 525/58, 525/59, 527/451.9, 527/481, 527/481.1
• US Class Current: 52/554
• CPC Class Codes: E04F 13/08 composed of a plurality of similar covering or lining elements, E04F13/072 takes precedence; borders, skirtings E04F19/02; of webs or fabrics E04F13/002; fixing strips E04F19/06; separate provisional spacers between adjacent tiles E04F21/0092; implements or means for setting tiles E04F21/18
• CPC Class Codes: E04F 13/141 with an outer layer of concrete E04F13/147 takes precedence

Abstract

Unitary modular shake panels, and methods for making and using such shake panels. In one aspect of the invention, a unitary modular shake panel includes an interconnecting section composed of a siding material and several integral shake sections projecting from the interconnecting section. The panel preferably has a quadrilateral shape with first and second edges along a longitudinal dimension that are separated from each other by a width of the panel along a transverse dimension. Additionally, the shake sections are separated from one another by slots extending from the second edge to an intermediate width in the panel. In a preferred embodiment, the panel is composed of a unitary piece of fiber-cement siding with a simulated wood grain running along the transverse dimension. The interconnecting section is preferably a web portion of the fiber-cement siding piece, and the shake sections are different portions of the same fiber-cement siding piece defined by the slots extending in the transverse dimension from the web portion to the second edge of the panel. Modular shake panels in accordance with the invention may be made using several different processes. In one embodiment, for example, a unitary modular shake panel is manufactured by the cutting planks from a sheet of siding material, and then forming slots in the panel to define the web portion and the shake sections. The planks are preferably cut from the sheet in a direction transverse to a wood grain on the surface of the sheet. The slots are preferably cut in the planks in the direction of the wood grain from a longitudinal edge to an intermediate depth within the plank.

Claims

1. An exterior siding panel for a structure, comprising:

a fiber-cement plank having a first longitudinal edge, a second longitudinal edge spaced apart from the first longitudinal edge by a panel width, a first side edge extending transverse to the first and second longitudinal edges, a second side edge spaced apart from the first side edge by a panel length and extending transverse to the first and second longitudinal edges, a first surface having a simulated wood-grain defining an exterior surface of the siding panel, and a second surface defining a back surface of the siding panel that is spaced apart from the exterior surface by a desired thickness for the siding panel, and the fiber-cement plank being composed of a contiguous sheet formed of one fiber-cement slurry from the back surface to the exterior surface; and

the one fiber-cement slurry comprising cement, cellulose fiber, and silica; and

a plurality of slots through the plank, the slots extending from the second longitudinal edge to an intermediate location between the first and second longitudinal edges, and the slots being spaced apart from one another along the second longitudinal edge to form an interconnecting section in the plank and a plurality of shake sections integral with the interconnecting section and projecting from the interconnecting section.

2. The exterior siding panel of claim 1 wherein the slots have widths from approximately 0.1 inch to approximately 0.3 inch.

3. The exterior siding panel of claim 1 wherein the slots are irregularly spaced apart from one another along the second longitudinal edge.

4. The exterior siding panel of claim 1 wherein the slots are equally spaced apart from one another along the second longitudinal edge.

5. The exterior siding panel of claim 1 wherein the shake sections have scalloped ends.

6. The exterior siding panel of claim 1 wherein the shake section have different lengths.

7. An exterior siding panel for a structure, comprising:

a fiber-cement plank having a first longitudinal edge, a second longitudinal edge spaced apart from the first longitudinal edge by a panel width, a first side edge extending transverse to the first and second longitudinal edges, a second side edge spaced apart from the first side edge by a panel length and extending transverse to the first and second longitudinal edges, an exterior surface defining a first outer surface of the siding panel having a simulated wood-grain extending transverse to the first and second longitudinal edges, and a back surface defining a second outer surface of the siding panel, the back surface being generally planar and spaced apart from the exterior surface by a desired thickness for the siding panel, and the fiber-cement plank consisting of a contiguous sheet formed of one fiber-cement slurry from the back surface to the exterior surface, and the one fiber-cement slurry comprising cement, cellulose fiber, and silica sand; and

a plurality of slots through the plank, the slots extending from the second longitudinal edge to an intermediate location between the first and second longitudinal edges, and the slots being spaced apart from one another along the second longitudinal edge to form an interconnecting section in the plank and a plurality of shake sections integral with the interconnecting section and projecting from the interconnecting section.

8. The exterior siding panel of claim 7 wherein the slots have widths from approximately 0.1 inch to approximately 0.3 inch.

9. The exterior siding panel of claim 7 wherein the slots are irregularly spaced apart from one another along the longitudinal edges.

10. The exterior siding panel of claim 7 wherein the shake sections have scalloped ends.

11. The exterior siding panel of claim 7 wherein the shake sections have different lengths.

12. An exterior siding panel for a structure, comprising:

a fiber-cement plank having a first longitudinal edge, a second longitudinal edge spaced apart from the first longitudinal edge by a panel width, a first side edge extending transverse to the first and second longitudinal edges, a second side edge spaced apart from the first side edge by a panel length and extending transverse to the first and second longitudinal edges, an exposed exterior surface having a simulated wood-grain extending transverse to the first and second longitudinal edges, and a back surface spaced apart from the exterior surface by a desired thickness for the siding panel, the back surface being a generally planar surface, and the fiber-cement plank being composed of a contiguous sheet formed from one fiber-cement slurry from the back surface to the exterior surface, and the one fiber-cement slurry comprising cement, cellulose fiber, and silica sand; and

a plurality of slots through the plank, the slots extending from the second longitudinal edge to an intermediate location between the first and second longitudinal edges, and the slots being spaced apart from one another along the second longitudinal edge to form an interconnecting section in the plank and a plurality of shake sections integral with the interconnecting section and projecting from the interconnecting section.

13. The exterior siding panel of claim 12 wherein the slots have widths from approximately 0.1 inch to approximately 0.3 inch.

14. The exterior siding panel of claim 12 wherein the slots are irregularly spaced apart from one another along the second longitudinal edge.

15. The exterior siding panel of claim 12 wherein the slots are equally spaced apart from one another along the second longitudinal edge.

16. The exterior siding panel of claim 12 wherein the shake sections have scalloped ends.

17. The exterior siding panel of claim 12 wherein the shake sections have different lengths.

18. An exterior siding panel for a structure fabricated according to a method, comprising:

providing one fiber-cement slurry comprising cement, cellulose fiber, and silica sand, the one fiber-cement slurry defining a fiber-cement material;

providing a first roller having a stimulated wood-grain pattern on an engaging surface and a second roller having a surface spaced apart from the first roller by a desired sheet thickness for the siding panel;

rotating the second roller through the slurry to pick up a layer of fiber-cement siding material on the second roller;

rotating the first roller with the second roller while the engaging surface contacts one side of the layer of the fiber-cement siding material on the second roller to press the fiber-cement siding material into a sheet of fiber-cement material made from one fiber-cement slurry that has the desired sheet thickness and s simulated wood-grain pattern on one surface defining an exterior surface of the siding panel;

cutting the sheet of fiber-cement material into at least one plank having a first longitudinal edge, a second longitudinal edge spaced apart from the first longitudinal edge by a panel width, a first side edge extending transverse to the first and second longitudinal edges, a second side edge spaced apart from the first side edge by a panel length and extending transverse to the first and second longitudinal edges, and a back surface apart from the exterior surface by the desired sheet thickness, the wood-grain on the exterior surface extending transverse to the first and second longitudinal edges, the back surface being a generally planar surface, and the fiber-cement plank being composed of the sheet formed of the one fiber-cement slurry from the back surface to the exterior surface;

curing the sheet of fiber-cement material; and

forming a plurality of slots through the plank after curing the fiber-cement material, the slots extending from the second longitudinal edge to an intermediate location between the first and second longitudinal edges, and the slots being spaced apart from one another along the second longitudinal edge to form an interconnecting section in the plank and a plurality of shake sections integral with and projecting from the interconnecting section.

19. A method of fabricating an exterior siding panel, comprising:

providing a sheet of fiber-cement material made from one fiber-cement slurry, the sheet having an a first surface defining an exterior surface of the siding panel and a second surface defining a generally planar back surface of the siding panel, the first surface being spaced apart from the second surface by a desired panel thickness, the sheet being a contiguous member formed of one fiber-cement slurry from the first surface to the second surface, and the one fiber-cement slurry comprising cement, cellulose fiber, and silica sand;

cutting the sheet of fiber-cement material into at least one plank having a first longitudinal edge, a second longitudinal edge spaced apart from the first longitudinal edge by a panel width, a first side edge extending transverse to the first and second longitudinal edges, a second side edge spaced apart from the first side edge by a panel length and extending transverse to the first and second longitudinal edges, the sheet being cut so that the wood-grain on the exterior surface extends transverse to the first and second longitudinal edges;

curing the fiber-cement material; and

forming a plurality of slots through the plank of cured fiber-cement material, the slots extending from the second longitudinal edge to an intermediate location between the first and second longitudinal edges, and the slots being spaced apart from one another along the second longitudinal edge to form an interconnecting section in the plank and a plurality of shake sections integral with and projecting from the interconnecting section.