Decorative wall covering with improved interlock system

• US 8,074,417 B2
• Filed: 06/17/2011
• Issued: 12/13/2011
• Est. Priority Date: 10/27/2006
• Status: Active Grant

• Current Assignee: Derby Building Products Incorporated (Quebec, Inc. /9293-3985/)
• Original Assignee: Exteria Building Products, LLC (Quebec, Inc. /9293-3985/)
• Inventors: Trabue, Robert, Schwarz, Stefan
• Primary Examiner(s): Canfield, Robert
• Assistant Examiner(s): AHMAD, CHARISSA L
• Application Number:
  US13/163,245
• Publication Number:
  US 20110265417A1
• Time in Patent Office: 179 Days
• Field of Search: 523/021, 523/023, 525/19, 525/20, 525/21, 525/22, 525/33, 525/39
• US Class Current: 52/533
• CPC Class Codes: E04D 1/265 the roofing elements being rigid, e.g. made of metal, wood or concrete
• CPC Class Codes: E04D 1/2918 the fastening means taking hold directly on adjacent elements of succeeding rows
• CPC Class Codes: E04D 1/2921 having resilient detents adapted to be biased to a position to resist separation
• CPC Class Codes: E04F 13/0858 fixed by means of spring action

Abstract

A roof or wall covering comprising a plurality of horizontal courses of molded plastic panels each formed with a single row of simulated shake shingles. The panels have a continuous upper interlock flange that facilitates inner-engagement of the panels of overlying courses without cumbersome handling of numerous small interlock fingers which can be missed during installation. Cooperating detents are provided between the overlying lower and upper marginal edge regions which facilitate proper positioning of the panels and which support the weight of the panel during securement to a wall surface. A bottom interlock flange is supported transversely across a rear side of the panel by vertically-spaced support plates which facilitate both liquid drainage and air circulation through the installed wall covering. In the preferred embodiment, the panels in alternate courses are identically formed with different shake patterns for enhancing the natural appearance of the wall covering.

Claims

1. A wall covering for mounting on a support surface comprising:

a plurality of panels each having a body portion formed with simulated building elements having non-planar forward facing and rearward facing surfaces, each panel having a substantially planar upper marginal edge region including an upper edge of the panel and a substantially planar lower marginal edge region including a lower edge of the panel;

the panels being mountable on the support surface in a plurality of horizontal courses with the lower marginal edge region of each panel in one horizontal course overlying the upper marginal edge region of a previously mounted panel in a downwardly adjacent horizontal course,

the upper marginal edge region of each panel having a continuous upper interlock flange depending forwardly and downwardly from the upper marginal edge region at a position below the upper edge of the panel and extending substantially the length of the panel, the upper interlock flange being forwardly spaced apart from the upper marginal edge region by a plurality of substantially horizontal support plates so as to define a vertically extending gap between the upper interlock flange and the upper marginal edge region, the support plates spaced apart from one another so as to define openings therebetween, the support plates separating the upper interlock flange from the upper marginal edge region so that the upper interlock flange extends substantially parallel to the upper marginal edge region that it overlies,

the lower marginal edge region of each panel having at least one lower elongated interlock flange extending rearwardly and upwardly from the lower marginal edge region at a position spaced apart from and above the lower edge of the panel and extending substantially the length of the panel, the lower interlock flange being rearwardly spaced apart from the rearward facing surface by a plurality of substantially horizontal lower support plates so as to define a vertically extending gap between the lower interlock flange and the rearward facing surface, the lower support plates spaced apart from one another so as to define openings therebetween, the lower support plates separating the lower interlock flange from the rear facing surface so that the lower interlock flange extends substantially parallel to the rear facing surface that it overlies, and

the at least one lower interlock flange of the panel in the one horizontal course being engageable with the continuous upper interlock flange of the previously mounted panel in the downwardly adjacent horizontal course as an incident to upward movement of the panel in the one horizontal course with respect to the panel in the downwardly adjacent horizontal course for positively securing together the overlying upper and lower marginal edge regions of the respective panels when mounted on the support surface,

the overlying upper and lower marginal edge regions having detent elements adapted for positive snap action engagement as an incident to engagement of the upper and lower interlock flanges, the detent elements being disposed above the lower edge of the mounted panel in the one horizontal course such that the overlying lower marginal edge region covers and hides the detent elements from viewing from a front side of the mounted panels;

wherein the detent elements include a first detent element on a rear side of the at least one lower interlock flange and a second detent element on a front side of the upper marginal edge region of the panel opposite the upper interlock flange, one of the detent elements being an elongated protruding nib and the other the detent element being a nib-receiving recess; and

wherein the positive engagement of the detent elements occurs when the protruding nib is seated within the nib-receiving recess.

2. The wall covering of claim 1 wherein the at least one lower interlock flange of each panel comprises a plurality of elongated integrally aligned rail segments which each extends a transverse length greater than the width of two of the simulated building elements.

3. The wall covering of claim 1 wherein the detent recess extends substantially the length of the panel.

4. The wall covering of claim 3 wherein the detent nib comprises a plurality of rib segments disposed substantially along the length of the panel.

5. The wall covering of claim 1 wherein the first and second detent elements are adapted for snap action engagement with sufficient retention force to support the weight of an overlying panel during securement to the wall surface.

6. The wall covering of claim 1 wherein the upper interlock flange has a lower terminal lip that flares outwardly with respect to the upper marginal edge region for guiding the at least one lower interlock flange of an overlying panel into engaging relation with the upper interlock flange.

7. The wall covering of claim 1 wherein the lower support plates form a plurality of openings between the lower interlock flange and the rear facing surface of the panel.

8. The wall covering of claim 1 wherein there are a plurality of spaced apart openings formed in the upper marginal edge region rearward from the upper interlock flange so that the downward extension of the upper interlock flange substantially overlies the openings.

9. The wall covering of claim 1, wherein the upper marginal edge region of each panel includes a plurality of laterally-spaced openings to allow tooling to protrude through the panel for forming the continuous upper interlock flange.

10. The wall covering of claim 1, wherein the plurality of laterally-spaced plates are integrally formed with the panel.

11. The wall covering of claim 1 wherein the laterally-spaced plates are integrally formed with the lower interlock flange so as to form an L-shaped cross section, and wherein the laterally-spaced plates are attached to the panel by brackets.

12. A wall covering for mounting on a support surface comprising:

a plurality of panels each having a body portion formed with simulated building elements;

the panels each having an upper marginal edge region including an upper edge of the panel and a lower marginal edge region including a lower edge of the panel;

the panels being mountable on the support surface in a plurality of horizontal courses with the lower marginal edge region of a panel in one horizontal course overlying the upper marginal edge region of a previously mounted panel in a downwardly adjacent horizontal course,

the upper marginal edge region of each panel having at least one upper elongated interlock flange depending forwardly and downwardly from the upper marginal edge region at a position below the upper edge of the panel and extending substantially along the length of the panel, the upper interlock flange being forwardly spaced apart from upper marginal edge region by a plurality of substantially horizontal support plates so as to define a vertically extending gap between the upper interlock flange and the upper marginal edge region with the upper interlock flange being substantially parallel to the portion of the upper marginal edge region that it overlies, the support plates spaced apart from one another so as to define openings therebetween,

the lower marginal edge region of each panel having at least one lower elongated interlock flange extending rearwardly and upwardly from the lower marginal edge region at a position spaced apart from and above the lower edge of the panel and extending substantially the length of the panel, the lower interlock flange being rearwardly spaced apart from the rearward facing surface by a plurality of substantially horizontal lower support flanges so as to define a vertically extending gap between the lower interlock flange and the rearward facing surface with the lower interlock flange being substantially parallel to the portion of the rear facing surface that it overlies, the lower support plates spaced apart from one another so as to define openings therebetween,

the at least one lower interlock flange of the panel in the one horizontal course being engageable with the at least one upper interlock flange of the panel in the downwardly adjacent horizontal course as an incident to upward movement of the panel in the one horizontal course with respect to the panel in the downwardly adjacent horizontal course for positively securing together the overlying upper and lower marginal edge regions of the respective panels when mounted on the support surface, and

the overlying upper and lower marginal edge regions having detent elements adapted for positive snap action engagement as an incident to engagement of the at least one upper and lower interlock flanges,

the detent elements being disengagable and reengageable with each other in response to temperature expansion and contraction of the panels while the upper and lower interlock flanges remain in engaged relation for continuing to positively secure the overlying upper and lower marginal edge regions of the respective mounted panels.

13. The wall covering of claim 12 in which the detent elements include a first detent element on a rear side of the at least one lower interlock flange and a second detent element on the upper marginal edge region of the panel opposite the at least one upper interlock flange.

14. The wall covering of claim 13 in which one of the detent elements is an elongated protruding nib and the other the detent element is a nib receiving recess.

15. The wall covering of claim 13 in which the first and second detent elements are adapted for snap action engagement with sufficient retention force to support the weight of an overlying panel during securement to the wall surface.