Patent Application
20050284051
Not Applicable
The present invention does not involve any form of federally sponsored research or development.
The present invention relates to simulated wood siding, including, but not limited to, columns for use in a siding system that simulates wood log construction. Log columns and methods for use with either natural wood or simulated wood siding that attaches to walls, particularly exterior walls, are known. The wood siding can include planks and columns that attach to walls. The columns can be attached anywhere along a sided wall. For esthetic reasons the columns are preferably attached at joints between sided wall sections, at ends of the sided wall, or at corners. The columns can function to cover the ends of planks or to help join adjacent wall planks that meet at wall corners so as to give the appearance of wood log construction. Whether the siding is natural or simulated wood, the columns are typically made of natural wood.
There are a number of problems with existing columns used with siding that simulates wood log construction. Often rough hewn boards are used as columns, particularly at sided wall corners. Esthetically the boards detract from an appearance of log construction. Columns made of natural wood are heavy and require special anchoring to be securely attached to the wall. The weight of natural wood columns makes siding construction laborious. The siding corners made from natural wood are susceptible to degradation caused by moisture and insects such as termites, and thus columns made of wood must be either chemically protected or replaced periodically. Generally, wood is an expensive material of construction, and columns made of natural wood may be considered a less desirable use of natural resources.
Accordingly, there is a need for a log column for and method of siding walls that uses columns that are lightweight, easy to handle, easy to attach, water and insect resistance, insulating, and inexpensive to manufacture, yet can simulates wood siding having the appearance of wood log construction.
A log column and a method for use with simulated wood siding are provided. The column includes a partial cylindrical core, lateral supports, and a decorative skin attached to a curved surface of the core. In a method of the present invention, a column is attached adjacent to planks so as to form a sided wall having the appearance of wood log construction.
The present invention includes a column and method for siding a wall to simulate wood log construction. The column includes a partial cylindrical core having a channel that is formed to complement the shape of a wall, and a decorative skin attached to a curved surface of the core. The column can be used in a siding system for simulating wood log construction that includes at least one column and a plurality of siding planks.
A simulated log column 100 for use in the siding of a wall is shown in
Lateral edges 109, 111 are formed at the intersection of a curved surface 123 of the core 101 and either the first flat surface 105 and the second flat surface 107. Although the column 100 is formed from a generally cylindrical core 101, the lateral edges 109, 111 can be formed to have an outer surface that is generally tangential to the curved surface 123. The lateral edges so formed are generally perpendicular to the wall to which the column is mounted. Also, lateral edges that meet the wall perpendicularly provide a straighter edge to which planks can butt up against.
Grooves 113, 115 are formed along lateral edges 109, 111 to receive lateral supports 117, 119. The lateral supports can be attached with adhesive or bonded to the grooves, and have an edge with a surface adjacent to the curved surface 103 so as to form a continuous surface. Generally, the lateral supports run the whole length of the column. Alternatively, the supports can be divided in several pieces such that only a portion of the grooves 113, 115 is occupied. The lateral supports 117, 119 provide rigidity to the column 100 and are generally made of a nailable material such as a wood. Thus, the column 100 can be attached to the wall by nailing the column 100 through the lateral supports 117, 119. A decorative skin 121, such as hardboard, attaches to the curved surface 123 and the lateral supports 113, 115. Alternatively, the decorative skin can include multiple layers which can include an outer veneer made of wood.
A simulated wood siding plank 200 for use in a siding system having simulated log columns 100 is shown in
Lower spline 215 and upper spline 217 are disposed laterally along the corresponding lateral edges 207, 209 so as to form an interlocking tongue and groove system on adjacent planks. The splines can be form as part of a rigid member 219 that attaches to the flat surface 205. Alternatively, the splines can be form by other construction techniques. For example, splines can be formed from a plurality of rigid members attached to the flat surface 205 and/or each other. The splines could also be molded in the case the rigid member is made from a molded material such as plastic.
The rigid member 219 can be formed to engage an alignment member 211 that protrudes from and continues laterally down the flat surface 205. The alignment member 219 facilitates plank manufacturing. The rigid member 219 can be made of material such as plywood or other rigid materials. For example, the alignment member could be molded into a rigid member made of plastic and bonded to the cylindrical core.
The upper spline 217 can be formed into a tongue 221 that extends past the decorative skin 213 and has a surface 223. The surface 223 is used to receive nails or other devices for attaching the plank 200 to the wall. The height of the surface 223 can be varied to allow the application of grout to further help simulate wood log construction.
The use of a column 100 in a simulated wood siding system is as shown in
The siding system also includes a plurality of planks 200 attached to the walls. Adjacent planks are joined by interlocking splines, the lower spline 215 and the upper spline 217 of adjacent planks 200. Typically, the plank 200 is secured to the wall by nails 301 that are driven through the upper portion of the plank 200 near the upper spline 217 and into the wall, preferably into the studs. The next plank is installed by interlocking the lower spline 215 into the upper spline of the plank nailed to the wall. The lower spline 215 of adjacent planks 200 conceals the nails 401 that attach the nailed plank 200 to the wall. Alternatively, the plank can be attached to the wall by other means such as screws, special fasters, adhesive, and so forth. Also, the planks can be designed and constructed so that the lower spline is nailed to the wall instead of the upper spline. Planks 200 adjacent to the column 100 are cut or formed so as to butt up against the column 100 when the plank is attached to the wall.
For planks having the tongue surface 223 constructed to receive grout, the grout can be applied once adjacent planks 200 are attached to the wall. The grout can be carried into openings adjacent to the column 100 and between adjacent planks to form a sealed and water-resistant siding system. The materials used to form the columns and planks, such as a polystyrene cores and hardboard decorative skin, make the siding system resistant to attack by insects.
A flow diagram for a method of installing a column as part of a siding system is as shown in
In the method for the siding system, at step 401, at least one column 100 is attached to the wall, typically at a corner formed by adjacent wall sections. Preferably, the column 100 is nailed to studs 301 through the lateral supports 117, 119. Alternatively, the column 100 can be attached with screws and other types of fasteners, or even adhesive. Two or more columns 100 can be used in combination next to each other vertically or horizontally, as needed. The joints between adjacent columns 100 can be caulked or grouted, as deemed appropriate.
At step 403, planks 200 adjacent to the column 100 are cut to a desired length so that the planks butt up against the column when attached to the wall. At step 405, a plurality of planks 200 are attached to the wall. Adjacent planks 200 interlocked through the engagement of complimentary lower splines 215 to upper splines 217 on adjacent planks 200. The planks 200 are secured to the wall by preferably driving nails 305 through the plank near the upper spline 217. The planks 200 adjacent to the column 100 can help hid the nails used to attach the column 100 to the wall. Grout can be applied between adjacent planks as appropriate. In addition, joints between columns 100 and plank 200 can be caulked and/or grouted so as to form a water-resistant siding system.
The columns 100 are formed by a number of manufacturing steps. A commercially available rigid polystyrene foam block is machined by a hot wire to yield a plurality of generally cylindrical cores 101 having a curved surface 103, a first flat surface 105, and a second flat surface 107. Grooves 113, 115 are formed by machining of the core along lateral edges 109, 111. Lateral supports 117, 119 are bonded along grooves 113, 115, respectively. The later supports are formed such that the outer surfaces of the lateral supports and the curved surface of the core form a continuous surface. A decorative skin 121 is laminated to the continuous surface by a vacuum table diaphragm press having a rubber diaphragm that conforms to the curved shape of the column. The decorative skin can be hardboard having one side embossed with a hewn log or other esthetic appearance. Alternatively, the decorative skin can be a veneer laminated to plain hardboard without embossing. The veneer, a decorative outer layer, is laminated to plain hardboard that is laminated to the core. The veneer is laminated to the plain hardboard by a vacuum table diaphragm press have a rubber diaphragm that conforms to the curved shape of the column. The outer surface of the decorative skin can then be painted or stained as appropriate.
An advantage of the present invention is a siding system that simulates wood log construction that is made up of columns and planks that lightweight and insulating. The light weight of the siding system components simplifies installation saving both time and cost. The columns and planks are easy to handle and can be nailed directly to the wall, and preferably to the studs, without the needs for special support members, channels, or fasteners. Alternatively, the lightweight column can also be attached to the wall with adhesive and caulk. The siding system is insulating and can eliminate the need for the installation of a separate layer of insulation. The siding is esthetically pleasing because nails and fasteners used to install the planks and columns can be hidden. The overlapping design of adjacent planks forms a water resistant siding system. The materials used to form the siding system components are insect resistant, and can be treated to increase fire resistant. The siding system, except for the possible use of a wood veneer, is made from synthetic materials that minimize the environmental impact on forests.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
