EXTERIOR CLADDING PANEL

Abstract

An example exterior cladding panel includes a reveal surface. The reveal surface comprises a first end portion and a second end portion. A first end connector is adjacent the first end portion of the reveal surface. A second end connector is adjacent the second end portion of the reveal surface. The first end connector is configured to be connected to a second end panel connector of a first panel of an adjoining first course to define a first space between the reveal surface and a reveal surface of the first panel. The second end connector is configured to be connected to a first end panel connector of a second panel of an adjoining second course to define a second space between the reveal surface and a reveal surface of the second panel. The first space and/or the second space are adjustable.

Description

TECHNICAL FIELD

This disclosure relates to embodiments of exterior cladding panels.

BACKGROUND

The exterior walls and exterior ceilings of buildings may be covered by panels, or exterior cladding. Exterior cladding may be fabricated of a variety of materials, such as wood, aluminum, vinyl, or brick. When attached to a structure, the exterior cladding panel protects the structure from weather, temperature changes, pests, and other external factors that may harm a structure. For example, some exterior cladding may be waterproof, and some exterior cladding may provide additional insulation to a structure when used. The use of exterior cladding also provides for additional aesthetic customization options in exterior home design.

Exterior cladding panels may be attached not only to exterior surfaces, but also to adjacent exterior cladding panels. The exterior cladding panels may be attached to one another in a variety of ways. In some methods of attachment, some portions of the panels may overlap with portions of adjacent panels. The panels may attach to one another at the overlapping portions.

SUMMARY

This disclosure relates to embodiments of exterior cladding panels. More specifically, exterior cladding panels may attach to other exterior cladding panels using an attachment structure. The attachment structure may include ribs and grooves that are configured to mate with the ribs and grooves of other attachment structures.

The exterior cladding panels described herein may allow for selection among multiple difference spacing configurations between connected panels. Different spacings provide different visual impressions. Some building owners may prefer the look of tight spacing between panels, while others may prefer more space between panels. A single type of panel disclosed herein may have attachment structure that allows the panel to be attached to other panels in a variety of spacing configurations. If the attachment structure is connected in a first manner, the spacing between panels may be smaller, whereas if the attachment structure is connected in a second manner, the spacing between panels may be larger. Several variations of attachment structure are disclosed herein to provide for a variety of spacing options that a building owner may select.

One embodiment includes an exterior cladding panel comprising a reveal surface. The reveal surface comprises a first end portion and a second end portion. A first end connector is adjacent the first end portion of the reveal surface. A second end connector is adjacent the second end portion of the reveal surface. The first end connector is configured to be connected to a second end panel connector of a first panel of an adjoining first course to define a first space between the reveal surface and a reveal surface of the first panel. The second end connector is configured to be connected to a first end panel connector of a second panel of an adjoining second course to define a second space between the reveal surface and a reveal surface of the second panel. The first space and/or the second space are independently adjustable.

In a further embodiment of the exterior cladding panel, the first end connector comprises a first groove and a second groove. Each groove is configured to mate with a first rib of the second end panel connector of the first panel. The first space is greater when the first groove is mated with the first rib than when the second groove is mated with the first rib.

In a further embodiment of the exterior cladding panel, the second end connector comprises a second rib configured to mate with each of a third groove and a fourth groove of the first end panel connector of the second panel. The second space is greater when the second rib is mated with the third groove than when the second rib is mated with the fourth groove.

In a further embodiment of the exterior cladding panel, the first groove and the second groove each extend continuously along the first end connector. The second rib extends continuously along the second end connector.

In a further embodiment of the exterior cladding panel, the first groove and the second groove each extend continuously along the first end connector. The second rib extends intermittently along the second end connector.

In a further embodiment of the exterior cladding panel, the second end connector comprises a second end trough that includes a second end trough rear wall. The second end trough rear wall comprises the second rib. The second end connector is configured to be connected to the first end panel connector of the second panel by the second end trough fitting over a first end panel connector trough of the first end panel connector. The first end panel connector trough comprising the third groove and the fourth groove.

In a further embodiment of the exterior cladding panel, the second end trough rear wall comprises a connected end and a free end, the second rib being near the free end. The connected end of the second end trough rear wall contacts a fastening flange of the first end panel connector when the second end trough is fitted over the first end panel connector trough and the second rib is mated with the third groove or the fourth groove.

In a further embodiment of the exterior cladding panel, the free end of the second end trough rear wall extends forwardly from the connected end.

In a further embodiment of the exterior cladding panel, the first end connector further comprises a third groove configured to mate with the first rib of the second end panel connector of the first panel. The first space is greater when the second groove is mated with the first rib than when the third groove is mated with the first rib.

In a further embodiment of the exterior cladding panel, the first end connector comprises a first rib and a second rib, each configured to mate with a first groove of the second end panel connector of the first panel. The first space is greater when the first rib is mated with the first groove than when the second rib is mated with the first groove.

In a further embodiment of the exterior cladding panel, the second end connector comprises a second groove configured to mate with each of a third rib and a fourth rib of the first end panel connector of the second panel. The second space is greater when the third rib is mated with the second groove than when the fourth rib is mated with the second groove.

In a further embodiment of the exterior cladding panel, the first end connector further comprises a third rib configured to mate with the first groove of the second end panel connector of the first panel. The first space is greater when the second rib is mated with the first groove than when the third rib is mated with the first groove.

In a further embodiment of the exterior cladding panel, the first end portion comprises an upper end portion of the reveal surface. The second end portion comprises a lower end portion of the reveal surface. The first space comprises a first vertical space. The second space comprises a second vertical space.

In a further embodiment of the exterior cladding panel, the first end portion comprises a right side portion of the reveal surface. The second end portion comprises a left side portion of the reveal surface. The first space comprises a first horizontal space. The second space comprises a second horizontal space.

In a further embodiment of the exterior cladding panel, the first end connector comprises a broad groove configured to mate with a rib of the second end panel connector of the first panel. The first space is adjustable by varying a position of the rib within the broad groove.

Another embodiment of the exterior cladding panel comprises a reveal surface comprising an upper end portion and a lower end portion. An upper connector is adjacent the upper end portion of the reveal surface. The upper connector comprises a first groove and a second groove. Both the first groove and the second groove extending horizontally. A lower connector is adjacent the lower end portion of the reveal surface. The lower connector comprises a first rib, the first rib extending horizontally. The upper connector is configured to be connected to a lower panel connector of an upper panel of an adjoining upper course to define an upper vertical space between the reveal surface and a reveal surface of the upper panel. The first groove and the second groove each are configured to mate with a second rib of the lower panel connector, the second rib extending horizontally. The lower connector is configured to be connected to an upper panel connector of a lower panel of an adjoining lower course to define a lower vertical space between the reveal surface and a reveal surface of the lower panel. The first rib is configured to mate with each of a third groove and a fourth groove of the upper panel connector, both the third groove and the fourth groove extending horizontally. The upper vertical space is greater when the first groove is mated with the second rib than when the second groove is mated with the second rib. The lower vertical space is greater when the first rib is mated with the third groove than when the first rib is mated with the fourth groove.

In a further embodiment of the exterior cladding panel, the first groove and the second groove each extend continuously along the upper connector. The first rib extends continuously along the lower connector.

In a further embodiment of the exterior cladding panel, the lower connector comprises a lower trough that includes a lower trough rear wall. The lower trough rear wall comprises the first rib. The lower connector is configured to be connected to the upper panel connector of the lower panel by the lower trough fitting over an upper panel connector trough of the upper panel connector. The upper panel connector trough comprises the third groove and the fourth groove.

In a further embodiment of the exterior cladding panel, the lower trough rear wall comprises a connected end and a free end that extends forwardly from the connected end. The first rib is near the free end. The connected end of the lower trough rear wall contacts a fastening flange of the of the upper panel connector when the lower trough is fitted over the upper panel connector trough and the first rib is mated with the third groove or the fourth groove.

In a further embodiment of the exterior cladding panel, the upper connector further comprises a fifth groove configured to mate with the second rib. The fifth groove extends horizontally. The upper vertical space is greater when the second groove is mated with the second rib than when the fifth groove is mated with the second rib.

The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF DRAWINGS

The following drawings are illustrative of particular examples of the present invention and therefore do not limit the scope of invention. The drawings are not necessarily to scale, though embodiments can include the scale illustrated, and are intended for use in conjunction with the explanations in the following detailed description wherein like reference characters denote like elements. Examples of the present invention will hereinafter be described in conjunction with the appended drawings.

FIG. 1A is a front perspective view of a horizontal configuration of courses of exterior cladding panels.

FIG. 1B is a front perspective view of a vertical configuration of courses of exterior cladding panels.

FIG. 1C is a front perspective view of a soffit configuration of courses of exterior cladding panels.

FIG. 2A is a perspective view of an exterior cladding panel.

FIG. 2B is a front view of the exterior cladding panel of FIG. 2A.

FIG. 2C is a side view of the exterior cladding panel of FIG. 2A.

FIG. 2D is a close-up side view of a portion of the exterior cladding panel of FIG. 2A.

FIG. 2E is a close-up side view of a portion of the exterior cladding panel of FIG. 2A.

FIG. 3A is a side view of an exterior cladding panel for use in a course.

FIG. 3B is a side view of two exterior cladding panels to be mated.

FIG. 3C is a side view of two mated exterior cladding panels.

FIG. 3D is a side view of two mated exterior cladding panels and one exterior cladding panel to be mated.

FIG. 3E is a side view of three mated exterior cladding panels.

FIG. 4A is a side view of an exterior cladding panel for use in a course.

FIG. 4B is a side view of two exterior cladding panels to be mated.

FIG. 4C is a side view of two mated exterior cladding panels.

FIG. 4D is a side view of two mated exterior cladding panels and one exterior cladding panel to be mated.

FIG. 4E is a side view of three mated exterior cladding panels.

FIG. 5A is a perspective view of an exterior cladding panel with an illustrative rib configuration.

FIG. 5B is a perspective view of an exterior cladding panel with an illustrative rib configuration.

FIG. 6A is a side view of an exterior cladding panel.

FIG. 6B is a side view of an exterior cladding panel.

FIG. 7A is a close-up side view of a portion of an exterior cladding panel.

FIG. 7B is a perspective view of a cross section of the exterior cladding panel of FIG. 7A, taken along A-A.

FIG. 8A is a side view of an exterior cladding panel.

FIG. 8B is a side view of an exterior cladding panel.

FIG. 9 is a flow diagram of an embodiment of a method for installing exterior cladding panel.

DETAILED DESCRIPTION

The various embodiments herein relate to exterior cladding panels. The exterior cladding panels can connect and/or interlock with one another, positioning the panels into place against a surface of a structure. Certain implementations include an exterior cladding panel including a first end connector and a second end connector configured to attach an exterior cladding panel to an adjacent exterior cladding panel.

FIGS. 1A-1C each show exemplary embodiments of exterior cladding panel 20 installed on the exterior of buildings. FIG. 1A shows the exterior cladding panels 20 installed in a horizontal configuration. FIG. 1B shows the exterior cladding panels 20 installed in a vertical configuration. FIG. 1C shows the exterior cladding panels 20 as a soffit.

FIGS. 2A-2E show an illustrative exterior cladding panel 20. The exterior cladding panel 20 can have a reveal surface 22. The reveal surface 22 can have a first end portion 24 and a second portion 26. The exterior cladding panel 20 can have a thickness at the reveal surface. The thickness of the exterior cladding panel 20 can vary depending on the panel material. Some examples of the exterior cladding panel 20 can be made of aluminum, composite wood, plastic, or other materials.

As noted, the exterior cladding panel 20 may be configured for use in a horizontal configuration, as shown in FIG. 1A. Referring again to FIGS. 2A-2E, in some embodiments, the first end portion 24 may comprise an upper end portion 24 of the reveal surface 22 and second end portion 26 may comprise a lower end portion 26 of the reveal surface 22. In horizontal configurations, some examples of the reveal surface 22 can have a width ranging from 2 inches to 12 inches and a length ranging from 36 inches to 192 inches. In other embodiments, the reveal surface 22 can have a width of 4 inches to 6 inches and a length of 120 inches to 150 inches.

As noted, the exterior cladding panel 20 may be configured for use in a vertical configuration, as shown in FIG. 1B. Referring again to FIGS. 2A-2E, in a vertical configuration, the first end portion 24 may comprise a right side portion or left side portion of the reveal surface 22, and the second end portion 26 may comprise the left side portion or the right side portion of the reveal surface 22. In vertical configurations, the reveal surface can have a width ranging from 3 inches to 12 inches and a length ranging from 36 inches to 192 inches. Panels in a horizontal or vertical configuration can be the same width and/or length. In some embodiments, panels in a vertical configuration can have a larger width and/or length than panels in a horizontal configuration because of aesthetic considerations.

As noted, in some embodiments, the exterior cladding panel 20 may be configured for use as a soffit 13, as shown in FIG. 1C. In these embodiments, the exterior cladding panel 20 may be attached to the underside of an architectural or construction feature or element. The exterior cladding panel 20 may be generally parallel to the element to which it is attached, or may be at an angle from that element. In some instances, the reveal surface 22 can be the surface opposite the element to which the soffit 13 is attached. The soffit 13 may be generally horizontal or may be at an angle from a generally horizontal plane. The reveal surface 22 can be generally perpendicular to a vertical structure 15, including a seam 17 where the soffit 13 and vertical structure 15 meet. Referring again to FIGS. 2A-2E, in some embodiments, the first end portion 24 and second end portion 26 of the reveal surface 22 can be generally parallel to the seam 17. In other embodiments, the first end portion 24 and second end portion 26 of the reveal surface 22 can be generally perpendicular to such a seam 17.

The illustrative exterior cladding panel 20 includes a fastening flange 30. In some embodiments, the fastening flange 30 can extend past the reveal surface 22 of the exterior cladding panel 20. The fastening flange 30 can extend the entire length or width of the exterior cladding panel 20, depending on its orientation. The fastening flange 30 can be located near a first end portion 24 of an exterior cladding panel 20. The fastening flange 30 can include a plurality of openings 32. The openings 32 can be sized to accommodate a fastener used to attach an exterior cladding panel 20 to a structure. The fastener can be a nail, screw, or other mechanical fastener.

The exterior cladding panel 20 can include connectors to connect to adjoining courses of exterior cladding panels. The exterior cladding panel 20 can include an end connector 42 adjacent to end portion 24. The exterior cladding panel 20 can include an end connector 46 adjacent to end portion 26. In some embodiments, end connector 42 and end connector 46 can be rearward of the reveal surface 22.

As shown, connector 42 includes a trough 64, and connector 46 includes a trough 56. Trough 64 can include a wall 66 and a wall 68. One or more grooves 52A, 52B may be formed in wall 68. The grooves 52A, 52B may extend from wall 68 toward wall 66 a distance of a radius that is between 2 times and 6 times the thickness of the panel material. Two grooves 52A, 52B are shown, though any suitable number of grooves may be implemented. Trough 56 can include a wall 57 and a wall 58. One or more ribs 54 may be formed in wall 58. The ribs 54 may protrude from wall 58 toward wall 57 a distance of between 2 times and 6 times the thickness of the panel material. The distance of the protrusion of the ribs can be less than the distance of the radius of the grooves, which can allow the rib(s) to be engaged with the groove(s). One rib 54 is shown, though any suitable number of ribs may be implemented. As is discussed in greater detail elsewhere herein, the grooves 52A, 52B of one exterior cladding panel 20 are designed to interact with the rib 54 of an adjoining exterior cladding panel 20.

As shown in FIGS. 3A-3E and FIGS. 4A-4E, the panel 20A, the first panel 20B, and the second panel 20C can have substantially similar connection hardware. First end panel connector and first end connector are terms used to describe such similar connection hardware. Similarly, the terms second end panel connector and second end connector are used to describe substantially the same components on different panels. Further, it should be noted that description of the three panels herein refers to an exterior cladding panel, a first exterior cladding panel, and a second exterior cladding panel, wherein the first exterior cladding panel and second exterior cladding panel are panels that are adjacent to the exterior cladding panel. This adjacent proximity can be on the left and right of the exterior cladding panel, or above and below the exterior cladding panel.

FIGS. 3A-3E and FIGS. 4A-4E show exterior cladding panels 20A, 20B, 20C, which correspond to adjoining courses 12A, 12B, 12C in FIGS. 1A-1C. The exterior cladding panels 20A, 20B, 20C can be the same as or similar to the exterior cladding panel 20 of FIGS. 2A-2E. Referring again to FIGS. 3A-3E and FIGS. 4A-4E, exterior cladding panel 20A can include a first end connector 42A adjacent to the first end portion 24 of the reveal surface 22A and a second end connector 46A adjacent to the second end portion 26 of the reveal surface 22A. Exterior cladding panel 20B can have a first end panel connector 42B and a second end panel connector 46B. Exterior cladding panel 20C can have a first end panel connector 42C and a second end panel connector 46C.

As noted, the exterior cladding panel 20A, 20B, 20C can include a fastening flange 30. In some embodiments, the fastening flange 30 of the exterior cladding panel 20A, 20B, 20C can be part of the of the first end connector 42A, 42B, 42C. The fastening flange 30 of exterior cladding panel 20A can be in contact with a second end panel connector 46B of adjacent exterior cladding panel 20B when the first end connector 42A is adjacent to the second end panel connector 46B of adjacent exterior cladding panel 20B.

The first end connector 42A and the second end connector 46A of the exterior cladding panel 20A can help facilitate connection of the exterior cladding panel to adjoining courses. The first end connector 42A may be configured to be connected to the second end panel connector 46B of exterior cladding panel 20B in an adjoining first course (12B in FIGS. 1A-1C). The second end connector 46A can be configured to be connected to the first end panel connector 42C of exterior cladding panel 20C of an adjoining second course (12C in FIGS. 1A-1C).

As noted, in some examples, such as those in FIGS. 3A-3E and FIGS. 4A-4E, the exterior cladding panels 20A, 20B, 20C are configured horizontally. The first end portion 24 may be an upper portion 24, and the first end connector 42A, 42B, 42C may be an upper connector 42A, 42B, 42C. In some embodiments, the second end connector 46A, 46B, 46C may be a lower connector 46A, 46B, 46C, and the second end portion 26 may be a lower end portion 26. The lower connector 46A, 46B, 46C may be adjacent to the lower end portion 26 of the reveal surface 22.

In some embodiments in which the exterior cladding panels 20A, 20B, 20C are configured horizontally, upper connector 42A may be configured to be connected to lower panel connector 46B of an upper exterior cladding panel 20B of an adjoining upper course (12B in FIG. 1A). Lower connector 46A may be configured to be connected to an upper panel connector 42C of a lower exterior cladding panel 20C of an adjoining panel lower course (12C in FIG. 1A).

FIGS. 3A-3E show the process of connecting three exterior cladding panels 20A, 20B, 20C to one another to form a first common spacing 50A between the panels 20A, 20B, 20C. FIG. 3A shows exterior cladding panel 20C including connector 42C and connector 46C. Connector 46C can include a panel connector rib 54C. In use, a course including exterior cladding panel 20C can first be affixed to a surface via the fastening flange 30. Then, another course of exterior cladding panels can be attached to the initial course of exterior cladding panels using connector 42C.

FIG. 3B shows exterior cladding panel 20A in position to be attached to exterior cladding panel 20C of the adjoining initial course. Exterior cladding panel 20A can be positioned adjacent (e.g., above in a horizontal configuration) exterior cladding panel 20C. Connector 46A of exterior cladding panel 20A can be positioned so that the trough 56A can be fitted over connector 42C of exterior cladding panel 20C.

FIG. 3C shows exterior cladding panel 20A attached to exterior cladding panel 20C. Connector 46A of panel 20A is mated with connector 42C of panel 20C, with rib 54A mated with groove 52D. In this configuration, a space 50A is defined between the reveal surface 22A of panel 20A and the reveal surface 22C of panel 20C. As shown, when trough 56A is fitted over connector 42C, trough 56A is in contact with the fastening flange of panel 20C.

FIG. 3D shows the positioning of exterior cladding panel 20B of an adjoining course to be attached to exterior cladding panel 20A. Similar to exterior cladding panel 20A and exterior cladding panel 20C, exterior cladding panel 20B can be positioned such that the trough 56B of connector 46B can be fitted over connector 42A.

FIG. 3E shows connector 46B of exterior cladding panel 20B fitted over connector 42A of exterior cladding panel 20A, with rib 54B of panel 20B mated with groove 52B of panel 20A. In this configuration, the space 50A is defined between the reveal surface 22B of panel 20B and the reveal surface 22A of panel 20A. The space 50A can be consistent between multiple courses of panels if the rib of each panel is mated with the same groove of the adjoining panel. In other embodiments, the space 50A can be of inconsistent size between multiple courses of panels, as the ribs can be mated with a different groove of the adjoining panel. Exterior cladding panel 20B can include a connector 42B, which can include one or more grooves 52F, 52G configured for use with additional cladding panels.

FIGS. 4A-4E show a similar configuration to that of FIGS. 3A-3E, but with variation in spacing between the panels 20A, 20B, 20C. FIG. 4A shows exterior cladding panel 20C including connector 42C and connector 46C. Connector 46C can include rib 54C. In use, a second or lower course of exterior cladding panels can first be affixed to a surface (not pictured). Then, additional exterior cladding panels can be attached to the second or lower course of exterior cladding panels.

FIG. 4B shows exterior cladding panel 20A in position to be attached to exterior cladding panel 20C of an adjoining second course. Exterior cladding panel 20A can be positioned adjacent (e.g., above in a horizontal configuration) exterior cladding panel 20C. Connector 46A of exterior cladding panel 20A can be positioned so that trough 56A can fitted over connector 42C.

FIG. 4C shows such a fit of connector 46A mated with connector 42C, defining a space 50B between reveal surface 22A of panel 20A and reveal surface 22C of panel 20C. Rib 54A of connector 46A can be mated with groove 52C of connector 42C of panel 20C. As can be seen, space 50B is larger than space 50A of FIGS. 3C-3E. Different configurations of ribs and grooves can facilitate different panel spacing options.

FIG. 4D shows the positioning of exterior cladding panel 20B of an adjoining course to be attached to exterior cladding panel 20A. Similar to exterior cladding panel 20A and exterior cladding panel 20C, exterior cladding panel 20B can be positioned such that the trough 56B of connector 46B is fitted over connector 42A. Exterior cladding panel 20B can include connector 42B, which can include two grooves 52F, 52G configured for use with additional exterior cladding panels.

FIG. 4E shows connector 46B of exterior cladding panel 20B fitted over connector 42A of exterior cladding panel 20A, with rib 54B of panel 20B mated with groove 52A of panel 20A. In this configuration, the space 50B is defined between the reveal surface 22B of panel 20B and the reveal surface 22A of panel 20A. The space 50B can be consistent between multiple courses of panels if the rib of each panel is mated with the same groove of the adjoining panel.

As noted, how connectors 42A, 42B, 42C and connectors 46A, 46B, 46C are connected to one another can enable adjustment of the spacing between courses of exterior cladding panels. The space 50A of FIGS. 3C-3E is smaller than the space 50B of FIGS. 4C-4E. The space between reveal surfaces of adjoining panels can range from 1/16 of an inch to 1 inch. In some embodiments, space 50A can be 1/16 of an inch and space 50B can be ½ of an inch. In other embodiments, the spaces 50A and 50B can be any size compatible with use of the panels. In some embodiments the spacing between panels can be varied (e.g., space 50A between panel 20A and panel 20C, and space 50B between panel 20B and panel 20A).

Referring again to FIG. 1B and FIGS. 2A-2E, in some examples, the exterior cladding panels 20 are configured vertically. Connector 42 may be adjacent a left side portion or a right side portion of the reveal surface 22, and connector 46 can be adjacent the opposite portion of the reveal surface 22.

The vertical and horizontal configurations may affect the orientation of the spaces 50A, 50B between courses 12A, 12B, 12C of exterior cladding panels. When the exterior cladding panels 20 are in a horizontal configuration, the spaces 50A, 50B may be vertical spaces, including an upper vertical space and a lower vertical space. When the exterior cladding panels 20 are in a vertical configuration, the spaces 50A, 50B may be horizontal spaces, including a right-side horizontal space and a left-side horizontal space. When the exterior cladding panel 20 is in a soffit configuration 13, the spaces 50A, 50B may be horizontal spaces.

Referring generally to FIGS. 3E and 4E, connector 42A of exterior cladding panel 20A may attach to exterior cladding panel 20B using a variety of configurations. In some embodiments, connector 42A can include a first groove 52A and a second groove 52B. The first and second grooves 52A, 52B may be configured to mate with a rib 54B of connector 46B of exterior cladding panel 20B. The space formed when the rib 54B is mated with the first groove 52A is greater than the space formed when the rib 54B is mated with the second groove 52B.

Connector 46A of exterior cladding panel 20A may attach to exterior cladding panel 20C using a variety of configurations. In some embodiments, connector 46A can include a rib 54A configured to mate with each of groove 52C and groove 52D of connector 42C of exterior cladding panel 20C. The space formed when the rib 54A is mated with groove 52C is greater than the space formed when the rib 54A is mated with groove 52D.

In examples in which exterior cladding panels 20A, 20B, 20C are oriented horizontally, grooves 52A, 52F, 52C, grooves 52B, 52G, 52D, and ribs 54A, 54B, 54C can all extend horizontally. In such embodiments, the spacing between the panels 20A, 20B, 20C can be vertical spaces.

FIGS. 5A-5B show different embodiments may comprise different rib and/or groove configurations. FIG. 5A shows a rib 54 that extends continuously along connector 46—as shown, all the way from the left side of the panel 20 to the right side of the panel 20. FIG. 5B shows two ribs 54A, 54D. Rib 54A extends continuously along connector 46. Rib 54D extends intermittently along connector 46. Ribs that extend intermittently can fit well with grooves that extend continuously. Various intermittent groove configurations can be implemented.

Trough 56 may comprise various structural characteristics. Wall 58 may comprise a connected end 60 and a free end 62. Rib 54 may be located near the free end 62. In some examples, the free end 62 of wall 58 may extend forwardly from the connected end 60. The connected end 60 of wall 58 may contact a fastening flange (30 in other Figures) when trough 56 is fitted over trough 64 and rib 54 is mated with one of the associated grooves. This is shown in FIGS. 3C-3E and FIGS. 4C-4E.

In some embodiments, three or more different spacings between courses of exterior cladding panels may be selected. FIGS. 6A-6B illustrate such configurations. In FIG. 6A, connector 42 includes three grooves 652A, 652B, 652C. When one panel 80 is joined to another panel 80, rib 54 of one panel 80 mates with groove 652A or groove 652B or groove 652C of the other panel 80 to achieve three different possible spacings between the panels 80. In FIG. 6C, connector 46 includes three ribs 654A, 654B, 654C. When one panel 90 is joined to another panel 90, one of the ribs 654A, 654B, 654C of one panel 90 is mated with the groove 52 of the other panel 90 to achieve three different possible spacings between the panels 80.

Some embodiments use ribs and/or grooves adjacent either end portion. Connector 42 may comprise multiple ribs, each of which may be configured to mate with a single groove of connector 46 of a different panel. When one rib is mated with the groove, the space formed may be greater than when the other rib is mated with the groove. Multiple different spacings may be achieved by using various combinations of ribs and grooves.

The exterior cladding panel 100 may have additional structures for customization in attachment to other panels, such as FIGS. 7A-7B. In some embodiments, connector 42 may comprise a broad groove 53 configured to mate with a rib of another panel's connector. The space between the panels may be adjustable by varying a position of the rib within the broad groove 53. The broad groove 53 can extend the length of the panel 100. In some embodiments, the groove can have a height of 1/16 of an inch to greater than one inch.

Referring again to FIGS. 3A-3E and FIGS. 4A-4E, it is common that the exterior cladding panels 20A, 20B, 20C are oriented horizontally (e.g., FIG. 1A). When oriented horizontally, exterior cladding panel 20B is positioned directly above exterior cladding panel 20A. Thus, exterior cladding panel 20B may be referred to as an upper panel 20B. When oriented horizontally, exterior cladding panel 20C is positioned directly below exterior cladding panel 20A. Thus, exterior cladding panel 20C may be referred to as a lower panel 20C. With a horizontal orientation, a panel 20 as shown in FIGS. 2A-2E has a reveal surface 22, an upper end portion 24, a lower end portion 26, an upper connector 42 adjacent to the upper end portion 24, and a lower connector 46 adjacent to the lower end portion 26.

This paragraph refers to FIG. 3B-3C and assumes, for purposes of illustration, a horizontal panel orientation. In some embodiments, lower connector 46A may comprise a lower trough 56A that includes a lower trough rear wall 58A. The lower trough rear wall 58A may comprise the first rib 54A. Lower connector 46A may be configured to be connected to upper panel connector 42C of the lower panel 20C. This connection may occur by fitting the lower trough 56A over an upper panel connector trough 64C of the upper panel connector 42C. The upper panel connector trough 64C may comprise grooves 52C, 52D.

The features of the lower trough rear wall 58A may affect how lower connector 46A interacts with panel 20C. The lower trough rear wall 58A may comprise a connected end 60A and a free end 62A. The free end 62A can extend forwardly from the connected end 60A. The first rib 54A may be near the free end 62A. When the lower trough 56A is fitted over the upper panel connector trough 64C, the connected end 60A of the lower trough rear wall 58A may contact a fastening flange 30 of the upper panel connector 42C. This contact may occur when the lower trough 56A is fitted over the upper panel connector trough 64C and the first rib 54A is mated with groove 52D (or groove 52C in FIGS. 4C-4E). In some embodiments, the connected end 60A of the lower trough rear wall 58A may be near the fastening flange 30 of the upper panel connector 42C without actually contacting the fastening flange 30.

The reveal surface 22 may include a variety of features, as shown in FIGS. 8A-8B. In some embodiments, the reveal surface 22 may be flat (e.g., FIGS. 2A-2E). In some embodiments, the reveal surface 22 may comprise additional features. In some embodiments, the reveal surface 22 may be embossed. In some embodiments, the reveal surface 22 may have multiple levels. For example, FIG. 8A shows a reveal surface 22 with one or more flat front levels 33 and one or more flat recessed levels 34. The flat front levels 33 and flat recessed levels 34 can be connected by a sloped surface 36. In some such embodiments, the flat front levels 33 of an exterior cladding panel 110 can be level with the flat front levels 33 of an adjacent exterior cladding panel 110. The recessed levels 34 of an exterior cladding panel 110 can be level with the recessed levels 34 of an adjacent exterior cladding panel 110. The recessed levels 34 and flat front levels 33 can be equally spaced from one another. For example, when multiple exterior cladding panels are assembled in adjacent courses (also referred to herein as “adjoining courses” or “courses”), the recessed levels 34 can be generally equidistant from one another. FIG. 8B shows an angled reveal surface 22 of an exterior cladding panel 120. The angle θ may be such that the distance from the reveal surface 22 back to the first end connector 42 at the first end portion 24 is smaller than the distance from the reveal surface 22 back to the second end connector 46 at the second end portion 26.

FIG. 9 shows a method of using exterior cladding panels depending on the orientation of the exterior cladding panels. The method can include providing an exterior cladding panel, such as any of those described herein (905).

The method can include deciding whether the panel will be attached in a vertical, horizontal, or soffit configuration (910). In evaluating how the panel will be attached, the method can include evaluating the surface on which the exterior cladding is to be attached. Some examples of the method can include evaluating the desired aesthetic design of the surface and determining which configuration of the soffit can achieve such an aesthetic design.

The method can include selecting the desired spacing between the panels (915A, 915B, 915C). This selection can determine the spacing between courses. The spacing between the panels can be the same, or different, depending on the configuration chosen by a user.

The method can include adjusting the alignment of a first panel's rib(s) into a second panel's groove(s) to correspond to the selected spacing configuration (920A, 920B, 920C). Examples of this method can include fitting the second end trough over a first end panel connector trough.

The method can include attaching a first panel to a second panel (925A, 925B, 925C). Attaching the first panel to the second panel can include configuring a first panel connector to connect to a second panel connector. The resulting space between the first panel and second panel can have different orientations depending on the configuration of each of panels. When the panels are attached in the horizontal configuration, the space between the first panel and the second panel is a vertical space (925A). When the panels are attached in a vertical configuration, the space between the first panel and second panel is a horizontal space (925B). When the panels are attached in a soffit configuration, the resulting space between the first and second panel can be generally parallel to the ground, or generally perpendicular to a surface adjacent to the soffit (925C).

The method can include determining whether additional panels are needed (930A, 930B, 930C). As shown with a solid line, if an additional panel is needed and if the same spacing is desired for the additional panel, a user can attach an additional panel to already provided panel. As shown with a dashed line, if an additional panel is needed and if a different spacing is desired for the additional panel, alignment of the additional panel's and already provided panel's rib(s)/groove(s) can achieve the desired spacing, and then the additional panel can be attached to the already provided panel. The method can include continuing to provide panels until the surface on which the panels are attached to is covered in the desired amount of exterior cladding panels. This can include covering an entire surface in exterior cladding panels.

While the various systems described above are separate implementations, any of the individual components, mechanisms, or devices, and related features and functionality, within the various system embodiments described in detail above can be incorporated into any of the other system embodiments herein.

Claims

1. An exterior cladding panel comprising: (a) a reveal surface comprising a first end portion and a second end portion;(b) a first end connector adjacent the first end portion of the reveal surface; and(c) a second end connector adjacent the second end portion of the reveal surface,wherein:the first end connector is configured to be connected to a second end panel connector of a first panel of an adjoining first course to define a first space between the reveal surface and a reveal surface of the first panel,the second end connector is configured to be connected to a first end panel connector of a second panel of an adjoining second course to define a second space between the reveal surface and a reveal surface of the second panel, andthe first space and/or the second space are adjustable.

2. The exterior cladding panel of claim 1, wherein: the first end connector comprises a first groove and a second groove, each configured to mate with a first rib of the second end panel connector of the first panel, andthe first space is greater when the first groove is mated with the first rib than when the second groove is mated with the first rib.

3. The exterior cladding panel of claim 2, wherein: the second end connector comprises a second rib configured to mate with each of a third groove and a fourth groove of the first end panel connector of the second panel, andthe second space is greater when the second rib is mated with the third groove than when the second rib is mated with the fourth groove.

4. The exterior cladding panel of claim 3, wherein: the first groove and the second groove each extend continuously along the first end connector, andthe second rib extends continuously along the second end connector.

5. The exterior cladding panel of claim 3, wherein: the first groove and the second groove each extend continuously along the first end connector, andthe second rib extends intermittently along the second end connector.

6. The exterior cladding panel of claim 3, wherein: the second end connector comprises a second end trough that includes a second end trough rear wall, the second end trough rear wall comprising the second rib, andthe second end connector is configured to be connected to the first end panel connector of the second panel by the second end trough fitting over a first end panel connector trough of the first end panel connector, the first end panel connector trough comprising the third groove and the fourth groove.

7. The exterior cladding panel of claim 6, wherein: the second end trough rear wall comprises a connected end and a free end, the second rib being near the free end,the connected end of the second end trough rear wall contacts a fastening flange of the first end panel connector when the second end trough is fitted over the first end panel connector trough and the second rib is mated with the third groove or the fourth groove.

8. The exterior cladding panel of claim 7, wherein the free end of the second end trough rear wall extends forwardly from the connected end.

9. The exterior cladding panel of claim 2, wherein: the first end connector further comprises a third groove configured to mate with the first rib of the second end panel connector of the first panel, andthe first space is greater when the second groove is mated with the first rib than when the third groove is mated with the first rib.

10. The exterior cladding panel of claim 1, wherein: the first end connector comprises a first rib and a second rib, each configured to mate with a first groove of the second end panel connector of the first panel, andthe first space is greater when the first rib is mated with the first groove than when the second rib is mated with the first groove.

11. The exterior cladding panel of claim 10, wherein: the second end connector comprises a second groove configured to mate with each of a third rib and a fourth rib of the first end panel connector of the second panel, andthe second space is greater when the third rib is mated with the second groove than when the fourth rib is mated with the second groove.

12. The exterior cladding panel of claim 10, wherein: the first end connector further comprises a third rib configured to mate with the first groove of the second end panel connector of the first panel, andthe first space is greater when the second rib is mated with the first groove than when the third rib is mated with the first groove.

13. The exterior cladding panel of claim 1, wherein: the first end portion comprises an upper end portion of the reveal surface,the second end portion comprises a lower end portion of the reveal surface,the first space comprises a first vertical space, andthe second space comprises a second vertical space.

14. The exterior cladding panel of claim 1, wherein: the first end portion comprises a right side portion of the reveal surface,the second end portion comprises a left side portion of the reveal surface,the first space comprises a first horizontal space, andthe second space comprises a second horizontal space.

15. The exterior cladding panel of claim 1, wherein: the first end connector comprises a broad groove configured to mate with a rib of the second end panel connector of the first panel, andthe first space is adjustable by varying a position of the rib within the broad groove.

16. An exterior cladding panel comprising: (a) a reveal surface comprising an upper end portion and a lower end portion;(b) an upper connector adjacent the upper end portion of the reveal surface, the upper connector comprising a first groove and a second groove, both the first groove and the second groove extending horizontally; and(c) a lower connector adjacent the lower end portion of the reveal surface, the lower connector comprising a first rib, the first rib extending horizontally,wherein:the upper connector is configured to be connected to a lower panel connector of an upper panel of an adjoining upper course to define an upper vertical space between the reveal surface and a reveal surface of the upper panel, the first groove and the second groove each being configured to mate with a second rib of the lower panel connector, the second rib extending horizontallythe lower connector is configured to be connected to an upper panel connector of a lower panel of an adjoining lower course to define a lower vertical space between the reveal surface and a reveal surface of the lower panel, the first rib being configured to mate with each of a third groove and a fourth groove of the upper panel connector, both the third groove and the fourth groove extending horizontally,the upper vertical space is greater when the first groove is mated with the second rib than when the second groove is mated with the second rib, andthe lower vertical space is greater when the first rib is mated with the third groove than when the first rib is mated with the fourth groove.

17. The exterior cladding panel of claim 16, wherein: the first groove and the second groove each extend continuously along the upper connector, andthe first rib extends continuously along the lower connector.

18. The exterior cladding panel of claim 16, wherein: the lower connector comprises a lower trough that includes a lower trough rear wall, the lower trough rear wall comprising the first rib, andthe lower connector is configured to be connected to the upper panel connector of the lower panel by the lower trough fitting over an upper panel connector trough of the upper panel connector, the upper panel connector trough comprising the third groove and the fourth groove.

19. The exterior cladding panel of claim 18, wherein: the lower trough rear wall comprises a connected end and a free end that extends forwardly from the connected end, the first rib being near the free end, andthe connected end of the lower trough rear wall contacts a fastening flange of the of the upper panel connector when the lower trough is fitted over the upper panel connector trough and the first rib is mated with the third groove or the fourth groove.

20. The exterior cladding panel of claim 16, wherein: the upper connector further comprises a fifth groove configured to mate with the second rib, the fifth groove extending horizontally, andthe upper vertical space is greater when the second groove is mated with the second rib than when the fifth groove is mated with the second rib.