Patent Grant
11498357
The present disclosure relates generally to surface panels for covering a building surface, for example, suitable for covering the exterior surface of a house. The present disclosure relates more particularly to a surface panel kit for covering a building surface with a plurality of panels that form a decorative design.
Many building surfaces are constructed with a supporting structure, such as a frame or substrate layer, that is covered with a decorative layer. For example, exterior walls may include an exterior sheathing that is covered with cladding that is, or appears to be, wood siding, brick, or stone. Other walls may include panels attached to a frame or furring strips. Likewise, a floor may be constructed with a floor sublayer that is covered with decorative flooring, such as tile or wood.
There are various advantages that a decorative layer formed from a synthetic product might have compared to a layer formed from a natural product. For example, the synthetic product may be less expensive, more durable and/or easier to install than the natural counterpart. However, customers often desire a building surface with a decorative layer that has the aesthetic of a traditional natural product. A common visible distinction between synthetic products and natural products is that natural products typically vary in appearance, while synthetic products are often uniform in appearance. One attempt to avoid the uniformity of synthetic products has been to replicate the appearance of a natural product. Thus, a building surface panel may appear as a single natural product, or a group of natural products that includes the varying grains or edges that a natural product might have. However, even if a panel has a very natural aesthetic, observers are apt to notice if the aesthetic repeats. Accordingly, a discernible repetitive pattern can reveal that a building surface is made of a synthetic product, rather than a natural product.
One attempt to avoid a repetitive pattern is to make several types of panels that each have a different appearance. But there is still a risk of an installer placing the panels in a repeating pattern, which will identify the decorative surface as synthetic. Another option is to use a very large number of different panel types so that few, if any, of the same panel type is used in an installation. But creating such a large number of panel types can be very expensive.
Observers also find abstract patterns interesting if they are non-repetitive, as they have a custom appearance. Accordingly, with both natural decorative designs and abstract decorative designs, non-repetitive patterns can be advantageous.
The present inventors have recognized that a kit for installing building surface panels that easily avoids repetition would be attractive to builders.
In one aspect, the present disclosure provides a wall panel kit comprising:
In another aspect, the disclosure provides
Additional aspects of the disclosure will be evident from the disclosure herein.
The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.
As described above, the present inventors have noted that many decorative building surfaces can have unintended repetition that is identifiable by observers. The present inventors have determined that a surface panel kit that can be easily installed while avoiding repetition would be attractive to builders.
Accordingly, one aspect of the disclosure is a wall panel kit including a set of panels configured for attachment to a support structure. Each of the panels includes an upper side, a lower side, opposing ends, and a panel body. The panel body has a front face that includes a decorative design. The ends of each panel are configured to mate with the ends of other panels in the set of panels to form a linear row of panels that includes a continuous decorative surface formed by the front faces of the panel bodies in the linear row. Each end of the panels includes one of a group of end configurations, and the group of end configurations includes a first end configuration and a second end configuration. The first end configuration is mateable with a first portion of the group of end configurations and is unmateable with a second portion of the group of end configurations. Further, the second end configuration is mateable with a third portion of the group of end configurations and is unmateable with a fourth portion of the group of end configurations. The set of panels has at least three panel types including a first panel type that includes the first end configuration with the second end configuration, a second panel type that includes the first end configuration without the second end configuration, and a third panel type that includes the second end configuration without the first end configuration.
In some embodiments, as explained in more detail below, the portions of the group of end configurations that are mateable with some end configurations and not with others include a single end configuration. In other words, in some embodiments, an end configuration is mateable with one end configuration in the group and/or unmateable with one end configuration in the group. In other embodiments, the portions include multiple end configurations. Further, as also explained in more detail below, in some embodiments the first portion of the group that is mateable with the first end configuration is the same as the fourth portion of the group that is unmateable with the second end configuration. Likewise, in some embodiments, the second portion of the group that is unmateable with the first end configuration the same as the third portion that is mateable with the second end configuration.
The term mateable, as used herein, refers to mechanical compatibility between two end configurations that allows the panels to be positioned adjacent to one another such that the front faces of the adjacent panel bodies forms a substantially continuous front surface. For example, panels with mateable end configurations may be positioned such that the rear surfaces of both panels, which are configured to abut the support structure, are coplanar, while the front faces are adjacent along the bordering ends. In contrast, unmateable end configurations prevent two panels from being installed on a support structure with the respective unmateable end configurations connected and the front face of the panels forming a continuous front surface.
A portion of such a surface panel kit is schematically shown in a front view in
For example,
Referring again to
The set of panels includes four panel types 142, 144, 146, 148 which are represented in
This pairing of end configurations and panel types fosters randomization of the design on the front surface without the need for specific panel arrangements. After each panel is placed on the support structure, the selection of the subsequent tile is limited to two panel types of the set, while the other two panel types will be unmateable. This gives the installer a constrained option for the following panel that will be installed, which introduces randomness into the order of panels in a given row of panels. Accordingly, the decorative design of the installed panels has a high likelihood of having a randomized appearance.
In certain embodiments as otherwise described herein, each end configuration is either a left-side configuration that is mateable with a matching right-side configuration or a right-side configuration that is mateable with a matching left side configuration. In some embodiments, the first end configuration is a first left side configuration and the second end configuration is a first right-side configuration, and the group of end configurations further comprises a second left side configuration and a second right side configuration.
For example, each of the end configurations 130, 132, 134, 136 is configured to mate with a matching end configuration from the group of end configurations. In particular, first end configuration 130 is a left-side configuration that is mateable with third end configuration 134, which is a right-side configuration. Likewise, second end configuration 132 is a right-side configuration that is mateable with fourth end configuration 136, which is a second left-side configuration.
In certain embodiments as otherwise described herein, the set of panels comprises at least four panel types including the first panel type that includes the first left-side configuration and the first right-side configuration, the second panel type that includes the first left-side configuration and the second right-side configuration, the third panel type that includes the second left-side configuration and the first right-side configuration, and a fourth panel type that includes the second left-side configuration and the second right-side configuration. For example, in surface panel kit 100 first panel type 142 includes first left-side configuration 130 and first right-side configuration 132, second panel type 144 includes first left-side configuration 130 and second right-side 134, third panel type 146 includes second left-side configuration 136 and first right-side configuration 132, and fourth panel type 148 includes second left-side configuration 136 and second right-side configuration 134. Thus, as an example, the first end 116 of first panel type 142, which includes the first left-side configuration 130, is mateable with the second panel type 144 and the fourth panel type 148, both of which include second right-side configuration 134 that matches first left-side configuration 130. Likewise, the second end 118 of first panel type 142, which includes the first right-side configuration 132, is mateable with the third panel type 146 and the fourth panel type 148, both of which include second left-side configuration 136.
In certain embodiments as otherwise described herein, the first end configuration and the second end configuration are rotationally symmetrical about an axis that is perpendicular to the front face. For example, in some embodiments, such a rotationally symmetrical end configuration includes a projection on an upper portion of the end configuration and a matching indentation on a lower portion of the end configuration. Accordingly, the projection of the end configuration can be inserted into the matching indentation on a panel having the same end configuration. Thus, in some embodiments, a particular end configuration is mateable with the same type of end configuration on another panel. In particular, in some embodiments, this connection is possible when one of the panels is rotated by 180 degrees with respect to the other about an axis that is perpendicular to the front face.
In certain embodiments as otherwise described herein, the first end configuration is mateable with the first end configuration and is unmateable with the second end configuration. Further, in some embodiments, the second end configuration is mateable with the second end configuration and is unmateable with the first end configuration. A surface panel kit including such end configurations is shown in
One of each panel type that is included in kit 400 is shown in
In certain embodiments as otherwise described herein, both ends of the second panel type include the first end configuration, and both ends of the third panel type include the second end configuration. For example, panel kit 400 includes a first panel type 442 that includes the first end configuration 430 with the second end configuration 432, a second panel type 444 that includes the first end configuration 430 at both ends 416, 418, and a third panel type 446 that includes the second end configuration 432 at both ends 416, 418. Thus, the second panel type 444 is mateable with itself, as the first end configuration 430 is mateable with itself, and also mateable with the first panel type 442, because it includes the first end configuration. Similarly, the third panel type 446 is mateable with itself and with the first panel type 442.
While surface panel kit 400 includes three panel types and two end configurations, and surface panel kit 100 includes four panel types and four end configurations, in other embodiments the surface panel kit includes more than four panel types and more than four end configurations. For example, in some embodiments, the surface panel kit includes three left-side end configurations and three right-side end configurations, totaling six end configurations. Some embodiments including six end configurations have nine panel types, including a different panel type for each pair of end configurations (e.g., A-A′, A-B′, A-C′, B-A′, B-B′, B-C′, C-A′, C-B′, C-C′). Other embodiments including six end configurations have six panel types, including a different type for each pair of end configurations but excluding matching end configurations on the same panel type (e.g., A-B′, A-C′, B-A′, B-C′, C-A′, C-B′). Such an embodiment prevents any two panels in a row from being the same, as no panel may be connected with a panel of the same type.
In addition to having different end configurations, the different panel types may also have different decorative designs. Indeed, in some embodiments, the surface panel kit includes different panel types that have the same end configurations but different decorative designs on the front face. For example, a surface panel kit may include a fifth panel type that has the same end configurations as the first panel type, but has a different decorative design on the front face.
In certain embodiments as otherwise described herein, each of the panels includes a first fastening strip disposed along the upper side thereof, the fastening strip being configured to secure the panel to the support structure. For example, panels 102, 104, 106 and 108 each include a fastening strip 160 across the upper side thereof. The fastening strip is configured to receive mechanical fasteners, such as nails or screws, for attaching the panel to the support strip. In some embodiments, the fastening strip includes apertures for receiving the mechanical fasteners. In other embodiments, the mechanical fasteners may be driven through the fastening strip.
In certain embodiments as otherwise described herein, each of the panels includes a second fastening strip disposed along the lower side thereof. For example, panels 402, 404 and 406 shown in
In other embodiments, the panels are configured for attachment to a support structure using an adhesive. For example, in some embodiments, the panels include a rear face that is substantially planar to form a surface for receiving the adhesive. As will be appreciated by those of ordinary skill in the art, the rear face may be flat or have a texture to promote adhesion. In some embodiments, the adhesive is an organic adhesive, such as a curable glue, a single component epoxy, a two component epoxy, a hot-melt thermoplastic, or a polyurethane resin. In other embodiments, the adhesive is an inorganic adhesive, such as mortar or cement.
In certain embodiments as otherwise described herein, the first end configuration includes a first contoured edge of a panel body and is mateable with an end configuration including a matching contoured edge of another panel body. The term contoured edge, as used herein, refers to a non-linear edge extending between the upper side and the lower side of the panel body, and that includes at least one projection or indentation between the upper side and lower side. In particular, the projection and/or indentation extends across the entire thickness of the panel body, such that an undulating silhouette of the contoured edge is visible when viewing the front face of the panel body. For example, first end configuration 130 is formed by a first contoured edge 150 that includes a central indentation 170 between the upper side 112 and the lower side 114. Further first contoured edge 150 also includes chamfered corners 172 that contribute to the contour of the edge.
The phrase matching contoured edge, as used herein, refers to a substantially reversed contour such that the two matching end configurations can fit together in a manner similar to a puzzle. Thus, for each projection in the contoured edge of an end configuration, a matching end configuration includes a corresponding indentation, and for each indentation in the end configuration, the matching end configuration includes a corresponding projection. Moreover, the matching end configurations are mateable such that they fit together without substantial gaps formed between the front faces of each panel body. As a result, mateable panels with matching end configurations form a continuous front surface that extends over both panels. For example, third end configuration 134 (shown on second panel 104) is mateable with first end configuration 130 and includes a matching contoured edge 152 that couples with contoured edge 150. In particular, matching contoured edge 152 includes a central projection 174 between the upper side and lower side of the respective panel that is configured for insertion into the central indentation 170 of first contoured edge 150. Likewise, matching contoured edge 152 also includes angled projections 176 at the upper and lower sides of the edge that are configured to match the chamfered corners 172 of first contoured edge 150.
In certain embodiments as otherwise described herein, the second end configuration includes a second contoured edge of a panel body and is mateable with an end configuration including a matching contoured edge of another panel body. For example, in surface panel kit 100, second end configuration 132 has a contoured edge that matches the contoured edge of fourth end configuration 136, which allows second end configuration 132 and fourth end configuration 136 to be mateable with one another.
While all of the end configurations in surface panel kit 100 include contoured edges of the panel bodies, in some embodiments at least a portion of the end configurations include a panel body with a linear edge. For example, in certain embodiments as otherwise described herein, the second end configuration includes a linear edge of the panel body. For example, the linear edge may extend directly between the upper side and lower side of the panel in a direction perpendicular to the line of the row formed by the panels, i.e., a straight edge, or the linear edge may be at an angle to line of the row. An end configuration with such a linear edge is mateable with another end configuration having a linear edge at a complimentary angle, but is unmateable with an end configuration having a contoured edge. For example, none of the end configurations 130, 132, 134, 136 shown in
In certain embodiments as otherwise described herein, each first end configuration includes a connector comprising at least one fastener configured to attach to a matching fastener of another connector on another panel. Each of the fasteners may be formed as any of a variety of different structures for connecting one panel to another, including a plug, a socket, a hook, a loop, a flange, a prong, a tongue, a groove, a slot, a stud, a magnet, a snap-fit connector, or another connecting structure. For example, surface panel kit 600, shown in
First panel type 642 includes a first end configuration 630 on the left side that is formed by a connector 654 that includes a single socket 656 toward the upper side of the panel. First panel type 642 also includes a second end configuration 632 on the right side that is formed by a connector 654 that includes two plugs. Second panel type 644 includes the first end configuration 630 on the left side and a third end configuration 634 on the right side that is formed by a connector 654 including a single plug 656 toward the upper side of the panel. The plug on the connector 654 of the third end configuration 634 is mateable with the socket on the connector of the first end configuration 630. Thus, the right side of the second panel type 644 is mateable with the left side of either the first panel type 642 or the second panel type 644.
The third panel type 646 includes a fourth end configuration 638 formed by a connector that includes two sockets on the left side and the second end configuration 632 on the right side. Thus, the first panel type 642 is mateable on the right side with the third panel type 646 or the fourth panel type 648. The first panel type 642 is also mateable on the left side with the second panel type 644 or the fourth panel type 648. The second panel type 644 is mateable on the left side with another copy of the second panel type 644 or the fourth panel type 648, and is mateable on the right side with the first panel type 642 or another copy of the second panel type 644. The third panel type 646 is mateable on the left side with the first panel type 642 or another copy of the third panel type 646, and mateable on the right side with another copy of the third panel type 646 or the fourth panel type 648. The fourth panel type 648 is mateable on the left side with the first panel type 642 or the third panel type 646 and is mateable on the right side with the first panel type 642 or the second panel type 644.
In certain embodiments as otherwise described herein, the connector is attached to the panel body. For example, in some embodiments, the connector is a metal or plastic structure that is secured to the panel body using mechanical fasteners. In other embodiments, the connector is welded to the panel body. Still in other embodiments, the connector is integrally formed with the panel body. For example, in some embodiments, the connectors are formed as plugs and sockets extend from or into a side wall of the panel body. In other embodiments, the connectors are formed as tongue and groove configurations in the side walls of the panel bodies. Other configurations of the connectors that are integrally formed with the panel body are also possible.
In certain embodiments as otherwise described herein, the first end configuration includes a connector with a different number of fasteners than the connector of the second end configuration. For example, first end configuration 632 in surface panel kit 600 includes a connector 654 with a single fastener 656, while second end configuration 634 includes a connector 654 with two fasteners 656.
In certain embodiments as otherwise described herein, the first end configuration includes a different shaped fastener than the second end configuration. For example, surface panel kit 700, shown in
In certain embodiments as otherwise described herein, a fastener of the first end configuration is in a different position than a fastener of the second end configuration. For example, surface panel kit 800, shown in
In certain embodiments as otherwise described herein, the panel body of each panel has a width in a range from 4 inches to 12 feet, e.g., 18 inches to 8 feet, e.g., 30 inches to 6 feet. The panel body includes the visible portion of the panel and comprises the decorative front face. Any portion of the panel that is hidden behind another panel, such as the fastening strip, is described herein as a separate element, though it may be integrally formed with the panel body.
In certain embodiments as otherwise described herein, each panel body includes an upper edge and a lower edge, and wherein the upper edge is the same length as the lower edge. In some embodiments, the upper edge of each panel in the surface panel kit is the same length. Embodiments in which there is uniformity in the upper and/or lower edges allows uniform spacing of the panels along each row. Such uniform spacing allows matching of panels between adjacent rows in addition to along the row. In other embodiments, the upper edge and lower edge have different lengths. For example, the upper edge of panel type 142 of surface panel kit 100, shown in
In certain embodiments as otherwise described herein, the panel body of each panel has a height in a range of 4 inches to 8 feet, e.g., 8 inches to 3 feet, e.g., 12 inches to 36 inches. Again, as set forth above, the panel body, as referred to herein, does not include any fastening strip included in the panel.
In certain embodiments as otherwise described herein, each of the panel bodies has the same height. In other embodiments, some of the panels have different heights. For example, in some embodiments, an additional panel type has twice the height of the other panels, and each side of this panel includes two end configurations configured to match with the other panels.
In certain embodiments as otherwise described herein, the panel body of each panel includes an upper edge and a lower edge, and wherein the upper edge and the lower edge are straight.
In certain embodiments as otherwise described herein, the panel body of each panel includes an upper edge having a first contoured shape and a lower edge having a second contoured shape. Further, the first contoured shape is mateable with the second contoured shape. For example, in some embodiments, each of the panels includes a central upward projection along each upper edge and a central upward indentation along each lower edge. Accordingly, in such embodiments, the projection of each panel fits into the indentation of an upward neighboring panel. Such a configuration allows the boundary between adjacent rows to be non-linear. Further, in some embodiments, the upper and lower edges are only mateable with certain other panels in the set.
In certain embodiments as otherwise described herein, panels of the same panel type include the same decorative design. For example, in surface panel system 190, shown in
In certain embodiments as otherwise described herein, the decorative design of each panel is a non-repetitive design. As used herein, a non-repetitive design includes any design in which shapes or design elements are not regularly repeated in a predictable pattern. In other words, the shapes or design elements are not repeated at a consistent distance from one another. For example, the decorative design of the panels of surface panel kit 100 (
In certain embodiments as otherwise described herein, the front face of each panel body includes a surface texture. The term surface texture, as used herein, refers to the specific three dimensional shape of the front face, including all of the peaks, pits, ridges, and valleys of the surface's contour. In certain embodiments as otherwise described herein, surface texture has a contour depth range that is no more than 5 cm, e.g., no more than 2 cm, e.g., no more than 1 cm, e.g., no more than 0.5 cm. The term contour depth range, as used herein, refers to the difference in depth, with respect to a direction perpendicular to the front surface of a panel, between the lowest valley and the highest peak across the front surface of a respective panel. For example, the stone elements in surface panel kit 100 are three dimensional and form a surface texture across each of the panels.
In certain embodiments as otherwise described herein, panels of the same panel type include the same surface texture. For example, in some embodiments, panels of the same panel type include panel bodies that are cast or otherwise formed in the same mold (or molds having the same three-dimensional shape). For instance, surface panel system 190, shown in
In certain embodiments as otherwise described herein, the decorative design of each panel replicates wood or bamboo.
In certain embodiments as otherwise described herein, the decorative design of each panel replicates masonry units. For example, in some embodiments, the decorative design of each panel replicates flat polished stone, such as marble blocks. In other embodiments, the decorative design of each panel replicates split stone masonry units. The term split stone masonry units broadly refers to any stones that have been broken or worked to a desired shape and thereby have a textured contour that replicates a fractured surface of the stone. Thus, the term split stone encompasses most stone surfaces that are generally flat but have not been polished to a smooth surface. Still in other embodiments, the decorative design of each panel replicates rounded stones, for example, stones that have been naturally worn to a smooth surface through abrasion or by water. For example, in some embodiments, the decorative design replicates river rocks. Further, in some embodiments, the decorative design replicates other masonry units, such as brick. As an example, the decorative design of surface panel kit 100 includes split stone elements.
In certain embodiments as otherwise described herein, the decorative design of each panel includes an image of a natural construction product. For example, in certain embodiments, the decorative design of each panel includes a printed image of one or more pieces of wood, bamboo or stones. Thus, the decorative designs of the panels may appears as wood planks, parquet, individual stones, or groups of stones, such as in surface panel system 100.
In certain embodiments as otherwise described herein, the surface texture includes a digitized rendering of a natural construction product. For example, in some embodiments one or more natural construction materials is scanned using either a laser scanner or a white light scanner to form a digital 3D rendering of the natural construction material(s). For instance, a wooden plank, or a surface formed by a group of stones may be scanned. A mold is then fabricated using the digital rendering and the panels are produced with the digitized rendering of the natural material from the mold. In other embodiments, digital rendering of the natural material is used by a 3D printer to create the panels. Still in other embodiments, a cast is made from the naturally occurring material, and a mold is subsequently made based on the cast.
In certain embodiments as otherwise described herein, the decorative design of two mateable panels extends from a panel body of a first of the two panels to a panel body of a second of the two panels. For example, the panel bodies in surface panel kit 900, shown in
In certain embodiments as otherwise described herein, each panel includes indicia indicative of one of the end configurations of the group of end configurations that is mateable with an end configuration of the panel. For example, an alphanumeric indicator may be printed or inscribed at either end of the panel to guide an installer in choosing a neighboring panel to mate with the first panel. The indicia may be included at various locations, such as on the end of the panel bodies, on the rear surfaces of the panels, or on the fastening strip.
In certain embodiments as otherwise described herein, each of the panels is formed of a polymer material. In some embodiments, each of the panels is formed of one or more of polypropylene, polyethylene, polyvinyl chloride (PVC), acrylonitrile styrene acrylate (ASA), polyurethane, or acrylonitrile butadiene styrene (ABS). Further, while the system includes panel bodies formed of a polymer material, in that the structure and shape of the panel body is associated with a polymer construction, the panel bodies can include a large percentage of filler. For example, a panel formed with a polyurethane matrix may include a majority of filler (such as fly ash) and still be considered a “formed of a polymer material,” as will be appreciated by those of ordinary skill in the art. Likewise, the panel bodies may include small sections that are made from another material, such as a metal. For example, in some embodiments the corners of the panel bodies may include a metal frame for stability. Further, in some embodiments, the panels include a cementitious material. The term cementitious, as used herein, refers to material that reacts with or binds water to a high degree and can form a mortar-like material in the set form, such as Portland cement. In other embodiments, the panels include other materials.
In certain embodiments as otherwise described herein, each of the panel bodies includes a coating disposed over at least the front face. In some embodiments, the coating blocks ultraviolet (UV) light to protect the body of the panel from UV degradation. In some embodiments, the coating is decorative and imparts a particular visual aspect to the panel body. For example, in some embodiments the coating is opaque and has a particular color. In other embodiments, the coating is transparent. In some embodiments, the coating is variegated, such that different portions of the surface of the panel body have different colors. For example, in some embodiments, the coating is partially transparent such that sections of the underlying material of the panel body show through the coating while other sections are overlaid with an opaque covering. In some embodiments the coating includes an image of a natural product. In some embodiments, the coating provides a texture to the surface of the panel, for example to provide a desired tactile sensation when the panel is touched.
In certain embodiments, the coating is applied directly to the outer surface of the panel body. In other embodiments, the coating is applied to the surface of a mold and is secured to the material of the panel body during a molding process. In some embodiments, the coating is provided as a liquid that is sprayed or otherwise applied onto the panel body or into a mold. In other embodiments the coating is a film or laminate that is stretched over or otherwise applied to the panel body. Still, in other embodiments the film or laminate coating is inserted into a mold before the molding process.
In certain embodiments as otherwise described herein, each of the panel bodies is injection molded, thermoformed, or rotational molded. Further, in some embodiments, the entire panel is injection molded, thermoformed, or rotational molded. In other embodiments, each of the panels is blow molded, extruded, or cast. For example, in some embodiments the panels are formed of polyethylene and roto-molded. In some embodiments the panel bodies are fabricated through an additive process. For example, in some embodiments the panel bodies are made by 3D printing.
In certain embodiments as otherwise described herein, the surface panel kit further includes end panels including an end configuration from the group of end configurations at a first end of the panel and a straight edge at a second end of the panel. For example, in some embodiments, the surface panel kit includes panels with one end that is configured to mate with other panels of the kit and another end that has a straight edge for cooperating with another surface at an end of the panelized wall. The surface panel kit may also include corner panels, as will be appreciated by those of ordinary skill in the art.
In certain embodiments as otherwise described herein, the panels are configured to form a decorative surface of a wall. For example, the surface panel kit 100 shown in
In another aspect, the disclosure provides a surface panel system including a support structure and an array of panels of the surface panel kit according to the disclosure attached to the support structure. The array of panels is arranged in linear rows with mateable end configurations coupled to one another. For example,
In some embodiments, the support structure is a continuous surface, for example a sheet of material that forms a substrate, such as a wooden board. In other embodiments, the support structure is in the form of a frame formed by a plurality of framing elements, such as studs or furring strips. In some embodiments, the support structure forms a planar surface that receives the panels. In other embodiments the support structure is curved and the panels form a curved building surface.
In certain embodiments as otherwise described herein, the array of panels includes a first panel of the first panel type coupled to a second panel of the first panel type, and wherein the second panel is rotated 180 degrees with respect to the first panel. For example,
In certain embodiments as otherwise described herein, each of the panels is attached to the support structure using a mechanical fastener. For example, in some embodiments the panels are attached to the support structure using screws, nails, bolts, or staples that pass through the fastening strip and into the support structure. Other fasteners for attaching the panels to the support structure are also possible, as will be appreciated by those of ordinary skill in the art.
In certain embodiments as otherwise described herein, the surface panel system forms a wall surface. For example, surface panel system 190 is part of an exterior wall of a building. In other embodiments, the surface panel system forms a floor surface or a ceiling surface. For example, in some embodiments the support structure is an exterior sheathing. As will be understood by those of ordinary skill in the art, such an exterior sheathing can include a rain protection layer, house wrap, and/or may include furring strips. In other embodiments, the support structure is another flat structural component of a construction wall. Still, in other embodiments, the support structure is a floor sublayer, or a ceiling support structure.
In certain embodiments as otherwise described herein, the array of panels is arranged in columns, with the ends of each panel aligned with the ends of adjacent panels in a neighboring row. For example, in surface panel system 190, the panels are arranged in columns such that the ends of the panels in one row are aligned with the ends of the panels in another row. In other embodiments, the linear rows of panels are offset from neighboring rows such that the ends of each panel are staggered with the ends of adjacent panels in a neighboring row. Such an offset avoids a continuous boundary line extending vertically across the building surface.
Additional embodiments of the disclosure are provided by the enumerated embodiments provided below, which can be combined in any number and in any combination not logically or technically inconsistent:
Embodiment 1. A surface panel kit comprising:
It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
This application claims the benefit of priority of U.S. Provisional Patent Application No. 62/864,156, filed Jun. 20, 2019, which is hereby incorporated herein by reference in its entirety.
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| 20200398609 A1 | Dec 2020 | US |
| Number | Date | Country | |
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| 62864156 | Jun 2019 | US |
