Simulated Masonry Wall Panel with Improved Seam Integration

Abstract

A wall covering comprised of a plurality of panels formed with a stone and mortar design. The panels are mounted in horizontal courses with a lower marginal edge region of one panel being in overlying relation to the upper marginal edge region of a panel in a previously mounted course. The upper and lower marginal edge regions have a tapered seating design which enable close positioning of the stone and mortar of two mating panels with the mortar lines between the stone being in substantially coplanar relation with each other and where a portion of the simulated stone protrudes downward in different locations so as to create a non-uniform mortar distance between simulates stones on an upper panel from simulated stones on a lower panel, thus further obscuring the seam formed between the panels.

Description

FIELD OF THE INVENTION[0001]The present invention relates generally to wall and roof coverings primarily intended for outdoor usage, and more particularly, to wall coverings comprised of relatively large panels where each are molded or otherwise formed with simulated building elements, and particularly building elements in the form of simulated hand laid masonry, such as stone.BACKGROUND OF THE INVENTION[0002]Various synthetic roof and wall coverings are known, such as those formed of elongated thermoplastic wall panels that are nailed or screwed to a wall or support surface in horizontal courses or rows in partially overlapping relation to each other so as to provide a substantially water repellant, protective layer over the support surface. Such panels, which usually are identically molded, commonly are formed with a plurality of horizontal rows of simulated building elements. Since the panels are identically molded, a panel-to-panel identity can be easily noticed if the panels ar...

AI Technical Summary

Benefits of technology

[0005]It is an object of the present invention to provide a wall covering comprised of panels formed with rows of simulated masonry that can be installed with a more aesthetic and natural appearance.

[0006]Another object is to provide a wall covering as characterized above in which the gaps between stone or brick masonry of adjacently mounted panels can be more tightly and precisely controlled for a more natural appearance and that an overlap between adjacent panels can be introduced to minimize seam visibility during thermal expansion and to more properly simulate stone panels.

[0008]Yet another object is to provide a wall covering of the foregoing type in which the mortar lines between masonry of adjacently mounted panels enhances the aesthetic appearance of the juncture between the rows of simulated masonry of adjacent panels, as well as the mating engagement of the adjacent panels.

[0009]Another object is to provide a wall covering having panels of the above type which are adapted for easier installation and which enable a more robust interlocking of overlapping side marginal regions of adjacent panels.

[0010]A further object is to provide such a wall panel which facilitates precise alignment of the rows of simulated building elements of adjacent panels as an incident to installation.

[0011]Still a further object is to provide a plastic wall panel of the foregoing type which can be economically molded with more reliable and easier to use tooling.

Problems solved by technology

Since the panels are identically molded, a panel-to-panel identity can be easily noticed if the panels are not carefully installed, which can be tedious and time consuming.

Concealing the panel-to-panel identity of panels formed with simulated hand laid stone or brick patterns has been particularly difficult.

Because of the small depth of the flange receiving slot, particularly with the shorter height simulated stone or brick, the tooling required during injection molding of the panel must be so thin that it can be subjected to warpage or breakage, causing variances in formation of the slot that can impede the precision by which the panels can be inter-engaged, resulting in unslightly and unnatural gaps between the simulated masonry of the adjacent panels.

Moreover, because the simulated hand-laid stone or brick are separated by simulated mortar lines, irregular or inconsistent gaps between the stone or brick at adjoining ends of the panels that are not consistent with the mortar lines throughout the panel can be particularly noticeable.

A further problem with panels formed with such simulated masonry is that the seam between adjacent panels can become visible due to molding inconsistencies and thermal expansion.

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