Interlocking column surround panels

Abstract

A panel system includes four panels that are coupled using tongue and groove joints to form a column surround or wrap.

Description

BACKGROUND

[0001] The present disclosure relates to panel systems, such as generally flat sections used in building, construction and other applications, including in walls, siding, flooring, soffits, ceilings, tiling, shelving, furniture and like. In non-limiting examples, a panel and system of interlocking panels form a column surround or wrap.SUMMARY

[0002] A panel system in an example comprises a first panel including a first groove and a second groove, a second panel including a first protrusion forming a first end of the second panel and a second protrusion forming a second end of the second panel, a third panel including a first groove and a second groove, and a fourth panel including a first protrusion forming a first end of the fourth panel and a second protrusion forming a second end of the fourth panel. The second protrusion of the second panel is operable to be received by the first groove of the first panel. The first protrusion of the second panel is operable to be received by the second groove of the third panel. The first protrusion of the fourth panel is operable to be received by the second groove of the first panel. The second protrusion of the fourth panel is operable to be received by the first groove of the third panel.

[0003] In examples, each of the first panel and the third panel includes a first shoulder and a second shoulder.

[0004] In some examples, the first shoulder and the second shoulder have a length in a range between about ½ inch to about ¾ inch.

[0005] In some examples, each of the second panel and the fourth panel includes a first recess proximate the first protrusion and a second recess proximate the second protrusion. In some examples, the first panel, the second panel, the third panel, and the fourth panel are coupled together using an adhesive, the first recess and the second recess operable to receive at least a portion of the adhesive.

[0006] In some examples, each of the first panel, the second panel, the third panel, and the fourth panel are covered by an overlay layer. In some examples, the overlay layer is composed of at least one of plastic, vinyl, or rubber.

[0007] In some examples, the first panel and the third panel have a length of about 6-3 / 4 inches.

[0008] In some examples, the second panel and the fourth panel have a length of about 6-1 / 8 inches.

[0009] In some examples, the first panel, the second panel, the third panel, and the fourth panel have a thickness of about 1 / 2 inches.

[0010] A method for manufacturing a column surround. The method comprises forming a first groove and a second groove in a first panel, forming a first protrusion and a second protrusion on a second panel, forming a first groove and a second groove in a third panel, and forming a first protrusion and a second protrusion on a fourth panel. The second protrusion of the second panel is operable to be received by the first groove of the first panel. The first protrusion of the second panel is operable to be received by the second groove of the third panel. The first protrusion of the fourth panel is operable to be received by the second groove of the first panel. The second protrusion of the fourth panel is operable to be received by the first groove of the third panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a perspective view of a system of interlocking panels forming a column surround in one example; and

[0012] FIG. 2 is a top view of the system of interlocking panels of FIG. 1.

[0013] FIG. 3 is a detail view of a tongue and groove joint of FIG. 2.

[0014] FIG. 4 is a top view of a panel in one example.

[0015] FIG. 5 is a top view of a panel in one example.

[0016] FIG. 6 is a flow chart showing an example method for manufacturing the system of FIG. 1.

[0017] FIG. 7 is a flow chart showing an example method for assembling the system of FIG. 1.DETAILED DESCRIPTION

[0018] The following description is intended to convey examples and details involving a siding panel assembly forming a column surround or wrap. It is understood, however, that the invention is not limited to these specific examples and details, which are exemplary only. It is further understood that one possessing ordinary skill in the art, in light of known devices, systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative examples.

[0019] Generally speaking, panel systems of the present invention are generally flat sections used in building, construction and other applications, including in walls, siding, flooring, ceiling, soffits, tiling, shelving, furniture and like. In one described but non-limiting example, a panel system of the present disclosure includes a plurality of panels that are coupled together to provide a column surround or wrap. The plurality of panels are joined together to form a single unit to provide an exterior siding surface of a building that covers a surface, such as a column of a building. As used herein, the terms “horizontal” and “vertical” are not intended to be limited to a specific orientation and reflect generally perpendicular sides, edges or ends with respect to one another. The references of “horizontal” and “vertical” as describing one example of the invention are intended to continue to reference the respective edge, side or end in other examples where a panel or panel system is provided in another orientation relative to the ground or horizon.

[0020] In various examples, the panels and their components may be made from solid or foamed polymers, such as vinyl or cellular polyvinyl chloride (PVC). However, the examples are not so limited. The panels and their components may be made from any known or later-developed material used for siding and building panels including, but not limited to, wood, aluminum, steel and other metals, polymer materials, plastics, masonry, stone, brick, concrete, composites and combinations thereof. Panels of various materials may be shaped by extrusion, milling, molding, and the like. One having ordinary skill in the art would understand how to apply the teachings of various materials and panel manufacturing methods to various examples of the invention.

[0021] Referring to FIGS. 1-5, an example system 100 of interlocking panels that form a column surround or wrap. The system 100 includes a first panel 102, a second panel 104, a third panel 106, and a fourth panel 108 coupled to each other using tongue and groove joints and, for example, adhesive, fasteners, etc. In an implementation, the first panel 102, the second panel 104, the third panel 106, and the fourth panel 108 are generally elongated and planar and substantially flat. In an implementation, the first panel 102, the second panel 104, the third panel 106, and the fourth panel 108 are formed from a ½ inch thick material. Although four panels are shown, the disclosure is not limited as such and any suitable number of panels may be used depending on the shape of the column.

[0022] In an implementation, the first panel 102 and the third panel 106 are identical. In this implementation, each of the first panel 102 and the third panel 106 include a first end 110 and a second end 112. A first groove 114 is formed proximate the first end 110, and a second groove 116 is formed proximate the second end 112. A first shoulder 118 extends from the first end 110 for a distance past the first groove 114, and a second shoulder 120 extends from the second end 112 for the distance past the second groove 116. In an implementation, the distance is in a range between about ½ inch to about ¾ inch. In an implementation, each of the first panel 102 and the third panel 106 is covered with an overlay layer 122, such as a laminate composed of plastic, vinyl, rubber, etc. In an implementation, each of the first panel 102 and the third panel 106 have a length d, such as, for example, 6-3 / 4 inches.

[0023] In an implementation, the second panel 104 and the fourth panel 108 are identical. In this implementation, each of the second panel 104 and the fourth panel 108 include a first protrusion 124 forming a first end and a second protrusion 126 forming a second end. A first recess 128 is formed proximate the first protrusion 124, and a second recess 130 is formed proximate the second protrusion 126. In an implementation, each of the first recess 128 and the second recess 130 is operable to receive an adhesive used to couple the first panel 102, the second panel 104, the third panel 106, and the fourth panel 108 to each other, thereby restricting adhesive squeeze out. In an implementation, each of the first panel 102 and the third panel 106 is covered with an overlay layer 132, such as a laminate composed of plastic, vinyl, rubber, etc. In an implementation, each of the second panel 104 and the fourth panel 108 have a length, such as, for example, 6-1 / 8 inches.

[0024] When the first panel 102, the second panel 104, the third panel 106, and the fourth panel 108 are coupled to each other, the second protrusion 126 of the second panel 104 is received by the first groove 114 of the first panel 102, the first protrusion 124 of the second panel 104 is received by the second groove 116 of the third panel 106, the first protrusion 124 of the fourth panel 108 is received by the second groove 116 of the first panel 102, and the second protrusion 126 of the fourth panel 108 is received by the first groove 114 of the third panel 106. In an implementation, a portion of the overlay layer 122, 132 is disposed between the plurality of panels to mechanically secure the layer.

[0025] FIG. 6 shows a method 200 for manufacturing the system 100. At step 202, the first groove 114 and the second groove 116 are formed in the first panel 102. At step 204, the first protrusion 124 and the second protrusion 126 are formed on the second panel 104. At step 206, the first groove 114 and the second groove 116 are formed in the third panel 106. At step 208, the first protrusion 124 and the second protrusion 126 are formed on the fourth panel 108. The steps provided in FIG. 6 may be performed in the order shown, or in another order, without departing from the disclosure.

[0026] FIG. 7 shows a method 300 for assembling the system 100. At step 302, the first panel 102 is coupled to the second panel 104. At step 304, the first panel 102 is coupled to the fourth panel 108. At step 306, the second panel 104 and the fourth panel 108 are each coupled to the third panel 106. The steps provided in FIG. 7 may be performed in the order shown, or in another order, without departing from the disclosure.

[0027] While various preferred examples have been described with reference to the accompanying drawings, it will be evident that various modifications and changes may be made thereto, and additional examples may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.

Claims

1. A column surround system comprising:a first panel including a first groove and a second groove;a second panel including a first protrusion forming a first end of the second panel and a second protrusion forming a second end of the second panel;a third panel including a first groove and a second groove; anda fourth panel including a first protrusion forming a first end of the fourth panel and a second protrusion forming a second end of the fourth panel,wherein the second protrusion of the second panel is operable to be received by the first groove of the first panel, the first protrusion of the second panel is operable to be received by the second groove of the third panel, the first protrusion of the fourth panel is operable to be received by the second groove of the first panel, and the second protrusion of the fourth panel is operable to be received by the first groove of the third panel.

2. The system of claim 1, wherein each of the first panel and the third panel includes a first shoulder and a second shoulder.

3. The system of claim 2, wherein the first shoulder and the second shoulder have a length in a range between about ½ inch to about ¾ inch.

4. The system of claim 1, wherein each of the second panel and the fourth panel includes a first recess proximate the first protrusion and a second recess proximate the second protrusion.

5. The system of claim 4, wherein the first panel, the second panel, the third panel, and the fourth panel are coupled together using an adhesive, the first recess and the second recess operable to receive at least a portion of the adhesive.

6. The system of claim 1, wherein each of the first panel, the second panel, the third panel, and the fourth panel are covered by an overlay layer.

7. The system of claim 6, wherein the overlay layer is composed of at least one of plastic, vinyl, or rubber.

8. The system of claim 1, wherein the first panel and the third panel have a length of about 6-3 / 4 inches.

9. The system of claim 1, wherein the second panel and the fourth panel have a length of about 6-1 / 8 inches.

10. The system of claim 1, wherein the first panel, the second panel, the third panel, and the fourth panel have a thickness of about 1 / 2 inches.

11. A method for manufacturing a column surround system, the method comprising:forming a first groove and a second groove in a first panel;forming a first protrusion and a second protrusion on a second panel;forming a first groove and a second groove in a third panel; andforming a first protrusion and a second protrusion on a fourth panel,wherein the second protrusion of the second panel is operable to be received by the first groove of the first panel, the first protrusion of the second panel is operable to be received by the second groove of the third panel, the first protrusion of the fourth panel is operable to be received by the second groove of the first panel, and the second protrusion of the fourth panel is operable to be received by the first groove of the third panel.

12. The method of claim 11, wherein each of the first panel and the third panel includes a first shoulder and a second shoulder.

13. The method of claim 12, wherein the first shoulder and the second shoulder have a length in a range between about ½ inch to about ¾ inch.

14. The method of claim 11, wherein each of the second panel and the fourth panel includes a first recess proximate the first protrusion and a second recess proximate the second protrusion.

15. The method of claim 14, wherein the first panel, the second panel, the third panel, and the fourth panel are coupled together using an adhesive, the first recess and the second recess operable to receive at least a portion of the adhesive.

16. The method of claim 11, wherein each of the first panel, the second panel, the third panel, and the fourth panel are covered by an overlay layer.

17. The method of claim 16, wherein the overlay layer is composed of at least one of plastic, vinyl, or rubber.

18. The method of claim 11, wherein the first panel and the third panel have a length of about 6-3 / 4 inches.

19. The method of claim 11, wherein the second panel and the fourth panel have a length of about 6-1 / 8 inches.

20. The method of claim 11, wherein the first panel, the second panel, the third panel, and the fourth panel have a thickness of about 1 / 2 inches.

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