System, method and apparatus for manufactured building panel

Patent metadata

Field	Value
Publication number	US-9869098-B2
Application number	US-201514861868-A
Country	US
Kind code	B2
Filing date	Sep 22, 2015
Priority date	Oct 24, 2012
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

Abstract

A manufactured panel includes a body having a front, back, top, bottom and side walls, the side walls extend between the front and back, and an interior volume located between the front, back, top, bottom and side walls. An insert having an interior portion is embedded within the interior volume of the body, and an exterior portion extends from the interior portion to an exterior of the body. The exterior portion includes stand-offs protruding from the body, such that at least some of the stand-offs are connected to each other inside the interior volume of the body. At least some of the stand-offs are independent and detached from each other on the exterior of the body.

First claim

What is claimed is:

1. A panel, comprising:
a body having a front, back, top, bottom and side walls, and an interior volume located between the front, back, top, bottom and side walls; and
an insert having an interior portion embedded within the interior volume of the body, and an exterior portion extending from the interior portion to an exterior of the body, wherein the exterior portion comprises a fastener hem and a plurality of stand-offs protruding from the body, wherein a back of the fastener hem and backs of the stand-offs are co-planar,
wherein a first stand-off is located near a top of the body, a second stand-off is located near a bottom of the body, and the insert connects the first stand-off to the second stand-off,
wherein the insert comprises a curved portion extending from the insert adjacent the fastening hem,
wherein at least some of the stand-offs are connected directly to each other inside the interior volume of the body by the interior portion, and at least some of the stand-offs are independent and detached from each other on the exterior of the body; and
the fastener hem and the stand-offs are configured to directly contact a mounting wall to provide a rainscreen between the panel and the mounting wall.

2. The panel of claim 1 , wherein the plurality of stand-offs extend directly out of the back of the body, and all of the stand-offs are directly connected to each other inside the interior volume of the body at the interior portion.

3. The panel of claim 1 , wherein the interior portion extends throughout the interior volume of the body adjacent to the top, bottom and side walls, the stand-offs comprise an array of tabs between and spaced apart from the top, bottom and side walls, such that the panel is configured to be partitioned along vertical, horizontal or diagonal cut lines extending between adjacent ones of the tabs, and a partition includes at least one of the stand-offs such that the at least one of the stand-offs can function as a rainscreen for direct contact between the partition and the mounting wall.

4. The panel of claim 3 , wherein the array of tabs are in a substantially symmetrical pattern on the back of the body from adjacent the top to adjacent the bottom, and the partition includes at least two of the stand-offs that, together with a fastener hem, form the rainscreen with at least three points of contact between the partition and the mounting wall.

5. The panel of claim 1 , wherein the top of the body comprises a first upper landing that is contiguous with and substantially perpendicular to the front of the body, a first lower landing contiguous and uninterrupted with the back, and a first bevel extending between the upper and lower landings.

6. The panel of claim 5 , wherein the bottom of the body includes a second upper landing, a second bevel and a second lower landing that are complementary in shape to the first upper landing, the first bevel and the first lower landing, respectively, of the top of the body; and
wherein the side walls comprise third and fourth beveled, third and fourth upper landing surfaces and third and fourth lower landing surfaces, respectively, that are complementary in shape to one another.

7. The panel of claim 1 , further comprising a second panel configured identical to the panel, a bottom of the second panel is mounted to the top of the panel, and the panel and the second panel are configured to make substantially planar contact in substantially only two dimensions.

8. The panel of claim 7 , wherein the top of the body of each of the panel and the second panel comprises an upper landing that is contiguous with and substantially perpendicular to the front of the body, a lower landing contiguous and uninterrupted with the back, and a bevel extending between the upper and lower landings, the bottom of each body includes an upper landing, a bevel and a lower landing that are complementary in shape to the upper landing, bevel and lower landing, respectively, of the top of the body, only the upper landings of the panels are configured to make contact with each other when vertically stacked, and the bevels and the lower landings of vertically stacked panels have clearances such that they are configured to be respectively free of contact with each other when vertically stacked.

9. The panel of claim 7 , wherein the backs of the stand-offs are substantially flush with each other.

10. The panel of claim 1 , wherein the fastener hem is substantially flat and has no non-planar features.

11. The panel of claim 1 , wherein the fastener hem of the panel is configured to be spaced apart from and free of contact with another panel, such that no contact is made there between.

12. The panel of claim 1 , wherein the fastener hem is spaced apart from the top and protrudes exclusively from the back of the body and extends above the top of the body.

13. The panel of claim 1 , wherein the insert further comprises positioning stops adjacent the bottom of the body, the positioning stops are configured for use only during formation of the body, and the positioning stops are configured to not contact another panel when installed.

14. The panel of claim 1 , wherein the insert is configured to interact only with a mounting wall and the insert is configured to be completely free of contact with another panel.

15. The panel of claim 1 , wherein the panel is configured to be secured to the mounting wall only at a top of the panel with fasteners through the fastener hem, and no other separate mounting brackets are required to secure the panel to the mounting wall.

16. The panel of claim 1 , wherein the plurality of stand-offs are configured to be independently deformed or cut to accommodate irregularities in a surface of a mounting wall to which the panel is to be mounted, such that the plurality of stand-offs are customizable to flushly mount the panel to the irregular mounting wall surface.

17. A panel, comprising:
a body having a front, back, top, bottom and side walls, and an interior volume located between the front, back, top, bottom and side walls; and
an insert having an interior portion embedded completely within the interior volume of the body, and an exterior portion extending from the interior portion to an exterior of the body,
wherein the exterior portion comprises a fastener hem that protrudes exclusively from the back of body and only adjacent the top of the body, and a plurality of stand-offs protrude from the body,
wherein the insert comprises a curved portion extending from the insert adjacent the fastening hem,
wherein the stand-offs are connected to each other inside the interior volume of the body at the interior portion, and the fastener hem and the stand-offs are independent and detached from each other on the exterior of the body; and
wherein a back of the fastener hem and backs of the stand-offs are co-planar and configured to contact a support wall.

18. The panel of claim 17 , wherein the fastener hem of the panel is configured to be spaced apart from and free of contact with a bottom of another panel, such that no contact is made there between.

19. The panel of claim 17 , wherein the fastener hem is spaced apart from the top and extends above the top of the body.

20. Panels, each panel comprising:
a body having a front, back, top, bottom and side walls, and an interior volume located between the front, back, top, bottom and side walls; and
an insert having
an interior portion embedded completely within the interior volume of the body, wherein th

Assignees

• Certain Teed Corp

Inventors

• Steffes Stephen W
• Stucky David J
• Brandt Andrew Clyde
• Shaw Robert D
• Whitney Nikki J

Classifications

• E04F13/0851

  Hooking means on the back side of the covering elements · CPC title

• E04F13/0835 Primary

  the fastening elements extending into the back side of the covering elements (E04F13/0851 takes precedence) · CPC title

• E04F13/0873 Primary

  the visible surface imitating natural stone, brick work, tiled surface or the like (E04F13/105, E04F13/123, E04F13/147, E04F13/165, E04F13/185 take precedence) · CPC title

• E04F13/0864

  composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover · CPC title

• B28B23/0056

  Means for inserting the elements into the mould or supporting them in the mould (B28B23/022 takes precedence) · CPC title