Nickel-Gap Flat Siding Product with Locking Joint

This application is a continuation-in-part of U.S. patent application Ser. No. 18/097,447, filed Jan. 16, 2023, which claims benefit of and priority to U.S. Provisional App. No. 63/299,844, filed Jan. 14, 2022, both of which are incorporated herein in their entireties by specific reference for all purposes.

This invention relates to a “nickel-gap” flat siding product with a unique locking reverse curve shiplap joint attachment.

Flat siding is an exterior cladding product that may be installed in horizontal, vertical or diagonal orientations. It may be installed fully flush with the wall. It may come in various dimensions (e.g., ½″ thick×8″ wide×16′ long), with various surface textures (e.g., smooth, cedar, and the like). It may be fashioned of various materials, including, but not limited to, sawn wood, engineered wood composites of various types, cellulose fiber cement, or combinations thereof. Oriented, multilayer wood strand boards of the above-described type, and examples of processes for pressing and production thereof, are described in detail in U.S. Pat. Nos. 3,164,511, 4,364,984, 5,435,976, 5,470,631, 5,525,394, 5,718,786, 6,461,743, and U.S. patent application Ser. No. 17/747,930, all of which are incorporated herein in their entireties by specific reference for all purposes.

Installation of flat siding products present a unique challenge when the aesthetic desire for a “blind nail” attachment (i.e., the nail head is not visible and does not penetrate the outer surface of the siding) is coupled with the engineering need to meet local building code requirements for specified wind loads (i.e., so that adjacent pieces remain fully flush on the wall and resist being pulled away or detached from the wall). A modified form of a tongue-and-groove joint has the potential to solve this problem, but the siding thickness must be increased to allow for the machining of the joint. This is problematic from a cost, weight, and fastener capacity viewpoint.

Accordingly, what is needed is a siding joint that provides a “blind nail” attachment and the ability to withstand specified wind loads without an increase in siding thickness.

In various exemplary embodiments, the present invention comprises a unique modified shiplap joint with matching or corresponding reverse curves (S-curve), where two simple curves turn in opposite directions (e.g., a first curve followed immediately by a second curve in the opposite direction). The point where the curves meet is the point of reverse curvature.

The opposing edges or ends of a piece of flat siding comprise one-half of the modified shiplap joint: an underlap edge, and an overlap edge. In a horizontal configuration, the underlap is the top edge of the siding, and the overlap is the lower edge of the siding, so that when two siding pieces are assembled, any water or moisture on the exterior of the siding will run down the exterior side or face of the siding, and not enter or flow into the joint and thus potentially get behind the siding. The modified shiplap joint may also be used in a vertical configuration.

The reverse curves have several advantages over a straight cut or line angle, or linear or rectilinear configuration. The end of each curve at the respective face does not come to a sharp point, as would a straight cut, and thus is stronger and less likely to break off. The curves themselves provide stronger and more stable connectivity between the siding edges, thereby providing greater resistance to wind and similar environmental factors. Further, the reverse curve shape allows the joint to function properly with partial contact, even if the siding pieces are not fully pushed adjacent. In contrast, a straight cut or line angle requires the siding pieces to be in contact along their face, and a partial insertion results in little or no contact, weakening the joint. In addition, in several embodiments the reverse curve feature allows the gap between successive courses of siding to vary without reducing the wind load ratings of the siding.

On the exterior face, the forward edge of the overlap, and the back edge of the underlap, are angled (they are supplementary angles, so that together they add to 180 degrees). The length of the back face of the overlap portion is slightly shorter than the front face of the underlap portion, so that when the joint is formed, a gap appears on the front face (i.e., commonly referred to as a “nickel gap”). The forward and back edges are parallel, and thus form a constant-width gap. The relative lengths of the overlap and underlap portions can be set to achieve a desired gap width. While the gap may be angled in any direction (e.g., upward, downward, or orthogonal with respect to the exterior face(s)), in an exterior horizontal configuration, the gap typically would be directed downward when assembled, so that any water or moisture on the exterior of the siding will run down the exterior side or face of the siding, and not enter or flow into the joint and thus potentially get behind the siding, as discussed above.

In some embodiments, one or both of the forward and/or back edge angles may vary slightly so as to not be precisely supplementary, and chosen so that the gap may reduce in width from the outer surface. Further, the angles may be opposing, so as to form a V-shape or notch when assembled.

The outer or front face of the underlap further comprises a fastener groove or channel extending linearly parallel to the edge for some or all of the corresponding length of the piece of siding. A nail or other fastener is driven into this groove or channel when the siding is mounted on a frame or sheathing, and forms a “blind nail” attachment when the overlap end of the adjacent piece of siding is placed over this area (and thus the nail head cannot be seen). The depth of the groove or channel is such as to accommodate the nail or fastener head (i.e., the top of the nail or fastener head does not extend above the outer or front face of the underlap), and allows the overlap portion, and thus the siding, to lie flat.

The modified shiplap joint thus ensures that the two adjacent pieces of siding of standard thickness are properly and adequately connected to each other, and, through the nail in the underlap portion of the joint, to the wall. The joint connection thus is strong enough to withstand specified wind loads without an increase in joint or overall thickness of the pieces of siding.

In various exemplary embodiments, as seen in, the present invention comprises a unique modified shiplap jointwith matching and/or corresponding reverse curves (S-curve) on the respective edges (or ends) of two adjacent pieces of siding. Each reverse curvecomprises two simple curves turning in opposite directions (e.g., a first curvefollowed immediately by a second curvein the opposite direction). The point in the reverse curve where the first and second curves meet is the point of reverse curvature.

The opposite or opposing edges or ends of a piece of flat sidingcomprise one-half of the modified shiplap joint: an underlap edge, and an overlap edge. In a horizontal configuration (i.e., where the piece of flat siding extends horizontally along the wall or structure) the underlapis the lower edge, and the overlapis the top edge, so that when assembled, any water or moisture on the exterior of the siding will run down the exterior side or face of the siding, and not enter or flow into the joint and thus potentially get behind the siding.

The reverse curveshave several advantages over a straight cut or line angle, or linear or rectilinear configuration. The end of each curve at the respective face does not come to a sharp point, as would a straight cut, and thus is stronger and less likely to break off. The curves themselves provide stronger and more stable connectivity between the siding edges, thereby providing greater resistance to wind and similar environmental factors. Further, the reverse curve shape allows the joint to function properly with partial contact, even if the siding pieces are not fully pushed adjacent. In contrast, a straight cut or line angle requires the siding pieces to be in contact along their face, and a partial insertion results in little or no contact, weakening the joint. In addition, in several embodiments the reverse curve feature allows the gap between successive courses of siding to vary without reducing the wind load ratings of the siding.

The first curve and second curve that make up a single reverse curve may have the same radii of curvature, or different radii of curvature. Likewise, the corresponding curves of the reverse curves on the respective edges that form the joint may have the same radii of curvature, or different radii of curvature. In, for example, the radii of curvature is same for all four corresponding curves.shows an example where the first curve and the second curve of the overlap section have different radii of curvature, and both are different from radii of curvature of the first and second curves in the reverse curve of the underlap section (see).

The slight variation in the radius of curvature helps ensure that there is sufficient engagement between the two reverse curves, even when the two edges are not completely matched. Thus, in the embodiment represented by the underlap section ofand the overlap section of, the first curve of the overlap section of(adjacent to the interior face) has a smaller radius of curvature than that of the corresponding first curve in the underlap section of(adjacent to the interior face), while the second curve of the overlap section ofhas a larger radius of curvature than that of the corresponding second curve in the underlap section of. During installation, the underlap section () will be already fastened to the wall or other structure (as discussed below). The first curve of the overlap section () will be inserted first, and its smaller radius of curvature, and the larger radius of curvature of the second curve, will help with the ease and depth of insertion, and ensure sufficient contact and engagement between the joint elements.

On the exterior face, the forward edgeof the overlap and the back edgeof the underlap, are angled. In the embodiment shown, in, they are supplementary angles with respect to their exterior faces, so that together they add to 180 degrees. The angle of the cut on the underlap back edgeis 75 degrees with respect to the exterior face (which is 15 degrees from the transverse orthogonal plane across the thickness of the piece of siding). The angle of the cut on the overall back edge is 105 degrees with the respect to the exterior face (which likewise is 15 degrees from the transverse orthogonal plane).

The length of the back faceof the overlap portion is slightly shorter than the front faceof the underlap portion, so that when the joint is formed, a gapappears on the exterior or front face (i.e., commonly referred to as a “nickel gap”). The forward edgeand back edgeare parallel in this embodiment, and thus form a constant-width gap, determined by the difference in length of back faceand front face. The relative lengths can be set to achieve a desired gap width. In several embodiments, the gap width may be 1/32″, 1/16″, ⅛″, or another width as desired. While the gap may be angled in any direction (e.g., upward, downward, or orthogonal with respect to the exterior face(s)), in an exterior horizontal configuration, the gap typically would be directed or angled downward with respect to the exterior face when assembled, so that any water or moisture on the exterior of the siding will run down the exterior side or face of the siding, and not enter or flow into the jointand thus potentially get behind the siding, as discussed above.

In some embodiments, one or both of the forward and/or back edge angles may vary slightly so as to not be precisely supplementary, and chosen so that the gap may reduce in width from the exterior face or surface.shows the forward edgeand back edgewith an approximately 2.5 degree difference, so that the gap reduces in width from the exterior face. In alternative embodiments, the difference in angles may be such that they appear to be opposing, as seen in, so as to form a V-shape or notch when assembled.

The front faceof the underlap further comprises a fastener groove or channelextending linearly parallel to the edge for some or all of the corresponding length of the piece of siding. A nail or other fasteneris driven into this groove or channelwhen the piece of siding is mounted on a frame or sheathing, and forms a “blind nail” attachment when the overlap end of the adjacent piece of siding is placed over this area (and thus the nail headcannot be seen). The depth of the groove or channel is such as to accommodate the nail or fastener head(i.e., the top of the nail or fastener head does not extend above the front faceof the underlap), and allows the overlap portion, and thus the adjacent pieces of siding, to lie flat when the jointis formed.

The modified shiplap jointthus ensures that the two adjacent pieces of siding are properly and adequately connected to each other, and, through the nail in the underlap portion of the joint, to the wall. The unique configuration of the joint allows a “blind nail” attachment while being strong enough to withstand specified wind loads without an increase in joint or overall thickness of the pieces of siding.

An example of the installation process, to produce an assembly as seen in(which shows partial portions of siding pieces), would proceed as follows: (1) a lower piece of sidingis installed and fastened to the wall with the underlap edge or part of the joint facing up; (2) and an upper piece of sidingis placed above the lower piece and moved downward so the reverse curve machined on the overlap part of the joint along the bottom edge of the upper piece enters and engages the corresponding recessed reverse curve machined into the back of the underlap part of the joint. Where the end jointsbetween siding pieces on the same level do not align (i.e., are offset) with end joints on the adjacent levels, a second upper piece of sidingis placed above the lower piece, and adjacent to the end of the first upper piece, and moved downward so the reverse curve machined on the overlap part of the joint along the bottom edge of the second upper pieceenters and engages the corresponding recessed reverse curve machined into the back of the underlap part of the lower piece of siding. The joint between the ends of the pieces of the siding on the same level (e.g.,,) typically form butt joints, but other joint configurations may also be used. The butt (or other) joints may be flashed and/or sealed. Variations of this process may be used for vertically-aligned or diagonally-aligned siding.

The present invention thus positively locates and positions adjacent rows of siding, interlocking them and assisting in securely attaching the siding to the wall. This is especially valuable in high wind zones where additional face-penetrating nails or similar fasteners would be required absent the use of the present invention. An additional feature of the present invention is resistance to the penetration of moisture (e.g., wind-driven rain) and flames (e.g., an exterior wildfire event). The only penetration through the siding is hidden behind the overlap section of the adjacent piece of siding, and as discussed above, the direction of the gap downward resists and/or prevents the flow of rain and water through the fastener penetrations, or into the gap and joint itself.

The profiles of the underlap edgeand the overlap edgeof the modified shiplap joint may vary in one or more aspects from the profiles described above.shows a nail-clearance recessin the back faceover the overlap portion. This recess provides a space for movement of the nail or other fastenerdriven into the fastener groove or channel. A nail can become loose over time after installation, and thus move outward and putting pressure on the back face of the adjacent piece of siding, which can result in unsightly protrusion of a portion of the overlap edgeaway from the wall. The recessis positioned to accommodate fastener movement of this sort without allowing or permitting movement of the overlap section. The recessmay be the same size, depth and dimensions as the fastener groove or channel(e.g., extending linearly parallel to the edge for some or all of the corresponding length of the piece of siding), or may vary in size and/or in one or more dimensions or depth. In some exemplary embodiments, the recessmay accommodate a fire-resistant caulk or gasket, especially in regions or areas where such a feature is desired or required by applicable building code or similar requirements.

show variations in the profile of the forward edgeof the overlap, which is shown inas an angled, straight edge. In, the forward edge is curved for the full width of the edge, which may be angled as shown, forming a “hidden” recess or pocketto accommodate moisture that is driven by wind or otherwise into that space. In, only a portion of the edge is curvedto form a similar recess or pocket. This provides more time for the moisture collected to be evacuated out of the gap by gravity, as compared to be driven further into the gap or even further into the joint. The recess or pocket is hidden in the sense that it is not readily or easily visible from the front of the siding. In some exemplary embodiments, the recessmay accommodate a fire-resistant caulk or gasket, especially in regions or areas where such a feature is desired or required by applicable building code or similar requirements.

show further variations in the profile of the forward edgeof the overlap, where the back corner where the forward edge and the back face meet is cut or “docked”at a different angle from the rest of the forward edge. This provides a hidden recess or pocketto accommodate moisture that is driven by wind or otherwise into that space, in a similar manner and for similar reasons for the curved hidden recesses or pocketsdescribed above.shows the cutat a steeper angle, which results in a clear recess/pocket/openingup to and into the fastener groove or channel, and possibly the nail-clearance recess(if present). In some exemplary embodiments, the recessmay accommodate a fire-resistant caulk or gasket, especially in regions or areas where such a feature is desired or required by applicable building code or similar requirements.

show further variations for the reverse curves.shows the bottom edge of the overlap reverse curve being rounded, so that the bottom section is different from the top section (which in this embodiment remains the same as described above). This rounding forming a gap or spaceon the back side of the joint where the siding pieces are fit together. The gap or space provides room for expansion due to moisture, helping to avoid distortion or protrusion of a siding piece or pieces in the joint area. In some exemplary embodiments, the gap or spacemay accommodate a fire-resistant caulk or gasket, especially in regions or areas where such a feature is desired or required by applicable building code or similar requirements.

shows the bottom edge of the overlap reverse curve with a docking cut, so that the bottom section is different from the top section (which in this embodiment remains the same as described above). This cut similarly forms a gap or spaceon the back side of the joint where the siding pieces are fit together, for the same purposes and reasons as described above regarding gap or space. In some exemplary embodiments, the gap or spacemay accommodate a fire-resistant caulk or gasket, especially in regions or areas where such a feature is desired or required by applicable building code or similar requirements.

shows where this same rounding or docking cut are applied to the top edge of the underlap reverse curve, so that the top section is different from the bottom section (which in this embodiment remains the same as described above). As described above,shows the roundingforming a gap or spaceinside the joint. The gap or space provides room for expansion due to moisture, helping to avoid distortion or protrusion of a siding piece or pieces in the joint area. In some exemplary embodiments, the gap or spacemay accommodate a fire-resistant caulk or gasket, especially in regions or areas where such a feature is desired or required by applicable building code or similar requirements.

shows the top edge of the underlap reverse curve with a docking cut, so that the bottom section is different from the top section (which in this embodiment remains the same as described above). This cut similarly forms a gap or spaceinside the joint where the siding pieces are fit together, for the same purposes and reasons as described above regarding gap or space. In some exemplary embodiments, the gap or spacemay accommodate a fire-resistant caulk or gasket, especially in regions or areas where such a feature is desired or required by applicable building code or similar requirements.

Some of the above features may used in combination with each other., for example, shows the bottom edge of the overlap reverse curve being rounded(from) used in combination with the top edgeof the underlap reverse curve with a docking cut, forming two recesses or pockets, oneon the back of the joint, the otherin the interior of the joint. One or both recesses/pockets may have a fire-resistant caulk or gasket. Other variations include two rounded edges or two docked edges.

Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art.