U.S. patent application number 11/227921 was filed with the patent office on 2006-12-07 for device and a process for producing insulated siding panels.
This patent application is currently assigned to LANXESS Corporation. Invention is credited to Roy L. Hobbie.
Application Number | 20060272257 11/227921 |
Document ID | / |
Family ID | 36968895 |
Filed Date | 2006-12-07 |
United States Patent
Application |
20060272257 |
Kind Code |
A1 |
Hobbie; Roy L. |
December 7, 2006 |
Device and a process for producing insulated siding panels
Abstract
An apparatus for producing insulated panels, comprising in
sequence two congruous sheet fines, a former, a foaming structure,
and an extruder.
Inventors: |
Hobbie; Roy L.;
(Lawrenceburg, IN) |
Correspondence
Address: |
LANXESS CORPORATION
111 RIDC PARK WEST DRIVE
PITTSBURGH
PA
15275-1112
US
|
Assignee: |
LANXESS Corporation
|
Family ID: |
36968895 |
Appl. No.: |
11/227921 |
Filed: |
September 15, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60687752 |
Jun 6, 2005 |
|
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Current U.S.
Class: |
52/519 ;
52/554 |
Current CPC
Class: |
B29C 44/326 20130101;
B29C 44/5654 20130101; B29C 44/1233 20130101 |
Class at
Publication: |
052/519 ;
052/554 |
International
Class: |
E04D 1/00 20060101
E04D001/00 |
Claims
1. An apparatus for producing insulated panels, comprising: two
congruous sheet lines; a former; a foaming structure; and an
extruder.
2. The apparatus according to claim 1, further comprising a curing
unit positioned between the foaming structure and the extruder.
3. The apparatus according to claim 1, wherein a suction device is
positioned between a cooling unit and a sizing unit.
4. A process for producing a foam in place siding panel,
comprising: forming two siding profiles; arranging the two siding
panels at a distance from each other; foaming an insulating
material between the two siding panels, thereby forming a FIP
block; cutting the FIP block at a position parallel to the siding
profiles.
5. The process for producing the foam in place siding panel of
claim 4, wherein the forming, foaming and cutting is a continuous
process.
6. A siding panel, comprising: a panel siding member; and an
insulating material having a first surface and a second surface;
wherein the first surface is integrally attached to the panel
siding member to form a continuously joined interface.
7. The integral panel of claim 6, wherein the insulating material
is a polyurethane.
8. The integral panel of claim 6, wherein the insulating material
and panel siding member are less than 0.040 mils.
Description
FIELD OF THE INVENTION
[0001] The invention concerns insulated siding panels and process
for the manufacture of insulated siding panels, and more
particularly siding panels that are foamed in place with insulating
material.
BACKGROUND OF THE INVENTION
[0002] The production of vinyl siding or other laminated panels
that are combined with insulating materials is well-known. In
principle, the exterior of the panel is a siding profile and forms
a protective weather resistant surface for use on the exterior of
buildings. The siding profile may be PVC or other plastic resins.
Further, the interior of the panel is formed by an insulating
material. The insulating material may be PU foams. The insulating
material is adhered to the siding profile with an adhesive.
[0003] In securing the siding profile to the insulating material,
several draw backs exists, including adhesion. PVC resins do not
possess good adhesive properties to PU foams without a
preconditioning of the surface for example, Corona etching). An
alternate option is use of hot glue to adhere PVC resins to
expandable polystyrene (EPS) or polystyrene (PS) foams. Although
various adhesives may be selected with properties for use with both
vinyl and insulating materials, the current vinyl siding or other
laminated panels requires the hot glue adhesive and process to
attach the insulating material to the siding profile. The
insulating material is an EPS, PU or PS foam and the siding profile
is PVC resin. The hot glue is distributed to select areas between
the insulating material and the back side of the siding profile.
The siding profile is attached to the foam only where there is
glue.
[0004] The inventors of the present invention recognized that there
are undesirable effects that result from the placement of glue
between the insulating material and siding profile. For example,
the glued insulating material to siding profile results in air
pocket formation where moisture may collect, even though the
permeability of the foam is recognized. Further, when wind blows
against the glued insulated siding panels, undesirable noise may
occur as the foam backing shifts because its attachment to the
panel is not securely maintained.
[0005] The present invention provides improvements for insulated
siding panels as compared to typical vinyl siding panels. The
present invention provides an insulating material application and
product that results in a more secure attachment between the
insulating foam and the siding profile.
SUMMARY OF THE INVENTION
[0006] One aspect of the present invention is to provide an
insulated resin siding in which the adhesion of the external resin
panel and an insulation material is foamed in place and produces an
improved rigidity, durability and decreased size.
[0007] Another aspect is to provide a process for producing an
insulated resin siding with an improved shape to the profile of the
siding panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of a process for producing the
resin siding of the present invention;
[0009] FIG. 2 is a side view of a former for use in the process of
the present invention; and
[0010] FIG. 3 is a side view of the insulated vinyl siding panels
of the present invention after the pieces are cut from FIP
block.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Accordingly, the invention provides an insulated siding
panel and process for producing the same. The insulated siding
profile of the present invention includes a siding profile formed
as an exterior and an insulating panel formed as an interior. The
siding profile can be made of any appropriate resin that is durable
under a variety of weather conditions and temperatures, and has
adhesive characteristics that are compatible with the selected
insulating material. Further, the siding profile can include one or
more materials and/or layers, such as a cap-stock and a substrate.
The siding profile may also be extruded, co-extruded or laminated.
Resins that are appropriate include for example, but not limited
to, AES, ASA, PVDF, acrylic, or PVC or combinations thereof. The
cap-stock layer may also be an extruded sheet layer, a laminated
film layer or a combination of various film layers. The substrate
may be made for strength and may include PVC or ABS.
[0012] The insulating material may be any appropriate material that
has good insulating characteristics related to sound or noise. For
example, polyurethane (PU) or EPS may be selected as an insulating
material.
[0013] Referring to FIG. 1, a novel process 10 is provided for
making the foam in place (FIP) siding or insulated siding panel of
the present invention. A first profile is extruded at 12 and a
second profile is extruded at 14 to each form a panel at 16 and 18,
respectively. The forming of two panels at 16, 18 are oriented in a
configuration such that the first panel forms a top and the second
panel forms a bottom at 20.
[0014] The FIP siding is formed at 22. The top and the bottom are
positioned in a jig assembly in which an insulating volume is
formed between the top and bottom. The jigs are arranged to be
utilized with an injection molding apparatus that provides
insulating material into the volume or interior portion formed
between the top and bottom panels at 22. Once the insulating
material is supplied to the insulating volume, the assembly is
cooled at 24. The insulation material and panels combination is
cured, thereby forming a FIP block.
[0015] The FIP process provides an improved fit and more secured
insulating material to the siding profile than a "cut to fit"
process. In a "cut to fit" process, the shaped insulating material
is formed by cutting the insulating material to the size and shape
of the siding profile. Thus, the "cut to fit" product does not have
a precise fit of the insulating material to the siding profile.
Whereas, the present invention fits the exact profile as the
insulating material is sized and shaped when attached to the siding
profile.
[0016] With a more uniform fit of the insulated material to the
siding profile, the insulated siding panel of the present invention
has an improved impact strength as compared to the typical "hot
glue" vinyl siding. The insulated siding panels have improved
rigidity and strength because the entire surface of the siding
profile is adhered to the insulating material. Further, the
insulated siding panel provides a more rigid structure that is less
prone to movement and warping under high temperature conditions.
Another benefit is that for the insulating material breaking in the
packaging, shipping, and installation phases is minimized. Further,
the size of the insulated siding profile can be minimized and may
be at a width of between 0.035 mils and 0.054 mils.
[0017] The process of forming the FIP siding may include a
continuous or batch process. In a continuous process, two lines of
production terminate in producing one FIP block. Two sheets are
positioned in-line and with a former or extruder. A foaming device
is located near the former. A cutting device is provided at the
output of the former. Also with the FIP process, if continuous, may
result in desired handling and energy savings.
[0018] The former 22 is a chamber that forms the two siding
profiles in a FIP structure. The FIP structure includes an
insulating volume. The top and bottom are positioned in a jig
assembly in which an insulating volume is formed between the top
and bottom. The jigs are arranged to be utilized with an injection
molding apparatus, and a process provides insulating material into
the volume of interior position formed between the top and bottom
panels at 22. FIG. 2 provides a preferred embodiment of the former.
Foam or insulating material is then supplied to the volume of the
FIP structure. The FIP block is then fed to a curing device that
cools and cures the FIP block, thereby adhering the foam to the
siding profiles at 24. The two sided FIP block is then provided to
a cutting device at an orientation which causes the FIP block to be
severed into two separate insulated siding panels at 26. The two
pieces each are integrally formed having a first side formed of the
siding profile and a second side formed by the insulating material
at 28.
[0019] FIG. 2 is a former 30 used to produce the FIP siding. The
sheet lines extrude resin into a former. The former receives the
extruded resin and provides a shape and texture to the resin such
that each produces a FIP siding panel. A top jig 32, bottom jig 34,
and end jig 36 are oriented to position a first panel 38 and a
second panel 40, thereby forming an insulating chamber 42 that has
a volume sufficient to hold a predetermined amount of foam
insulation material 44. However, the former 30 may include any
appropriate jigs or supports to create a desired volume, size and
shape. A foam injection nozzle 46 is placed at a position to fill
the insulating chamber 42. A pinch plate 48 is provided at one
portion of the insulating chamber to maintain a flat nailing
surface on the volume of foam insulation material. The insulation
chamber 42 is filled with the expanding foam insulation material
44. A cut line, axis A-A, is selected at a position between the
first and second panel 38, 40 so that the insulation block may be
severed at this line.
[0020] ABS is designed to maximize adhesion with PU foams. The
substrate could be ABS and the surface cap-stock can be an ASA,
AES, or UV stabilized resin or other similar resin. The resin panel
may also include biocides or other materials to protect the house
from environmental elements.
[0021] The present invention can include PU and PS foams. It is
possible that alternate foams could be used, that are compatible
with adhering to the resin of the panel.
[0022] The insulating panel may be formed from a material that
provides good adhesion ability with the selected resins, for
example but not limited to, ABS. Typical exterior siding profile
widths are in the range of 0.040 mils to 0.054 mils. The Vinyl
Siding Institution standards require a minimum of 0.035 mils for
VSI certification of the product. It is possible for a minimization
in resin sheet width since the PU foam adhesion is uniform, thus
adding addition strength to the composite structure.
[0023] FIG. 3 illustrates separated foam siding panels, 38, 40 and
50, 52, of the present invention in a configuration for placing on
a building.
[0024] Although the present invention has been described in detail
in the foregoing for the purpose of illustration, it is to be
understood that such detail is solely for that purpose and that
variations may be made therein by those skilled in the art without
departing from the spirit and scope of the invention except as it
may be limited by the claims.
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