U.S. patent application number 11/747094 was filed with the patent office on 2007-11-15 for insulative siding apparatus and method of making the same.
Invention is credited to LESLIE D. CULLEN.
Application Number | 20070261353 11/747094 |
Document ID | / |
Family ID | 38683798 |
Filed Date | 2007-11-15 |
United States Patent
Application |
20070261353 |
Kind Code |
A1 |
CULLEN; LESLIE D. |
November 15, 2007 |
INSULATIVE SIDING APPARATUS AND METHOD OF MAKING THE SAME
Abstract
The present invention is (in some embodiments) a system of
decorative siding panels made from high-density expanded
polystyrene (EPS) foam, such panels configured for overlapping,
having interlocking tongue and groove structure. These panels for
covering a surface, such as wall sheathing, of a structure.
Inventors: |
CULLEN; LESLIE D.;
(MERIDIAN, ID) |
Correspondence
Address: |
DYKAS, SHAVER & NIPPER, LLP
P.O. BOX 877
BOISE
ID
83701-0877
US
|
Family ID: |
38683798 |
Appl. No.: |
11/747094 |
Filed: |
May 10, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60746910 |
May 10, 2006 |
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Current U.S.
Class: |
52/590.2 |
Current CPC
Class: |
E04F 13/0885 20130101;
E04F 2201/025 20130101; E04F 13/04 20130101; E04F 13/0878 20130101;
E04F 19/02 20130101 |
Class at
Publication: |
52/590.2 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. An insulative siding panel system comprising: a first siding
panel a first planar side opposite a second planar side and having
a tongue and a fastener receiving portion adjacent said tongue,
wherein a fastener can be inserted through said first siding panel
at said fastener receiving portion and into a building surface,
thereby allowing said first siding panel to be attached to said
surface; a fastener for fastening said first siding panel to said
surface; and a second siding panel having a first planar side
opposite a second planar side and having a first end extending to a
second end, wherein, said second end comprises a groove configured
for receiving therein the tongue of the first siding panel, said
groove defined by a pair of opposing flanges, wherein when the
tongue of said first siding panel is inserted into the groove of
said second siding panel one of said flanges extends to cover said
fastener receiving portion thereby hiding said fastener from
view.
2. The insulative siding panel system of claim 1, wherein: said
second siding panel second end has a tongue and a fastener
receiving portion adjacent said tongue, wherein at least one
fastener can be inserted through said second siding panel at said
fastener receiving portion and into said surface, thereby allowing
said second siding panel to be attached to said surface; and said
insulative siding panel system comprises a third siding panel
having a second end, said third siding panel second end having a
groove configured for receiving therein the tongue of said second
siding panel, said third siding panel groove defined by a pair of
opposing flanges, namely an outside flange and an inside flange;
wherein when the tongue of said second siding panel is inserted
into the groove of said third siding panel said third siding panel
outside flange extends to cover said fastener receiving portion of
said second siding panel thereby hiding the fastener attached
there-to from view.
3. The insulative siding panel system of claim 1, wherein said
panels are comprised of high density foam.
4. The insulative siding panel system of claim 3, wherein said high
density foam is selected from the group consisting of expanded
polystyrene and polyurethane.
5. The insulative siding panel system of claim 1, wherein one or
more of said second planar surfaces are covered with a coating,
said coating selected from the group consisting of epoxy, polyurea
and urethane.
6. The insulative siding panel system of claim 1, wherein one or
more of said second planar surfaces are covered with a coating,
said coating selected from the group consisting of epoxy, polyurea
and urethane, wherein said coating includes a textured material,
wherein a paint coat is applied to said coating to create a
stucco-like appearance.
7. The insulative siding panel system of claim 1, wherein one or
more of said second planar surfaces are covered with a coating,
said coating selected from the group consisting of epoxy, polyurea
and urethane, said coating including a quantity of a textured
material, wherein said coating and textured material is then
painted and additional textured material applied thereto, and
wherein finally the resulting planar surface is coated with a
urethane sealer.
8. The insulative siding panel system of claim 1, wherein one or
more of said second planar surfaces are decorative.
9. The insulative siding panel system of claim 1, wherein said
sheathing is fixed to said panel through use of an adhesive.
10. The insulative siding panel system of claim 1, wherein said
second panel outside flange is longer than said second panel inside
flange; and where the first panel has an inner rabbet and an outer
rabbet adjacent said groove, said rabbets shaped to mate with the
flanges of said second panel.
11. An insulative siding panel system comprising: a first siding
panel having a first planar side opposite a second planar side,
said first siding panel having a tongue and a fastener receiving
portion adjacent said tongue, wherein at least one fastener can be
inserted through said first siding panel at said fastener receiving
portion and into sheathing, thereby allowing said first siding
panel to be attached to said sheathing and holding said first panel
first planar side against said sheathing; at least one fastener for
fastening said first siding panel to said sheathing, wherein; and a
second siding panel having a first end extending to a second end
and a first planar side opposite a second planar side, said second
siding panel second end having a groove configured for receiving
therein the tongue of the first siding panel, said groove defined
by a pair of opposing flanges, namely an outside flange and an
inside flange; wherein when the tongue of said first siding panel
is inserted into the groove of said second siding panel said
outside flange extends to cover said fastener receiving portion
thereby hiding said fastener from view; and wherein said inside
flange is sandwiched between said tongue and said sheathing,
thereby holding said second panel first planar side against said
sheathing.
12. The insulative siding panel system of 11, wherein: said second
siding panel second end has a tongue and a fastener receiving
portion adjacent said tongue, wherein at least one fastener can be
inserted through said second siding panel at said fastener
receiving portion and into said sheathing, thereby allowing said
second siding panel to be attached to said sheathing and holding
said second panel first planar side against said sheathing; and
said insulative siding panel system comprises a third siding panel
having a first end opposite a second end and a first planar side
opposite a second planar side, said third siding panel second end
having a groove configured for receiving therein the tongue of said
second siding panel, said third siding panel groove defined by a
pair of opposing flanges, namely an outside flange and an inside
flange; wherein when the tongue of said second siding panel is
inserted into the groove of said third siding panel said third
siding panel outside flange extends to cover said fastener
receiving portion of said second siding panel thereby hiding the
fastener attached there-to from view; and wherein said third panel
inside flange is sandwiched between said second panel tongue and
said sheathing, thereby holding said third panel first planar side
against said sheathing.
13. The insulative siding panel system of claim 11, wherein said
panels are comprised of high density foam.
14. The insulative siding panel system of claim 13, wherein said
high density foam is selected from the group consisting of expanded
polystyrene and polyurethane.
15. The insulative siding panel system of claim 11, wherein one or
more of said second planar surfaces are covered with a coating,
said coating selected from the group consisting of epoxy, polyurea
and urethane.
16. The insulative siding panel system of claim 11, wherein one or
more of said second planar surfaces are covered with a coating,
said coating selected from the group consisting of epoxy, polyurea
and urethane, wherein said coating includes a textured material,
wherein a paint coat is applied to said coating to create a
stucco-like appearance.
17. The insulative siding panel system of claim 11, wherein one or
more of said second planar surfaces are covered with a coating,
said coating selected from the group consisting of epoxy, polyurea
and urethane, said coating including a quantity of a textured
material, wherein said coating and textured material is then
painted and additional textured material applied thereto, and
wherein finally the resulting planar surface is coated with a
urethane sealer.
18. The insulative siding panel system of claim 11, wherein one or
more of said second planar surfaces are decorative.
19. The insulative siding panel system of claim 11, wherein said
sheathing is fixed to said panel through use of an adhesive.
20. The insulative siding panel system of claim 11, wherein said
second panel outside flange is longer than said second panel inside
flange; and where the first panel has an inner rabbet and an outer
rabbet adjacent said groove, said rabbets shaped to mate with the
flanges of said second panel.
Description
PRIORITY
[0001] The present invention is a non-provisional of U.S.
Application Ser. No. 60/746,910, filed on May 10, 2006, the
disclosure of which is incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to coverings for
structures such as homes, commercial or industrial buildings. One
embodiment of the present invention particularly relates to foam
insulative panels for such structures.
BACKGROUND
[0003] Stucco has been used for many years as a veneer covering for
both commercial and residential walls. There are three typical
representative methods of stucco construction:
[0004] (1) The house is first covered with plywood, wafer board
(OSB) or insulation board, then lathe is attached to the walls and
sprayed with a cement coating to form a stucco wall. The surface
would then be painted.
[0005] (2) The utilization of an Exterior Insulated Finishing
System ("EIFS"). In one example implementation of EIFS, the
relevant portions of the exterior of the house is covered with
one-pound extruded polystyrene foam ("EPS"), one-inch thick. Lathe
or fiberglass mesh is then attached to the EPS. A coating, called
"brown coat," is then troweled or sprayed onto the EPS as an under
coat. After the brown coat dries, a finish coat of synthetic stucco
is applied, usually with the coloring in it.
[0006] (3) Most recently, due to water intrusion problems which can
result in mold issues, a combination of the two (stucco and EIFS)
has been tried to reduce costs. Installation of this hybrid system
usually begins with the exterior side of the sheathing covering the
house being covered with a water resistant barrier of house wrap or
weather resistant felt paper. The barrier covered house is then
covered with a wall sheathing or surface (in example, plywood, OSB
and EPS foam). Chicken wire or mesh (called lathe) then is
installed over the substrate. A concrete layer is then either
sprayed or troweled directly on the substrate/lathe. After drying,
the concrete layer is painted with an acrylic top coat. This is
commonly referred to as a "two-coat" or "three-coat" stucco system.
The "three-coat stucco system" requires a "brown" coat, a second
concrete coat, and then the finish coat (usually an elastomeric
acrylic stucco or paint coating).
[0007] The problems with these prior systems include: (1) if the
concrete coating ever fractures, which it inevitably does, water
can run in behind the stucco and/or foam and cause problems (in
example, mold, mildew, or wood rot) since the moisture cannot
escape; (2) as the seasonal temperature changes, a large wall
without expansion joints is continually stressed and develops
waves, bulges, and eventually cracks; and (3) the onsite labor time
window required is not especially friendly to stucco construction,
for instance, bad weather can bring stucco work to a halt, low
temperatures may result in the concrete not curing correctly (which
itself results in later cracks and peeling), and freezing
temperatures often negatively affect the curing of cement
products.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a partial, side view of a first embodiment of a
panel.
[0009] FIG. 2 is a side view of an embodiment of a starter
section.
[0010] FIG. 3 is a side view of an embodiment of an adapter.
[0011] FIG. 4. is a side view of an embodiment of a block out.
[0012] FIG. 5 is a side view of an embodiment of a rail
section.
[0013] FIG. 6 is a partial, side view of one embodiment of two
panels (of the embodiment of FIG. 1) about to be connected
together, also showing the sheathing.
[0014] FIG. 7 is a partial, side view of one embodiment of two
panels (of the embodiment of FIG. 1) connected together, also
showing the sheathing.
[0015] FIG. 8 is a partial, side view of a panel (of the embodiment
of FIG. 1) about to be connected with a starter section (of the
embodiment of FIG. 2), also showing the building structure.
[0016] FIG. 9 is a partial, side view of a panel (of the embodiment
of FIG. 1) connected to a block out (of the embodiment of FIG. 4)
connected with a starter section (of the embodiment of FIG. 2),
also showing the building structure.
[0017] FIG. 10 is a partial, side view of a panel (of the
embodiment of FIG. 1) connected to a rail section (of the
embodiment of FIG. 5) connected to a second embodiment of panel,
also showing sheathing.
[0018] FIG. 11. is a partial, side view of a panel (of the
embodiment of FIG. 1) connected to an adapter (of FIG. 3) connected
to a third embodiment of panel, also showing sheathing.
[0019] FIG. 12 is a plan view of an embodiment of insulated siding
installed on a stud wall, showing a corner connection.
[0020] FIG. 13 is a partial, side view showing an embodiment of
insulated siding installed on a stud wall.
[0021] FIG. 14A is a first side view of the panel of FIG. 1.
[0022] FIG. 14B is a first end view of the panel of FIG. 1.
[0023] FIG. 14C is a perspective view of the second side of the
panel of FIG. 1.
[0024] FIG. 15 is a partial, side view of a fourth embodiment of a
panel (two panels shown) shown about to be connected together.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The present invention is a system for covering the inside or
outside surface of a structure, and the method of making said
covering and its components.
[0026] While the present invention is susceptible of various
modifications and alternative constructions, certain illustrated
embodiments thereof have been shown in the drawings and will be
described below in detail. It should be understood, however, that
there is no intention to limit the invention to the specific form
disclosed, but, on the contrary, the invention is to cover all
modifications, alternative constructions, and equivalents falling
within the spirit and scope of the invention as defined in the
claims.
[0027] In the following description, the use of "or" indicates a
non-exclusive, alternative without limitation unless otherwise
noted. The use of "for example," "in example," "i.e.," "e.g.,"
"such as," and the like indicates the disclosure of certain listed
examples with the express intention that there are other objects of
the same category that are not listed. The use of "including" means
"including, but not limited to," unless otherwise noted.
[0028] The figures show a number of embodiments of the present
invention. One or more of these embodiments could be used in a wall
panel system. One representative wall panel system would comprise
the application of decorative siding panels (and associated
structure) made from high-density expanded polystyrene (EPS) foam
to the outside wall surface of a structure. These siding panels
configured for overlapping, having an interlocking tongue and
groove structure, for purposes of sealing out moisture.
[0029] Referring to FIG. 1, shown is one embodiment of a decorative
siding panel 10. It is preferred that the panel (as well as the
other components of these embodiments, including but not limited to
the starter sections, block outs, rail sections, corner covers,
etc.) be made from high density foam board, for instance expanded
polystyrene (EPS), polyurethane, etc. It is preferred that the foam
used have a density of 3-lb or greater, for instance 3.3-lb dense.
Softer foams (such as, 1-lb, 2-lb, etc.) can likewise be used,
preferably provided that they are coated with a hard coating such
as epoxies, urethanes, elastomers, polyurea, minerals, cement,
fiber cement, fiberglass, etc. Such foam board could also be
mold-resistant and/or insect-resistant.
[0030] Because they are comprised of foam board, the panels can be
cut into various decorative patterns, including but not limited to
flat, grooved, lapboard, log shapes for log cabin look, etc. The
panels could even be embossed by stamping, or various designs, such
as brick patterns, rock or stone patterns, etc., could be applied
or melted therein. The panels can also be colored and/or covered
with various finishing treatments, as desired, to further add to
their appearance. This variety of panel shapes and configurations
(including how they are configured for attachment to one another)
allows a designer and/or an installer great freedom in creating
decorative patterns in the structure's covering.
[0031] In this description, the term "panels" refers to a sheet,
regardless of length, width, thickness or shape, that forms a
distinct (usually flat) section or component of a structure.
[0032] In the preferred embodiment, the main panels are 4' by 8' in
size. One example of such a 4'.times.8' panel can be seen in FIG.
14A. Other panel sizes are likewise envisioned, for example, 2'' by
8'' to 96''.times.192'' and everything in between.
[0033] The panels are configured to be interlocking and for being
generally water/air tight. Being interlocking prevents water from
traveling through the tongue and groove of the panels and/or from
running horizontally (like lapboard siding typically does), thereby
preventing water damage and/or mold.
[0034] Referring to FIGS. 1 and 14A, the panel 10 having a top side
12, a bottom side 14, a first side 16 and a second side 18. The
panel 10 also having a face side (the first planar side) 20 and a
back side (the second planar side) 22.
[0035] It is preferred that one or more of the
top/bottom/first/second sides is configured to interlock with one
or more adjacent panels/structures. The preferred manner of
interlocking is through use of "tongue and groove" style
interlocking. By such interlocking (overlapping/abutting), water
and vapor flow is blocked and the resulting damage is
prevented.
[0036] In such a tongue and groove arrangement, at least one of the
sides has a tongue or other flange extending there-from. This
tongue is for receipt into a groove on a second panel or building
structural element. Note: while the phrase "tongue and groove" is
used herein, such exact functionality is not required, for instance
opposing flanges are intended within the definition of "tongue and
groove."
[0037] Referring particularly to FIG. 1, the top side 12 has a
tongue 24 defined therein and the bottom side 14 has a groove 26
defined therein. The tongue 24 defined by a weather overlap rabbet
23 and a locking rabbet 25. The groove 26 defined by an outside
flange (weather overlap) 32 and an inside flange (locking flange)
34. In this embodiment, the taper .THETA. serves as an anti-siphon
feature, preventing water at the seam from moving through the joint
when there is relatively negative pressure in the building
structure. This is a preferred feature that is present in this
embodiment, but may not be present in other embodiments.
[0038] As is shown in FIGS. 6-7, the flange 24 of a first panel 10
is configured for interlocking receipt into the groove 126 of a
second panel 110 to form a tongue and groove joint 36. FIG. 6
showing the two panels (10, 110) unlocked, whereas FIG. 7 shows the
two panels interlocked.
[0039] In the embodiment shown in FIGS. 6-7, the panels (10, 110)
generally have a one and one-half inch overlap (shiplap). Providing
such a degree of overlap may make a building wrap (such as DuPont
Tyvek.RTM.) optional, depending on code requirements.
[0040] FIGS. 6-7 showing another feature, covering up the fastener
heads/holes. The fastener 28 would clearly be visible from the
outside (left) in FIG. 6. As the connection is made (FIG. 7), the
outside flange 132 overlaps the tongue 24, thereby hiding the head
of the fastener 28. Overlapping in such a manner is very
aesthetically pleasing because the fastener heads cannot be
seen.
[0041] Such tongues and grooves can be formed in a number of ways,
including but not limited to being cut or otherwise formed in the
foam and being made from a separate material (metal, plastic, etc.)
that is attached to the panel side (for example, by adhesives or
fasteners).
[0042] Preferably, as is shown in FIGS. 6-7, the tongue 24 is
configured to provide an attachment surface through which a
fastener 28 (including but limited to staples, screws, bolts, and
nails) can be driven therethrough (at a fastener receiving portion
adjacent said tongue) and into a surface 30 (such as an exterior
wall). This fastener 28 thus used to attach the panel 10 to the
surface 30. These fasteners are preferably used every three to
twelve inches along the tongue side of the panel, however other
spacing is possible.
[0043] The term "surface 30" when used herein intended to represent
not only the outside or exterior "surface" of the building
structure, but also includes any and all construction materials
that the panel and associated components can be attached to, such
as a sheet of OSB, plywood, dry wall, etc., regardless of their
location on the structure (exterior, interior, etc.).
[0044] It may be desirable to have tongues on at least one of the
horizontal ends as well as on the vertical ends, and grooves on one
of the horizontal ends and one of the perpendicular ends. Such an
arrangement would allow adjacent panels to interlock together and
would allow the panels to be installed either vertically or
horizontally in a continual pattern to achieve a desired height or
width.
[0045] However, do to the layout used in constructing the wall (for
instance, it may be advantageous to start at the ends of the wall
and work towards the center), situations may arise where adjacent
panels are not configured for such "tongue and groove"
interlocking, for instance, as shown in FIG. 11, where the two
panels (10, 210) to be joined both have grooves. In such a case it
may be useful to use a female-to-female adapter 38 (shown in FIGS.
3 and 11) having a pair of opposing tongues (39, 40) that can be
installed into the grooves (26, 226) to allow the two panels to
interlock. It is preferred that such an adapter be configured for
fastening, for instance through use of the screw 28 shown) to the
surface 30. In such an instance, a special overlapping piece may be
necessary to join in the center. Installation starting at the
center and going outwards is discussed later in this
description.
[0046] It is preferred that, on the panels, the tongue be
consistently on one side (left or right) and the top, with the
groove on the other side and the bottom. If the side grooves are
reversed, the panels must be left and right handed and cannot be
rotated interchangeably. Further, panels can be made with the
tongue on top and the groove on the other edges, with the
utilization of an adapter that can be glued or otherwise fastened
into a groove to provide a tongue as required.
[0047] Using such interlocking joints allows for expansion and
contraction to take place, something that traditional foam/stucco
methods, such as the EIFS, 2- and 3-part systems mentioned
previously, are not particularly effective at doing. Because EIFS
doesn't account for such expansion and/or contraction, oftentimes
cracking in the finish results.
[0048] As discussed above, the panels can be fastened to the
structure through use of at least one fastener (for example, a
screw or staple), inserted through the tongue (as shown in FIGS.
6-7). The panels could be fastened to the structure using an
adhesive (preferably a 100% silicone, or low temperature urethane
adhesive, preferably one that can be applied down to -20 degrees
F.), either along with or separate from the utilization of a
fastener. The utilization of both fasteners and adhesive is
preferred. Such an adhesive, or a waterproof sealant (i.e., caulk,
paintable silicone), could further be used on the tongue and groove
joints, as well as any other locations that could be permeated by
water or vapor, to sealed such joints and connections water
tight.
[0049] It is preferred that the vertical seams be sealed, while the
horizontal seams are not. This allows the wall system to ventilate
vapor and/or moisture out from the interior portions of the
building structure while inhibiting exterior water penetration.
Further, the backsides of the panels could be vertically or
diagonally grooved to assist in the evacuation of
moisture/condensation.
[0050] Referring now to FIG. 2, shown is a starter section 42.
Starter sections 42 be used on the ends of the panels as they
terminate adjacent the ground (as shown in FIGS. 8-9), between
panels, etc. For instance, FIG. 8 showing the starter section 42
having a tongue 44 configured for receipt into the groove 26 of the
panel 10. FIG. 9 showing the starter section 42 having a tongue 44
configured for receipt into the groove 26 of the block out 46
(discussed below). A preferred starter section comprises a piece of
EPS foam. Other starter section configurations include but are not
limited to a metal clips (for instance a "J-shaped" clips), or
plastic structures generally shaped to fit the groove with a
defining channel therein to receive the bottom edge of a siding
panel therein.
[0051] Preferably, a fastener 28 would be utilized to attach the
starter section 42 to the structure 30. The starter section can be
the first general structure attached (using fasteners) mounted to
the wall surface, providing a flange (or groove) that the lowermost
siding panel bottom edge mates with.
[0052] FIG. 4 shows a "block out" (also referred to as a "design
band" or "pop out") 46 having a tongue 48 and a groove 50. FIG. 9
shows this block out 46 installed on a surface 30, where the tongue
48 is configured for receipt into a connected panel's 10 groove 26.
The block out's groove 50 receives therein adjacent tongue, for
instance the tongue 44 of a starter section 42.
[0053] FIGS. 5 and 10 showing a rail section 70. The rail section
70 having an upper end having a tongue 39 configured for connection
with the groove 26 of the panel 10. A fastener 28 could extend
through the tongue 39 for attaching the rail section 70 to the
surface 30. The opposite portion of the rail section 70 comprising
a rabbet or lower connection 74 configured for attachment to a
panel 310 having a flat side 314. The rail section 70 serving as a
decorative addition to a wall, and may also serve other functional
purposes, for instance as a plant shelf or window sill. It is
preferred that when a rail section is used under a window, the
tongue section of the rail would be removed and the rail sealed
with caulk to the window.
[0054] FIGS. 8 and 9 further showing, for purposes of
representation, general structure that may or may not be present in
a common structure upon which these embodiments are installed.
Disclosure of this structure is intended to supplement the reader's
understanding of general concepts and are not necessarily intended
to be required structure in any structure. Specifically, these
Figures showing a foundation wall 52 upon which a floor joist 56
rests, typically with a moisture barrier 54 such as a sill seal
gasket sandwiched there-between. The floor joist(s) connect with
one or more rim joists 58 which cooperate to support a sub-floor
60. An underlayment 62 is placed over the sub-floor 60. The bottom
plate 64 of a stud wall 66 rests on the sub-floor, this stud wall
comprising a plurality of studs 68. The outside surface of the stud
walls having a wall sheathing or other surface 30 attaching
there-to. Sheathing including but not limited to OSB, plywood,
particle board, wood products, metal coverings, plastic coverings,
composite coverings, concrete board, ceramic fiber board, fireproof
materials, etc. Again, this description merely intended as a
general discussion of components typically found in a common
structure.
[0055] Referring now to FIG. 12, shown is a top view of one
embodiment of the present invention. This figure showing a pair of
stud walls (66, 66') connected together at a corner. Sheathing 30,
30' covers the stud walls. Attaching to this sheathing are a
plurality of components of the present invention, a panel 10'
having a grooved end interlocking with a panel's 510 tongue. The
opposite end 514 of this panel 510 having a flat end. The panels
could also be directly attached to the studs.
[0056] The flat end of this panel (510) connecting to the flat end
of a second panel (510') so as to make a corner. This corner being
covered by a corner cover 76. Such a corner cover being a trim
piece designed to be glued in place without use of fasteners after
siding panels are secured to the structure. Corner trims allow the
present invention to traverse around corners without showing
fasteners on the outside thereof. A second type of corner trim
would be an outside 45-degree corner--a shallow pop-out design
designed to be used on 45-degree corners such as bay window or
angled walls. Another type of corner trim would be on the inside
corner which is shaped like a triangle shape designed to be used on
an inside corner of a structure to hide the seam where the siding
joins.
[0057] This panel 510' connecting with a panel 10. These panels
(10, 10', 510, 510') connecting to the sheathing 30, 30' for
covering the structure.
[0058] Referring now to FIG. 13, shown is one example of how a
building structure could be covered using this insulative siding. A
starter section 42 is attached to the rim joist 58. A panel 10,
external to a stud wall 66, would connect with this starter section
42 and itself would be fastened to the sheathing 30 at its tongue
end. A decorative block out 46 could attach o the top end of the
panel 10, this block out further configured for connection with a
panel 310''. This panel 310'' connecting with a rail section 70
that is a portion of the window assembly 2. From the top portion of
the window assembly extends a panel 310' configured for connection
with another decorative block out portion 46. This block out
portion 46 configured for attaching to a panel 310, which is
external to a stud wall 66 is configured for abutting (through use
of additional structure) the building's soffit. The main purpose of
this drawing being to show that various of the components of the
present invention can be assembled as desired by the
designer/installer to form a decorative wall assembly.
[0059] Another example (not particularly shown in FIG. 13) would be
the application of a wainscot (e.g., rock, block, brick) onto the
outer surface of the panel, with stucco and/or sandstone panel
styles (discussed below) for the upper wall portion.
[0060] The panels may be coated with any number of coatings,
including but not limited to hard finishes, rubbery "stucco-like"
coatings, etc. Resins including hardeners and fireproofing can be
applied to the outside. These coatings preferably being applied at
the factory, rather than in at the job site, but could be applied
at the job site. Noise reduction is another benefit of the present
invention, a benefit that may be enhanced through use of coatings.
Preferred coatings include but are not limited to a "stucco"
finish, "sandstone" finish, and "smooth" finish.
[0061] "Stucco" finish. One example would be the application, to
the panels and/or other components of the present invention, of a
hard coating of an epoxy, polyurea or urethane (or any such coating
mentioned herein). The coating could include a quantity of sand (or
other granular/textured material) for texture/added strength and a
paint coat to create a stucco-like appearance. This granular
material can be added to the coating before or after it is applied
to the components. Multiple plies of the coating and the material
may be applied to increase the strength of the coating. Various
grits of the material could be used to change the roughness of the
finish.
[0062] "Sandstone" finish. One example would be the application, to
the panels and/or other components of the present invention, of an
epoxy, polyurea or urethane coating (or any such coating mentioned
herein) with a quantity of sand (or other granular/textured
material). A coating of paint (preferably acrylic) would then be
applied, followed by a second (or more) coat of the
granular/textured material. The granular/textured material
preferably being applied and immediately shaken off so as to
provide an attractive "sandstone" finish. A urethane sealer,
preferably clear, can then be applied as a finish coat. The color
of the paint (preferably acrylic paint) can reflect through the
sand to change the apparent color of the sandstone finish.
[0063] "Smooth" finish. One example would be the application, to
the panels and/or other components of the present invention, of a
coating of urethane, polyurea, or the like (without sand),
resulting in a smooth finish. Multiple coats can be applied for
extra hardness and strength.
[0064] Referring now to FIGS. 14A, 14B and 14C, shown are
additional views of the panel of FIG. 1. FIG. 14A showing a front
side view, FIG. 14B showing a front side perspective view, and FIG.
14C showing a second end view (FIG. 1 showing a partial, first end
view) of one embodiment of a panel 10 of the present invention.
[0065] Referring now to FIG. 15, shown is another embodiment of the
present invention. This embodiment showing the provision of a
tongue 78 that is separate from the panels (410, 410') themselves.
Utilization of a such a tongue would allow a single form of panel
to be used, whereby (if the double tongued section is used and all
the panels are grooved all the way around) by merely flipping the
panel 180 degrees and inserting the tongue would allow it to mate
up with another panel section. In such an arrangement, a fastener
could be used to fasten the tongue to the panel 410' (410) and to
the sheathing 130' (130). Adhesive could likewise be used. Further,
instead of the tongue 78, a female-to-female adapter 38 (discussed
above) could be utilized.
[0066] Optionally, as shown in the drawing, the sheathing wouldn't
be a single piece but would be adhered directly to the panel 410'
(as described infra). In such an embodiment the fastener would pass
through the sheathing and into a stud of the stud wall (or other
structure), thereby attaching the panel to the structure. The
sheathing, in this Figure, is shown configured for overlapping the
joints of the connection, however such overlapping isn't mandatory
and the sheathing could terminate that the end of rabbets.
[0067] As discussed above, the panels could be manufactured with
the panels themselves backed, laminated, adhered or otherwise
attached directly to the sheathing (the sheathing thus becoming, in
this embodiment, a portion of the panel). Doing so would eliminate
the need for the wall sheathing to be separately attached to the
framed structure (for instance to the exterior portions of the stud
wall).
[0068] This figure (FIG. 17) showing both the features of the
removable tongue 78 and the attachment (before installation) of the
sheathing to the panel. While these two features are shown herein
together, they could just as likely be separately utilized and/or
could be used (together or apart) as part of other embodiments of
the present invention.
[0069] A foil coating and/or film could be applied to the back
(house) side of the panels, this foil or other coating serving as
additional R-value, as a moisture barrier, and/or providing a
location for installation, instructions and other written materials
to be printed.
[0070] Utilization of high-density expanded polystyrene (or
equivalent foam) has an insulative benefit. Such panels provide an
insulative R-value, typically an R-4.9 value for every inch of
panel thickness. If the invented siding is used on the outside of a
structure, the amount of insulation required within the building's
wall can be reduced and/or eliminated, thereby saving construction
costs and providing other benefits. For instance, if part of the
R-value desired to be used in a wall, is applied to the outside of
the building (as insulative siding), then the thickness of the
walls themselves can be lower; from 2' by 6' construction, to 2' by
4' construction thereby saving the building and lumber costs.
[0071] In one example, two and one-quarter inch thick EPS foam is
installed over a 2''.times.4'' framed stud wall having typical R-13
insulation. Such a combination would result in a wall with an
overall thickness of approximately six (6) inches having a R-value
of approximately R-24. Must most current walls (2''.times.6''
construction) have R-values around R-21. Thus, utilization of this
embodiment in a 2''.times.4'' wall could achieve greater insulative
value while reducing the costs of construction materials and labor
over traditional 2''.times.6'' construction.
[0072] In another example, currently framed building structures
have lower R-values at the location of studs and other structural
members. Since the insulative siding's insulative value is applied
over the entire exterior surface of the wall, as opposed to merely
being insulated in-between the studs (as fiberglass insulation is,
for example), the present invention provides superior insulation
characteristics and a true R-value gain at all points in the
wall.
[0073] Installation (in one embodiment) could start in the center
of a stud wall with a panel having double tongue center pieces or
using a female-to-female adapter (38) to convert a groove into a
tongue. The installer would then work outwards both directions from
there so that trimming would be equally on the wall's ends. Doing
so would result in the most centered look upon the wall. Such a
center piece thus designed as a starter panel for the center of a
large wall. Thus allowing other siding panels to be installed on
the sides creating even spacing at the end of the wall. Such a
double tongue center piece could be used to utilize waste panel
sections as well as on gables where a panel grooved on all sides is
used. After cutting the panel diagonally, the tongue can be glued
into the waste piece to locate the tongue where desired and make
the panel usable.
[0074] Another manner of starting the wall would be to install a
starter section (42) at the base of the wall. The installer could
then begin at one side, preferably the left, and install the panels
from left to right. The first panel is installed at the corner of
the structure with the groove side of the panel adjacent to the
corner. The groove side can be secured to the wall with the starter
section or with screws or staples that will be hidden by the
outside corner trim. For taller walls, the process would be
repeated with the lower panel providing the tongue to interlock
into the upper panels.
[0075] There are benefits to using some of the embodiments of the
present invention. Some embodiments will be much quicker to install
than traditional vinyl siding. Installation, in comparison to
traditional stucco, has the potential of having about a
thirty-percent (30%) lower installed cost than "EIFS" stucco
applications and be competitively priced with "2 or 3 coat" stucco
systems. Other benefits include the insulation R-value, expansion
joints, reduced potential for cracks, flatness and consistency of
the wall, and elimination of problems created from applying water
based coatings under inclement weather conditions (i.e. freezing
temperatures can inhibit or destroy the curing of cement or other
water based products products).
[0076] Since installation of the insulative siding is a siding
process, it does not "shutdown" the construction of the building
while it is being installed (a common problem with the installation
of stucco). In addition, there is little mess and no overspray to
get on windows or other parts of the structure that may be in a
finished state. These benefits, again, are related to specific
embodiments and may not be present in each embodiment.
[0077] There are many different types of siding panels that
comprise the preferred embodiments of the present invention. This
paragraph lists five examples of the many types. The first type
being a siding panel that is 24''.times.48'' long having a tongue
on top and one side, the groove on the bottom and the other side. A
second being a 48''.times.48'' siding panel having a tongue on top
and one side with a groove on the bottom and another side. Another
siding panel could be the 24''.times.96'' panel having a tongue on
top and on one side, the groove on the bottom and the other side. A
fourth would be 48''.times.96'' in dimension having a tongue on top
and one side, the groove on the bottom and the other side. Finally,
a fifth would be a double tongue center panel having a tongue on
top and on both sides with a groove on the bottom side. Other panel
embodiments likewise exist.
[0078] The purpose of the Abstract is to enable the public, and
especially the scientists, engineers, and practitioners in the art
who are not familiar with patent or legal terms or phraseology, to
determine quickly from a cursory inspection, the nature and essence
of the technical disclosure of the application. The Abstract is
neither intended to define the invention of the application, which
is measured by the claims, nor is it intended to be limiting as to
the scope of the invention in any way.
[0079] Still other features and advantages of the present invention
will become readily apparent to those skilled in this art from the
following detailed description describing preferred embodiments of
the invention, simply by way of illustration of the best mode
contemplated by carrying out my invention. As will be realized, the
invention is capable of modification in various obvious respects
all without departing from the invention. Accordingly, the drawings
and description of the preferred embodiments are to be regarded as
illustrative in nature, and not as restrictive in nature.
[0080] While there is shown and described the present preferred
embodiment of the invention, it is to be distinctly understood that
this invention is not limited thereto, but may be variously
embodied to practice within the scope of the following claims. From
the foregoing description, it will be apparent that various changes
may be made without departing from the spirit and scope of the
invention as defined by the following claims.
* * * * *