U.S. patent application number 12/729743 was filed with the patent office on 2010-07-15 for moisture diverting insulated siding panel.
This patent application is currently assigned to CERTAINTEED CORPORATION. Invention is credited to David H. Beck, Thomas C. Gilbert, Gregory F. Jacobs.
Application Number | 20100175341 12/729743 |
Document ID | / |
Family ID | 36099534 |
Filed Date | 2010-07-15 |
United States Patent
Application |
20100175341 |
Kind Code |
A1 |
Gilbert; Thomas C. ; et
al. |
July 15, 2010 |
MOISTURE DIVERTING INSULATED SIDING PANEL
Abstract
A siding panel product is provided comprising a first polymeric
siding panel having a butt end and a top end, a front surface
comprising a plurality of front faces defined between the top and
butt ends and separated by at least one shoulder surface to define
a stepped contour, and a rear surface. An insulation backing is
coupled to the rear surface of the siding panel. The insulation
backing comprises at least first and second insulation members
coupled to the rear surface of said siding panel. The first
insulation member has a bottom edge thereof coupled proximate to
the stepped contour and the second insulation member has a top edge
thereof coupled proximate to the stepped contour.
Inventors: |
Gilbert; Thomas C.;
(Clarklake, MI) ; Jacobs; Gregory F.; (Oreland,
PA) ; Beck; David H.; (Jackson, MI) |
Correspondence
Address: |
DUANE MORRIS LLP - Philadelphia;IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Assignee: |
CERTAINTEED CORPORATION
Valley Forge
PA
|
Family ID: |
36099534 |
Appl. No.: |
12/729743 |
Filed: |
March 23, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11093465 |
Mar 30, 2005 |
7712276 |
|
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12729743 |
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10955405 |
Sep 30, 2004 |
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11093465 |
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Current U.S.
Class: |
52/302.1 ;
52/582.1; 52/588.1; 52/794.1 |
Current CPC
Class: |
B32B 13/02 20130101;
B32B 2419/04 20130101; Y10T 428/249976 20150401; B32B 13/12
20130101; E04F 13/0871 20130101; B32B 2266/0278 20130101; B32B
2419/06 20130101; B32B 2307/712 20130101; E04F 13/141 20130101;
B32B 13/045 20130101; E04F 13/0866 20130101; B32B 2307/7265
20130101; B32B 2607/00 20130101; E04F 13/185 20130101; B32B 2266/08
20130101; E04F 13/0864 20130101; B32B 5/18 20130101; B32B 2266/025
20130101; E04F 13/0869 20130101; Y10T 428/249982 20150401; B32B
7/08 20130101; B32B 2262/04 20130101; B32B 2250/02 20130101; Y10T
428/249953 20150401 |
Class at
Publication: |
52/302.1 ;
52/588.1; 52/794.1; 52/582.1 |
International
Class: |
E04B 1/70 20060101
E04B001/70; E04F 13/26 20060101 E04F013/26; E04C 2/34 20060101
E04C002/34; E04F 13/24 20060101 E04F013/24 |
Claims
1. A siding panel product comprising: a first polymeric siding
panel comprising a butt end and a top end, a front surface
comprising at least one front face defined between said top and
butt ends, and a rear surface, the siding panel including
interlocking means for interlocking with a second similar siding
panel product, the interlocking means having a downwardly depending
male member disposed at said butt end and an upwardly open female
portion at the top end to receive the downwardly depending male
portion of the second similar siding panel product; and an
insulation backing coupled to the rear surface of the siding
panel.
2. The siding panel product of claim 1, wherein the insulation
backing is secured to the first polymeric siding panel at least in
part by a mechanical fit with the first polymeric siding panel.
3. The siding panel product of claim 2, wherein a top end of the
insulation backing is mechanically secured to the first polymeric
siding panel at the top end of the first polymeric siding panel and
a bottom end of the insulation back is mechanically secured to the
first polymeric siding panel at the butt end of the first polymeric
siding panel.
4. The siding panel product of claim 3, wherein the insulation
backing comprises a continuous piece of foam backing extending from
the top end of the first polymeric siding panel to the butt end of
the first polymeric siding panel.
5. The siding panel product of claim 1, wherein the first polymeric
siding panel has a nailing hem positioned at the top end thereof,
wherein a rear surface of the insulation backing is substantially
planar with a rear surface of the nailing hem.
6. The siding panel product of claim 1, wherein the front surface
of the first polymeric siding panel includes a plurality of front
faces defined between the top and butt ends and separated by at
least one shoulder surface to define a stepped contour between the
faces, wherein a front surface of the insulation backing is shaped
to substantially conform with the rear surface of the first
polymeric siding panel.
7. The siding panel product of claim 1, wherein the first polymeric
siding panel comprises one or more weep openings formed at the butt
end thereof.
8. The siding panel product of claim 7, wherein the insulation
backing comprises one or more channels formed through the
insulation backing configured to transport moisture from a rear
surface of said insulation backing toward said one or more weep
openings.
9. The siding panel product of claim 8, wherein the one or more
channels slope from the rear surface of the insulation backing
toward a front surface of the insulation backing.
10. The siding panel product of claim 1, wherein the first
polymeric siding panel comprises a rear wall at the butt end of the
first polymeric siding panel, the rear wall being spaced from the
front face of the first polymeric siding panel, wherein the front
face and the rear wall form a cavity for receiving a bottom end of
the insulation backing, wherein the bottom end of the insulation
backing is secured to the first polymeric siding panel at least in
part by a mechanical fit within the cavity.
11. The siding panel product of claim 10, wherein the rear wall
extends from the downwardly depending male member.
12. The siding panel product of claim 1, wherein the first
polymeric siding panel product includes a nailing hem wall at the
top end thereof, and an intermediate wall disposed between the
nailing hem wall and the front face of the first polymeric siding
panel, the intermediate wall being connected to both the front face
of the polymeric siding panel and the nailing hem wall, wherein the
intermediate wall and the nailing hem wall form a portion of the
upwardly open female portion of the interlocking means.
13. The siding panel product of claim 12, wherein the intermediate
wall and the front face of the polymeric siding panel form a recess
for receiving a portion of the top end of the insulation backing,
wherein the top end of the insulation backing is secured to the
first polymeric siding panel at least in part by a mechanical fit
within the recess.
14. The siding panel product of claim 1, wherein the insulation
backing has a plurality of channel-forming spacing elements formed
on a front or rear surface thereof.
15. A siding panel product comprising: a first polymeric siding
panel comprising a butt end and a top end, a front surface
comprising a plurality of front faces defined between said top and
butt ends and separated by at least one shoulder surface to define
a stepped contour, and a rear surface, the siding panel including
interlocking means having a downwardly depending male member
disposed at said butt end and an upwardly open female portion
disposed proximate to said top end to receive the downwardly
depending male portion of a second similar siding panel product,
the first polymeric siding panel having a nailing hem at the top
end thereof; and a foam insulation backing disposed behind the
first polymeric siding panel and shaped to conform generally with
the rear surface of the siding panel, the foam insulation backing
being secured to the first polymeric siding panel at least in part
by a mechanical fit within a profile of the first polymeric siding
panel.
16. The siding panel product of claim 15, a rear surface of the
insulation backing is substantially planar with a rear surface of
the nailing hem.
17. The siding panel product of claim 15, wherein the first
polymeric siding panel comprises one or more weep openings formed
at the butt end thereof.
18. The siding panel product of claim 17, wherein the insulation
backing comprises one or more channels formed through the
insulation backing configured to transport moisture from a rear
surface of said insulation backing toward said one or more weep
openings, wherein the one or more channels slope from the rear
surface of the insulation backing toward a front surface of the
insulation backing.
19. The siding panel product of claim 15, wherein the first
polymeric siding panel comprises a rear wall at the butt end of the
first polymeric siding panel, the rear wall being spaced from a
bottommost one of the front faces of the first polymeric siding
panel, wherein the bottommost one of the front faces and the rear
wall form a cavity for receiving a bottom end of the insulation
backing to mechanically secure the bottom end of the insulation
backing within the cavity.
20. The siding panel product of claim 19, wherein the first
polymeric siding panel product includes an intermediate wall
disposed between a wall of the nailing hem and the topmost one of
the front faces of the first polymeric siding panel, the
intermediate wall being connected to both the topmost one of the
front face of the polymeric siding panel and the nailing hem wall,
wherein the intermediate wall and the nailing hem wall form a
portion of the upwardly open female portion of the interlocking
means and wherein the intermediate wall and the topmost one of the
front faces of the polymeric siding panel form a recess for
receiving a portion of the top end of the insulation backing,
wherein the top end of the insulation backing is secured to the
first polymeric siding panel at least in part by a mechanical fit
within the recess.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional patent application of U.S.
patent application Ser. No. 11/093,465 filed Mar. 30, 2005, now
U.S. Pat. No. ______, which is a continuation-in-part of U.S.
patent application Ser. No. 10/955,405 to Rick James Morse, Robert
D. Shaw and Gregory F. Jacobs, filed Sep. 30, 2004, now abandoned,
the entirety of each of which is hereby incorporated by reference
herein.
FIELD OF THE INVENTION
[0002] The present invention relates to building materials
generally, and more specifically to siding panel building
materials.
BACKGROUND
[0003] Current insulated siding panels are designed to create a
thermal barrier layer behind a thin vinyl siding layer. The lower
butt sections of these vinyl siding layers are generally designed
with weep holes to allow moisture trapped behind the siding to
escape or weep out. This moisture can come from wind blown rain,
condensation or other source. An example of one prior art insulated
siding panel system is provided in U.S. Pat. No. 6,029,415 to
Culpepper et al. (the "'415 patent").
[0004] The advent of the insulation layer attached to the back of
the siding creates a barrier which significantly limits the ability
of the siding veneer to successfully weep this moisture away.
Moisture can become trapped between the insulation layer and the
siding panel and between the building wall and the insulation
layer. The trapped moisture can cause significant damage to wall
systems and building structures as well as significantly reduce the
effectiveness of the insulation materials as they become
saturated.
[0005] There remains a need for an improved siding system that
better allows trapped moisture to escape. Therefore, an improved
siding panel product and system are desired.
SUMMARY OF THE INVENTION
[0006] A siding panel product is provided comprising a first
polymeric siding panel having a butt end and a top end, a front
surface comprising a plurality of front faces defined between the
top and butt ends and separated by at least one shoulder surface to
define a stepped, or other, contour, and a rear surface. An
insulation backing is coupled to the rear surface of the siding
panel. The insulation backing comprises at least first and second
insulation layers, coating panels or boards (hereinafter
collectively referred to as "members") coupled to the rear surface
of said siding panel. The first insulation member has a bottom edge
thereof located proximate to the stepped, or other, contour and the
second insulation member has a top edge thereof located proximate
to the stepped, or other, contour.
[0007] Use of an insulation backing that comprises more than one
insulation member helps to reduce scrap waste and improve handling
and ease of assembly, all without reducing thermal and acoustic
insulation performance.
[0008] In another embodiment of a siding panel product, the siding
panel product includes one or more insulation members coupled to
the rear surface of the siding panel where the one or more
insulation members includes a plurality of spacing elements on at
least one of the major surfaces thereof forming at least one
channel. Depending on the orientation of the spacing elements, the
insulated siding product can provide for a better adhesive
connection between the insulation backing and the siding panel,
and/or provide for improved or enhanced water drainage. Improved
drainage can provide a diminished probability of occurrence of
mold, mildew and/or rot formation behind a siding panel product. In
some embodiments, the siding product includes an improved locking
means that provides for an easier installation of the siding
product, thereby providing both cost and manpower savings.
[0009] The above and other features of the present invention will
be better understood from the following detailed description of the
preferred embodiments of the invention that is provided in
connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings illustrate preferred embodiments
of the invention, as well as other information pertinent to the
disclosure, in which:
[0011] FIG. 1 is a partial perspective view of an embodiment of a
siding panel product having a multi-component insulation
backing;
[0012] FIG. 2 is a profile view of the siding panel product of FIG.
1;
[0013] FIG. 2A is a profile view of two interlocked and installed
siding panel products of FIG. 2;
[0014] FIG. 2B is a partial front plan view of a portion of the
insulation backing of the siding panel product of FIG. 1 according
to one embodiment;
[0015] FIG. 2C is a partial cross-sectional profile view showing
the male end of the locking means of the siding panel of the siding
panel product of FIG. 2;
[0016] FIG. 3 is a profile view of an embodiment of a siding panel
product having a moisture diverting means;
[0017] FIG. 3A is a profile view of two interlocked and installed
siding panel products of FIG. 3;
[0018] FIG. 4 is a profile view of an embodiment of a stackable
siding panel product;
[0019] FIG. 4A is a profile view of two interlocked and installed
siding panel products of FIG. 4;
[0020] FIG. 5 is a profile view of an embodiment of a siding panel
product having an insulation backing having a non-planar major
surface;
[0021] FIGS. 5A-5D are partial front plan views of alternative
embodiments of the insulation backing shown in FIG. 5; and
[0022] FIGS. 6A and 6B illustrate siding panels having alternative
faces.
DETAILED DESCRIPTION
[0023] Provided herein is an improved insulation product comprising
a thin walled polymeric siding panel and an insulation backing
coupled thereto. FIG. 1 is a partial perspective view showing two
coupled insulation products 12a, 12b according to a first
embodiment. As can be seen from FIG. 1 and as described in more
detail in connection with FIGS. 2 and 2A, each insulation product
12a, 12b includes a respective siding panel 14a, 14b coupled, in a
preferred embodiment, by an adhesive 22 to respective insulation
backing 20a, 20b. The panels can be coupled to insulation members,
such as layers, panels, boards or coatings (hereinafter
collectively referred to as "members"), for example. In the
embodiment shown in FIG. 1, each insulation backing 20a, 20b
comprises a plurality of insulation members 16a, 18a and 16b, 18b,
respectively, which are described in more detail below in
connection with FIGS. 2 and 2A.
[0024] FIG. 2 is a profile view of an individual siding panel
product 12 shown in FIG. 1. As noted, the siding panel product 12
includes siding panel 14 and insulation backing 20 coupled thereto.
In a preferred embodiment, the insulation backing 20 is coupled to
a rear surface of siding panel 14 using an adhesive, such as an
adhesive described in the '415 patent, which is incorporated by
reference herein in its entirety. Other suitable adhesives
includes, but are not limited to, UV curable adhesives and hot melt
adhesives, such as polyamines and urethanes, glue, thermosetting or
thermoplastic adhesives, pressure sensitive adhesives or
solvent-based adhesives. Other suitable adhesives include, but are
not limited to Super77 multiple adhesive and high-strength 90 spray
adhesive by Minnesota Mining and Manufacturing Co. (3M), St. Paul,
Minn. Alternatively, the insulation backing 20 can be sprayed onto
the rear facing surface of the siding panel 14, such as in the form
of a foamed insulation.
[0025] The insulation backing 20 is preferably coupled to the panel
14 during manufacturing, i.e., before distribution of the siding
product for installation in the field, but the product 12 may also
be assembled in the field. The adhesive may be applied to
substantially coat the rear major surface of the siding panel 14
and front major surface of the insulation backing 20, or in
patterns such as stripes, blocks or the like. The adhesive
application may be to one or both surfaces prior to or during
assembly.
[0026] The siding panel 14 is preferably polymeric, and most
preferably formed from polyvinylchloride (PVC) or polypropylene
(PP). In one embodiment, the siding panel 14 includes a plurality
of front faces, or simulated board or shake members (optionally
having a wood grain pattern molded or embossed thereon) defined
between the top and butt ends of the siding panel 14. In the
embodiment shown in FIG. 2, the siding panel 14 comprises an upper
front face 24 and lower front face 25. The front faces 24, 25 may
be substantially flat or planar, or may be arcuate in shape. Upper
front face 24 and lower front face 25 meet at shoulder 26 that
defines a stepped contour. Each face corresponds visually to a
siding board, shingle or other patterned course.
[0027] The siding panel 14 also includes locking means for
interlocking the siding panel 14 with similar panels installed
above and/or below the panel 14. In one embodiment, the locking
means includes a male hook member 30 located at a butt end of the
siding panel 14 and a corresponding female member 28 located
proximate to a top end of the siding panel 14 and below the nailing
hem 34, in one embodiment. Nailing hem 34 may have apertures formed
therein as shown in FIG. 1 for easy placement of nails, screws or
other fasteners. The connection between these members and members
of other similar products is best seen in FIG. 2A described
below.
[0028] In one embodiment, the insulation backing 20 comprises two
or more vertical insulation members that together provide the
insulation backing with a substantially planar rear major surface
and a front major surface that substantially conforms to the
profile of the siding panel 14, except as discussed below. In one
embodiment, the members of the insulation backing comprise a foam.
The foam may be any of a variety of porous or non-porous closed
cell foams. A closed cell foam will not soak up and hold water the
way a sponge does. A preferred foam material, for example, can be a
porous, closed-cell composite, formed by fusing together resilient,
closed cell polymer beads only at their tangent points, providing a
durable, non-absorptive composite that allows water to flow freely
through the interstices throughout the material and to drain from
the foam. The foam may be made of a thermosetting resin, such as
polyurethane, or a thermoplastic resin, such as an olefin, like
polypropylene or polyethylene, for example. Examples of suitable
foams are "BREATHE-N-DRAIN.TM.", FPP2.1, FPP3.0, and FPP5.5 porous,
closed cell polypropylene composites made by Brock USA of Boulder
Colo., or FPE2.7, FXPE2.1 and FXPE 3.2 porous closed cell
polyethylene composites, also made by Brock USA. Alternatively,
polystyrene and polyurethane foams could be used.
[0029] In the embodiment shown in FIG. 2, the insulation backing 20
comprises a first insulation member 16 coupled to the rear surface
of the siding panel 14 with a substantial portion thereof above the
stepped contour of the shoulder section 26 (i.e., the bottom edge
of insulation member 16 is proximate to shoulder section 26) and a
second insulation member 18 coupled to the rear surface of the
siding panel 14 with a substantial portion thereof below the
shoulder section 26 (i.e., a top edge of insulation member 18 is
proximate to shoulder section 26). Second insulation member 18 has
a top surface at a top edge thereof that is generally flush with
the bottom edge of the first insulation member 16. The top edge of
first insulation member 16 is preferably substantially flush and
planar with the top edge of the nailing hem 34 of the siding panel
14. While first insulation member 16 has a width that is
substantially equal to the width between the top edge of siding
panel 14 and shoulder 26, the second insulation member 18 has a
width that is smaller than the width between shoulder 26 and the
butt end of the siding panel 14, i.e., siding product 12 has a
portion 35 where the insulation backing 20 does not cover the rear
surface of siding panel 14 for reasons described below.
[0030] FIG. 2A illustrates, in partial, two siding panel products
12a, 12b coupled together by interlocking members 28b and 30a.
Siding panel product 12b is shown coupled to the exterior surface
102 of structure 100 with a series of fasteners 50 (one of which is
shown). The insulation backing 20 substantially fills the space
between the siding panel 14 and the exterior surface 102 of the
structure 100 and forms a substantially continuous insulation
surface against exterior surface 102. As one of ordinary skill will
understand, fastener 50 may comprise nails, screws, staples,
adhesives, or other fastening means. Portion 35 (described in
connection with FIG. 2) is sized so that when panel products 12a,
12b are coupled together, second insulation member 18a of siding
product 12a abuts the top edge of first insulation member 16b of
siding product 12b to form a substantially continuous insulation
layer between the siding panels 14a, 14b and surface 102.
[0031] By forming the insulation backing in two or more vertical
sections, scrap waste is reduced in comparison to conventional
one-piece insulation backing. Conventional foam backed siding
products have foam sections that often are cut from large cubes or
billets. Because the foam is cut to match the siding profiles,
there are large amounts of scrap produced when the parts are cut.
These one-piece foam sections are also difficult to handle and are
very fragile in thinner areas, such as at the shoulder region,
leading to possible fractures that can cause problems in coupling
the foam backing to the siding panel and durability concerns. Use
of the insulation backing 20, which comprises more than one
insulation member, helps to reduce scrap waste and improve
handling, and ease of assembly, all without reducing thermal and
acoustic insulation performance.
[0032] In one embodiment, best shown in the partial front plan view
of insulation member 18 of FIG. 2B, the bottom edge 38 of the
insulation member 18 comprises one or more channels 32 formed
therein from the front to rear surfaces of the insulation member
18. When a insulation member 18a is installed over a insulation
member 16b, as shown in FIG. 2A, the channels 32 allow water to
migrate from behind the insulation backing 20, i.e., proximate to
the exterior surface 102 of structure 100, through channels 32, and
to open weep area 36 between the upper end of siding panel product
12b and butt end of siding panel product 12a. Although not shown in
FIG. 2A but as should be familiar to those in the art, the butt end
of siding panel product 12a preferably includes one or more weep
holes that allow the moisture to weep from the installed siding
panel product. FIG. 2C is a partial cross-sectional profile view
showing the male portion 30a of the locking means of the siding
panel 12a having a weep hole formed therethrough.
[0033] Although the insulation backing 20 of FIG. 2A is shown as
comprising two insulation sections with horizontal abutting
surfaces at the bottom of section 16a and top of section 18a and at
the top of section 16b and bottom of section 18a (FIG. 2A), other
configurations are also contemplated. For example, the abutting
surfaces could be at a matching angle with respect to the wall 100,
preferably with the front edges (i.e., proximate to the front
surface of backing 20) lower than the back edges (i.e., proximate
to the rear surface of backing 20 and wall 100). In some
embodiments, this configuration may help with moisture diversion,
such as when channels 32 are formed at the bottom of sections 16 or
18 and/or at the top of sections 16 or 18, along with the formation
of weep areas at weep area 36 and/or shoulder 26 and/or in
connection with channels or protrusions formed in the front surface
of the insulation backing as shown in FIGS. 5-5D.
[0034] With reference to FIG. 3, another embodiment of a siding
panel product 120 is illustrated. Features similar to those shown
in the siding panel product 12 of FIG. 2 share the same reference
numbers. Siding panel 140 is identical to siding panel 14 except
that siding panel 140 includes a water diverting means comprising,
in the illustrated embodiment, return leg 142 disposed over the
upper surface of insulation member 16 and a second leg section 144
extending upward from the return leg 142 and positioned to sit
against the exterior surface 102 of structure 100 when the siding
panel product 120 is installed as shown in FIG. 3A. Siding panel
140 may be coupled to a one-piece insulation backing of the prior
art, but is more preferably coupled to a multi-piece insulation
backing 20 as shown in FIG. 3 and described in detail above in
connection with FIGS. 2 and 2A.
[0035] With reference to FIG. 3A, the return leg 142b and upwardly
facing leg 144b help to prevent or at least reduce moisture that
gravitates down exterior surface 102 behind insulation section 18a
installed above insulation section 16b from continuing behind
insulation backing section 16b. The leg 144b and return leg 142b
also help to direct the moisture toward weep area 36, particularly
when used in connection with channels 32 in insulation section 18a
described above. The improved drainage path so formed can help to
keep the structure 100 drier, when compared to conventional
designs, improve the insulation value of the foam polymer in
insulation backing 20 and reduce potential issues associated with
moisture infiltrating the wall of structure 100 where it can do
significant damage through rotting, molding or mildew. In one
embodiment, the vertical portion of the return leg 144b could be
sized to be used as a nailing flange, rather than nailing through
the foam 16b as shown in FIG. 3A.
[0036] In one embodiment, a recessed region 146 of second
insulation member 18 is shaved, cut or otherwise formed into the
insulation member 18 to match and provide a tight fit with the
return leg 142 and upwardly oriented leg 144, as shown in FIG. 3A.
Although the moisture diverting means is shown as a generally "L"
shaped structure in the embodiment of FIG. 3, other shapes may also
be used. For example, return portion 142 could be angled or curved.
Appropriate mating recesses for these embodiments could also be
formed at the bottom edge of insulation backing section 18, like
recessed portion 146 only corresponding to the angled or curved
shape of modified return leg.
[0037] FIG. 4 is a side profile view of an embodiment of an
insulated siding panel product 220 having an alternative means for
interlocking the siding panel with similar siding panel products
disposed above and/or below the siding panel product 220. In
contrast to the locking means shown in FIGS. 2 and 3, where the
male portion 30 of the locking means is upwardly oriented and the
female portion 28 is downwardly oriented, the locking means of this
embodiment includes an upwardly facing female portion 280 proximate
to nailing hem 340 and a downwardly depending male member 300. As
shown in the installation assembly of FIG. 4A, the siding panel
products 220a, 220b can be interlocked using a simplified stacking
process. A first siding product 220b is aligned along, and secured
to, the wall 100 using fasteners 50 disposed through nailing hem
340. The second siding product 220a is then coupled to the first
siding product 220b by positioning the product 220a above the
installed product 220b, with male member 300a aligned over female
member 280b, and moving the product 220a downward to guide and
dispose the male member 300a thereof into the female member 280b of
the first siding product 220b. The siding product 220a is then
fastened to the wall 100 while it is supported by already fastened
product 220b.
[0038] Siding products 220, which are configured for a downward
coupling, are easier to install than those using conventional
locking means of the prior art, which require panels to be lifted
upwards to make the connection between male member 30 and female
member 28 and which require a second installer to hold the top
panel in place while the first installer provides the fasteners.
With siding products 220, however, because the male member 300a is
oriented downward and comes to rest in the upwardly oriented female
member 280b, the fixed panel 200b supports the panel 200a while
fasteners are applied to secure panel product 200a to structure
100, thereby reducing or eliminating the need for another installer
to support the second panel product 200a during the fastening
step.
[0039] As shown in FIG. 4, siding panel product 220 includes a
single piece (at least width wise) insulation backing 200. While
multiple section insulation backings can certainly be used as
described above, the design of siding panel product 220, and
specifically of siding panel 240, is particularly suited for use
with single piece insulation backings that are at least partially
mechanically supported within the profile of siding panel 240. This
mechanical, fitted connection between the siding panel profile 240
and insulation backing 200 allows for an elimination of or
reduction in the adhesive used for coupling the siding panel 240 to
the insulation backing 200. Optionally, one or more channels 232,
preferably diagonally oriented, could be provided through the foam
backing to facilitate moisture transport from behind the backing to
a weep area in front of and/or below the backing.
[0040] FIGS. 5-5B illustrate an alternative embodiment of a siding
panel product 320 having an insulation backing having channels
formed in at least one major surface thereof. Siding panel product
320 include a siding panel 14 as shown and described in connection
with FIG. 2, although other siding panels, such as those shown in
FIGS. 3 and 4 may also be used. In the embodiment shown in FIG. 5,
siding panel product 320 includes an insulation backing 300 having
channels or openings formed into at least one of its front or back
major surfaces. In the embodiment shown in FIG. 5, the insulation
backing 300 includes a plurality of horizontal channels formed in
its front major surface, i.e., the major surface that faces the
rear surface of the siding panel 14. The channels can be formed by
a plurality of horizontal holes, humps, ribs, grooves or
protrusions 400, or other spacing elements, that create an
irregular surface for increasing the surface area for bonding to
the rear surface of the siding panel 14, thereby providing an
improved bond between the insulation backing 300 and the siding
panel 14. The humps, ribs, grooves or protrusions preferably, but
not necessarily, substantially cover the entire front major surface
of the insulation backing 300.
[0041] In alternative embodiments of the insulation backing shown
in the front plan views of FIGS. 5A and 5B, the channels are
oriented at an angle relative to horizontal. As shown in the
embodiment of FIG. 5A, insulation backing 300a may include a
plurality of substantially vertical channel forming protrusions
400a, or other spacing elements, formed in the front major surface
of the insulation backing 300a. In the embodiment shown in FIG. 5B,
the insulation backing 300b includes a plurality of channel forming
protrusions 400b oriented diagonally, i.e., at an oblique angle to
the horizontal. In these embodiments, where the channels are
perpendicular or at an oblique angle to the horizontal, the
channels help facilitate the movement of water towards weep
channels formed in the butt end of the siding panel 14. To that
end, the channels are preferably at an angle of between about
45-90.degree. to the horizontal. In these embodiments where it is
desired to use the channels as weep channels in the front major
surface of the insulation backing, the adhesive is preferably not
applied to the entire front major surface of the insulation
backing, so as to avoid clogging or otherwise blocking the
channels. Rather, the adhesive is preferably applied in spaced
vertical strips. Although the adhesive does not cover substantially
the entire front major surface of the insulation backing in these
embodiments, the adhesive should create an improved localized bond
between the insulation backing and the siding panel due to the
localized increased surface area, as described above with channel
forming protrusions 400. In alternative embodiments shown in FIGS.
5C and 5D, the channel forming protrusions are discontinuous, or
put another way, each diagonal, vertical and/or horizontal
protrusion line is formed from a plurality of discrete protrusions.
As shown with the backings 300c and 300d of FIGS. 5C and 5D,
respectively, these protrusions 400c, 400d can take on any number
of shapes, such as squares (protrusions 400c), rounded bumps
(protrusions 400d) or other shapes. These configurations form
criss-crossing channels to provide multiple drainage channels and
paths. Adhesive could be applied in a measured amount to provide
for adhesion at substantially only the peaks or outer most surface
of these protrusions, leaving the channels free for drainage.
[0042] In one embodiment, the channels are formed on both the front
and rear major surfaces of the insulation backing FIG. 5 shows in
shadow the channels 402 formed on the rear major surface of
insulation backing 300. Although not shown, channels may also be
formed along the sides of the insulation backing to modulate
drainage of water from sides of the product.
[0043] The channels in the insulation backing can be formed to any
width or depth. The spacing of the channels or protrusions may be
any distance, and may be varied within a single section of
insulation backing. The ratio between the portion of the insulation
backing covered by the protrusions and any non-protrusioned portion
(which may be otherwise flat, curved or textured) may be varied.
The channels also need not be straight, but can be wavy, for
example. Also, the channels can take on any cross-sectional shape,
such as a semi-circular, square, rectangular, V-shaped,
semi-elliptical. In one exemplary embodiment, the protrusions are
spaced between about 1.0 to about 10 mm, preferably about 2.0 to
about 8 mm, and at a depth of between about 0.5 to about 5 mm,
preferably about 1.0 to about 3.0 mm. The protrusions may be formed
directly in the profile during formation of the insulation backing
300, by cutting backing 300, by pressing or embossing the
protrusions in the surfaces of backing 300, or by burning channels
in the backing 300, for example.
[0044] As described above, the channels may be formed by holes,
humps, ribs, grooves, or protrusions formed on one or more major
surfaces of the insulation backing. Other examples of spacing
elements that may be used to provide a non-planar surface for
diverting moisture towards weep area include bosses, spacers, or
adhesive build up areas.
[0045] A method of using an exemplary product comprises: providing
a first siding panel product as described herein and mounting the
first siding panel product to a building by a variety of fasteners,
including, but not limited to, nails, staples, screws, and the like
or, alternatively adhesive means such as, for example, glues or
tapes. Then, a second siding panel product is provided, coupled to
the first siding panel and mounted to the building.
[0046] Some embodiments of insulated siding products described
herein provide for improved or enhanced water drainage. Improved
drainage can provide a diminished probability of occurrence of
mold, mildew and/or rot formation behind a siding panel product. In
other embodiments, the siding product includes an improved locking
means that provides for an easier installation of the siding
product, thereby providing both cost and manpower savings.
[0047] Although the siding panels shown in FIGS. 2-5 have faces
consistent with traditional clapboard siding panel faces, other
siding panel profiles can certainly be employed. For example, in
certain embodiments, the siding panels may be configured as a
so-called "Dutchlap" siding panel having more planar faces, as
shown in FIG. 6B, or even as a so-called "single beaded" siding
panel having a single major panel face, in certain embodiments.
[0048] Although the invention has been described in terms of
exemplary embodiments, it is not limited thereto. Rather, the
appended claims should be construed broadly to include other
variants and embodiments of the invention that may be made by those
skilled in the art without departing from the scope and range of
equivalents of the invention.
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