Wall Panel Systems And Methods Of Assembling And Refinishing Wall Panel Systems

Abstract

A wall panel system includes a plurality of extruded composite building panels for mounting to a wall that can be repaired or refinished. The panels include a plurality of ribs for contacting the wall and a lip for overlapping one of the plurality of panels immediately below. The wall panel system includes joint clips and flashings that over lap seams between abutting panels.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/164,993, filed on May 21, 2015, which is hereby incorporated herein by reference.

FIELD

[0002] The present disclosure relates to wall panel systems, components thereof, and methods of assembling and refinishing wall panels systems, specifically extruded composite building panels for siding panel systems.

BACKGROUND

[0003] The following patents are incorporated herein by reference in their entirety:

[0004] U.S. Pat. No. 6,758,996 discloses a granulated papermaking sludge that is combined with a plastic to form composite materials that may be shaped into structural and non-structural articles.

[0005] U.S. Pat. No. 5,730,371 discloses a device and a process for delumping pasty masses in waste materials from paper manufacture. The delumping means employs at least one rotating cylindrical drum having a plurality of flexible fingers mounted on the drum.

[0006] Wall panel systems, including siding panel systems and siding panels, for building structures may be formed of several different component materials, including wood, plastic or vinyl materials such as polyvinyl chloride (PVC), engineered wood composites, and fiber cement. It is desirable to create a siding panel that provides improved weatherability, durability, fade resistance, low maintenance, lower energy inputs, repairable and adaptability to various architectures.

[0007] A major trend in global building products is to create "resilient" building products that are designed to meet the conditions and reality of a post carbon, climate changing world. Various factors have become important to resilient products after devastating hurricane events such as hurricanes Sandy and Katrina. Low carbon inputs and lower energy inputs are considerations of resilient products, but durability and robustness in design are also important. Materials use to construct the resilient products need to provide more protection against potentially catastrophic weather and the increasing number of severe or even dangerous weather events that climate change can produce. Protection from hail impact, strong winds, and other general issues related to siding are considerations for a resilient building product. In addition, resilient products strive for longer product life and stability over a wide range of environmental conditions.

[0008] Thus, the resilient building movement refers, in part, to a material's ability to withstand the impact of nature including normal climatic conditions and natural disasters like hurricane, earthquakes, tornadoes, wildfires, winter storms, and flooding. More attention has been given to create building materials, products and practices that can withstand these events with less damage, durability and longevity. As mentioned, resilient products also take into account energy inputs to the product and installation along with the ability to be serviced and maintained with local materials, parts, and labor. As a result, there is a need for a new generation of resilient and repairable building materials, and particularly siding composites and wall materials that can withstand more energetic weather conditions without failure or damage. In addition, there is a need for a siding product of high resilience and durability that if damaged can be repaired easily by the owner.

[0009] The environmental benefits of productively utilizing paper-making sludge and avoiding its disposal are considerable. Pulp and paper sludge (a byproduct of primary pulping operations, recycle streams or waste paper pulping and the like) represents an environmental and disposal problem for manufacturers of pulp and paper. Generally, pulp and paper sludge are unsuitable for paper making even though they contain the same components--cellulose, lignin, hemicellulose, calcium carbonate, clay, and other inorganic components--as those present in the paper pulp itself. Calcium carbonate typically constitutes 20% and up to 75% of the sludge dry content, along with clay. These two minerals are typically loaded into paper as a coating and filler to improve the mechanical characteristics as well as the appearance of paper. The resulting paper-making sludge, particularly mixed office paper sludge, consists primarily of two major components, i.e., fiber and minerals finely mixed with each other.

[0010] Paper sludge has traditionally been disposed of by landfilling, composting, incorporation into cement, and incineration. The latter option, in turn, creates another problem, namely, disposal of the resulting ash, which often makes up to 50% or more of the volume of the sludge itself. The principal components of paper sludge ash are calcium carbonate in the form of precipitated calcium carbonate (PCC) or ground calcium carbonate (GCC).

[0011] A typical recycling mill processing 600 tons of wastepaper per day will yield 450 tons of pulp and produce 150 tons of paper-making sludge. The 228 mills currently under operation in North America produce 9 million tons of pulp residues, approximately 5 million tons of which is cellulose. The 154 European pulp and paper mills produce about 8 million tons of pulp residues, approximately 4 million tons of which is cellulose. The conversion of such waste material into value-added products has, therefore, long been desired.

[0012] Kadent GranTek, Inc. (Green Bay, Wis.) manufactures controlled size dust-free granules, made of pulp and paper sludge, under the registered trademark BIODAC. The granules are a tight composite of organic and inorganic materials, i.e., cellulose fiber and minerals, and possess a developed porous structure. This granulated paper-making sludge is described, for example, in U.S. Pat. No. 5,730,371, which is incorporated here by reference. The granules have a controlled size and possess a developed porous structure; they are composed of organic and inorganic materials, i.e., cellulose fiber and minerals. It has been found that granulated pulp and paper sludge absorbs oil, lubricant or other hydrophobic fluids to a high extent.

[0013] It is also found that granulated pulp and paper sludge, compared with loose cellulose fiber, greatly improves the properties of fiber-plastic composites. Moreover, while reinforcement of polymer matrices by incorporation of cellulose fiber is well-known, the incorporation of cellulose fiber into polymer hot melt is difficult to accomplish. Intensive prolonged mixing is ordinarily required to disperse the fiber. It is particularly difficult to obtain high-strength fiber-plastic composites, since fibers typically possess a high degree of fiber-fiber interaction, tending to stick together in bundles of fibers and resisting dispersion of the individual fibers. It has been found, however, that granulation of pulp and paper sludge, approximately half of which is typically cellulose fiber, reduces fiber-to-fiber interaction prior to incorporation into the matrix, and improves the mechanical properties of the composite.

[0014] As noted, oil, lubricant or other hydrophobic fluids may be incorporated into a paper sludge mix. One commonly used lubricant system is a blend of zinc stearate with an N,N'-ethylene bis-stearamide (EBS) wax. Other lubricants include calcium stearate, magnesium stearate, non-metallic stearates; paraffin wax, polyester wax, polypropylene wax, fatty acid derived bis-amides, ethylene bis-oleamide, esters such as stearyl stearate, distearyl phthalate, pentaerythritol adipate stearate, ethylene glycol distearate, pentaerythritol tetrastearate, glycerol tristearate, polyethylene glycol 400 monostearate, glycerol monooleate, glycerol distearate, and blended complex modified fatty acid esters.

[0015] Siding panels are one of the most visible and important parts of a home as it provides functional protection as a sealing of the building envelope and also provides aesthetic value to the home owner. Houses in America often have their exterior walls clad with siding panels to protect the predominately wooden construction from natural elements.

[0016] Current plastic or composite siding panels such as vinyl, cement fiber composite and OSB (engineered wood) siding have various problems and issues related to weatherability, moisture absorption, impact resistance, robustness, and durability. In addition, these types of siding panel systems are not easily repairable if scratched, dented, cracked, marred or impacted and they show signs of defects that cannot be repaired easily or at all. In most cases weather or human damaged siding requires replacement. In many cases siding can also color fade due to the coating or painting requirement of siding to protect the siding from moisture.

[0017] Most current composite siding products require a coating comprised of a high performance paint, powder coating, or co-extruded cap stock to protect the siding from direct moisture. Even using these methods, water vapor can still penetrate through or behind the composite siding which can cause damage that cannot be repaired or fixed thus requiring replacement of the siding or siding piece.

[0018] Mechanical issues such as impacts, scratches, marring or other mechanical damage are also problematic for traditional composite siding. Replacement is often required. Current composite siding is not repairable due to the material makeup, required coatings, and embossed surface textures.

[0019] Vinyl siding has become popular over the last several decades because it is inexpensive, relatively easy to clean and relatively durable. Vinyl siding is usually produced by extruding a plastic polyvinyl chloride (PVC) or other plastic material with a colorant into a shape wherein a glossy or embossed surface is produced. These surfaces are typically of a higher gloss, but will show most any type of impact, mar, scratch or heat distortion. Since vinyl siding is derived from thin PVC, it will follow a wall very closely, but it also has many disadvantages including low impact resistance due to being thin and produced from a brittle plastic. Vinyl siding is also prone to heat distortion, melting, chipping marring, scratching, and provides limited protection of the home building envelope. If vinyl siding is heated or burned, it gives off a toxic and deadly gas substantially increasing the danger for the people within a home during a fire. Fire fighters are also subject to these deadly fumes when fighting the many home fires in the United States annually. Furthermore, these gasses can even be released as a result of exposure to the direct hot sun.

[0020] Another new problem for vinyl siding is melting due to indirect sunlight that can be reflected from new low E energy efficient windows. According to the National Association of Home Builders, double pane low-e window reflection of the sun can focus sunlight almost like a magnifying glass on a vinyl siding. Vinyl has also come under attack given that PVC commonly integrates various phthalate plasticizers which are known carcinogens and creates many other health concerns in its production, installation and end of life. There are no current means to repair vinyl other than costly replacement.

[0021] Another example type of siding is orientated strand board (OSB) and masonite siding, collectively referred to as "engineered wood" products. Engineered wood siding is well known to those skilled in the art wherein wood particles are compressed with various binders and additives into a sheet which can then be made into various siding products. Engineered wood siding products are made from various combinations of wood veneer, fibers or flakes, bound together with glues, resins, and/or waxes. Engineered wood composites for siding are typically produced using compression under heat and pressure which creates a smooth or embossed surface that requires painting. For example, U.S. Pat. No. 5,908,496 discloses lignocellulosic materials with a polyisocyanate binder to create siding. Plywood, oriented strand board (OSB) and hardboard are basic engineered wood siding materials. Several different types and brands of engineered wood siding have experienced moisture-related failures and major lawsuits due to the product defects. Softwoods commonly used in these products can have a significant moisture uptake resulting in moisture swelling, mold, linear expansion, and rot issues. Although water proof resins or glues are used to hold the wood together and impart improved moisture resistance, these products still absorb water or moisture from within the air that can create these problems. In all cases, engineered wood products require some form of paint coating to protect the primary engineered wood composite siding core. Even with painting, paints can wear, scratch or degrade over time allowing moisture transfer into the siding to create the potential for a myriad of problems for the homeowner. OSB siding can be prone to failures due to mold, degradation, and other failures relating to moisture uptake. Similarly "Masonite", a wood and resin mixture, has various problems and lawsuits for lack of performance, mold, moisture degradation and other means of failure. Some engineered wood composites require painting, coating and edge-sealing by their manufacturers. Even with paint protection, material failures may persist.

[0022] Another example type of siding is fiber cement or fiberboard cement siding/cladding that has recently developed into an alternative siding system, especially as the acceptance of durable and renewable materials increases. Fiber cement is a product made generally of sand, cement and cellulose, and in most forms is a composite manufactured from slurries of cement, sand, wood fibers, and water. The type of fibers, together with their composition and orientation, are important as these characteristics give the composite its mechanical properties. Kraft wood pulp is preferred as Kraft pulping largely removes alkaline-sensitive lignin, resulting in fiber compositions rich in cellulose (70-80%) and hemicellulose (20-30%). Manufactured products such as panels, planks, or shingles are formed by sequentially layering multiple thin films. Although manufacturing processes vary, these films represent heterogeneous matrices having one side that is fiber rich and the other that is fiber poor. Bonding characteristics between laminates play important roles in the materials' durability and in-service performance. Formed sheets are either air-dried or autoclaved for the purpose of curing and moisture removal. The preferred method of autoclaving aids in the reaction of sand with calcium hydroxide to form calcium silica hydrate. Improved hydration gives autoclaved fiber cement greater strength, but may also increase susceptibility to chemical attack, moisture movement and subsequent thermal-moisture stressing. Examples of fiber cement products are disclosed in U.S. Patent Applications and U.S. patents related to fiber cement siding including U.S. Patent Application No. 2009/0019814, U.S. Patent Application No. 2009/0283201, and U.S. Pat. No. 6,418,610. As a siding material, fiber cement provides several advantageous properties such as rot resistance, termite resistance and being non-combustible. Because of these properties, fiber cement siding has become widely used in regions prone brush fires and elsewhere in the industry.

[0023] Although there are other advantageous properties in fiber cement siding relative to real wood siding, problems with moisture absorption, mineral, and chemical leaching, lack of impact resistance, weight, brittleness and other problems exist with fiber cement siding in addition to being one of the most expensive siding options. In addition cement fiber siding is very expensive and energy intensive in its production. Many public reports discuss the degradation problems of fiber cement siding over time. Fiber cement siding is often coated or painted not only for color, but to reduce its high moisture absorbance of the cement and cellulose fiber mixture. Fiber cement siding planks used in the siding are relatively heavy, brittle and require unique installation practices so that paint coatings are subjected to scratching, mar, cracking, breakage and other damage. These coatings or paints typically cannot be repaired and therefore a portion or full replacement of the siding may be required. Recently a number of problems and class action lawsuits have arose relating to decomposition and mold due to high moisture uptake and "leaching" of various minerals from the cement mixtures that have led to further mold problems and cracking of cement fiber siding.

[0024] Fiber cement board is subject to many of the same processes as other cement-based materials. One of the more important processes is carbonation, which results from the exposure of calcium-based phases of the cement component to CO.sub.2 in air and water (Ca(OH).sub.2+CO.sub.2.fwdarw.CaCO.sub.3+H.sub.2O). Carbonation of the matrix increases flexural strength through improved bonding between the laminated films. As the product enters its second year of service, the degree of inter-laminar bonding may be countered by thermal and moisture stresses. Although carbonation initially aids in inter-laminar bonding, carbon reactions with hydration products may also serve to increase moisture movement, which compounds the effects of thermal and moisture stresses. Weathering results in repeated cycles of moisture movement that ultimately serve to disrupt the cementitious matrix and reduce inter-laminar bonding. By moisture movement, we refer to shrinkage and expansion due to the entry of water into and out of the pulp fiber. Through continued thermal and moisture cycling, the matrix-fiber interface becomes disrupted, ultimately reducing bonds between laminates and individual fibers. Further de-bonding results in partial delamination; albeit scarcely perceptible to the naked eye. Also, at the molecular level, cellulose and hemicellulose are altered by atmospheric oxygen, alkali attack, and early biological degradation by fungi and other microorganisms. Much like incipient decay of wood, this stage of degradation lacks softening, evident delamination, cracking or other signs commonly recognized as degradation. Physical and mechanical properties are nonetheless affected, and it is reasonable to assume a minimum 10% reduction in strength at five years. Various tests have been performed on cement fiberboard siding over a 10-30 year period and reports show at this stage, composite degradation is near complete and the product is now at the end of its serviceable life. Disrupted matrixes, cellulose depolymerization, and delamination are pervasive and strength was reduced to half of as-manufactured conditions. Exposed surfaces may show matrix sloughing, material loss, extreme delamination, cracking, and softening. Advanced degradation is usually accompanied by visible fungal growth, which can be profuse--particularly on concealed surfaces subject to poor drying. Being comprised largely of cellulose and hemicellulose, fiber cement may give rise to rich fungal assemblages that include common species of Aspergillums, Penicillium, Stachybotrys, Chaetomium, Aureobasidium, and Acremonium.

[0025] Yet another example type of siding is wood plastic composites ("WPC") which can comprise various wood geometries mixed with a thermoplastic and various additives to create building products. Wood plastic composites refer to any composite that contains wood such as wood flour or wood fiber and plastic such as polyethylene, polypropylene, polyvinyl or polyvinyl chloride. The WPC or "synthetic lumber" industry has grown dramatically in the past ten years in North America. The main applications include decking, railing, boardwalk, porch, park bench seats and wood trim. The use of wood plastic composites in place of traditional wood materials is driven by the characteristics of better resistance to moisture and rot, better resistance to insects, less routine maintenance, and resistance to cracking, splitting, warping or splintering. Synthetic lumber has been used as a substitute for wood in areas where wood can deteriorate quickly due to environmental conditions. Although in the past, the commercialization of synthetic lumber was limited by costs, modern recycling techniques and low cost extrusion manufacturing capability have permitted greater penetration by polymer-fiber composite materials into the commercial and residential markets. One such product manufactured under the trademark TREX, by Trex Company, LLC, Winchester, Va., consists of a polyethylene-wood fiber blend which is extruded into board dimensions for decking applications. WPC used for window applications are smooth and also integrate a cap stock coating for protection from UV light degradation and moisture absorption. Example U.S. Patents related thermosetting molding compounds containing cellulose fiber as filler are disclosed in U.S. Pat. No. 3,367,917, U.S. Pat. No. 3,407,154, U.S. Pat. No. 3,407,155, U.S. Pat. No. 4,282,119, U.S. Pat. No. 4,362,827, and U.S. Pat. No. 4,737,532. In addition, several issued U.S. Patents disclose composite materials comprising polyethylene (high- or low-density, HDPE and LDPE, respectively) in combination with cellulose fibers, such as U.S. Pat. No. 5,082,605, U.S. Pat. No. 5,088,910, U.S. Pat. No. 5,096,046, U.S. Pat. No. 5,474,722, U.S. Pat. No. 5,480,602, and U.S. Pat. No. 6,758,996.

[0026] Wood plastic composite lumber being derived from soft thermoplastic has an issues related to scratch, mar and dent resistance. Often, an extrusion that is smooth or embossed is commonly used for decking and window applications. Although wood plastic composites are being evaluated for siding, these are generally limited to smooth or embossed siding products. These smooth or smooth embossed surfaces also have a higher gloss due to the plastic loadings. A smooth or smooth embossed surface for wood composite decking is required in order to avoid exposure of the raw wood particles which will decrease moisture resistance and potentially create mold on the surface. Furthermore due to the wood inputs, many of these wood plastic lumber composites require some form of coating or capstock to protect it from fade and degradation of the lignin containing wood within the composite matrix.

[0027] Various methods are commonly used in the production of composite siding including embossing. The embossing process uses a metal roller with a wood like texture to press a wood texture image into the composite under heat and pressure conditions. Example U.S. Patents and U.S. Patent Application related to embossing include U.S. Pat. No. 8,955,281, U.S. Patent Application No. 2005/0053767, U.S. Patent Application No. 2005/0127345, U.S. Pat. No. 5,331,602, U.S. Pat. No. 4,141,944, U.S. Pat. No. 5,906,840, U.S. Pat. No. 5,314,325, U.S. Pat. No. 6,823,794, U.S. Pat. No. 6,641,384, U.S. Pat. No. 5,053,176, U.S. Pat. No. 5,866,054, U.S. Pat. No. 5,869,176, U.S. Pat. No. 5,387,381, and U.S. Pat. No. 3,936,518.

[0028] Most composite panels such as wood composites, wood plastic composites, and cement fiberboard all have the ability to expand and contract with changes in moisture content or heat changes related to direct sunlight or extreme temperature changes. In many cases such as wood composites and cement fiberboard composite siding panels, siding panels are cut and butted together in which the edges of the composite siding are sealed and the seams are caulked for protection. In many cases directly beneath the seam joints, a flashing tape or piece is nailed so that if water does follow or penetrate a siding but joint, the house sheathing does not become wet or mold. Example U.S. Patents related joint and flashing systems include U.S. Pat. No. 6,564,521, U.S. Pat. No. 5,344,700, U.S. Pat. No. 5,373,678, U.S. Pat. No. 5,950,389, U.S. Pat. No. 5,628,158, U.S. Pat. No. 5,842,314, U.S. Pat. No. 5,349,796, U.S. Pat. No. 5,519,971, and U.S. Pat. No. 5,373,678.

SUMMARY

[0029] This Summary is provided to introduce a selection of concepts that are further described herein in the Detailed Description. This Summary is not intended to identify key or central features from the claimed subject matter, nor is it intended to be used in limiting the scope of the claimed subject matter.

[0030] Certain examples of wall panel systems for mounting to a wall include a panel having opposite side ends, an upper end, a lower end opposite the upper end, a front surface, a rear surface opposite the front surface, a first rib on the rear surface that extends outwardly from the rear surface, and a second rib on the rear surface that extend outwardly from the rear surface. The first rib has a rib surface for contacting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the first rib, and the second rib has a rib surface for contracting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the second rib. The rib depth of the second rib is greater than the rib depth of the first rib. The panel can further comprise a third rib on the rear surface that extends outwardly from the rear surface. The third rib has a rib surface for contracting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the third rib. The rib depth of the third rib is greater than the rib depth of the second rib, and the rib surface of the third rib and the rib surface of the second rib are coplanar. The panel can include a first portion having a front surface and an inner surface and a second portion having a rear surface and an inner surface that abuts the inner surface of the first portion. The first portion includes a plurality of scores each including a first score depth defined as a distance between the front surface and the inner surface, and the second portion is removably coupled to the first portion such that scores can be included in the second portion to mimic the scores included in the first portion.

[0031] Certain examples of wall panel systems for mounting to a wall include a first panel and a second panel each having opposite side ends, an upper end, a lower end opposite the upper end, and opposite front and rear surfaces. The first and second panels are arranged in parallel orientation such that the opposite end of the first panel abuts one opposite end of the second panel to define a seam. Each of the panels includes a plurality of aligned holes that are parallel to the upper surface and positioned closer to the upper surface than the lower surface. A joint clip for coupling the panels is included such that the panels remain coupled to each other as the panels thermally deform. The joint clip has a first pin that is received in one of the plurality of holes of the first panel and a second pin that is received in one of the plurality of holes of the second panel.

[0032] Various other features, objects and advantages of the present disclosure will be made apparent from the following description taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Examples of wall panel systems, components thereof, and methods of assembling and refinishing wall panels systems are described with reference to the following drawing FIGURES. The same numbers are used throughout the FIGURES to reference like features and components.

[0034] FIG. 1 is a side view of an example wall panel system constructed of an extruded composite material panels.

[0035] FIG. 2 is a cross section of an individual panel used in the wall panel system of FIG. 1.

[0036] FIG. 3A is a front view of an example panel.

[0037] FIG. 3B is a front view of two example panels of FIG. 3A abutting each other.

[0038] FIG. 4 is an enlarged view of line 4-4 shown on FIG. 2 depicting scores and material projections in a first undamaged position.

[0039] FIG. 5 is an enlarged view of line 4-4 shown in FIG. 2 depicting the material projections in a second damaged position.

[0040] FIG. 6 is an enlarged view of line 4-4 shown in FIG. 2 depicting portions of the material projections removed.

[0041] FIG. 7 is an enlarged view of line 4-4 shown in FIG. 2 depicting the scores and material projections with portions of the material projections removed with reference in phantom to the scores and the material projections in the first undamaged position shown in FIG. 4.

[0042] FIG. 8 is an enlarged view of line 8-8 shown in FIG. 2 depicting a first portion and a second portion of an example panel.

[0043] FIG. 9 is a side view of an example wall panel system constructed of extruded composite material panels.

[0044] FIG. 10 is a cross section of an individual panel used in the system of FIG. 9.

[0045] FIG. 11 is a side view of an example wall panel system constructed of extruded composite material panels.

[0046] FIG. 12 is a cross section of an individual panel used in the system of FIG. 11.

[0047] FIG. 13 is a side view of an example wall panel system constructed of extruded composite material panels.

[0048] FIG. 14 is a cross section of an individual panel used in the system of FIG. 13.

[0049] FIG. 15 is a side view of a starter strip.

[0050] FIG. 16 is a top view of a joint clip.

[0051] FIG. 17 is a side view of the joint clip of FIG. 16.

[0052] FIG. 18 is a front view of an example flashing.

[0053] FIG. 19 is a side view of an example flashing.

[0054] FIG. 20 is a front view of the example flashing of FIG. 19.

DETAILED DESCRIPTION OF THE DRAWINGS

[0055] In the present disclosure, certain terms are used for brevity, clearness and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different apparatuses, systems and methods described herein may be used alone or in combination with other apparatuses, systems and methods. Various equivalents, alternatives and modifications are possible within the scope of the appended claims.

[0056] The present disclosure is described herein using several definitions, as set forth below and throughout the application. Unless otherwise specified or indicated by context, the terms "a", "an", and "the" mean "one or more." For example, "a compound" should be interpreted to mean "one or more compounds."

[0057] As used herein, "about," "approximately," "substantially," and "significantly" will be understood by persons of ordinary skill in the art and will vary to some extent on the context in which they are used. If there are uses of these terms which are not clear to persons of ordinary skill in the art given the context in which they are used, "about" and "approximately" will mean plus or minus <10% of the particular term and "substantially" and "significantly" will mean plus or minus >10% of the particular term.

[0058] As used herein, the terms "include" and "including" have the same meaning as the terms "comprise" and "comprising" in that these latter terms are "open" transitional terms that do not limit claims only to the recited elements succeeding these transitional terms. The term "consisting of," while encompassed by the term "comprising," should be interpreted as a "closed" transitional term that limits claims only to the recited elements succeeding this transitional term. The term "consisting essentially of," while encompassed by the term "comprising," should be interpreted as a "partially closed" transitional term which permits additional elements succeeding this transitional term, but only if those additional elements do not materially affect the basic and novel characteristics of the claim.

[0059] Wall panel systems can vary and can include siding panel systems (or siding panels) for cladding exterior walls of buildings, interior accent walls for cladding interior walls for aesthetic and non-aesthetic purposes, screen walls for concealing air handling equipment, and/or the like. In the instance of siding panel systems, various siding panel systems are commercially available and can include lap siding (i.e. long panels designed to overlap with each other), board and batten siding (i.e. a vertical pattern created using boards and battens of various widths), sheet or panel siding (i.e. sheets of material laminated onto foam), shaking siding (i.e. constructed from pieces of wood that are split), solid surface resilient composite shakes (i.e. extruded boards or planks that are deep wire brushed and then cut into various geometries and shapes for shake appearance), imitation log siding (i.e. a solid surface resilient composite siding plank that has been deep wire brushed processed can be either extruded or post heat formed into a semicircle or similar rounded shape with a nailing strip on top to emulate a natural log siding), and the like.

[0060] Through research and experimentation the present inventors have developed the concepts in the present disclosure, which include wall panel components, wall panel systems, and methods for assembling and refinishing wall panel systems. The present inventors have recognized that extruded composite wall panel systems offer significant benefits over existing wall panel systems. Furthermore, the inventors have discovered wall panel systems that can be easily repaired or refinished can increase the lifespan of the wall panel systems. Various components, systems, and methods for wall panel systems will become apparent from the following non-limiting descriptions and drawings herein.

[0061] Referring first to FIG. 1, the wall panel system 8 includes a plurality of extruded composite building panels 10 for mounting to a wall 4. The panels 10 are formed by an extrusion process similar to the process described in the U.S. Pat. No. 6,758,996, which is incorporated by reference above. The panels 10 comprise a composite material including a papermaking sludge and a polymer composition having a synthetic polymer resin, which is described in U.S. Pat. No. 6,758,996. The composite material further comprises an additive including a colorant such that the cross-section of the panel 10 has a homogeneous color. The panel 10 is configured to absorb impacts with out breaking or fracturing.

[0062] The additive further comprises a blowing or foaming agent for facilitating bonding or fusing of the cellulose and the synthetic polymer resin. The amount of blowing agent included is between 0.5-5.0 percent of the amount of the thermoplastic material. As described in U.S. Pat. No. 6,758,996, the papermaking sludge comprises chemically processed cellulose materials. The present inventors have discovered that the chemically processed cellulose materials has an acidic pH that assists in bonding the cellulose material composition to the synthetic polymer resin (e.g. polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS)) and that other thermoplastics that do not typically bond with non-chemically processed cellulose materials. The present inventors have also discovered that the composite material including the additive with the blowing agent further facilitates or assists (or otherwise increases) the bonding of the cellulose material composition to the synthetic polymer resin of the composite material. The blowing agent reduces the profile density of the extruded composite material by 20-25 percent while maintaining the characteristics of the composite material and ability to score or heavy wire brush the surface as discussed herein and in U.S. Pat. No. 6,758,996. The present inventors have also discovered that the composite material including the additive with the blowing agent absorbs less water and/or moisture than conventional composite materials that comprise wood particles.

[0063] The blowing agent can be any composition of chemicals which release a gas during thermal decomposition. The blowing agent utilized can be selected from chemicals containing decomposable groups such as azo, N-niroso, carboxylate, carbonate, hetero-cyclic nitrogen-containing and sulfonyl hydrazide groups, that generally, liberate gas when heated by means of a chemical reaction or upon decomposition. Examples of blowing agents include azodicarbonamide, bicarbonates, dinitrosopentamethylene tetramethylene tetramine, p,p'-oxy-bis (ben-zenesulfonyl)-hydrazide, benzene-1,3-disulfonyl hydrazide, aso-bis-(isobutyronitrile), biuret, urea, and any like composition.

[0064] Other natural blowing agents can be added to impart nitrogen or carbon dioxide foaming. The natural blowing agents can comprise various proteins such as chemically processed corn proteins from ethanol production and other proteinaceous materials that release carbon dioxide and/or nitrogen when placed under heat and or kinetic energy inputs. The release of carbon dioxide and/or nitrogen initiates from each protein particle at a slower rate, thus providing a microcellular nucleated foaming process.

[0065] Foaming agents can be used in place of the blowing agent as described above. Foaming agents can be selected from endothermic and exothermic varieties, such as dinitrosopentamethylene tetramine, p-toluene solfonyl semicarbazide, 5-phenyltetrazole, calcium oxalate, trihydrazino-s-triazine, 5-phenyl-3,6-dihydro-1,3,4-oxandiazin-2-one, 3,6-dihydro 5,6-diphenyl-1,3,4-oxadiazin-2-one, azodicarbonamide, sodium bicarbonate, and mixtures thereof.

[0066] The panels 10 are extruded such that the material composition of the panel 10 is homogeneous, and the panel 10 has a uniform cross-section (see FIG. 2) and is rectangular (see FIG. 3A). Referring now to FIGS. 4-7, each panel 10 includes an integral first portion 11 and an integral second portion 21. The first and second portions 11, 21 are extruded together such that the composition of the first and second portions 11, 21 are uniform and coupled to each other. The first portion 11 has a front surface 12 and an inner surface 15 opposite the front surface 12. The second portion 21 has a rear surface 22 and an inner surface 23 opposite the rear surface 22 (see also FIG. 8). The rear surface 22 is positioned closer to the wall 4 than the front surface 12 (see FIG. 1). The inner surface 15 of the first portion 11 is abuts the inner surface 23 of the second portion 21.

[0067] The first portion 11 includes a plurality of grooves or scores 16 configured to form a pattern, texture, or visual appearance on the first portion 11 and each score 16 extends inwardly from the front surface 12. Each score 16 has a first score depth 17 defined as a distance between the front surface 12 and the inner surface 15 of the first portion 11 (see also FIG. 8). The scores 16 may be applied to the first portion 11 by a wire brush that rotates over the front surface 12 of the first portion 11 after the panel 10 is extruded. The scores 16 are scored or etched into the first portion 11 through the front surface 12 of the first portion 11 such that material projections 18 are defined in and included with the first portion 11. The material projections 18 are disposed between adjacent scores 16. In other examples, the scores 16 are applied during the extrusion process. The number of scores 16 in the first portion 11 can vary. The orientation of the scores 16 can vary such as linear, crosshatched, random, and/or the like. In some examples, the scores 16 create a wood texture pattern that mimics the appearance of real wood. In other examples, the scores 16 create a dull visual appearance in contrast to a glossy visual appearance.

[0068] The scores 16 included with the first portion 11 are configured to be repaired and/or reconstructed. FIG. 4 depicts the scores 16 and the material projections 18 undamaged. However, the panel 10 can be damaged by impact (e.g. hail, rail, tree branches, baseballs), wear and tear and/or environmental impact (e.g. sunlight, moisture) that can change the visual appearance of the panel 10 and/or damage the scores 16 and/or material projections 18 included with the first portion 11. FIG. 5 depicts damaged material projections 18 where the material projections extend or bend into adjacent scores 16. Specifically, material projections 18 of the first portion 11 may be bent from a first undamaged position (the dashed lines on FIG. 5 represent the first undamaged position of the material projections 18) to a second damaged position (see the solid lines on FIG. 5 that represents an example of the material projections 18 moving into the adjacent scores 16 due to an external damaging force) such that the material projections 18 move into the scores 16 disposed adjacent to the material projections 18. The movement of the material projections 18 into the scores 16 changes the visual appearance of the panel 10. In one example, the panel 10 is repaired or refinished by bending the material projection back to the first undamaged position (see FIG. 4). The material projections 18 are bent by a tool such as a wire brush. In another example, the panel 10 is repaired or refinished by removing portions of the material projections 18 that moved into the adjacent scores 16 (the dashed lines of FIG. 6 represent the portion of the material projections 18 that are removed and the solid lines represent the remaining material projections 18; the dashed lines of FIG. 7 represent the first undamaged position of the material projections 18 and the solid lines of FIG. 7 represent the portions of the material projections 18 remaining). The portions of the material projections 18 can be removed by a tool, such as a razor or a wire brush.

[0069] In another alternative shown in FIG. 8, the panel 10 is repaired or refinished by removing the first portion 11 and adding scores to the second portion 21 as described above with reference to the scores 16 of the first portion 11. The first portion 11 is removably coupled to the second portion 21 such that the first portion can be removed, or otherwise modified, to expose the second portion 21. The first portion 11 can be removed or modified by a tool such as a wire brush, razor, or the like. Removal of the first portion 11 exposes the second portion 21. The second portion 21 receives scores 26 and defines material projections 28 similar to the scores 16 and material projections 18 described with reference to the first portion 11 such that the visual appearance of the panel 10 without the first portion 11 is identical to the visual appearance of the panel 10 with the first portion 11 (see FIG. 8). The scores 26 of the second portion 21 are identical to the scores 16 of the first portion 11 such that the pattern, texture, or visual appearance of the inner surface 23 of the second portion 21 mimics or is identical to the pattern, texture, or visual appearance of the front surface 12 of the first portion 11. The scores 26 included and received by the second portion 21 have a second score depth 27 defined between the inner surface 23 of the second portion 21 and a score depth plane 29 defined between the rear surface 22 and inner surface 23 of the second portion 21. The second score depth 27 is equivalent to the first score depth 17.

[0070] Non-limiting examples of wall panel systems 8 are depicted in FIGS. 1-2, 9-10, 11-12, and 13-14. The example wall panel systems 8 depicted can include any of the features or combination of features described herein. Each wall panel system 8 includes a plurality of panels 10, and the panels 10 may have the scoring characteristics described above.

[0071] Referring to FIGS. 3A-3B, the each panel 10 includes opposite side ends 30 that abut the opposite side ends 30 of parallel panels such that the opposite side ends 30 of the parallel panels 10 define a seam 32 between each panel 10. The panels 10 are arranged in a parallel abutting end-to-end orientation such that the panels 10 span a length of the wall 4. The panels 10 are stacked immediately above lower panels such that the panels 10 span a vertical height of the wall 4 (see FIG. 1). Each panel 10 includes an upper end 36 having a tongue 38 configured to mate with a groove 62 (to be described herein) of the panel 10 immediately above (see also FIG. 1) and a lower end 44 having a lip 46 configured to overlap the upper end 36 of the panel 10 immediately below. As demonstrated in FIGS. 1, 2, 3A and 3B, the lip 46 is configured to overlap holes 40 (described herein below) of the panel 10 immediately below. The lip 46 includes a sloped surface 47 defined by an angle A from a vertical direction V.

[0072] The panels 10 include a plurality of aligned holes 40 for securing the panels 10 to the wall 4 with a fastener 41, such as nail or screw. (see FIGS. 1 and 3A-3B). The holes 40 are aligned on the panel 10 and extend between the front and rear surfaces 12, 22 of the panel 10. The holes 40 are parallel to the upper end 36 and positioned closer to the upper end 36 than the lower end 44 (see FIG. 3A-3B). The shape of the holes 40 can vary. In one example, at least one hole 40 is oblong and at least one hole 40 is circular. The holes 40 are equidistant from each other and/or uniformly spaced on the panel 10. The number, spacing, and shape of the holes 40 depicted in FIGS. 3A-3B are merely exemplary and the holes 40 may vary from that which is shown.

[0073] Referring to FIG. 2, the panel 10 includes a first rib 51, a second rib 54, and a third rib 57 on the rear surface 22. The ribs 51, 54, 57 extend outwardly from the rear surface 22. In one non-limiting example, the ribs 51, 54, 57 span continuously along the rear surface 22 between the opposite side ends 30. Each rib 51, 54, 57 has a rib surface 52, 55, 58, respectively, for contacting the wall 4 (see FIG. 1) and a rib depth 53, 56, 59, respectively, defined as a distance between the rear surface 22 and the rib surface 52, 55, 58, respectively (i.e. the first rib 51 has a rib surface 52 and a rib depth 53, the second rib 54 has a rib surface 55 and a rib depth 56, and the third rib 57 has a rib surface 58 and a rib depth 59). The rib depth 59 of the third rib 57 is greater than the rib depth 56 of the second rib 54, and the rib depth 56 of the second rib 54 is greater than the rib depth 53 of the first rib 51 (see FIG. 2). The rib surfaces 52, 55, 58 are coplanar (see plane P depicted on FIG. 2), and rib surfaces 52, 55, 58, lie flush with the wall 4 when the panel 10 is mounted to the wall 4 (see FIG. 1). At least one rib includes a groove 62 configured to receive the tongue 38 of the upper end 36 (which is described above) of the panel 10 immediately below when the panels 10 are stacked (see FIG. 1). In certain examples, the third rib 57 includes the groove 62 (see FIGS. 2, 10, 12, 14). At least one rib includes a starter groove 64 (see FIG. 12) configured to receive a starter tongue 69 of a starter strip 68 (described herein below) (see FIG. 15).

[0074] Referring to FIG. 2, the panel 10 includes a recess 13 configured to receive the fastener 33 such that fastener 33 is flush with the front surface 12 of the panel 10. The recess 13 is aligned with the holes 40, and the recess 13 extends along a length of the panel 10. The front surface 12 of the panel 10 includes a sloped surface 14 defined by angle A. The sloped surface 14 of the front surface 12 is parallel to the sloped surface 47 of the lip 46 of the lower end 44 such that the sloped surface 47 of the lip 46 of the panel 10 immediately above lies or is flush with the sloped surface 14 of the front surface 12 of the panel 10 immediately below (see FIG. 1). The rear surface 22 includes a sloped surface 24 that is parallel to the sloped surface 14 of the front surface 12. In another example, the front and rear surfaces 12, 22 are vertical and parallel to each other (see FIG. 14).

[0075] Referring to FIG. 15, the wall panel system 6 includes the starter strip 68 for mounting to the wall 4 and configured to contact with the panel 10 immediately above (see FIG. 12). The starter strip 68 includes the starter tongue 69 that is configured to be received in the starter groove 64 of a second rib 54 (see FIG. 12). The starter strip 68 includes a fastener 70 for mounting the starter strip 68 to the wall 4 (see FIG. 11).

[0076] Referring to FIGS. 16-17, the wall panel system 8 includes a plurality of joint clips 80 for coupling the panels 10 in parallel end-to-end orientation (described above). The joint clip 80 allows the panels 10 to thermally expand and contract relative to each other. The joint chip 80 maintains a mechanical connection between the panels 10. The joint clip 80 includes a base 82, a first pin 84 for engaging with the hole 40 of the panel 10, and a second pin 86 for engaging with the hole 40 of the parallel abutting panel 10 such that the joint clip 80 overlaps the seam 32 between the panels 10 (see FIG. 3B). The first and second pins 84, 86 are on the base 82 and project outwardly away from the base 82. The first and second pins 84, 86 are dimensioned to be received in the holes 40 of the panels 10. The number of pins on the base 82 can vary. The first and second pins 84, 86 are received by the holes 40 such that the base 82 is adjacent to the rear surface 22. The first and second pins 84, 86 comprise a plurality of barbs 88 for engaging with the holes 40 such that the joint clip 80 securely attaches to the panels 10. The barbs 88 project radially from the pins 84, 86 and elastically deform as pins 84, 86 are inserted into the holes 40 of the panels 10. The barbs 88 resist removal of the joint clip 80 from the holes 40.

[0077] Referring to FIGS. 18-20, the wall panel system 8 includes a plurality of flashings 90 for covering the seams 32 between abutting parallel panels 10. The flashing 90 is sandwiched between the joint clip 80 and the rear surfaces 22 of abutting panels 10 such that the flashing 90 overlaps the seam 32. The flashing 90 prevents rain, ice, and/or other elements from reaching the wall 4 (see FIG. 1). The flashing 90 has a height that corresponds to the distance between the upper end 36 and the lower end 44 of the panel 10. The height and number of holes 40 of the flashing 90 can vary.

[0078] In one example (depicted by FIG. 18), each flashing 90 includes an upper end 92, a first flashing hole 96, and a second flashing hole 98 which is aligned with the first flashing hole 96. The first and second flashing holes 96, 98 are parallel and adjacent to the upper end 92 of the flashing 90. The flashing 90 is a flat metal plate. In operation, the first flashing hole 96 is aligned with the hole 40 of the panel 10 and the second flashing hole 98 is aligned with the hole 40 of the abutting panel 10 (see also FIG. 3B). The first flashing hole 96 receives the first pin 84 of the joint clip 80 and the second flashing hole 98 receives the second pin 86 of the joint clip 80 such that the joint clip 80 and flashing 90 overlap the seam 32 and the flashing 90 is adjacent to the rear surfaces 22 of the panels 10. In an alternative example, the first and second flashing holes 96, 98 are formed when the first and second pins 84, 86 of the joint clip 80 pierce the flashing 90. In another example (depicted by FIGS. 19-20), the flashing 90 is a bent metal plate having a plurality of channels 99 for engaging and/or locking to the panels 10. The flashing 90 includes a plurality of holes 100 which align with holes 40 of the panels 10 (see FIG. 3B).

[0079] Certain examples of wall panel systems include solid surface resilient composite siding panels further comprising a cellulose, mineral, thermoplastic composite, wherein the extruded composite siding is homogenous and also includes a color throughout the siding shape. Certain examples of wall panel systems include scores or deep wire brushed surfaces that impart functional performance and aesthetic surface properties providing both high durability and robustness while being repairable and having a very low gloss with a surface resembling cross cut lumber.

[0080] Certain examples of wall panel systems include high levels of granulated paper-making sludge mixed with plastic, and, if desired, cellulose fiber, to form composite materials that exhibit high strength, high modulus, high impact resistance, and good resistance to decay, non-flammable properties. Certain examples of wall panel systems include composite formulation useful as a feedstock in the manufacture of composite end products. The feedstock composite can contain granulated paper-making sludge and plastic. The feedstock may also contain cellulose fiber (e.g., agricultural by-products in a short-fiber form, such as rice hulls, cotton linters, ground cotton and other plant fibrous materials, fibers from textile manufacturing, pulping and paper converting operations, recycling of paper and wood products, etc.), and, if desired, additives such as reinforcing agents, lubricants, colorants, compatibilizers, and/or flame retardants. Certain examples of wall panel systems can utilize paper-making sludge that would otherwise be disposed of as industrial waste. Certain examples of wall panel systems utilize a paper mill waste product. Certain examples of wall panel systems include cellulosic particulate selected from the group consisting of wood fiber, wood flour and combinations thereof. It will be understood by a person skilled in the art that wood pulp can be any known wood pulp material, for example, thermo-mechanical wood pulp, chemical thermo-mechanical wood pulp and combinations thereof.

[0081] Certain examples of wall panel systems include material or particulates. Certain examples of wall panel systems included additives and/or colorants. Certain examples of wall panel systems include antioxidants, UV stabilizers, foaming agents, dyes, pigments, cross-linking agents, inhibitors, and/or accelerators. Certain examples of wall panel systems include means for compounding and removing moisture. Certain examples of wall panel systems include using a rotary wire brush on a spinning mandrel to create a random linear surface from a depth from 0.010'' to 0.2''. Certain examples of wall panel systems include using a high speed laser engraving. Certain examples of wall panel systems include scores or a deep wire brush effect to a depth of 0.010'' to over 0.125'' into the surface. Certain examples of wall panel systems include resilient and repairable composite panels, siding, and/or siding panels. Certain examples of wall panel systems include panels in the shape of a lap siding, board, plank, panel, board and batten, or other wall or siding shape with a flat area that represents the outside surface of the panel. Certain examples of wall panel systems include brushing the panel with a heavy wire rotary brush in line with the composite extrusion system or process to a depth between 0.005'' to over 0.2''

[0082] Certain examples of wall panel systems include resilient, robust, durable and repairable panels that reduce or overcome some or all of the difficulties inherent in prior known devices. Certain examples of wall panel systems can create a resilient and repairable composite lap panel that integrates holes and a joint clip as to allow the panels to expand or contract without creating large gaps at the seams between siding boards. Certain examples of wall panel systems include joint clips that holds panels and panel seams together during siding movement and a flashing beneath the panels and/or panel seams to prevent water or moisture to reach the plywood or OSB shell or walls of a building that is mounted to the wall panel system instead of the walls of the building. Certain examples of wall panel systems include panels that can expand and contract in a "floating" process such that the joint clip holds the abutting panels together at the seams so that no gaps between the panels are defined. In certain examples, the flashings align with the seams for water and air flow protection.

[0083] Through research and experimentation, examples of the composite material of the present disclosure that include the blowing agent or foaming agent have been observed to reduce the profile density of the composite material by 20-25 percent when compared to composite material without the blowing agent. The composite material with the blowing agent maintains the characteristics of the composite material without the blowing agent including the solid surface nature and ability to score or heavy wire brush the surface without increasing the water absorption of the composite material. In one example experiment, a sample of the composite material with the blowing agent and a sample of a commercially available wood plastic composite were compared for water resistance. Moisture resistance can increase resistance to expansion, mold, and degradation of the composite material. The thickness of the samples were 0.25 inches, and the sample set included a commercial wood plastic with a smooth surface, a commercial wood plastic with a wire brushed surface, the composite material with blowing agent and a smooth surface, and the composite material with blowing agent and a wired brushed surface. The wired brushed surface samples were scored or brushed to an approximate depth of 1/16 inches. The samples were placed in water for 24 hours and measured for both the weight gain and expansion of the samples. The weight gain results included: the commercial wood plastic with a smooth surface +2.2 percent weight gain; the commercial wood plastic with a wire brushed surface +2.7 percent weight gain; the composite material with blowing agent and a smooth surface +0.62 percent weight gain; and the composite material with blowing agent and a wired brushed surface +0.62 percent weight gain. The 24 hour immersion weight gain showed significant increase in water absorption within the commercial wood plastic due to the water reaching individual particles of wood within the composite. The composite material with blowing agent showed less than half of the water absorption than the wood plastic composite. In addition, the commercial wood plastic gained more moisture weight with a brushed surface, and the weight gain of the composite material with blowing agent did not change with a brushed surface.

[0084] The samples were also measured for expansion based on the 24 hour soak. The commercial wood plastic expanded more and had a bumpy texture due to the expansion of the wood particles, and the composite material with blowing agent remained smooth with little to no expansion.

[0085] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A wall panel system for mounting to a wall, the wall panel system comprising: a panel comprising: opposite side ends; an upper end; a lower end opposite the upper end; a front surface; a rear surface opposite the front surface; a first rib on the rear surface that extends outwardly from the rear surface, the first rib having a rib surface for contacting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the first rib; and a second rib on the rear surface that extend outwardly from the rear surface, the second rib having a rib surface for contracting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the second rib, wherein the rib depth of the second rib is greater than the rib depth of the first rib.

2. The wall panel system according to claim 1, wherein the rib surface of the first rib and the rib surface of the second rib are coplanar.

3. The wall panel system according to claim 2, wherein the panel is one of plurality of panels, wherein the panels are arranged in a stacked and parallel abutting end-to-end orientation; the lower end of the panel comprises a lip configured to overlap the upper end of one of the plurality of panels immediately below.

4. The wall panel system according to claim 3, wherein the panel comprises a plurality of holes aligned parallel with the upper end, and wherein the lip of the lower end is configured to over lap the plurality of holes of one of the plurality of panels immediately below.

5. The wall panel system according to claim 4, wherein the lip comprises a sloped surface configured to have flush contact with the front surface of one of the plurality of panels immediately below.

6. The wall panel system according to claim 5, wherein the front surface comprises a sloped surface that is parallel to the sloped surface of the lip.

7. The wall panel system according to claim 1, wherein panel comprises a papermaking sludge and a polymer composition having a synthetic polymer resin.

8. The wall panel system according to claim 7, wherein the panel comprises a blowing agent.

9. The wall panel system according to claim 1, wherein the panel is one of plurality of panels, and wherein the panels are arranged in a stacked and parallel abutting end-to-end orientation; wherein the panel further comprises a third rib on the rear surface that extend outwardly from the rear surface, the third rib having a rib surface for contracting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the third rib, wherein the rib depth of the third rib is greater than the rib depth of the second rib, the rib surface of the third rib and the rib surface of the second rib are coplanar.

10. The wall panel system according to claim 9, wherein the third rib further comprises a groove configured to receive the upper end one of the plurality of panels immediately below.

11. The wall panel system according to claim 1, wherein the panel further comprises: a first portion having a front surface and an inner surface, the first portion having a plurality of scores each including a first score depth defined as a distance between the front surface and the inner surface; a second portion having a rear surface and an inner surface that abuts the inner surface of the first portion, wherein the second portion is removably coupled to the first portion such that scores can be included in the second portion to mimic the scores included in the first portion.

12. The wall panel system according to claim 11, wherein the first portion and the second portion extrude as a unitary panel; and wherein the first portion and the second portion comprise a papermaking sludge and a polymer composition having a synthetic polymer resin.

13. The wall panel system according to claim 12, wherein the first and second portions comprise an additive including a colorant.

14. The wall panel system according to claim 13, wherein the second portion has a maximum score depth plane defined between the rear surface of the second portion and the inner surface of the second portion; and wherein the second portion is configured to receive a plurality of scores each having a second score depth defined as the distance between the inner surface of the second portion and the maximum score depth plane.

15. The wall panel system according to claim 14, wherein the second score depth is equivalent to the first score depth.

16. A wall panel system for mounting to a wall, the wall panel system comprising: a first panel and a second panel each having an opposite side ends, an upper end, a lower end opposite the upper end, and opposite front and rear surfaces, wherein one opposite end of the first panel abuts one opposite end of the second panel to define a seam; each of the panels includes a plurality of aligned holes that are parallel to the upper surface and positioned closer to the upper surface than the lower surface; and a joint clip for coupling the panels such that the panels remain coupled to each other as the panels thermally deform, the joint clip has a first pin that is received in one of the plurality of holes of the first panel and a second pin that is received in one of the plurality of holes of the second panel.

17. The wall panel system according to claim 16, wherein each joint clip comprises a base configured to couple with the first and second pins, wherein the base overlaps the seam.

18. The wall panel system according to claim 17, wherein the first and second pins each comprise a barb configured to elastically deform and secure the joint clip to the pair of panels.

19. The wall panel system according to claim 16, further comprising: a flashing for covering the seam, each flashing having an upper end, a lower end, a first flashing hole and a second flashing hole aligned with the first flashing hole, the first and second flashing hole are parallel to the upper end of the flashing and positioned closer to the upper end of the flashing than the lower end of the flashing; wherein the first flashing hole aligns with one of the plurality of holes of the first panel and the second flashing hole aligns with one of the plurality of holes of the second panel.

20. The wall system according to claim 18, wherein the first and second flashing holes receive the first and second pins of the joint clip.

21. The wall system according to claim 16, wherein the pair of panels comprise a composite material comprising a papermaking sludge and a polymer composition comprising a synthetic polymer resin.

22. The wall panel system according to claim 21 wherein the composite material further comprises a blowing agent.