Note: Descriptions are shown in the official language in which they were submitted.
CA 02571910 2009-07-14
EXTERIOR WALL PANEL WITH
ENHANCED INTERIOR FACING SURFACE
BACKGROUND
[0002] The present invention relates to a sidewall panel such as a siding
element for an
exterior wall of a building. The invention also relates to a backing member
for use with siding.
In particular, the invention provides a backing member and/or wall panel with
an enhanced
drainage plane located on the rear face of a backing member. The drainage
plane can be
composed of various geometric configurations sufficient to allow water to more
efficiently
dissipate from the surfaces within the exterior wall of a building.
[0003] The construction industry, both new construction and remodeling, is
increasingly
confronted with problems associated with the buildup of moisture on surfaces
within exterior
walls. The moisture buildup can cause degradation of the exterior wall
material and may result
in growth of various types of molds. Such molds are frequently blamed for
causing serious
respiratory illnesses and other health conditions in humans and animals. Thus,
it is desirable to
provide material that minimizes the opportunity for mold growth. Building
codes have long
required that exterior walls be permeable so that moisture can escape in the
event that moisture is
introduced or established in the wall. In spite of serious efforts to prevent
moisture buildup on
exterior walls, occasionally water can find its way into these regions. Water
introduction may be
due to poor installation, inadequate flashing, leaking pipes, or
irregularities in building practice.
In some cases, water can be found or introduced into the exterior wall system
in such large
quantities that it overwhelms the system. In other words, the exterior wall
material and system
simply cannot dissipate the moisture fast enough to prevent or minimize the
conditions that can
promote mold growth and dry rot of the wooden framing. Thus, it is desirable
to provide a
system whereby moisture can be readily dissipated or removed from the exterior
wall system.
[0004] Exterior wall systems also must provide appropriate insulation
characteristics to
minimize undesired heat loss or heat dissipation. Such systems can include
various backing or
liner members adapted to be interposed between waterproof or essentially
waterproof siding
material and the exterior wall. It is desirable to provide a backing member
and/or an integrated
panel system having enhanced drainage characteristics.
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2
SUMMARY
[0005] Disclosed herein is an insulated siding panel for mounting on a wall
that
includes a backing member and a siding layer affixed to a backing member. The
backing
member includes a rear face and an opposed front face. The backing member is
composed of closed cells of expanded polymeric foam or cellular plastic with
the rear
face of the backing member having a planar surface and at least one geometric
region
defined thereon that deviates from the planar surface. The backing member may
be
shape-molded.
[0006] Also disclosed herein is a shape-molded insulation backing element for
use with an insulated siding product. The insulation backing element comprises
a central
core composed of a closed cell expanded polymeric foam. The outer surface of
the
insulation backing element will have at least one outer surface region that
exhibits a
tough, smooth skin composed of closed-cell polymeric foam. The insulation
backing
element has a front face region and a rear face region in contiguous contact
with the
central core and composed of closed cell expanded polymeric foam. The rear
face region
is adapted to overly at least one wall and includes at least one geometric
element defined
herein. The insulation backing element may be shape-molded.
[0006a] Accordingly, in one aspect there is provided an insulated siding panel
for
mounting on a wall, the panel comprising:
a backing member having a rear face and an opposed front face, the
backing member composed of a closed cell polymeric material, the rear face of
the
backing member including a planar surface and at least one region that
deviates
geometrically from the planar surface; and
a siding layer affixed to the front face of the backing member,
wherein the closed cell polymeric material of the backing member is
composed of a plurality of cells and wherein cells in a central core region
have a certain
size or density and cells in a denser skin-like region surround the central
core region and
define the front face and both the planar surface and the at least one region
that deviates
geometrically from the planar surface of the rear face.
[0006b] According to another aspect there is provided an insulation backing
for
use with a siding product, the insulation backing comprising:
CA 02571910 2009-07-14
2a
a central core composed of a closed cell expanded polymeric foam;
a front face region adapted to contact the siding product, the front face
region in contiguous contact with the central core and composed of closed cell
expanded
polymeric foam; and
a rear face region in contiguous contact with the expanded foam central
core and composed of closed cell expanded polymeric foam, wherein the rear
face region
includes at least one geometric element defined therein, and wherein the
closed cell
polymeric foam has two or more different densities at different locations in
the insulation
backing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The description herein makes reference to the accompanying drawings
wherein like reference numerals refer to like parts through the several views,
and
wherein,
[0008] Fig. 1 is a front perspective view of a composite siding panel
including an
enhanced drainage plane as disclosed herein;
[0009] Fig. 2 is a rear exploded perspective view of an insulation backing for
use
with a siding product including an enhanced drainage plane as disclosed
herein;
[0010] Figs. 3A through 3D are rear plan views of the rear face or face region
of
Figs. 1 or 2 having various grooves and/or channels defining various patterns.
[0011] Figs. 4A through 4D are rear plan views of insulation backing or the
backing member of a panel of Figs. 1 or 2 having at least one protruding
geometric
element in combination with at least one groove or channel; AND
[0012] Figs. 5A through 5D are rear plan views of the insulation backing or
backing member of a panel in Figs. I and 2 showing various nonlimiting
examples of
protruding geometric elements defined therein.
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3
DESCRIPTION
[0013] Disclosed herein is an insulated siding panel having an enhanced
drainage plane
positioned on its rear face. The construction market utilizes a large number
of insulated siding
panel devices. One nonlimiting example of insulated siding panel devices
includes the device
depicted in Fig. 1. As broadly disclosed herein, the insulated siding panel 10
depicted in Fig. 1
includes a backing member 14 that can be attached or mounted to a siding layer
12. The siding
layer 12 can be a contoured siding product and/or the backing member can be
contoured, either
complimentarily to the siding layer or contoured to provide or form geometric
elements to the
applied siding layer.
[0014] The backing member 14 may be composed of a shape-molded polymeric
material
in whole or in part as desired or required. The term "shape-molded" as used
herein is taken to
mean that the contours and/or outer surfaces of one or more faces of the
backing member 14 are
fabricated by a molding operation or operations. Such molding operations will
generally impart
contours and geometric regions to the backing member 14. These contours and
geometric
regions typically possess a tough smooth outer skin. Nonlimiting examples of
shape-molding
processes that can impart such surface characteristics include molding
processes employed with
encapsulated cellular foam materials.
[0015] It is contemplated that one or more faces can be composed in whole or
in part of
shape-molded surfaces as desired or required. Where less than all faces are
characterized by
shape-molded surfaces, it is contemplated that at minimum the rear face will
exhibit at least a
partially shape-molded surface. Where the backing member 14 has surfaces that
are not shape-
molded, the nonshape-molded surfaces and any contours thereon can be produced
by any suitable
method. Nonlimiting examples of such methods include wire-cutting.
[0016] Thus it is contemplated that the shape-molding can provide or produce a
finished
product. However, it is also contemplated that the shape-molding process can
be employed in
combination with other cutting or formation process to provide additional
features.
[0016] It is contemplated that the rear face of the backing member 14 will be
shape-
molded in whole or in part. It is contemplated that, in various embodiments,
the backing member
14 can have portions of at least front and rear faces that are shape-molded.
In other embodiments
it is contemplated that, in addition to shape-molding on the front and rear
surfaces, various other
surfaces such as side edges and top and bottom ends can be shape-molded, as
desired or required.
[0017] The siding layer 12 can be affixed to the backing member 14 in a wide
variety of
fashions. Such attachment fashions include, but need not be limited to,
adhesive bonding, heat
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bonding, chemical bonding, interlocking of complimentary surfaces, mechanical
fasteners, and/or
the insertion or "dropping in" of the backing member 14 on site.
[0018] Also disclosed herein is a shape-molded insulation backing 114 for use
with a
suitable siding product 112. The shape-molded insulation backing 114 can have
characteristics
as previously described with backing member 14. It is contemplated that at
least a portion of at
least one face of the shape-molded insulation backing member 114 will possess
a tough, smooth
skin.
[0019] It is contemplated that various cellular plastics can be employed as
the material
for the backing member 14 or insulation backing 114 disclosed herein. As used
herein, the
term(s) "cellular foam" or "cellular foam plastic" are taken to mean a plastic
or polymeric
material with numerous cells of trapped air distributed throughout its mass.
Nonlimiting
examples of such materials can also be referred to as expanded plastics or
foamed plastics with
expanded polystyrene being but one nonlimiting example.
[0020] "Polystyrene foam" as used herein refers to cellular foam plastic made
from
polystyrene typically by incorporation of a volatile blowing agent into
polystyrene beads as they
are polymerized or afterward. In expanded polystyrene, beads of polystyrene
are first pre-
expanded and allowed to rest for a suitable interval, then molded in a closed
steam-heated mold
to produce closed-cell foams. The size and density of the closed cells can
vary from application
to application depending on the characteristics required. Thus it is
contemplated that cell density
can be varied by suitable processing parameters to produce foam size suitable
for the desired end
use application. Variation in characteristics attributable to density can
include, but need not be
limited to, insulation capacity, dent or break resistance, and the like.
[0021] As depicted in Figs. 2, 3, and 4, backing member 14 or the insulation
backing 114,
respectively, have a rear face 30, 130, and an opposed front face 32, 132. The
rear face of the
shape-molded backing member 14 or shape-molded insulation backing 114 defines
a planar
surface having at least one geometric element or region that deviates from the
planar surface
either positively or negatively. The geometric element can be of any suitable
shape, size, and/or
configuration and can either extend outward from the surface of the rear face
region 30, 130, or
be depressed into the rear face region 30, 130. As depicted in Figs. 2, 3, and
4, the geometric
element can be at least one groove or channe134, 134, or an outward projection
such as ridge 36,
136. The geometric element such as groove or channe134, 134, and/or ridge 36,
136, can have
any suitable shape or configuration. The disclosure herein contemplates shape-
molded backing
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Reference No. CBC-167-B Patent
members 14 or shape-molded insulation backing elements 114 that have either
depressed
geometric elements, projecting geometric elements, or a combination of both.
[0022] The geometric element can have any suitable contour desired or required
and can
be configured into any suitable pattern or orientation as desired or required.
As illustrated in
Figs. 2 and 3D, the grooves 34, 134 make up a grid network. Grooves 34, 134
can be positioned
in interlocking relationship in a manner that facilitates drainage of any
accumulated or condensed
liquid through the grooves away from the closed-cell backing member 14 or
closed-cell
insulation backing element 114. As shown in Figs. 2 and 3D, the grooves 34,
134 can be
positioned in a diamond pattern. Other configurations are contemplated. The
water can be
conveyed by gravity through the grid made up of drainage grooves 34, 134 to a
suitable exit or
egress point. Egress can be from any suitable location. As depicted in the
drawing figure, a
series of drainage exit grooves 40, 140 can be positioned at the lowermost
region of the backing
member as in the layered lower region 42, 142. The drainage grooves 34, 134
can communicate
with drainage exit grooves 40, 140 in order to convey collected water or
condensate away from
the rear face 30, 130 of the backing member.
[0023] It is to be understood that the cellular plastic employed herein is
capable of
transmission of discrete volumes of water vapor through the closed-cell
plastic material to
external surfaces and faces of the closed-cell backing member 14 or closed-
cell insulation
backing element 114 for transmission or dispersion to the external
enviromnent. In certain
situations, liquid condensate can form between the wall and associated siding
element such as
siding element 10. It is understood that condensed liquid as opposed to water
vapor does not
easily transpire through the closed-cell cellular plastic. Liquid condensate
is conveyed through
channels, grooves, and suitable surfaces defined in the face to a suitable
exit point where it can
drain or evaporate.
[0024] As depicted in Fig. 3A, the drainage grooves 34 can be arranged in a
diamond
pattern at roughly a 30 angle from a vertical orientation. It is to be
understood that this
configuration is illustrative of various configurations and patterns that can
be established. Thus,
grooves 34, 134 can be positioned at a wide variety of angles to one another
and in a wide variety
of patterns.
[0025] With reference to Figs. 3B-3D, there is illustrated a plurality of
examples of
groove arrangements. These arrangements can include diagonal patterns such as
those illustrated
in Fig. 3B, vertical patterns as illustrated in Fig. 3C, and/or square
patterns with drainage grooves
positioned at an angle of 45 from vertical orientation as illustrated in Fig.
3D.
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[0026] The number of grooves 34, 134 employed can be any number necessary to
provide
an appropriate drainage plane for the shape-molded backing member 14, 114, or
shape-molded
backing element 114. Additionally, the depth of the grooves is that sufficient
to provide
appropriate drainage. By way of nonlimiting example, it is contemplated that
grooves having a
maximum depth between 1/16 inch and %2 inch can be placed in spaced
relationship to one
another. By way of nonlimiting example, the interval between grooves can be
0.1 to 5 inches.
[0027] Turning now to Figs. 4A through 4D, there is depicted a variety of
configurations
for the rear surface of the shape-molded backing member 14, or shape-molded
backing element
114, including a combination of grooves 34, and protrusions 36. It is
contemplated that the
protrusions can have any suitable shape or configuration. It is also
contemplated that the
protrusions 36 can be positioned as desired or required. As a nonlimiting
example, protrusions
36 are positioned in the diamond grid as shown in Fig. 4A. In Fig. 4B, the
protrusions are a
series of elongated ridges positioned proximate to the diagonal grooves in
Fig. 4B, or centrally
between the grooves 34 in Fig. 4C. It is also contemplated that protrusions 36
can be located
proximate to suitable corner members as in Fig. 4D. Other suitable
configurations and
combinations of grooves 34, 134 and protrusions 36, 136 are also contemplated.
[0028] It is also contemplated that the shape-molded backing member 14, or
shape-
molded insulation backing element 114 can be configured solely with
protrusions 36, 136.
Nonlimiting examples of such configurations are set forth in Figs. 5A through
5D. As depicted
in Fig. 5A, the rear face 30 can include outwardly protruding members 36
positioned in external
corners of the member. In Fig. 5A additional protrusions 36, are located in
the central region of
the rear face. In Fig. 5B, the outward protrusions are similarly positioned.
However, the
outward protrusions 36 are shaped as diamond members. It is contemplated that
the shape,
location, and size of the protrusion can be any configuration suitable for
maintaining the planar
portion of rear face 30 away from the associated wall. The distance or
standoff maintained will
be that sufficient to facilitate drainage. Other nonlimiting examples of such
protrusions include
ridges such as vertical ridges shown in Fig. 5C and random spherical elements
shown in Fig. 5D.
It is also contemplated that indentations and/or protrusions can be utilized
and positioned in a
manner to depict brand names, instructions, orientation aids, or the like.
[0029] The geometric regions 34, 36, 134, 136 are composed of closed cell
expanded
polymeric foam. It is contemplated that the outer surface of the respective
geometric regions is
characterized by a surface defined by closed polymeric cells. It is
contemplated that the surface
of the geometric region will be characterized by intact, unruptured cells
thereby defining a
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smooth surface that facilitates transfer of water therethrough. The outer
surface of the geometric
regions 34, 134, 36, 136 is characterized by a tough smooth skin. The skin is
one that provides
suitable compressive and/or flexural strength to the geometric region. This is
typically a skin
structure imparted by the shape-molding process. The tough smooth skin of the
outer surface of
geometric regions 34, 134, 36, 136 can be contiguous to the surface region of
the surrounding
planar regions of rear face 30, 130.
[0030] Heretofore, geometric regions present in backing members were defined
by
surfaces produced by cut or ruptured cells. Such surfaces possessed numerous
concavities in
which water could collect and be held. Without being bound to any theory, it
is believed that the
closed cell smooth surface reduces the surface tension between water and the
geometric surface
to facilitate water transfer.
[0031] As defined herein, it is contemplated that at least the geometric
regions have a
smooth closed cell surface. It is also contemplated that, in some embodiments,
planar regions
surrounding the geometric regions may have a smooth surface defined by closed
expanded
polymeric cells. Where desired or required, it is contemplated that the entire
planar surface can
be a smooth, closed-cell surface characterized by the tough, smooth skin.
[0032] The backing member 14 and insulation backing 114 can also include an
opposed
front face 32, 132. The opposed front face cellular polymeric material surface
is characterized by
closed polymeric cells. The material surface can be defined by a tough smooth
skin typically
formed in the shape-molding process. It is also contemplated that surfaces of
the side edges
and/or upper and lower end forms can be formed of closed cell polymeric
material and can have
the tough smooth skin described previously.
[0033] It is contemplated that the closed polymeric cells in the shape-molded
backing
member 14 or shape-molded insulation backing element 114 may have an
essentially uniform
volumetric size throughout the respective members. However, it is within the
purview of this
disclosure to have variation of the cell volume and configuration between the
various regions of
the member 14, 114. Thus, it is contemplated that the shape-molded backing
member 14, or
shape-molded insulation backing element 114 can include a central core having
cells of a certain
size and density. Where desired or required, the cells in the region proximate
to the rear face 30
and/or front face 32 can be compressed and/or elongated to form a denser skin-
like region along
the respective surface or surfaces.
[0034] The front face 32, 132 can be configured in any suitable shape or
contour. Where
the shape-molded backing member 14, or shape-molded insulation backing element
114 is to be
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8
integrated into an exterior siding panel, it is contemplated that the front
face may include at least
one suitable outwardly projecting extension extending vertically along the
first side of the
backing member or insulation backing to roughly approximate the configuration
of siding
overlap.
[0035] Where desired or required, it is contemplated that the shape-molded
backing
member 14 or shape-molded insulation backing 114 can be composed of closed
cell polymeric
material having two or more different densities at different locations in the
shape-molded
backing member 14, or shape-molded insulation backing element 114. It is
contemplated that
higher density material will be located in regions where greater localized
panel strength is
required. Nonlimiting examples of such regions are areas prone. to abuse and
damage such as
overhangs, protrusions, and the like. As used herein, strength can be measured
and quantified as
characteristics including, but not limited to, compressive strength, flexural
modulus, and the like.
By way of nonlimiting example, it is contemplated that the panel can have a
general density of 1
lb per square foot while selected regions have elevated densities of 2 lb per
square foot or greater.
[0036] Where desired or required, the backing member 14, or insulation backing
114 can
include a suitable detent 40 extending vertically inward along a lower side to
position and receive
a suitable mating siding panel.
[0037] It is contemplated that the shape-molded backing member 14 can be
affixed to a
suitable siding layer 12 in a wide variety of fashions. Such attachment can
include, but is not
limited to, adhesives, chemical bonding, heat bonding, interlocking of
complimentary surfaces,
fastening, and the like. It is also contemplated that the backing member 14 or
insulation backing
14 can be "dropped in" to the siding element at the job site.
[0038] The siding layer 12 may be composed of any suitable polymeric,
metallic,
cementious or composite material. It is contemplated that the siding material
will be one capable
of providing suitable environmental resistance and durability. The siding
material will have
sufficient thickness to maintain its shape and contour throughout the useful
life of the associated
siding panel when integrated with a suitable backing member. Appropriate
materials include, but
are not limited to, polymeric vinyls and the like. Other nonlimiting examples
of suitable
materials include various cementious components. It is contemplated that the
siding layer 12 will
be suitably contoured to conform to the contours of the shape-molded backing
member 14. The
correspondence in respective contours can be exact. However, it is
contemplated that the
contours can vary depending upon the nature of the end product.
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[0039] It is contemplated that the shape-molded backing member 14, or
insulation
backing 114 can have a length of between 36 inches and 240 inches and will
typically have
lengths of 144 to 240 inches, as desired or required. The resulting element
and/or associated
insulated siding panel 10 will be essentially straight and free from camber
and bowing.
[0040] The backing member 14, or shape-molded insulation backing element 114
can
have a suitable width. Nonlimiting examples of suitable widths would be
between 7 and 48
inches, with typical widths between 8 and 36 inches in various applications.
[0041] The shape-molded backing member 14, or shape-molded insulation backing
element 114 can have a suitable thickness such that the resulting unit 10 has
a thickness between
250 thousandths of an inch and 4 inches.
[0042] The panels 10 can be used in suitable combination to be affixed to and
cover the
desired wall or portions thereof. When installed, it is contemplated that the
various panels 10
will contact or abut one another such that the various channels or grooves
connect or
communicate with one another or with suitable drainage vents positioned in the
siding layer 12.
[0043] While the invention has been described in connection with what is
presently
considered to be the most practical and preferred embodiment, it is to be
understood that the
invention is not to be limited to the disclosed embodiments but, on the
contrary, is intended to
cover various modifications and equivalent arrangements included within the
spirit and scope of
the appended claims, which scope is to be accorded the broadest interpretation
so as to
encompass all such modifications and equivalent structures as is penmitted
under the law.
