Note: Descriptions are shown in the official language in which they were submitted.
CA 02588294 2007-05-10
INSULATIVE SIDING APPARATUS AND METHOD OF MAKING THE SAME
FIELD OF THE INVENTION
[00011 The present invention generally relates to coverings for structures
such as
homes, commercial or industrial buildings. One embodiment of the present
invention
particularly relates to foam insulative panels for such structures.
BACKGROUND
[00021 Stucco has been used for many years as a veneer covering for both
commercial and residential walls. There are three typical representative
methods of
stucco construction:
[00031 (1) The house is first covered with plywood, wafer board (OSB) or
insulation
board, then lathe is attached to the walls and sprayed with a cement coating
to form a
stucco wall. The surface would then be painted.
[00041 (2) The utilization of an Exterior Insulated Finishing System
("EIFS"). In one
example implementation of EIFS, the relevant portions of the exterior of the
house is
covered with one-pound extruded polystyrene foam ("EPS"), one-inch thick.
Lathe or
fiberglass mesh is then attached to the EPS. A coating, called "brown coat,"
is then
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troweled or sprayed onto the EPS as an under coat. After the brown coat dries,
a finish
coat of synthetic stucco is applied, usually with the coloring in it.
[0005] (3) Most recently, due to water intrusion problems which can result
in mold
issues, a combination of the two (stucco and EIFS) has been tried to reduce
costs.
Installation of this hybrid system usually begins with the exterior side of
the sheathing
covering the house being covered with a water resistant barrier of house wrap
or
weather resistant felt paper. The barrier covered house is then covered with a
wall
sheathing or surface (in example, plywood, OSB and EPS foam). Chicken wire or
mesh
(called lathe) then is installed over the substrate. A concrete layer is then
either sprayed
or troweled directly on the substrate/lathe. After drying, the concrete layer
is painted
with an acrylic top coat. This is commonly referred to as a "two-coat" or
"three-coat"
stucco system. The "three-coat stucco system" requires a "brown" coat, a
second
concrete coat, and then the finish coat (usually an elastomeric acrylic stucco
or paint
coating).
[0006] The problems with these prior systems include: (1) if the concrete
coating
ever fractures, which it inevitably does, water can run in behind the stucco
and/or foam
and cause problems (in example, mold, mildew, or wood rot) since the moisture
cannot
escape; (2) as the seasonal temperature changes, a large wall without
expansion joints is
continually stressed and develops waves, bulges, and eventually cracks; and
(3) the
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onsite labor time window required is not especially friendly to stucco
construction, for
instance, bad weather can bring stucco work to a halt, low temperatures may
result in
the concrete not curing correctly (which itself results in later cracks and
peeling), and
freezing temperatures often negatively affect the curing of cement products.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Fig. 1 is a partial, side view of a first embodiment of a panel.
[0009] Fig. 2 is a side view of an embodiment of a starter section.
[00091 Fig. 3 is a side view of an embodiment of an adapter.
[0010] Fig. 4. is a side view of an embodiment of a block out.
[00111 Fig. 5 is a side view of an embodiment of a rail section.
[0012] Fig. 6 is a partial, side view of one embodiment of two panels (of
the
embodiment of Fig. 1) about to be connected together, also showing the
sheathing.
[0013] Fig. 7 is a partial, side view of one embodiment of two panels (of
the
embodiment of Fig. 1) connected together, also showing the sheathing.
[0014] Fig. 8 is a partial, side view of a panel (of the embodiment of Fig.
1) about to
be connected with a starter section (of the embodiment of Fig. 2), also
showing the
building structure.
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[0015] Fig. 9 is a partial, side view of a panel (of the embodiment of Fig.
1) connected
to a block out (of the embodiment of Fig. 4) connected with a starter section
(of the
embodiment of Fig. 2), also showing the building structure.
[0016] Fig. 10 is a partial, side view of a panel (of the embodiment of
Fig. 1)
connected to a rail section (of the embodiment of Fig. 5) connected to a
second
embodiment of panel, also showing sheathing.
[0017] Fig. 11. is a partial, side view of a panel (of the embodiment of
Fig. 1)
connected to an adapter (of Fig. 3) connected to a third embodiment of panel,
also
showing sheathing.
[0018] Fig. 12 is a plan view of an embodiment of insulated siding
installed on a stud
wall, showing a corner connection.
[0019] Fig. 13 is a partial, side view showing an embodiment of insulated
siding
installed on a stud wall.
[0020] Fig. 14A is a first side view of the panel of Fig. 1.
[0021] Fig. 14B is a first end view of the panel of Fig. 1.
[0022] Fig. 14C is a perspective view of the second side of the panel of
Fig. 1.
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[0023] Fig. 15 is a partial, side view of a fourth embodiment of a panel
(two panels
shown) shown about to be connected together.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[00241 The present invention is a system for covering the inside or outside
surface of
a structure, and the method of making said covering and its components.
[0025] While the present invention is susceptible of various modifications
and
alternative constructions, certain illustrated embodiments thereof have been
shown in
the drawings and will be described below in detail. It should be understood,
however,
that there is no intention to limit the invention to the specific form
disclosed, but, on the
contrary, the invention is to cover all obvious modifications, alternative
constructions,
and equivalents of what is disclosed here.
[00261 In the following description, the use of "or" indicates a non-
exclusive,
alternative without limitation unless otherwise noted. The use of "for
example," "in
example," "i.e.," "e.g.," "such as," and the like indicates the disclosure of
certain listed
examples with the express intention that there are other objects of the same
category
that are not listed. The use of "including" means "including, but not limited
to," unless
otherwise noted.
[00271 The figures show a number of embodiments of the present invention.
One or
more of these embodiments could be used in a wall panel system. One
representative
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wall panel system would comprise the application of decorative siding panels
(and
associated structure) made from high-density expanded polystyrene (EPS) foam
to the
outside wall surface of a structure. These siding panels configured for
overlapping,
having an interlocking tongue and groove structure, for purposes of sealing
out
moisture.
[0028] Referring to Figure 1, shown is one embodiment of a decorative
siding panel
10. It is preferred that the panel (as well as the other components of these
embodiments, including but not limited to the starter sections, block outs,
rail sections,
corner covers, etc.) be made from high density foam board, for instance
expanded
polystyrene (EPS), polyurethane, etc. It is preferred that the foam used have
a density
of 3-lb or greater, for instance 3.3-lb dense. Softer foams (such as, 1-1b, 2-
1b, etc.) can
likewise be used, preferably provided that they are coated with a hard coating
such as
epoxies, urethanes, elastomers, polyurea, minerals, cement, fiber cement,
fiberglass, etc.
Such foam board could also be mold-resistant and/or insect-resistant.
[0029] Because they are comprised of foam board, the panels can be cut into
various
decorative patterns, including but not limited to flat, grooved, lapboard, log
shapes for
log cabin look, etc. The panels could even be embossed by stamping, or various
designs, such as brick patterns, rock or stone patterns, etc., could be
applied or melted
therein. The panels can also be colored and/or covered with various finishing
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treatments, as desired, to further add to their appearance. This variety of
panel shapes
and configurations (including how they are configured for attachment to one
another)
allows a designer and/or an installer great freedom in creating decorative
patterns in
the structure's covering.
[0030] In this description, the term "panels" refers to a sheet, regardless
of length,
width, thickness or shape, that forms a distinct (usually flat) section or
component of a
structure.
[0031] In the preferred embodiment, the main panels are 4' by 8' in size.
One
example of such a 4' x 8' panel can be seen in Fig 14A. Other panel sizes are
likewise
envisioned, for example, 2" by 8" to 96" x 192" and everything in between.
[0032] The panels are configured to be interlocking and for being generally
water/air
tight. Being interlocking prevents water from traveling through the tongue and
groove
of the panels and/or from running horizontally (like lapboard siding typically
does),
thereby preventing water damage and/or mold.
[0033] Referring to Figs. 1 and 14A, the panel 10 having a top side 12, a
bottom side
14, a first side 16 and a second side 18. The panel 10 also having a face side
(the first
planar side) 20 and a back side (the second planar side) 22.
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[0034] It is preferred that one or more of the top/bottom/first/second
sides is
configured to interlock with one or more adjacent panels/structures. The
preferred
manner of interlocking is through use of "tongue and groove" style
interlocking. By
such interlocking (overlapping/abutting), water and vapor flow is blocked and
the
resulting damage is prevented.
[00351 In such a tongue and groove arrangement, at least one of the sides
has a
tongue or other flange extending there-from. This tongue is for receipt into a
groove on
a second panel or building structural element. Note: while the phrase "tongue
and
groove" is used herein, such exact functionality is not required, for instance
opposing
flanges are intended within the definition of "tongue and groove."
[0036] Referring particularly to Fig. 1, the top side 12 has a tongue 24
defined therein
and the bottom side 14 has a groove 26 defined therein. The tongue 24 defined
by a
weather overlap rabbet 23 and a locking rabbet 25. The groove 26 defined by an
outside
flange (weather overlap) 32 and an inside flange (locking flange) 34. In this
embodiment, the taper e serves as an anti-siphon feature, preventing water at
the seam
from moving through the joint when there is relatively negative pressure in
the
building structure. This is a preferred feature that is present in this
embodiment, but
may not be present in other embodiments.
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[0037] As is shown in Figs. 6-7 The flange 24 of a first panel 10 is
configured for
interlocking receipt into the groove 126 of a second pane1110 to form a tongue
and
groove joint 36. Fig. 6 showing the two panels (10, 110) unlocked, whereas
Fig. 7 shows
the two panels interlocked.
[0038] In the embodiment shown in Figs. 6-7, the panels (10, 110) generally
have a
one and one-half inch overlap (shiplap). Providing such a degree of overlap
may make
a building wrap (such as DuPont Tyvek ) optional, depending on code
requirements.
[0039] Figs. 6-7 showing another feature, covering up the fastener
heads/holes. The
fastener 28 would clearly be visible from the outside (left) in Fig. 6. As the
connection is
made (Fig. 7), the outside flange 132 overlaps the tongue 24, thereby hiding
the head of
the fastener 28. Overlapping in such a manner is very aesthetically pleasing
because the
fastener heads cannot be seen.
[0040] Such tongues and grooves can be formed in a number of ways,
including but
not limited to being cut or otherwise formed in the foam and being made from a
separate material (metal, plastic, etc.) that is attached to the panel side
(for example, by
adhesives or fasteners).
[0041] Preferably, as is shown in Figs. 6-7, the tongue 24 is configured to
provide an
attachment surface through which a fastener 28 (including but limited to
staples,
screws, bolts, and nails) can be driven therethrough (at a fastener receiving
portion
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adjacent said tongue) and into a surface 30 (such as an exterior wall). This
fastener 28
thus used to attach the panel 10 to the surface 30. These fasteners are
preferably used
every three to twelve inches along the tongue side of the panel, however other
spacing
is possible.
100421 A feature of the disclosed design is the cross sectional shape of
the tongue.
Shown in Figures 1, 6, 7, and 12 is a tongue in which the cross section of the
tongue
includes a curving sidewall of the tongue. The adjoining groove also has a
curving
surface which interfits with the curve of the side of the tongue.
[00431 The term "surface 30" when used herein intended to represent not
only the
outside or exterior "surface" of the building structure, but also includes any
and all
construction materials that the panel and associated components can be
attached to,
such as a sheet of OSB, plywood, dry wall, etc., regardless of their location
on the
structure (exterior, interior, etc.).
[00441 It may be desirable to have tongues on at least one of the
horizontal ends as
well as on the vertical ends, and grooves on one of the horizontal ends and
one of the
perpendicular ends. Such an arrangement would allow adjacent panels to
interlock
together and would allow the panels to be installed either vertically or
horizontally in a
continual pattern to achieve a desired height or width.
CA 02588294 2013-09-20
[0045] However, do to the layout used in constructing the wall (for
instance, it may
be advantageous to start at the ends of the wall and work towards the center),
situations
may arise where adjacent panels are not configured for such "tongue and
groove"
interlocking, for instance, as shown in Fig. 11, where the two panels (10,
210) to be
joined both have grooves. In such a case it may be useful to use a female-to-
female
adapter 38 (shown in Figs. 3 and 11) having a pair of opposing tongues (39,
40) that can
be installed into the grooves (26, 226) to allow the two panels to interlock.
It is
preferred that such an adapter be configured for fastening, for instance
through use of
the screw 28 shown) to the surface 30. In such an instance, a special
overlapping piece
may be necessary to join in the center. Installation starting at the center
and going
outwards is discussed later in this description.
[0046] It is preferred that, on the panels, the tongue be consistently on
one side (left
or right) and the top, with the groove on the other side and the bottom. If
the side
grooves are reversed, the panels must be left and right handed and cannot be
rotated
interchangeably. Further, panels can be made with the tongue on top and the
groove
on the other edges, with the utilization of an adapter that can be glued or
otherwise
fastened into a groove to provide a tongue as required.
[0041 Using such interlocking joints allows for expansion and contraction
to take
place, something that traditional foam/stucco methods, such as the EIFS, 2-
and 3-part
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systems mentioned previously, are not particularly effective at doing. Because
EIFS
doesn't account for such expansion and/or contraction, oftentimes cracking in
the finish
results.
[0048] As discussed above, the panels can be fastened to the structure
through use of
at least one fastener (for example, a screw or staple), inserted through the
tongue (as
shown in Figs. 6-7). The panels could be fastened to the structure using an
adhesive
(preferably a 100% silicone, or low temperature urethane adhesive, preferably
one that
can be applied down to -20 degrees F), either along with or separate from the
utilization
of a fastener. The utilization of both fasteners and adhesive is preferred.
Such an
adhesive, or a waterproof sealant (i.e., caulk, paintable silicone), could
further be used
on the tongue and groove joints, as well as any other locations that could be
permeated
by water or vapor, to sealed such joints and connections water tight.
[0049] It is preferred that the vertical seams be sealed, while the
horizontal seams are
not. This allows the wall system to ventilate vapor and/or moisture out from
the
interior portions of the building structure while inhibiting exterior water
penetration.
Further, the backsides of the panels could be vertically or diagonally grooved
to assist
in the evacuation of moisture/condensation.
[00501 Referring now to Fig. 2, shown is a starter section 42. Starter
sections 42 be
used on the ends of the panels as they terminate adjacent the ground (as shown
in Figs.
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8-9), between panels, etc. For instance, Fig. 8 showing the starter section 42
having a
tongue 44 configured for receipt into the groove 26 of the panel 10. Fig. 9
showing the
starter section 42 having a tongue 44 configured for receipt into the groove
26 of the
block out 46 (discussed below). A preferred starter section comprises a piece
of EPS
foam. Other starter section configurations include but are not limited to a
metal clips
(for instance a "J-shaped" clips), or plastic structures generally shaped to
fit the groove
with a defining channel therein to receive the bottom edge of a siding panel
therein.
[0051] Preferably, a fastener 28 would be utilized to attach the starter
section 42 to
the structure 30. The starter section can be the first general structure
attached (using
fasteners) mounted to the wall surface, providing a flange (or groove) that
the
lowermost siding panel bottom edge mates with.
[00521 Fig. 4 shows a "block out" (also referred to as a "design band" or
"pop out")
46 having a tongue 48 and a groove 50. Fig. 9 shows this block out 46
installed on a
surface 30, where the tongue 48 is configured for receipt into a connected
panel's 10
groove 26. The block out's groove 50 receives therein adjacent tongue, for
instance the
tongue 44 of a starter section 42.
[00531 Figs. 5 and 10 showing a rail section 70. The rail section 70 having
an upper
end having a tongue 39 configured for connection with the groove 26 of the
panel 10. A
fastener 28 could extend through the tongue 39 for attaching the rail section
70 to the
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surface 30. The opposite portion of the rail section 70 comprising a rabbet or
lower
connection 74 configured for attachment to a panel 310 having a flat side 314.
The rail
section 70 serving as a decorative addition to a wall, and may also serve
other
functional purposes, for instance as a plant shelf or window sill. It is
preferred that
when a rail section is used under a window, the tongue section of the rail
would be
removed and the rail sealed with caulk to the window.
[0054] Figs. 8 and 9 further showing, for purposes of representation,
general
structure that may or may not be present in a common structure upon which
these
embodiments are installed. Disclosure of this structure is intended to
supplement the
reader's understanding of general concepts and are not necessarily intended to
be
required structure in any structure. Specifically, these Figures showing a
foundation
wall 52 upon which a floor joist 56 rests, typically with a moisture barrier
54 such as a
sill seal gasket sandwiched there-between. The floor joist(s) connect with one
or more
rim joists 58 which cooperate to support a sub-floor 60. An underlayment 62 is
placed
over the sub-floor 60. The bottom plate 64 of a stud wall 66 rests on the sub-
floor, this
stud wall comprising a plurality of studs 68. The outside surface of the stud
walls
having a wall sheathing or other surface 30 attaching there-to. Sheathing
including but
not limited to OSB, plywood, particle board, wood products, metal coverings,
plastic
coverings, composite coverings, concrete board, ceramic fiber board, fireproof
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materials, etc. Again, this description merely intended as a general
discussion of
components typically found in a common structure.
[00551 Referring now to Fig. 12, shown is a top view of one embodiment of
the
present invention. This figure showing a pair of stud walls (66, 66')
connected together
at a corner. Sheathing 30, 30' covers the stud walls. Attaching to this
sheathing are a
plurality of components of the present invention, a panel 10' having a grooved
end
interlocking with a panel's 510 tongue. The opposite end 514 of this panel 510
having a
flat end. The panels could also be directly attached to the studs.
[0056] The flat end of this panel (510) connecting to the flat end of a
second panel
(510') so as to make a corner. This corner being covered by a corner cover 76.
Such a
corner cover being a trim piece designed to be glued in place without use of
fasteners
after siding panels are secured to the structure. Corner trims allow the
present
invention to traverse around corners without showing fasteners on the outside
thereof.
A second type of corner trim would be an outside 45-degree corner -- a shallow
pop-out
design designed to be used on 45-degree corners such as bay window or angled
walls.
Another type of corner trim would be on the inside corner which is shaped like
a
triangle shape designed to be used on an inside corner of a structure to hide
the seam
where the siding joins.
CA 02588294 2013-09-20
[00571 This panel 510' connecting with a panel 10. These panels (10, 10',
510, 510')
connecting to the sheathing 30, 30' for covering the structure.
[00581 Referring now to Fig. 13, shown is one example of how a building
structure
could be covered using this insulative siding. A starter section 42 is
attached to the rim
joist 58. A panel 10, external to a stud wall 66, would connect with this
starter section
42 and itself would be fastened to the sheathing 30 at its tongue end. A
decorative
block out 46 could attach o the top end of the panel 10, this block out
further configured
for connection with a panel 310". This panel 310" connecting with a rail
section 70 that
is a portion of the window assembly 2. From the top portion of the window
assembly
extends a panel 310' configured for connection with another decorative block
out
portion 46. This block out portion 46 configured for attaching to a panel 310,
which is
external to a stud wall 66 is configured for abutting (through use of
additional
structure) the building's soffit. The main purpose of this drawing being to
show that
various of the components of the present invention can be assembled as desired
by the
designer/installer to form a decorative wall assembly.
[0059] Another example (not particularly shown in Fig. 13) would be the
application
of a wainscot (e.g., rock, block, brick) onto the outer surface of the panel,
with stucco
and/or sandstone panel styles (discussed below) for the upper wall portion.
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[00601 The panels may be coated with any number of coatings, including but
not
limited to hard finishes, rubbery "stucco-like" coatings, etc. Resins
including hardeners
and fireproofing can be applied to the outside. These coatings preferably
being applied
at the factory, rather than in at the job site, but could be applied at the
job site. Noise
reduction is another benefit of the present invention, a benefit that may be
enhanced
through use of coatings. Preferred coatings include but are not limited to a
"stucco"
finish, "sandstone" finish, and "smooth" finish.
[0061] "Stucco" finish. One example would be the application, to the panels
and/or
other components of the present invention, of a hard coating of an epoxy,
polyurea or
urethane (or any such coating mentioned herein). The coating could include a
quantity
of sand (or other granular/textured material) for texture/added strength and a
paint coat
to create a stucco-like appearance. This granular material can be added to the
coating
before or after it is applied to the components. Multiple plies of the coating
and the
material may be applied to increase the strength of the coating. Various grits
of the
material could be used to change the roughness of the finish.
[0062] "Sandstone" finish. One example would be the application, to the
panels
and/or other components of the present invention, of an epoxy, polyurea or
urethane
coating (or any such coating mentioned herein) with a quantity of sand (or
other
granular/textured material). A coating of paint (preferably acrylic) would
then be
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applied, followed by a second (or more) coat of the granular/textured
material. The
granular/textured material preferably being applied and immediately shaken off
so as
to provide an attractive "sandstone" finish. A urethane sealer, preferably
clear, can then
be applied as a finish coat. The color of the paint (preferably acrylic paint)
can reflect
through the sand to change the apparent color of the sandstone finish.
[00631 "Smooth" finish. One example would be the application, to the panels
and/or
other components of the present invention, of a coating of urethane, polyurea,
or the
like (without sand), resulting in a smooth finish. Multiple coats can be
applied for extra
hardness and strength.
[00641 Referring now to Figs. 14A, 14B and 14C, shown are additional views
of the
panel of Fig. 1. Fig. 14A showing a front side view, Fig. 14B showing a front
side
perspective view, and Fig. 14C showing a second end view (Fig. 1 showing a
partial,
first end view) of one embodiment of a panel 10 of the present invention.
[0065] Referring now to Fig. 15, shown is another embodiment of the present
invention. This embodiment showing the provision of a tongue 78 that is
separate from
the panels (410, 410') themselves. Utilization of a such a tongue would allow
a single
form of panel to be used, whereby (if the double tongued section is used and
all the
panels are grooved all the way around) by merely flipping the panel 180
degrees and
inserting the tongue would allow it to mate up with another panel section. In
such an
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arrangement, a fastener could be used to fasten the tongue to the panel 410'
(410) and to
the sheathing 130' (130). Adhesive could likewise be used. Further, instead of
the
tongue 78, a female-to-female adapter 38 (discussed above) could be utilized.
[00661 Optionally, as shown in the drawing, the sheathing wouldn't be a
single piece
but would be adhered directly to the panel 410' (as described infra). In such
an
embodiment the fastener would pass through the sheathing and into a stud of
the stud
wall (or other structure), thereby attaching the panel to the structure. The
sheathing, in
this Figure, is shown configured for overlapping the joints of the connection,
however
such overlapping isn't mandatory and the sheathing could terminate that the
end of
rabbets.
[0061 As discussed above, the panels could be manufactured with the panels
themselves backed, laminated, adhered or otherwise attached directly to the
sheathing
(the sheathing thus becoming, in this embodiment, a portion of the panel).
Doing so
would eliminate the need for the wall sheathing to be separately attached to
the framed
structure (for instance to the exterior portions of the stud wall).
[0068] This figure (Fig. 17) showing both the features of the removable
tongue 78
and the attachment (before installation) of the sheathing to the panel. While
these two
features are shown herein together, they could just as likely be separately
utilized
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and/or could be used (together or apart) as part of other embodiments of the
present
invention.
[0069] A foil coating and/or film could be applied to the back (house) side
of the
panels, this foil or other coating serving as additional R-value, as a
moisture barrier,
and/or providing a location for installation, instructions and other written
materials to
be printed.
[0070] Utilization of high-density expanded polystyrene (or equivalent
foam) has an
insulative benefit. Such panels provide an insulative R-value, typically an R-
4.9 value
for every inch of panel thickness. If the invented siding is used on the
outside of a
structure, the amount of insulation required within the building's wall can be
reduced
and/or eliminated, thereby saving construction costs and providing other
benefits. For
instance, if part of the R-value desired to be used in a wall, is applied to
the outside of
the building (as insulative siding), then the thickness of the walls
themselves can be
lower; from 2' by 6' construction, to 2' by 4' construction thereby saving the
building
and lumber costs.
[0071] In one example, two and one-quarter inch thick EPS foam is installed
over a
2" x 4" framed stud wall having typical R-13 insulation. Such a combination
would
result in a wall with an overall thickness of approximately six (6) inches
having a R-
value of approximately R-24. Must most current walls (2" x 6" construction)
have R-
CA 02588294 2013-09-20
values around R-21. Thus, utilization of this embodiment in a 2" x 4" wall
could
achieve greater insulative value while reducing the costs of construction
materials and
labor over traditional 2"x6" construction.
[0072] In another example, currently framed building structures have lower
R-
values at the location of studs and other structural members. Since the
insulative
siding's insulative value is applied over the entire exterior surface of the
wall, as
opposed to merely being insulated in-between the studs (as fiberglass
insulation is, for
example), the present invention provides superior insulation characteristics
and a true
R-value gain at all points in the wall.
[0073] Installation (in one embodiment) could start in the center of a stud
wall with a
panel having double tongue center pieces or using a female-to-female adapter
(38) to
convert a groove into a tongue. The installer would then work outwards both
directions from there so that trimming would be equally on the wall's ends.
Doing so
would result in the most centered look upon the wall. Such a center piece thus
designed as a starter panel for the center of a large wall. Thus allowing
other siding
panels to be installed on the sides creating even spacing at the end of the
wall. Such a
double tongue center piece could be used to utilize waste panel sections as
well as on
gables where a panel grooved on all sides is used. After cutting the panel
diagonally,
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the tongue can be glued into the waste piece to locate the tongue where
desired and
make the panel usable.
[00741 Another manner of starting the wall would be to install a starter
section (42)
at the base of the wall. The installer could then begin at one side,
preferably the left,
and install the panels from left to right. The first panel is installed at the
corner of the
structure with the groove side of the panel adjacent to the corner. The groove
side can
be secured to the wall with the starter section or with screws or staples that
will be
hidden by the outside corner trim. For taller walls, the process would be
repeated with
the lower panel providing the tongue to interlock into the upper panels.
[00751 There are benefits to using some of the embodiments of the present
invention.
Some embodiments will be much quicker to install than traditional vinyl
siding.
Installation, in comparison to traditional stucco, has the potential of having
about a
thirty-percent (30%) lower installed cost than "EIFS" stucco applications and
be
competitively priced with "2 or 3 coat" stucco systems. Other benefits include
the
insulation R-value, expansion joints, reduced potential for cracks, flatness
and
consistency of the wall, and elimination of problems created from applying
water based
coatings under inclement weather conditions (i.e. freezing temperatures can
inhibit or
destroy the curing of cement or other water based products products).
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CA 02588294 2013-09-20
[00761 Since installation of the insulative siding is a siding process, it
does not
"shutdown" the construction of the building while it is being installed (a
common
problem with the installation of stucco). In addition, there is little mess
and no
overspray to get on windows or other parts of the structure that may be in a
finished
state. These benefits, again, are related to specific embodiments and may not
be present
in each embodiment.
[00771 There are many different types of siding panels that comprise the
preferred
embodiments of the present invention. This paragraph lists five examples of
the many
types. The first type being a siding panel that is 24"X48" long having a
tongue on top
and one side, the groove on the bottom and the other side. A second being a
48"X48"
siding panel having a tongue on top and one side with a groove on the bottom
and
another side. Another siding panel could be the 24"X96" panel having a tongue
on top
and on one side, the groove on the bottom and the other side. A fourth would
be
48"X96" in dimension having a tongue on top and one side, the groove on the
bottom
and the other side. Finally, a fifth would be a double tongue center panel
having a
tongue on top and on both sides with a groove on the bottom side. Other panel
embodiments likewise exist.
[0078] The purpose of the Abstract is to enable the public, and especially
the
scientists, engineers, and practitioners in the art who are not familiar with
patent or
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CA 02588294 2013-09-20
legal terms or phraseology, to determine quickly from a cursory inspection,
the nature
and essence of the technical disclosure of the application. The Abstract is
neither
intended to define the invention of the application, which is measured by the
claims,
nor is it intended to be limiting as to the scope of the invention in any way.
[00791 Still other features and advantages of the present invention will
become
readily apparent to those skilled in this art from the following detailed
description
describing preferred embodiments of the invention, simply by way of
illustration of the
best mode contemplated by carrying out my invention. As will be realized, the
invention is capable of modification in various obvious respects all without
departing
from the invention. Accordingly, the drawings and description of the preferred
embodiments are to be regarded as illustrative in nature, and not as
restrictive in
nature.
[00801 While there is shown and described the present preferred embodiment
of the
invention, it is to be distinctly understood that this invention is not
limited thereto, but
may be variously embodied to practice within the scope of the following
claims.
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