Note: Descriptions are shown in the official language in which they were submitted.
CA 02678632 2012-09-11
INSULATED SIDING SYSTEM
BACKGROUND
The present disclosure relates to insulated siding panels for use on the
exterior
of a building, such as a house. Methods and processes for making and/or using
such
insulated siding panels are also disclosed.
In a building structure, such as a house, a frame is typically built. An
exterior
wall of plywood or material of similar function is then placed upon the frame
to
provide an exterior surface. A weatherproofing layer may cover the exterior
wall. An
insulation layer can then be placed, and finally a cladding, paneling,
sheathing,
veneer, or siding is placed to provide the final exterior view.
Vinyl siding is a popular substitute for wood paneling and aluminum siding. It
is
easily cleaned, and it is resistant to deterioration. It may also be easily
installed
around windows and doors. Moreover, it may be produced in a variety of shapes
and
colors by known extrusion and molding processes at a relatively low cost per
sheet or
panel.
To enhance the thermal insulation of building structures, one or more layers
of
insulating material can be placed between the vinyl siding and the exterior
wall of the
building. For example, a layer of insulation can be placed on a exterior wall,
and the
vinyl siding then installed over the insulating layer. In other insulated
siding systems,
an insulated panel is generally attached to a veneer, such as a vinyl siding
panel.
It would be desirable to produce additional insulated siding panel systems or
assemblies that allow for simple production and easy installation and greater
insulating properties.
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BRIEF DESCRIPTION
The present application discloses, in various exemplary embodiments,
insulated siding panels for use on the exterior surfaces or walls of a
building. The
insulated siding panels contain foam insulation, which provides strength,
enables a
wide variety of design options, and provides increased R-values.
Disclosed in embodiments is an insulated siding panel comprising a foam
insulation layer and an attachment member. The foam insulation layer comprises
a
front face, a rear face, a first joining element defined in a first end edge,
and a second
joining element defined in a second end edge. The attachment member is mounted
to the rear face and extends beyond the first end edge. The first and second
joining
elements are substantially complementary in shape so that adjacent panels can
engage each other. For example, one joining element is a tongue and the other
joining element is a groove. The foam insulation layer may further comprise a
recess
in the rear face along the second end edge.
The attachment member may comprise a main portion and a male connecting
member extending approximately transversely from the main portion. The main
portion may comprise one or more fastener receptacles.
In some embodiments, the attachment member comprises a plurality of male
connecting members, the foam insulation layer comprises a plurality of female
connecting members, and each male connecting member extends into a female
connecting member.
The main portion may further comprise a curved section spaced from the male
connecting member. The curved section cooperates with a section of the rear
face of
the foam insulation layer having a complementary shape.
The foam insulation layer may be formed from a polystyrene, polyurethane,
polyisocyanurate, polyethylene, polypropylene, or combinations thereof.
In some embodiments, the insulated siding panel further comprises a veneer
layer attached to the front face of the foam insulation layer. The veneer
layer may
include a channel cooperating with a lip of the front face of the foam
insulation layer.
A first end edge of the veneer layer may not extend beyond the first end edge
of the
foam insulation layer. However, a second end edge of the veneer layer may
extend
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beyond the second end edge of the foam insulation layer. The veneer layer may
also
comprise a flexible seal extending downwards and outwards from a first front
end
edge of the veneer layer.
The veneer layer can be formed from vinyl, polypropylene, a fiber-cement
material, aluminum, steel, a wood-plastic composite, a cementitious coating,
wood, or
combinations thereof.
The foam insulation layer may be denser at both the first end edge and the
second end edge, compared to a center region of the foam insulation layer.
Also disclosed in embodiments is an insulated siding panel comprising an
foam insulation layer and an attachment member. The foam insulation layer
comprising a front face, a rear face, a tongue extending from a first end
edge, a
groove extending into a second end edge, and at least one slot defined in the
rear
face. The attachment member comprises a main portion and a flange extending
approximately transversely from the main portion. The flange of the attachment
member is inserted into the at least one slot of the foam insulation layer so
the
attachment member extends beyond the first end edge of the foam insulation
layer.
Disclosed in still other embodiments is an insulated siding panel comprising
an
foam insulation layer, an attachment member, and a veneer layer. The foam
insulation layer comprises a front face, a rear face, a tongue extending from
an upper
edge, a groove extending into a lower edge, and at least one slot defined in
the rear
face. The attachment member comprises a main portion, an attachment rail, and
a
flange extending approximately transversely from the main portion. The flange
of the
attachment member is inserted into the at least one slot of the foam
insulation layer
so the attachment rail extends beyond the upper edge of the foam insulation
layer.
The veneer layer is attached to the front face of the foam insulation layer,
and an
upper edge of the veneer layer does not extend beyond the upper edge of the
foam
insulation layer.
These and other non-limiting characteristics of the disclosure are more
particularly disclosed below.
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BRIEF DESCRIPTION OF THE DRAWINGS
The following is a brief description of the drawings, which are presented for
the
purposes of illustrating the exemplary embodiments disclosed herein and not
for the
purposes of limiting the same.
Figure 1 is a perspective view of a first exemplary embodiment of an insulated
siding panel according to the present disclosure.
Figure 2 is a side view of a second exemplary embodiment of an insulated
siding panel according to the present disclosure.
Figure 3 is a side view of two insulated siding panels of a third exemplary
embodiment according to the present disclosure joined together.
Figure 4 is a side view of a fourth exemplary embodiment of an insulated
siding panel according to the present disclosure.
Figure 5 is a side view showing two insulated siding panels according to the
first exemplary embodiment of Figure 1 joined together.
Figure 6 is a side view showing two insulated siding panels according to the
second exemplary embodiment of Figure 2 joined together.
DETAILED DESCRIPTION
A more complete understanding of the components, processes and
apparatuses disclosed herein can be obtained by reference to the accompanying
drawings. These figures are merely schematic representations based on
convenience and the ease of demonstrating the present disclosure, and are,
therefore, not intended to indicate relative size and dimensions of the
devices or
components thereof and/or to define or limit the scope of the exemplary
embodiments.
Although specific terms are used in the following description for the sake of
clarity, these terms are intended to refer only to the particular structure of
the
embodiments selected for illustration in the drawings, and are not intended to
define
or limit the scope of the disclosure. In the drawings and the following
description
below, it is to be understood that like numeric designations refer to
components of
like function.
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Referring to Figure 1, an insulated siding panel 10 comprises a foam
insulation layer 20, an attachment member 50, and a veneer layer 60. The foam
insulation layer 20 comprises a front face 22 and a rear face 24. A tongue,
protrusion, or first joining element 26 is defined in a first end edge 28. A
groove,
rabbet, or second joining element 30 is defined in a second end edge 32. The
first
joining element 26 and second joining element 30 are substantially
complementary in
shape so that adjacent panels can engage each other (see Figures 3, 5, and 6).
In
some embodiments, the joining elements, which are complementary shapes, may
also form a seal. As shown here, the first and second joining elements form a
tongue-and-groove engagement. At least one slot, channel, groove, or female
connecting member 34 is defined in the rear face 24.
The attachment member 50 comprises a main portion 52 and at least one
flange, ridge, or male connecting member 54 extending approximately
transversely
from the main portion. The male connecting member 54 generally extends from a
bottom portion 56 of the main portion 52. A top portion of the main portion
may
comprise, for example, an attachment rail 55 comprising one or more openings
or
fastener receptacles 53. A curved portion 57 is spaced from the male
connecting
member 54 and cooperates with a section 27 of the rear face 24 having a
complementary shape. This curved portion aids in rigidizing the attachment
member.
The male connecting member 54 of the attachment member 50 is inserted into the
female connecting member 34 of the foam insulation layer 20. The veneer layer
60 is
attached to the front face 22 of the foam insulation layer 20.
The front face 22 may be contoured as desired. The main portion 52 of the
attachment member 50 generally extends beyond the first end edge 28. The rear
face 24 is generally flat or planar, but can include a recess 25 sized to
accept the
main portion 52 of the attachment member. When insulated siding panels are
stacked on top of one another, the attachment rail 55 can fit in the recess
25. The
first female connecting member 30 may be considered as being defined by front
shoulder 37 and rear shoulder 38.
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The veneer layer 60 and the attachment member 50 are attached to the foam
insulation layer 20. They can be attached in a variety of ways including, but
not
limited to, adhesive, chemical bonding, interlocking complementary surfaces,
and/or
fasteners. For example, the attachment member may be pressed into the foam
insulation layer. Typically, however, adhesives are used. The adhesive may be
used
over the entire surface of the veneer layer or attachment member, or used in
discrete
locations. Suitable adhesives may include, but are not limited to, UV curable
adhesives and hot melt adhesives, such as polyamines and urethanes, glue,
thermosetting or thermoplastic adhesives, pressure sensitive adhesives or
solvent-
based adhesives. Alternatively, the attachment member may be embedded in the
foam insulation layer during the shape molding process, as described further
below.
The attachment member 50 may be located to allow the insulated siding panel 10
to
be fastened to the wall without creating penetrations in the veneer layer 60
or the
foam insulation layer 20.
In Figure 1, the foam insulation layer 20 further comprises a lip 40 extending
from the second end edge 32 along the front face 22. The veneer layer 60 has a
first
end edge 62 and a second end edge 64. An inwardly opening channel 63 is
located
along the second end edge 64, and the lip 40 is received into the channel 63.
The
shape of the channel may vary. The channel is not needed and is absent in some
embodiments.
Referring to Figure 2, an insulated siding panel 110 comprises a foam
insulation layer 120, an attachment member 150, and a veneer layer 160. The
foam
insulation layer 120 comprises a front face 122, a rear face 124, a tongue 126
extending from an upper edge 128, a groove 130 extending into a lower edge
132,
and a plurality of slots 134 along an upper portion 136 of the rear face 124.
The
attachment member 150 comprises an attachment rail 155 and a plurality of
flanges
154 extending approximately transversely from a main portion 152 of the
attachment
member. Each flange 154 of the attachment member 150 is inserted into a slot
134 in
the foam insulation layer 120. The veneer layer 160 is attached to the front
face 122
of the foam insulation layer 120. The groove 130 can be considered as being
defined
by or between front shoulder 137 and rear shoulder 138.
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In the embodiment shown in Figure 2, the veneer layer 160 comprises an
upper wall 170, a lower wall 180, and a platform 190. Each wall 170, 180 has
an
upper edge 172, 182; a middle portion 174, 184; and a lower edge 176, 186.
Each
wall 170, 180 is also angled such that the upper edge 172, 182 is not in a
plane
defined by the middle portion 174, 184 and the lower edge 176, 186. The
platform
190 joins the lower edge 176 of the upper wall 170 with the upper edge 182 of
the
lower wall 180.
The veneer layer is generally placed as desired on the front face of the foam
insulation layer. Referring to Figure 3, the veneer layer 300 can be a flat
panel. A
second end edge 302 of the veneer layer can extend beyond the second end edge
312 of the foam insulation layer 310. A first end edge 304 of the veneer layer
generally does not extend beyond the first end edge 314 or the first joining
element
316 of the foam insulation layer 310, though it may as long as the
complementary
joining relationship of the first and second joining elements is not impacted.
In
addition, the first end edge 314 may form a ledge 318 over the first end edge
304 of
the veneer layer 300.
In other embodiments as seen in Figure 4, the veneer layer 400 may comprise
a flexible seal 402 extending downwards and outwards from a first front end
edge 404
of the veneer layer. This flexible seal may reduce the amount of water and/or
wind
that can enter between the seams of two insulated siding panels, for example
if a
homeowner is washing the veneer and directs water from a hose at an angle
between
the two insulated siding panels. The flexible seal may also aid in connecting
insulated siding panels together by providing a tapering surface.
Any male / female connecting relationship may be used for the various joining
elements and connecting members. For example, the tongue 126 and groove 130
relationship shown in Figure 2 corresponds to the first joining element 26 and
the
second joining element 30 of Figure 1. Put in other words, a tongue may extend
from one end edge of the foam insulation layer and a groove may extend into
the
other end edge of the foam insulation layer. Similarly, for the attachment
member,
the flange 154 and slot 134 relationship shown in Figure 2 corresponds to the
male
connecting member 54 and the female connecting member 34 of Figure 1. There is
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no requirement that all male / female connecting members have the same size,
shape, or relative dimensions.
The foam insulation layer may comprise a plurality of female connecting
members 34 or slots 134 in the rear face. As seen in Figure 1, not all slots
must be
used. However, the attachment member may comprise a plurality of male
connecting
members 54 or flanges 154 extending approximately transversely from the
attachment member, wherein each male connecting member 54 or flange 154 of the
attachment member is inserted into a female connecting member 34 or slot 134.
When there are a plurality of female connecting members or slots, they do not
all
need to be oriented in the same direction or at the same angle, though
generally they
are. Similarly, the male connecting members or flanges do not all need to be
oriented
in the same direction or at the same angle.
Referring to Figure 3, the male connecting member 354 and the main portion
352 of the attachment member may form any angle R which allows the attachment
member to be mounted to the rear face of the foam insulation layer. This angle
R is
not particularly critical and may range from about 20 to about 160 . However,
angles between about 45 and about 1350 are preferable. In particular
embodiments,
the male connecting member and the main portion of the attachment member are
oriented substantially perpendicular to each other. In different words, the
male
connecting member extends substantially perpendicularly from the main portion
of the
attachment member.
The foam insulation layer may be shape molded. Such molding operations will
generally impart the desired contours and/or design to the foam insulation
layer.
Typically, beads and/or pellets of a polymeric precursor material, such as pre-
expanded polystyrene, are placed in a suitably configured die mold, then
reacted in
the presence of water and heat (i.e. steam) to expand during the reaction
process.
The polymeric precursor material expands and presses against the die surface
to
form compressed elongated closed cells that form a characteristic tough smooth
skin.
The shape molded process produces a panel that is essentially straight and/or
free of
camber. During this process, if desired, the attachment member may be embedded
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in the insulation panel as it is expanded, such that no secondary fasteners
are
needed.
The foam insulation layer provides structural integrity to the insulated
siding
panel. For example, the foam insulation layer is the platform to which the
veneer
layer and the attachment member are connected. The foam insulation layer may
be
shaped to provide the desired profile for the overall insulated siding panel.
For
example, the shape of the foam insulation layer may be obtained by computer
numerical control (CNC) cutting. The grooves on the rear face may also be
milled or
wire-cut.
The foam insulation layer is generally made from a cellular foam product, i.e.
a
plastic or polymeric material with numerous cells of trapped air distributed
throughout
its mass. For example, expanded polystyrene (EPS) is a cellular foam plastic
made
from beads of polystyrene beads that are first pre-expanded and allowed to
rest for a
suitable interval, then molded in closed steam-heated shaped molds to produce
closed-cell molded foams. The size and density of the closed cells can be
controlled
and may vary depending upon the application. Suitable materials for the foam
insulation layer can include extruded polystyrene (XPS), expanded polystyrene
(EPS), polyurethane, polyisocyanurate, polyethylene, polypropylene, or
combinations
thereof. In some embodiments, the foam insulation layer is made from a rigid
foam
material.
The foam insulation layer can be of any density desired, or be tuned to
provide
different densities depending on the location. For example, it may be
desirable to
have higher densities near the edges of the panel, and lower densities near
the
center (where the veneer layer covers the foam insulation layer). In
particular
embodiments, the foam insulation layer has a higher density along the first
end edge
or upper edge than in the center of the foam insulation layer (i.e. the middle
region of
the foam insulation layer between the first end edge and the second end edge).
Similarly, the foam insulation layer may also have a higher density along the
second
end edge or lower edge than in the center of the foam insulation layer. In
other
words, the foam insulation layer may be thought of as having a top region, a
bottom
region, and a middle region, and the middle region has a lower foam density
than at
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least one of the top region and the bottom region, and possible both regions.
This
increased foam density can strengthen the joining areas of the foam insulation
layer.
Expanded or extruded polystyrene are particularly desirable materials for the
foam insulation layer because they provide a solid feel; improve the R-value;
deaden
noise transmitted through the siding; and allow moisture to migrateaway from
the
exterior wall into the external environment, protecting the exterior wall
behind the
foam insulation layer and reducing the risk of mold growth.
The veneer layer is optional and is not present in all embodiments, but is
generally desired. The veneer layer provides environmental resistance and
durability.
It is contemplated that the veneer layer is generally contoured to conform to
the
contours of the foam insulation layer. Generally, siding must be thick to
resist
sagging and retain the desired shape. However, the foam insulation layer
allows the
veneer layer to be thinner than otherwise necessary. The veneer layer only has
to
provide weatherability to the insulated siding panel. Whereas traditional
vinyl veneer
sidings have a minimum material thickness of 0.040 inches, the veneer layers
used in
this disclosure may have a thickness from 0.020 to 0.036 inches.
The veneer layer can be formed from any suitable polymeric, metallic,
cementious or composite material. Exemplary materials include vinyl,
polypropylene,
fiber-cement material, polyolefins, polyvinyls, polycarbonates, polyacetals,
polysulfones, polyesters, polyamides, multilayer films, polyethylene (HDPE),
polypropylene, low density polyethylene (LDPE), CPVC ABS, ethyl-vinyl acetate,
various extruded ionomeric films, polyethylene based films, wood, or
combinations
thereof. Other siding materials suitable for the veneer layer include wood,
aluminum,
and steel.
Generally, the bottom of each insulated siding panel will overlap the top of
the
insulated siding panel below it. As seen in Figures 5 and 6, a lip 40, 140 of
the top
foam insulation layer 70, 192 will extend beyond the first end edge 28 or
upper edge
128 of the bottom foam insulation layer 80, 194. As shown in Figure 3, the
second
end edge 302 of the top veneer layer 300 of panel 310 extends beyond the first
end
edge 374 of the bottom veneer layer 370 of panel 360; in other words, the
veneer
layers overlap. The front face 22 and rear face 24 are generally not parallel
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CA 02678632 2009-09-14
other to provide this overlapping feature. The construction of the insulated
siding
panel creates a uniform barrier from the foam insulation layers 70, 80.
Again referring to Figure 3, the veneer layer 300 will have a height 305 which
is measured between the first end edge 304 and second end edge 302. Similarly,
the
foam insulation layer 310 will have a height 315 which is measured between the
first
end edge 314 and second end edge 312. In some specific embodiments, the height
305 of the veneer layer is greater than the height 315 of the foam insulation
layer.
The insulated siding panel 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 insulated siding panel will be essentially straight and free from camber
and
bowing. The insulated siding panel can have a width of between 7 and 48
inches,
with typical widths between 8 and 36 inches in various applications. The
insulated
siding panel can have a total thickness of from about 0.2 to about 10 inches.
If desired, the rear face of the foam insulation layer may also have drainage
grooves formed or fabricated into it. Such grooves are described in U.S.
Patent
Publication Nos. 2005/0081468 and 2007/0175154, the disclosures of which are
hereby fully incorporated by reference.
The insulated siding panels are used in suitable combinations to be affixed to
or attached to exterior walls of a building. They can be used on several types
of
structures including, but not limited to, wood-frame, cement block, structural
insulated
panels (SIPS), insulating concrete forms (ICFs), steel studs, etc. When
installed, the
resulting insulation layer is uniform and forms a complete seal. In addition,
any
perforations in the wall are sealed off from outside elements by the
insulation. The
attachment member also provides fewer perforations overall in the exterior
wall. The
foam insulation layers and veneer layers themselves are not perforated either.
Nails,
screws, or staples can be used with equal ease and can be more accurately
placed
and are more secure because they are applied directly to the exterior wall
instead of
through a flexible insulation layer.
Other benefits of the insulated siding panels described herein relate to
production. The amount of insulation can be increased by simply adding more
foam,
without any other cost in materials. A single foam insulation layer can be
used with
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multiple veneer layers to provide desired assemblies. The veneer layer can be
reduced in thickness, reducing waste.
While particular embodiments have been described, alternatives,
modifications, variations, improvements, and substantial equivalents that are
or may
be presently unforeseen may arise to applicants or others skilled in the art.
Accordingly, the appended claims as filed and as they may be amended are
intended
to embrace all such alternatives, modifications variations, improvements, and
substantial equivalents.
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