ATTACHMENT MEMBER FOR INSULATION PANEL

ELEMENT DE FIXATION POUR PANNEAU ISOLANT

English Abstract

Attachment members are disclosed for use with an insulation panel or
composite siding panel. The attachment member includes a male connecting
member, a hem portion, and a connection portion joining the male connecting
member and the hem portion. The male connecting member extends into the body
of a foam insulating layer along a first end edge. The attachment member and
the
first end edge cooperate to be complementary in shape with the second end edge

such that adjacent panels can engage each other.

Claims

THE EMBODIMENT OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. An attachment member comprising:
a main portion having a forward edge and a rear edge;
a nailing hem extending transversely from the rear edge of the main
portion in an upper direction, the nailing hem having a base and an apex, the
base
including an arched portion extending in a forward direction; and
at least one lower leg extending transversely from the main portion in
a lower direction.
2. The attachment member of claim 1, wherein the apex of the nailing
hem is rounded and includes an end strip.
3. The attachment member of claim 1, wherein the attachment member
has a plurality of lower legs extending transversely from the main portion in
the
lower direction.
4. The attachment member of claim 3, wherein the plurality of lower
legs have the same length.
5. The attachment member of claim 3, wherein the plurality of lower
legs has more than one length.
6. The attachment member of claim 5, wherein the plurality of lower
legs are arranged so that for each pair of adjacent lower legs, the lower leg
closer
to the forward edge of the main portion is shorter than the other lower leg.

51

7. The attachment member of claim 5, wherein the plurality of lower
legs are arranged so that the lower leg closest to the forward edge of the
main
portion and the lower leg closest to the rear edge of the main portion are
longer
than the other lower legs.
8. The attachment member of claim 5, wherein the plurality of lower
legs are arranged so that for each pair of adjacent lower legs, the lower leg
closer
to the center of the main portion is longer than the other lower leg.
9. The attachment member of claim 1, further comprising a forward wall
and a lip, the forward wall extending from the forward edge of the main
portion in
the upper direction, wherein the forward wall has a first end and a second
end, the
second end of the forward wall is connected to the main portion, and the lip
extends transversely from the first end of the forward wall in the forward
direction
away from the nailing hem.
10. The attachment member of claim 1, further comprising at least one
flange extending transversely from the at least one lower leg.
11. The attachment member of claim 10, wherein the at least one flange
has a stop surface and an angled surface that extends away from the main
portion.
12. The attachment member of claim 1, further comprising a side leg
extending transversely from the nailing hem in a backward direction.
13. The attachment member of claim 12, wherein the side leg further
comprises a flange extending transversely from the side leg.

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14. The attachment member of claim 1, further comprising a primary
flange and a secondary flange each extending transversely from the at least
one
lower leg, wherein the primary flange is located along the at least one lower
leg
further from the main portion than the secondary flange, and wherein the
secondary flange is longer than the primary flange.
15. An insulation panel comprising:
a foam insulating layer comprising a front face, a rear face, a first end
edge, and a second end edge that define a body of the foam insulating layer;
and
an attachment member comprising:
a main portion having a forward edge and a rear edge;
a nailing hem extending transversely from the rear edge of the
main portion in an upper direction, the nailing hem having a base and an apex,
the
base including an arched portion extending in a forward direction; and
at least one lower leg extending transversely from the main
portion in a lower direction at a point between the forward edge and the rear
edge;
wherein the at least one lower leg of the attachment member extends
into the body of the foam insulating layer along the first end edge, the
attachment
member and the first end edge cooperating to be complementary in shape with
the
second end edge such that adjacent panels can engage each other.
16. The insulation panel of claim 15, further comprising a veneer panel
attached to the front face of the foam insulating layer, the veneer panel
having a
first end edge at the same end of the insulation panel as the first end edge
of the
foam insulating layer and a second end edge.
17. The insulation panel of claim 15, wherein the foam insulating layer
includes an upper wall extending from the first end edge along the rear face
in the
upper direction.

53

18. The insulation panel of claim 17, wherein the upper wall has an
upper edge extending to at least the apex of the nailing hem, a front face,
and a
rear face.
19. The insulation panel of claim 17, wherein the foam insulating layer
further comprises a recess in the rear face along the second end edge, the
recess
being shaped to accommodate the nailing hem and the upper wall.
20. The insulation panel of claim 15, wherein the front face of the foam
insulating layer has a contour formed from a central lateral ridge, a central
depressed region extending downwards from the central lateral ridge, an
outwardly
extending angled region connected to the central depressed region, and a
planar
region connected to the outwardly extending angled region.

54

Description

CA 02798666 2012-12-12
,
TITLE: ATTACHMENT MEMBER FOR INSULATION PANEL
BACKGROUND
This application is a continuation-in-part of U.S. Patent Application No.
13/570,892, filed August 9, 2012, which claimed priority to U.S. Provisional
Patent
Application Serial No. 61/523,084, filed on August 12, 2011; to U.S.
Provisional
Patent Application Serial No. 61/569,382, filed on December 12, 2011; and to
U.S.
Provisional Patent Application Serial No. 61/569,396, filed on December 12,
2011.
This application also claims priority to U.S. Provisional Patent Application
Serial
No. 61/569,382, filed on December 12, 2011. This application also claims
priority
to U.S. Provisional Patent Application Serial No. 61/569,396, filed on
December
12, 2011. The disclosures of these applications are hereby fully incorporated
by
reference in their entirety.
The present disclosure relates to attachment members and insulation
panels including the same. The insulation panels may be used on the exterior
surface of a roofed and walled structure built for permanent use, including a
building, a house, etc.
In a building structure, such as a house, a frame is typically built out of
wood, steel, block, or similar material. 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 layer 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
attached
to an exterior wall, and the vinyl siding then installed over the insulating
layer. In
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CA 02798666 2012-12-12
other insulated siding systems, an insulated panel is generally attached to a
veneer, such as vinyl siding panel.
It would be desirable to produce additional insulated siding panel systems
or assemblies, as well as components thereof, that allow for simple
production,
easy installation, and greater insulating properties.
BRIEF DESCRIPTION
The present application discloses, in various exemplary embodiments,
various installation / attachment members that can be used to form an
insulation
panel or composite siding panel. The insulation panels are particularly useful
on
the exterior surfaces or walls of a building. The insulation panels include
foam
insulation, which provides strength, enables a wide variety of design options,
and
provides increased R-values.
Disclosed in embodiments is an insulation panel comprising a foam
insulating layer and an attachment member. The foam insulating layer includes
a
front face, a rear face, a first end edge, a second end edge, and a female
connecting member extending into a body of the foam insulating layer along the

first end edge. The attachment member includes a male connecting member
extending into the female connecting member of the foam insulating layer, a
hem
portion substantially aligned with the rear surface of the foam insulating
layer, and
a connection portion joining the male connecting member and the hem portion.
The attachment member and the first end edge cooperate to be complementary in
shape with the second end edge such that adjacent panels can engage each
other.
The male connecting member and the hem portion may be substantially
parallel to each other.
The attachment member may further include an anchor portion extending
from the male connecting member. The anchor portion may be substantially
parallel to the connection portion. The connection portion may be connected to
a
first end of the male portion and the anchor portion may be connected to a
second
end of the male portion.
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CA 02798666 2012-12-12
The male portion may include a first end and a second end. The anchor
portion may be located between the first end and the second end.
The foam insulating layer may further include a tongue extending from the
first end edge and a groove extending into the second end edge.
The attachment member may further include a forward wall connected to
the connection member and extending away from the foam insulating layer. The
foam insulating layer may further include a groove extending from the second
end
edge into the body. The forward wall and the grove may be complementary in
shape.
The insulation panel may include a veneer panel attached to the front face
of the foam insulating layer. The veneer panel may have a first end edge and a

second end edge. The veneer panel may include a first wall extending
transversely rearward from the first end edge and a second wall extending
transversely rearward from the second end edge.
The first wall may extend from the first end edge of the veneer panel
beyond the first end edge of the foam insulating layer. The second wall may
extend transversely rearward from the second end edge.
The insulation panel may include a pocket between the second wall of the
veneer panel and the second end edge of the foam insulating layer.
The veneer panel may include a channel along a second end edge. The
second end edge of the foam insulating layer may include a forward segment
extending into the channel.
The veneer panel may be formed from vinyl, polypropylene, a fiber-cement
material, aluminum, steel, a wood-plastic composite, a cementitious coating,
wood,
or combinations thereof.
The foam insulating layer may be formed from a polystyrene, polyurethane,
polyisocyanurate, polyethylene, polypropylene, or combinations thereof.
The front face of the foam insulating layer may be angled with respect to the
rear face of the foam insulating layer.
The second end edge of the foam insulating layer may be thicker than the
first end edge of the foam insulating layer.
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CA 02798666 2012-12-12
The front face of the foam insulating layer may be substantially parallel to
the rear face of the foam insulating layer.
Also disclosed in embodiments is an insulation panel comprising a foam
insulating layer, an attachment member, and a veneer panel. The foam
insulating
layer includes a front face, a rear face, a first end edge, a second end edge,
and a
female connecting member extending into a body of the foam insulating layer
along the first end edge. The attachment member includes a male connecting
member extending into the female connecting member of the foam insulating
layer,
a hem portion substantially aligned with the rear face of the foam insulating
layer,
an anchor portion extending from a free end of the male connecting member, and
a connection portion joining the male connecting member and the hem portion.
The veneer panel is attached to the front face of the foam insulating layer.
The
attachment member and the first end edge are complementary to the second end
edge.
The attachment member may further include a forward wall. The forward
wall, connection portion, and hem portion cooperate to form a shape
complementary to the second end edge.
Further disclosed in embodiments is an attachment member comprising a
main portion, a nailing hem, and a lower leg. The main portion has a forward
edge and a rear edge. The nailing hem extends transversely from the rear edge
of
the main portion in an upper direction. The lower leg extends transversely
from
the main portion in a lower direction.
The lower leg may connect to the main portion along the forward edge.
The attachment member may further include a forward wall extending from
the forward edge of the main portion in the upper direction.
The lower leg, the forward wall, and the nailing hem may be substantially
parallel to each other.
The lower leg and the nailing hem may be substantially parallel to each
other and extend substantially perpendicularly from the main portion.
The lower leg may connect to the main portion at a central location.
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CA 02798666 2012-12-12
The attachment member may further include a forward wall extending from
the forward edge of the main portion in the upper direction.
The lower leg, forward wall, and nailing hem may be substantially parallel to
each other.
The forward wall may have a first end and a second end. The second end
of the forward wall may be connected to the main portion. A lip may extend
transversely from the first end of the forward wall in a forward direction
away from
the nailing hem.
The attachment member may further include a flange extending
transversely from the lower leg. The lower leg may have a first end and a
second
end. The first end of the lower leg may be connected to the main portion. The
flange may extend from the second end of the lower leg.
The main portion and the flange may be substantially parallel to each other.
A base of the nailing hem connecting to the main portion may be thicker
than an apex of the nailing hem.
A base of the nailing hem may further comprise a spur extending
transversely in the lower direction.
The attachment member may further include a forward wall extending from
the forward edge of the main portion in the upper direction.
The lower leg, forward wall, and nailing hem may be substantially parallel to
each other and extend substantially perpendicularly from the main portion.
The nailing hem may be longer than the forward wall.
Still further disclosed is an attachment member comprising a main portion, a
nailing hem, a forward wall, and a lower leg. The main portion may have a
forward
edge and a rear edge. The nailing hem may extend perpendicularly from the rear
edge of the main portion in an upper direction. The forward wall may extend
perpendicularly from the forward edge of the main portion in the upper
direction.
The lower leg extending perpendicularly from the forward edge of the main
portion
in a lower direction.
Yet further disclosed is an attachment member comprising a main portion, a
nailing hem, and a lower leg. The main portion may have a forward edge and a
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CA 02798666 2012-12-12
rear edge. The nailing hem may extend perpendicularly from the rear edge of
the
main portion in an upper direction. The lower leg may extend perpendicularly
from
the main portion in a lower direction at a point between the forward edge and
the
rear edge.
The attachment member may further include a forward wall extending
perpendicularly from the forward edge of the main portion in the upper
direction.
The point may be the midpoint of the main portion.
Also disclosed is an attachment member comprising a main portion, a
nailing hem, a forward wall, a lower leg, and a flange. The main portion has a
forward edge and a rear edge. The nailing hem extends perpendicularly from the
rear edge of the main portion in an upper direction. The forward wall extends
perpendicularly from the forward edge of the main portion in the upper
direction.
The lower leg has an upper end and a lower end. The lower leg extends
perpendicularly from the main portion in a lower direction at a point between
the
forward edge and the rear edge and the upper end connects to the main portion.
The flange extending perpendicularly from the lower end of the lower leg.
A base of the nailing hem connecting to the main portion may be thicker
than an apex of the nailing hem.
Still further disclosed is an attachment member comprising a main portion, a
nailing hem, a forward wall, a lower leg, at least one spur, and a flange. The
main
portion has a forward edge and a rear edge. The nailing hem extends
perpendicularly from the rear edge of the main portion in an upper direction.
The
forward wall extends perpendicularly from the forward edge of the main portion
in
the upper direction. The lower leg has an upper end and a lower end, and
extends
perpendicularly from the main portion in a lower direction. The upper end of
the
lower leg is connected to the main portion. The at least one spur extends
transversely from the nailing hem in the lower direction and in a forward
direction.
The flange extends perpendicularly from the lower end of the lower leg.
Yet further disclosed is an insulation panel comprising a foam insulating
layer and an attachment member. The foam insulating layer includes a front
face,
a rear face, a first end edge, and a second end edge that define a body of the
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CA 02798666 2012-12-12
foam insulating layer. The attachment member includes a main portion, a
nailing
hem, a forward wall, and a lower leg. The main body portion has a forward edge

and a rear edge. The nailing hem extends transversely from the rear edge of
the
main portion in an upper direction. The forward wall extends transversely from
the
forward edge of the main portion in the upper direction. The lower leg extends

transversely from the forward edge of the main portion in a lower direction.
The
lower leg of the attachment member extends into the body of the foam
insulating
layer along the first end edge. The attachment member and the first end edge
cooperate to be complementary in shape with the second end edge such that
adjacent panels can engage each other.
The insulation panel may further include a veneer panel attached to the
front face of the foam insulating layer.
The veneer panel may have a second wall that extends rearward along the
second end edge of the foam insulating layer.
The veneer panel may have a first wall that extends rearward and is at the
height of an upper edge of the forward wall.
The first end edge of the foam insulating layer may include a tongue and the
second end edge of the foam insulating layer includes a groove. The tongue is
shaped to fit within the groove.
The foam insulating layer may further include a recess in the rear face that
is shaped to accommodate the nailing hem.
Also disclosed is an insulation panel comprising a foam insulating layer and
an attachment member. The foam insulating layer includes a front face, a rear
face, a first end edge, and a second end edge that define a body of the foam
insulating layer. The attachment member includes a main portion, a nailing
hem, a
forward wall, and a lower leg. The main portion has a forward edge and a rear
edge. The nailing hem extends transversely from the rear edge of the main
portion
in an upper direction. The forward wall extends transversely from the forward
edge of the main portion in the upper direction. The lower leg extends
transversely
from the main portion in a lower direction at a point between the forward edge
and
the rear edge. The lower leg of the attachment member extends into the body of
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CA 02798666 2012-12-12
the foam insulating layer along the first end edge. The attachment member and
the first end edge cooperate to be complementary in shape with the second end
edge such that adjacent panels can engage each other.
The insulation panel may further include a veneer panel attached to the
front face of the foam insulating layer. The veneer panel may have a first end

edge adjacent the first end edge of the foam insulating layer and a second end

edge. The veneer panel may further include a first wall that extends
transversely
upward from the first end edge of the veneer panel beyond the first end edge
of
the foam insulating layer and a second wall that extends transversely rearward
from the second end edge of the veneer panel.
The foam insulating layer may further include a rear segment extending
from the second end edge of the foam insulating layer along the rear face. The

rear segment may be complementary to a channel formed by the first wall of the

veneer panel and the attachment member.
The second end edge of the veneer panel may extend beyond the second
end edge of the foam insulating layer. A pocket may be formed between the rear

segment of the foam insulating layer, the second end edge of the foam
insulating
layer, and the second wall of the veneer panel.
The second end edge of the veneer panel may extend beyond the second
end edge of the foam insulating layer, and the veneer panel may further
include a
second wall that extends transversely rearward from the second end edge of the

veneer panel.
The foam insulating layer may further include a recess in the rear face. The
recess is shaped to accommodate the nailing hem.
Still further disclosed is an insulation panel comprising a foam insulating
layer and an attachment member. The foam insulating layer includes a front
face,
a rear face, a first end edge, and a second end edge that define a body of the

foam insulating layer. The attachment member includes a main portion, a
nailing
hem, a forward wall, a lower leg, and a flange. The main portion has a forward
edge and a rear edge. The nailing hem extends transversely from the rear edge
of
the main portion in an upper direction. The forward wall extends transversely
from
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CA 02798666 2012-12-12
the forward edge of the main portion in the upper direction. The lower leg has
an
upper end and a lower end. The lower leg extends transversely from the main
portion in a lower direction at a point between the forward edge and the rear
edge.
The flange extends transversely from the lower end of the lower leg. The lower
leg
and the flange of the attachment member are embedded in the body of the foam
insulating layer along the first end edge. The attachment member and the first
end
edge cooperate to be complementary in shape with the second end edge such that

adjacent panels can engage each other.
The insulation panel may further include a veneer panel attached to the
front face of the foam insulating layer. The veneer panel has a first end edge

adjacent the first end edge of the foam insulating layer and a second end
edge.
The veneer panel may further include a first wall that extends transversely
upward from the first end edge of the veneer panel beyond the first end edge
of
the foam insulating layer and is adjacent to the forward wall of the
attachment
member.
The veneer panel may further include a channel along the second end
edge. The second end edge of the foam insulating layer may include a groove
that
forms a front ridge and a rear ridge in the second end edge. The front ridge
of the
foam insulating layer enters the channel of the veneer panel.
The first end edge of the foam insulating layer is planar from the front face
to the rear face.
The rear face of the foam insulating layer may include a recess shaped to
accommodate the nailing hem of the attachment member.
A base of the nailing hem connecting to the main portion may thicker than
an apex of the nailing hem.
A length of the second end edge of the foam insulating layer may be greater
than a length of the first end edge of the foam insulating layer.
A thickness of the foam insulating layer between the front face and the rear
face may be generally constant from the first end edge to the second end edge.
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CA 02798666 2012-12-12
'
The second end edge of the foam insulating layer may comprise a groove
complementary to the forward wall of the attachment member. The groove may be
located along the front face of the foam insulating layer.
Yet further disclosed is an insulation panel comprising a foam insulating
layer and an attachment member. The foam insulating layer includes a front
face,
a rear face, a first end edge, and a second end edge that define a body of the

foam insulating layer. The attachment member includes a main portion, a
nailing
hem, a forward wall, a lower leg, and at least one spur. The main portion has
a
forward edge and a rear edge. The nailing hem extends transversely from the
rear
edge of the main portion in an upper direction. The forward wall extends
transversely from the forward edge of the main portion in the upper direction.
The
lower leg extends transversely from the forward edge of the main portion in a
lower
direction. The at least one spur extends transversely from the nailing hem in
the
lower direction and in a forward direction. The lower leg of the attachment
member extends into the body of the foam insulating layer along the first end
edge.
The attachment member and the first end edge cooperate to be complementary in
shape with the second end edge such that adjacent panels can engage each
other.
The first end edge of the foam insulating layer may be planar from the front
face to the rear face.
The rear face of the foam insulating layer may include a recess shaped to
accommodate the nailing hem of the attachment member.
A thickness of the foam insulating layer between the front face and the rear
face may be generally constant from the first end edge to the second end edge.
The second end edge of the foam insulating layer may comprise a groove
complementary to the forward wall of the attachment member. The groove may be
located along the front face of the foam insulating layer.
The first end edge of the foam insulating layer may be substantially
perpendicular to the front face and the rear face of the foam insulating
layer.
The forward wall of the attachment member may be substantially parallel
with the front face of the foam insulating layer.

CA 02798666 2012-12-12
The insulation may further comprise a veneer panel attached to the front
face of the foam insulating layer.
Also disclosed in embodiments is an insulation panel comprising a foam
insulating layer and an attachment member. The attachment member includes a
main portion, a nailing hem, a forward wall, and a lower leg. The main portion
has
a forward edge and a rear edge. The nailing hem extends transversely from the
rear edge of the main portion in an upper direction. The forward wall extends
transversely from the forward edge of the main portion in the upper direction.
The
lower leg extends transversely from the main portion in a lower direction. The
foam insulating layer comprises a front face, a rear face, a first end edge,
and a
second end edge that define a body of the foam insulating layer. The front
face is
angled with respect to the rear face. A groove in the second end edge forms a
front ridge and a rear ridge in the second end edge. The lower leg of the
attachment member extends into the body of the foam insulating layer along the
first end edge, the attachment member and the first end edge cooperating to be

complementary in shape with the second end edge such that adjacent panels can
engage each other.
The insulation panel may further comprise a veneer panel attached to the
front face of the foam insulating layer. The veneer panel comprises a front
face, a
rear face, a first end edge, and a second end edge. The first end edge of the
veneer panel is adjacent to an upper edge of the forward wall of the
attachment
member.
The veneer panel can further comprise a lower wall extending rearwards
from the second end edge, the lower wall running adjacent to the front ridge
of the
foam insulating layer. The lower wall of the veneer panel may be part of a
channel, the front ridge of the foam insulating layer entering the channel.
The
forward wall of the attachment member is angled to be parallel with the front
face
of the foam insulating layer.
The attachment member may further comprise a flange extending
transversely from a lower end of the lower leg.
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CA 02798666 2012-12-12
,
The attachment member may further comprise a lip extending transversely
from an upper edge of the forward wall in a forward direction.
The base of the nailing hem may further comprise a spur extending in a
forward direction. The spur sometimes also extends in a lower direction.
The rear face of the foam insulating layer may include a recess that is
shaped to accommodate the nailing hem of the attachment member.
Also disclosed is an insulation panel comprising an attachment member, a
foam insulating layer, and a veneer panel. The foam insulating layer comprises
a
front face, a rear face, a first end edge, and a second end edge that define a
body
of the foam insulating layer. The attachment member comprises a main portion
resting upon the first end edge of the foam insulating layer, a forward wall
extending transversely from a forward edge of the main portion away from the
foam insulating layer, and a lower leg extending transversely from the main
portion
into the body of the foam insulating layer. The veneer panel is attached to
the
front face of the foam insulating layer, a first end edge of the veneer panel
being
adjacent to an upper edge of the forward wall of the attachment member.
Also described in various embodiments is an attachment member
comprising a main portion, a nailing hem, a lower leg, and at least one
flange. The
main portion has a forward edge and a rear edge. The nailing hem extends
transversely from the rear edge of the main portion in an upper direction. The
lower leg extends transversely from the main portion in a lower direction. The
at
least one flange extends transversely from the lower leg, with each flange
having a
stop surface and an angled surface that extends away from the main portion.
The lower leg may connect to the main portion along the forward edge.
Alternatively, the lower leg can connect to the main portion in a central
location.
The attachment member may further comprise a forward wall extending
from the forward edge of the main portion in the upper direction. The nailing
hem
can be longer than the forward wall. The lower leg, the forward wall, and the
nailing hem may be substantially parallel to each other. An optional lip may
extend
transversely from an upper end of the forward wall in a forward direction away
from
the nailing hem. The lip may be substantially parallel to the main portion.
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CA 02798666 2012-12-12
=
The lower leg and the nailing hem may be substantially parallel to each
other and extend substantially perpendicularly from the main portion.
A base of the nailing hem connecting to the main portion can be thicker than
an apex of the nailing hem. In some embodiments, the base of the nailing hem
further comprises at least one spur extending transversely in a forward
direction.
The spur can also extend transversely in the lower direction.
An angle w between the stop surface and the angled surface of the flange
may be acute. In embodiments, the angle w is from about 150 to about 75 .
The stop surface of the flange may be substantially parallel to a lower
surface of the main portion. The lower end of the lower leg can also be
pointed.
In particular embodiments, a plurality of flanges are spaced along the lower
leg. The stop surfaces of the plurality of flanges may have the same length.
The plurality of flanges can include a primary flange and a secondary
flange, the primary flange being located closer to the lower end of the lower
leg,
wherein the secondary flange is longer than the primary flange. The plurality
of
flanges can also include a tertiary flange located closer to the main portion
than
the secondary flange, wherein the tertiary flange is longer than the secondary

flange.
Also disclosed in embodiments is an insulation panel comprising a foam
insulating layer and an attachment member. The foam insulating layer comprises
a front face, a rear face, a first end edge, and a second end edge that define
a
body of the foam insulating layer. The attachment member comprises a main
portion, a nailing hem, a lower leg, and at least one flange. The main portion
has a
forward edge and a rear edge. The nailing hem extends transversely from the
rear
edge of the main portion in an upper direction. The lower leg extends
transversely
from the main portion in a lower direction. The at least one flange extends
transversely from the lower leg, with each flange having a stop surface and an

angled surface that extends away from the main portion. The lower leg of the
attachment member extends into the body of the foam insulating layer along the
first end edge, the attachment member and the first end edge cooperating to be
13

CA 02798666 2012-12-12
complementary in shape with the second end edge such that adjacent panels can
engage each other.
The insulation panel may further comprise a veneer panel attached to the
front face of the foam insulating layer. The first end edge of the foam
insulating
layer may include a tongue, with the second end edge of the foam insulating
layer
including a groove, and the tongue being shaped to fit within the groove. The
foam
insulating layer may further comprise a recess in the rear face that is shaped
to
accommodate the nailing hem. The second end edge of the foam insulating layer
may include a groove that forms a front ridge and a rear ridge in the second
end
edge. The first end edge of the foam insulating layer may be planar from the
front
face to the rear face.
The front face of the foam insulating layer may be angled with respect to the
rear face. Alternatively, a thickness of the second end edge of the foam
insulating
layer may be greater than a thickness of the first end edge of the foam
insulating
layer. Sometimes, a thickness of the foam insulating layer between the front
face
and the rear face is generally constant from the first end edge to the second
end
edge.
Also described in other embodiments is an attachment member comprising
a main portion, a nailing hem, a lower leg, a primary flange, and a secondary
flange. The main portion has a forward edge and a rear edge. The nailing hem
extends transversely from the rear edge of the main portion in an upper
direction.
The lower leg extends transversely from the main portion in a lower direction.
The
primary flange and the secondary flange each extend transversely from the
lower
leg, with the primary flange being located along the lower leg further from
the main
portion than the secondary flange. The secondary flange is longer than the
primary flange.
The primary flange and the secondary flange may each have a stop surface
and an angled surface that extends away from the main portion. The stop
surface
of each flange may be substantially parallel to a lower surface of the main
portion.
An angle w between the stop surface and the angled surface of the flange may
be
acute. In embodiments, the angle w is from about 15 to about 750

.
14

CA 02798666 2012-12-12
The attachment member may further comprise a tertiary flange located
closer to the main portion than the secondary flange, wherein the tertiary
flange is
longer than the secondary flange. The primary flange, the secondary flange,
and
the tertiary flange may each have a stop surface and an angled surface that
extends away from the main portion. The stop surface of each flange may be
substantially parallel to a lower surface of the main portion. An angle w
between
the stop surface and the angled surface of the flange may be acute. In
embodiments, the angle w is from about 15 to about 75 .
The lower leg may connect to the main portion along the forward edge.
Alternatively, the lower leg may connect to the main portion in a central
location.
The lower end of the lower leg may be pointed.
The attachment member may further comprise a forward wall extending
from the forward edge of the main portion in the upper direction. The nailing
hem
may be longer than the forward wall. The lower leg, the forward wall, and the
nailing hem may be substantially parallel to each other. An optional lip may
extend
transversely from an upper end of the forward wall in a forward direction away
from
the nailing hem. The lip can be substantially parallel to the main portion.
The lower leg and the nailing hem may be substantially parallel to each
other and extend substantially perpendicularly from the main portion.
A base of the nailing hem connecting to the main portion may be thicker
than an apex of the nailing hem. The base of the nailing hem further comprises
at
least one spur extending transversely in a forward direction. The spur can
also
extend transversely in the lower direction.
Also disclosed in embodiments is an insulation panel comprising a foam
insulating layer and an attachment member. The foam insulating layer comprises
a front face, a rear face, a first end edge, and a second end edge that define
a
body of the foam insulating layer. The attachment member comprises a main
portion, a nailing hem, a lower leg, a primary flange, and a secondary flange.
The
main portion has a forward edge and a rear edge. The nailing hem extends
transversely from the rear edge of the main portion in an upper direction. The
lower leg extends transversely from the main portion in a lower direction. The

CA 02798666 2012-12-12
primary flange and the secondary flange each extend transversely from the
lower
leg, with the primary flange being located along the lower leg further from
the main
portion than the secondary flange. The secondary flange is longer than the
primary flange.
The insulation panel may further comprise a veneer panel attached to the
front face of the foam insulating layer. The first end edge of the foam
insulating
layer may include a tongue, with the second end edge of the foam insulating
layer
including a groove, and the tongue being shaped to fit within the groove. The
foam
insulating layer may further comprise a recess in the rear face that is shaped
to
accommodate the nailing hem. The second end edge of the foam insulating layer
may include a groove that forms a front ridge and a rear ridge in the second
end
edge. The first end edge of the foam insulating layer may be planar from the
front
face to the rear face.
The front face of the foam insulating layer may be angled with respect to the
rear face. Alternatively, a thickness of the second end edge of the foam
insulating
layer may be greater than a thickness of the first end edge of the foam
insulating
layer. Sometimes, a thickness of the foam insulating layer between the front
face
and the rear face is generally constant from the first end edge to the second
end
edge.
Also disclosed in various embodiments is an attachment member
comprising a main portion, a nailing hem, and at least one lower leg. The main

portion has a forward edge and a rear edge. The nailing hem extends
transversely
from the rear edge of the main portion in an upper direction, and has a base
and
an apex. The base includes an arched portion extending in a forward direction.
The at least one lower leg has an upper end and a lower end, and extends
transversely from the main portion in a lower direction. The upper end of the
lower
leg is connected to the main portion.
The apex of the nailing hem of the attachment member may be rounded
and include an end strip.
The attachment member can further comprise a forward wall and a lip, the
forward wall extending from the forward edge of the main portion in the upper
16

CA 02798666 2012-12-12
direction, wherein the forward wall has a first end and a second end, the
second
end of the forward wall is connected to the main portion, and the lip extends
transversely from the first end of the forward wall in the forward direction
away
from the nailing hem.
In some embodiments, the attachment member has a plurality of lower legs
extending transversely from the main portion in the lower direction. The
plurality of
lower legs may have the same length. Alternatively, the plurality of lower
legs may
have more than one length. The plurality of lower legs can be arranged so that
for
each pair of adjacent lower legs, the lower leg closer to the forward edge of
the
main portion is shorter than the other lower leg. In other variations, the
plurality of
lower legs are arranged so that the lower leg closest to the forward edge of
the
main portion and the lower leg closest to the rear edge of the main portion
are
longer than the other lower legs. In still other variations, the plurality of
lower legs
are arranged so that for each pair of adjacent lower legs, the lower leg
closer to
the center of the main portion is longer than the other lower leg.
A lower leg can have a flange extending transversely from itself. In
embodiments having more than one lower leg, any number of lower legs may have
a flange. The flanges may be the same or different shapes. In some
embodiments, the flange has a stop surface and an angled surface extending
away from the main portion. In other embodiments, a primary flange and a
secondary flange can each extend transversely from the at least one lower leg,

wherein the primary flange is located along the at least one lower leg further
from
the main portion than the secondary flange, and wherein the secondary flange
is
longer than the primary flange.
In some embodiments, the attachment member may further comprise a side
leg extending transversely from the nailing hem in a backward direction. A
flange
can extend transversely from the side leg.
Also disclosed in embodiments, is an insulation panel comprising a foam
insulating layer and an attachment member. The foam insulating layer comprises
a front face, a rear face, a first end edge, and a second end edge that define
a
body of the foam insulating layer. The attachment member comprises a main
17

CA 02798666 2012-12-12
portion, a nailing hem, and at least one lower leg. The main portion has a
forward
edge and a rear edge. The nailing hem extends transversely from the rear edge
of
the main portion in an upper direction. The nailing hem has a base and an
apex,
and the base includes an arched potion extending in a forward direction. At
least
one lower leg extends transversely from the main portion in a lower direction
at a
point between the forward edge and the rear edge. The at least one lower leg
of
the attachment member extends into the body of the foam insulating layer along

the first end edge, the attachment member and the first end edge cooperating
to
be complementary in shape with the second end edge such that adjacent panels
can engage each other.
The front face of the foam insulating layer may have a contour formed from
a central lateral ridge, a central depressed region extending downwards from
the
central lateral ridge, an outwardly extending angled region connected to the
central
depressed region, and a planar region connected to the outwardly extending
angled region.
The insulation panel may further comprise a veneer panel attached to the
front face of the foam insulating layer. The veneer panel has a first end edge
at
the same end of the insulation panel as the first end edge of the foam
insulating
layer and a second end edge.
The first end edge of the foam insulating layer may further comprise an
upper wall extending from the first end edge along the rear face in the upper
direction. The upper wall may have an upper edge extending to at least the
apex of
the nailing hem, a front face, and a rear face. The second end edge of the
foam
insulating layer can include a recess in the rear face that is shaped to
accommodate the nailing hem and the upper wall. The first end edge of the foam
insulating layer may be planar from the front face to the rear face.
These and other non-limiting characteristics of the disclosure are more
particularly disclosed below.
18

CA 02798666 2012-12-12
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.
FIG. 1 is a side view of a first exemplary embodiment of an attachment
member according to the present disclosure.
FIG. 2 is a side view of a second exemplary embodiment of an attachment
member according to the present disclosure.
FIG. 3 is a side view of a third exemplary embodiment of an attachment
member according to the present disclosure.
FIG. 4 is a side view of a fourth exemplary embodiment of an attachment
member according to the present disclosure, having a spur.
FIG. 5 is a perspective view of the attachment member of FIG. 2.
FIG. 6 is an exploded view of a first exemplary embodiment of an insulation
panel according to the present disclosure.
FIG. 7 is a side view of the insulation panel of FIG. 6 in an assembled form.
FIG. 8 is a side view showing two insulation panels of FIG. 6 stacked upon
each other.
FIG. 9 is an exploded view of a second exemplary embodiment of an
insulation panel according to the present disclosure.
FIG. 10 is a side view of the insulation panel of FIG. 9 in an assembled
form.
FIG. 11 is a side view showing two insulation panels of FIG. 10 stacked
upon each other.
FIG. 12 is an exploded view of a third exemplary embodiment of an
insulation panel according to the present disclosure.
FIG. 13 is a side view of the insulation panel of FIG. 12 in an assembled
form.
FIG. 14 is a side view showing two insulation panels of FIG. 13 stacked
upon each other.
19

CA 02798666 2012-12-12
FIG. 15 is an exploded view of a fourth exemplary embodiment of an
insulation panel according to the present disclosure.
FIG. 16 is a side view of the insulation panel of FIG. 15 in an assembled
form.
FIG. 17 is a side view showing two insulation panels of FIG. 16 stacked
upon each other.
FIG. 18 is an exploded view of a fifth exemplary embodiment of an
insulation panel according to the present disclosure.
FIG. 19 is a side view showing two insulation panels of FIG. 18 stacked
upon each other.
FIG. 20 is an exploded view of a sixth exemplary embodiment of an
insulation panel according to the present disclosure.
FIG. 21 is a side view of the insulation panel of FIG. 20.
FIG. 22 is a side view showing two insulation panels of FIG. 20 stacked
upon each other.
FIG. 23 is a side view of a fifth exemplary embodiment of an attachment
member.
FIG. 24 is a perspective view of the attachment member of FIG. 23.
FIG. 25 is a side view of a variation on the attachment member of FIG. 23.
FIG. 26 is a side view of a sixth exemplary embodiment of an attachment
member, having an arched portion instead of a spur.
Fig 27 is a side view of a seventh exemplary embodiment of an attachment
member, having a different arched portion.
FIG. 28 is an exploded view of a seventh exemplary embodiment of an
insulation panel according to the present disclosure.
FIG. 29 is a side view of the of the insulation panel of FIG. 28.
FIG. 30 is side view showing two insulation panels of FIG. 28 stacked upon
each other.
FIG. 31 is an exploded view of a eighth exemplary embodiment of an
insulation panel according to the present disclosure. Here, the foam
insulating
layer includes an upper wall behind the attachment member.

CA 02798666 2012-12-12
FIG. 32 is a side view of the of the insulation panel of FIG. 31.
FIG. 33 is side view showing two insulation panels of FIG. 31 stacked upon
each other.
FIG. 34 is a side view of an eighth exemplary embodiment of an attachment
member, having two lower legs of equal length.
FIG. 35 is a side view of a ninth exemplary embodiment of an attachment
member, having two lower legs of equal length with flanges.
FIG. 36 is a side view of a tenth exemplary embodiment of an attachment
member, having three lower legs of equal length.
FIG. 37 is a side view of an eleventh exemplary embodiment of an
attachment member, having three lower legs that get longer from the front to
the
rear.
FIG. 38 is a side view of a twelfth exemplary embodiment of an attachment
member, having three lower legs that get longer from the front to the rear and
triangular flanges.
FIG. 39 is a side view of a thirteenth exemplary embodiment of an
attachment member, having four lower legs, with the two outermost legs being
longer than the two central legs.
FIG. 40 is a side view of a fourteenth exemplary embodiment of an
attachment member, having five lower legs that get longer closer to the center
of
the member. Flanges are present on some of the legs.
FIG. 41 is a side view of a fifteenth exemplary embodiment of an
attachment member, having four lower legs and a side leg extending from the
nailing hem.
FIG. 42 is a side view of a sixteenth exemplary embodiment of an
attachment member, having three lower legs and a side leg extending from the
nailing hem, and the side leg having a flange.
DETAILED DESCRIPTION
A more complete understanding of the components, processes and
apparatuses disclosed herein can be obtained by reference to the accompanying
21

CA 02798666 2012-12-12
=
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.
The modifier "about" used in connection with a quantity is inclusive of the
stated value and has the meaning dictated by the context (for example, it
includes
at least the degree of error associated with the measurement of the particular
quantity). When used in the context of a range, the modifier "about" should
also be
considered as disclosing the range defined by the absolute values of the two
endpoints. For example, the range "from about 2 to about 4" also discloses the

range "from 2 to 4."
The term "between" is used in some places to describe a range of locations
with respect to two endpoints. This term should be construed to also include
the
two endpoints. For example, a member that is described as being located
"between a first end and a second end" should be construed to possibly be
located
at the first end and the second end as well.
The modifiers "substantially" and "generally" when used herein in
connection with an angle permits no more than 2 degrees of variance in either
direction.
The present disclosure relates to various embodiments of attachment
members which can be used to attach insulation to the wall of a building. The
attachment member can be part of an insulation panel (also referred to as a
composite siding panel). The insulation panel includes the attachment member
and a foam insulation layer in which the attachment member is embedded. The
22

CA 02798666 2012-12-12
insulation panel can also include a veneer panel or siding panel which is
attached
to the front of the foam insulation layer.
Referring to the exemplary embodiment of FIG. 1, an attachment member
100 generally has three parts. A connection portion or main portion 110 of the
attachment member has a forward edge 112 and a rear edge 114. A hem portion
or nailing hem 120 extends transversely from the rear edge 114 of the main
portion
in an upper direction (indicated by arrow 102). The hem portion / nailing hem
includes openings or receptacles (not visible) through which fasteners (e.g.
nails,
staples, etc.) are inserted. A male connecting member or lower leg 130 extends
transversely from the main portion 110 in a lower direction (indicated by
arrow
104). The upper direction 102 is opposite the lower direction 104. Described
in
another way, the connection portion 110 joins the male connecting member 130
and the hem portion 120 together. The male connecting member / lower leg 130
has an upper or first end 132, and a lower or second end 134. The first end
132 of
the lower leg is connected to the connection portion / main portion 110.
In particular embodiments, the nailing hem 120 and the lower leg 130
extend substantially perpendicularly from the main portion 110. Put another
way,
the hem portion / nailing hem 120 and the male connecting member / lower leg
130 are substantially parallel to each other.
In the exemplary embodiment shown in FIG. 1, the lower leg 130 is
connected to the main portion 110 along the forward edge 112. The attachment
member also includes a forward wall 140, which has a first end 142 and a
second
end 144. The second end 144 of the forward wall connects to the main portion
110 along the forward edge 112. The first end 142 can also be referred to as
the
upper edge of the first wall. The forward wall 140 extends in the upper
direction
102 from the main portion 110. As shown here, the lower leg 130, the forward
wall
140, and the nailing hem 120 may be substantially parallel to each other. Put
another way, the lower leg 130, the forward wall 140, and the nailing hem 120
extend substantially perpendicularly from the main portion 110. Also, the
height
125 of the nailing hem is greater than the height 145 of the forward wall.
23

CA 02798666 2012-12-12
=
FIG. 2 is a second exemplary embodiment of an attachment member.
Here, the lower leg 130 connects to the main portion 110 in a central location
116,
rather than along the forward edge 112 as in FIG. 1. Put another way, the
lower
leg 130 connects to the main portion 110 at a point between the forward edge
112
and the rear edge 114. In specific embodiments, the lower leg connects 130 to
the
main portion 110 at the midpoint 118 of the main portion. No forward wall is
present here.
FIG. 3 is a third exemplary embodiment of an attachment member. Here,
the nailing hem 120 has a base 122 that connects to the main portion 110, and
an
apex 124 at the opposite end. The base 122 is thicker than the apex 124. The
top
of the base has an angle 8 which is shown here as being 135 , and may
generally
be from about 120 to about 160 . This embodiment includes a forward wall 140.

An optional lip 150 may extend transversely from the first end or upper edge
142 of
the forward wall. In addition, an anchor portion or flange 160 extends
transversely
from the male connecting member / lower leg 130. As shown here, the flange 160
extends from the second end 134 of the lower leg. Generally the flange 160 can

extend away from the lower leg anywhere between the first end 132 and the
second end 134 of the lower leg, though usually closer to the second end than
the
first end. In embodiments, the anchor portion / flange 160 is substantially
parallel
to the connection portion / main portion 110. Here, the flange 160 extends for
an
equal distance forward and backward of the lower leg 130. However, it is
contemplated that the flange 160 may extend in only one direction from the
lower
leg 130, or that the flange can extend for different distances in the two
directions
from the lower leg.
FIG. 4 is a fourth exemplary embodiment of an attachment member. Here,
the attachment member 100 includes the forward wall 140, lip 150, and flange
160
previously discussed in the other exemplary embodiments. Two spurs 170 extend
from the base of the nailing hem. The spurs extend transversely in the lower
direction 104 and in the forward direction 106. It should be noted that the
apex
124 of the nailing hem here is rounded off in comparison to the embodiments of
FIGS. 1-3.
24

CA 02798666 2012-12-12
Referring back to FIG. 3, the main portion 110 of the attachment member
may have a thickness 115 of from about 1.0 inches to about 2.0 inches. The
nailing hem 120 of the attachment member may have a total height 125 of from
about 1.0 inches to about 4.5 inches. The base 122 of the nailing hem may have
a
height 123 of from about 0.5 inches to about 2.0 inches. Generally, the bottom
half
of the nailing hem should be considered the base. The remainder of the nailing

hem may be considered the apex 124. The forward wall 140 of the attachment
member may have a height 145 of from about 0.25 inches to about 3 inches,
including from about 0.25 inches to about 1 inch. Again, it should be
mentioned
that when a forward wall is present, the height 145 of the forward wall is
less than
the height 125 of the nailing hem. The lip 150 of the attachment member may
have a width 155 of from about 0.01 inches to about 0.1 inches. The lower leg
130
of the attachment member may have a height 135 of from about 0.5 inches to
about 2.0 inches. The flange 160 of the attachment member may have a width
165 of from about 0.25 inches to about 1.5 inches. It should be noted that the
flange 160 is shorter than the main portion 110 of the attachment member, i.e.

width 165 is less than thickness 115.
FIG. 5 is a perspective view of the attachment member of FIG. 2, and
illustrates additional aspects of the attachment member which apply to all
embodiments described herein. Here, the openings / receptacles 126 in the
nailing hem 120 are visible. In addition, one or more apertures 136 may be
present in the lower leg 130 of the attachment member as well. As explained
further herein, the lower leg can be embedded in a foam insulating layer
during
formation of the foam layer, and these apertures can further anchor the
attachment
member into the foam layer when foam passes through the apertures and
solidifies. Such apertures in the lower leg are not necessary, and may be
absent.
The upper surface 117 of the main portion is flat. The attachment member may
have any desired length 105, although it is contemplated that the length will
be
from about 3 feet to about 6 feet, including about 4 feet.
The attachment members of the present disclosure are useful in forming
insulation panels or composite siding panels. The attachment members can be

CA 02798666 2012-12-12
inserted into a foam insulating layer, or can be embedded into the foam
insulating
layer during the manufacture of the foam insulating layer. It is contemplated
that
this combination of attachment member and foam insulating layer can be sold as

an intermediate product to a producer. A veneer panel or siding panel can also
be
attached to the insulation panel / composite siding panel.
FIG. 6 is an exploded view of a first exemplary embodiment of an insulation
panel or composite siding panel. FIG. 7 shows the insulation panel in an
assembled form. FIG. 8 shows two insulation panels stacked upon each other to
illustrate how their various parts interact.
The insulation panel 600 includes an attachment member 610, a foam
insulating layer 630, and a veneer panel 650. The attachment member 610 shown
here is the same as that of FIG. 1. A fastening means, illustrated here as a
nail
602, extends through the nailing hem 612 to attach the insulation panel to,
for
example, an exterior wall of a building.
The foam insulating layer 630 includes a front face 632 which is spaced
apart from a rear face 634. A first end edge 636 and a second end edge 638
join
the front face 632 and the rear face 634 at opposite ends of the foam
insulating
layer. (It should be noted that the first end edge and the second end edges
are
also surfaces, but are referred to as edges from this side view.) The front
face
632, rear face 634, first end edge 636, and second end edge 638 define a body
640 of the foam insulating layer. The front face 632 is angled with respect to
the
rear face 634. Put another way, the thickness 637 at the first end edge 636 is
less
than the thickness 639 at the second end edge 638.
When the attachment member 610 is inserted into the foam insulating layer,
the foam insulating layer 630 may be considered to have a female connecting
member 642 extending into the body 640 along the first end edge 636, into
which
the male connecting member / lower leg 614 extends. Alternatively, the male
connecting member / lower leg 614 may simply be described as extending into
the
body 640 along the first end edge 636. The nailing hem 612 of the attachment
member is substantially aligned with the rear face 634 of the foam insulating
layer.
Described another way, in this embodiment, the main portion 618 of the
26

CA 02798666 2012-12-12
attachment member does not extend to the front face 632 of the foam insulating

layer.
The veneer panel 650 has a front face 652, a rear face 654, a first end edge
656, and a second end edge 658. The veneer panel 650 is attached to the front
face 632 of the foam insulating layer by its rear face 654. The veneer panel
shown
in FIG. 6 also has a first wall 660 that extends transversely rearward from
the first
end edge 656. This first wall 660 is located at the height of the upper edge
617 of
the forward wall 616 of the attachment member, or is placed to cover the upper

surface 645 of the tongue 644 of the foam insulating layer 630. The veneer
panel
650 also has a second wall 662 that extends transversely rearward from the
second end edge 658. In this embodiment, the first wall 660 and second wall
662
of the veneer panel are substantially parallel to each other.
Generally speaking, the attachment member 610 and the first end edge 636
cooperate to be complementary in shape with the second end edge 638 of the
foam insulating layer. This allows adjacent panels to engage each other. In
this
exemplary embodiment, a tongue, protrusion, or first joining element 644
extends
from the first end edge 636 of the foam insulating layer along the front face
632.
Similarly, a groove, rabbet, or second joining element 646 extends into the
second
end edge 638. The tongue 644 is shaped to fit within the groove 646. The
groove
646 is sized to receive the tongue 644 of the foam insulating layer, the
forward wall
616 of the attachment member, and the first wall 660 of the veneer panel. A
recess 648 is present in the rear face 634 of the foam insulating layer along
the
second end edge 638 and is shaped to accommodate the nailing hem 612 of the
attachment member. As a result, as seen in FIG. 8, adjacent panels can engage
each other.
FIG. 9 is an exploded view of a second exemplary embodiment of an
insulation panel or composite siding panel. FIG. 10 shows the insulation panel
in
an assembled form. FIG. 11 shows two insulation panels stacked upon each other

to illustrate how their various parts interact.
The insulation panel 900 includes an attachment member 910, a foam
insulating layer 930, and a veneer panel 950. The attachment member 910 shown
27

CA 02798666 2012-12-12
here is the same as that of FIG. 2. A fastening means, illustrated here as a
nail
902, extends through the nailing hem 912 to attach the insulation panel to,
for
example, an exterior wall of a building.
Again, the foam insulating layer 930 includes a front face 932 which is
spaced apart from a rear face 934. A first end edge 936 and a second end edge
938 join the front face 932 and the rear face 934 at opposite ends of the foam

insulating layer. The front face 932, rear face 934, first end edge 936, and
second
end edge 938 define a body 940 of the foam insulating layer. The front face
932 is
angled with respect to the rear face 934. Put another way, the thickness 937
at
the first end edge 936 is less than the thickness 939 at the second end edge
938.
Also, compared to the embodiment of FIG. 6, the first end edge 936 is flat
(i.e.
planar) from the front face 932 to the rear face 934. No joining element
extends
from the first end edge. The attachment member 910 entirely covers the first
end
edge 936 of the foam insulating layer.
The foam insulating layer 930 may be considered to have a channel or
female connecting member 942 extending into the body 940 along the first end
edge 936, into which the male connecting member / lower leg 914 extends.
Alternatively, the male connecting member / lower leg 914 may simply be
described as extending into the body 940 along the first end edge 936. The
nailing
hem 912 of the attachment member is substantially aligned with the rear face
934
of the foam insulating layer.
The veneer panel 950 has a front face 952, a rear face 954, a first end edge
956, and a second end edge 958. The veneer panel 950 is attached to the front
face 932 of the foam insulating layer by its rear face 954. Here, the first
end edge
956 of the veneer panel is adjacent the first end edge 936 of the foam
insulating
layer. A first wall 960 of the veneer panel extends transversely upward from
the
first end edge 956 of the veneer panel beyond the first end edge 936 of the
foam
insulating layer. However, the upper edge 961 of the first wall 960 of the
veneer
panel is below the apex 913 of the nailing hem 912. Compared to the embodiment
of FIGS. 6-8, the first wall 960 could be considered a rough equivalent of the
forward wall 516 of the attachment member. In specific embodiments, the first
wall
28

CA 02798666 2012-12-12
960 of the veneer panel is substantially parallel to the nailing hem 912 of
the
attachment member, or in other words is substantially perpendicular to the
main
portion 918 of the attachment member.
The second end edge 958 of the veneer panel extends beyond the second
end edge 938 of the foam insulating layer. The veneer panel 950 also has a
second wall 962 that extends transversely rearward from the second end edge
958. A rear segment 949 extends from the second end edge 938 of the foam
insulating layer along the rear face 934.
Again, the attachment member 910 and the first end edge 936 cooperate to
be complementary in shape with the second end edge 938 of the foam insulating
layer, so that adjacent panels can engage each other. As seen in FIG. 10, the
rear
segment 949 is complementary to a channel 970 formed by the first wall 960 of
the
veneer panel and the attachment member 910. The second wall 962 has a width
964 such that a pocket 972 is formed between the rear segment 949 of the foam
insulating layer, the second end edge 938 of the foam insulating layer, and
the
second wall 962 of the veneer panel. The first wall 960 of the veneer panel
fits
between the second wall 962 and the rear segment 949. A recess 948 is present
in the rear face 934 of the foam insulating layer along the second end edge
938
and is sized to accommodate the nailing hem 912 of the attachment member. As
a result, as seen in FIG. 11, adjacent panels can engage each other.
FIG. 12 is an exploded view of a third exemplary embodiment of an
insulation panel or composite siding panel. FIG. 13 shows the insulation panel
in
an assembled form. FIG. 14 shows two insulation panels stacked upon each other

to illustrate how their various parts interact.
The insulation panel 1200 includes an attachment member 1210, a foam
insulating layer 1230, and a veneer panel 1250. The attachment member 1210
shown here is similar to the one depicted in FIG. 3, and does not have the
lip.
Rather, the attachment member is made up of the main portion 1218, nailing hem

1212, lower leg 1214, forward wall 1216, and the flange 1220 extending
transversely from the lower end of lower leg 1214. The base 1223 of the
nailing
hem 1212 is thicker than the apex 1221 of the nailing hem. A fastening means
is
29

CA 02798666 2012-12-12
illustrated here as a nail 1202 extending through the nailing hem 1212. The
flange
is useful in improving wind load performance of the overall panel, as well as
increasing pull-out resistance (i.e. separation of the attachment member from
the
foam insulating layer).
Again, the foam insulating layer 1230 includes a front face 1232 which is
spaced apart from a rear face 1234. A first end edge 1236 and a second end
edge
1238 join the front face 1232 and the rear face 1234 at opposite ends of the
foam
insulating layer. The front face 1232, rear face 1234, first end edge 1236,
and
second end edge 1238 define a body 1240 of the foam insulating layer. The
front
face 1232 is angled with respect to the rear face 1234. Put another way, the
thickness 1237 at the first end edge 1236 is less than the thickness 1239 at
the
second end edge 1238. Here, like the embodiment of FIG. 9, the first end edge
1236 is planar (i.e. flat) from the front face 1232 to the rear face 1234. No
joining
element extends from the first end edge. The attachment member 1210 entirely
covers the first end edge 1236 of the foam insulating layer. A groove 1242 is
located in the second end edge 1238 of the foam insulating layer. The groove
divides the body along the second end edge 1238 into a front ridge 1244 and a
rear ridge 1246.
In this embodiment, the male connecting member / lower leg 1214 and the
flange 1220 are embedded in the body 1240 along the first end edge 1236. The
nailing hem 1212 of the attachment member is substantially aligned with the
rear
face 1234 of the foam insulating layer.
The veneer panel 1250 has a front face 1252, a rear face 1254, a first end
edge 1256, and a second end edge 1258. The veneer panel 1250 is attached to
the front face 1232 of the foam insulating layer by its rear face 1254. The
first end
edge 1256 of the veneer panel is adjacent the first end edge 1236 of the foam
insulating layer. As depicted here, the main portion 1218 of the attachment
member extends beyond the front face 1232 of the foam insulating layer, such
that
the first end edge 1256 of the veneer panel also abuts the lower surface 1224
of
the main portion 1218.

CA 02798666 2012-12-12
However, it is also possible that a first wall of the veneer panel could
extend
transversely upward from the first end edge 1256 of the veneer panel beyond
the
first end edge 1236 of the foam insulating layer, similar to the veneer panel
depicted in FIG. 9. That first wall would be adjacent to the forward wall 1216
of the
attachment member and the upper edge of that first wall would end below the
apex
1221 of the nailing hem 1212. It is also possible that the attachment member
would include a lip, with the lip capping the first wall extending from the
veneer
panel.
Returning to FIG. 12, the veneer panel includes a channel 1280 that
extends transversely rearward from the second end edge 1258 of the veneer
panel. The channel 1280 is made from a lower wall 1282 and a rear wall 1284
that
extends upwards from the end of the lower wall. The front ridge 1244 on the
second end edge of the foam insulating panel enters the channel 1280. The rear

wall 1284 enters the groove 1242.
Again, the attachment member 1210 and the first end edge 1236 cooperate
to be complementary in shape with the second end edge 1238 of the foam
insulating layer, so that adjacent panels can engage each other. As seen in
FIG.
14, the rear ridge 1246 fits into the attachment member 1210. The groove 1242
on
the second end edge of the foam insulating layer is complementary to the
forward
wall 1216 of the attachment member, so that the forward wall 1216 enters the
groove 1242. A recess 1248 is present in the rear face 1234 of the foam
insulating
layer along the second end edge 1238 and is sized to accommodate the nailing
hem 1212 of the attachment member. As a result, adjacent panels can engage
each other.
FIG. 15 is an exploded view of a fourth exemplary embodiment of an
insulation panel or composite siding panel. FIG. 16 shows the insulation panel
in
an assembled form. FIG. 17 shows two insulation panels stacked upon each other

to illustrate how their various parts interact.
The insulation panel 1500 includes an attachment member 1510, a foam
insulating layer 1530, and a veneer panel 1550. The attachment member 1510
shown here is similar to the one depicted in FIG. 3, again without the lip.
The
31

CA 02798666 2012-12-12
attachment member is made up of the main portion 1518, nailing hem 1512, lower

leg 1514, forward wall 1516, and the flange 1520 extending transversely from
the
lower end of lower leg 1514. The base 1523 of the nailing hem 1512 is thicker
than the apex 1521 of the nailing hem. A fastening means is illustrated here
as a
nail 1502 extending through the nailing hem 1512.
Again, the foam insulating layer 1530 includes a front face 1532 which is
spaced apart from a rear face 1534. A first end edge 1536 and a second end
edge
1538 join the front face 1532 and the rear face 1534 at opposite ends of the
foam
insulating layer. The front face 1532, rear face 1534, first end edge 1536,
and
second end edge 1538 define a body 1540 of the foam insulating layer.
Here, like the embodiments of FIG. 9 and FIG. 12, the first end edge 1536 is
planar (i.e. flat) from the front face 1532 to the rear face 1534. No joining
element
extends from the first end edge. The attachment member 1510 entirely covers
the
first end edge 1536 of the foam insulating layer. However, unlike those two
embodiments, here, the front face 1532 is substantially parallel to the rear
face
1534. Put another way, the thickness 1537 of the foam insulating layer between

the front face 1532 and the rear face 1534 is generally constant from the
first end
edge 1536 to the second end edge 1538. The exceptions to this statement relate

to the presence of a groove 1542 in the front face 1532 of the foam insulating
layer
along the second end edge, and the presence of a recess 1548 in the rear face
of
the foam insulating layer along the second end edge. The groove 1542 could
also
be considered a front recess, in comparison to the recess 1548 in the rear
face.
The first end edge 1536 is substantially perpendicular to the front face 1532
and
the rear face 1534.
Again, the male connecting member / lower leg 1514 and the flange 1520
are embedded in the body 1540 along the first end edge 1536. The nailing hem
1512 of the attachment member is substantially aligned with the rear face 1534
of
the foam insulating layer. The forward wall 1516 of the attachment member is
substantially parallel to the front face 1532 of the foam insulating layer.
The veneer panel 1550 has a front face 1552, a rear face 1554, a first end
edge 1556, and a second end edge 1558. The veneer panel 1550 is attached to
32

CA 02798666 2012-12-12
the front face 1532 of the foam insulating layer by its rear face 1554. The
first end
edge 1556 of the veneer panel is adjacent the first end edge 1536 of the foam
insulating layer. As depicted here, the main portion 1518 of the attachment
member extends beyond the front face 1532 of the foam insulating layer, such
that
the first end edge 1556 of the veneer panel also abuts the lower surface 1524
of
the main portion 1518. The second end edge 1558 of the veneer panel abuts the
top of the groove 1542 in the front face.
Generally speaking, the veneer panel 1550 here is flat. Described another
way, the front face 1552 is substantially parallel to the rear face 1554. Put
in other
words, the thickness 1553 of the foam insulating layer between the front face
1552
and the rear face 1554 is generally constant from the first end edge 1556 to
the
second end edge 1558.
Again, it is also possible that a first wall of the veneer panel could extend
transversely upward from the first end edge 1556 of the veneer panel beyond
the
first end edge 1536 of the foam insulating layer, similar to the veneer panel
depicted in FIG. 9. That first wall would be adjacent to the forward wall 1516
of the
attachment member and the upper edge of that first wall would end below the
apex
1521 of the nailing hem 1512. It is also possible that the attachment member
would include a lip, with the lip capping the first wall extending from the
veneer
panel.
Again, the attachment member 1510 and the first end edge 1536 cooperate
to be complementary in shape with the second end edge 1538 of the foam
insulating layer, so that adjacent panels can engage each other. As seen in
FIG.
17, the second end edge 1538 of the foam insulating layer fits into the
attachment
member 1510. The forward wall 1516 of the attachment member enters the
groove 1542 in the front face of the foam insulating layer. The recess 1548 in
the
rear face 1534 of the foam insulating layer is sized to accommodate the
nailing
hem 1512 of the attachment member. As a result, adjacent panels can engage
each other.
33

CA 02798666 2012-12-12
FIG. 18 is view of an assembled fifth exemplary embodiment of an
insulation panel or composite siding panel. FIG. 19 shows two insulation
panels
stacked upon each other to illustrate how their various parts interact.
This fourth embodiment of an insulation panel 1800 is very similar to the
-- embodiment shown in FIG. 15. One large difference is that this insulation
panel is
formed only from an attachment member 1810 and a foam insulating layer 1830.
No veneer panel is present. The attachment member 1810 shown here is the one
depicted in FIG. 4. The attachment member is made up of the main portion 1818,

nailing hem 1812, lower leg 1814, forward wall 1816, the flange 1820 extending
-- transversely from the lower end of lower leg 1814, and the lip 1826
extending
transversely from the upper end of the forward wall 1816. The base 1823 of the

nailing hem 1812 includes spurs 1828. A fastening means is illustrated here as
a
nail 1802 extending through the nailing hem 1812.
Again, the foam insulating layer 1830 includes a front face 1832 which is
-- spaced apart from a rear face 1834. A first end edge 1836 and a second end
edge
1838 join the front face 1832 and the rear face 1834 at opposite ends of the
foam
insulating layer. The front face 1832, rear face 1834, first end edge 1836,
and
second end edge 1838 define a body 1840 of the foam insulating layer.
The first end edge 1836 is planar (i.e. flat) from the front face 1832 to the
-- rear face 1834. No joining element extends from the first end edge. The
attachment member 1810 entirely covers the first end edge 1836 of the foam
insulating layer. The front face 1832 is substantially parallel to the rear
face 1834.
Put another way, the thickness of the foam insulating layer between the front
face
1832 and the rear face 1834 is generally constant from the first end edge 1836
to
the second end edge 1838. The exceptions to this statement relate to the
presence of a groove 1842 in the front face 1832 of the foam insulating layer
along
the second end edge, and the presence of a recess 1848 in the rear face of the

foam insulating layer along the second end edge. The groove 1842 could also be

considered a front recess, in comparison to the recess 1848 in the rear face.
The
-- first end edge 1836 is substantially perpendicular to the front face 1832
and the
rear face 1834.
34

CA 02798666 2012-12-12
Again, the male connecting member / lower leg 1814 and the flange 1820
are embedded in the body 1840 along the first end edge 1836. The nailing hem
1812 of the attachment member is substantially aligned with the rear face 1834
of
the foam insulating layer. The forward wall 1816 of the attachment member is
substantially parallel to the front face 1832 of the foam insulating layer.
The attachment member 1810 and the first end edge 1836 cooperate to be
complementary in shape with the second end edge 1838 of the foam insulating
layer, so that adjacent panels can engage each other. As seen in FIG. 19, the
second end edge 1838 of the foam insulating layer fits into the attachment
member
1810. The forward wall 1816 of the attachment member enters the groove 1842 in
the front face of the foam insulating layer. The recess 1848 in the rear face
1834
of the foam insulating layer is sized to accommodate the nailing hem 1812 of
the
attachment member. As a result, adjacent panels can engage each other. The
spurs 1828 help to prevent separation between the adjacent panels.
FIG. 20 is an exploded side view of a sixth exemplary embodiment of an
insulation panel or composite siding panel. FIG. 21 is a side view of the
insulation
panel. FIG. 22 shows two insulation panels stacked upon each other to
illustrate
how their various parts interact.
The insulation panel 2000 includes an attachment member 2010, a foam
insulating layer 2030, and a veneer panel 2050. The attachment member 2010
shown here is similar to the one depicted in FIG. 4. The attachment member is
made up of the main portion 2018, nailing hem 2012, lower leg 2014, forward
wall
2016, the lip 2026 extending from an upper edge of the forward wall 2016, and
the
flange 2020 extending transversely from the lower end of lower leg 2014. The
base 2023 of the nailing hem 2012 is depicted with only one spur 2028. It
should
be noted that this spur differs from FIG. 4 in that the spur extends
perpendicularly
from the base in a forward direction 2006, and does not extend in the lower
direction, and there is only one spur. However, multiple spurs could be used,
and
if desired the spur could also extend in the lower direction. A fastening
means is
illustrated here as a nail 2002 extending through the nailing hem 2012. The
flange
is useful in improving wind load performance of the overall panel, as well as

CA 02798666 2012-12-12
increasing pull-out resistance (i.e. separation of the attachment member from
the
foam insulating layer).
Again, the foam insulating layer 2030 includes a front face 2032 which is
spaced apart from a rear face 2034. A first end edge 2036 and a second end
edge
2038 join the front face 2032 and the rear face 2034 at opposite ends of the
foam
insulating layer. The front face 2032, rear face 2034, first end edge 2036,
and
second end edge 2038 define a body 2040 of the foam insulating layer. The
front
face 2032 is angled with respect to the rear face 2034. Put another way, the
thickness 2037 at the first end edge 2036 is less than the thickness 2039 at
the
second end edge 2038. The first end edge 2036 is planar (i.e. flat) from the
front
face 2032 to the rear face 2034. No joining element extends from the first end

edge. The attachment member 2010 entirely covers the first end edge 2036 of
the
foam insulating layer. A groove 2042 is located in the second end edge 2038 of

the foam insulating layer. The groove divides the body along the second end
edge
2038 into a front ridge 2044 and a rear ridge 2046.
In this embodiment, the lower leg 2014 and the flange 2020 of the
attachment member are embedded in the body 2040 of the foam insulating layer
along the first end edge 2036. The nailing hem 2012 of the attachment member
is
substantially aligned with the rear face 2034 of the foam insulating layer.
The veneer panel 2050 has a front face 2052, a rear face 2054, a first end
edge 2056, and a second end edge 2058. The veneer panel 2050 is attached to
the front face 2032 of the foam insulating layer by its rear face 2054. The
first end
edge 2056 of the veneer panel extends transversely upwards beyond the first
end
edge 2036 of the foam insulating layer, so that the first end edge 2056 is
adjacent
the upper edge 2017 of the forward wall 2016. The lip 2026 caps the veneer
panel
2050. In this regard, it should be noted that the forward wall 2016 of the
attachment member depicted in FIG. 20 is slightly different from the forward
wall
140 of the attachment member depicted in FIG. 4. In FIG. 4, the forward wall
140
is perpendicular to the main portion 110. Here in FIG. 20, the forward wall
2016 is
angled, so that the forward wall 2016 is parallel to the front face 2032 of
the foam
insulating layer. Thus, the front face 2052 of the veneer panel can be flat.
36

CA 02798666 2012-12-12
The veneer panel 2050 includes a lower wall 2082 that extends transversely
rearward from the second end edge 2058 of the veneer panel. The lower wall
2082 runs adjacent the front ridge 2044 on the second end edge of the foam
insulating layer, and ends at the groove 2042. If desired, the lower wall
could be
part of a channel like that depicted in FIG. 12.
Again, the attachment member 2010 and the first end edge 2036 cooperate
to be complementary in shape with the second end edge 2038 of the foam
insulating layer, so that adjacent panels can engage each other. As seen in
FIG.
22, the rear ridge 2046 fits into the attachment member 2010. The groove 2042
on
the second end edge of the foam insulating layer is complementary to the
forward
wall 2016 of the attachment member, so that the forward wall 2016 and a
portion
of the veneer panel 2050 enter the groove 2042. A recess 2048 is present in
the
rear face 2034 of the foam insulating layer along the second end edge 2038 and
is
sized to accommodate the nailing hem 2012 of the attachment member. As a
result, adjacent panels can engage each other.
More generally, the insulation panel 2000 could be described as being
formed from an attachment member 2010, a foam insulating layer 2030, and a
veneer panel 2050. The foam insulating layer has a front face 2032, a rear
face
2034, a first end edge 2036, and a second end edge 2038 that define a body
2040
of the foam insulating layer. The attachment member 2010 comprises a main
portion 2018 resting upon the first end edge 2036 of the foam insulating
layer, a
forward wall 2016 extending transversely from a forward edge of the main
portion
2018 away from the foam insulating layer 2030, and a lower leg 2014 extending
transversely from the main portion into the body 2040 of the foam insulating
layer.
The veneer panel 2050 is attached to the front face 2032 of the foam
insulating
layer, a first end edge 2056 of the veneer panel being adjacent to an upper
edge
2017 of the forward wall 2016 of the attachment member.
FIG. 23 is a side view of a variation on the attachment member which can
apply to all embodiments described herein, including at least FIGS. 1-4. FIG.
24 is
a perspective view. The attachment member 2300 has a main portion 2310, a
37

CA 02798666 2012-12-12
hem portion or nailing hem 2320, and a lower leg 2330. The main portion 2310
of
the attachment member has a forward edge 2312 and a rear edge 2314.
The hem portion 2320 extends transversely from the rear edge 2314 of the
main portion in an upper direction (indicated by arrow 2302). The nailing hem
2320 has a base 2322 that connects to the main portion 2310, and an apex 2324
at the opposite end. The nailing hem also includes openings or receptacles
2326
(visible in FIG. 24) for fasteners. One spur 2370 extends from the base 2322
of
the nailing hem. Again, these spurs extend only in the forward direction 2306,
or
put another way parallel to the main portion 2310, and do not extend in the
lower
direction 2304. Again, more than one spur may be present. The apex 2324 of the
nailing hem here is rounded off.
The embodiment illustrated in FIG. 23 and FIG. 24 also includes a forward
wall 2340, which has a first end 2342 and a second end 2344. It should be
noted
again that the forward wall is optional (as seen in FIG. 2). The second end
2344 of
the forward wall connects to the main portion 2310 along the forward edge
2312.
The first end 2342 can also be referred to as the upper edge of the first
wall. The
forward wall 2340 extends in the upper direction 2302 from the main portion
2310.
As shown here, the lower leg 2330, the forward wall 2340, and the nailing hem
2320 may be substantially parallel to each other. Put another way, the lower
leg
2330, the forward wall 2340, and the nailing hem 2320 extend substantially
perpendicularly from the main portion 2310. Also, the height 2325 of the
nailing
hem is greater than the height 2345 of the forward wall. An optional lip 2350
may
extend transversely from the first end or upper edge 2342 of the forward wall
in the
forward direction 2306.
The lower leg 2330 extends transversely from the main portion 2310 in a
lower direction (indicated by arrow 2304). The upper direction 2302 is
opposite the
lower direction 2304. Described in another way, the connection portion 2310
joins
the lower leg 2330 and the hem portion 2320 together. The lower leg 2330 has
an
upper or first end 2332, and a lower or second end 2334. The first end 2332 of
the
lower leg is connected to the main portion 2310. Here, the lower leg 2330
connects to the main portion 2310 in a central location 2316. Put another way,
the
38

CA 02798666 2012-12-12
lower leg 2330 connects to the main portion 2310 at a point between the
forward
edge 2312 and the rear edge 2314, such as the midpoint 2318 of the main
portion.
In particular embodiments, the nailing hem 2320 and the lower leg 2330
extend substantially perpendicularly from the main portion 2310. Put another
way,
the hem portion 2320 and the lower leg 2330 are substantially parallel to each

other.
The main variation illustrated here is in the shape of the lower leg 2330 and
the flange(s) 2360 extending from the lower leg. As explained further below,
one
method of joining the attachment member to a foam insulating layer involves
"stabbing" the foam insulating layer with the lower leg of the attachment
member to
fasten the two components together. The flange increases the pull-out
resistance
of the attachment member. However, the shape of the lower leg and the flange
can both increase the ease of insertion and increase the pull-out resistance.
In the variation of FIG. 23 and FIG. 24, one or more flanges 2360 are
present extending transversely from the lower leg 2330. Together, the lower
leg
2330 and the flange(s) 2360 have the shape of an inverted tree. Put another
way,
the lower leg has an arboriform or dendriform shape. The lower leg 2330 can be

thought of here as the "trunk". The flanges 2360 are the "branches" and have a

pointed shape.
Each flange includes a stop surface 2402 and an angled surface 2404. The
stop surface increases the difficulty of pulling the attachment member out of
the
foam insulating layer after insertion. The stop surface 2402 extends
transversely
from the lower leg 2330. The angled surface 2404 is angled with respect to the

stop surface 2402, shown here as angle w. Angle w is acute and generally has a
value of from about 15 to about 75 . The angled surface 2404 angles away from
the main portion 2310 toward the lower end 2334 of the lower leg 2330. The
angled surface eases the insertion of the attachment member into the foam
insulating layer. The stop surface 2402 of each flange is closer to the main
portion
2310 than the angled surface 2404. The stop surface is usually substantially
parallel to the lower surface 2319 of the main portion 2310. However, the stop
39

CA 02798666 2012-12-12
surface can also be angled with respect to the lower surface 2319 of the main
portion as well.
At least one flange is present, but generally any number of flanges may be
present. In FIG. 23, there are three flanges 2360, numbered here as tertiary
flange 2382, secondary flange 2384, and primary flange 2386. The primary
flange
is located at the lower end 2334 of the lower leg 2330. The other flanges are
spaced along the length of the lower leg. Put another way, the primary flange
is
further from the main portion than the other flanges. The lower end 2334
itself is
pointed. Dotted lines are present in FIG. 23 to show the difference between
the
lower leg 2330 and the flanges 2360.
As seen in the embodiment of FIG. 23, the stop surface 2402 has a length
2365. In FIG. 23, the stop surfaces of all three flanges 2382, 2384, 2386 have
the
same length.
FIG. 24 is a perspective view of the attachment member of FIG. 23. The
receptacles 2326 in the nailing hem 2320 are visible. The upper surface 2317
of
the main portion is flat. The stop surfaces 2402 on each flange 2360 are also
flat.
The attachment member may have any desired length 2305.
FIG. 25 depicts a different embodiment in which the stop surfaces of
different flanges have different lengths. In FIG. 25, there are three flanges
numbered here as tertiary flange 2410, secondary flange 2420, and primary
flange
2430. Tertiary flange 2410 has a stop surface 2412 and an angled surface 2414.

The tertiary stop surface 2412 has a tertiary length 2413. Secondary flange
2420
has a stop surface 2422 and an angled surface 2424. The secondary stop surface

2422 has a secondary length 2423. Primary flange 2430 has a stop surface 2432
and an angled surface 2434. The primary stop surface 2432 has a primary length
2433. The lengths 2413, 2423, 2433 of the stop surfaces are measured from the
lower leg 2330 parallel to the lower surface 2319 of the main portion 2310.
Tertiary length 2413 is greater than both secondary length 2423 and
primary length 2433. Secondary length 2423 is less than tertiary length 2413
and
greater than primary length 2433. Primary length 2433 is less than both
tertiary
length 2413 and secondary length 2423. In other words, the tertiary flange is

CA 02798666 2012-12-12
longer than the secondary flange, which is longer than the primary flange.
Generally, a flange which is relatively closer to the main portion 2310 should
have
a stop surface whose length is greater than that of a flange which is
relatively
further from the main portion 2310.
FIG. 26 is a side view of another variation on the attachment member. The
features shown here can be combined with the features illustrated in the other

figures of this disclosure. This view is provided with reference to upper
direction
2602, lower direction 2604, forward direction 2606, and backward direction
2608.
The attachment member 2600 includes the main portion 2610, nailing hem 2620,
and lower leg 2630. The forward wall 2640, lip 2650, and flange 2660 are
optional
features which are also illustrated. The nailing hem 2620 has a base 2622 that

connects to the main portion 2610, and an apex 2624 at the opposite end. The
nailing hem has a height 2625 and the base has a height 2623. The base 2622 of

the nailing hem 2620 includes an arched portion 2670. The arched portion 2670
extends in the forward direction 2606. The arched portion 2670 could also be
described as round, curved, bowed, rotund, semi-circled, or semi-cylindrical
in the
forward direction.
The apex 2624 of the nailing hem 2620 is rounded off. The apex 2624 may
further comprise an end strip 2680 which extends in the lower direction 2604.
The
end strip extends to a height 2627, wherein the height 2627 is less than the
difference between the height of the nailing hem 2625 and the base 2623. In
other
words, the end strip 2680 does not extend to the base 2622 of the nailing hem
2620.
The nailing hem 2620 has a constant thickness 2675 throughout. In other
words, the base 2622, the apex 2624, the arched portion 2670, and the end
strip
2680 are the same thickness 2675.
FIG. 27 is a side view of a variation on the attachment member of FIG. 26.
This variation differs from that depicted in FIG. 26 in that the nailing hem
2620
does not have a constant thickness. Here, the arched portion 2670 is formed by
increasing the thickness 2677 of the nailing hem. The apex 2624, and the end
strip
2680 are the same thickness 2675. However, the thickness 2677 is greater than
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CA 02798666 2012-12-12
the thickness 2655. The rear surface of the nailing hem in FIG. 27 is
straight,
whereas the rear surface of the nailing hem in FIG. 26 curves with the arched
portion.
FIG. 28 is an exploded view of a seventh embodiment of an insulation panel
or composite siding panel. FIG. 29 shows the insulation panel in an assembled
form. FIG. 30 shows two insulation panels stacked upon each other to
illustrate
how their various parts interact.
The insulation panel 2800 includes an attachment member 2810, a foam
insulating layer 2830, and a veneer panel 2850. The attachment member 2810
shown here is the same as that of FIG. 26, and includes the main portion 2818,

nailing hem 2812, lower leg 2814, forward wall 2816, lip 2819, and the flange
2820
extending transversely from the lower end of lower leg 2814. The flange is
useful
in improving wind load performance of the overall panel, as well as increasing
pull-
out resistance (i.e. separation of the attachment member from the foam
insulating
layer).
Again, the foam insulating layer 2830 includes a front face 2832 which is
spaced apart from a rear face 2834. A first end edge 2836 and a second end
edge
2838 join the front face 2832 and the rear face 2834 at opposite ends of the
foam
insulating layer. (It should be noted that the first end edge and the second
end
edges are also surfaces, but are referred to as edges from this side view.)
The
front face 2832, rear face 2834, first end edge 2836, and second end edge 2838

define a body 2840 of the foam insulating layer.
As depicted in FIG. 28, the front face 2832 of the foam insulating layer 2830
has a contour formed by a central lateral ridge 2833, a central depressed
region
2831 extending downward from the central lateral 2833. The central depressed
region 2831 is contiguously connected to an outwardly extending angled region
2835. The outwardly extending region 2835 is contiguously joined to a planar
region 2841. Together the central lateral ridge 2833, the central depressed
region
2831, the angled region 2835 and the planar region 2841 form a contour 2837.
It
is contemplated that the foam insulating layer can be contoured as desired or
required.
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CA 02798666 2012-12-12
The attachment member 2810 entirely covers the first end edge 2836 of the
foam insulating layer. A groove 2842 is located in the second end edge 2838 of

the foam insulating layer. The groove divides the body along the second end
edge
2838 into a front ridge 2844 and a rear ridge 2846
In this embodiment, the male connecting member / lower leg 2814 and the
flange 2820 are embedded in the body 2840 along the first end edge 2836. The
nailing hem 2812 of the attachment member is substantially aligned with the
rear
face 2834 of the foam insulating layer.
The veneer panel 2850 has a front face 2852, a rear face 2854, a first end
edge 2856, and a second end edge 2858. The veneer panel 2850 is attached to
the front face 2832 of the foam insulating layer by its rear face 2854. The
first end
edge 2856 of the veneer panel 2850 extends beyond the first end edge 2836 of
the
foam insulating layer 2830. In embodiments the first end edge 2856 of the
veneer
panel 2850 extends onto the forward wall of the attachment member, but not to
the
upper end edge of the forward wall of the attachment member.
The veneer panel 2850 is shaped to complement the front face of the foam
insulating layer. This includes the central depressed region 2831, the central

lateral 2833, the outwardly extending angled region 2835, and the planar
region
2841.
The veneer panel 2850 includes a channel 2880 that extends transversely
rearward from the second end edge 2858 of the veneer panel. The channel 2880
is made from a lower wall 2882 and a rear wall 2784 that extends upwards from
the end of the lower wall. The front ridge 2844 on the second end edge of the
foam insulating panel enters the channel 2880. The rear wall 2884 enters the
groove 2842.
The attachment member 2810 and the first end edge 2836 cooperate to be
complementary in shape with the second end edge 2838 of the foam insulating
layer, so that adjacent panels can engage each other. As seen in FIG. 30, the
rear
ridge 2846 fits into the attachment member 2810. The groove 2842 on the second
end edge of the foam insulating layer is complementary to the forward wall
2816
and lip 2819 of the attachment member, so that the forward wall 2816, lip
2819,
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CA 02798666 2012-12-12
and the rear wall 2884 enters the groove 2842. A recess 2848 of width 2849 is
present in the rear face 2834 of the foam insulating layer along the second
end
edge 2838 and is sized to accommodate the nailing hem 2812 of the attachment
member. As a result, adjacent panels can engage each other.
FIG. 31 is an exploded view of an eighth embodiment of an insulation panel
or composite siding panel. FIG. 32 shows the insulation panel in an assembled
form. FIG. 33 shows two insulation panels stacked upon each other to
illustrate
how their various parts interact.
This foam insulating layer is similar to that in FIG. 28. Here, the foam
insulation layer 2830 also has an upper wall 2890 extending from the first end
edge 2836 along the rear face 2834 in the upper direction. The upper wall has
an
upper edge 2892. In embodiments, the upper edge 2892 extends to at least the
apex 2624 of the nailing hem 2812 (see FIG. 32). Here, the width 2849 of the
recess 2848 is sized to accommodate both the nailing hem 2812 and the upper
wall 2890. It should be noted that in this variation, the attachment member
does
not cover the first end edge 2836 from the front face 2832 to the rear face
2834.
FIGS. 34-42 illustrate several different embodiments and variations of the
attaching member. These attachment members vary in the number of lower legs,
and the arrangement and lengths of the lower legs. The attachment members can
also vary on the presence of flanges on the lower legs, their shape, and their
arrangement. Some of the attachment members have a side leg attached
transversely to nailing hem in the backward direction. Again, the features
disclosed in these embodiments can be combined with the features described
elsewhere herein, such as the structure of the nailing hem and the presence of
apertures in the lower leg(s).
FIG 34 is an eighth embodiment of an attachment member. The attachment
member 3400 includes the main portion 3410, nailing hem 3420, and lower legs
3430 and 3432. The main portion has a forward edge 3412 and a rear edge 3414.
The forward wall 3440 and lip 3450 are optional features, but are illustrated.
This
embodiment includes two lower legs 3430 and 3432 connected to the main portion
3410. Here, the lower legs are the same length (3431, 3433 respectively).
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CA 02798666 2012-12-12
The variation illustrated in FIG 35 differs from that of FIG. 34 by including
flanges 3460 and 3462 on the lower legs 3430 and 3432 respectively.
The embodiment shown in FIG. 36 includes three lower legs 3430, 3432,
and 3434. Here, the lower legs are the same length (3431, 3433, 3435
respectively). There are spaces 3411, 3413 between the lower legs. The lower
legs can be evenly or unevenly spaced along the main portion 3410.
In FIG. 37, the lower legs 3430, 3432, and 3434 are of different lengths
(3431, 3433, 3435 respectively). The lengths increase from the forward edge to
the
rear edge of the main portion 3410. In other words, length 3431 is shorter
than
length 3433, which is shorter than length 3435. Put another way, for each pair
of
lower legs, the lower leg closer to the forward edge of the main portion is
shorter
than the other lower leg (compare pairs 3430/3432 and 3432/3434). The lower
legs can be evenly or unevenly spaced along the main portion 3410.
In FIG 38, the nailing hem is illustrated with an arched portion as in FIG.
26.
Compared to FIG. 37, the three lower legs 3430, 3432, and 3434 are also of
different lengths, which increase from the forward edge to the rear edge of
the
main portion 3410. Each leg also includes triangular flanges as described in
FIGS.
23-25. Here, lower leg 3430 has one flange 3460, lower leg 3432 has two
flanges
3461 and 3462, and lower leg 3434 has three flanges 3463, 3464, and 3465. The
number of flanges on each leg may vary, and their spacing along the length of
the
lower leg may vary as well.
The embodiment of FIG. 39 has two differences compared to the prior
embodiments. First, four lower legs 3430, 3432, 3434, and 3436 are present.
The
legs may differ in length (3431, 3433, 3435, 3437 respectively). As seen here,
the
legs are arranged so that lower legs 3430 and 3436 are longer than legs 3432
and
3434. Put another way, the lower legs are arranged so that the lower leg
closest
to the forward edge 3412 and the lower leg closest to the rear edge 3414. Legs

3430 and 3436 may be considered as end legs, while legs 3432 and 3434 are
considered as central legs. The end legs may be of the same length in such
variations. The central legs may also be of the same length.

CA 02798666 2012-12-12
The embodiment of FIG 40 has five lower legs 3430, 3432, 3434, 3436 and
3438. The legs may differ in length (3431, 3433, 3435, 3437, 3439
respectively).
Here, the lower legs are arranged so that for each pair of adjacent lower
legs, the
lower leg closest to the center of the main portion is longer than the other
lower
leg. The center lower leg 3436 is the longest of the five legs illustrated.
Also
illustrated here is that the lower legs may vary in the presence of, and the
shape
of, any flange. Here, the lower legs, 3430, 3434, and 3438, have flanges
(3460,
3462, and 3464 respectively). Lower legs 3432 and 3436 do not have flanges.
Flange 3462 is a triangular flange similar to that seen in FIGS. 23-25, while
flanges
3460 and 3464 are rectangular. Generally, the attachment member may have
from 2 to 7 lower legs, which can vary in length and in spacing along the main

portion.
FIG. 41 is another embodiment of the attachment member.
This
embodiment includes four lower legs 3430, 3432, 3434, 3436, all of which are
the
same length. This attachment member also includes a side leg 3470 extending
transversely from the nailing hem 3420 in the backward direction.
The embodiment of FIG. 42 has three legs of different lengths as in FIG. 37.
This embodiment also includes a flange 3490 attached transversely to the side
leg
3470 extending from the rear surface 3422 of the nailing hem.
Referring to FIG. 18 though applying to all embodiments, the foam
insulating layer generally has a thickness of from about 1.0 inches to about
4.0
inches, with the thickness varying if the foam insulating layer is contoured.
This
thickness may be measured along the first end edge (reference numeral 1837) or

along the second end edge (reference numeral 1839). The foam insulating layer
may have a height 1805 of from about 8 inches to about 48 inches, as desired.
In
some embodiments, the height 1805 is from about 12 inches to about 24 inches.
The attachment member is typically made from a polymeric material known
in the art. The attachment member is typically made by injection processes
where
the polymeric material is melted and injected into a die mold. The polymeric
46

CA 02798666 2012-12-12
The veneer panel and the attachment member can be attached to the
insulating layer in a variety of ways including, but not limited to, adhesive,
chemical
bonding, interlocking complementary surfaces, and/or fasteners.
Typically,
however, adhesives are used. The adhesive may be used over the entire surface
of the veneer panel or the 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.
At least three ways of attaching the attachment member to the foam
insulating layer are contemplated. First, the foam insulating layer is made
with the
first end edge containing a channel, and the lower leg of the attachment
member is
slid into the channel from the side. Second, the foam insulating layer is made

without a channel in the first end edge, and the attachment member may be
pressed or stabbed into the foam insulating layer and adhered in place. Third,
the
attachment member may be embedded in the foam insulating layer during the
shape molding process, as described further below. The attachment member may
be located to allow the insulation panel to be fastened to the wall without
creating
penetrations in the veneer panel or the foam insulating layer.
The foam insulating layer may be shape molded. Such molding operations
will generally impart the desired contours and/or design to the foam
insulating
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 calls that form a
characteristic tough smooth skin. The shape molded process produces a panel
that is essentially straight and/or free of camber. It is contemplated that
the
attachment member can be placed in the die mold prior to the expansion of the
polymeric precursor material. This embeds the attachment member into the foam
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CA 02798666 2012-12-12
insulating layer as the polymeric material is expanded, such that no secondary

fasteners are needed.
The foam insulating layer provides structural integrity to the insulated
siding
panel. For example, the foam insulating layer is the platform to which the
veneer
panel and the attachment member are connected. The foam insulating layer may
be shaped to provide the desired profile for the overall insulated siding
panel. For
example, the shape of the foam insulating layer may be obtained by either
suitable
shaping of the die mold, or by computer numerical control (CNC) cutting. The
grooves and/or female attachment members may also be milled or wire-cut.
The foam insulating 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 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 insulating layer can include extruded polystyrene (XPS), expanded
polystyrene (EPS), polyurethane, polyisocyanurate, polyethylene,
polypropylene,
or combinations thereof. In some embodiments, the foam insulating layer is
made
from a rigid foam material.
The foam insulating 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 panel covers the foam insulating layer). In
particular embodiments, the foam insulating 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
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CA 02798666 2012-12-12
has a lower foam density than at least one of the top region and the bottom
region,
and possibly both the top and bottom 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 panel; and allow moisture to migrate away

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 panel is optional and is not present in all embodiments, but is
generally desired. The veneer panel provides environmental resistance and
durability. It is contemplated that the veneer panel is generally contoured to

conform to the contours of the foam insulating layer. Generally, siding must
be
thick to resist sagging and retain the desired shape. However, the foam
insulating
layer allows the veneer panel to be thinner than otherwise necessary. The
veneer
panel only has to provide weatherability to the composite siding panel.
Whereas
traditional vinyl veneer sidings have a minimum material thickness of 0.040
inches,
the veneer panels used in this disclosure may have a thickness of from 0.020
to
0.036 inches.
The veneer panel can be formed from any suitable polymeric, metallic,
cementitious, or composite material.
Exemplary materials include vinyl,
polypropylene, fiber-cement material, polyolefins, polyvinyls, polycarbonates,

polyacetals, polysulfones, polyesters, polyamides, multilayer films,
polyethylene
including high density polyethylene (HDPE) and low density polyethylene
(LDPE),
polypropylene, CPVC ABS, ethyl-vinyl acetate, various extruded ionomeric
films,
polyethylene-based films, wood, or combinations thereof. Other siding
materials
suitable for the veneer panel include wood, aluminum, and steel.
If desired, the rear face of the foam insulating 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.
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CA 02798666 2012-12-12
The insulation 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 insulating 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 insulating layer and veneer panels themselves are not
perforated either. Nails, screws, or staples can be used with equal ease and
can
be more accurately placed and more secure because they are applied directly to

the exterior wall instead of through a flexible insulating layer.
Other benefits of the insulation 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
multiple veneer panels to provide desired assemblies. The veneer panel can be
reduced in thickness, thereby reducing waste.
The present disclosure has been described with reference to
exemplary embodiments. Obviously, modifications and alterations will occur to
others upon reading and understanding the preceding detailed description. It
is
intended that the present disclosure be construed as including all such
modifications and alterations insofar as they come within the scope of the
appended claims or the equivalents thereof.
30

Representative Drawing