Siding panel assembly

• US 10,557,272 B1
• Filed: 02/22/2019
• Issued: 02/11/2020
• Est. Priority Date: 12/21/2018
• Status: Active Grant

• Current Assignee: Associated Materials LLC (Associated Materials Group, Inc.)
• Original Assignee: Associated Materials LLC (Associated Materials Group, Inc.)
• Inventors: Moses, Jr., Charles Bryan, Ziemer, Michael Danny, Brown, Randall Jay, Thompson, Nicholas Daniel, Green, Daniel H.
• Primary Examiner(s): Kwiecinski, Ryan D
• Application Number:
  US16/283,580
• Time in Patent Office: 354 Days
• CPC Class Codes: B32B 15/082 comprising vinyl resins; comprising acrylic resins
• CPC Class Codes: B32B 15/12 of paper or cardboard
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 19/04 next to another layer of the same or of a different material next to a glass layer B32B17/067
• CPC Class Codes: B32B 19/041 of metal
• CPC Class Codes: B32B 19/045 of synthetic resin
• CPC Class Codes: B32B 19/047 of foam
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2266/0214 Materials belonging to B32B27/00
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/0235 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2266/025 Polyolefin
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2266/04 Inorganic
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2266/08 : Closed cell foam
• CPC Class Codes: B32B 2307/102 : Insulating
• CPC Class Codes: B32B 2307/30 : having particular thermal properties
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/5825 : Tear resistant
• CPC Class Codes: B32B 2307/712 : Weather resistant
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/734 : Dimensional stability
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• CPC Class Codes: B32B 3/263 : characterised by a layer having non-uniform thickness
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04F 13/073 : for particular building parts, e.g. corners or columns
• CPC Class Codes: E04F 13/075 : for insulation or surface protection, e.g. against noise or impact not used; for insulation, e.g. against noise E04B1/00
• CPC Class Codes: E04F 13/077 : composed of several layers, e.g. sandwich panels E04F13/075 takes precedencenot used, see E04F13/0866
• CPC Class Codes: E04F 13/0837 : extending completely through the covering elements
• CPC Class Codes: E04F 13/0864 : composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
• CPC Class Codes: E04F 13/0866 : composed of several layers, e.g. sandwich panels or layered panels layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence
• CPC Class Codes: E04F 13/0876 : the covering layer comprising mutual alignment or interlocking means
• CPC Class Codes: E04F 13/0889 : characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
• CPC Class Codes: E04F 13/0894 : with tongue and groove connections
• CPC Class Codes: E04F 13/18 : of organic plastics with or without reinforcements or filling materials of plastic-bound fibres or chips E04F13/16 or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles E04F13/0864 takes precedence

Abstract

A siding panel assembly includes a thermoplastic siding panel and a foam backing panel that is adhered to the thermoplastic siding panel. The siding panel assembly has a coefficient or linear thermal expansion of no more than about 2.04×10⁻⁵ (in/in/deg F.) and a planar (e.g., flat) outward facing surface.

Claims

1. A thermoplastic siding panel assembly, comprising:

a siding panel defined by a single continuous sheet and made of thermoplastic material, the siding panel having a flat course surface that extends along a width of five to twelve inches, the siding panel comprising

a weatherable capstock layer, and

a substrate layer comprising a thermoplastic resin composition reinforced with a high aspect ratio filler such that the siding panel has a coefficient of linear thermal expansion of between 8.95×

10⁶ in/in/deg F. and approximately 2.33×

10<sup>−

5</sup> in/in/deg F. when tested in accordance with ASTM D696-16 procedure;

a backing panel attached to the siding panel, the backing panel defined by a foam material and having a front facing surface with a shape that substantially corresponds with a shape of a rear facing surface of the siding panel; and

an adhesive disposed between the siding panel and the backing panel and configured to adhere the backing panel to the siding panel, the adhesive configured to maintain adhesion between the backing layer and the siding panel and maintain the flat course surface of the siding panel when installed on a wall surface and exposed to a temperature of approximately 180 degrees Fahrenheit.

2. The siding panel assembly of claim 1, wherein a side edge of the backing panel aligns with a side edge of the siding panel and so that an opposite side edge of the siding panel extends past an opposite side edge of the backing panel to define an overhang portion of the siding panel and a notch having a width of between about ½

inches and about 1¼

inches, and wherein during installation of the siding panel assembly adjacent a second siding panel assembly, the backing panel of the second siding panel assembly extends into the notch and the overhang portion of the siding panel assembly overlaps with the siding panel of the second siding panel assembly.

3. The siding panel assembly of claim 1, wherein the thermoplastic resin composition comprises a fire retardant chemical in an amount of 0.5% to 5% of the composition, the siding panel assembly having a Class A fire rating when tested per ASTM E-84 procedure.

4. The siding panel assembly of claim 3, wherein the fire retardant chemical is Zinc HydroxyStannate.

5. The siding panel assembly of claim 4, wherein the fire retardant chemical is Ammonium OctaMolybdate.

6. The siding panel assembly of claim 3, wherein the fire retardant chemical is a Molybdate containing composition including Zinc Molybdate on Talc.

7. The siding panel assembly of claim 1, wherein the substrate layer further comprises an impact modifier in an amount of 5% to 15% of the composition and having a mean failure energy of between 35 in-lbf and 73 in-lbf.

8. The siding panel assembly of claim 7, wherein the impact modifier is Chlorinated Polyethylene.

9. The siding panel assembly of claim 8, wherein Chlorinated Polyethylene is used in an amount of approximately 12% of the composition.

10. The siding panel assembly of claim 7, wherein the impact modifier is Butyl acrylate rubber core with a methyl methacrylate shell.

11. The siding panel assembly of claim 10, wherein Butyl acrylate rubber core with a methyl methacrylate shell is used in an amount of approximately 10% of the composition.

12. The siding panel assembly of claim 7, wherein the impact modifier is Methyl methacrylate Butadiene Styrene terpolymer.

13. The siding panel assembly of claim 7, wherein the siding panel has a mean failure energy of between about 51 in-lbf and 73 in-lbf.

14. The siding panel assembly of claim 1, wherein the siding panel further comprises a substantially planar nail hem at a proximal end of the siding panel, the nail hem having a lower end spaced behind the substantially planar course surface and generally aligned with a rear surface of the backing panel, the nail hem extending past an upper end of the substantially planar course surface.

15. The siding panel assembly of claim 14, wherein the substantially planar nail hem comprises a reinforcement strip.

16. The siding panel assembly of claim 15, wherein the reinforcement strip is embedded in the substantially planar nail hem.

17. The siding panel assembly of claim 14, wherein the siding panel further comprises

a lock portion defined in a proximal portion of the siding panel between the substantially planar course surface and the substantially planar nail hem and comprising a tongue portion having a bulbous end, and

a buttlock portion defined in a distal portion of the siding panel and comprising a channel configured to resiliently receive the tongue portion of the lock of an adjacent siding panel assembly.

18. The siding panel assembly of claim 1, wherein the assembled siding panel, adhesive layer and backing panel have a maximum combined thickness of between ½

inches and ¾

inches.

19. The siding panel assembly of claim 1, wherein the single continuous sheet has a substantially uniform thickness.

20. The siding panel assembly of claim 1, wherein the thermoplastic material comprises a thermoplastic resin reinforced with a high aspect ratio filler.

21. The siding panel assembly of claim 20, wherein the thermoplastic resin is Polyvinyl chloride.

22. The siding panel assembly of claim 20, wherein the high aspect ratio filler comprises fiberglass in an amount of between 5% and 20% of the composition.

23. The siding panel assembly of claim 20, wherein the high aspect ratio filler comprises Wollastonite in an amount between 10% and 80% of the composition.

24. The siding panel assembly of claim 1, wherein the foam material is chosen from the group consisting of polyvinyl chloride (PVC) foam, expanded polystyrene (EPS) foam, graphite poly styrene (GPS) foam, extruded polystyrene (XPS) foam, polyurethane foam, and polypropylene foam.

25. The siding panel assembly of claim 24, wherein the foam material has a density between 0.75 lb/ft³ and 2.10 lb/ft³.

26. The siding panel assembly of claim 1, wherein the adhesive is a crosslinked polyurethane (PUR) adhesive.

27. A thermoplastic siding panel assembly, comprising:

a siding panel defined by a single continuous sheet and made of thermoplastic material, the siding panel having a flat course surface that extends along a width of five to twelve inches, the siding panel comprising

a weatherable capstock layer, and

a substrate layer comprising a polyvinyl chloride resin composition reinforced with a high aspect ratio filler such that the siding panel has a coefficient of linear thermal expansion of between 8.95×

10<sup>−

6</sup> in/in/deg F. approximately 2.33×

10<sup>−

5</sup> in/in/deg F. when tested in accordance with ASTM D696-16 procedure;

a backing panel attached to the siding panel, the backing panel defined by a foam material and having a front facing surface with a shape that substantially corresponds with a shape of a rear facing surface of the siding panel; and

an adhesive disposed between the siding panel and the backing panel and configured to adhere the backing panel to the siding panel, the adhesive configured to maintain adhesion between the backing layer and the siding panel and maintain the flat course surface of the siding panel when installed on a wall surface and exposed to a temperature ranging of approximately 180 degrees Fahrenheit.

28. The siding panel assembly of claim 27, wherein a side edge of the backing panel aligns with a side edge of the siding panel and so that an opposite side edge of the siding panel extends past an opposite side edge of the backing panel to define an overhang portion of the siding panel and a notch having a width of between about ½

inches and about 1¼

inches, and wherein during installation of the siding panel assembly adjacent a second siding panel assembly, the backing panel of the second siding panel assembly extends into the notch and the overhang portion of the siding panel assembly overlaps with the siding panel of the second siding panel assembly.

29. The siding panel assembly of claim 27, wherein the thermoplastic resin composition comprises a fire retardant chemical in an amount of 0.5% to 5% of the composition, the siding panel assembly having a Class A fire rating when tested per ASTM E-84 procedure.

30. The siding panel assembly of claim 27, wherein the substrate layer further comprises an impact modifier in an amount of 5% to 15% of the composition and having a mean failure energy of between 35 in-lbf and 73 in-lbf.