Siding panel assembly

• US 10,590,658 B1
• Filed: 02/22/2019
• Issued: 03/17/2020
• 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): Vo, Hai
• Application Number:
  US16/283,598
• Time in Patent Office: 389 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 vinyl or acrylic copolymers B32B2266/0221, B32B2266/0242
• 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 thermoplastic composite sheet for exterior cladding applications includes an outer layer with a thermoplastic resin composition reinforced with a high aspect ratio filler such that the outer layer has a coefficient of linear thermal expansion of no more than approximately 2.33×10⁻⁵ in/in/deg F., and a backing layer bonded to the outer layer, the backing layer defined by a foam material. The outer layer and the backing later define a body having a substantially planar outer surface.

Claims

1. A thermoplastic composite sheet for exterior cladding applications, comprising:

an outer layer comprising a thermoplastic resin composition reinforced with a filler having an aspect ratio of at least 5 to 1 such that the outer layer has a coefficient of linear thermal expansion of no more than approximately 2.33×

10<sup>−

5</sup> in/in/deg F., wherein the filler is fiberglass in an amount of between 5% and 20% of the composition;

a preformed backing panel bonded to the outer layer, the backing panel being substantially rigid and defined by a foam material; and

a thermoset adhesive disposed between the outer layer and the backing panel to bond the backing panel to the outer layer,

wherein the outer layer and the backing panel define a flat body having a flat outer surface, and wherein the thermoset adhesive maintains adhesion between the backing panel and the outer layer and the body maintains the flat outer surface when exposed to a temperature of between 180 degrees and 210 degrees Fahrenheit.

2. The composite sheet of claim 1, wherein the filler is randomly distributed in the thermoplastic resin.

3. The composite sheet of claim 1, wherein the thermoplastic resin is Poly(vinyl chloride).

5. The composite sheet 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.

6. The composite sheet of claim 5, wherein the foam material has a density between 0.75 lb/ft³ and 2.10 lb/ft³.

7. The composite sheet of claim 1, wherein the adhesive is a crosslinked polyurethane (PUR) adhesive.

8. The composite sheet of claim 1, wherein the adhesive is configured to maintain adhesion between the backing panel and the outer layer, and the body maintains the substantially planar profile, under outdoor exposure to sunlight.

9. The composite sheet of claim 1, wherein the fiber further comprises Wollastonite in an amount of between 10% and 80% of the composition.

4. The composite sheet of claim wherein filler has an aspect ratio of at least 10 to 1.

10. A thermoplastic composite sheet for exterior cladding applications, comprising:

an outer layer comprising a Poly(vinyl chloride) thermoplastic resin composition reinforced with a filler having an aspect ratio of at least 5 to 1 such that the outer layer has a coefficient of linear thermal expansion of no more than approximately 2.33×

10″

⁵ in/in/deg F., wherein the filler is fiberglass in an amount of between 5% and 20% of the composition;

a preformed backing panel attached to the outer layer, the hacking panel defined by a foam material and being substantially rigid; and

a thermoset adhesive disposed between the outer layer and the backing panel to bond the backing panel to the outer layer,

wherein the outer layer and the backing panel define a flat body having a flat outer surface, and wherein the thermoset adhesive maintains adhesion between the backing panel and the outer layer and the body maintains the flat outer surface when exposed to a temperature of between 180 degrees and 210 degrees Fahrenheit.

11. The composite sheet of claim 10, wherein the filler is randomly distributed in the thermoplastic resin.

12. The composite sheet of claim 10, 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.

13. The composite sheet of claim 12, wherein the foam material has a density between 0.75 lb/ft³ and 1.5 lb/ft³.

14. The composite sheet of claim 10, wherein the adhesive is a crosslinked polyurethane (PUR) adhesive.

15. The composite sheet of claim 10, wherein the adhesive is configured to maintain adhesion between the backing panel and the outer layer, and the body maintains the substantially planar profile, under outdoor exposure to sunlight.

16. The composite sheet of claim 10, wherein the fiber further comprises Wollastonite in an amount of between 10% and 80% of the composition.