Decorative siding panel and method of manufacture

• US 20040211141A1
• Filed: 04/28/2003
• Published: 10/28/2004
• Est. Priority Date: 04/28/2003
• Status: Abandoned Application

• Current Assignee: Howard M. Sandy
• Original Assignee: Howard M. Sandy
• Inventors: Sandy, Howard M.
• Application Number:
  US10/424,969
• Publication Number:
  US 20040211141A1
• Time in Patent Office: Days
• US Class Current: 52/506.01
• 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 13/0871 having an ornamental or specially shaped visible surface E04F13/0867 takes precedence
• CPC Class Codes: E04F 13/0875 having a basic insulating layer and at least one covering layer
• CPC Class Codes: E04F 13/185 with an outer layer imitating natural stone, brick work, tiled surface or the like

Abstract

A decorative siding panel is disclosed. The panel preferably comprises a thermoformed unit which includes upper and lower attachment flanges bordering a central area which is formed with a raised profile to simulate natural stone. The panel preferably includes means for attachment to adjacent panels forming a given horizontal course. The panels are preferably thermoformed to a desired shape, a textured coating in a series of coating stages, a color is applied to the texture and the coatings fixed to the unit.

Claims

1. A wall panel adapted to be fastened to a mounting surface, said panel comprising:

(a) a formed, thermoplastic panel defining a back and a front surface where said front surface is outwardly-curved whereby said outwardly-curved surface is bounded by one or more attachment flanges where each said flange extends to said mounting surface, said curved surface defining a void space between said mounting surface and said outwardly curved surface; and

(b) said front surface of said panel including;

(i) one or more textured layers; and

(ii) one or more pigmented layers, where each of said layers are thermobonded to said panel.

2. The wall panel of claim 1 further including means to attach a given panel to adjacent, horizontally-oriented panels.

3. The wall panel of claim 2 where said panel further defines a first and second end where each said first end includes a male connector which is receivable in a female connector disposed on said second end on an adjacent panel.

4. The wall panel of claim 1, wherein each said mounting flange defines a planar surface which is adapted to contact said mounting surface.

5. The wall panel of claim 1 wherein the thermoplastic panel is made of acrylic.

6. The wall panel of claim 1 further including means to drain any fluid trapped in said void space.

7. The wall panel of claim 6 wherein said drainage means includes one or more apertures formed on a bottom-most portion of said curved surface.

8. The wall panel of claim 1 wherein said textured layers are partially comprised of a mixture including an aggregate, sand, silica, quartz crystals and a binding agent.

9. The wall panel of claim 7 where said aperture includes means to limit access into the void space through said aperture.

10. The wall panel of claim 1 where said attachment flange, when said panel is joined to the other panels in a series of horizontal courses, resembles a motor joint.

11. A siding assembly for an exterior wall surface made up of a plurality of siding units, said units adapted to be affixed to the wall surface with similar units in overlapping horizontal courses with the units of each course lying in overlapping relation to each other, each of said units comprising:

a main body portion including a front face and a rear face, said front face including a substantially convex main portion bounded by one or more linear lip portions; and

said front face defining at one end a male connector where said male connector is adapted to fit into an aperture in an adjoining siding unit, said front face defining at the opposite end a female connector adapted to receive a male connector disposed on an adjoining siding unit;

said lip portion adapted to contact said wall surface such that the convex portion defines a void space between said rear face and said wall surface; and

a textured layer thermobonded to said front face.

12. The siding assembly of claim 11 wherein said front surface defines means to drain the void space.

13. The siding assembly of claim 12 wherein said drainage means comprises one or more apertures disposed in the lower surface of the convex main portion such that any moisture collecting in said void space may pass through said aperture.

14. The siding assembly of claim 11 where said main body portion is comprised of a thermoformable material.

15. The siding assembly of claim 14 where said thermoformable material includes acrylic/pvc.

16. The siding assembly of claim 11 wherein said textured layer includes alternating layers of a texturing agent and a pigment.

17. The siding assembly of claim 11 where said textured layer is formed from a method comprising the steps of:

(a) heating the main body portion;

(b) applying a base coating to the front surface of said main body portion;

(c) drying said base coat about said main-body portion;

(d) applying a primer coat to the front surface of said main body portion;

(e) heat drying said primer coat for a selected time interval;

(f) applying a textured coating; and

(g) heating the main body portion to dry each for a selected time interval.

18. The method of claim 17 further including the steps of:

(a) applying a pigment to the textured coating;

(b) heat drying the coating for a selected time interval; and

(c) applying a sealer to the frontal surface of the main body portion.

19. The method of claim 17 wherein the textured coating is drawn from a group consisting of one or more of an aggregate, sand, silica, and/or quartz crystals and a binder emulsion.

20. The method of claim 17 wherein the main body portion is heated to a temperature of 80°

F.

21. The method of claim 17 where the steps of heat drying occur in a range of 120-170°

F.

22. The method of claim 17 where the pigmentation is applied irregularly over the textured surface.

23. A facing panel structure for a wall comprising a plurality of sheets whose outer surface is contoured for simulating at least one of various construction facing materials, positioned thereon in spaced relation with each other and with mortar line portions simulated between said construction material, each of said sheets having flange portions extending one or more edge portions, said flange portions bounding a substantially convex portion, said convex portion defining at one end a mating protrusion and at the second end a mating aperture adapted to receive the mating portion from an adjacent panel structure, said convex portions defining one or more drainage apertures about their bottom surface, whereby upon mounting said sheets of material on said wall said mating protrusions of one sheet are received in said mating protrusion on adjoining sheets of material, said outer surface of said panel provided with a pigmented, textured coating which is sealed and thermally bonded to said outer surface.

24. The facing panel structure of claim 23 wherein said substantially convex portion of said sheet defines a void area between the facing panel structure and the wall.

25. The facing panel of claim 23 wherein said sheets are formed of a cellular polyethylene.

26. The facing panel of claim 23 wherein the textured coating is applied using the sequential steps of:

(a) applying a base coating to the front surface of said sheet;

(b) drying said base coat about said sheet;

(c) applying a primer coat to the front surface of said sheet;

(d) heat drying said primer coat for a selected time interval;

(e) applying a textured coating;

(f) applying a pigment to the textured coating;

(g) heat drying the coating for a selected time interval;

(h) applying a sealer to the frontal surface of the sheet; and

(i) heating the sheet to dry each for a selected time interval.

27. The method of claim 25 further including the initial step of first heating the sheet.

28. A siding assembly for an exterior wall surface made up of at least a first siding unit and a second siding unit where each of said siding units defines a front and back surface, each of siding units comprising:

a body molded in a described configuration to define a face surface bounded by one or more attachment portions, the front surface of said body including one or more textured layers bonded to said surface;

said body including a first and a second end where said first end includes a raised portion and said second end defines an aperture, where said raised portion is adapted to be received in said aperture formed in said second siding unit to align said horizontal flange portions of the first and second siding unit;

said flange portion defining a substantially coplanar surface adapted to contact said wall surface;

said first surface defining a void area between said back surface and said wall; and

means to allow the drainage of moisture which may collect in said void area.

29. The siding assembly of claim 28 wherein the body is comprised of a thermoplastic.

30. The siding assembly of claim 28 wherein the body is comprised of a moldable material.

31. The siding assembly of claim 28 wherein said flanges are formed horizontally.

33. The method of claim 31 further including the step of applying a fifth sealant coat to said fourth, pigmented coating.

34. The method of claim 31 further including the steps of curing the first and second layers prior to the application of a subsequent layer.

35. The method of claim 31 where said curing step is accomplished by circulating a hot gas across the front surface of said bound member.

36. The method of claim 31 wherein said gas is air.

37. The method of claim 31 where the gas is heated to a temperature in the range of 100-120°

F.

38. The method of claim 31 further including the step of first forming the base member into a profile having a convex face bounded by horizontal flange members.

39. The method of claim 31 where the textured coating comprises a binding agent and one or more compositions drawn from the group of aggregate, sand, silica or quartz crystals.

40. The method of claim 31 wherein the coatings are sprayed, atomized, brushed or trowelled.

41. The method of claim 31 where in the hot gas is applied to the front surface for approximately fifteen minutes.

42. The method of claim 31 further including a step taken prior to the application of the sealing coating wherein the textured frontal surface is immersed in a mixture of water over which has been dispersed a coating of a water-insoluble pigment.

43. The method of claim 41 where the water/pigment mixture is in the range of 100 parts water and 125 parts pigment.

32. A method of manufacturing a siding member which includes a base member having a front and back surface, comprising the steps of:

(a) applying a first base coating to a front surface of the base member;

(b) applying a second, primer coating to said first surface of the base member;

(c) applying a third textured coating to said first surface of said base member;

(d) applying a fourth, pigmented coating to said first surface of said base member;

(e) applying a fifth sealant coat to said fourth, pigmented coating; and

(f) curing said multiple layers.