Composite siding using a shape molded foam backing member

• US 20070193177A1
• Filed: 12/29/2006
• Published: 08/23/2007
• Est. Priority Date: 12/30/2005
• Status: Active Grant

• Current Assignee: Progressive Foam Technologies Incorporated
• Original Assignee: Progressive Foam Technologies Incorporated
• Inventors: Wilson, Richard, Culpepper, Patrick
• Granted Patent: US 7,908,814 B2
• Time in Patent Office: Days
• US Class Current: 52/518
• 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

Abstract

A panel for mounting on an exterior wall includes a shaped, molded backing member and a siding member attached to the backing member wherein the shape-molded backing member includes a rear face and an opposing front face. The shape-molded backing member is composed of closed cell expanded polystyrene foam, the front and rear faces having an outer surface composed of a tough smooth skin.

Claims

1. A panel for mounting on a wall comprising:

a shape-molded backing member; and

a siding member attached to the backing member;

wherein the shape-molded backing member includes a rear face and an opposed front face and is composed of closed cell expanded polystyrene foam, the front and rear faces of the shape-molded backing member having an outer surface composed of a tough smooth skin and the shape-molded backing member is camber free and the dimensions of the shape-molded backing member are stable and predictable.

2. The panel member of claim 1, wherein the tough smooth skin is composed of closed, compressed polystyrene cells.

3. The panel member of claim 1, wherein the shape-molded backing member has a thickness between 1/4 inch and 4 inches.

4. The panel member of claim 1, wherein the front face of the backing member has at least one contour defined therein.

5. The panel member of claim 4, wherein the contour is at least one shape-molded ridge extending along at least a portion of the front face of the backing member.

6. The panel member of claim 4, wherein the siding member is composed of a vinyl sheet, the vinyl material sheet in overlying relationship with the front face of the shape-molded backing member.

7. The panel member of claim 4, wherein the vinyl sheet has a thickness less than 0.039 inches.

8. The panel member of claim 4, wherein the vinyl sheet has a thickness between 0.020 and 0.036 inches inclusive.

9. The panel member of claim 8, further comprising an adhesive layer interposed between at least a portion of the front face of the backing member and the siding layer, wherein the adhesive is continuously flexible, non-latex adhesive.

10. The panel member of claim 1, wherein the shape-molded backing member is configured to provide structural integrity and support to a resulting siding panel through dual densities.

11. The panel member of claim 1, wherein the shape-molded backing member further includes at least one side face contiguously positioned between the front and rear faces, the side face composed of closed cell expanded polystyrene foam.

12. The panel member of claim 11, wherein the side face has a tough smooth skin surface.

13. The panel member of claim 1, wherein the backing member has three dimensional features located on at least one of the front face, rear face, top end and bottom end.

14. The panel member of claim 11, further wherein the siding member is composed of a vinyl sheet, the vinyl sheet is contoured in overlying relationship with the front face of the shape-molded backing member, the vinyl sheet projecting outwardly beyond a first side of the backing panel member.

15. The panel member of claim 14, wherein the contour is a linear detent defined in the second side of the backing member and wherein the vinyl sheet extends over the detent to form a channel.

16. The panel member of claim 1, wherein the shape-molded backing member further includes at least one upper face contiguously positioned between the front and rear faces, the upper face composed of closed cell expanded polymeric foam having a tough smooth surface.

17. The panel member of claim 16 wherein the upper face of the shape-molded backing member includes at least one outwardly projecting lip member.

18. The panel member of claim 17, wherein the shape-molded backing member further includes at least one lower face contiguously positioned between the front and rear faces, the lower face composed of closed cell expanded polystyrene foam.

19. The panel member of claim 18, wherein the lower face of the shape-molded member includes at least one detent defined therein, the detent configured to receive a projecting lip of a contiguous panel member.

20. The panel member of claim 1, wherein the shape-molded backing member includes a water management means for directing water down and out of the wall.