Process for manufacturing insulated siding

• US 20070212970A1
• Filed: 12/30/2006
• Published: 09/13/2007
• Est. Priority Date: 07/11/2005
• Status: Abandoned Application

• Current Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Vermilion, Donn, Rockwell, Anthony, Graham, W., Chakrabarty, Kaushik
• Application Number:
  US11/648,073
• Publication Number:
  US 20070212970A1
• Time in Patent Office: Days
• US Class Current: 442/394
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2310/028 using vibration, e.g. sonic or ultrasonic
• CPC Class Codes: D04H 1/4218 Glass fibres
• CPC Class Codes: D04H 1/43835 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/48 in combination with at least one other method of consolidation
• CPC Class Codes: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 1/60 the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
• CPC Class Codes: D21H 13/14 Polyalkenes, e.g. polystyrene polyethylene
• CPC Class Codes: D21H 13/24 Polyesters
• CPC Class Codes: D21H 13/40 vitreous, e.g. mineral wool, glass fibres
• CPC Class Codes: D21H 21/18 Reinforcing agents
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 442/608 Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/615 Strand or fiber material is blended with another chemically different microfiber in the same layer
• CPC Class Codes: Y10T 442/631 Glass strand or fiber material
• CPC Class Codes: Y10T 442/674 Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/677 Fluorinated olefin polymer or copolymer sheet or film [e.g., TeflonR, etc.]
• CPC Class Codes: Y10T 442/697 Containing at least two chemically different strand or fiber materials

Abstract

A siding panel assembly includes an ornamental facing and a first insulation layer made from fibrous insulating material. That fibrous insulating material is selected from glass fibers, polymer fibers, natural fibers and mixtures thereof having a compressive strength of between about 14 to about 220 pounds of force and a wet and dry recovery of at least 98%. A method for making the siding panel assembly includes the steps of molding a first surface of a sheet of fibrous insulating material to match in profile a concavity in an ornamental facing and engaging the molded sheet of fibrous insulating material in that concavity.

Claims

1. A siding panel assembly, comprising:

an ornamental facing; and

a first insulation layer made from fibrous insulating material.

2. The assembly of claim 1, wherein said fibrous insulating material is selected from a group of materials consisting of glass fibers, polymer fibers, natural fibers and mixtures thereof providing a compressive strength of between about 14 and about 220 pounds of force and a wet and dry recovery of at least 98%.

3. The assembly of claim 1, wherein said fibrous insulating material is selected from a group of materials consisting of glass fibers, polyolefin fibers, polyester fibers, polypropylene fibers, polyethylene fibers, polyethylene terephthalate fibers, polybutylene terephthalate fibers cotton fibers, hemp fibers, jute fibers, kenaf fibers, rayon fibers, nylon fibers, acrylic fibers, copolyester fibers and mixtures thereof.

4. The assembly of claim 2, wherein said first insulation layer is a nonwoven mat or veil.

5. The assembly of claim 4, wherein said fibers in said mat or veil are continuous and have a diameter of between about 2.0 and about 60.0 microns.

6. The assembly of claim 4, wherein said fibers in said mat or veil are chopped to a length of between about 0.635 to about 7.62 cm and have a diameter of between about 2.0 and about 60.0 microns.

7. The assembly of claim 1, wherein said first insulation layer comprises by weight percent between about 10 to about 70% glass fibers and about 90 to about 30% polymer binder fibers.

8. The assembly of claim 7, wherein said glass fibers have a length of between about 0.635 to about 7.62 cm and a diameter of between about 2.0 to about 25.0 microns and said polymer binder fibers have a length of between about 1.20 to about 7.62 cm and a diameter of between about 8.0 to about 60.0 microns.

9. The assembly of claim 1, wherein said first insulation layer comprises 100% polyester fibers having a length of between about 1.20 to about 7.62 cm and a diameter of between about 8.0 to about 60.0 microns.

10. The assembly of claim 1, wherein said first insulation layer has a density of between about 0.7 Lbs/cubic foot and about 3 Lbs/cubic foot.

11. The assembly of claim 10, wherein said first insulation layer comprises 100% polyester fibers having a length of between about 1.20 to about 7.62 cm and a diameter of between about 8.0 to about 60.0 microns.

12. The assembly of claim 11, wherein said first insulation layer is adhered to the ornamental facing using a rigid adhesive.

13. The assembly of claim 1, further including a second insulation layer, said first insulation layer being sandwiched between said ornamental facing and said second insulation layer.

14. The assembly of claim 1 or 13, further including a film backing.

15. The assembly of claim 14, wherein said film backing is breathable.

16. The assembly of claim 13, wherein said film backing is made from a material selected from a group consisting of polypropylene, polyethylene, polyolefin and mixtures thereof.

18. The assembly of claim 14, said second insulation layer is constructed from a material selected from a group consisting of glass fibers, polymer fibers, natural fibers, EVA, foam and mixtures thereof.

19. The assembly of claim 1, wherein said ornamental facing is constructed from a material selected from a group consisting of fiberglass, vinyl, polyvinyl chloride, aluminum, steel, ABS and mixtures thereof.

20. The assembly of claim 1, wherein said ornamental facing includes a concavity having a contoured face and said first insulation layer has a first face substantially matching and engaging said contoured face and a second, flat face.

21. The assembly of claim 20, wherein said assembly has a total thickness of about 1.905 cm.

22. The assembly of claim 1, further including a fiberglass rod, strand or roving running along at least one of said ornamental facing and said first insulation layer.

31. The assembly of claim 13, further including a film backing.

32. The assembly of claim 31, wherein said film backing is breathable.

23. A method of making a siding panel assembly, comprising:

molding a first surface of a sheet of fibrous insulating material to match in profile a concavity in a sheet of ornamental facing; and

engaging said molded sheet of fibrous insulating material in said concavity of said sheet of ornamental facing.

24. The method of claim 23, further including a step of cutting a channel in said first surface of said sheet of fibrous material before molding.

25. The method of claim 24, wherein said molding step includes heating and shaping said fibrous insulating material with one of rollers, mechanical forming shoes, belts, a press, and a combination thereof.

26. The method of claim 23, further including feeding said fibrous insulating material from a roll.

27. The method of claim 23, further including fastening said sheet of fibrous insulating material to said sheet of ornamental facing with one of an adhesive, chemical welding, ultrasonic welding, mechanical entrapment, mechanical fasteners, melting, vibration welding, or a combination thereof.

28. A siding panel assembly, comprising:

an ornamental facing;

a fiberglass rod, strand or roving running along said ornamental facing; and

a resin securing said fiberglass rod, strand or roving to said ornamental facing.

29. An insulation backing for a siding panel assembly, comprising:

an insulation layer; and

a reinforcing member running along a portion of said insulation layer;

.

30. An insulation backing according to claim 29, wherein the reinforcing member comprises a fiberglass rod, strand or roving running along said insulation layer;

and a resin securing said fiberglass rod, strand or roving to said insulation layer.