Straight face vinyl siding

• US 7,204,062 B2
• Filed: 12/29/2000
• Issued: 04/17/2007
• Est. Priority Date: 11/20/2000
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: Crane Plastics Company LLC
• Inventors: Fairbanks, Larry R., DeWorth, Samuel W., Barber, David C.
• Primary Examiner(s): YIP, WINNIE S
• Application Number:
  US09/751,185
• Publication Number:
  US 20060026920A1
• Time in Patent Office: 2,300 Days
• Field of Search: 52518-520, 52535-536, 525/39, 525/43, 523/098, 525/22, 525/45, 525/49, 525/55, 527/941, 527/981, 527/481
• US Class Current: 52/522
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/90 with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
• CPC Class Codes: B29C 48/914 cooling drums
• CPC Class Codes: B29C 48/919 using a bath, e.g. extruding into an open bath to coagulate or cool the material
• 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

The present invention is a vinyl siding panel and a method of making the vinyl siding panel. The vinyl siding panel comprises a planar portion extending the longitudinal length of the vinyl siding panel. The planar portion comprises a first edge and a second edge. The width from the first edge to the second edge is at least about 4.0 inches. The planar portion has a surface variance of less than about 0.05 inches relative to an imaginary straight line connecting the first edge and the second edge, and the radius curvature between the first edge and the second edge is at least about 85 inches.

Claims

1. A vinyl siding panel unit comprising:

a vinyl siding panel comprising a first substantially planar portion extending the longitudinal length of the vinyl siding panel, said first substantially planar portion comprising;

a first edge and a second edge;

a width of at least about 4.0 inches from said first edge to said second edge; and

a slight curvature between said first edge and said second edge such that said slight curvature has a surface variance of less than about 0.05 inches relative to an imaginary straight line connecting said first edge and said second edge; and

a reinforcement panel adjacent to said first substantially planar portion;

wherein said surface variance is determined prior to said first substantially planar portion being positioned adjacent to said reinforcement panel; and

wherein said vinyl siding panel unit simulates the appearance of straight face siding.

2. The vinyl siding panel unit of claim 1 wherein said reinforcement panel is comprised of foam.

3. The vinyl siding panel unit of claim 1 wherein said first substantially planar portion has an average thickness in the range from about 0.040 inches to about 0.050 inches.

4. The vinyl siding panel unit of claim 1 wherein said first substantially planar portion has said width of at least about 6.0 inches from said first edge to said second edge.

5. The vinyl siding panel unit of claim 1 wherein said surface variance is less than about 0.04 inches.

6. The vinyl siding panel unit of claim 1 wherein said surface variance is less than about 0.03125 inches.

7. The vinyl siding panel unit of claim 1 wherein:

said first substantially planar portion has said width of at least about 6.0 inches from said first edge to said second edge; and

said surface variance is less than about 0.04 inches.

8. The vinyl siding panel unit of claim 1 further comprising a second substantially planar portion extending the longitudinal length of the vinyl siding panel, said second substantially planar portion comprising:

a first edge and a second edge;

a width of at least about 4.0 inches from said first edge to said second edge of said second substantially planar portion; and

a slight curvature between said first edge and said second edge such that said slight curvature has a surface variance of less than about 0.05 inches relative to an imaginary straight line connecting said first edge and said second edge of said second substantially planar portion;

wherein said second substantially planar portion is connected to said first substantially planar portion by a first seam to define a stepped contour; and

wherein said reinforcement panel is adjacent to said second substantially planar portion.

9. The vinyl siding panel unit of claim 8 wherein a height of said first seam is at least about 0.5 inches.

10. The vinyl siding panel unit of claim 8 wherein said first substantially planar portion is substantially similar in curvature to said second substantially planar portion.

11. The vinyl siding panel unit of claim 8 further comprising a third substantially planar portion extending the longitudinal length of the vinyl siding panel, said third substantially planar portion comprising:

a first edge and a second edge;

a width of at least about 4.0 inches from said first edge to said second edge of said third substantially planar portion; and

a slight curvature between said first edge and said second edge such that said slight curvature has a surface variance of less than about 0.05 inches relative to an imaginary straight line connecting said first edge and said second edge of said third substantially planar portion;

wherein said third substantially planar portion is connected to said first substantially planar portion by a second seam to define a stepped contour; and

wherein said reinforcement panel is adjacent to said third substantially planar portion.

12. The vinyl siding panel unit of claim 11 wherein a height of said second seam is at least about 0.5 inches.

13. The vinyl siding panel unit of claim 11 wherein said first substantially planar portion, said second substantially planar portion, and said third substantially planar portion are substantially similar in curvature.

14. A vinyl siding panel unit comprising:

a vinyl siding panel comprising a first substantially planar portion extending the longitudinal length of the vinyl siding panel, said first substantially planar portion comprising;

a first edge and a second edge;

a width of at least about 4.0 inches from said first edge to said second edge; and

a radius curvature between said first edge and said second edge of at least about 85 inches; and

a reinforcement panel adjacent to said first substantially planar portion;

wherein said radius curvature is determined prior to said first substantially planar portion being positioned adjacent to said reinforcement panel; and

wherein said vinyl siding panel unit simulates the appearance of straight face siding.

15. The vinyl siding panel of claim 14 wherein said reinforcement panel is comprised of foam.

16. The vinyl siding panel unit of claim 14 wherein said first substantially planar portion has an average thickness in the range from about 0.040 inches to about 0.050 inches.

17. The vinyl siding panel unit of claim 14 wherein said first substantially planar portion has said width of at least about 6.0 inches from said first edge to said second edge.

18. The vinyl siding panel unit of claim 14 wherein said radius curvature is at least about 117 inches.

19. The vinyl siding panel unit of claim 14 wherein said radius curvature is at least about 148 inches.

20. The vinyl siding panel unit of claim 14 wherein:

said first substantially planar portion has said width of at least about 6.0 inches from said first edge to said second edge; and

said radius curvature is at least about 117 inches.

21. The vinyl siding panel unit of claim 14 further comprising a second substantially planar portion extending the longitudinal length of the vinyl siding panel, said second substantially planar portion comprising:

a first edge and a second edge;

a width of at least about 4.0 inches from said first edge to said second edge of said second substantially planar portion; and

a radius curvature between said first edge and said second edge of said second substantially planar portion of at least about 85 inches;

wherein said second substantially planar portion is connected to said first substantially planar portion by a first seam to define a stepped contour; and

wherein said reinforcement panel is adjacent to said second substantially planar portion.

22. The vinyl siding panel unit of claim 21 wherein a height of said first seam is at least about 0.5 inches.

23. The vinyl siding panel unit of claim 21 wherein said first substantially planar portion and said second substantially planar portion are substantially similar in curvature.

24. The vinyl siding panel unit of claim 21 further comprising a third substantially planar portion extending the longitudinal length of the vinyl siding panel, said third substantially planar portion comprising:

a first edge and a second edge;

a width of at least about 4.0 inches from said first edge to said second edge of said third substantially planar portion; and

a radius curvature between said first edge and said second edge of said third substantially planar portion of at least about 85 inches;

wherein said third substantially planar portion is connected to said first substantially planar portion by a second seam to define a stepped contour; and

wherein said reinforcement panel is adjacent to said third substantially planar portion.

25. The vinyl siding panel unit of claim 24 wherein a height of said second seam is at least about 0.5 inches.

26. The vinyl siding panel unit of claim 24 wherein said first substantially planar portion, said second substantially planar portion, and said third substantially planar portion are substantially similar in curvature.