Moisture diverting insulated siding panel

• US 7,712,276 B2
• Filed: 03/30/2005
• Issued: 05/11/2010
• Est. Priority Date: 09/30/2004
• Status: Expired due to Fees

• Current Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Jacobs, Gregory F., Beck, David H., Gilbert, Thomas C.
• Primary Examiner(s): Chilcot, Jr.; Richard E
• Assistant Examiner(s): Herring; Brent W
• Application Number:
  US11/093,465
• Publication Number:
  US 20060075712A1
• Time in Patent Office: 1,868 Days
• Field of Search: 525/33, 525/34, 525/29, 525/30, 523/098, 523/021, 523/023, 525/39, 521/695
• US Class Current: 52/529
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/045 of foam
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• 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 2266/08 Closed cell foam
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• 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 13/0864 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 13/0869 having conduits for fluids
• CPC Class Codes: E04F 13/0871 having an ornamental or specially shaped visible surface E04F13/0867 takes precedence
• CPC Class Codes: E04F 13/141 with an outer layer of concrete E04F13/147 takes precedence
• CPC Class Codes: E04F 13/185 : with an outer layer imitating natural stone, brick work, tiled surface or the like
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249976 : Voids specified as closed
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent

Abstract

A siding panel product is provided comprising a first polymeric siding panel having a butt end and a top end, a front surface comprising a plurality of front faces defined between the top and butt ends and separated by at least one shoulder surface to define a stepped contour, and a rear surface. An insulation backing is coupled to the rear surface of the siding panel. The insulation backing comprises at least first and second insulation members coupled to the rear surface of said siding panel. The first insulation member has a bottom edge thereof coupled proximate to the stepped contour and the second insulation member has a top edge thereof coupled proximate to the stepped contour.

Claims

1. A siding panel product comprising:

a first polymeric siding panel comprising a butt end and a top end, a front surface comprising a plurality of front faces defined between said top and butt ends and separated by at least one shoulder surface to define a stepped contour, and a rear surface; and

an insulation backing system coupled to the rear surface of the siding panel, said insulation backing system comprising at least first and second discrete insulation members coupled to the rear surface of said siding panel, said first discrete insulation member disposed above said second discrete insulation member, said first discrete insulation member having a bottom surface thereof seated in part on said shoulder surface and extending laterally to be seated in part on a top surface of said second discrete insulation member, wherein the first and second discrete insulation members have rear surfaces that are coplanar with one another.

2. The siding panel product of claim 1, wherein said first polymeric siding panel comprises a locking means for interlocking said first polymeric siding panel with siding panels disposed above and below said first polymeric siding panel, and a nailing hem positioned proximate to a top end thereof.

3. The siding panel product of claim 2,

wherein said locking means comprises a male portion disposed at the butt end and a female portion disposed below said nailing hem at said top end;

and

wherein said first insulation member has an uppermost top surface thereof substantially planar with an uppermost top surface of said first polymeric siding panel.

4. The siding panel product of claim 3, wherein said second discrete insulation member is sized such that a bottom surface thereof abuts the uppermost top surface of a first discrete insulation member of a second, similar siding panel product interlocked with said male portion of said first polymeric siding panel.

5. The siding panel product of claim 4, wherein a bottom end of said second discrete insulation member comprises a plurality of channels formed therethrough extending between front and rear faces of the second insulation member.

6. The siding panel product of claim 2, wherein said locking means comprises a downwardly depending male portion disposed at said butt end and an upwardly facing female portion disposed proximate to said top end to receive the downwardly depending male portion of a second similar siding panel product.

7. The siding panel product of claim 1, wherein said siding panel comprises moisture diverting means disposed at said top end over a top surface of said first discrete insulation member for directing moisture towards said front surface.

8. The siding panel product of claim 7, wherein said moisture diverting means comprises a return portion extending over a top end of said first discrete insulation member and a leg extending upwardly from said return portion and disposed to lie against an exterior surface of a structure when said siding panel product is installed against said exterior surface, whereby said return portion and leg help divert moisture from above said siding panel product to away from said exterior surface.

9. The siding panel product of claim 1, wherein a bottom end of said second discrete insulation member comprises a plurality of channels formed therethrough extending between front and rear faces of the second discrete insulation member.

10. The siding panel product of claim 1, wherein said insulation members have front major surfaces, the front major surface of each insulation member including a plurality of spacing elements, wherein the front major surfaces of the insulation members are coupled to the rear surface of the siding panel by an adhesive bond.

17. The siding panel product of claim 10, wherein said insulation backing comprises front and rear major surfaces, said front major surface coupled to the rear surface of said siding panel, at least said rear major surface comprising said plurality of spacing elements.

18. The siding panel product of claim 17, wherein said spacing elements comprise channel-forming humps, ribs, grooves, protrusions or a combination thereof forming a plurality of said at least one channel.

11. A siding panel product comprising:

a first siding panel comprising a butt end and a top end, a front surface, and a rear surface, wherein the first siding panel comprises a locking means for interlocking said first polymeric siding panel with siding panels disposed above and below said first polymeric siding panel, and wherein said locking means comprises a male portion disposed at the butt end and a female portion disposed at said top end; and

an insulation backing system comprising a pair of discrete insulation members having front major surfaces coupled to the rear surface of the siding panel, a first one of said pair of discrete insulation members disposed above a second one of said discrete insulation members, said pair of discrete insulation members having rear major surfaces that are coplanar with one another, said pair of discrete insulation members comprising a plurality of spacing elements on at least one of their front and rear major surfaces thereof forming at least one channel,

wherein said at least one channel is oriented to direct moisture from behind said first siding panel toward said butt end,

wherein said first siding panel comprises one or more weep holes or openings formed at the male portion of the locking means of said butt end thereof.

12. The siding panel product of claim 11,

wherein when said siding panel is installed on an exterior surface of a structure, said exterior surface defines a plane having a horizontal and vertical axes, said butt end being parallel to said horizontal axis after installation, said at least one channel being oriented at an angle either oblique to or perpendicular to said horizontal axis.

13. The siding panel product of claim 12, wherein said angle is at or between about 45-90°

to said horizontal axis.

14. The siding panel product of claim 11,

wherein said front surface comprises a plurality of front faces defined between said top and butt ends and separated by at least one shoulder surface to define a stepped contour;

and

wherein said insulation backing comprises front and rear major surfaces, said front major surface coupled to the rear surface of said siding panel, said front major surface shaped to substantially conform to the profile of said siding panel, including corresponding front faces and stepped contour,

wherein at least said front major surface comprises said plurality of spacing elements, said spacing elements formed in at least said corresponding front faces of said front major surface of said insulation backing.

15. The siding panel product of claim 14, wherein said spacing elements comprise channel-forming humps, ribs, grooves, protrusions or a combination thereof.

16. The siding panel product of claim 15, wherein said one or more insulation members are coupled to the rear surface of said siding panel with an adhesive.

19. The siding panel product of claim 11, wherein said insulation backing is at least in part mechanically supported within the profile of the first siding panel.

20. The siding panel product of claim 11, wherein said spacing elements comprise channel-forming humps, ribs, grooves, protrusions or a combination thereof forming a plurality of said at least one channel.

21. The siding panel product of claim 11,

wherein said spacing elements are formed on a front major surface of the one or more insulation members, wherein said spacing elements comprise channel-forming humps, ribs, grooves, protrusions or a combination thereof, and

wherein said insulation backing is coupled to the rear surface of the siding panel by an adhesive.

22. The siding panel product of claim 21, wherein said adhesive is applied in a pattern so as to allow said at least one channel to direct moisture from behind said first siding panel toward said butt end.

23. The siding panel product of claim 11, wherein the first one of the pair discrete insulation members has a bottom surface thereof seated in part on the shoulder surface and extending laterally to be seated in part on a top surface of said second one of the pair of discrete insulation members.

24. A siding panel product comprising:

a first polymeric siding panel comprising a butt end and a top end, a front surface comprising a plurality of front faces defined between said top and butt ends and separated by at least one shoulder surface to define a stepped contour, and a rear surface; and

an insulation backing system coupled at least in part by an adhesive to the rear surface of the siding panel, said insulation backing system comprising at least first and second discrete insulation members coupled to the rear surface of said siding panel, said first discrete insulation member disposed above said second discrete insulation member, said first discrete insulation member having a bottom surface thereof seated in part on said shoulder surface and extending laterally to be seated in part on a top surface of said second discrete insulation member, said discrete insulation members cooperating to form a substantially continuous front major surface in contact with the rear surface of said siding panel for said insulation backing, said discrete insulation members having rear major surfaces coplanar with one another cooperating to form a planar rear major surface for said insulation backing system,

said insulation backing system comprising a plurality of channel-forming spacing elements disposed on at least one of the front major surface, the rear major surface, and a bottom end of said insulation backing system to form a plurality of channels.