Laminated vinyl siding

• US 6,029,415 A
• Filed: 10/24/1997
• Issued: 02/29/2000
• Est. Priority Date: 10/24/1997
• Status: Expired due to Term

• Current Assignee: Progressive Foam Technologies Incorporated
• Original Assignee: ABCO, Inc.
• Inventors: Culpepper, Patrick M., Wilson, Richard C.
• Primary Examiner(s): Aubrey, Beth
• Application Number:
  US08/957,564
• Time in Patent Office: 858 Days
• Field of Search: 52/518-520, 52/309.9, 52/522, 52/530, 52/535, 52/553, 52/534, 52/536, 52/407.1, 52/588.1, 52/309.4, 52/309.5, 52/309.8
• US Class Current: 52/522
• 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 13/18 of organic plastics with or without reinforcements or filling materials of plastic-bound fibres or chips E04F13/16 or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles E04F13/0864 takes precedence

Abstract

A composite interlocking vinyl or other veneer siding having an elongated insulating member bonded to a vinyl panel with a permanently flexible adhesive that is compatible with both vinyl and insulation material and does not harden. The insulating member is configured such that a front face of the insulating material exactly coincides with the profile of the front face of the vinyl member. The insulating member forms a shallow shelf at an upper edge of the insulating member and an adjacent insulating member forms another shelf to overlap the adjacent shallow shelf to form a shiplap seal when assembled. Horizontal and vertical edges of the vinyl siding and insulating member are configured to overlap when mounted.

Claims

1. In a composite siding panel having an elongate outer panel formed from vinyl with first and second spaced longitudinally extending edges with a nailing hem adjacent one of the first and second longitudinally extending edges of the outer panel, the improvement comprising:

an elongate insulating member having a plurality of flat planar outer surfaces separated from one another by at least one shoulder surface to define a stepped contour, each flat planar outer surface secured to an inner surface of the outer panel with a permanently flexible adhesive to form a laminated composite siding panel, the insulating member having first and second longitudinally extending ends, wherein said first longitudinally extending end extends beyond said nailing hem.

2. The improvement of claim 1, wherein the outer surface of the insulating member has a complementary profile with respect to the inner surface of the outer panel.

3. The improvement of claim 1, wherein the nailing hem is on the first edge of the outer panel and the second edge of the outer panel extends beyond the second longitudinally extending end of the insulating member.

4. The improvement of claim 1, wherein the first longitudinally extending end of the insulating member defines a shelf and the second longitudinally extending end defines a shelf-receiving recess, such that the shelf-receiving recess is approximately a mirror image of the shelf so that the first and second longitudinally extending ends of adjacent insulating members are adapted to overlap each other when two adjacent outer panels are interlocked with respect to one another.

5. The improvement of claim 1, wherein one of the vertically extending edges of the insulating member forms a shelf and the other vertically extending edge of the insulating member forms a shelf-receiving recess, such that the shelf of one insulating member is adapted to overlap the shelf-receiving recess of a horizontally adjacent insulating member to form a seal when two horizontally adjacent composite siding panels are installed with respect to one another.

6. The improvement of claim 1, wherein the vertically extending edge of the outer panel of one composite siding panel is adapted to be received between a second vertically extending end and insulating member of an adjacent composite siding panel when two horizontally adjacent composite siding panels are installed with respect to one another.

7. A composite siding panel comprising:

an elongate outer panel formed of thin material having first and second spaced longitudinally extending edges with a predetermined profile extending therebetween;

interlocking means extending along each of said first and second spaced edges for releasibly connecting a first edge of one panel with a second edge of an adjacent panel during installation;

an elongate insulating member having an outer surface with a complementary profile with respect to an inner surface of the outer panel, said insulating member having a generally flat inner surface portion and having first and second longitudinally extending ends, said first and second longitudinally extending ends forming first and second complementary shelves respectively such that adjacent composite siding panels are adapted to position said complementary shelves in overlapping relationship with respect to one another to form a seal when two adjacent composite side panels are secured in interlocking relationship; and

a permanently flexible adhesive securing the insulating member to the inner surface of the outer panel.

8. The composite siding panel of claim 7, wherein the first edge of the outer panel defines a nailing hem positioned proximate the first longitudinally extending end of the insulating member on an outer surface of the first shelf.

9. The composite siding panel of claim 8, wherein the second edge of the outer panel extends beyond the second longitudinally extending end of the insulating member.

10. The composite siding panel of claim 7, wherein the insulating member is secured to the inner surface of the outer panel with a moisture cured urethane adhesive.

11. The composite siding panel of claim 7, wherein the elongate outer panel and insulating member have vertically extending edges and ends respectively, and the vertically extending edges of the outer panel extend longitudinally beyond the vertically extending ends of the insulating member.

12. The composite siding panel of claim 11, wherein one of the vertically extending ends of the insulating member forms a shelf and the other vertically extending end of the insulating member forms a shelf-receiving recess, such that the shelf of one insulating member is adapted to overlap the shelf-receiving recess of a horizontally adjacent insulating member to form a seal when two horizontally adjacent composite siding panels are installed with respect to one another.

13. The composite siding panel of claim 11, further comprising means for defining a nailing hem on one of the first and second spaced longitudinally extending edges of the outer panel wherein a horizontal dimension of the nailing hem is less than a horizontal dimension of the insulating member.

14. The composite siding panel of claim 11, wherein the vertically extending edge of the outer panel of one composite siding panel is adapted to be received between a second vertically extending end and insulating member of an adjacent composite siding panel when two horizontally adjacent composite siding panels are installed with respect to one another.

15. The composite siding panel of claim 11, wherein the vertically extending edge of the outer panel of a first composite siding panel is disposed between the vertically extending edge of the outer panel and the insulating member of an adjacent composite siding panel when installed with respect to one another.

16. The composite siding panel of claim 7, wherein the thickness of the outer panel is less than 0.035".

17. The composite siding panel of claim 7, wherein the width of the outer panel is greater than 12 inches.

18. The composite siding panel of claim 7, wherein the insulating member is secured to the inner surface of the outer panel with a permanently flexible adhesive selected from the group consisting of a heat and pressure sensitive adhesive, a latex based adhesive, and a moisture cured urethane adhesive.

19. The composite siding panel of claim 7, wherein the insulating member increases impact and crack resistance of the vinyl siding panel by supporting a full surface profile of the vinyl siding panel.

20. A composite siding panel comprising:

an elongate outer panel of weather impervious material having first and second longitudinally extending edges, and first and second transversely extending ends;

a fastening hem extending longitudinally along the first edge of the outer panel;

interlocking means formed on the outer panel and defined by a male portion extending longitudinally along the second edge and a complementary female portion adjacent to and extending longitudinally along the first edge for interlocking two vertically adjacent outer panels in parallel, abutting edge-to-edge relationship with respect to one another;

an insulating member mounted to an inner surface of the outer panel and extending outwardly beyond the first edge of the outer panel, while spaced inwardly from the second edge and spaced inwardly from at least one of the first and second ends of the outer panel; and

means for sealing a transversely extending end joint between horizontally adjacent composite panels when in abutting end-to-end relationship with one another with at least one staggered, overlapping joint disposed between the ends of the adjacent composite panels.

21. The composite siding panel of claim 20, wherein the sealing means further comprises:

the insulating member having mating, overlapping, complementary male and female portions extending transversely along opposite ends.

22. The composite siding panel of claim 20, wherein at least one of the overlapping joints defines a rabbet joint between adjacent composite panels.

23. A backing member for a composite siding panel comprising:

an elongate insulating member having a uniform cross section along substantially an entire longitudinal length with a plurality of outer surfaces separated from one another by at least one shoulder surface to define a stepped contour on a front face, the insulating member having first and second transversely extending edges, wherein the first transversely extending edge of the insulating member defines a projection and the second transversely extending edge defines a projection-receiving recess, such that the projection-receiving recess is approximately a mirror image of the projection so that the first and second transversely extending edges of two horizontally adjacent insulating members are adapted to overlap each other when two horizontally adjacent insulating members are assembled with respect to one another.

24. The backing member of claim 23 further comprising:

the insulating member having first and second longitudinally extending edges, wherein the first longitudinally extending edge of the insulating member defines a second projection and the second longitudinally extending edge defines a second projection-receiving recess, such that the second projection-receiving recess is approximately a mirror image of the second projection so that the first and second longitudinally extending edges of two vertically adjacent insulating members are adapted to overlap each other when two vertically adjacent insulating members are assembled with respect to one another.

25. The backing member of claim 23 further comprising:

the plurality of outer surfaces on the front face of the insulating member defining at least two flat planar outer surfaces, each flat planar outer surface adapted to receive a permanently flexible adhesive layer engageable with an inner surface of an outer panel of weather impervious material to define a composite siding panel.