Static structures (e.g. – buildings) – Lapped multiplanar surfacing; e.g. – shingle type – Interfitted sections
Reexamination Certificate
2000-02-09
2001-03-06
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
Lapped multiplanar surfacing; e.g., shingle type
Interfitted sections
C052S535000
Reexamination Certificate
active
06195952
ABSTRACT:
FIELD OF THE INVENTION
The present invention is concerned with lap siding panels of a certain type wherein elongated siding panels of vinyl or other new generations of veneer siding are laminated to a foam insulating material and formed with mating, interlocking means along their opposed longitudinally spaced edges for interlocked installation on a building wall for imitation of conventional wooden lap siding.
BACKGROUND OF THE INVENTION
Metal panels of this type have been known in the art. The panels function solely to provide a weatherproof exterior sheathing of the buildings and do not provide any structural support. The panels are conventionally made of a relatively thin material which does not provide any substantial heat insulation to the building or structural support. In an effort to reduce material costs, various vinyl siding manufacturers have reduced the thickness of their siding panels. However, subsequent performance and appearance complaints have caused the industry to establish a minimum thickness of 0.035″. Accordingly, it has been proposed to back such panels with board like members of heat insulating material. Although insulating material has successfully been laminated to aluminum siding, inherent problems were associated with the lamination of insulating material for vinyl siding.
Unlike aluminum and steel siding which can be manufactured with flat faces, vinyl siding has to be manufactured with an unnatural appearing concave face. The concave or mechanical set face was introduced to vinyl siding panels to reduce or eliminate the occurrence of oil canning. Oil canning is a condition where unacceptably large bubbles or distorted areas appear on the face of the siding panel. Oil canning occurs during changing temperature and weather conditions when the vinyl expands and contracts; and because the vinyl is thin and cannot maintain its own shape. The mechanical set of a concave face diminishes the oil canning problems which have presented substantial warranty costs to the industry. However, this problem has caused the industry to limit the exposure of the horizontal siding to ten or eleven inches. (A ten inch exposure provides two five inch faces.) Vinyl panels wider than 10-11″ have been withdrawn from the market because the panels failed to perform up to industry standards. Despite the improvements, oil canning continues to represent significant customer dissatisfaction and warranty claims.
For added insulation, aluminum siding jobs used drop-in backer boards. Initially, the same foam drop-in backer boards were also used for vinyl siding jobs, but were quickly prohibited by vinyl siding producers. The flat surfaces associated with the thin drop-in foam insulation tended to straighten out the concave set placed in vinyl siding faces to resist oil canning. The flat surface drop-in insulation material had been designed specifically for use with aluminum siding and was not configured to be compatible with the new concave set of the vinyl faces. Further, mechanical binding or obstructions developed between the vinyl and insulation materials at some job sites, because of poor application techniques. Because the previous drop-in foam insulation panels were thin and lacked a registration point, it was easy for the applicator to drop the backer board into the vinyl siding lock mechanism. Then, when the vinyl siding panel was locked into place, the backer board would be trapped in the vinyl siding's interlocking mechanism, thereby restricting the movement of the vinyl siding panel. As a result, the vinyl siding industry banned the use of drop in backer boards. The vinyl siding panel needs to freely move to accommodate its high coefficient of expansion and contraction. If the backer board was trapped in the interlocking mechanism, further distortion occurred in the vinyl siding. In addition, the drop-in backer boards were not manufactured with a consistent thickness. The foam thickness was often varied from run to run and manufacturer to manufacturer resulting in a unacceptable, uneven, poorly appearing wall.
Another problem relating to the lamination of vinyl siding and insulating material is a condition called “telegraphing”. This is a condition that occurs when the adhesive glue line is seen under certain lighting conditions through the face of the siding. The telegraphing condition provides an unacceptable appearance. Therefore, a different adhesive and application system is required to solve the telegraphing problem. At the same time it is necessary to provide an adhesive that is compatible with both the vinyl and insulation material and will hold the siding faces to the insulation material for the entire life of the vinyl siding. In addition, the adhesive must remain flexible throughout the entire life of the composite product.
Another problem occurring in the industry with the vinyl siding installed over current insulation materials is that the vertical edges of adjacent vinyl siding panels often do not lay flat as a result of the deformation of the shape of the vinyl due to improper manufacturing, handling or installation. The resulting open lap is unacceptable from an aesthetic standpoint and, the siding panels can be subject to water, dirt and debris, as well as air infiltration.
Still another problem occurring in the industry with the insulation material is that the vertical edges of adjacent drop-in backer board insulation panels do not provide adequate insulation and structural strength for the vinyl. The current drop-in backer board insulation does not provide a seal between vertically adjacent vinyl siding panels since the insulation material does not extend to the vertical edges.
SUMMARY OF THE INVENTION
It is the intention of the current invention to address the aforementioned concerns. In accordance with the present invention, a board like insulating member is formed to be bonded to a vinyl panel. The insulating member has a coefficient of expansion and contraction which is essentially the same as the vinyl panel. The insulating member is configured such that horizontal and vertical edges of adjacent insulating members overlap each other when installed to provide an airtight seal while not interfering with the interlocking ends of the vinyl siding. This arrangement effectively reduces thermal loss due to air infiltration. The configuration of the insulating member is such that the rear surface of the insulating member has a generally flat surface; and the front surface of the insulating board is configured to coincide with the exact profile of the vinyl sheet. The intent of this feature is to provide support for the vinyl and to make the siding look and feel more like wood. This feature also increases the impact and crack resistance of the vinyl siding by supporting the surface profile of the panel. The profile of the insulating board includes a mid-butt extension coinciding with the simulated overlap extension of the vinyl sheet. The mid-butt extension of the insulating board also serves as a registration point to maintain the insulating backer in its proper location and to prevent it from sliding into the top and bottom longitudinal locks of the vinyl siding. This feature also provides a custom cut cradle, or bed, for the vinyl that is consistently manufactured to the vinyl manufacturer's intended profile. As a result, the insulating board will provide a correct and consistent base upon which the vinyl is laminated.
The vinyl siding is laminated to the insulating board by means of an adhesive that provides some elongation factor. The adhesive is a type that does not harden over time and is compatible with both vinyl and foam over the long term to prevent degradation, discoloration or other defects to the vinyl. The adhesive bonds the vinyl to a foam cradle thereby conforming the vinyl to a stronger and dimensionally consistent backer system; such that all composite panels will conform consistently to the manufacturer's intended design shape and overcome the inconsistencies experienced in the field currently due to poor war
Culpepper Patrick M.
Wilson Richard C.
Abco, Inc.
Stephan Beth A.
Young & Basile P.C.
LandOfFree
Laminated vinyl siding does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Laminated vinyl siding, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Laminated vinyl siding will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2500901