Moisture diverting insulated siding panel

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.

FIELD OF THE INVENTION

The present invention relates to building materials generally, and more specifically to siding panel building materials.

BACKGROUND

Current insulated siding panels are designed to create a thermal barrier layer behind a thin vinyl siding layer. The lower butt sections of these vinyl siding layers are generally designed with weep holes to allow moisture trapped behind the siding to escape or weep out. This moisture can come from wind blown rain, condensation or other source. An example of one prior art insulated siding panel system is provided in U.S. Pat. No. 6,029,415 to Culpepper et al. (the “'415 Patent”).

The advent of the insulation layer attached to the back of the siding creates a barrier which significantly limits the ability of the siding veneer to successfully weep this moisture away. Moisture can become trapped between the insulation layer and the siding panel and between the building wall and the insulation layer. The trapped moisture can cause significant damage to wall systems and building structures as well as significantly reduce the effectiveness of the insulation materials as they become saturated.

There remains a need for an improved siding system that better allows trapped moisture to escape. Therefore, an improved siding panel product and system are desired.

SUMMARY OF THE INVENTION

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, or other, 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 layers, coating panels or boards (hereinafter collectively referred to as “members”)coupled to the rear surface of said siding panel. The first insulation member has a bottom edge thereof located proximate to the stepped, or other, contour and the second insulation member has a top edge thereof located proximate to the stepped, or other, contour.

Use of an insulation backing that comprises more than one insulation member helps to reduce scrap waste and improve handling and ease of assembly, all without reducing thermal and acoustic insulation performance.

In another embodiment of a siding panel product, the siding panel product includes one or more insulation members coupled to the rear surface of the siding panel where the one or more insulation members includes a plurality of spacing elements on at least one of the major surfaces thereof forming at least one channel. Depending on the orientation of the spacing elements, the insulated siding product can provide for a better adhesive connection between the insulation backing and the siding panel, and/or provide for improved or enhanced water drainage. Improved drainage can provide a diminished probability of occurrence of mold, mildew and/or rot formation behind a siding panel product. In some embodiments, the siding product includes an improved locking means that provides for an easier installation of the siding product, thereby providing both cost and manpower savings.

The above and other features of the present invention will be better understood from the following detailed description of the preferred embodiments of the invention that is provided in connection with the accompanying drawings.

DETAILED DESCRIPTION

Provided herein is an improved insulation product comprising a thin walled polymeric siding panel and an insulation backing coupled thereto.FIG. 1is a partial perspective view showing two coupled insulation products12a,12baccording to a first embodiment. As can be seen fromFIG. 1and as described in more detail in connection withFIGS. 2 and 2A, each insulation product12a,12bincludes a respective siding panel14a,14bcoupled, in a preferred embodiment, by an adhesive22to respective insulation backing20a,20b. The panels can be coupled to insulation members, such as layers, panels, boards or coatings (hereinafter collectively referred to as “members”), for example. In the embodiment shown inFIG. 1, each insulation backing20a,20bcomprises a plurality of insulation members16a,18aand16b,18b, respectively, which are described in more detail below in connection withFIGS. 2 and 2A.

FIG. 2is a profile view of an individual siding panel product12shown inFIG. 1. As noted, the siding panel product12includes siding panel14and insulation backing20coupled thereto. In a preferred embodiment, the insulation backing20is coupled to a rear surface of siding panel14using an adhesive, such as an adhesive described in the '415 Patent, which is incorporated by reference herein in its entirety. Other suitable adhesives includes, but are not limited to, UV curable adhesives and hot melt adhesives, such as polyamines and urethanes, glue, thermosetting or thermoplastic adhesives, pressure sensitive adhesives or solvent-based adhesives. Other suitable adhesives include, but are not limited to Super77 multiple adhesive and high-strength 90 spray adhesive by Minnesota Mining and Manufacturing Co. (3M), St. Paul, Minn. Alternatively, the insulation backing20can be sprayed onto the rear facing surface of the siding panel14, such as in the form of a foamed insulation.

The insulation backing20is preferably coupled to the panel14during manufacturing, i.e., before distribution of the siding product for installation in the field, but the product12may also be assembled in the field. The adhesive may be applied to substantially coat the rear major surface of the siding panel14and front major surface of the insulation backing20, or in patterns such as stripes, blocks or the like. The adhesive application may be to one or both surfaces prior to or during assembly.

The siding panel14is preferably polymeric, and most preferably formed from polyvinylchloride (PVC) or polypropylene (PP). In one embodiment, the siding panel14includes a plurality of front faces, or simulated board or shake members (optionally having a wood grain pattern molded or embossed thereon) defined between the top and butt ends of the siding panel14. In the embodiment shown inFIG. 2, the siding panel14comprises an upper front face24and lower front face25. The front faces24,25may be substantially flat or planar, or may be arcuate in shape. Upper front face24and lower front face25meet at shoulder26that defines a stepped contour. Each face corresponds visually to a siding board, shingle or other patterned course.

The siding panel14also includes locking means for interlocking the siding panel14with similar panels installed above and/or below the panel14. In one embodiment, the locking means includes a male hook member30located at a butt end of the siding panel14and a corresponding female member28located proximate to a top end of the siding panel14and below the nailing hem34, in one embodiment. Nailing hem34may have apertures formed therein as shown inFIG. 1for easy placement of nails, screws or other fasteners. The connection between these members and members of other similar products is best seen inFIG. 2Adescribed below.

In one embodiment, the insulation backing20comprises two or more vertical insulation members that together provide the insulation backing with a substantially planar rear major surface and a front major surface that substantially conforms to the profile of the siding panel14, except as discussed below. In one embodiment, the members of the insulation backing comprise a foam. The foam may be any of a variety of porous or non-porous closed cell foams. A closed cell foam will not soak up and hold water the way a sponge does. A preferred foam material, for example, can be a porous, closed-cell composite, formed by fusing together resilient, closed cell polymer beads only at their tangent points, providing a durable, non-absorptive composite that allows water to flow freely through the interstices throughout the material and to drain from the foam. The foam may be made of a thermosetting resin, such as polyurethane, or a thermoplastic resin, such as an olefin, like polypropylene or polyethylene, for example. Examples of suitable foams are “BREATHE-N-DRAIN™”, FPP2.1, FPP3.0, and FPP5.5 porous, closed cell polypropylene composites made by Brock USA of Boulder Colo., or FPE2.7, FXPE2.1 and FXPE 3.2 porous closed cell polyethylene composites, also made by Brock USA. Alternatively, polystyrene and polyurethane foams could be used.

In the embodiment shown inFIG. 2, the insulation backing20comprises a first insulation member16coupled to the rear surface of the siding panel14with a substantial portion thereof above the stepped contour of the shoulder section26(i.e., the bottom edge of insulation member16is proximate to shoulder section26) and a second insulation member18coupled to the rear surface of the siding panel14with a substantial portion thereof below the shoulder section26(i.e., a top edge of insulation member18is proximate to shoulder section26). Second insulation member18has a top surface at a top edge thereof that is generally flush with the bottom edge of the first insulation member16. The top edge of first insulation member16is preferably substantially flush and planar with the top edge of the nailing hem34of the siding panel14. While first insulation member16has a width that is substantially equal to the width between the top edge of siding panel14and shoulder26, the second insulation member18has a width that is smaller than the width between shoulder26and the butt end of the siding panel14, i.e., siding product12has a portion35where the insulation backing20does not cover the rear surface of siding panel14for reasons described below.

FIG. 2Aillustrates, in partial, two siding panel products12a,12bcoupled together by interlocking members28band30a. Siding panel product12bis shown coupled to the exterior surface102of structure100with a series of fasteners50(one of which is shown). The insulation backing20substantially fills the space between the siding panel14and the exterior surface102of the structure100and forms a substantially continuous insulation surface against exterior surface102. As one of ordinary skill will understand, fastener50may comprise nails, screws, staples, adhesives, or other fastening means. Portion35(described in connection withFIG. 2) is sized so that when panel products12a,12bare coupled together, second insulation member18aof siding product12aabuts the top edge of first insulation member16bof siding product12bto form a substantially continuous insulation layer between the siding panels14a,14band surface102.

By forming the insulation backing in two or more vertical sections, scrap waste is reduced in comparison to conventional one-piece insulation backing. Conventional foam backed siding products have foam sections that often are cut from large cubes or billets. Because the foam is cut to match the siding profiles, there are large amounts of scrap produced when the parts are cut. These one-piece foam sections are also difficult to handle and are very fragile in thinner areas, such as at the shoulder region, leading to possible fractures that can cause problems in coupling the foam backing to the siding panel and durability concerns. Use of the insulation backing20, which comprises more than one insulation member, helps to reduce scrap waste and improve handling, and ease of assembly, all without reducing thermal and acoustic insulation performance.

In one embodiment, best shown in the partial front plan view of insulation member18ofFIG. 2B, the bottom edge38of the insulation member18comprises one or more channels32formed therein from the front to rear surfaces of the insulation member18. When a insulation member18ais installed over a insulation member16b, as shown inFIG. 2A, the channels32allow water to migrate from behind the insulation backing20, i.e., proximate to the exterior surface102of structure100, through channels32, and to open weep area36between the upper end of siding panel product12band butt end of siding panel product12a. Although not shown inFIG. 2Abut as should be familiar to those in the art, the butt end of siding panel product12apreferably includes one or more weep holes that allow the moisture to weep from the installed siding panel product.FIG. 2Cis a partial cross-sectional profile view showing the male portion30aof the locking means of the siding panel12ahaving a weep hole31formed therethrough.

Although the insulation backing20ofFIG. 2Ais shown as comprising two insulation sections with horizontal abutting surfaces at the bottom of section16aand top of section18aand at the top of section16band bottom of section18a(FIG. 2A), other configurations are also contemplated. For example, the abutting surfaces could be at a matching angle with respect to the wall100, preferably with the front edges (i.e., proximate to the front surface of backing20) lower than the back edges (i.e., proximate to the rear surface of backing20and wall100). In some embodiments, this configuration may help with moisture diversion, such as when channels32are formed at the bottom of sections16or18and/or at the top of sections16or18, along with the formation of weep areas at weep area36and/or shoulder26and/or in connection with channels or protrusions formed in the front surface of the insulation backing as shown inFIGS. 5-5D.

With reference toFIG. 3, another embodiment of a siding panel product120is illustrated. Features similar to those shown in the siding panel product12ofFIG. 2share the same reference numbers. Siding panel140is identical to siding panel14except that siding panel140includes a water diverting means comprising, in the illustrated embodiment, return leg142disposed over the upper surface of insulation member16and a second leg section144extending upward from the return leg142and positioned to sit against the exterior surface102of structure100when the siding panel product120is installed as shown inFIG. 3A. Siding panel140may be coupled to a one-piece insulation backing of the prior art, but is more preferably coupled to a multi-piece insulation backing20as shown inFIG. 3and described in detail above in connection withFIGS. 2 and 2A.

With reference toFIG. 3A, the return leg142band upwardly facing leg144bhelp to prevent or at least reduce moisture that gravitates down exterior surface102behind insulation section18ainstalled above insulation section16bfrom continuing behind insulation backing section16b. The leg144band return leg142balso help to direct the moisture toward weep area36, particularly when used in connection with channels32in insulation section18adescribed above. The improved drainage path so formed can help to keep the structure100drier, when compared to conventional designs, improve the insulation value of the foam polymer in insulation backing20and reduce potential issues associated with moisture infiltrating the wall of structure100where it can do significant damage through rotting, molding or mildew. In one embodiment, the vertical portion of the return leg144bcould be sized to be used as a nailing flange, rather than nailing through the foam16bas shown inFIG. 3A.

In one embodiment, a recessed region146of second insulation member18is shaved, cut or otherwise formed into the insulation member18to match and provide a tight fit with the return leg142and upwardly oriented leg144, as shown inFIG. 3A. Although the moisture diverting means is shown as a generally “L” shaped structure in the embodiment ofFIG. 3, other shapes may also be used. For example, return portion142could be angled or curved. Appropriate mating recesses for these embodiments could also be formed at the bottom edge of insulation backing section18, like recessed portion146only corresponding to the angled or curved shape of modified return leg.

FIG. 4is a side profile view of an embodiment of an insulated siding panel product220having an alternative means for interlocking the siding panel with similar siding panel products disposed above and/or below the siding panel product220. In contrast to the locking means shown inFIGS. 2 and 3, where the male portion30of the locking means is upwardly oriented and the female portion28is downwardly oriented, the locking means of this embodiment includes an upwardly facing female portion280proximate to nailing hem340and a downwardly depending male member300. As shown in the installation assembly ofFIG. 4A, the siding panel products220a,220bcan be interlocked using a simplified stacking process. A first siding product220bis aligned along, and secured to, the wall100using fasteners50disposed through nailing hem340. The second siding product220ais then coupled to the first siding product220bby positioning the product220aabove the installed product220b, with male member300aaligned over female member280b, and moving the product220adownward to guide and dispose the male member300athereof into the female member280bof the first siding product220b. The siding product220ais then fastened to the wall100while it is supported by already fastened product220b.

Siding products220, which are configured for a downward coupling, are easier to install than those using conventional locking means of the prior art, which require panels to be lifted upwards to make the connection between male member30and female member28and which require a second installer to hold the top panel in place while the first installer provides the fasteners. With siding products220, however, because the male member300ais oriented downward and comes to rest in the upwardly oriented female member280b, the fixed panel200bsupports the panel200awhile fasteners are applied to secure panel product200ato structure100, thereby reducing or eliminating the need for another installer to support the second panel product200aduring the fastening step.

As shown inFIG. 4, siding panel product220includes a single piece (at least width wise) insulation backing200. While multiple section insulation backings can certainly be used as described above, the design of siding panel product220, and specifically of siding panel240, is particularly suited for use with single piece insulation backings that are at least partially mechanically supported within the profile of siding panel240. This mechanical, fitted connection between the siding panel profile240and insulation backing200allows for an elimination of or reduction in the adhesive used for coupling the siding panel240to the insulation backing200. Optionally, one or more channels232, preferably diagonally oriented, could be provided through the foam backing to facilitate moisture transport from behind the backing to a weep area in front of and/or below the backing.

FIGS. 5-5Billustrate an alternative embodiment of a siding panel product320having an insulation backing having channels formed in at least one major surface thereof. Siding panel product320include a siding panel14as shown and described in connection withFIG. 2, although other siding panels, such as those shown inFIGS. 3 and 4may also be used. In the embodiment shown inFIG. 5, siding panel product320includes an insulation backing300having channels or openings formed into at least one of its front or back major surfaces. In the embodiment shown inFIG. 5, the insulation backing300includes a plurality of horizontal channels formed in its front major surface, i.e., the major surface that faces the rear surface of the siding panel14. The channels can be formed by a plurality of horizontal holes, humps, ribs, grooves or protrusions400, or other spacing elements, that create an irregular surface for increasing the surface area for bonding to the rear surface of the siding panel14, thereby providing an improved bond between the insulation backing300and the siding panel14. The humps, ribs, grooves or protrusions preferably, but not necessarily, substantially cover the entire front major surface of the insulation backing300.

In alternative embodiments of the insulation backing shown in the front plan views ofFIGS. 5A and 5B, the channels are oriented at an angle relative to horizontal. As shown in the embodiment ofFIG. 5A, insulation backing300amay include a plurality of substantially vertical channel forming protrusions400a, or other spacing elements, formed in the front major surface of the insulation backing300a. In the embodiment shown inFIG. 5B, the insulation backing300bincludes a plurality of channel forming protrusions400boriented diagonally, i.e., at an oblique angle to the horizontal. In these embodiments, where the channels are perpendicular or at an oblique angle to the horizontal, the channels help facilitate the movement of water towards weep channels formed in the butt end of the siding panel14. To that end, the channels are preferably at an angle of between about 45-90° to the horizontal. In these embodiments where it is desired to use the channels as weep channels in the front major surface of the insulation backing, the adhesive is preferably not applied to the entire front major surface of the insulation backing, so as to avoid clogging or otherwise blocking the channels. Rather, the adhesive is preferably applied in spaced vertical strips. Although the adhesive does not cover substantially the entire front major surface of the insulation backing in these embodiments, the adhesive should create an improved localized bond between the insulation backing and the siding panel due to the localized increased surface area, as described above with channel forming protrusions400. In alternative embodiments shown inFIGS. 5C and 5D, the channel forming protrusions are discontinuous, or put another way, each diagonal, vertical and/or horizontal protrusion line is formed from a plurality of discrete protrusions. As shown with the backings300cand300dofFIGS. 5C and 5D, respectively, these protrusions400c,400dcan take on any number of shapes, such as squares (protrusions400c), rounded bumps (protrusions400d) or other shapes. These configurations form criss-crossing channels to provide multiple drainage channels and paths. Adhesive could be applied in a measured amount to provide for adhesion at substantially only the peaks or outer most surface of these protrusions, leaving the channels free for drainage.

In one embodiment, the channels are formed on both the front and rear major surfaces of the insulation backing.FIG. 5shows in shadow the channels402formed on the rear major surface of insulation backing300. Although not shown, channels may also be formed along the sides of the insulation backing to modulate drainage of water from sides of the product.

The channels in the insulation backing can be formed to any width or depth. The spacing of the channels or protrusions may be any distance, and may be varied within a single section of insulation backing. The ratio between the portion of the insulation backing covered by the protrusions and any non-protrusioned portion (which may be otherwise flat, curved or textured) may be varied. The channels also need not be straight, but can be wavy, for example. Also, the channels can take on any cross-sectional shape, such as a semi-circular, square, rectangular, V-shaped, semi-elliptical. In one exemplary embodiment, the protrusions are spaced between about 1.0 to about 10 mm, preferably about 2.0 to about 8 mm, and at a depth of between about 0.5 to about 5 mm, preferably about 1.0 to about 3.0 mm. The protrusions may be formed directly in the profile during formation of the insulation backing300, by cutting backing300, by pressing or embossing the protrusions in the surfaces of backing300, or by burning channels in the backing300, for example.

As described above, the channels may be formed by holes, humps, ribs, grooves, or protrusions formed on one or more major surfaces of the insulation backing. Other examples of spacing elements that may be used to provide a non-planar surface for diverting moisture towards weep area include bosses, spacers, or adhesive build up areas.

A method of using an exemplary product comprises: providing a first siding panel product as described herein and mounting the first siding panel product to a building by a variety of fasteners, including, but not limited to, nails, staples, screws, and the like or, alternatively adhesive means such as, for example, glues or tapes. Then, a second siding panel product is provided, coupled to the first siding panel and mounted to the building.

Some embodiments of insulated siding products described herein provide for improved or enhanced water drainage. Improved drainage can provide a diminished probability of occurrence of mold, mildew and/or rot formation behind a siding panel product. In other embodiments, the siding product includes an improved locking means that provides for an easier installation of the siding product, thereby providing both cost and manpower savings.

Although the siding panels shown inFIGS. 2-5have faces consistent with traditional clapboard siding panel faces, other siding panel profiles can certainly be employed. For example, in certain embodiments, the siding panels may be configured as a so-called “Dutchlap” siding panel having more planar faces, as shown inFIG. 6B, or even as a so-called “single beaded” siding panel having a single major panel face, in certain embodiments.