US20160047128A1 - Insulating panel - Google Patents

Insulating panel Download PDF

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Publication number
US20160047128A1
US20160047128A1 US14/822,165 US201514822165A US2016047128A1 US 20160047128 A1 US20160047128 A1 US 20160047128A1 US 201514822165 A US201514822165 A US 201514822165A US 2016047128 A1 US2016047128 A1 US 2016047128A1
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United States
Prior art keywords
face
edge
backing member
veneer
insulating panel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US14/822,165
Inventor
Clarence Yoder
John Timothy Holt
Ryan Beach
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Progressive Foam Technologies Inc
Original Assignee
Progressive Foam Technologies Inc
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Filing date
Publication date
Application filed by Progressive Foam Technologies Inc filed Critical Progressive Foam Technologies Inc
Priority to US14/822,165 priority Critical patent/US20160047128A1/en
Publication of US20160047128A1 publication Critical patent/US20160047128A1/en
Abandoned legal-status Critical Current

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0875Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
    • E04F13/0876Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer the covering layer comprising mutual alignment or interlocking means
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/072Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
    • E04F13/075Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements for insulation or surface protection, e.g. against noise or impact
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/072Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
    • E04F13/076Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/072Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
    • E04F13/077Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements composed of several layers, e.g. sandwich panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801Separate fastening elements
    • E04F13/0832Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
    • E04F13/0833Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable
    • E04F13/0846Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements engaging holes or grooves in the side faces of the covering elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0864Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0866Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels

Definitions

  • the present disclosure relates to a thin-walled insulating panel for use on the exterior of a building, such as a house.
  • the insulating panel is comprised of a backing member and a siding member.
  • a frame In a building structure, such as a house, a frame is typically built. An exterior wall of plywood or material of similar function is then placed upon the frame to provide an exterior surface. A weatherproofing layer may cover the exterior wall. An insulation layer can then be placed, and finally a cladding, paneling, sheathing, veneer, or siding is placed to provide the final exterior view.
  • Vinyl siding is a popular substitute for wood paneling and aluminum siding. It is easily cleaned, and it is resistant to deterioration. It may also be easily installed around windows and doors. Moreover, it may be produced in a variety of shapes and colors by known extrusion and molding processes at a relatively low cost per sheet or panel.
  • one or more layers of insulating material can be placed between the vinyl siding and the exterior wall of the building.
  • a layer of insulation can be placed on an exterior wall, and the vinyl siding then installed over the insulating layer.
  • an insulated panel is generally attached to a veneer, such as a siding panel.
  • the present application discloses a thin-walled insulating panel for use on the exterior surfaces or walls of a building.
  • the insulating panel comprises a thin-walled backing member which is generally attached to a siding member.
  • the backing member may be composed of a rigid foam insulation, which provides strength, enables a wide variety of design options, and provides increased R-values.
  • the backing member has a maximum thickness (depth) at its base of about 0.80 inches or less, including about 0.75 inches.
  • the backing member has a front face, a rear face, a top face having a front edge and a rear edge, a bottom face, a first side face, and a second side face.
  • the top face of the backing member is angled from the front edge to the rear edge such that the angle between the top face and the rear face of the backing member is an acute angle.
  • a bottom edge of the rear face of the backing member has a horizontal detent running from the first side face to the second side face of the backing member. The horizontal detent is configured to receive a nailing hem of an adjacent insulating panel.
  • the siding member has a veneer, a top wall, and a nailing hem.
  • the veneer has a front face, a rear face, a top edge, and a bottom edge.
  • the rear face of the veneer is attached to the front face of the backing member, for example by lamination.
  • the top wall has a front edge and a rear edge and extends rearwardly from the top edge of the veneer.
  • the nailing hem extends upwardly from the rear edge of the top wall.
  • the top edge of the veneer has a hook extending forward.
  • the bottom edge of the veneer extends beyond the bottom face of the backing member and has a lip extending rearward.
  • the hook and the lip are generally complementary in shape.
  • multiple insulating panels may be installed adjacent one another, with the first insulating panel located above the second insulating panel, the lip of the upper insulating panel engaging the hook of the lower insulating panel.
  • the nailing hem of the lower insulating panel fits within the horizontal detent of the upper insulating panel.
  • the height of the horizontal detent can be equal to or greater than the height of the nailing hem.
  • the front face of the backing member is angled with respect to the rear face of the backing member.
  • the bottom face of the backing member of the upper insulating panel generally does not contact the top wall of the lower insulating panel. In this way, a gap is present between the bottom face of the backing member of the upper panel and the top wall of the adjacent panel. This gap can be about 3 ⁇ 8 inch.
  • the backing member can be made of a closed-cell rigid foam, such as expanded polystyrene (EPS).
  • EPS expanded polystyrene
  • the veneer generally has a constant thickness from the top edge to the bottom edge.
  • the veneer is generally flat.
  • the front and rear faces of the veneer are generally parallel from the top edge to the bottom edge of the veneer.
  • the veneer may be relatively thin as well.
  • the rear face of the veneer may be adhesively attached to the front face of the backing member, for example by lamination.
  • the top wall may also be adhesively attached to the top face of the backing member to product greater structural stability.
  • the rear face of the backing member may include a drainage system.
  • the top face of the backing member is angled from the front edge to the rear edge. This angle is generally between 60° to 89° and more preferably between 70° to 85°.
  • the top wall may be angled from the front edge to the rear edge of the top wall.
  • the top wall is angled complementary to the top face of the backing member. In this way, the angle between the top wall and the nailing hem of the siding member is generally between 91° and 120° and more preferably between 130° and 95°.
  • the top wall of the siding member rests on the top face of the backing member and may be adhesively attached thereto.
  • the bottom face of the backing member may also be angled such that the angle between the bottom face and the rear face of the backing member is obtuse. As a result, the bottom face of the backing member is angled such that the bottom face is parallel to the top face of the backing member.
  • the veneer is not flat, but rather is formed from an upper wall, a lower wall, and a longitudinal platform joining a lower edge of the upper wall with an upper edge of the lower wall.
  • the insulating panels of the present disclosure have many advantages.
  • the overall height of the insulating panel facilitates the use of standard trim accessories.
  • the nailing hem of the siding member provides a quick and easy way to attach the siding member to an exterior surface or wall of a building and improves rigidity and handling.
  • the angling of the top wall of the siding panel facilitates access to the nailing hem for a hammer head or stapler head during installation.
  • the angling of the top wall of the siding member additionally facilitates the shedding of bulk moisture that could otherwise accumulate on the top wall.
  • the siding panel facilitates the runoff of moisture.
  • the rear face of the backing member may have a drainage system, which facilitates the drainage of moisture and condensate between the backing member and the exterior surface or wall of the building.
  • the hook and lip of the siding panel allow adjacent panels to be installed adjacent one another in a way that maximizes coverage of the backing member behind the siding member and reduces the amount of the exterior surface or wall of the building that is uncovered by the backing member.
  • FIG. 1 is a side view of a first exemplary embodiment of an insulating panel of the present disclosure.
  • FIG. 2 is a side view of two adjacent insulating panels of the first exemplary embodiment of FIG. 1 joined together. One insulating panel is located above the other insulating panel.
  • FIG. 3 is a side view of a second exemplary embodiment of an insulating panel of the present disclosure.
  • approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not be limited to the precise value specified, in some cases.
  • the modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.”
  • the terms “front” and “rear” and “forward” and “rearward” are relative to a center, with the front being located opposite to the rear and an element that extends “forward” always extending away from the center in a direction opposite an element that extends “rearward.”
  • the terms “top” and “bottom” and “upward” and “downward” are relative to an absolute reference, i.e. the surface of the earth. Put another way, a top location is always located at a higher elevation than a bottom location and an element that extends “upward” always extends away from the surface of the earth, whereas an element that extends “downward” extends toward the surface of the earth.
  • horizontal indicates a direction that is parallel with the surface of the earth.
  • the front and rear are located along an x-axis
  • the left and right are located along a y-axis
  • the top and bottom are located along a z-axis, wherein the three axes are perpendicular to each other.
  • planar and “planar” should be construed in a layman's manner to refer generally to a common level, and should be construed as referring to a volume, not as a flat surface.
  • parallel should be construed in a layman's manner as two edges or faces generally continuously having the same distance between them, and should not be strictly construed in mathematical terms as requiring that the two edges or faces cannot intersect when extended for an infinite distance.
  • perpendicular should not be construed as requiring that two faces meet at an angle of absolutely 90°.
  • the present disclosure relates to an insulating panel formed from a foam backing member and a siding member, joined together to form what might also be considered a composite insulation panel.
  • the siding member is shaped in a manner that improves rigidity and handling, facilitates access for a hammer head or stapler head during fastening, and increases shedding of bulk moisture.
  • FIG. 1 is a side cross-sectional view of a first exemplary embodiment of the insulating panel.
  • the insulating panel 10 comprises a backing member 100 and a siding member 200 .
  • the backing member 100 has a front face 110 , a rear face 120 , a top face 130 , a bottom face 140 , a first side face 150 , and a second side face (not visible).
  • the front face 110 is located opposite the rear face 120 .
  • the top face 130 is located opposite the bottom face 140 .
  • the first side face 150 is located opposite the second side face (not visible).
  • the front face 110 , the rear face 120 , the top face 130 , and the bottom face 140 are each independently flat.
  • a bottom edge 142 of the rear face 120 of the backing member 100 has a horizontal detent 180 running from the first side face 150 to the second side face of the backing member 100 .
  • the front face 110 of the backing member 100 is angled with respect to the rear face 120 of the backing member 100 .
  • the backing member does not have a constant thickness between the front face 110 and the rear face 120 as one moves upward from the bottom face 140 to the top face 130 .
  • the top face 130 of the backing member 100 has a front edge 132 and a rear edge 134 .
  • the front edge 132 can also be considered to be the top edge of the front face 110
  • the rear edge 134 can also be considered to be the top edge of the rear face 120 .
  • the top face 130 of the backing member is angled from the front edge 132 to the rear edge 134 , such that the angle A between the top face 130 and the rear face 120 of the backing member 100 is an acute angle. Put another way, the top face 130 of the backing member 100 is angled such that the top face 130 is visible from the front of the backing member 100 .
  • the angle A is generally from 60° to 89°, and more preferably from 70° to 85°.
  • the top face 130 of the backing member 100 is sloped downward from the rear edge 134 to the front edge 132 , such that moisture will run off towards the front face 110 .
  • the edges 132 , 134 , 142 where the various faces of the backing member meet are illustrated here as sharp edges (i.e. straight lines). It is also contemplated that these edges can be rounded.
  • the bottom face 140 of the backing member 100 is angled such that the angle B between the bottom face 140 and the rear face 120 of the backing member 100 is obtuse. Generally, the bottom face 140 is parallel to the top face 130 .
  • the angle B is generally from 91° to 120° , and more preferably from 95° to 110°.
  • the rear face 120 of the backing member 100 may also include a drainage system. It is contemplated that the drainage system could be in the form of drainage grooves formed or fabricated into the rear face 120 of the backing member 100 . Such a drainage system is described in U.S. Patent Publication Nos. 2005/0081468 and 2007/0175154, the disclosures of which are hereby fully incorporated by reference.
  • the siding member 200 has a veneer 210 , a top wall 220 , and a nailing hem 230 . While these sections of the siding member are referred to and discussed separately herein, it is noted that the siding member is formed as one integral piece.
  • the veneer 210 of the siding member 200 has a front face 212 , a rear face 214 , a top edge 216 , and a bottom edge 218 .
  • the veneer 210 is flat and has a constant thickness between the front face 212 and the rear face 214 from the top edge 216 to the bottom edge 218 .
  • the top edge 216 of the veneer 210 has a hook 240 extending forward, which may also be considered as extending downwards.
  • the bottom edge 218 of the veneer 210 extends beyond the bottom face 140 of the backing member 100 . Put another way, the veneer 210 is longer than the front face 110 of the backing member.
  • a lip 250 extends rearward from the bottom edge 218 as well as upwards, and is complementary in shape to the hook 240 .
  • the top wall 220 of the siding member 200 extends rearwardly from the top edge 216 of the veneer 210 .
  • the top wall 220 has a front edge 222 and a rear edge 224 .
  • the front edge 222 joins the top edge 216 of the veneer.
  • the top wall 220 of the siding panel 200 is angled from the front edge 222 to the rear edge 224 of the top wall 220 .
  • the top wall 220 is angled complementary to the top face 130 of the backing member 100 .
  • the angle C between the top wall 220 and the nailing hem 230 of the siding member 200 is obtuse. More specifically, the angle C is generally from 91° to 120° , and more preferably from 95° to 110°.
  • the top wall 220 of the siding member 200 rests on the top face 130 of the backing member 100 and may be adhesively attached thereto. This slope causes moisture to run off towards the veneer 210 .
  • the nailing hem 230 extends upwardly from the rear edge 224 of the top wall 220 . No portion of the nailing hem extends downwards past the top wall 220 . It is to be understood that the nailing hem 230 is for mounting the insulating panel 10 to an exterior surface or wall of a building. Though not visible here, it is contemplated that the nailing hem 230 includes apertures through which a wide variety of fasteners (such as nails, screws, or staples) may pass. It is noted that the nailing hem 230 and the rear face 120 of the backing member are generally in the same plane.
  • the front face 110 of the backing member 100 is generally shaped to be complementary with the veneer 210 of the siding member 200 .
  • the rear face 214 of the veneer 210 is attached to the front face 110 of the backing member 100 .
  • This attachment can be accomplished in a wide variety of fashions. Attachment can also occur at any time between manufacture and installation such that the siding member 200 and the backing member 100 are joined to one another in the installed or “in use” configuration.
  • the backing member and the siding member can be joined together by mechanical fasteners, adhesive bonding, or chemical bonding at any location either prior to or during installation. Typically, however, adhesives are used.
  • the adhesive may be used over the entire surface of the siding member or in discrete locations instead.
  • the adhesive material can be applied as a bead, as a thin layer, or the like.
  • Suitable adhesives may include, 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. Where adhesive materials are to be employed, the adhesive can be applied by any suitable method.
  • FIG. 2 a side view of two identical insulating panels 10 , 20 of the exemplary embodiment of FIG. 1 joined together is illustrated.
  • the hook 240 and the lip 250 of the siding panel 200 are generally complementary in shape, and engage each other to lock the two panels together.
  • multiple insulating panels 10 , 20 may be installed adjacent one another, with one insulating panel 10 located above another insulating panel 20 , the lip 250 of the upper insulating panel 10 engaging the hook 240 of the lower insulating panel 20 .
  • the exposed front face has a height of about seven (7) inches. However, other sizes are also suitable, including for example four (4), five (5), eight (8), nine (9), or ten (10) inches, or more.
  • the horizontal detent 180 is configured to receive the nailing hem 230 .
  • the height 185 of the horizontal detent 180 is equal to or greater than the height 235 of the nailing hem 230 . This construction minimizes air infiltration and presents a visually continuous surface.
  • the bottom face 140 of the backing member 100 of the upper insulating panel 10 does not contact the top wall 220 of the lower insulating panel 20 . Rather, a gap 190 is present between the bottom face 140 of the backing member 100 of the upper panel 10 and the top wall 220 of the siding member 200 of the adjacent panel 20 . This gap is generally about 3 ⁇ 8 inch.
  • the insulating panel 30 comprises a backing member 100 and a siding member 300 .
  • the backing member 100 has the same features as described above with respect to FIG. 1 .
  • the main difference in the backing member is the shape of the front face 110 , which can be described with reference to the siding member 300 .
  • the siding member 300 of the insulating panel 30 of FIG. 3 also has the same features as described above with respect to FIG. 1 , with a veneer 310 , a top wall 320 , and a nailing hem 330 .
  • the veneer 310 of the siding member 300 has a front face 312 , a rear face 314 , a top edge 316 , and a bottom edge 318 .
  • the rear face 314 of the veneer is attached to the front face 110 of the backing member 100 , the front face 110 being complementary in shape to the veneer 310 .
  • the top edge 316 of the veneer 310 has a hook 340 extending forward.
  • the bottom edge 318 of the veneer 310 extends beyond the bottom face 140 of the backing member 100 . Put another way, the veneer 310 is longer than the front face 110 of the backing member.
  • a lip 350 extends rearward from the bottom edge 318 , and is complementary in shape to the hook 340 .
  • the top wall 320 of the siding member 300 extends rearwardly from the top edge 316 of the veneer 310 .
  • the top wall 320 has a front edge 322 and a rear edge 324 .
  • the front edge 322 joins the top edge 316 of the veneer.
  • the top wall 320 of the siding panel 300 is angled from the front edge 322 to the rear edge 324 of the top wall 320 . Generally, the top wall 320 is angled complementary to the top face 130 of the backing member 100 . The top wall 320 of the siding member 300 rests on the top face 130 of the backing member 100 and may be adhesively attached thereto.
  • the nailing hem 330 extends upwardly from the rear edge 324 of the top wall 320 . No portion of the nailing hem extends downwards past the top wall 320 .
  • the shape of the veneer 310 is different from that of FIG. 1 .
  • the veneer 310 is formed from an upper wall 360 , a lower wall 370 , and a longitudinal platform 380 .
  • the upper wall 360 is adjacent the top edge 316
  • the lower wall 370 is adjacent the bottom edge 318 .
  • the upper wall 360 and the lower wall 370 are angled relative to the rear face 120 of the backing member 100 .
  • the longitudinal platform 380 joins a lower edge 362 of the upper wall 360 with an upper edge 372 of the lower wall 370 , and is oriented horizontally.
  • the upper wall and the lower wall each have an exposed height of about six (6) inches.
  • the backing member provides structural integrity to the insulating panel.
  • the backing member is the platform to which the siding member is connected.
  • the backing member may be shaped to provide the desired profile for the overall insulating panel.
  • the shape of the backing member may be obtained by computer numerical control (CNC) cutting.
  • the rear face of the backing member may include a drainage system, such as drainage grooves, which may be milled or wire-cut. It is noted that the backing member 100 is very thin. The depth of the backing member (from the front face to the rear face) is about three-quarters of an inch (0.75inches) at its deepest point.
  • the backing member is generally made from a cellular foam product, i.e. a plastic or polymeric material with numerous cells of trapped air distributed throughout its mass.
  • expanded polystyrene EPS
  • EPS expanded polystyrene
  • Suitable materials for the backing member can include extruded polystyrene (XPS), expanded polystyrene (EPS), polyurethane, polyisocyanurate, polyethylene, polypropylene, or combinations thereof. It is also contemplated that the backing member could be made from a rigid foam material.
  • Expanded or extruded polystyrene are particularly desirable materials for the backing member because they provide a solid feel; improve the R-value; deaden noise transmitted through the siding; and allow moisture to migrate away from the exterior wall into the external environment, protecting the exterior wall behind the backing member and reducing the risk of mold growth.
  • the backing member may be shape molded. Such molding operations will generally impart the desired contours and/or design to the backing member.
  • beads and/or pellets of a polymeric precursor material such as pre-expanded polystyrene, are placed in a suitably configured die mold, then reacted in the presence of water and heat (i.e. steam) to expand during the reaction process.
  • the polymeric precursor material expands and presses against the die surface to form compressed elongated closed cells that form a characteristic tough smooth skin.
  • the shape molded process produces a panel that is essentially straight and/or free of camber.
  • the siding member provides environmental resistance and durability. It is contemplated that the siding member is generally contoured to conform to the contours of the backing member and be adhesively attached thereto. Generally, the siding member must be thick enough to resist sagging and retain the desired shape. However, the backing member allows the siding member to be thinner than would otherwise be necessary. The siding member only has to provide weatherability to the insulating panel.
  • the siding member can be formed from any suitable polymeric, metallic, cementious or composite material.
  • exemplary materials include vinyl, polypropylene, fiber-cement material, polyolefins, polyvinyls, polycarbonates, polyacetals, polysulfones, polyesters, polyamides, multilayer films, polyethylene (HDPE), polypropylene, low density polyethylene (LDPE), CPVC ABS, ethyl-vinyl acetate, various extruded ionomeric films, polyethylene based films, wood, or combinations thereof.
  • Other siding materials suitable for the siding member layer include wood, aluminum, and steel.
  • the insulating panels are used in suitable combinations to be affixed to or attached to exterior walls of a building. They can be used on several types of structures including, but not limited to, wood-frame, cement block, structural insulated panels (SIPS), insulating concrete forms (ICFs), steel studs, etc.
  • the resulting backing member When installed, the resulting backing member is uniform and forms a complete seal.
  • any perforations in the wall are sealed off from outside elements by the backing member.
  • the siding member has a nailing hem, which minimizes the overall amount of perforations in the exterior wall. Nails, screws, or staples can be used with equal ease and can be more accurately placed and are more secure because they are applied directly to the exterior wall through the nailing hem in the siding panel, instead of through the flexible backing member.
  • the amount of insulation in the backing member can be increased by simply adding more foam, without any other cost in materials.
  • a single backing member can be used with multiple veneer layers to provide desired assemblies.
  • the siding member layer can also be reduced in thickness, thus reducing waste.

Abstract

An insulating panel comprises a backing member and a siding member. The backing member has a front face, a rear face, a top face, a bottom face, a first side face, and a second side face. The siding member has a veneer, a top wall, and a nailing hem. The rear face of the veneer is attached to the front face of the backing member. The top edge of the veneer has a hook extending forward and the bottom edge of the veneer extends beyond the bottom face of the backing member and has a lip extending rearward. The top wall of the siding member extends rearward from the veneer, and the nailing hem extends upwards from the rear edge of the top wall, to lie in the same plane as the rear face of the backing member.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This application claims priority to U.S. Provisional Patent Application Ser. No. 62/036,859, filed on Aug. 13, 2014, the entirety of which is incorporated by reference herein.
  • BACKGROUND
  • The present disclosure relates to a thin-walled insulating panel for use on the exterior of a building, such as a house. The insulating panel is comprised of a backing member and a siding member.
  • In a building structure, such as a house, a frame is typically built. An exterior wall of plywood or material of similar function is then placed upon the frame to provide an exterior surface. A weatherproofing layer may cover the exterior wall. An insulation layer can then be placed, and finally a cladding, paneling, sheathing, veneer, or siding is placed to provide the final exterior view.
  • Vinyl siding is a popular substitute for wood paneling and aluminum siding. It is easily cleaned, and it is resistant to deterioration. It may also be easily installed around windows and doors. Moreover, it may be produced in a variety of shapes and colors by known extrusion and molding processes at a relatively low cost per sheet or panel.
  • To enhance the thermal insulation of building structures, one or more layers of insulating material can be placed between the vinyl siding and the exterior wall of the building. For example, a layer of insulation can be placed on an exterior wall, and the vinyl siding then installed over the insulating layer. In other insulated siding systems, an insulated panel is generally attached to a veneer, such as a siding panel.
  • It would be desirable to produce additional insulating panel systems or assemblies that allow for simple production and easy installation and greater insulating properties.
  • BRIEF DESCRIPTION
  • The present application discloses a thin-walled insulating panel for use on the exterior surfaces or walls of a building. The insulating panel comprises a thin-walled backing member which is generally attached to a siding member. The backing member may be composed of a rigid foam insulation, which provides strength, enables a wide variety of design options, and provides increased R-values. The backing member has a maximum thickness (depth) at its base of about 0.80 inches or less, including about 0.75 inches.
  • In the embodiments disclosed herein, the backing member has a front face, a rear face, a top face having a front edge and a rear edge, a bottom face, a first side face, and a second side face. The top face of the backing member is angled from the front edge to the rear edge such that the angle between the top face and the rear face of the backing member is an acute angle. A bottom edge of the rear face of the backing member has a horizontal detent running from the first side face to the second side face of the backing member. The horizontal detent is configured to receive a nailing hem of an adjacent insulating panel.
  • The siding member has a veneer, a top wall, and a nailing hem. The veneer has a front face, a rear face, a top edge, and a bottom edge. The rear face of the veneer is attached to the front face of the backing member, for example by lamination. The top wall has a front edge and a rear edge and extends rearwardly from the top edge of the veneer. The nailing hem extends upwardly from the rear edge of the top wall. The top edge of the veneer has a hook extending forward. The bottom edge of the veneer extends beyond the bottom face of the backing member and has a lip extending rearward.
  • The hook and the lip are generally complementary in shape. In this way, multiple insulating panels may be installed adjacent one another, with the first insulating panel located above the second insulating panel, the lip of the upper insulating panel engaging the hook of the lower insulating panel. When adjacent insulating panels are installed one above another, the nailing hem of the lower insulating panel fits within the horizontal detent of the upper insulating panel. The height of the horizontal detent can be equal to or greater than the height of the nailing hem.
  • In particular embodiments, the front face of the backing member is angled with respect to the rear face of the backing member.
  • Additionally, in some embodiments, when multiple insulating panels are installed above one another, the bottom face of the backing member of the upper insulating panel generally does not contact the top wall of the lower insulating panel. In this way, a gap is present between the bottom face of the backing member of the upper panel and the top wall of the adjacent panel. This gap can be about ⅜ inch.
  • The backing member can be made of a closed-cell rigid foam, such as expanded polystyrene (EPS).
  • In other embodiments, the veneer generally has a constant thickness from the top edge to the bottom edge. Put another way, the veneer is generally flat. In other words, the front and rear faces of the veneer are generally parallel from the top edge to the bottom edge of the veneer. The veneer may be relatively thin as well.
  • The rear face of the veneer may be adhesively attached to the front face of the backing member, for example by lamination. The top wall may also be adhesively attached to the top face of the backing member to product greater structural stability.
  • The rear face of the backing member may include a drainage system.
  • The top face of the backing member is angled from the front edge to the rear edge. This angle is generally between 60° to 89° and more preferably between 70° to 85°. The top wall may be angled from the front edge to the rear edge of the top wall. Generally, the top wall is angled complementary to the top face of the backing member. In this way, the angle between the top wall and the nailing hem of the siding member is generally between 91° and 120° and more preferably between 130° and 95°. When the angle between the rear face and the top face of the backing member is complementary to the angle between the top wall and the nailing hem of the siding member, the top wall of the siding member rests on the top face of the backing member and may be adhesively attached thereto. The bottom face of the backing member may also be angled such that the angle between the bottom face and the rear face of the backing member is obtuse. As a result, the bottom face of the backing member is angled such that the bottom face is parallel to the top face of the backing member.
  • In other embodiments, the veneer is not flat, but rather is formed from an upper wall, a lower wall, and a longitudinal platform joining a lower edge of the upper wall with an upper edge of the lower wall.
  • The insulating panels of the present disclosure have many advantages. For example, the overall height of the insulating panel facilitates the use of standard trim accessories. The nailing hem of the siding member provides a quick and easy way to attach the siding member to an exterior surface or wall of a building and improves rigidity and handling. Furthermore, the angling of the top wall of the siding panel facilitates access to the nailing hem for a hammer head or stapler head during installation. The angling of the top wall of the siding member additionally facilitates the shedding of bulk moisture that could otherwise accumulate on the top wall. Similarly, the siding panel facilitates the runoff of moisture. Further yet, the rear face of the backing member may have a drainage system, which facilitates the drainage of moisture and condensate between the backing member and the exterior surface or wall of the building. The hook and lip of the siding panel allow adjacent panels to be installed adjacent one another in a way that maximizes coverage of the backing member behind the siding member and reduces the amount of the exterior surface or wall of the building that is uncovered by the backing member.
  • These and other non-limiting characteristics and advantages of the disclosure are more particularly disclosed below.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • The following is a brief description of the drawings, which are presented for the purposes of illustrating the exemplary embodiments disclosed herein and not for the purposes of limiting the same.
  • FIG. 1 is a side view of a first exemplary embodiment of an insulating panel of the present disclosure.
  • FIG. 2 is a side view of two adjacent insulating panels of the first exemplary embodiment of FIG. 1 joined together. One insulating panel is located above the other insulating panel.
  • FIG. 3 is a side view of a second exemplary embodiment of an insulating panel of the present disclosure.
  • DETAILED DESCRIPTION
  • A more complete understanding of the components, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.
  • Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.
  • The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
  • As used in the specification, various devices and parts may be described as “comprising” other components. The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional components. However, such description should be construed as also describing the devices and parts as “consisting of” and “consisting essentially” of the enumerated components, and excluding other components.
  • Numerical values should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of the conventional measurement technique used to determine the value.
  • As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not be limited to the precise value specified, in some cases. The modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.”
  • Some of the terms used herein are relative terms. For example, the terms “front” and “rear” and “forward” and “rearward” are relative to a center, with the front being located opposite to the rear and an element that extends “forward” always extending away from the center in a direction opposite an element that extends “rearward.” The terms “top” and “bottom” and “upward” and “downward” are relative to an absolute reference, i.e. the surface of the earth. Put another way, a top location is always located at a higher elevation than a bottom location and an element that extends “upward” always extends away from the surface of the earth, whereas an element that extends “downward” extends toward the surface of the earth. The term “horizontal” indicates a direction that is parallel with the surface of the earth. As used herein, the front and rear are located along an x-axis, the left and right are located along a y-axis, and the top and bottom are located along a z-axis, wherein the three axes are perpendicular to each other.
  • The terms “plane” and “planar” should be construed in a layman's manner to refer generally to a common level, and should be construed as referring to a volume, not as a flat surface.
  • The term “parallel” should be construed in a layman's manner as two edges or faces generally continuously having the same distance between them, and should not be strictly construed in mathematical terms as requiring that the two edges or faces cannot intersect when extended for an infinite distance. Similarly, the term “perpendicular” should not be construed as requiring that two faces meet at an angle of absolutely 90°.
  • The term “substantially”, as used herein refers to a variance of plus/minus 5% (±5%) when used in conjunction with a numerical value.
  • The present disclosure relates to an insulating panel formed from a foam backing member and a siding member, joined together to form what might also be considered a composite insulation panel. In particular, the siding member is shaped in a manner that improves rigidity and handling, facilitates access for a hammer head or stapler head during fastening, and increases shedding of bulk moisture.
  • FIG. 1 is a side cross-sectional view of a first exemplary embodiment of the insulating panel. The insulating panel 10 comprises a backing member 100 and a siding member 200.
  • The backing member 100 has a front face 110, a rear face 120, a top face 130, a bottom face 140, a first side face 150, and a second side face (not visible). The front face 110 is located opposite the rear face 120. The top face 130 is located opposite the bottom face 140. The first side face 150 is located opposite the second side face (not visible). The front face 110, the rear face 120, the top face 130, and the bottom face 140 are each independently flat.
  • A bottom edge 142 of the rear face 120 of the backing member 100 has a horizontal detent 180 running from the first side face 150 to the second side face of the backing member 100.
  • As illustrated here, the front face 110 of the backing member 100 is angled with respect to the rear face 120 of the backing member 100. Put another way, the backing member does not have a constant thickness between the front face 110 and the rear face 120 as one moves upward from the bottom face 140 to the top face 130.
  • The top face 130 of the backing member 100 has a front edge 132 and a rear edge 134. The front edge 132 can also be considered to be the top edge of the front face 110, and the rear edge 134 can also be considered to be the top edge of the rear face 120. The top face 130 of the backing member is angled from the front edge 132 to the rear edge 134, such that the angle A between the top face 130 and the rear face 120 of the backing member 100 is an acute angle. Put another way, the top face 130 of the backing member 100 is angled such that the top face 130 is visible from the front of the backing member 100. The angle A is generally from 60° to 89°, and more preferably from 70° to 85°. As a result, the top face 130 of the backing member 100 is sloped downward from the rear edge 134 to the front edge 132, such that moisture will run off towards the front face 110. It is noted that the edges 132, 134, 142 where the various faces of the backing member meet are illustrated here as sharp edges (i.e. straight lines). It is also contemplated that these edges can be rounded.
  • The bottom face 140 of the backing member 100 is angled such that the angle B between the bottom face 140 and the rear face 120 of the backing member 100 is obtuse. Generally, the bottom face 140 is parallel to the top face 130. The angle B is generally from 91° to 120° , and more preferably from 95° to 110°.
  • If desired, the rear face 120 of the backing member 100 may also include a drainage system. It is contemplated that the drainage system could be in the form of drainage grooves formed or fabricated into the rear face 120 of the backing member 100. Such a drainage system is described in U.S. Patent Publication Nos. 2005/0081468 and 2007/0175154, the disclosures of which are hereby fully incorporated by reference.
  • Next, the siding member 200 has a veneer 210, a top wall 220, and a nailing hem 230. While these sections of the siding member are referred to and discussed separately herein, it is noted that the siding member is formed as one integral piece.
  • The veneer 210 of the siding member 200 has a front face 212, a rear face 214, a top edge 216, and a bottom edge 218. As illustrated in FIG. 1, the veneer 210 is flat and has a constant thickness between the front face 212 and the rear face 214 from the top edge 216 to the bottom edge 218. The top edge 216 of the veneer 210 has a hook 240 extending forward, which may also be considered as extending downwards. The bottom edge 218 of the veneer 210 extends beyond the bottom face 140 of the backing member 100. Put another way, the veneer 210 is longer than the front face 110 of the backing member. A lip 250 extends rearward from the bottom edge 218 as well as upwards, and is complementary in shape to the hook 240.
  • The top wall 220 of the siding member 200 extends rearwardly from the top edge 216 of the veneer 210. The top wall 220 has a front edge 222 and a rear edge 224. The front edge 222 joins the top edge 216 of the veneer.
  • The top wall 220 of the siding panel 200 is angled from the front edge 222 to the rear edge 224 of the top wall 220. Generally, the top wall 220 is angled complementary to the top face 130 of the backing member 100. The angle C between the top wall 220 and the nailing hem 230 of the siding member 200 is obtuse. More specifically, the angle C is generally from 91° to 120° , and more preferably from 95° to 110°. The top wall 220 of the siding member 200 rests on the top face 130 of the backing member 100 and may be adhesively attached thereto. This slope causes moisture to run off towards the veneer 210.
  • The nailing hem 230 extends upwardly from the rear edge 224 of the top wall 220. No portion of the nailing hem extends downwards past the top wall 220. It is to be understood that the nailing hem 230 is for mounting the insulating panel 10 to an exterior surface or wall of a building. Though not visible here, it is contemplated that the nailing hem 230 includes apertures through which a wide variety of fasteners (such as nails, screws, or staples) may pass. It is noted that the nailing hem 230 and the rear face 120 of the backing member are generally in the same plane.
  • The front face 110 of the backing member 100 is generally shaped to be complementary with the veneer 210 of the siding member 200. The rear face 214 of the veneer 210 is attached to the front face 110 of the backing member 100. This attachment can be accomplished in a wide variety of fashions. Attachment can also occur at any time between manufacture and installation such that the siding member 200 and the backing member 100 are joined to one another in the installed or “in use” configuration. The backing member and the siding member can be joined together by mechanical fasteners, adhesive bonding, or chemical bonding at any location either prior to or during installation. Typically, however, adhesives are used. The adhesive may be used over the entire surface of the siding member or in discrete locations instead. The adhesive material can be applied as a bead, as a thin layer, or the like. Suitable adhesives may include, 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. Where adhesive materials are to be employed, the adhesive can be applied by any suitable method.
  • Turning now to FIG. 2, a side view of two identical insulating panels 10, 20 of the exemplary embodiment of FIG. 1 joined together is illustrated. Again, the hook 240 and the lip 250 of the siding panel 200 are generally complementary in shape, and engage each other to lock the two panels together. In this way, multiple insulating panels 10, 20 may be installed adjacent one another, with one insulating panel 10 located above another insulating panel 20, the lip 250 of the upper insulating panel 10 engaging the hook 240 of the lower insulating panel 20. The exposed front face has a height of about seven (7) inches. However, other sizes are also suitable, including for example four (4), five (5), eight (8), nine (9), or ten (10) inches, or more.
  • As previously mentioned, the horizontal detent 180 is configured to receive the nailing hem 230. Thus, the height 185 of the horizontal detent 180 is equal to or greater than the height 235 of the nailing hem 230. This construction minimizes air infiltration and presents a visually continuous surface.
  • When locked together, the bottom face 140 of the backing member 100 of the upper insulating panel 10 does not contact the top wall 220 of the lower insulating panel 20. Rather, a gap 190 is present between the bottom face 140 of the backing member 100 of the upper panel 10 and the top wall 220 of the siding member 200 of the adjacent panel 20. This gap is generally about ⅜ inch.
  • Referring now to FIG. 3, a cross-sectional view of a second exemplary embodiment of an insulating panel is shown. The insulating panel 30 comprises a backing member 100 and a siding member 300. The backing member 100 has the same features as described above with respect to FIG. 1. The main difference in the backing member is the shape of the front face 110, which can be described with reference to the siding member 300.
  • The siding member 300 of the insulating panel 30 of FIG. 3 also has the same features as described above with respect to FIG. 1, with a veneer 310, a top wall 320, and a nailing hem 330. The veneer 310 of the siding member 300 has a front face 312, a rear face 314, a top edge 316, and a bottom edge 318. The rear face 314 of the veneer is attached to the front face 110 of the backing member 100, the front face 110 being complementary in shape to the veneer 310.
  • The top edge 316 of the veneer 310 has a hook 340 extending forward. The bottom edge 318 of the veneer 310 extends beyond the bottom face 140 of the backing member 100. Put another way, the veneer 310 is longer than the front face 110 of the backing member. A lip 350 extends rearward from the bottom edge 318, and is complementary in shape to the hook 340.
  • The top wall 320 of the siding member 300 extends rearwardly from the top edge 316 of the veneer 310. The top wall 320 has a front edge 322 and a rear edge 324. The front edge 322 joins the top edge 316 of the veneer.
  • The top wall 320 of the siding panel 300 is angled from the front edge 322 to the rear edge 324 of the top wall 320. Generally, the top wall 320 is angled complementary to the top face 130 of the backing member 100. The top wall 320 of the siding member 300 rests on the top face 130 of the backing member 100 and may be adhesively attached thereto.
  • The nailing hem 330 extends upwardly from the rear edge 324 of the top wall 320. No portion of the nailing hem extends downwards past the top wall 320.
  • The shape of the veneer 310 is different from that of FIG. 1. Here, the veneer 310 is formed from an upper wall 360, a lower wall 370, and a longitudinal platform 380. The upper wall 360 is adjacent the top edge 316, and the lower wall 370 is adjacent the bottom edge 318. Generally, the upper wall 360 and the lower wall 370 are angled relative to the rear face 120 of the backing member 100. The longitudinal platform 380 joins a lower edge 362 of the upper wall 360 with an upper edge 372 of the lower wall 370, and is oriented horizontally. The upper wall and the lower wall each have an exposed height of about six (6) inches.
  • The backing member provides structural integrity to the insulating panel. For example, the backing member is the platform to which the siding member is connected. The backing member may be shaped to provide the desired profile for the overall insulating panel. For example, the shape of the backing member may be obtained by computer numerical control (CNC) cutting. If desired, the rear face of the backing member may include a drainage system, such as drainage grooves, which may be milled or wire-cut. It is noted that the backing member 100 is very thin. The depth of the backing member (from the front face to the rear face) is about three-quarters of an inch (0.75inches) at its deepest point.
  • The backing member is generally made from a cellular foam product, i.e. a plastic or polymeric material with numerous cells of trapped air distributed throughout its mass. For example, expanded polystyrene (EPS) is a cellular foam plastic made from beads of polystyrene beads that are first pre-expanded and allowed to rest for a suitable interval, then molded in closed steam-heated shaped molds to produce closed-cell molded foams. The size and density of the closed cells can be controlled and may vary depending upon the application. Suitable materials for the backing member can include extruded polystyrene (XPS), expanded polystyrene (EPS), polyurethane, polyisocyanurate, polyethylene, polypropylene, or combinations thereof. It is also contemplated that the backing member could be made from a rigid foam material.
  • Expanded or extruded polystyrene are particularly desirable materials for the backing member because they provide a solid feel; improve the R-value; deaden noise transmitted through the siding; and allow moisture to migrate away from the exterior wall into the external environment, protecting the exterior wall behind the backing member and reducing the risk of mold growth.
  • The backing member may be shape molded. Such molding operations will generally impart the desired contours and/or design to the backing member. Typically, beads and/or pellets of a polymeric precursor material, such as pre-expanded polystyrene, are placed in a suitably configured die mold, then reacted in the presence of water and heat (i.e. steam) to expand during the reaction process. The polymeric precursor material expands and presses against the die surface to form compressed elongated closed cells that form a characteristic tough smooth skin. The shape molded process produces a panel that is essentially straight and/or free of camber.
  • The siding member provides environmental resistance and durability. It is contemplated that the siding member is generally contoured to conform to the contours of the backing member and be adhesively attached thereto. Generally, the siding member must be thick enough to resist sagging and retain the desired shape. However, the backing member allows the siding member to be thinner than would otherwise be necessary. The siding member only has to provide weatherability to the insulating panel.
  • The siding member can be formed from any suitable polymeric, metallic, cementious or composite material. Exemplary materials include vinyl, polypropylene, fiber-cement material, polyolefins, polyvinyls, polycarbonates, polyacetals, polysulfones, polyesters, polyamides, multilayer films, polyethylene (HDPE), polypropylene, low density polyethylene (LDPE), CPVC ABS, ethyl-vinyl acetate, various extruded ionomeric films, polyethylene based films, wood, or combinations thereof. Other siding materials suitable for the siding member layer include wood, aluminum, and steel.
  • The insulating panels are used in suitable combinations to be affixed to or attached to exterior walls of a building. They can be used on several types of structures including, but not limited to, wood-frame, cement block, structural insulated panels (SIPS), insulating concrete forms (ICFs), steel studs, etc. When installed, the resulting backing member is uniform and forms a complete seal. In addition, any perforations in the wall are sealed off from outside elements by the backing member. The siding member has a nailing hem, which minimizes the overall amount of perforations in the exterior wall. Nails, screws, or staples can be used with equal ease and can be more accurately placed and are more secure because they are applied directly to the exterior wall through the nailing hem in the siding panel, instead of through the flexible backing member.
  • Other benefits of the insulating panel described herein relate to production. For example, the amount of insulation in the backing member can be increased by simply adding more foam, without any other cost in materials. A single backing member can be used with multiple veneer layers to provide desired assemblies. The siding member layer can also be reduced in thickness, thus reducing waste.
  • While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims (20)

1. An insulating panel, comprising:
a backing member having a front face, a rear face, a top face having a front edge and a rear edge, a bottom face, a first side face, and a second side face;
wherein the top face of the backing member is angled from the front edge to the rear edge, such that the angle between the top face and the rear face of the backing member is acute;
a siding member having a veneer, a top wall, and a nailing hem;
wherein the veneer has a front face, a rear face, a top edge, and a bottom edge, the rear face of the veneer being attached to the front face of the backing member;
wherein the top wall extends rearwardly from the top edge of the veneer, the top wall having a front edge and a rear edge;
wherein the nailing hem extends upwardly from the rear edge of the top wall;
wherein the top edge of the veneer has a hook extending forward;
wherein the bottom edge of the veneer extends beyond the bottom face of the backing member and has a lip extending rearward; and
wherein a bottom edge of the rear face of the backing member has a horizontal detent running from the first side face to the second side face of the backing member, the horizontal detent configured to receive the nailing hem of an adjacent panel.
2. The insulating panel of claim 1, wherein the hook and the lip are complementary in shape.
3. The insulating panel of claim 1, wherein the horizontal detent has a height equal to or greater than a height of the nailing hem.
4. The insulating panel of claim 1, wherein the front face of the backing member is angled with respect to the rear face of the backing member.
5. The insulating panel of claim 1, wherein the bottom face of the backing member does not contact the top wall of an adjacent panel, such that a gap is present between the bottom face of the backing member and the top wall of the adjacent panel.
6. The insulating panel of claim 1, wherein the backing member is composed of closed-cell expanded foam.
7. The insulating panel of claim 1, wherein the veneer has a constant thickness from the top edge to the bottom edge.
8. The insulating panel of claim 1, wherein the rear face of the siding member is adhesively attached to the front face of the backing member.
9. The insulating panel of claim 1, wherein the top wall of the siding member is adhesively attached to the top face of the backing member.
10. The insulating panel of claim 1, wherein the angle between the rear face and the top face of the backing member is between 60° to 89°.
11. The insulating panel of claim 1, wherein the top wall of the siding member is angled from the front edge to the rear edge of the top wall.
12. The insulating panel of claim 11, wherein the angle between the top wall and the nailing hem of the siding member is between 91° and 120°.
13. The insulating panel of claim 11, wherein the angle between the rear face and the top face of the backing member is complementary to the angle between the top wall and the nailing hem of the siding member, such that the top wall of the siding member rests on the top face of the backing member.
14. The insulating panel of claim 1, wherein the bottom face of the backing member is angled such that the angle between the bottom face and the rear face of the backing member is obtuse.
15. The insulating panel of claim 14, wherein the top face of the backing member is parallel to the bottom face of the backing member.
16. The insulating panel of claim 1, wherein the veneer of the siding panel is made up of an upper wall, a lower wall, and a longitudinal platform joining a lower edge of the upper wall with an upper edge of the lower wall.
17. A siding member, comprising:
a veneer having a front face, a top edge, a bottom edge, and a rear face, wherein the top edge of the veneer has a hook extending forward and the bottom edge of the veneer has a lip extending rearward;
a top wall extending rearwardly from the top edge of the veneer, the top wall having a front edge and a rear edge; and
a nailing hem extending upwardly from the rear edge of the top wall.
18. The siding member of claim 17, wherein the angle between the top wall and the nailing hem is obtuse.
19. The siding member of claim 17, wherein the veneer has a constant thickness from the top edge to the bottom edge.
20. The siding member of claim 17, wherein the veneer includes an upper wall, a lower wall, and a longitudinal platform joining a lower edge of the upper wall with an upper edge of the lower wall.
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USD818151S1 (en) 2015-12-23 2018-05-15 Certainteed Corporation Siding panel
US20180202166A1 (en) * 2017-01-18 2018-07-19 Progressive Foam Technologies, Inc. Siding panel and assembly
CN109098376A (en) * 2018-09-11 2018-12-28 檀安建筑材料(上海)有限公司 Keep the temperature leakproof decorative panel
US11041316B1 (en) * 2016-07-29 2021-06-22 Metal Design Systems, Inc. Wall cladding system
CN114033119A (en) * 2021-11-30 2022-02-11 广州康普顿至高建材有限公司 Overlapping type interlocking mounting structure of wall panel

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USD818151S1 (en) 2015-12-23 2018-05-15 Certainteed Corporation Siding panel
USD863604S1 (en) 2015-12-23 2019-10-15 Certainteed Corporation Siding panel
USD943120S1 (en) 2015-12-23 2022-02-08 Certainteed Corporation Siding panel
USD979101S1 (en) 2015-12-23 2023-02-21 Certainteed Llc Siding panel
US11041316B1 (en) * 2016-07-29 2021-06-22 Metal Design Systems, Inc. Wall cladding system
US20180202166A1 (en) * 2017-01-18 2018-07-19 Progressive Foam Technologies, Inc. Siding panel and assembly
US10458123B2 (en) * 2017-01-18 2019-10-29 Progressive Foam Technologies, Inc. Siding panel and assembly
CN109098376A (en) * 2018-09-11 2018-12-28 檀安建筑材料(上海)有限公司 Keep the temperature leakproof decorative panel
CN114033119A (en) * 2021-11-30 2022-02-11 广州康普顿至高建材有限公司 Overlapping type interlocking mounting structure of wall panel

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