Siding containing composite building material and siding clip

Abstract

Siding including composite building material and a siding clip are provided. The panel has male and female interlocking elements and may be formed from a composite building material having a foamed substrate having a foamed inner core and a dense integral skin, wherein the foamed substrate includes a polymer matrix and a reinforcing filler, and a urethane / acrylic coating applied to the foamed substrate at the front face of the siding panel, wherein the coating includes an IR-reflective pigment, wherein the urethane / acrylic coating is chemically and / or physically bound to the substrate.

Description

RELATED APPLICATIONS[0001]This application claims benefit to U.S. Provisional Patent Application Ser. No. 61 / 118,102, filed on Nov. 26, 2008, which is expressly incorporated herein in its entirety by reference thereto.FIELD OF THE INVENTION[0002]The present invention is directed to exterior wall cladding containing composite building materials and a siding clip. More specifically, the present invention is directed to siding containing foamed composite building materials. Also, the present invention is directed to siding having foamed composite building materials that are coated with a high performance urethane / acrylic coating.BACKGROUND OF THE INVENTION[0003]Conventional building products, particularly for use in siding, trim, railing, decking and fencing, have included natural wood. Natural wood has been used traditionally for its availability and relatively low cost (although wood siding and trim may be a more expensive product when maintenance costs are considered). However, draw...

AI Technical Summary

Benefits of technology

[0040]The present invention provides a siding panel including an upper portion having an upper male locking element and an upper female locking element, a bottom portion having a bottom male locking element and a bottom female locking element, and a front face that faces outwardly and is exposed when the siding panel is installed. The upper male locking element and the upper female locking element engage, respectively, corresponding bottom female and male locking elements of like panels. The bottom male locking element and the bottom female locking element engage, respectively, corresponding upper female and male locking elements of like panels. The panel is formed from a composite building material having a foamed substrate having a foamed inner core and a dense integral skin, where the foamed substrate includes a polymer matrix and a reinforcing filler, and preferably a urethane / acrylic coating or a decorative laminate film applied to the foamed substrate at the front face of the siding panel, where the coating and / or film includes an IR-reflective pigment, and where the urethane / acrylic coating or laminate film is chemically and / or physically bound to the substrate. Another technique replaces some the integral skin which is removed by milling and replacing that skin with a backprinted film having color and image laminated to the machined foamed product in a fashion that provides a infinite pattern selection. The image film can be coated with any UV protecting film used to prevent substrate deterioration due to UV exposure. Stable backprints utilize back printed inks which reflect the sun's near-infrared energy, thus reducing the sidewall temperature. Solar reflectance is critical to retard those degradation reactions that create color and physical property deterioration over time.

[0059]An additional advantage of the siding according to the present invention is that the siding may be stronger, more durable, and less prone to buckling than other siding. As a result the siding may have a longer lifespan than other siding.

Problems solved by technology

Natural wood has been used traditionally for its availability and relatively low cost (although wood siding and trim may be a more expensive product when maintenance costs are considered).

However, drawbacks to natural wood exist.

For example, the quality of available natural wood has diminished over time.

Some treatment processes have been deemed environmentally unsound and have been prohibited in some jurisdictions, further diminishing the use of natural wood.

In addition, natural wood has the drawback that it splinters, rots, discolors and / or requires significant maintenance when used in applications exposed to the outdoors, such as siding, e.g., home siding.

Although the cement composite material is resistant to permanent water and termite damage when it is properly coated and installed, the cement composite suffers from several drawbacks.

One disadvantage of the cement composite of the '103 patent is that the material is susceptible to cracking and chipping during transit, warehousing, job site storage, handling and installation.

Another undesirable characteristic of the cement composite is that exterior products formed from the cement composite are subject to degradation of mechanical properties in geographic regions that experience freezing and thawing conditions.

Another objectionable feature of the cement composite is that the density of the material is high, leading to heavy building components susceptible to sagging and / or breaking.

The product is unforgiving of improper installation, and without proper sealing and drainage, it can be eroded by moisture penetration.

Further the high density also increases labor requirements—e.g., a 3-man installation crew is common with fiber cement.

Also, there may be concern about the carcinogenic silica dust released when the material is field cut—respirators may be required, although enforcement of this requirement may be difficult.

One disadvantage is that the final product has a high density, increasing the shipping and handling demands.

A further objectionable feature is a tendency to sag when used as a semi-load bearing material as in seating or decking.

The wood fiber itself is prone to color shift when exposed to ordinary weathering forces, usually shifting to a weathered grey appearance.

Another undesirable feature is that the wood-thermoplastic composite material, as disclosed in the '532 patent, absorbs and retains significantly high heat levels when exposed to sunlight due to the excessive absorption of infrared light.

Another undesirable feature of the wood-thermoplastic composite material is that the cellulosic components therein contain nutrients that can support the growth of mold and / or mildew.

Low stain, scratch and mar resistance are also undesirable features of these compositions.

Another disadvantage of the polymer-fiber composite disclosed in the '268 patent is that the material experiences relatively rapid degradation of mechanical properties when exposed to outdoor conditions.

Heat distortion may result from excessive heat build and the resulting strains plus its expansion and contraction due to heat load from below freezing to well over 140 degrees (insolation) causes stresses.

These expansion / contraction stresses may result in distortion difficulties and poor aesthetics on the wall.

Its popularity may be dropping, however, due to aesthetics and perceived lack of structural integrity.

Exterior building products, such as siding, are exposed to the full solar radiation spectrum of light including damaging UV and IR wave lengths and to cycles of heating and cooling upon exposure to the sun.

UV and heat sensitive substrates such as vinyl, polyolefins, styrenics (including ABS, ASA), polycarbonates, polyesters and other material are susceptible to UV light and heat degradation over long periods of time.

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