Building surface panels and method of forming the same

Abstract

A building surface panel can include an outer element; a backing component with a first backing layer attached to a second backing layer, wherein the first backing layer is attached to the outer element to form the building surface panel, wherein the building surface panel further comprises one of: a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%, a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel, a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element, a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3, and a combination thereof.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This Application is a Continuation-in-Part of U.S. patent application Ser. No. 19 / 042,055, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME, by Ashley A. SCHULTZ et al., filed Jan. 31, 2025, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 627,527, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Ashley A. SCHULTZ et al., filed Jan. 31, 2024, and also claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 710,660, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Greg Thomas HOLLAND, filed Oct. 23, 2024, all of which are assigned to the current assignee hereof and the entire disclosures of these applications are incorporated herein by reference in their entireties.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to a building surface panel for covering a building surface. The present disclosure relates more particularly to a backed or reinforced building surface panel for covering a building surface.BACKGROUND

[0003] Building surface panels, such as cladding or siding, are visible elements that cover an underlying support structure. Siding panels are typically used in the construction of homes, businesses, and other buildings on exterior walls. These siding panels can provide protection to the underlying support structure from weather and other elements.

[0004] There is a wide variety of distinct types of building surface panels that may be used to cover exterior walls. Such surface panels may exhibit heat distortion and / or buckling while installed on a building surface, due to environmental conditions and changing conditions. Therefore, improvements in building surface panels are continually needed.SUMMARY

[0005] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

[0006] One general aspect includes a building surface panel with an outer element; and a backing component, which can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, where the building surface panel further can include one of: a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%, a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel, a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element, a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3, and a combination thereof.

[0007] One general aspect includes a building surface panel with an outer element; and a backing component can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, and where the backing component further can include one or more longitudinally extending ribs that protrude from the backing component.

[0008] One general aspect includes a building surface panel with an outer element; and a backing component can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, and where the backing component can include at least one of: a longitudinally extending groove; a longitudinally extending tongue; and a density that is at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3.

[0009] One general aspect includes a building surface panel with an outer element; and a backing component can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, and where the outer element has a first front side, a first rear side, and a first thickness as measured between the first front side and the first rear side; and the backing component has a second front side, a second rear side, and a second thickness as measured between the second front side and the second rear side, where the second front side of the backing component is attached to the first rear side of the outer element, where the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

[0010] One general aspect includes a building surface panel with an outer element with a first element layer that can include acrylonitrile styrene acrylate (ASA) that is attached to a second element layer that can include polyvinyl chloride (PVC); and a backing component with a first backing layer that can include ASA that is attached to a second backing layer that can include PVC, where the first element layer is attached to the first backing layer to form the building surface panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Embodiments are illustrated by way of example and are not limited to the accompanying figures. These and other features, aspects, and advantages of present embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0012] FIG. 1 is a schematic depiction of side-view of a portion of a building surface panel according to an embodiment described herein;

[0013] FIG. 2 is a schematic depiction of a front-view of a portion of a building surface panel according to an embodiment described herein;

[0014] FIG. 3 is a representative perspective view of a portion of a building covered by building surface panels, in accordance with certain embodiments;

[0015] FIG. 4A is a representative full view of a building surface panel formed as a unitary body with an outer element and a backing component formed together, prior to folding, in accordance with certain embodiments;

[0016] FIG. 4B is a representative perspective view of a building surface panel formed as a unitary body with an outer element and a backing component formed together, prior to folding, in accordance with certain embodiments;

[0017] FIG. 4C is a representative perspective view of a building surface panel formed as a unitary body with an outer element and a backing component formed together and the backing component folded to engage the outer element, in accordance with certain embodiments;

[0018] FIG. 5A is a representative perspective view of a unitary body formed with an outer element and a backing component, and the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0019] FIG. 5B is a representative partial cross-sectional view 5B-5B, as indicated in FIG. 5A, of a building surface panel, in accordance with certain embodiments;

[0020] FIG. 5C is a representative detail view of the detail region 5C, as indicated in FIG. 5B, of a building surface panel, in accordance with certain embodiments;

[0021] FIG. 6A is a representative perspective view of multiple building surface panels with a reinforced outer element assembled together, in accordance with certain embodiments;

[0022] FIG. 6B is a representative partial cross-sectional view 6B-6B, as indicated in FIG. 6A, of multiple building surface panels assembled together on a building surface, in accordance with certain embodiments;

[0023] FIG. 7A is a representative perspective view of a unitary body formed with an outer element and a backing component, with the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0024] FIG. 7B is a representative partial cross-sectional view 7B-7B, as indicated in FIG. 7A, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0025] FIG. 8A is a representative perspective view of multiple building surface panels with a reinforced outer element assembled together, in accordance with certain embodiments;

[0026] FIG. 8B is a representative partial cross-sectional view 8B-8B, as indicated in FIG. 8A, of multiple building surface panels assembled together on a building surface, in accordance with certain embodiments;

[0027] FIG. 9A is a representative perspective view of a unitary body formed with an outer element and a backing component, with the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0028] FIG. 9B is a representative partial cross-sectional view 9B-9B, as indicated in FIG. 9A, of a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0029] FIG. 10A is a representative perspective view of an outer element of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0030] FIG. 10B is a representative perspective view of a backing component of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0031] FIG. 10C is a representative perspective view of a building surface panel formed from a two-piece construction by attaching the backing component to the outer element, in accordance with certain embodiments;

[0032] FIG. 10D is a representative partial cross-sectional view 10D-10D, as indicated in FIG. 10C, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0033] FIG. 11A is a representative perspective view of an outer element of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0034] FIG. 11B is a representative perspective view of a backing component of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0035] FIG. 11C is a representative perspective view of a building surface panel formed from a two-piece construction by attaching the backing component to the outer element, in accordance with certain embodiments;

[0036] FIG. 11D is a representative partial cross-sectional view 11D-11D, as indicated in FIG. 11C, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0037] FIG. 11E is a representative perspective rear view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments;

[0038] FIGS. 12A-12D are representative partial cross-sectional views 12-12, as indicated in FIG. 11E, of reinforcement elements in a backing component to reinforce an outer element of a building surface panel, in accordance with certain embodiments;

[0039] FIGS. 13A-13B are representative cross-sectional views of a portion of an outer element of a building surface panel, in accordance with certain embodiments;

[0040] FIGS. 14A-14B are representative cross-sectional views of a portion of a backing component of a building surface panel, in accordance with certain embodiments; and

[0041] FIGS. 15-20 are representative cross-sectional views of a portion of an outer element of a building surface panel attached to a portion of a backing component of a building surface panel, in accordance with certain embodiments.

[0042] FIGS. 21-22 are representative cross-sectional views of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments.

[0043] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.DETAILED DESCRIPTION

[0044] The following discussion will focus on specific implementations and embodiments of the teachings. The detailed description is provided to assist in describing certain embodiments and should not be interpreted as a limitation on the scope or applicability of the disclosure or teachings. It will be appreciated that other embodiments can be used based on the disclosure and teachings as provided herein.

[0045] The terms “comprises,”“comprising,”“includes,”“including,”“has,”“having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present), and B is false (or not present), A is false (or not present), and B is true (or present), and both A and B are true (or present).

[0046] Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one or the singular as also including the plural or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

[0047] The use of the word “about”, “approximately”, “generally”, or “substantially” is intended to mean that a value of a parameter is close to a stated value or position. However, minor differences may prevent the values or positions from being exactly as stated. Thus, differences of up to ten percent (10%) for the value are reasonable differences from the ideal goal of exactly as described. A significant difference can be when the difference is greater than ten percent (10%).

[0048] Embodiments described herein are generally directed to a building surface panel that may include an outer element and a backing component. As used herein, the term “outer element” is used interchangeably with “outer shell,”“outer layer,”“exterior layer,”“cladding face,” or “siding.” The outer element can be formed separately from the backing component and attached to the backing component by any suitable means, or the outer element and the backing component can be formed together as a unitary body and folded to attach the backing component to the outer element to form the backed or reinforced building surface panel. As used herein, the term “building surface panel” refers to a backed or reinforced building surface panel unless specified otherwise.

[0049] For purposes of illustration, FIG. 1 shows a schematic side-view of a portion of a building surface panel 100 according to embodiments described herein. As shown in FIG. 1, the building surface panel 100 may include an outer element 110 and a backing component 120. As also shown in FIG. 1, the outer element 110 may have a front side 112 and a rear side 114. As further shown in FIG. 1, the backing component 120 may be attached to rear side 114 of the outer element 110.

[0050] For purposes of further illustration, FIG. 2 shows a schematic front view of a portion of the building surface panel 100 according to embodiments described herein. Components of embodiments described herein may be described as having a length, height, and width (or thickness). It is noted that, for purposes of embodiments described herein and as shown in FIG. 2, “length” refers to the length (L2) in an X-direction along a longitudinal axis of the component oriented as it would be installed on a building, “height” refers to the height (H) in a Y-direction along a lateral axis of the component oriented as it would be installed on a building, and “width” refers to the width (W) in a Z-direction along a transversal axis of the component oriented as it would be installed on a building. As used herein, the longitudinal axis corresponds to the extrusion direction.

[0051] Foams can be adhered to the back of building surface panels to form a backing component that can reinforce the building surface panels. However, the insulative properties of foam can lead to issues with heat buildup and temperature differential across the panel. This can lead to differences in thermal expansion between the backing component and the outer element, thus creating distortions at the overlap between building surface panels or distortions anywhere on the face of the outer element that can lead to aesthetic defects in the panel. A building surface panel that includes a backing (or support) component that provides mechanical support while reducing temperature differential between the backing component and the outer element (which can also be referred to as an outer element) can minimize these issues.

[0052] Referring back to FIG. 1, it will be appreciated that for purposes of embodiments described herein, the outer element 110 may be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the outer element 110 may be formed of multiple layers that can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. For example, the outer element 110 may be formed of two layers that are coextruded or extruded separately and then attached together.

[0053] As stated above, the outer element 110 can be formed of multiple layers. FIGS. 13A-13B are representative cross-sectional views of an outer element 110 of a building surface panel 100, in accordance with certain embodiments. In an embodiment, as shown in FIG. 13A, the outer element 110 can include a first element layer 110a and a second element layer 110b. In a number of embodiments, the first element layer 110a can comprise a first element composition.

[0054] In a number of embodiments, the second element layer 110b can comprise a second element composition. In a number of embodiments, the first element layer 110a and the second element layer 110b can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. The first element layer 110a can form the front side 112 of the outer element 110, also referred to herein as a capstock layer, and the second element layer 110b can form the rear side 114 of the outer element 110. In a number of embodiments, the first element layer 110a can provide an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building, as shown in FIGS. 15, 16, and 18.

[0055] In some other embodiments, the second element layer 110b can form the front side 112 of the outer element 110, and the first element layer 110a can form the rear side 114 of the outer element 110. In a number of embodiments, the second element layer 110b can provide an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building, as shown in FIG. 17.

[0056] In a number of embodiments, as shown in FIG. 13B, the outer element 110 can include a third element layer 110c. In a number of embodiments, the third element layer 110c can comprise a third element composition.

[0057] Any suitable material can be used for the first element composition, the second element composition, or the third element composition, including, but not limited to, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0058] In some embodiments, the first element composition can be the same as the second element composition. In other embodiments, the first element composition can be different from that of the second element composition. In yet other embodiments, the third element composition can be the same as either of the first element composition or the second element composition. In some embodiments, the third element composition can be different from either of the first element composition or the second element composition.

[0059] For example, in a number of embodiments, the first element composition can comprise acrylonitrile styrene acrylate (ASA). In a number of embodiments, the first element composition can consist essentially of acrylonitrile styrene acrylate (ASA). In other embodiments, the second element composition can comprise polyvinyl chloride (PVC). In a number of embodiments, the second element composition can consist essentially of polyvinyl chloride (PVC). In a number of embodiments, the third element composition can comprise acrylonitrile styrene acrylate (ASA). In a number of embodiments, the third element composition can consist essentially of acrylonitrile styrene acrylate (ASA).

[0060] In a number of embodiments, as shown in FIG. 13B, the third element layer 110c can be attached to an opposite side of the second element layer 110b from the first element layer 110a, such as by coextruding or molding the first element layer 110a, the second element layer 110b, and / or the third element layer 110c together. In other embodiments, the outer element 110 comprising the first element layer 110a, the second element layer 110b, and / or the third element layer 110c can be formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0061] In yet another embodiment, any of the first element layer 110a, the second element layer 110b, and / or the third element layer 110c of the outer element 110 can comprise recycled PVC, including post-industrial recycled PVC and / or post-consumer recycled PVC, in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the outer element 110.

[0062] In yet another embodiment, any of the first element layer 110a, the second element layer 110b, and / or the third element layer 110c of the outer element 110 can comprise recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, any of the first element layer 110a, the second element layer 110b, and / or the third element layer 110c of the outer element 110 can comprise recycled PVC that includes portions of recycled PVC having different colors. In a number of embodiments, the second element layer 110b of the outer element 110 can have any of the above recited percentages of recycled PVC (post-industrial PVC or post-consumer recycled PVC). In a number of embodiments, the second element layer 110b of the outer element 110 can have at least 10% by weight of recycled PVC or post-consumer recycled PVC.

[0063] It will be appreciated that for purposes of embodiments described herein, the backing component 120 may be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the backing component 120 may be formed of multiple layers that can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0064] For example, the backing component 120 may be formed of two layers that are coextruded or extruded separately and then attached together. In an embodiment, the backing component may comprise one or more longitudinally extending reinforcement elements. The one or more reinforcement elements may comprise one or more longitudinally extending protrusions or longitudinally extending ribs, longitudinal corrugation, honeycomb pattern, embossed features, or an elongated piece that is adhered to the backing component. The elongated piece may be continuous, solid piece, corrugated, honeycomb, or a geometric pattern. In a non-limiting embodiment, the front side 122 and / or the back side 124 of the backing component 120 can be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc. In another embodiment, only the front side 122 of the backing component can be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc., such that the back side 124 is substantially smooth and uniform, and without any embossed feature.

[0065] In another embodiment, rear side 114 of the outer element 110 and the front side 122 of the backing component 120 may be attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. In another embodiment, at least one of the rear side 114 of the outer element 110 or the backing component 120 may undergo one or more treatments including, but not limited to chemical, plasma, corona, thermal, flame, or ultrasonic bonding, abrasion, prior to the application of adhesive.

[0066] As stated above, the backing component 120 can be formed of multiple layers. FIGS. 14A-14B are representative cross-sectional views of a backing component 120 that can be used to reinforce an outer element 110 of a building surface panel 100, in accordance with certain embodiments. In an embodiment, as shown in FIG. 14A, the backing component 120 can include a first backing layer 120a and a second backing layer 120b. In a number of embodiments, the first backing layer 120a can comprise of a first backing composition.

[0067] In a number of embodiments, the second backing layer 120b can comprise a second backing composition. In a number of embodiments, the first backing layer 120a and the second backing layer 120b can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. The first backing layer 120a can form the front side 122 of the backing component 120, also referred to herein as a capstock layer, and the second backing layer 120b can form the rear side 124 of the backing component 120.

[0068] In a number of embodiments, as shown in FIG. 14B, the backing component 120 can include a third backing layer 120c. In a number of embodiments, the third backing layer 120c can comprise a third backing composition.

[0069] In a number of embodiments, as shown in FIG. 14B, the third backing layer 120c can be attached to an opposite side of the second backing layer 120b from the first backing layer 120a, such as by coextruding or molding the first element layer 110a, the second element layer 110b, and / or the third element layer 110c together. In other embodiments, the outer element 110 comprising the first element layer 110a, the second element layer 110b, and / or the third element layer 110c can be formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0070] In yet another embodiment, any of the first backing layer 120a, the second backing layer 120b, and / or the third backing layer 120c of the backing component 120 can comprise recycled PVC, including post-industrial recycled PVC and / or post-consumer recycled PVC, in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the backing component 120.

[0071] In yet another embodiment, any of the first backing layer 120a, the second backing layer 120b, and / or the third backing layer 120c of the backing component 120 can comprise recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, any of the first backing layer 120a, the second backing layer 120b, and / or the third backing layer 120c of the backing component 120 can comprise recycled PVC that includes portions of recycled PVC having different colors. In a number of embodiments, the second backing layer 120b of the backing component 120 can have any of the above recited percentages of recycled PVC (post-industrial PVC or post-consumer recycled PVC). In a number of embodiments, the second backing layer 120b of the backing component 120 can have at least 10% by weight of recycled PVC or post-consumer recycled PVC.

[0072] In a number of embodiments, a first adhesive 111 (see FIGS. 15-20) can attach the rear side 114 of the outer element 110 to the front side 122 of the backing component 120. In a number of embodiments, the first adhesive in a cured state provides a bond shear strength as measured between the rear side 114 and the front side 122. In a number of embodiments, the first adhesive 111 can contain additives that can scavenge hydrochloric acid (HCl) or other acidic species generated during the thermal or environmental degradation of PVC, which can improve adhesion since HCl can cause loss of adhesion strength.

[0073] Suitable acid scavenger additives may include, but are not limited to, hydrotalcite-based materials, calcium stearate, zinc stearate, calcium carbonate, epoxidized oils, or any other material which is capable of capturing or neutralizing acidic impurities and thereby inhibiting autocatalytic polymer degradation. Incorporation of such HCl scavengers into the first adhesive 111 can enhance the long-term stability of the building surface panel 100, by preventing acid-catalyzed deterioration at the adhesive interface, improving interlayer adhesion durability, and preserving mechanical, aesthetic, and environmental performance.

[0074] For example, the shear strength between the rear side 114 and the front side 122 can be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C.

[0075] In particular embodiments, the first adhesive in a cured state provides a bond shear strength as measured between the rear side 114 and the front side 122 of at least about 0.10 MPa at room temperature.

[0076] FIGS. 15-20 are representative cross-sectional views of a portion of an outer element of a building surface panel attached to a portion of a backing component of a building surface panel, in accordance with certain embodiments. These figures show various arrangements of layers for both the outer element 110 and the backing component 120. However, it should be understood that that other layer arrangements are envisioned and the scope of this disclosure is not limited to the arrangements shown in FIGS. 15-20.

[0077] FIG. 15 shows the first element layer 110a forming the front side 112 of the outer element 110 and the second element layer 110b forming the rear side 114 of the outer element 110. FIG. 15 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the second backing layer 120b forming the rear side 124 of the backing component 120. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100. In an embodiment, the first element layer 110a can be capstock and the second element layer 110b and the second backing layer 120b can be support layers.

[0078] FIG. 16 shows the first element layer 110a forming the front side 112 of the outer element 110 and the second element layer 110b forming the rear side 114 of the outer element 110. FIG. 16 also shows the first backing layer 120a forming the rear side 124 of the backing component 120 and the second backing layer 120b forming the front side 122 of the backing component 120. In an embodiment, the first element layer 110a and the first backing layer 120a can be capstock and the second element layer 110b and the second backing layer 120b can be support layer. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0079] FIG. 17 shows the first element layer 110a forming the rear side 114 of the outer element 110 and the second element layer 110b forming the front side 112 of the outer element 110. FIG. 17 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the second backing layer 120b forming the rear side 124 of the backing component 120. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0080] FIG. 18 shows the first element layer 110a forming the rear side 114 of the outer element 110 and the second element layer 110b forming the front side 112 of the outer element 110. FIG. 18 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the third backing layer 120c forming the rear side 124 of the backing component 120, with the second backing layer 120b sandwiched therebetween. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0081] FIG. 19 shows the first element layer 110a forming the front side 112 of the outer element 110 and the second element layer 110b forming the rear side 114 of the outer element 110. FIG. 19 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the third backing layer 120c forming the rear side 124 of the backing component 120, with the second backing layer 120b sandwiched therebetween. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100. In an embodiment, the first element layer 110a and the third backing layer can be capstock and the second element layer 110b and the second backing layer 120b can be support layers.

[0082] FIG. 20 shows the first element layer 110a forming the front side 112 of the outer element 110 and the third element layer 110c forming the rear side 114 of the outer element 110 with the second element layer 110b sandwiched therebetween. FIG. 20 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the third backing layer 120c forming the rear side 124 of the backing component 120, with the second backing layer 120b sandwiched therebetween. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0083] Any of the first composition, the second composition, or the third composition can be any of polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0084] Any of the backing layers 120a, 120b, 120c or element layers 110a, 110b, 110c can be any color. These layers can have substantially the same color as other layers as well as can have a different color than one or more of the other layers.

[0085] In a number of embodiments, the building surface panel can have any suitable configuration of multilayer outer element 110 / adhesive 111 / multilayer backing component 120, including but not limited to the following configurations, where “ / ” indicates an attachment of adjacent layers:

[0086] PVC1 / PVC2 / Adhesive / PVC2 / PVC3

[0087] PVC1 / PVC2 / Adhesive / PVC3 / PVC1-r

[0088] PVC1 / PVC2 / PVC1 / Adhesive / PVC2 / PVC2

[0089] PVC1 / PVC1-r / PVC1 / Adhesive / PVC2 / PVC1-r

[0090] ASA1 / PVC2 / Adhesive / PVC2 / PVC2

[0091] ASA1 / PVC2 / Adhesive / PVC2 / PVC1-r

[0092] ASA1 / PVC2 / ASA2 / Adhesive / PVC2 / PVC2

[0093] ASA1 / PVC2 / ASA2 / Adhesive / PVC2 / PVC1-r

[0094] ASA1 / PVC1-r / ASA2 / Adhesive / PVC2 / PVC2

[0095] ASA1 / PVC1-r / ASA2 / Adhesive / PVC2 / PVC1-r

[0096] PVC1 / ASA1 / Adhesive / ASA2 / PVC2

[0097] PVC1 / ASA1 / Adhesive / ASA2 / PVC1-r

[0098] PVC1 / ASA1 / Adhesive / ASA2 / PVC2 / ASA3

[0099] PVC1 / ASA1 / Adhesive / ASA2 / PVC1-r / ASA3

[0100] PVC1 / PVC2 / ASA1 / Adhesive / ASA1 / PVC2

[0101] PVC1 / PVC2 / ASA1 / Adhesive / ASA2 / PVC1-r

[0102] PVC1 / PVC1-r / ASA1 / Adhesive / ASA2 / PVC2

[0103] PVC1 / PVC1-r / ASA1 / Adhesive / ASA1 / PVC2-r

[0104] PVC1 / PVC2 / ASA1 / Adhesive / ASA2 / PVC3 / ASA3

[0105] PVC1 / PVC2 / ASA1 / Adhesive / ASA2 / PVC1-r / ASA3

[0106] PVC1 / PVC1-r / ASA1 / Adhesive / ASA2 / PVC2 / ASA3

[0107] PVC1 / PVC1-r / ASA1 / Adhesive / ASA2 / PVC2-r / ASA3

[0108] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC3

[0109] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC1-r

[0110] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC3 / ASA4

[0111] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC1-r / ASA4

[0112] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2

[0113] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2-r

[0114] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2 / ASA4

[0115] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2-r / ASA4

[0116] Where each of the PVC1, PVC2, PVC3, and PVC4 represents one or more layers of the multilayer of the outer element 110 or the backing component 120 having a composition comprising PVC. However, PVC1, PVC2, PVC3, and PVC4 may be the same or differ in one or more of layer thickness and PVC composition in terms of amounts and chemical nature / type of one or more additives. Similarly, each of the PVC1-r and PVC2-r represents one or more layers of the multilayer of the outer element 110 or the backing component 120 having a composition comprising recycled PVC.

[0117] However, PVC1-r and PVC2-r may be the same or differ in one or more of layer thickness and recycled PVC composition in terms of amounts and chemical nature / type of one or more additives or the nature (PIR versus PCR) and amount of the recycled PVC. where each of the ASA1, ASA2, ASA3, and ASA4 represents one or more layers of the multilayer of the outer element 110 or the backing component 120 having a composition comprising ASA. However, ASA1, ASA2, ASA3, and ASA4 may be the same or differ in one or more of layer thickness and ASA composition in terms of amounts and chemical nature / type of one or more additives.

[0118] Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

[0119] It will be appreciated that for purposes of embodiments described herein, the outer element 110 and the backing component 120 may be a unitary body that is a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. As used herein, “unitary body” refers to a body that includes multiple components that are formed together as one piece with the components being integral to each other.

[0120] According to certain embodiments the building surface panel 100 may have a particular CTE mismatch measured between the outer element 110 and the backing component 120. It will be appreciated that the CTE mismatch described herein is equal to the absolute value of the difference between the CTE of the outer element 110 and the CTE of the backing component 120 divided by the average of the CTE of the outer element 110 and the CTE of the backing component 120, where the CTE of each element is measured according to American Society for Testing and Materials (ASTM) D696 at a temperature 25° C. According to particular embodiments, the building surface panel 100 may have a CTE mismatch of not greater than about 20%, such as not greater than about 19% or not greater than about 18% or not greater than about 17% or not greater than about 16% or not greater than about 15% or not greater than about 14% or not greater than about 13 percent or not greater than about 12% or not greater than about 11% or not greater than about 10% or not greater than about 9% or not greater than about 8% or not greater than about 7% or not greater than about 6% or even not greater than about 5% or even not greater than about 2% or even not greater than about 1% or even not greater than about 0.5% or even not greater than about 0.1%. It will be appreciated that the CTE mismatch of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the CTE mismatch of the building surface panel 100 may be any value between any of the values noted above. In another embodiment, the outer element 110 and the backing component 120 may have substantially the same CTE.

[0121] According to still other embodiments, the building surface panel 100 may have a particular deflection measurement if subjected to a curvature test at least 90 days after formation of the building surface panel 100. For purposes of embodiments described herein, the curvature test is performed at a temperature of 25° C., ambient humidity, according to the following steps: 1) remove a substantially flat strip of the layered structure from the building surface panel to be tested, the strip extending parallel to the length of the building surface panel and having a length of 33 inches and a width of 4.5 inches (any nail hem may be cut away), 2) define a first end point of the strip at a position on the front side of the outer element that is 1.5 inches from a first end of the strip and centered across the width of the strip, and define a second end point of the strip at a position on the front side of the outer element that is that is 1.5 inches from the second end of the strip and centered across the width of the strip, 3) position the strip such that the width is oriented vertically, the front side of the outer element faces a fixed reference plane, and a line that passes through the first and second end points is parallel to the reference plane, and 4) measure, using a laser position gage, the deflection measurement as equal to a difference between a first distance from the end points to the reference plane and a second distance from a peak on the front side of the outer element to the reference plane. According to particular embodiments, the building surface panel 100 may have a deflection measurement of not greater than about 10 mm, such as not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm. Additionally, the building surface panel 100 according to various embodiments of the present invention exhibits deflection measurement of not greater than 10 mm not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm, in a curvature test when exposed to 1000 W / m 2. It will be appreciated that the deflection measurement of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the deflection measurement of the building surface panel 100 may be any value between any of the values noted above.

[0122] According to yet other embodiments, the building surface panel 100 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the building surface panel 100 may have an R-value of not greater than about 0.60° F.·ft2·hr / BTU, such as not greater than about 0.57° F.·ft2·hr / BTU or not greater than about 0.55° F.·ft2·hr / BTU or not greater than about 0.53° F.·ft2·hr / BTU or not greater than about 0.50° F.·ft2·hr / BTU or not greater than about 0.47° F.·ft2·hr / BTU or not greater than about 0.45° F.·ft2·hr / BTU or not greater than about 0.43° F.·ft2·hr / BTU or not greater than about 0.40° F.·ft2·hr / BTU or not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that the R-value of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the R-value of the building surface panel 100 may be any value between any of the values noted above.

[0123] According to yet other embodiments, the outer element 110 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the outer element 110 may have an R-value of not greater than about 0.40° F.·ft2·hr / BTU, such as not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that the R-value of the outer element 110 may be between any of the values noted above. It will be further appreciated that the R-value of the outer element 110 may be any value between any of the values noted above.

[0124] According to yet other embodiments, the backing component 120 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal conductivity of the article as measured according to ASTM C518. According to certain embodiments, the backing component 120 may have an R-value of not greater than about 0.40° F.·ft2·hr / BTU, such as not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that the R-value of the backing component 120 may be between any of the values noted above. It will be further appreciated that the R-value of the backing component 120 may be any value between any of the values noted above.

[0125] According to still other embodiments, the building surface panel 100 may pass a surface distortion test as measured according to ASTM 7745, where the foam backer is replaced with the backing component 120 of the present invention. In particular, the building surface panel 100 may pass a surface distortion test as measured according to ASTM 7745 at a temperature of 150° F. (66° C.) by being free of bulges, waves, and ripples. In various embodiments, the building surface panels of the present invention are substantially free of surface distortion, which can also be referred to as oil-canning effect.

[0126] According to other embodiments, the building surface panel 100 may have a particular vertical face radius of curvature as measured at room temperature along the vertical face (i.e., along the y-axis) of the building surface panel 100. For example, the building surface panel 100 may have a vertical face radius of curvature of at least about 500 mm, such as at least about 550 mm or at least about 600 mm or at least about 650 mm or at least about 700 mm or at least about 750 mm or at least about 800 mm or at least about 850 mm or at least about 900 mm or at least about 950 mm or at least about 1000 mm or at least about 1050 mm or at least about 1100 mm or at least about 1150 mm or at least about 1200 mm or at least about 1250 mm or at least about 1300 mm or at least about 1350 mm or at least about 1400 mm or at least about 1450 mm or at least about 1500 mm or at least about 1550 mm or at least about 1600 mm or at least about 1650 mm or at least about 1700 mm or at least about 1750 mm or at least about 1800 mm or at least about 1850 mm or at least about 1900 mm or at least about 1950 mm or at least about 2000 mm or at least about 2050 mm or at least about 2100 mm or at least about 2150 mm or at least about 2200 mm or at least about 2250 mm or at least about 2300 mm or at least about 2350 mm or at least about 2400 mm or at least about 2450 mm or at least about 2500 mm or at least about 2550 mm or even at least about 2600 mm. It will be appreciated that the vertical face radius of curvature of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the vertical face radius of curvature of the building surface panel 100 may be any value between any of the values noted above.

[0127] According to still other embodiments, the outer element 110 of the building surface panel 100 may include a particular material. For example, the outer element 110 may include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic resin, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, polymer composite, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, and combinations thereof comprising a combination of one of the above virgin (new / non-recycled) material and one of the above recycled material. As used herein, the term “recycled material” refers to post-industrial recycled material including scrap and regrind material, post-consumer recycled material, and a combination thereof.

[0128] According to yet other embodiments the outer element 110 of the building surface panel 100 may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

[0129] According to still other embodiments, the outer element 110 of the building surface panel 100 may have a particular CTE as measured according to ASTM D696. For example, the outer element 110 may have a CTE of not greater than about 200 μm / (m·° C.), such as not greater than about 195 μm / (m·° C.) or not greater than about 190 μm / (m·° C.) or not greater than about 185 μm / (m·° C.)or not greater than about 180 μm / (m·° C.)or even not greater than about 175 μm / (m·° C.). It will be appreciated that the CTE of the outer element 110 may be within a range between any of the values noted above. It will be further appreciated that the CTE of the outer element 110 may be any value between any of the minimum and maximum values noted above.

[0130] According to other embodiments, the backing component 120 of the building surface panel 100 may include a particular material. For example the backing component may include polyvinyl chloride (PVC), cellular PVC, chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof and combinations thereof comprising a combination of one of the above virgin (new / non-recycled) material and one of the above recycled material. In an embodiment, the backing component comprises recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC in an amount greater than that present in the capstock layer and / or the support layer of the outer element 110.

[0131] In yet another embodiment, the backing component 120 comprises post-industrial recycled PVC or post-consumer recycled PVC in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the backing component 120. In yet another embodiment, the backing component 120 comprises recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, the backing component 120 comprises recycled PVC that includes portions of recycled PVC having different colors. In a number of embodiments, the first second backing layer 120b of the backing component 120 may have any of the above recited percentages of recycled PVC or post-consumer recycled PVC. In a number of embodiments, the second backing layer 120b of the backing component 120 may have at least 10% by weight of recycled PVC or post-consumer recycled PVC.

[0132] The backing component 120, as opposed to the outer element 110 can include recycled PVC with minimal contents of impurities from the group including adhesive, metal, different colored PVC, various other polymers, etc. These impurities can arise from the reclamation process for collecting used or not newly manufactured PVC (e.g., from a job site, from factory PVC waste material, etc.), and blending the recycled PVC into manufacturing processes to make a product, such as a backing component 120.

[0133] The various impurities that can be present in the recycled PVC can include, but are not limited to, at least one of polyvinylidene flouride (PVDF), acrylonitrile styrene acrylate (ASA), chlorinated PVC (CPVC), polyurethane, acrylic, silicone, rubber, chlorinated polyethylene, calcium carbonate, titanium dioxide, talc, and combinations thereof. The various polymers can account for less than 20%, or less than 15%, or less than 10%; or less than 5% by weight of the backing component 120. The metal can comprise aluminum or steel and can account for less than 1% by weight of the backing component 120.

[0134] In an embodiment of the building surface panel 100, the amount of recycled PVC in the backing component 120, is substantially greater than that of the outer element 110. In some embodiments of the building surface panel 100, the outer element 110 and the backing component 120 have substantially the same color. In other embodiments of the building surface panel 100, the outer element 110 and the backing component 120 have substantially different colors.

[0135] According to yet other embodiments, the backing component 120 of the building surface panel 100 may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof. For example, the backing component 120 may include one or more additives and a polymer including polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof.

[0136] In all embodiments in this disclosure, the outer element 110 can include a capstock disposed over a support layer, with the capstock forming the front side 112 and the backing component 120 being disposed over the outer element 110 on a side opposite the capstock, the rear side 114 of the outer element 110, as shown in FIG. 1. The capstock and backer material can be any of the materials disclosed below for the outer element 110. However, it can be preferrable that the capstock be made from a material that is more resistant to damage or degradation by environmental elements. Therefore, the capstock can be laminated to the outer element or coextruded with the support layer or tri-extruded with the support layer and the backer material or printed / painted on those surfaces of the outer element 110 that would be exposed to the elements when installed on a building.

[0137] Any suitable polymer can be used for capstock including, but not limited to, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof. The capstock may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

[0138] In a non-limiting embodiment, the capstock comprises a virgin polymer, such as acrylonitrile styrene acrylate (ASA), and the support layer or the backing component 120 comprises a suitable polymer such as polyvinyl chloride (PVC), or chlorinated polyvinyl chloride (CPVC), recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC or blends thereof.

[0139] In a non-limiting embodiment, the support layer of the outer element 110 and the backing component 120 comprises substantially the same polymeric composition (polymer and one or more additives). In a non-limiting embodiment, the outer element 110 comprising the capstock and the support layer forming the front side 112, comprises two different polymeric compositions, and the backing component 120 is formed of another polymeric composition different from that of the capstock and the support layer. The polymeric compositions of the capstock, the support layer, and the backing component 120 can differ in the amounts of one or more additives and / or the chemical composition of the polymers. In a non-limiting embodiment, the capstock, the support layer and the backing component 120 are all co-extruded or tri-extruded. In a non-limiting embodiment, capstock is laminated over the support layer. In yet another embodiment, capstock is painted, printed, spray coated, or roll coated over the support layer.

[0140] According to still other embodiments, the backing component 120 of the building surface panel 100 may have a particular CTE as measured according to ASTM D696. For example, the backing component 120 may have a CTE of not greater than about 200 μm / (m·° C.), such as not greater than about 195 μm / (m·° C.) or not greater than about 190 μm / (m·° C.) or not greater than about 185 μm / (m·° C.) or not greater than about 180 μm / (m·° C.) or even not greater than about 175 μm / (m·° C.). It will be appreciated that the CTE of the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the CTE of the backing component 120 may be any value between any of the minimum and maximum values noted above.

[0141] According to yet other embodiments, the outer element 110 may have a particular thickness. As used herein, “thickness” of the outer element 110 refers to the distance between the front side 112 and the rear side 114 as shown in at least FIG. 1. For example, the outer element 110 may have a thickness of at least about 0.1 mm, such as at least about 0.5 mm or at least about 1 mm or at least about 1.5 mm or at least about 2 mm or at least about 2.5 mm or at least about 3 mm or at least about 3.5 mm or at least about 4 mm or at least about 4.5 mm or even at least about 5 mm. According to still other embodiments, the outer element 110 may have a thickness of not greater than about 10 mm, such as not greater than about 9.5 mm or not greater than about 9.0 mm or not greater than about 8.5 mm or not greater than about 8 mm or even not greater than about 7.5 mm. It will be appreciated that the thickness of the outer element 110 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the outer element 110 may be any value between any of the minimum and maximum values noted above.

[0142] According to still other embodiments, the backing component 120 may have a particular thickness. As used herein, “thickness” of the backing component 120 refers to the distance between the front side 122 to the rear side 124 of the portions of the backing component 120 that are outside the reinforcement elements 126 as shown in at least FIGS. 12A-12D. As used herein, “thickness” of the outer element 110 refers to the distance between the front side 112 to the rear side 114 of the outer element 110 as shown in at least FIGS. 12A-12D. For example, the backing component 120 may have a thickness of at least about 0.2 mm, such as at least about 0.5 mm or at least about 0.1 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the backing component 120 may have a thickness of not greater than about 50 mm, such as not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm or not greater than about 15.0 mm or not greater than about 10 mm or not greater than about 5 mm or not greater than about 4 mm or not greater than about 3 mm. It will be appreciated that the thickness of the backing component 120 may be within a range between any of the minimum and maximum values noted above here it will be further appreciated that the thickness of the backing component 120 may be any value between any of the minimum and maximum values noted above.

[0143] According to still other embodiments, the building surface panel 100 may have a particular thickness or multiple thicknesses along the height (Y axis). For example, the building surface panel 100 may have a thickness of at least about 0.12 mm, such as at least about 0.13 mm or at least about 0.14 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the building surface panel 100 may have a thickness of not greater than about 60 mm, such as not greater than about 57.5 mm were not greater than about 55 mm were not greater than about 52.5 mm were not greater than about 50 mm were not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm. It will be appreciated that the thickness of the building surface panel 100 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the building surface panel 100 may be any value between any of the minimum and maximum values noted above. In some embodiments, the building surface panel 100 can have multiple thicknesses, along the height (Y axis), within a range between any of the minimum and maximum values noted above due to portions of the building surface panel 100 where the outer element 110 is attached to the backing component 120, and other portions of the building surface panel 100 where the outer element 110 has no backing component 120 attached to it.

[0144] The first element layer 110a or the third element layer 110c of the outer element 110 of any of the embodiments of the building surface panel 100 can have various thicknesses from 0.025 mm up to 0.254 mm, with the remainder of the thickness of the outer element 110 being a difference between one of these values and any one of the thickness values for the outer element 110 given in this disclosure. The second element layer 110b can be less than the remainder of the thickness of the outer element 110.

[0145] The first backing layer 120a or the third backing layer 120c of the backing component 120 of any of the embodiments of the building surface panel 100 can have various thicknesses from 0.025 mm up to 0.254 mm, with the remainder of the thickness of the backing component 120 being a difference between one of these values and any one of the thickness values for the backing component 120 given in this disclosure. The second backing layer 120b can be less than the remainder of the thickness of the backing component 120.

[0146] In a number of embodiments, as stated above the outer element 110 can have first front side 112, a first rear side 114, and a first thickness as measured between the first front side 112 and the first rear side 114. In a number of embodiments, as stated above, the backing component 120 can have a second front side 122, a second rear side 124, and a second thickness as measured between the second front side 122 and the second rear side 124.

[0147] In an embodiment, the second thickness of the backing component 120 can be greater than about 0.5 times, or greater than about 1.0 times, or greater than about 1.2 times, or greater than about 1.5 times, or greater than about 2.0 times, or greater than about 2.5 times, or greater than about 3.0 times or greater than about 3.5 times a first thickness of the outer element 110.

[0148] The second thickness of the backing component 120 can be less than about 5.0 times, or less than about 4.75 times, or less than about 4.25 times, or than about 3.75 times, or less than about 3.25 times, or less than about 2.75 times, or less than about 2.25 times, or less than about 1.75 times, or less than about 1.25 times, or less than about 0.75 times a first thickness of the outer element 110. It will be appreciated that the second thickness of the backing component 120 may be within a range between any of the minimum and maximum values noted above times the first thickness of the outer element 110.

[0149] As noted above, the outer element 110 can be attached to the backing component 120 or vice versa. Any suitable means could be used for attaching the outer element 110 and the backing component 120, including but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. According to certain embodiments, the outer element 110 can be attached to the backing component 120 through a particular means. For example, according to certain embodiments, the outer element 110 can be fused to the backing component 120, for example, through an ultrasonic weld. According to yet other embodiments, the outer element 110 can be mechanically attached to the backing component 120, for example, through a clip, nail, screw, or any other mechanical attachment component.

[0150] According to yet other embodiments, the backing component 120 can be fixedly attached to any portion of the outer element 110. According to still other embodiments, the outer element 110 can be adhered to any portion of the backing component 120, for example, with an adhesive. According to still other embodiments, the outer element 110 can be attached to the backing component 120, for example, through chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0151] According to still other embodiments, the building surface panel 100 may further include an adhesive layer (not shown in FIG. 1) between the outer element 110 and the backing component 120.

[0152] According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the outer element 110 and the backing component 120. For example, the shear strength between the outer element 110 and the backing component 120 may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C. It will be appreciated that the shear strength as measured between the outer element 110 and the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the outer element 110 and the backing component 120 may be any value between any of the values noted above.

[0153] According to still other embodiments, the adhesive layer may include a particular material. For example, the adhesive layer may include a solvent-based adhesive, a polyvinyl chloride (PVC) adhesive, an acrylic adhesive, a modified acrylic adhesive, a silicone adhesive, a one or two-component polyurethane adhesive, heat or moisture cured adhesive of these materials thereof, or any tape form of these materials thereof.

[0154] According to still other embodiments, the adhesive layer may consist essentially of a particular material. For example, the adhesive layer may consist essentially of a polyvinyl chloride (PVC) adhesive, an acrylic adhesive, a modified acrylic adhesive, a silicone adhesive, a one or two-component polyurethane adhesive, heat or moisture cured adhesive of these materials thereof, or any tape form of these materials thereof. The adhesives of this disclosure can be a low surface energy type of adhesive that can be used to adhere the outer element 110 to the backing component 120. The adhesive of the present disclosure can have a surface energy of greater than 15 dynes / cm or greater than 20 dynes / cm or greater than 25 dynes / cm or greater than 30 dynes / cm or greater than 35 dynes / cm or greater than 40 dynes / cm or greater than 45 dynes / cm and less than 55 dynes / cm or less than 50 dynes / cm or less than 45 dynes / cm or less than 40 dynes / cm or less than 35 dynes / cm or less than 30 dynes / cm or less than 30 dynes / cm or less than 25 dynes / cm or less than 23 dynes / cm. In an embodiment, the adhesive of the present disclosure can have a surface energy in the range of 30 to 45 dynes / cm. The adhesives of this disclosure can remain flexible throughout the life of the building surface panel 100.

[0155] The adhesives of this disclosure can have a shear modulus, when cured, of between about 1 MPa to about 900 MPa. The disclosed adhesives can have a shear modulus of greater than 1 MPa, or greater than 2 MPa, or greater than 3 MPa, or greater than 4 MPa, or greater than 5 MPa, or greater than 6 MPa, or greater than 7 MPa, or greater than 8 MPa, or greater than 9 MPa, or greater than 10 MPa or greater than 15 MPa, or greater than 20 MPa, or greater than 30 MPa, or greater than 35 MPa, or greater than 40 MPa, or greater than 60 MPa, or greater than 80 MPa, or greater than 100 MPa, or greater than 200 MPa, or greater than 300 MPa, or greater than 400 MPa.

[0156] The adhesives of this disclosure can have a shear modulus when cured of less than 900 MPa, or less than 890 MPa, or less than 880 MPa, or less than 870 MPa, or less than 850 MPa, or less than 800 MPa, or less than 700 MPa, or less than 600 MPa, or less than 500 MPa, or less than 400 MPa, or less than 300 MPa, or less than 200 MPa, or less than 100 MPa. It will be appreciated that the shear modulus of the adhesives disclosed herein may be within a range between any of the values noted above. It will be further appreciated that the shear modulus of the adhesives disclosed herein may be any value between any of the minimum and maximum values noted above.

[0157] According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the outer element 110 and the adhesive layer. For example, the bond shear strength between the outer element 110 and the adhesive layer may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C. It will be appreciated that the bond shear strength as measured between the outer element 110 and the adhesive layer may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the outer element 110 and the adhesive layer may be any value between any of the values noted above.

[0158] According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the adhesive layer and the backing component 120. For example, the bond shear strength between the adhesive layer and the backing component 120 may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa. It will be appreciated that the bond shear strength as measured between the adhesive layer and the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the adhesive layer and the backing component 120 may be any value between any of the values noted above.

[0159] According to yet other embodiments the adhesive layer may have a particular R-value. For purposes of embodiments described here in the R-value may be equal to the thickness of the article divided by the thermal conductivity of the article as measured according to ASTM C518. According to certain embodiments the adhesive layer may have an R-value of not greater than about 0.40° F.·ft2·hr / BTU, such as not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that R-value of the adhesive layer may be between any of the values noted above. It will be further appreciated that the R-value of the building adhesive layer may be any value between any of the values noted above.

[0160] According to yet other embodiments, the building surface panel 100 may have a particular height. For example, the building surface panel 100 may have a height of at least about 100 mm, such as at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the building surface panel 100 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the building surface panel 100 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the building surface panel 100 may be any value between any of the minimum and maximum values noted above.

[0161] According to yet other embodiments, the outer element 110 may have a particular height. For example, the outer element 110 may have a height of at least about 100 mm, such as at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the outer element 110 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the outer element 110 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the outer element 110 may be any value between any of the minimum and maximum values noted above. In an embodiment, the height of the outer element 110 may be substantially the same as that of the building surface panel 100. In another embodiment, the height of the outer element 110 may be less than that of the building surface panel 100.

[0162] According to yet other embodiments, the backing component 120 may have a particular height. For example, the backing component 120 may have a height of at least about 10 mm, such as at least about 25 mm or at least about 50 mm or at least about 75 mm or at least about 100 mm or at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the backing component 120 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the backing component 120 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the backing component 120 may be any value between any of the minimum and maximum values noted above. In an embodiment, the height of the backing component 120 may be substantially the same as that of the building surface panel 100. In another embodiment, the height of the backing component 120 may be less than that of the outer element 110. In yet another embodiment, the height of the backing component 120 may be more than that of the outer element 110.

[0163] According to still other embodiments, the building surface panel 100 may have a particular length. For example the building surface panel 100 may have a length of at least about 1 meter, such as at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the building surface panel 100 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the building surface panel 100 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the building surface panel 100 may be any value between any of the minimum and maximum values noted above.

[0164] According to still other embodiments, the outer element 110 may have a particular length. For example the outer element 110 may have a length of at least about 1 meter, such as at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the outer element 110 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the outer element 110 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the outer element 110 may be any value between any of the minimum and maximum values noted above. In an embodiment, the length of the outer element 110 is substantially the same as that of the building surface panel 100.

[0165] According to still other embodiments, the backing component 120 may have a particular length. For example the backing component 120 may have a length of at least about 0.5 meters, such as at least about 1.0 meters or at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the backing component 120 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the backing component 120 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the backing component 120 may be any value between any of the minimum and maximum values noted above. In another embodiment, the length of the backing component 120 is less than that of the outer element 110 and the building surface panel 100 for horizontally oriented building surface panels 100. In another embodiment, the length of the backing component 120 is substantially the same as that of the outer element 110 and the building surface panel 100 for vertically oriented building surface panels 100.

[0166] It will be appreciated that the outer element 110 of the building surface panel 100 may have any desirable shape, in horizontal or vertical orientation, including, but not limited to clapboard, dutchlap, board & batten, beaded, beveled edge, or v-groove. According to certain embodiments, and as shown in FIG. 1, the outer element 110 may have a rectangular or flat face shape. According to other embodiments, the outer element 110 may have a cylindrical or curved face shape. According to other embodiments, the outer element 110 may have a flat face shape with beveled edges. or a flat face shape with beveled edges and one or more longitudinal grooves. In an embodiment, the outer element 110 of the building surface panel 100 may have a shape, as disclosed in U.S. Pat. No. 11,920,356, incorporated by reference herein in its entirety. In an embodiment, the outer element 110 of the building surface panel 100 may have a decorative outer element, as disclosed in US Patent Publication No. 2024 / 0218670, incorporated by reference herein in its entirety.

[0167] It will be further appreciated that the backing component 120 of the building surface panel 100 may have any desirable shape. According to certain embodiments, and as shown in FIG. 1, the backing component 120 may have a rectangular or flat face shape. According to other embodiments, the backing component 120 may have a cylindrical or curved face shape.

[0168] According to certain embodiments, the shape of the outer element 110 will match the shape of the backing component 120. According to yet other embodiments, the shape of the outer element 110 will be different than the shape of the backing component 120. It will be appreciated that when the shape of the outer element 110 does not match the shape of the backing component 120, the backing component 120 may not completely contact the outer element 110 when attached. For example, portions of the backing component 120 may contact the outer element 110 when attached, but other portions of the backing component 120 may not contact the outer element, leaving voids between the two components.

[0169] According to certain embodiments, the outer element 110 of the building surface panel 100 may have any desirable profile. For example, the outer element 110 may have a flat profile. According to still other embodiments, the outer element 110 may have a contoured profile.

[0170] According to certain embodiments, the backing component 120 of the building surface panel 100 may have any desirable profile. For example, the backing component 120 may have a flat profile. According to still other embodiments, the backing component 120 may have a contoured profile.

[0171] According to certain embodiments, the backing component 120 may have a particular profile that matches the profile of the outer element 110. For example, the backing component 120 may have a flat profile that matches a flat profile of the outer element 110. According to still other embodiments, the backing component 120 may have a contoured profile that matches a contoured profile of the outer element 110.

[0172] According to still other embodiments, the backing component 120 may have a particular profile that does not match the profile of the outer element 110. It will be appreciated that when the profile of the outer element 110 does not match the profile of the backing component 120, the backing component 120 may not completely contact the outer element 110 when attached. For example, portions of the backing component 120 may contact the outer element 110 when attached, but other portions of the backing component 120 may not contact the outer element, leaving voids between the two components.

[0173] According to still other embodiments, the building surface panel 100 may be a siding panel and includes a fastener hem, an upper lock, a panel body, and a lower lock. As used herein, the term “tongue” is used interchangeably with lock or upper lock and the term “groove” is used interchangeably with butt leg, locking leg or lower leg. In an embodiment, the backing component 120 comprises a groove, and wherein the groove is adapted to receive a tongue of another building surface panel. In an embodiment, the outer element comprises a tongue that is proximate the fastener hem, and wherein the tongue is adapted to engage a groove of another building surface panel. In an embodiment, outer element 110 comprises the tongue and the backing component comprises the groove. In other embodiments, the backing component 120 comprises both the tongue and the groove. In a number of embodiments, the groove may be a longitudinally extending groove. In a number of embodiments, the tongue may be a longitudinally extending tongue.

[0174] According to yet another embodiment, a method of manufacturing a building surface panel may include providing an outer element 110 having a front side 112 and a rear side 114, and attaching a backing component 120 to the rear side 114 of the outer element 110. It will be appreciated that the building surface panel, the outer element, and the backing component described in reference to the method may have any of the characteristics or properties described in reference to the building surface panel 100, the outer element 110 or the backing component 120 described.

[0175] FIG. 3 is a representative perspective view of a portion of a building 30 covered by building surface panels 100 (e.g., building surface panels 100a, 100b, 100c, 100d) attached to a building surface 32 (or underlying support structure), in accordance with certain embodiments. The building surface panel 100 (e.g., building surface panel 100a) can have a longitudinal length L and a height H. The building surface panels 100 are shown as having a flat face profile, but the profile of the building surface panels 100 can be any of the profiles or shapes described herein. Although, FIGS. 4-11 illustrates some embodiments of the invention, the profiles are not limiting, and the invention is applicable to various profiles known in the art (not shown here), including those described in U.S. Pat. No. 11,920,356 and US Patent Publication No. 20240218670, incorporated by reference herein in their entirety.

[0176] FIG. 4A is a representative full view of a building surface panel 100 formed as a unitary body 106 with an outer element 110 and a backing component 120 formed together, prior to folding, in accordance with certain embodiments. The lower portion of the unitary body 106 can be seen as the outer element 110 with a front side 112, a rear side 114 (not shown, see FIG. 4B), a left side 132, a right side 134, and a bottom flange 138. When the building surface panel 100 is formed with a reinforced outer element 110 and attached to the building surface 32, the front side 112 of the outer element 110 can provide an aesthetic appearance, while covering a portion of the building surface 32, as shown in FIG. 3.

[0177] A tongue 130 can be formed at the top of the outer element 110 portion as well as a plurality of openings 118. The tongue 130 of one building surface panel 100 can be used to engage a groove 140 of another building surface panel 100, when multiple building surface panels 100 are attached to the building surface 32. The openings 118 can be used to receive fasteners when attaching the building surface panel 100 to a building surface 32.

[0178] The groove 140 can be formed at the top of the unitary body 106, which can be positioned at the bottom of the building surface panel 100 when the unitary body 106 is folded into a configuration where the backing component 120 is positioned behind the outer element 110 and attached to the rear side 114 of the outer element 110. The upper portion of the unitary body 106 can be seen as the backing component 120 portion with a front side 122 (not shown, see FIG. 4B), a rear side 124, a left side 102, a right side 104, and a groove 140. The groove 140 can be formed to mate and interlock with the tongue 130 of an adjacent building surface panel 100.

[0179] Openings 128 can be formed in the backing component 120 portion near the folding feature 150, such that when the unitary body 106 is folded into a configuration where the backing component 120 is positioned behind the outer element 110, the openings 128 can align with the openings 118, such that fasteners can be received in the aligned openings 118, 128. However, it is not a requirement to have the openings 128. The openings 118 can provide guidance for installation of fasteners, without having corresponding openings 128 in the backing component. The backing component 120 portion can include one or more longitudinally extending reinforcement elements, such as one or more longitudinally extending protrusions or longitudinally extending ribs 126 for enhanced, strength, rigidity, or stability of the building surface panel 100. The ribs 126 can be formed longitudinally along the backing component 120, and at a height that provides increased rigidity, strength, or stability while not interfering with attachment of the building surface panel 100 to a building surface 32.

[0180] A plurality of relief holes 136 can be provided in the backing component 120 portion to reduce weight of the building surface panel 100 while still providing sufficient rigidity and strength to the building surface panel 100. Any of the backing component 120 embodiments can include relief holes 136, which can preferably be located outside of the reinforcement elements 126. Foam generally used in foam backed siding can have a density that is much lower than a density of the outer element of the foam backed siding. For example, a density of a foam used in foam back siding can generally range from 0.15 grams / cm3 up to 0.32 grams / cm3, wherein material used to form the backing component 120 of this disclosure can range from 0.40 grams / cm3 up to 2.0 grams / cm3.

[0181] The density of either the outer element 110 or the backing component 120 of the building surface panels 100 can have a density that is greater than about 0.40 grams / cm3, or greater than about 0.50 grams / cm3, or greater than about 0.60 grams / cm3, or greater than about 0.70 grams / cm3, greater than about 0.80 grams / cm3, or greater than about 0.85 grams / cm3, or greater than about 0.90 grams / cm3, or greater than about 0.95 grams / cm3, or greater than about 1.00 grams / cm3, or greater than about 1.10 grams / cm3, or greater than about 1.20 grams / cm3, or greater than about 1.30 grams / cm3, or greater than about 1.40 grams / cm3, or greater than about 1.50 grams / cm3, or greater than about 1.55 grams / cm3, or greater than about 1.75 grams / cm3, or greater than about 1.85 grams / cm3, or greater than about 1.95 grams / cm3.

[0182] The density of either the outer element 110 or the backing component 120 of the building surface panels 100 can have a density that is less than about 2.00 grams / cm3, or less than about 1.95 grams / cm3, or less than about 1.90 grams / cm3, or less than about 1.85 grams / cm3, or less than about 1.80 grams / cm3, or less than about 1.75 grams / cm3, or less than about 1.70 grams / cm3, or less than about 1.60 grams / cm3, or less than about 1.50 grams / cm3, or less than about 1.40 grams / cm3, or less than about 1.30 grams / cm3. It will be appreciated that the density of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the density of the building surface panel 100 may be any value between any of the values noted above.

[0183] Providing relief holes 136 in the backing component 120 of the building surface panel 100 of this disclosure can provide significant weight reduction, while maintaining sufficient structural stability of the backing component 120. Additionally, the thickness of the backing component 120 can be adjusted to improve structural stability without significantly impacting the overall size of the building surface panel 100.

[0184] However, it is not required to have relief holes 136 in the backing component 120. A folding feature 150 can be formed in the unitary body 106 to enable folding of the backing component 120 to engage a rear side 114 of the outer element 110. The folding feature 150 can form a longitudinal peak in the unitary body 106 which can allow for deformation of the peak while allowing for alignment of the openings 118, 128 when the unitary body 106 is folded to form the building surface panel 100.

[0185] The folding feature 150 can also include holes 146 that can further assist in allowing the unitary body 106 to be folded about the axis 90. Additionally, or alternatively, the folding feature 150 can include a thinner or more pliable material to assist in folding the unitary body 106 along the folding feature 150. Additionally, or alternatively, the folding feature 150 can include a separate material than the outer element 110 or the backing component 120, with this separate material being a more resilient material than either the outer element 110 or the backing component 120, thereby minimizing forces needed to fold the unitary body 106 along the folding feature 150.

[0186] Since the building surface panels 100 can be assembled onto a building surface 32 with horizontally adjacent building surface panels 100 butted together, it can be desirable that the right side 134 of one building surface panel 100 overlaps the left side 132 of an adjacent building surface panel 100 to further protect the building surface 32 from environmental conditions. Therefore, to allow for this overlap, the tongue 130 and the backing component 120 portion can be cut-back from the left and right sides 132, 134 of the outer element 110 by a distance LI to form a cutback 116 in the unitary body 106. It should be understood that the cutback 116 can be desirable, but is not required.

[0187] FIG. 4B is a representative perspective view of a building surface panel 100 formed as a unitary body 106 with an outer element 110 and a backing component 120 formed together, in accordance with certain embodiments. After being formed as the unitary body 106, the backing component 120 portion can be rotated or folded (arrows 92) about the axis 90 relative to the outer element 110 portion, such that the front side 122 of the backing component 120 engages with the rear side 114 of the outer element 110. The outer element 110 can be attached to the backing component 120 through a particular means as described above. When the outer element 110 is attached to the backing component 120, the folded unitary body 106 can form the building surface panel 100, which includes the tongue 130 formed along the top of the building surface panel 100 and a groove 140 formed at the bottom of the building surface panel 100, as shown in FIG. 4C. The bottom flange 138 can be positioned just below the groove 140 for aesthetic purposes.

[0188] FIG. 5A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. The unitary body 106 has been folded at the folding feature 150 to engage the backing component 120 with the outer element 110. The openings 118 can be aligned with the openings 128 to form a fastener hem 170, which can receive fasteners when attaching the building surface panel 100 to a building surface 32 via fasteners (e.g., fasteners 34 shown in FIG. 6B). The tongue 130 can extend along the outer element 110, with the cutbacks 116 at each end. The front side 112 of the outer element 110 is shown as an angled flat face profile. However, the front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein. The one or more reinforcement elements such as ribs 126 can extend longitudinally along the backing component 120 to provide reinforcement and rigidity to the outer element 110 when the backing component 120 is attached to the outer element 110.

[0189] FIG. 5B is a representative partial cross-sectional view 5B-5B, as indicated in FIG. 5A, of a building surface panel 100, in accordance with certain embodiments. The unitary body 106 has been folded at the folding feature 150 and the backing component 120 has been attached by a particular means to the rear side 114 of the outer element 110. The outer element 110 can provide a flat-face appearance that is angled relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. When the openings 118 align with the openings 128, the building surface panel 100 can form a fastener hem 170 that is a double thickness of the material used to form that unitary body 106. The tongue 130 can be formed just below the fastener hem 170 and adapted to complimentarily mate with a groove 140 of an adjacent building surface panel 100. The bottom flange 138 can be formed to overlay the groove 140 to provide a more aesthetic look when the building surface panels 100 are installed on a building surface 32.

[0190] FIG. 5C is a representative detail view of the detail region 5C, as indicated in FIG. 5B, of a building surface panel 100, in accordance with certain embodiments. The front side 112 of the outer element 110 can provide an aesthetic look for the building surface panel 100. The front side 122 of the backing component 120 can be attached to the rear side 114 of the outer element 110. An adhesive or adhesive layer 144 can be used to attach the backing component 120 to the outer element 110. The rear side 124 of the backing component 120 faces the building surface 32 when the building surface panel 100 is installed on the building surface 32. The groove 140 can form a longitudinal channel 142 into which a tongue 130 of an adjacent building surface panel 100 can be received.

[0191] The bottom of the longitudinal channel 142 can be inclined relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. A plurality of weep holes 162 can be formed through the groove 140 to allow any trapped fluid to drain away from the longitudinal channel 142. The bottom flange 138 can also be inclined relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. The incline of the bottom flange 138 preferably matches the incline of the bottom of the longitudinal channel 142 but is not required to do so. A plurality of weep holes 160 can be formed through the bottom flange 138 to allow any trapped fluid to drain away from the bottom flange 138 to an external environment (e.g., a front side 112 of an adjacent building surface panel positioned below the current building surface panel 100), where the fluid can be evaporated or otherwise managed to prevent fluid from being trapped in the building surface panel 100.

[0192] FIG. 6A is a representative perspective view of multiple building surface panels 100 with a reinforced outer element 110 assembled together, in accordance with certain embodiments. The building surface panels 100 can be assembled on the building surface 32 horizontally aligned with other building surface panels 100 (e.g., building surface panels 100b, 100c, with the right side of the building surface panel 100b overlapping the left side of the building surface panel 100c). The cutback 116 can allow the right side of one building surface panel 100 to overlap the left side of an adjacent building surface panel 100 up to a distance that can be substantially equal to the distance L1.

[0193] FIG. 6B is a representative partial cross-sectional view 6B-6B, as indicated in FIG. 6A, of multiple building surface panels 100 assembled together on a building surface 32, in accordance with certain embodiments. The building surface panels 100 can be assembled on the building surface 32 vertically aligned with each other. For example, when assembled vertically, the upper building surface panel 100a can be positioned across an overlap of lower building surface panels 100b, 100c (see FIG. 6A). The groove 140 of the upper building surface panel 100a can engage a portion of the tongue 130′ of each of the building surface panels 100b, 100c. When the building surface panel 100a is engaged with the tongues 130′ and when fasteners 34 attach the fastener hem 170 of the building surface panel 100a to the building surface 32, then the engagement of the tongues 130′ of the building surface panels 100b, 100c with the groove 140 of the building surface panel 100a will secure the building surface panel 100a to the building surface 32, since the tongues 130′ are secured to the building surface 32 via the fasteners 34′.

[0194] The bottom flange 138 overlays the groove 140, which receives the tongue 130′. The building surface panel 100b can include the outer element 110′ and the backing component 120′ attached to the rear side of the building surface panel 100b. In a non-limiting embodiment, the building surface panels 100 assembled on the building surface 32 can form a surface (which can include the front sides 112, 112′) that covers the building surface 32 and forms a shiplap type look. It should be understood that many other finished surfaces are possible with this reinforced building surface panel 100.

[0195] Referring to FIGS. 7A-7B, FIG. 7A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 7B is a representative partial cross-sectional view 7B-7B, as indicated in FIG. 7A, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. Where the previously described building surface panel 100 forms a shiplap type look, the building surface panel 100 of FIGS. 7A-7B forms a beveled edge look, where there is an angled groove formed between adjacent building surface panels 100, with a flat-face surface between angled grooves. The beveled edge building surface panels 100 can form a flat-face with longitudinal V-shaped grooves evenly spaced apart in a vertical direction. The building surface panels 100 can also form other aesthetic looks such as clapboard, dutchlap, board & batten, tongue & groove.

[0196] It should be understood that the building surface panels 100 can be assembled on the building surface 32 in any orientation from horizontal to vertical. They are not limited to a horizontal orientation indicated in the figures. The building surface panel 100 is formed from a unitary body 106 folded at the folding feature 150 to engage the backing component 120 with the outer element 110, as discussed above. However, the shape of the outer element 110 and the backing component 120 are different than the shiplap type building surface panels 100. The folded unitary body 106 still forms the fastener hem 170 with the openings 118, 128 being aligned. The tongue 130 can be similar to the previous embodiments, such that it is formed to engage with a groove 140 of an adjacent building surface panel 100.

[0197] The front side 112 of the outer element 110 can form a flat face surface that can be substantially parallel with a building surface 32 when the building surface panel 100 is attached to the building surface 32. At the top of the front side 112 can be an angled portion 158, that is inclined from an upper portion of the building surface panel 100 to the front side 112. At the bottom of the front side 112, the bottom flange 138 can be formed as an angled portion that can engage (or at least be positioned proximate) an angled portion 158′ of an adjacent building surface panel 100b positioned below the current building surface panel 100a (see FIG. 8B).

[0198] The backing component 120 can include a complimentarily shaped angled portion 168 that can engage the angled portion 158 when the backing component 120 is attached to the outer element 110. The backing component 120 can also include one or more ribs 126 that provide additional stability for the backing component 120 and thus for the outer element 110, when the backing component 120 is attached to the outer element 110. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein. The front side 112 can also include one or more longitudinal recesses of various shapes, e.g., V-shaped, circularly shaped, rectangularly shaped, curve shaped, etc.

[0199] Referring to FIGS. 8A-8B, FIG. 8A is a representative perspective view of multiple building surface panels 100 with a reinforced outer element 110 assembled together, in accordance with certain embodiments. FIG. 8B is a representative partial cross-sectional view 8B-8B, as indicated in FIG. 8A, of multiple building surface panels 100 assembled together on a building surface 32, in accordance with certain embodiments.

[0200] As can be seen, the edge of the groove 140 of the upper building surface panel 100a can be received into the tongue 130′ of the lower building surface panel 100b. This can securely couple the groove 140 of the upper building surface panel 100a to the building surface 32 via the fasteners 34′ that can be used to secure the fastener hem 170 of the lower building surface panel 100b to the building surface 32. Fasteners 34 can be used to securely couple the fastener hem 170 of the upper building surface panel 100a to the building surface 32 in preparation for installing another building surface panel 100 above the upper building surface panel 100a. The lower building surface panel 100b can include an outer element 110′ with an angled portion 158′ and a bottom flange 138′, and a backing component 120′ with an angled portion 168′ and a groove 140′.

[0201] Referring to FIGS. 9A-9B, FIG. 9A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 9B is a representative partial cross-sectional view 9B-9B, as indicated in FIG. 9A, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments.

[0202] The building surface panel 100 is similar to the building surface panel 100 shown in FIGS. 7A-8B, except that this building surface panel 100 can have one or more additional longitudinal recesses formed in the front side 112 of the building surface panel 100. The building surface panel 100 of FIGS. 9A-9B forms a beveled edge look with a center longitudinal recess 117, where there is an angled groove formed between adjacent building surface panels 100, with a flat-face surface between angled grooves, and with one or more longitudinal recesses 117 being formed in the front side 112.

[0203] The beveled edge building surface panels 100 can form a flat-face with longitudinal V-shaped grooves evenly spaced apart in a vertical direction as well as the one or more longitudinal recesses 117 positioned between the V-shaped grooves. It should be understood that the one or more longitudinal recesses 117 can also be V-shaped as well as many other shapes.

[0204] It should be understood that the building surface panels 100 can be assembled on the building surface 32 in any orientation from horizontal to vertical. They are not limited to a horizontal orientation indicated in the figures. The building surface panel 100 is formed from a unitary body 106 folded at the folding feature 150 to engage the backing component 120 with the outer element 110, as discussed above. However, the shape of the outer element 110 and the backing component 120 are different than the shiplap type building surface panels 100. The folded unitary body 106 still forms the fastener hem 170 with the openings 118, 128 being aligned. The tongue 130 can be very similar to the previous embodiments, such that it is formed to engage with a groove 140 of an adjacent building surface panel 100.

[0205] The front side 112 of the outer element 110 can form a flat face surface that can be substantially parallel with a building surface 32 when the building surface panel 100 is attached to the building surface 32. At the top of the front side 112 can be an angled portion 158, that is inclined from an upper portion of the building surface panel 100 to the front side 112. At the bottom of the front side 112, the bottom flange 138 can be formed as an angled portion that can engage (or at least be positioned proximate) an angled portion 158 of an adjacent building surface panel 100 positioned below the current building surface panel 100. The front side 112 can include the one or more longitudinal recesses 117.

[0206] The backing component 120 can include a complimentarily shaped angled portion 168 that can engage the angled portion 158 when the backing component 120 is attached to the outer element 110. The backing component 120 can also include one or more ribs 126 that provide additional stability for the backing component 120 and thus for the outer element 110, when the backing component 120 is attached to the outer element 110. The backing component 120 can also include a complimentarily shaped one or more longitudinal recess 127 that can engage respective ones of the one or more longitudinal recess 117 when the backing component 120 is attached to the outer element 110.

[0207] It should be understood that many other shapes of a building surface panel 100 are envisioned that utilize the novel approach of forming a building surface panel 100 by forming a unitary body 106 and then folding the backing component 120 to engage the outer element 110. However, a novel building surface panel 100 can also be formed from two separately formed portions that are attached together to form the building surface panel 100.

[0208] Referring to FIGS. 10A-10D, FIG. 10A is a representative perspective view of an outer element 110 of a building surface panel 100, and FIG. 10B is a representative perspective view of a backing component 120 of the building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 10C is a representative perspective view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. FIG. 10D is a representative partial cross-sectional view 10D-10D, as indicated in FIG. 10C, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments.

[0209] The outer element 110 shown in FIG. 10A can include the front side 112, that forms a flat face, and a bottom flange 138 angled back and adapted to cover the groove 140 of the backing component 120 when the outer element 110 is attached to the backing component 120 to form the building surface panel 100. The outer element 110 can include a left side 132, a right side 134, and a top side 152. The length L2 can represent a distance from the left side 132 to the right side 134 of the outer element 110. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein.

[0210] The backing component 120 can be formed as a unitary body 108 with an upper portion containing the tongue 130 and the openings 118 with the upper portion being folded relative to the lower portion at the folding feature 150. This aligns the openings 118 with the openings 128 to form a double-thickness fastener hem 170 at the top of the building surface panel 100. The backing component 120 can include one or more ribs 126 that can provide reinforcement for the building surface panel 100 when the backing component 120 is attached to the outer element 110. The interaction of the tongue 130 with the groove 140 can be different than the previously described embodiments. The tongue 130 can be formed to provide a restricted clearance between the tongue and the body of the backing component 120. The groove 140 can include a bump feature that can be forced past the restricted clearance of the tongue 130 and held within the tongue 130 when an upper building surface panel 100 is engaged with the current building surface panel 100.

[0211] The length L3 can represent a distance from the left side 102 to the right side 104 of the backing component 120. It can be preferrable that the length L2 of the outer element 110 is larger than the length L3 of the backing component 120. This allows the top side 152 of the outer element 110 to form a cutback 116 of the building surface panel 100 (see FIG. 10C) formed when the backing component 120 is attached to the outer element 110. Because the backing component 120 is formed as a unitary body 106, alignment of the openings 118 with the openings 128 is built into the unitary body 106 so when the top portion if folded at the folding feature 150, the openings 118, 128 are aligned. Alignment of the outer element 110 with the backing component 120 can have loose tolerances, since precise alignment is not needed.

[0212] Referring to FIGS. 11A-11D, FIG. 11A is a representative perspective view of an outer element 110 of a building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 11B is a representative perspective view of a backing component 120 of a building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 11C is a representative perspective view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. FIG. 11D is a representative partial cross-sectional view 11D-11D, as indicated in FIG. 11C, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 11E is a representative perspective rear view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments.

[0213] The outer element 110 shown in FIG. 11A can include the front side 112, that forms a flat face, and a bottom flange 138 angled back and adapted to cover the groove 140 of the backing component 120 when the outer element 110 is attached to the backing component 120 to form the building surface panel 100. The outer element 110 can include a left side 132, a right side 134, and a top side 152. An upper portion of the outer element 110 can include a tongue 130 and openings 118. In this non-limiting embodiment, the fastener hem 170 can be a single thickness and includes openings 118 for receiving fasteners 34 to attach the building surface panel 100 to a building surface 32. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein.

[0214] The backing component 120 can include one or more ribs 126 that can provide reinforcement for the building surface panel 100 when the backing component 120 is attached to the outer element 110. The backing component 120 can include a left side 102, a right side 104, and a top side 154. The tongue 130 can be formed with the outer element 110 to provide a restricted clearance between the tongue and the body of the backing component 120. The groove 140 can be formed with the backing component 120 and can include a bump feature that can be forced past the restricted clearance of the tongue 130 and held by the tongue 130 when an upper building surface panel 100 is engaged with the current building surface panel 100.

[0215] The outer element 110 can have cutbacks 116 on the left side 132 and the right side 134 proximate the tongue 130. The width L4 can represent a distance from the left side 132 to the right side 134 of the outer element 110. The width L5 can represent a distance from the left side 102 to the right side 104 of the backing component 120. It can be preferrable that the width L4 of the outer element 110 is larger than the width L5 of the backing component 120. The width L5 can be substantially equal to the width L7 of the fastener hem 170 and tongue 130.

[0216] In a number of embodiments, the width L4 (representing a distance from the left side 132 to the right side 134 of the outer element 110) may be a first width and a width L5 (representing a distance from the left side 102 to the right side 104 of the backing component 120) may be a second width. In a number of embodiments, the first width L4 may be wider than the second width L5. In a number of embodiments, the first width L4 may be 1.5 times wider than the second width L5. In a number of embodiments, the first width L4 may be 2 times wider than the second width L5. In a number of embodiments, the first width L4 may be 2.5 times wider than the second width L5. In a number of embodiments, the first width L4 may be 3 times wider than the second width L5. In a number of embodiments, the first width L4 may be 4 times wider than the second width L5. In a number of embodiments, the first width L4 may be 5 times wider than the second width L5. In a number of embodiments, the first width L4 may be no greater than 25 times wider than the second width L5. In a number of embodiments, the first width L4 may be no greater than 20 times wider than the second width L5. In a number of embodiments, the first width L4 may be no greater than 15 times wider than the second width L5. It will be appreciated that the ratio of L4 to L5 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the ratio of L4 to L5 may be any value between any of the minimum and maximum values noted above.

[0217] When the backing component 120 is attached to the rear side 114 of the outer element 110, the backing component 120 can be aligned with the fastener hem 170 and the tongue 130 of the outer element 110, such that a distance approximately equal to the distance L1 of the cutback 116 can be provided between the left and right sides 132, 134 of the outer element 110 and the left and right sides 102, 104 of the backing component 120. As described previously, the cutback 116 allows overlap of the left and right sides of horizontally adjacent building surface panels 100 when installed onto the building surface 32.

[0218] Since features on either of the outer element 110 or the backing component 120 do not require precise alignment when they are being attached together, alignment of the outer element 110 with the backing component 120 can have loose tolerances.

[0219] The width L7 of the fastener hem 170 and tongue 130 can be substantially equal to the width L5 of the backing component 120, such that a cutback 116 can be formed on both sides of the building surface panel 100, such that the tongue 130 and the groove 140 are setback by a distance L6 (which can be substantially equal to distance L1) from both sides 132, 134 of the outer element 110 (or outer element 110) to allow overlapping the left and right sides 132, 134 of horizontally adjacent building surface panels 100.

[0220] FIGS. 12A-12D are representative partial cross-sectional views 12-12, as indicated in FIG. 11E, of reinforcement elements 126 of a backing component 120 to reinforce an outer element 110 of a building surface panel 100, in accordance with certain embodiments. The reinforcement elements 126 can extend longitudinally along the backing component as seen in FIG. 11E. However, it should be understood that the reinforcement elements 126 can extend longitudinally along the backing component 120 and can be substantially in parallel with the top side 152 of the outer element 110 or the top side 154 of the backing component 120. It should also be understood that the reinforcement elements 126 can extend longitudinally along the backing component 120 and can be angled relative to the top side 152 of the outer element 110 (or outer element) or the top side 154 of the backing component 120.

[0221] It should also be understood that the reinforcement elements 126 can extend axially across the backing component 120 and can be generally perpendicular to the top side 152 of the outer element 110 (or outer element) or the top side 154 of the backing component 120. In some embodiments, the reinforcement elements 126 comprises multiple reinforcement elements, such as ribs, arranged in a staggered manner to each other, each extending longitudinally such that each rib does not extend all the way along the backing component (not shown). In yet another embodiment, the backing component 120 comprises reinforcement elements that are embossed into the backing component 120, forming a plurality of dimples and / or protrusions, where the dimples bend inwards towards the rear side 114 of the outer element and may or may not be in contact with the outer element.

[0222] The reinforcement elements 126 can be seen as ribs 126 as shown in FIGS. 11E and 12A where the reinforcement element 126 is generally the same thickness as the other portions of the backing component but form a profile that protrudes from the rear side 124 and is spaced away from the front side 122. The reinforcement element 126 can form a hollow portion bounded by the outer element 110 and the reinforcement element 126. The profile of the reinforcement element 126 can provide increased rigidity for the backing component 120 and for the outer element 110 when it is attached to the backing component 120. A particular profile is shown for the reinforcement element 126 in FIG. 12A, but it should be understood that any other suitable profile can be used to provide increased rigidity to the building surface panel 100 when the backing component 120 is attached to the outer element 110 (or outer element 110). In an embodiment, the reinforcement element 126 is narrow, such that there is substantially no space in between the two side walls of the reinforcement element 126. The height and width of each reinforcing element 126 can be tailored to provide desired rigidity for a particular building panel having a particular profile of the outer element 110.

[0223] Alternatively, or in addition to, the reinforcement element 126 can be a separate piece that is adhered to the rear side 124 of the backing component 120 to provide increased rigidity to the building surface panel 100 or the reinforcement elements 126 can be formed with the backing component 120. FIGS. 12B-12D illustrate various cross-sectional shapes of elongated reinforcement elements 126 that can be adhered to the rear side 124 of (or formed with) the backing component 120. In these non-limiting embodiments, the backing component 120 can be formed without a reinforcement profile and a separate reinforcement element 126 can be adhered to the backing component 120. Also, the reinforcement element 126 can be formed with the backing component 120 and can have any suitable profile or cross-section shape.

[0224] FIG. 12B shows a reinforcement element 126 having a rectangular cross-section, where the thickness and width of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100. FIG. 12C shows a reinforcement element 126 having a triangular cross-section, where the legs of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100. FIG. 12D shows a reinforcement element 126 having a C-shaped cross-section, where the thickness and width of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100.

[0225] It should be understood that any of the reinforcement elements 126 (e.g., ribs 126) described in this disclosure can be used for any of the embodiments of the reinforcement elements 126 (e.g., ribs 126) disclosed herein.

[0226] FIG. 21 is a representative cross-sectional view of another building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. The building surface panel 100 can form a board and batten type siding configuration which can be installed on a building surface 32 in any orientation. However, a vertical orientation can be preferred. The ribs 126 of the backing component 120 can extend toward a building surface 32 and can contact the building surface 32 for additional support. However, it can be preferred that the ribs 126 extend enough to leave a gap between the ribs 126 and the building surface 32 when the building surface panel 100 is in an installed position on the building surface 32 and is in a steady state configuration, where the steady state configuration is where no outside forces are acting on the building surface panel 100.

[0227] The ribs 126 can also provide a more rigid feel when handling the building surface panel 100. For example, when the building surface panel 100 is installed on the building surface 32, when a user pushes on the outer element 110, the ribs 126 can engage the building surface 32 and resist further movement, thus giving the feel of the building surface panel 100 being more rigid.

[0228] The outer element 110 can include the tongue 130, the top side 152, the folding feature 150, and openings 118 that can receive fasteners in the fastener hem 170. The outer element 110 can also include the groove 140, which can engage a tongue 130 of an adjacent building surface panel 100. The outer element 110 can form the exterior shape of the building surface panel 100 that can be visible when it is installed on the building surface 32.

[0229] FIG. 22 is a representative cross-sectional view of another building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. The building surface panel 100 can form a shiplap type siding configuration which can be installed on a building surface 32 in any orientation. However, a horizontal orientation can be preferred. The ribs 126 of the backing component 120 can extend toward a building surface 32 and can contact the building surface 32 for additional support. However, it can be preferred that the ribs 126 extend enough to leave a gap between the ribs 126 and the building surface 32 when the building surface panel 100 is in an installed position on the building surface 32 and is in a steady state configuration.

[0230] The ribs 126 can include one or more weep holes 162 extending through a respective rib 126 to allow for fluid (e.g., water) to not be trapped between the building surface panel 100 and the building surface 32. Therefore, if the gap between the ribs 126 and the building surface 32 is substantially “0” zero, then the fluid can bypass the rib 126 and not get trapped by flowing through the weep holes 162. The groove 140 can also include one or more weep holes 160 to prevent fluid from collecting in the groove 140 when the building surface panel 100 is in an installed position on the building surface 32. As stated above with regard to FIG. 20, the ribs 126 can also provide a more rigid feel when handling the building surface panel 100.

[0231] The outer element 110 can include the tongue 130, the top side 152, the folding feature 150, and openings 118 that can receive fasteners in the fastener hem 170. The outer element 110 can also include the groove 140, which can engage a tongue 130 of an adjacent building surface panel 100. The outer element 110 can form the exterior shape of the building surface panel 100 that can be visible when it is installed on the building surface 32. The weep holes 160, 162 provide enhanced fluid flow management for the building surface panel 100.

[0232] The impact resistance of the building surface panel 100 can be measured according to ASTM D 4226 and can be greater than 60 mean failure energy (MFE) in-lbs. (6.78 Nm), or greater than 70 MFE in-lbs. (7.91 Nm), or greater than 80 MFE in-lbs. (9.4 Nm), or greater than 90 MFE in-lbs. (10.17 Nm), or greater than 100 MFE in-lbs. (11.30 Nm), or greater than 110 MFE in-lbs. (12.43 Nm), or greater than 120 MFE in-lbs. (13.56 Nm), or greater than 130 MFE in-lbs. (14.69 Nm), or greater than 140 MFE in-lbs. (15.82 Nm), or greater than 150 MFE in-lbs. (16.95 Nm), or greater than 155 MFE in-lbs. (17.5 Nm), or greater than 160 MFE in-lbs. (18.8 Nm), or greater than 165 MFE in-lbs. (18.64 Nm), or greater than 170 MFE in-lbs. (19.21 Nm), or greater than 175 MFE in-lbs. (19.77 Nm). The damage impact of the building surface panel 100 can be less than 190 MFE in-lbs. (21.47 Nm), or less than 185 MFE in-lbs. (20.90 Nm), or less than 180 MFE in-lbs. (20.34 Nm), or less than 175 MFE in-lbs. (19.77 Nm), or less than 170 MFE in-lbs. (19.21 Nm), or less than 165 MFE in-lbs. (18.64 Nm). It will be appreciated that the damage impact of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the damage impact of the building surface panel 100 may be any value between any of the values noted above.

[0233] The standard static test pressure rating of the building surface panel 100 can be measured according to testing requirements given in the ASTM D7445, which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding with Foam Plastic backing (Backed Vinyl Siding). The building surface panel 100 according to various embodiments of the present inventions are able to withstand a sustained static pressure of greater than 22.5 pounds per square foot (1.77 kPa), or greater than 25 pounds per square foot (1.20 kPa), or greater than 30 pounds per square foot (1.44 kPa), or greater than 35 pounds per square foot (1.68 kPa), or greater than 40 pounds per square foot (1.92 kPa), or greater than 45 pounds per square foot (2.16 kPa), or greater than 50 pounds per square foot (2.39 kPa), or greater than 55 pounds per square foot (2.63 kPa), or greater than 60 pounds per square foot (2.87 kPa), or greater than 64 pounds per square foot (3.6 kPa), or greater than 70 pounds per square foot (3.35 kPa), or greater than 75 pounds per square foot (3.59 kPa), or greater than 80 pounds per square foot (3.83 kPa), or greater than 85 pounds per square foot (4.7 kPa), or greater than 90 pounds per square foot (4.31 kPa), or greater than 95 pounds per square foot (4.55 kPa), or greater than 100 pounds per square foot (4.79 kPa). The standard design wind pressure rating of the building surface panel 100 can be less than 115 pounds per square foot (5.51 kPa), or less than 110 pounds per square foot (5.27 kPa), or less than 105 pounds per square foot (5.3 kPa), or less than 100 pounds per square foot (4.79 kPa), or less than 95 pounds per square foot (4.55 kPa), or less than 90 pounds per square foot (4.31 kPa). It will be appreciated that the standard design sustained static pressure rating of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the standard design wind pressure rating of the building surface panel 100 may be any value between any of the values noted above.

[0234] The standard design wind pressure rating of the building surface panel 100 can be measured according to testing requirements given in the ASTM D3679, which specifies a standard test procedure given in ASTM D5206, which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding. The building surface panel 100 according to various embodiments of the present inventions are able to withstand a standard design wind pressure rating of greater than 22.5 pounds per square foot (1.77 kPa), or greater than 25 pounds per square foot (1.20 kPa), or greater than 30 pounds per square foot (1.44 kPa), or greater than 35 pounds per square foot (1.68 kPa), or greater than 40 pounds per square foot (1.92 kPa), or greater than 45 pounds per square foot (2.16 kPa), or greater than 50 pounds per square foot (2.39 kPa), or greater than 55 pounds per square foot (2.63 kPa), or greater than 60 pounds per square foot (2.87 kPa), or greater than 64 pounds per square foot (3.6 kPa), or greater than 70 pounds per square foot (3.35 kPa), or greater than 75 pounds per square foot (3.59 kPa), or greater than 80 pounds per square foot (3.83 kPa), or greater than 85 pounds per square foot (4.7 kPa), or greater than 90 pounds per square foot (4.31 kPa), or greater than 95 pounds per square foot (4.55 kPa), or greater than 100 pounds per square foot (4.79 kPa). The standard design wind pressure rating of the building surface panel 100 can be less than 115 pounds per square foot (5.51 kPa), or less than 110 pounds per square foot (5.27 kPa), or less than 105 pounds per square foot (5.3 kPa), or less than 100 pounds per square foot (4.79 kPa), or less than 95 pounds per square foot (4.55 kPa), or less than 90 pounds per square foot (4.31 kPa). It will be appreciated that the standard design wind pressure rating of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the standard design wind pressure rating of the building surface panel 100 may be any value between any of the values noted above.

[0235] While there may be other backing systems for building surface panels that are known to have a backing component coupled to an outer element in a non-permanent manner, these are not necessarily subject to the same design constraints and issues when you fixedly or permanently attach the outer element to the backing component, such as problems (e.g., bulking, oil canning, etc.) that can occur due to CTE mismatches between the outer element and the backing component.

[0236] It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

[0237] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.VARIOUS EMBODIMENTSEmbodiment 1. A building surface panel comprising:

[0239] an outer element; and

[0240] a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel,

[0241] wherein the building surface panel further comprises one of:

[0242] a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%,

[0243] a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel,

[0244] a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element,

[0245] a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3, and

[0246] a combination thereof.

[0247] Embodiment 2. The building surface panel of embodiment 1, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0248] Embodiment 3. The building surface panel of embodiment 2, wherein a first adhesive attaches the first backing layer to the first element layer.

[0249] Embodiment 4. The building surface panel of embodiment 3, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0250] Embodiment 5. The building surface panel of embodiment 2, wherein the first backing composition is the same as the first element composition.

[0251] Embodiment 6. The building surface panel of embodiment 2, wherein the first backing composition is the same as the second backing composition.

[0252] Embodiment 7. The building surface panel of embodiment 1, wherein the first backing composition is different from the second backing composition.

[0253] Embodiment 8. The building surface panel of embodiment 1, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0254] Embodiment 9. The building surface panel of embodiment 8, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0255] Embodiment 10. The building surface panel of embodiment 2, wherein the first element composition is the same as the second element composition.

[0256] Embodiment 11. The building surface panel of embodiment 2, wherein the first element composition is different than the second element composition.

[0257] Embodiment 12. The building surface panel of embodiment 2, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0258] Embodiment 13. The building surface panel of embodiment 12, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0259] Embodiment 14. The building surface panel of embodiment 2, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0260] Embodiment 15. The building surface panel of embodiment 2, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0261] Embodiment 16. The building surface panel of embodiment 15, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0262] Embodiment 17. The building surface panel of embodiment 15, wherein the third element composition is different from either of the first element composition or the second element composition.

[0263] Embodiment 18. The building surface panel of embodiment 15, wherein the third element composition is ASA.

[0264] Embodiment 19. The building surface panel of embodiment 15, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0265] Embodiment 20. The building surface panel of embodiment 19, wherein the third element layer has a desired color.

[0266] Embodiment 21. The building surface panel of embodiment 15, wherein the first, second, and third element layers are of the same color or different colors.

[0267] Embodiment 22. The building surface panel of embodiment 15, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0268] Embodiment 23. The building surface panel of embodiment 1, wherein the backing component comprises one or more longitudinally extending reinforcement elements.

[0269] Embodiment 24. The building surface panel of embodiment 1, wherein the outer element further comprises a groove, and wherein the groove is adapted to receive a tongue of another building surface panel.

[0270] Embodiment 25. The building surface panel of embodiment 1, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0271] Embodiment 26. The building surface panel of embodiment 25, wherein the first, second, and third backing layers are of the same color or different colors.

[0272] Embodiment 27. The building surface panel of embodiment 25, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0273] Embodiment 28. The building surface panel of embodiment 25, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0274] Embodiment 29. The building surface panel of embodiment 25, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0275] Embodiment 30. The building surface panel of embodiment 25, wherein the third backing composition comprises ASA.

[0276] Embodiment 31. The building surface panel of embodiment 1, wherein the outer element comprises a tongue that is adapted to engage a groove of another building surface panel.

[0277] Embodiment 32. The building surface panel of embodiment 1, wherein the outer element comprises a fastener hem that is adapted to receive fasteners that secure the fastener hem to a building surface.

[0278] Embodiment 33. The building surface panel of embodiment 1, wherein the outer element is formed having a first width as measured from a first left side to a first right side of the outer element, and wherein the first width is wider than a second width of the backing component as measured from a second left side to a second right side of the backing component.

[0279] Embodiment 34. A building surface panel comprising:

[0280] an outer element; and a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel, and wherein the backing component further comprises one or more longitudinally extending ribs that protrude from the backing component.

[0281] Embodiment 35. The building surface panel of embodiment 34, wherein one or more of the longitudinally extending ribs comprises one or more weep holes formed therethrough.

[0282] Embodiment 36. The building surface panel of embodiment 34, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0283] Embodiment 37. The building surface panel of embodiment 36, wherein a first adhesive attaches the first backing layer to the first element layer.

[0284] Embodiment 38. The building surface panel of embodiment 37, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0285] Embodiment 39. The building surface panel of embodiment 36, wherein the first backing composition is the same as the first element composition.

[0286] Embodiment 40. The building surface panel of embodiment 36, wherein the first backing composition is the same as the second backing composition.

[0287] Embodiment 41. The building surface panel of embodiment 34, wherein the first backing composition is different from the second backing composition.

[0288] Embodiment 42. The building surface panel of embodiment 34, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0289] Embodiment 43. The building surface panel of embodiment 42, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0290] Embodiment 44. The building surface panel of embodiment 36, wherein the first element composition is the same as the second element composition.

[0291] Embodiment 45. The building surface panel of embodiment 36, wherein the first element composition is different than the second element composition.

[0292] Embodiment 46. The building surface panel of embodiment 36, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0293] Embodiment 47. The building surface panel of embodiment 46, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0294] Embodiment 48. The building surface panel of embodiment 36, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0295] Embodiment 49. The building surface panel of embodiment 36, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0296] Embodiment 50. The building surface panel of embodiment 49, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0297] Embodiment 51. The building surface panel of embodiment 49, wherein the third element composition is different than either of the first element composition or the second element composition.

[0298] Embodiment 52. The building surface panel of embodiment 49, wherein the third element composition comprises ASA.

[0299] Embodiment 53. The building surface panel of embodiment 49, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0300] Embodiment 54. The building surface panel of embodiment 53, wherein the third element layer has a desired color.

[0301] Embodiment 55. The building surface panel of embodiment 49, wherein the first, second, and third element layers are of the same color or different colors.

[0302] Embodiment 56. The building surface panel of embodiment 49, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0303] Embodiment 57. The building surface panel of embodiment 34, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0304] Embodiment 58. The building surface panel of embodiment 57, wherein the first, second, and third backing layers are of the same color or different colors.

[0305] Embodiment 59. The building surface panel of embodiment 57, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0306] Embodiment 60. The building surface panel of embodiment 57, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0307] Embodiment 61. The building surface panel of embodiment 57, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0308] Embodiment 62. The building surface panel of embodiment 57, wherein the third backing composition comprises ASA.

[0309] Embodiment 63. A building surface panel comprising:

[0310] an outer element; and

[0311] a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel, and

[0312] wherein the backing component comprises at least one of:

[0313] a longitudinally extending groove;

[0314] a longitudinally extending tongue; and

[0315] a density that is at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3.

[0316] Embodiment 64. The building surface panel of embodiment 63, wherein the longitudinally extending groove comprises one or more weep holes formed therethrough.

[0317] Embodiment 65. The building surface panel of embodiment 63, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0318] Embodiment 66. The building surface panel of embodiment 65, wherein a first adhesive attaches the first backing layer to the first element layer.

[0319] Embodiment 67. The building surface panel of embodiment 66, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0320] Embodiment 68. The building surface panel of embodiment 65, wherein the first backing composition is the same as the first element composition.

[0321] Embodiment 69. The building surface panel of embodiment 65, wherein the first backing composition is the same as the second backing composition.

[0322] Embodiment 70. The building surface panel of embodiment 63, wherein the first backing composition is different from the second backing composition.

[0323] Embodiment 71. The building surface panel of embodiment 63, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0324] Embodiment 72. The building surface panel of embodiment 71, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0325] Embodiment 73. The building surface panel of embodiment 65, wherein the first element composition is the same as the second element composition.

[0326] Embodiment 74. The building surface panel of embodiment 65, wherein the first element composition is different than the second element composition.

[0327] Embodiment 75. The building surface panel of embodiment 65, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0328] Embodiment 76. The building surface panel of embodiment 75, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0329] Embodiment 77. The building surface panel of embodiment 65, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0330] Embodiment 78. The building surface panel of embodiment 65, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0331] Embodiment 79. The building surface panel of embodiment 78, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0332] Embodiment 80. The building surface panel of embodiment 78, wherein the third element composition is different than either of the first element composition or the second element composition.

[0333] Embodiment 81. The building surface panel of embodiment 78, wherein the third element composition comprises ASA.

[0334] Embodiment 82. The building surface panel of embodiment 78, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0335] Embodiment 83. The building surface panel of embodiment 82, wherein the third element layer has a desired color.

[0336] Embodiment 84. The building surface panel of embodiment 78, wherein the first, second, and third element layers are of the same color or different colors.

[0337] Embodiment 85. The building surface panel of embodiment 78, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0338] Embodiment 86. The building surface panel of embodiment 63, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0339] Embodiment 87. The building surface panel of embodiment 86, wherein the first, second, and third backing layers are of the same color or different colors.

[0340] Embodiment 88. The building surface panel of embodiment 86, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0341] Embodiment 89. The building surface panel of embodiment 86, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0342] Embodiment 90. The building surface panel of embodiment 86, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0343] Embodiment 91. The building surface panel of embodiment 86, wherein the third backing composition comprises ASA.

[0344] Embodiment 92. A building surface panel comprising:

[0345] an outer element; and

[0346] a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel, and

[0347] wherein the outer element has a first front side, a first rear side, and a first thickness as measured between the first front side and the first rear side; and the backing component has a second front side, a second rear side, and a second thickness as measured between the second front side and the second rear side, wherein the second front side of the backing component is attached to the first rear side of the outer element, wherein the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

[0348] Embodiment 93. The building surface panel of embodiment 92, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0349] Embodiment 94. The building surface panel of embodiment 93, wherein a first adhesive attaches the first backing layer to the first element layer.

[0350] Embodiment 95. The building surface panel of embodiment 94, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0351] Embodiment 96. The building surface panel of embodiment 93, wherein the first backing composition is the same as the first element composition.

[0352] Embodiment 97. The building surface panel of embodiment 93, wherein the first backing composition is the same as the second backing composition.

[0353] Embodiment 98. The building surface panel of embodiment 92, wherein the first backing composition is different from the second backing composition.

[0354] Embodiment 99. The building surface panel of embodiment 92, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0355] Embodiment 100. The building surface panel of embodiment 99, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0356] Embodiment 101. The building surface panel of embodiment 93, wherein the first element composition is the same as the second element composition.

[0357] Embodiment 102. The building surface panel of embodiment 93, wherein the first element composition is different than the second element composition.

[0358] Embodiment 103. The building surface panel of embodiment 93, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0359] Embodiment 104. The building surface panel of embodiment 103, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0360] Embodiment 105. The building surface panel of embodiment 93, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0361] Embodiment 106. The building surface panel of embodiment 93, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0362] Embodiment 107. The building surface panel of embodiment 106, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0363] Embodiment 108. The building surface panel of embodiment 106, wherein the third element composition is different than either of the first element composition or the second element composition.

[0364] Embodiment 109. The building surface panel of embodiment 106, wherein the third element composition comprises ASA.

[0365] Embodiment 110. The building surface panel of embodiment 106, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0366] Embodiment 111. The building surface panel of embodiment 110, wherein the third element layer has a desired color.

[0367] Embodiment 112. The building surface panel of embodiment 106, wherein the first, second, and third element layers are of the same color or different colors.

[0368] Embodiment 113. The building surface panel of embodiment 106, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0369] Embodiment 114. The building surface panel of embodiment 92, wherein a standard design wind pressure rating of the building surface panel exceeds 62 pounds per square foot (2969 Pa) as determined by testing requirements given in the American Society for Testing and Materials (ASTM) specification D3679, test procedure D5206 which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding.

[0370] Embodiment 115. The building surface panel of embodiment 92, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0371] Embodiment 116. The building surface panel of embodiment 115, wherein the first, second, and third backing layers are of the same color or different colors.

[0372] Embodiment 117. The building surface panel of embodiment 115, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0373] Embodiment 118. The building surface panel of embodiment 115, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0374] Embodiment 119. The building surface panel of embodiment 115, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0375] Embodiment 120. The building surface panel of embodiment 115, wherein the third backing composition comprises ASA.

[0376] Embodiment 121. A building surface panel comprising:

[0377] an outer element with a first element layer that comprises acrylonitrile styrene acrylate (ASA) that is attached to a second element layer that comprises polyvinyl chloride (PVC); and

[0378] a backing component with a first backing layer that comprises ASA that is attached to a second backing layer that comprises PVC, wherein the first element layer is attached to the first backing layer to form the building surface panel.

[0379] Embodiment 122. The building surface panel of embodiment 121, wherein the outer element further comprises a third element layer that comprises ASA that is attached to an opposite side of the second element layer from the first element layer.

[0380] Embodiment 123. The building surface panel of embodiment 122, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0381] Embodiment 124. The building surface panel of embodiment 123, wherein the third element layer has a desired color.

[0382] Embodiment 125. The building surface panel of embodiment 122, wherein the first, second, and third element layers are of the same color or different colors.

[0383] Embodiment 126. The building surface panel of embodiment 121, wherein the backing component further comprises a third backing layer that comprises ASA that is attached to an opposite side of the second backing layer from the first backing layer.

[0384] Embodiment 127. The building surface panel of embodiment 126, wherein the first, second, and third backing layers are of the same color or different colors.

[0385] Embodiment 128. The building surface panel of embodiment 121, wherein a first adhesive attaches the first element layer to the first backing layer.

[0386] Embodiment 129. The building surface panel of embodiment 128, wherein the first adhesive in a cured state provides a bond shear strength between the first element layer and the first backing layer of at least about 0.10 MPa at room temperature.

[0387] Note that not all of the activities described above in the general description, or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

[0388] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0389] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Examples

embodiment 1

A building surface panel comprising:[0239]an outer element; and[0240]a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel,[0241]wherein the building surface panel further comprises one of:[0242]a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%,[0243]a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel,[0244]a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element,[0245]a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3, and[0246]a combination thereof.[0247]Embodiment 2. The buildi...

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This Application is a Continuation-in-Part of U.S. patent application Ser. No. 19 / 042,055, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME, by Ashley A. SCHULTZ et al., filed Jan. 31, 2025, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 627,527, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Ashley A. SCHULTZ et al., filed Jan. 31, 2024, and also claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 710,660, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Greg Thomas HOLLAND, filed Oct. 23, 2024, all of which are assigned to the current assignee hereof and the entire disclosures of these applications are incorporated herein by reference in their entireties.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to a building surface panel for covering a building surface. The present disclosure relates more particularly to a backed or reinforced building surface panel for covering a building surface.BACKGROUND

[0003] Building surface panels, such as cladding or siding, are visible elements that cover an underlying support structure. Siding panels are typically used in the construction of homes, businesses, and other buildings on exterior walls. These siding panels can provide protection to the underlying support structure from weather and other elements.

[0004] There is a wide variety of distinct types of building surface panels that may be used to cover exterior walls. Such surface panels may exhibit heat distortion and / or buckling while installed on a building surface, due to environmental conditions and changing conditions. Therefore, improvements in building surface panels are continually needed.SUMMARY

[0005] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

[0006] One general aspect includes a building surface panel with an outer element; and a backing component, which can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, where the building surface panel further can include one of: a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%, a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel, a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element, a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3, and a combination thereof.

[0007] One general aspect includes a building surface panel with an outer element; and a backing component can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, and where the backing component further can include one or more longitudinally extending ribs that protrude from the backing component.

[0008] One general aspect includes a building surface panel with an outer element; and a backing component can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, and where the backing component can include at least one of: a longitudinally extending groove; a longitudinally extending tongue; and a density that is at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3.

[0009] One general aspect includes a building surface panel with an outer element; and a backing component can include a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, where the first backing layer is attached to the outer element to form the building surface panel, and where the outer element has a first front side, a first rear side, and a first thickness as measured between the first front side and the first rear side; and the backing component has a second front side, a second rear side, and a second thickness as measured between the second front side and the second rear side, where the second front side of the backing component is attached to the first rear side of the outer element, where the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

[0010] One general aspect includes a building surface panel with an outer element with a first element layer that can include acrylonitrile styrene acrylate (ASA) that is attached to a second element layer that can include polyvinyl chloride (PVC); and a backing component with a first backing layer that can include ASA that is attached to a second backing layer that can include PVC, where the first element layer is attached to the first backing layer to form the building surface panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Embodiments are illustrated by way of example and are not limited to the accompanying figures. These and other features, aspects, and advantages of present embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0012] FIG. 1 is a schematic depiction of side-view of a portion of a building surface panel according to an embodiment described herein;

[0013] FIG. 2 is a schematic depiction of a front-view of a portion of a building surface panel according to an embodiment described herein;

[0014] FIG. 3 is a representative perspective view of a portion of a building covered by building surface panels, in accordance with certain embodiments;

[0015] FIG. 4A is a representative full view of a building surface panel formed as a unitary body with an outer element and a backing component formed together, prior to folding, in accordance with certain embodiments;

[0016] FIG. 4B is a representative perspective view of a building surface panel formed as a unitary body with an outer element and a backing component formed together, prior to folding, in accordance with certain embodiments;

[0017] FIG. 4C is a representative perspective view of a building surface panel formed as a unitary body with an outer element and a backing component formed together and the backing component folded to engage the outer element, in accordance with certain embodiments;

[0018] FIG. 5A is a representative perspective view of a unitary body formed with an outer element and a backing component, and the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0019] FIG. 5B is a representative partial cross-sectional view 5B-5B, as indicated in FIG. 5A, of a building surface panel, in accordance with certain embodiments;

[0020] FIG. 5C is a representative detail view of the detail region 5C, as indicated in FIG. 5B, of a building surface panel, in accordance with certain embodiments;

[0021] FIG. 6A is a representative perspective view of multiple building surface panels with a reinforced outer element assembled together, in accordance with certain embodiments;

[0022] FIG. 6B is a representative partial cross-sectional view 6B-6B, as indicated in FIG. 6A, of multiple building surface panels assembled together on a building surface, in accordance with certain embodiments;

[0023] FIG. 7A is a representative perspective view of a unitary body formed with an outer element and a backing component, with the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0024] FIG. 7B is a representative partial cross-sectional view 7B-7B, as indicated in FIG. 7A, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0025] FIG. 8A is a representative perspective view of multiple building surface panels with a reinforced outer element assembled together, in accordance with certain embodiments;

[0026] FIG. 8B is a representative partial cross-sectional view 8B-8B, as indicated in FIG. 8A, of multiple building surface panels assembled together on a building surface, in accordance with certain embodiments;

[0027] FIG. 9A is a representative perspective view of a unitary body formed with an outer element and a backing component, with the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0028] FIG. 9B is a representative partial cross-sectional view 9B-9B, as indicated in FIG. 9A, of a building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0029] FIG. 10A is a representative perspective view of an outer element of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0030] FIG. 10B is a representative perspective view of a backing component of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0031] FIG. 10C is a representative perspective view of a building surface panel formed from a two-piece construction by attaching the backing component to the outer element, in accordance with certain embodiments;

[0032] FIG. 10D is a representative partial cross-sectional view 10D-10D, as indicated in FIG. 10C, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0033] FIG. 11A is a representative perspective view of an outer element of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0034] FIG. 11B is a representative perspective view of a backing component of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

[0035] FIG. 11C is a representative perspective view of a building surface panel formed from a two-piece construction by attaching the backing component to the outer element, in accordance with certain embodiments;

[0036] FIG. 11D is a representative partial cross-sectional view 11D-11D, as indicated in FIG. 11C, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

[0037] FIG. 11E is a representative perspective rear view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments;

[0038] FIGS. 12A-12D are representative partial cross-sectional views 12-12, as indicated in FIG. 11E, of reinforcement elements in a backing component to reinforce an outer element of a building surface panel, in accordance with certain embodiments;

[0039] FIGS. 13A-13B are representative cross-sectional views of a portion of an outer element of a building surface panel, in accordance with certain embodiments;

[0040] FIGS. 14A-14B are representative cross-sectional views of a portion of a backing component of a building surface panel, in accordance with certain embodiments; and

[0041] FIGS. 15-20 are representative cross-sectional views of a portion of an outer element of a building surface panel attached to a portion of a backing component of a building surface panel, in accordance with certain embodiments.

[0042] FIGS. 21-22 are representative cross-sectional views of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments.

[0043] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.DETAILED DESCRIPTION

[0044] The following discussion will focus on specific implementations and embodiments of the teachings. The detailed description is provided to assist in describing certain embodiments and should not be interpreted as a limitation on the scope or applicability of the disclosure or teachings. It will be appreciated that other embodiments can be used based on the disclosure and teachings as provided herein.

[0045] The terms “comprises,”“comprising,”“includes,”“including,”“has,”“having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present), and B is false (or not present), A is false (or not present), and B is true (or present), and both A and B are true (or present).

[0046] Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one or the singular as also including the plural or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

[0047] The use of the word “about”, “approximately”, “generally”, or “substantially” is intended to mean that a value of a parameter is close to a stated value or position. However, minor differences may prevent the values or positions from being exactly as stated. Thus, differences of up to ten percent (10%) for the value are reasonable differences from the ideal goal of exactly as described. A significant difference can be when the difference is greater than ten percent (10%).

[0048] Embodiments described herein are generally directed to a building surface panel that may include an outer element and a backing component. As used herein, the term “outer element” is used interchangeably with “outer shell,”“outer layer,”“exterior layer,”“cladding face,” or “siding.” The outer element can be formed separately from the backing component and attached to the backing component by any suitable means, or the outer element and the backing component can be formed together as a unitary body and folded to attach the backing component to the outer element to form the backed or reinforced building surface panel. As used herein, the term “building surface panel” refers to a backed or reinforced building surface panel unless specified otherwise.

[0049] For purposes of illustration, FIG. 1 shows a schematic side-view of a portion of a building surface panel 100 according to embodiments described herein. As shown in FIG. 1, the building surface panel 100 may include an outer element 110 and a backing component 120. As also shown in FIG. 1, the outer element 110 may have a front side 112 and a rear side 114. As further shown in FIG. 1, the backing component 120 may be attached to rear side 114 of the outer element 110.

[0050] For purposes of further illustration, FIG. 2 shows a schematic front view of a portion of the building surface panel 100 according to embodiments described herein. Components of embodiments described herein may be described as having a length, height, and width (or thickness). It is noted that, for purposes of embodiments described herein and as shown in FIG. 2, “length” refers to the length (L2) in an X-direction along a longitudinal axis of the component oriented as it would be installed on a building, “height” refers to the height (H) in a Y-direction along a lateral axis of the component oriented as it would be installed on a building, and “width” refers to the width (W) in a Z-direction along a transversal axis of the component oriented as it would be installed on a building. As used herein, the longitudinal axis corresponds to the extrusion direction.

[0051] Foams can be adhered to the back of building surface panels to form a backing component that can reinforce the building surface panels. However, the insulative properties of foam can lead to issues with heat buildup and temperature differential across the panel. This can lead to differences in thermal expansion between the backing component and the outer element, thus creating distortions at the overlap between building surface panels or distortions anywhere on the face of the outer element that can lead to aesthetic defects in the panel. A building surface panel that includes a backing (or support) component that provides mechanical support while reducing temperature differential between the backing component and the outer element (which can also be referred to as an outer element) can minimize these issues.

[0052] Referring back to FIG. 1, it will be appreciated that for purposes of embodiments described herein, the outer element 110 may be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the outer element 110 may be formed of multiple layers that can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. For example, the outer element 110 may be formed of two layers that are coextruded or extruded separately and then attached together.

[0053] As stated above, the outer element 110 can be formed of multiple layers. FIGS. 13A-13B are representative cross-sectional views of an outer element 110 of a building surface panel 100, in accordance with certain embodiments. In an embodiment, as shown in FIG. 13A, the outer element 110 can include a first element layer 110a and a second element layer 110b. In a number of embodiments, the first element layer 110a can comprise a first element composition.

[0054] In a number of embodiments, the second element layer 110b can comprise a second element composition. In a number of embodiments, the first element layer 110a and the second element layer 110b can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. The first element layer 110a can form the front side 112 of the outer element 110, also referred to herein as a capstock layer, and the second element layer 110b can form the rear side 114 of the outer element 110. In a number of embodiments, the first element layer 110a can provide an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building, as shown in FIGS. 15, 16, and 18.

[0055] In some other embodiments, the second element layer 110b can form the front side 112 of the outer element 110, and the first element layer 110a can form the rear side 114 of the outer element 110. In a number of embodiments, the second element layer 110b can provide an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building, as shown in FIG. 17.

[0056] In a number of embodiments, as shown in FIG. 13B, the outer element 110 can include a third element layer 110c. In a number of embodiments, the third element layer 110c can comprise a third element composition.

[0057] Any suitable material can be used for the first element composition, the second element composition, or the third element composition, including, but not limited to, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0058] In some embodiments, the first element composition can be the same as the second element composition. In other embodiments, the first element composition can be different from that of the second element composition. In yet other embodiments, the third element composition can be the same as either of the first element composition or the second element composition. In some embodiments, the third element composition can be different from either of the first element composition or the second element composition.

[0059] For example, in a number of embodiments, the first element composition can comprise acrylonitrile styrene acrylate (ASA). In a number of embodiments, the first element composition can consist essentially of acrylonitrile styrene acrylate (ASA). In other embodiments, the second element composition can comprise polyvinyl chloride (PVC). In a number of embodiments, the second element composition can consist essentially of polyvinyl chloride (PVC). In a number of embodiments, the third element composition can comprise acrylonitrile styrene acrylate (ASA). In a number of embodiments, the third element composition can consist essentially of acrylonitrile styrene acrylate (ASA).

[0060] In a number of embodiments, as shown in FIG. 13B, the third element layer 110c can be attached to an opposite side of the second element layer 110b from the first element layer 110a, such as by coextruding or molding the first element layer 110a, the second element layer 110b, and / or the third element layer 110c together. In other embodiments, the outer element 110 comprising the first element layer 110a, the second element layer 110b, and / or the third element layer 110c can be formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0061] In yet another embodiment, any of the first element layer 110a, the second element layer 110b, and / or the third element layer 110c of the outer element 110 can comprise recycled PVC, including post-industrial recycled PVC and / or post-consumer recycled PVC, in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the outer element 110.

[0062] In yet another embodiment, any of the first element layer 110a, the second element layer 110b, and / or the third element layer 110c of the outer element 110 can comprise recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, any of the first element layer 110a, the second element layer 110b, and / or the third element layer 110c of the outer element 110 can comprise recycled PVC that includes portions of recycled PVC having different colors. In a number of embodiments, the second element layer 110b of the outer element 110 can have any of the above recited percentages of recycled PVC (post-industrial PVC or post-consumer recycled PVC). In a number of embodiments, the second element layer 110b of the outer element 110 can have at least 10% by weight of recycled PVC or post-consumer recycled PVC.

[0063] It will be appreciated that for purposes of embodiments described herein, the backing component 120 may be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the backing component 120 may be formed of multiple layers that can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0064] For example, the backing component 120 may be formed of two layers that are coextruded or extruded separately and then attached together. In an embodiment, the backing component may comprise one or more longitudinally extending reinforcement elements. The one or more reinforcement elements may comprise one or more longitudinally extending protrusions or longitudinally extending ribs, longitudinal corrugation, honeycomb pattern, embossed features, or an elongated piece that is adhered to the backing component. The elongated piece may be continuous, solid piece, corrugated, honeycomb, or a geometric pattern. In a non-limiting embodiment, the front side 122 and / or the back side 124 of the backing component 120 can be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc. In another embodiment, only the front side 122 of the backing component can be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc., such that the back side 124 is substantially smooth and uniform, and without any embossed feature.

[0065] In another embodiment, rear side 114 of the outer element 110 and the front side 122 of the backing component 120 may be attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. In another embodiment, at least one of the rear side 114 of the outer element 110 or the backing component 120 may undergo one or more treatments including, but not limited to chemical, plasma, corona, thermal, flame, or ultrasonic bonding, abrasion, prior to the application of adhesive.

[0066] As stated above, the backing component 120 can be formed of multiple layers. FIGS. 14A-14B are representative cross-sectional views of a backing component 120 that can be used to reinforce an outer element 110 of a building surface panel 100, in accordance with certain embodiments. In an embodiment, as shown in FIG. 14A, the backing component 120 can include a first backing layer 120a and a second backing layer 120b. In a number of embodiments, the first backing layer 120a can comprise of a first backing composition.

[0067] In a number of embodiments, the second backing layer 120b can comprise a second backing composition. In a number of embodiments, the first backing layer 120a and the second backing layer 120b can be attached together, such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. The first backing layer 120a can form the front side 122 of the backing component 120, also referred to herein as a capstock layer, and the second backing layer 120b can form the rear side 124 of the backing component 120.

[0068] In a number of embodiments, as shown in FIG. 14B, the backing component 120 can include a third backing layer 120c. In a number of embodiments, the third backing layer 120c can comprise a third backing composition.

[0069] In a number of embodiments, as shown in FIG. 14B, the third backing layer 120c can be attached to an opposite side of the second backing layer 120b from the first backing layer 120a, such as by coextruding or molding the first element layer 110a, the second element layer 110b, and / or the third element layer 110c together. In other embodiments, the outer element 110 comprising the first element layer 110a, the second element layer 110b, and / or the third element layer 110c can be formed separately and attached together through any suitable means including, but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0070] In yet another embodiment, any of the first backing layer 120a, the second backing layer 120b, and / or the third backing layer 120c of the backing component 120 can comprise recycled PVC, including post-industrial recycled PVC and / or post-consumer recycled PVC, in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the backing component 120.

[0071] In yet another embodiment, any of the first backing layer 120a, the second backing layer 120b, and / or the third backing layer 120c of the backing component 120 can comprise recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, any of the first backing layer 120a, the second backing layer 120b, and / or the third backing layer 120c of the backing component 120 can comprise recycled PVC that includes portions of recycled PVC having different colors. In a number of embodiments, the second backing layer 120b of the backing component 120 can have any of the above recited percentages of recycled PVC (post-industrial PVC or post-consumer recycled PVC). In a number of embodiments, the second backing layer 120b of the backing component 120 can have at least 10% by weight of recycled PVC or post-consumer recycled PVC.

[0072] In a number of embodiments, a first adhesive 111 (see FIGS. 15-20) can attach the rear side 114 of the outer element 110 to the front side 122 of the backing component 120. In a number of embodiments, the first adhesive in a cured state provides a bond shear strength as measured between the rear side 114 and the front side 122. In a number of embodiments, the first adhesive 111 can contain additives that can scavenge hydrochloric acid (HCl) or other acidic species generated during the thermal or environmental degradation of PVC, which can improve adhesion since HCl can cause loss of adhesion strength.

[0073] Suitable acid scavenger additives may include, but are not limited to, hydrotalcite-based materials, calcium stearate, zinc stearate, calcium carbonate, epoxidized oils, or any other material which is capable of capturing or neutralizing acidic impurities and thereby inhibiting autocatalytic polymer degradation. Incorporation of such HCl scavengers into the first adhesive 111 can enhance the long-term stability of the building surface panel 100, by preventing acid-catalyzed deterioration at the adhesive interface, improving interlayer adhesion durability, and preserving mechanical, aesthetic, and environmental performance.

[0074] For example, the shear strength between the rear side 114 and the front side 122 can be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C.

[0075] In particular embodiments, the first adhesive in a cured state provides a bond shear strength as measured between the rear side 114 and the front side 122 of at least about 0.10 MPa at room temperature.

[0076] FIGS. 15-20 are representative cross-sectional views of a portion of an outer element of a building surface panel attached to a portion of a backing component of a building surface panel, in accordance with certain embodiments. These figures show various arrangements of layers for both the outer element 110 and the backing component 120. However, it should be understood that that other layer arrangements are envisioned and the scope of this disclosure is not limited to the arrangements shown in FIGS. 15-20.

[0077] FIG. 15 shows the first element layer 110a forming the front side 112 of the outer element 110 and the second element layer 110b forming the rear side 114 of the outer element 110. FIG. 15 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the second backing layer 120b forming the rear side 124 of the backing component 120. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100. In an embodiment, the first element layer 110a can be capstock and the second element layer 110b and the second backing layer 120b can be support layers.

[0078] FIG. 16 shows the first element layer 110a forming the front side 112 of the outer element 110 and the second element layer 110b forming the rear side 114 of the outer element 110. FIG. 16 also shows the first backing layer 120a forming the rear side 124 of the backing component 120 and the second backing layer 120b forming the front side 122 of the backing component 120. In an embodiment, the first element layer 110a and the first backing layer 120a can be capstock and the second element layer 110b and the second backing layer 120b can be support layer. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0079] FIG. 17 shows the first element layer 110a forming the rear side 114 of the outer element 110 and the second element layer 110b forming the front side 112 of the outer element 110. FIG. 17 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the second backing layer 120b forming the rear side 124 of the backing component 120. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0080] FIG. 18 shows the first element layer 110a forming the rear side 114 of the outer element 110 and the second element layer 110b forming the front side 112 of the outer element 110. FIG. 18 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the third backing layer 120c forming the rear side 124 of the backing component 120, with the second backing layer 120b sandwiched therebetween. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0081] FIG. 19 shows the first element layer 110a forming the front side 112 of the outer element 110 and the second element layer 110b forming the rear side 114 of the outer element 110. FIG. 19 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the third backing layer 120c forming the rear side 124 of the backing component 120, with the second backing layer 120b sandwiched therebetween. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100. In an embodiment, the first element layer 110a and the third backing layer can be capstock and the second element layer 110b and the second backing layer 120b can be support layers.

[0082] FIG. 20 shows the first element layer 110a forming the front side 112 of the outer element 110 and the third element layer 110c forming the rear side 114 of the outer element 110 with the second element layer 110b sandwiched therebetween. FIG. 20 also shows the first backing layer 120a forming the front side 122 of the backing component 120 and the third backing layer 120c forming the rear side 124 of the backing component 120, with the second backing layer 120b sandwiched therebetween. The rear side 114 of the outer element 110 can be attached to the front side 122 of the backing component 120 to form a building surface panel 100.

[0083] Any of the first composition, the second composition, or the third composition can be any of polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0084] Any of the backing layers 120a, 120b, 120c or element layers 110a, 110b, 110c can be any color. These layers can have substantially the same color as other layers as well as can have a different color than one or more of the other layers.

[0085] In a number of embodiments, the building surface panel can have any suitable configuration of multilayer outer element 110 / adhesive 111 / multilayer backing component 120, including but not limited to the following configurations, where “ / ” indicates an attachment of adjacent layers:

[0086] PVC1 / PVC2 / Adhesive / PVC2 / PVC3

[0087] PVC1 / PVC2 / Adhesive / PVC3 / PVC1-r

[0088] PVC1 / PVC2 / PVC1 / Adhesive / PVC2 / PVC2

[0089] PVC1 / PVC1-r / PVC1 / Adhesive / PVC2 / PVC1-r

[0090] ASA1 / PVC2 / Adhesive / PVC2 / PVC2

[0091] ASA1 / PVC2 / Adhesive / PVC2 / PVC1-r

[0092] ASA1 / PVC2 / ASA2 / Adhesive / PVC2 / PVC2

[0093] ASA1 / PVC2 / ASA2 / Adhesive / PVC2 / PVC1-r

[0094] ASA1 / PVC1-r / ASA2 / Adhesive / PVC2 / PVC2

[0095] ASA1 / PVC1-r / ASA2 / Adhesive / PVC2 / PVC1-r

[0096] PVC1 / ASA1 / Adhesive / ASA2 / PVC2

[0097] PVC1 / ASA1 / Adhesive / ASA2 / PVC1-r

[0098] PVC1 / ASA1 / Adhesive / ASA2 / PVC2 / ASA3

[0099] PVC1 / ASA1 / Adhesive / ASA2 / PVC1-r / ASA3

[0100] PVC1 / PVC2 / ASA1 / Adhesive / ASA1 / PVC2

[0101] PVC1 / PVC2 / ASA1 / Adhesive / ASA2 / PVC1-r

[0102] PVC1 / PVC1-r / ASA1 / Adhesive / ASA2 / PVC2

[0103] PVC1 / PVC1-r / ASA1 / Adhesive / ASA1 / PVC2-r

[0104] PVC1 / PVC2 / ASA1 / Adhesive / ASA2 / PVC3 / ASA3

[0105] PVC1 / PVC2 / ASA1 / Adhesive / ASA2 / PVC1-r / ASA3

[0106] PVC1 / PVC1-r / ASA1 / Adhesive / ASA2 / PVC2 / ASA3

[0107] PVC1 / PVC1-r / ASA1 / Adhesive / ASA2 / PVC2-r / ASA3

[0108] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC3

[0109] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC1-r

[0110] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC3 / ASA4

[0111] ASA1 / PVC2 / ASA2 / Adhesive / ASA3 / PVC1-r / ASA4

[0112] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2

[0113] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2-r

[0114] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2 / ASA4

[0115] ASA1 / PVC1-r / ASA2 / Adhesive / ASA3 / PVC2-r / ASA4

[0116] Where each of the PVC1, PVC2, PVC3, and PVC4 represents one or more layers of the multilayer of the outer element 110 or the backing component 120 having a composition comprising PVC. However, PVC1, PVC2, PVC3, and PVC4 may be the same or differ in one or more of layer thickness and PVC composition in terms of amounts and chemical nature / type of one or more additives. Similarly, each of the PVC1-r and PVC2-r represents one or more layers of the multilayer of the outer element 110 or the backing component 120 having a composition comprising recycled PVC.

[0117] However, PVC1-r and PVC2-r may be the same or differ in one or more of layer thickness and recycled PVC composition in terms of amounts and chemical nature / type of one or more additives or the nature (PIR versus PCR) and amount of the recycled PVC. where each of the ASA1, ASA2, ASA3, and ASA4 represents one or more layers of the multilayer of the outer element 110 or the backing component 120 having a composition comprising ASA. However, ASA1, ASA2, ASA3, and ASA4 may be the same or differ in one or more of layer thickness and ASA composition in terms of amounts and chemical nature / type of one or more additives.

[0118] Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

[0119] It will be appreciated that for purposes of embodiments described herein, the outer element 110 and the backing component 120 may be a unitary body that is a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. As used herein, “unitary body” refers to a body that includes multiple components that are formed together as one piece with the components being integral to each other.

[0120] According to certain embodiments the building surface panel 100 may have a particular CTE mismatch measured between the outer element 110 and the backing component 120. It will be appreciated that the CTE mismatch described herein is equal to the absolute value of the difference between the CTE of the outer element 110 and the CTE of the backing component 120 divided by the average of the CTE of the outer element 110 and the CTE of the backing component 120, where the CTE of each element is measured according to American Society for Testing and Materials (ASTM) D696 at a temperature 25° C. According to particular embodiments, the building surface panel 100 may have a CTE mismatch of not greater than about 20%, such as not greater than about 19% or not greater than about 18% or not greater than about 17% or not greater than about 16% or not greater than about 15% or not greater than about 14% or not greater than about 13 percent or not greater than about 12% or not greater than about 11% or not greater than about 10% or not greater than about 9% or not greater than about 8% or not greater than about 7% or not greater than about 6% or even not greater than about 5% or even not greater than about 2% or even not greater than about 1% or even not greater than about 0.5% or even not greater than about 0.1%. It will be appreciated that the CTE mismatch of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the CTE mismatch of the building surface panel 100 may be any value between any of the values noted above. In another embodiment, the outer element 110 and the backing component 120 may have substantially the same CTE.

[0121] According to still other embodiments, the building surface panel 100 may have a particular deflection measurement if subjected to a curvature test at least 90 days after formation of the building surface panel 100. For purposes of embodiments described herein, the curvature test is performed at a temperature of 25° C., ambient humidity, according to the following steps: 1) remove a substantially flat strip of the layered structure from the building surface panel to be tested, the strip extending parallel to the length of the building surface panel and having a length of 33 inches and a width of 4.5 inches (any nail hem may be cut away), 2) define a first end point of the strip at a position on the front side of the outer element that is 1.5 inches from a first end of the strip and centered across the width of the strip, and define a second end point of the strip at a position on the front side of the outer element that is that is 1.5 inches from the second end of the strip and centered across the width of the strip, 3) position the strip such that the width is oriented vertically, the front side of the outer element faces a fixed reference plane, and a line that passes through the first and second end points is parallel to the reference plane, and 4) measure, using a laser position gage, the deflection measurement as equal to a difference between a first distance from the end points to the reference plane and a second distance from a peak on the front side of the outer element to the reference plane. According to particular embodiments, the building surface panel 100 may have a deflection measurement of not greater than about 10 mm, such as not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm. Additionally, the building surface panel 100 according to various embodiments of the present invention exhibits deflection measurement of not greater than 10 mm not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm, in a curvature test when exposed to 1000 W / m 2. It will be appreciated that the deflection measurement of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the deflection measurement of the building surface panel 100 may be any value between any of the values noted above.

[0122] According to yet other embodiments, the building surface panel 100 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the building surface panel 100 may have an R-value of not greater than about 0.60° F.·ft2·hr / BTU, such as not greater than about 0.57° F.·ft2·hr / BTU or not greater than about 0.55° F.·ft2·hr / BTU or not greater than about 0.53° F.·ft2·hr / BTU or not greater than about 0.50° F.·ft2·hr / BTU or not greater than about 0.47° F.·ft2·hr / BTU or not greater than about 0.45° F.·ft2·hr / BTU or not greater than about 0.43° F.·ft2·hr / BTU or not greater than about 0.40° F.·ft2·hr / BTU or not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that the R-value of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the R-value of the building surface panel 100 may be any value between any of the values noted above.

[0123] According to yet other embodiments, the outer element 110 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the outer element 110 may have an R-value of not greater than about 0.40° F.·ft2·hr / BTU, such as not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that the R-value of the outer element 110 may be between any of the values noted above. It will be further appreciated that the R-value of the outer element 110 may be any value between any of the values noted above.

[0124] According to yet other embodiments, the backing component 120 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal conductivity of the article as measured according to ASTM C518. According to certain embodiments, the backing component 120 may have an R-value of not greater than about 0.40° F.·ft2·hr / BTU, such as not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that the R-value of the backing component 120 may be between any of the values noted above. It will be further appreciated that the R-value of the backing component 120 may be any value between any of the values noted above.

[0125] According to still other embodiments, the building surface panel 100 may pass a surface distortion test as measured according to ASTM 7745, where the foam backer is replaced with the backing component 120 of the present invention. In particular, the building surface panel 100 may pass a surface distortion test as measured according to ASTM 7745 at a temperature of 150° F. (66° C.) by being free of bulges, waves, and ripples. In various embodiments, the building surface panels of the present invention are substantially free of surface distortion, which can also be referred to as oil-canning effect.

[0126] According to other embodiments, the building surface panel 100 may have a particular vertical face radius of curvature as measured at room temperature along the vertical face (i.e., along the y-axis) of the building surface panel 100. For example, the building surface panel 100 may have a vertical face radius of curvature of at least about 500 mm, such as at least about 550 mm or at least about 600 mm or at least about 650 mm or at least about 700 mm or at least about 750 mm or at least about 800 mm or at least about 850 mm or at least about 900 mm or at least about 950 mm or at least about 1000 mm or at least about 1050 mm or at least about 1100 mm or at least about 1150 mm or at least about 1200 mm or at least about 1250 mm or at least about 1300 mm or at least about 1350 mm or at least about 1400 mm or at least about 1450 mm or at least about 1500 mm or at least about 1550 mm or at least about 1600 mm or at least about 1650 mm or at least about 1700 mm or at least about 1750 mm or at least about 1800 mm or at least about 1850 mm or at least about 1900 mm or at least about 1950 mm or at least about 2000 mm or at least about 2050 mm or at least about 2100 mm or at least about 2150 mm or at least about 2200 mm or at least about 2250 mm or at least about 2300 mm or at least about 2350 mm or at least about 2400 mm or at least about 2450 mm or at least about 2500 mm or at least about 2550 mm or even at least about 2600 mm. It will be appreciated that the vertical face radius of curvature of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the vertical face radius of curvature of the building surface panel 100 may be any value between any of the values noted above.

[0127] According to still other embodiments, the outer element 110 of the building surface panel 100 may include a particular material. For example, the outer element 110 may include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic resin, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, polymer composite, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, and combinations thereof comprising a combination of one of the above virgin (new / non-recycled) material and one of the above recycled material. As used herein, the term “recycled material” refers to post-industrial recycled material including scrap and regrind material, post-consumer recycled material, and a combination thereof.

[0128] According to yet other embodiments the outer element 110 of the building surface panel 100 may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

[0129] According to still other embodiments, the outer element 110 of the building surface panel 100 may have a particular CTE as measured according to ASTM D696. For example, the outer element 110 may have a CTE of not greater than about 200 μm / (m·° C.), such as not greater than about 195 μm / (m·° C.) or not greater than about 190 μm / (m·° C.) or not greater than about 185 μm / (m·° C.)or not greater than about 180 μm / (m·° C.)or even not greater than about 175 μm / (m·° C.). It will be appreciated that the CTE of the outer element 110 may be within a range between any of the values noted above. It will be further appreciated that the CTE of the outer element 110 may be any value between any of the minimum and maximum values noted above.

[0130] According to other embodiments, the backing component 120 of the building surface panel 100 may include a particular material. For example the backing component may include polyvinyl chloride (PVC), cellular PVC, chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof and combinations thereof comprising a combination of one of the above virgin (new / non-recycled) material and one of the above recycled material. In an embodiment, the backing component comprises recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC in an amount greater than that present in the capstock layer and / or the support layer of the outer element 110.

[0131] In yet another embodiment, the backing component 120 comprises post-industrial recycled PVC or post-consumer recycled PVC in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the backing component 120. In yet another embodiment, the backing component 120 comprises recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, the backing component 120 comprises recycled PVC that includes portions of recycled PVC having different colors. In a number of embodiments, the first second backing layer 120b of the backing component 120 may have any of the above recited percentages of recycled PVC or post-consumer recycled PVC. In a number of embodiments, the second backing layer 120b of the backing component 120 may have at least 10% by weight of recycled PVC or post-consumer recycled PVC.

[0132] The backing component 120, as opposed to the outer element 110 can include recycled PVC with minimal contents of impurities from the group including adhesive, metal, different colored PVC, various other polymers, etc. These impurities can arise from the reclamation process for collecting used or not newly manufactured PVC (e.g., from a job site, from factory PVC waste material, etc.), and blending the recycled PVC into manufacturing processes to make a product, such as a backing component 120.

[0133] The various impurities that can be present in the recycled PVC can include, but are not limited to, at least one of polyvinylidene flouride (PVDF), acrylonitrile styrene acrylate (ASA), chlorinated PVC (CPVC), polyurethane, acrylic, silicone, rubber, chlorinated polyethylene, calcium carbonate, titanium dioxide, talc, and combinations thereof. The various polymers can account for less than 20%, or less than 15%, or less than 10%; or less than 5% by weight of the backing component 120. The metal can comprise aluminum or steel and can account for less than 1% by weight of the backing component 120.

[0134] In an embodiment of the building surface panel 100, the amount of recycled PVC in the backing component 120, is substantially greater than that of the outer element 110. In some embodiments of the building surface panel 100, the outer element 110 and the backing component 120 have substantially the same color. In other embodiments of the building surface panel 100, the outer element 110 and the backing component 120 have substantially different colors.

[0135] According to yet other embodiments, the backing component 120 of the building surface panel 100 may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof. For example, the backing component 120 may include one or more additives and a polymer including polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof.

[0136] In all embodiments in this disclosure, the outer element 110 can include a capstock disposed over a support layer, with the capstock forming the front side 112 and the backing component 120 being disposed over the outer element 110 on a side opposite the capstock, the rear side 114 of the outer element 110, as shown in FIG. 1. The capstock and backer material can be any of the materials disclosed below for the outer element 110. However, it can be preferrable that the capstock be made from a material that is more resistant to damage or degradation by environmental elements. Therefore, the capstock can be laminated to the outer element or coextruded with the support layer or tri-extruded with the support layer and the backer material or printed / painted on those surfaces of the outer element 110 that would be exposed to the elements when installed on a building.

[0137] Any suitable polymer can be used for capstock including, but not limited to, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof. The capstock may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

[0138] In a non-limiting embodiment, the capstock comprises a virgin polymer, such as acrylonitrile styrene acrylate (ASA), and the support layer or the backing component 120 comprises a suitable polymer such as polyvinyl chloride (PVC), or chlorinated polyvinyl chloride (CPVC), recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC or blends thereof.

[0139] In a non-limiting embodiment, the support layer of the outer element 110 and the backing component 120 comprises substantially the same polymeric composition (polymer and one or more additives). In a non-limiting embodiment, the outer element 110 comprising the capstock and the support layer forming the front side 112, comprises two different polymeric compositions, and the backing component 120 is formed of another polymeric composition different from that of the capstock and the support layer. The polymeric compositions of the capstock, the support layer, and the backing component 120 can differ in the amounts of one or more additives and / or the chemical composition of the polymers. In a non-limiting embodiment, the capstock, the support layer and the backing component 120 are all co-extruded or tri-extruded. In a non-limiting embodiment, capstock is laminated over the support layer. In yet another embodiment, capstock is painted, printed, spray coated, or roll coated over the support layer.

[0140] According to still other embodiments, the backing component 120 of the building surface panel 100 may have a particular CTE as measured according to ASTM D696. For example, the backing component 120 may have a CTE of not greater than about 200 μm / (m·° C.), such as not greater than about 195 μm / (m·° C.) or not greater than about 190 μm / (m·° C.) or not greater than about 185 μm / (m·° C.) or not greater than about 180 μm / (m·° C.) or even not greater than about 175 μm / (m·° C.). It will be appreciated that the CTE of the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the CTE of the backing component 120 may be any value between any of the minimum and maximum values noted above.

[0141] According to yet other embodiments, the outer element 110 may have a particular thickness. As used herein, “thickness” of the outer element 110 refers to the distance between the front side 112 and the rear side 114 as shown in at least FIG. 1. For example, the outer element 110 may have a thickness of at least about 0.1 mm, such as at least about 0.5 mm or at least about 1 mm or at least about 1.5 mm or at least about 2 mm or at least about 2.5 mm or at least about 3 mm or at least about 3.5 mm or at least about 4 mm or at least about 4.5 mm or even at least about 5 mm. According to still other embodiments, the outer element 110 may have a thickness of not greater than about 10 mm, such as not greater than about 9.5 mm or not greater than about 9.0 mm or not greater than about 8.5 mm or not greater than about 8 mm or even not greater than about 7.5 mm. It will be appreciated that the thickness of the outer element 110 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the outer element 110 may be any value between any of the minimum and maximum values noted above.

[0142] According to still other embodiments, the backing component 120 may have a particular thickness. As used herein, “thickness” of the backing component 120 refers to the distance between the front side 122 to the rear side 124 of the portions of the backing component 120 that are outside the reinforcement elements 126 as shown in at least FIGS. 12A-12D. As used herein, “thickness” of the outer element 110 refers to the distance between the front side 112 to the rear side 114 of the outer element 110 as shown in at least FIGS. 12A-12D. For example, the backing component 120 may have a thickness of at least about 0.2 mm, such as at least about 0.5 mm or at least about 0.1 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the backing component 120 may have a thickness of not greater than about 50 mm, such as not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm or not greater than about 15.0 mm or not greater than about 10 mm or not greater than about 5 mm or not greater than about 4 mm or not greater than about 3 mm. It will be appreciated that the thickness of the backing component 120 may be within a range between any of the minimum and maximum values noted above here it will be further appreciated that the thickness of the backing component 120 may be any value between any of the minimum and maximum values noted above.

[0143] According to still other embodiments, the building surface panel 100 may have a particular thickness or multiple thicknesses along the height (Y axis). For example, the building surface panel 100 may have a thickness of at least about 0.12 mm, such as at least about 0.13 mm or at least about 0.14 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the building surface panel 100 may have a thickness of not greater than about 60 mm, such as not greater than about 57.5 mm were not greater than about 55 mm were not greater than about 52.5 mm were not greater than about 50 mm were not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm. It will be appreciated that the thickness of the building surface panel 100 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the building surface panel 100 may be any value between any of the minimum and maximum values noted above. In some embodiments, the building surface panel 100 can have multiple thicknesses, along the height (Y axis), within a range between any of the minimum and maximum values noted above due to portions of the building surface panel 100 where the outer element 110 is attached to the backing component 120, and other portions of the building surface panel 100 where the outer element 110 has no backing component 120 attached to it.

[0144] The first element layer 110a or the third element layer 110c of the outer element 110 of any of the embodiments of the building surface panel 100 can have various thicknesses from 0.025 mm up to 0.254 mm, with the remainder of the thickness of the outer element 110 being a difference between one of these values and any one of the thickness values for the outer element 110 given in this disclosure. The second element layer 110b can be less than the remainder of the thickness of the outer element 110.

[0145] The first backing layer 120a or the third backing layer 120c of the backing component 120 of any of the embodiments of the building surface panel 100 can have various thicknesses from 0.025 mm up to 0.254 mm, with the remainder of the thickness of the backing component 120 being a difference between one of these values and any one of the thickness values for the backing component 120 given in this disclosure. The second backing layer 120b can be less than the remainder of the thickness of the backing component 120.

[0146] In a number of embodiments, as stated above the outer element 110 can have first front side 112, a first rear side 114, and a first thickness as measured between the first front side 112 and the first rear side 114. In a number of embodiments, as stated above, the backing component 120 can have a second front side 122, a second rear side 124, and a second thickness as measured between the second front side 122 and the second rear side 124.

[0147] In an embodiment, the second thickness of the backing component 120 can be greater than about 0.5 times, or greater than about 1.0 times, or greater than about 1.2 times, or greater than about 1.5 times, or greater than about 2.0 times, or greater than about 2.5 times, or greater than about 3.0 times or greater than about 3.5 times a first thickness of the outer element 110.

[0148] The second thickness of the backing component 120 can be less than about 5.0 times, or less than about 4.75 times, or less than about 4.25 times, or than about 3.75 times, or less than about 3.25 times, or less than about 2.75 times, or less than about 2.25 times, or less than about 1.75 times, or less than about 1.25 times, or less than about 0.75 times a first thickness of the outer element 110. It will be appreciated that the second thickness of the backing component 120 may be within a range between any of the minimum and maximum values noted above times the first thickness of the outer element 110.

[0149] As noted above, the outer element 110 can be attached to the backing component 120 or vice versa. Any suitable means could be used for attaching the outer element 110 and the backing component 120, including but not limited to chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. According to certain embodiments, the outer element 110 can be attached to the backing component 120 through a particular means. For example, according to certain embodiments, the outer element 110 can be fused to the backing component 120, for example, through an ultrasonic weld. According to yet other embodiments, the outer element 110 can be mechanically attached to the backing component 120, for example, through a clip, nail, screw, or any other mechanical attachment component.

[0150] According to yet other embodiments, the backing component 120 can be fixedly attached to any portion of the outer element 110. According to still other embodiments, the outer element 110 can be adhered to any portion of the backing component 120, for example, with an adhesive. According to still other embodiments, the outer element 110 can be attached to the backing component 120, for example, through chemical, plasma, corona, thermal, flame, ultrasonic bonding, abrasion, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof.

[0151] According to still other embodiments, the building surface panel 100 may further include an adhesive layer (not shown in FIG. 1) between the outer element 110 and the backing component 120.

[0152] According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the outer element 110 and the backing component 120. For example, the shear strength between the outer element 110 and the backing component 120 may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C. It will be appreciated that the shear strength as measured between the outer element 110 and the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the outer element 110 and the backing component 120 may be any value between any of the values noted above.

[0153] According to still other embodiments, the adhesive layer may include a particular material. For example, the adhesive layer may include a solvent-based adhesive, a polyvinyl chloride (PVC) adhesive, an acrylic adhesive, a modified acrylic adhesive, a silicone adhesive, a one or two-component polyurethane adhesive, heat or moisture cured adhesive of these materials thereof, or any tape form of these materials thereof.

[0154] According to still other embodiments, the adhesive layer may consist essentially of a particular material. For example, the adhesive layer may consist essentially of a polyvinyl chloride (PVC) adhesive, an acrylic adhesive, a modified acrylic adhesive, a silicone adhesive, a one or two-component polyurethane adhesive, heat or moisture cured adhesive of these materials thereof, or any tape form of these materials thereof. The adhesives of this disclosure can be a low surface energy type of adhesive that can be used to adhere the outer element 110 to the backing component 120. The adhesive of the present disclosure can have a surface energy of greater than 15 dynes / cm or greater than 20 dynes / cm or greater than 25 dynes / cm or greater than 30 dynes / cm or greater than 35 dynes / cm or greater than 40 dynes / cm or greater than 45 dynes / cm and less than 55 dynes / cm or less than 50 dynes / cm or less than 45 dynes / cm or less than 40 dynes / cm or less than 35 dynes / cm or less than 30 dynes / cm or less than 30 dynes / cm or less than 25 dynes / cm or less than 23 dynes / cm. In an embodiment, the adhesive of the present disclosure can have a surface energy in the range of 30 to 45 dynes / cm. The adhesives of this disclosure can remain flexible throughout the life of the building surface panel 100.

[0155] The adhesives of this disclosure can have a shear modulus, when cured, of between about 1 MPa to about 900 MPa. The disclosed adhesives can have a shear modulus of greater than 1 MPa, or greater than 2 MPa, or greater than 3 MPa, or greater than 4 MPa, or greater than 5 MPa, or greater than 6 MPa, or greater than 7 MPa, or greater than 8 MPa, or greater than 9 MPa, or greater than 10 MPa or greater than 15 MPa, or greater than 20 MPa, or greater than 30 MPa, or greater than 35 MPa, or greater than 40 MPa, or greater than 60 MPa, or greater than 80 MPa, or greater than 100 MPa, or greater than 200 MPa, or greater than 300 MPa, or greater than 400 MPa.

[0156] The adhesives of this disclosure can have a shear modulus when cured of less than 900 MPa, or less than 890 MPa, or less than 880 MPa, or less than 870 MPa, or less than 850 MPa, or less than 800 MPa, or less than 700 MPa, or less than 600 MPa, or less than 500 MPa, or less than 400 MPa, or less than 300 MPa, or less than 200 MPa, or less than 100 MPa. It will be appreciated that the shear modulus of the adhesives disclosed herein may be within a range between any of the values noted above. It will be further appreciated that the shear modulus of the adhesives disclosed herein may be any value between any of the minimum and maximum values noted above.

[0157] According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the outer element 110 and the adhesive layer. For example, the bond shear strength between the outer element 110 and the adhesive layer may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C. It will be appreciated that the bond shear strength as measured between the outer element 110 and the adhesive layer may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the outer element 110 and the adhesive layer may be any value between any of the values noted above.

[0158] According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the adhesive layer and the backing component 120. For example, the bond shear strength between the adhesive layer and the backing component 120 may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa. It will be appreciated that the bond shear strength as measured between the adhesive layer and the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the adhesive layer and the backing component 120 may be any value between any of the values noted above.

[0159] According to yet other embodiments the adhesive layer may have a particular R-value. For purposes of embodiments described here in the R-value may be equal to the thickness of the article divided by the thermal conductivity of the article as measured according to ASTM C518. According to certain embodiments the adhesive layer may have an R-value of not greater than about 0.40° F.·ft2·hr / BTU, such as not greater than about 0.37° F.·ft2·hr / BTU or not greater than about 0.35° F.·ft2·hr / BTU or not greater than about 0.33° F.·ft2·hr / BTU or not greater than about 0.30° F.·ft2·hr / BTU or not greater than about 0.27° F.·ft2·hr / BTU or not greater than about 0.25° F.·ft2·hr / BTU or not greater than about 0.23° F.·ft2·hr / BTU or not greater than about 0.20° F.·ft2·hr / BTU or not greater than about 0.17° F.·ft2·hr / BTU or not greater than about 0.15° F.·ft2·hr / BTU or not greater than about 0.13° F.·ft2·hr / BTU or even not greater than about 0.10° F.·ft2·hr / BTU. It will be appreciated that R-value of the adhesive layer may be between any of the values noted above. It will be further appreciated that the R-value of the building adhesive layer may be any value between any of the values noted above.

[0160] According to yet other embodiments, the building surface panel 100 may have a particular height. For example, the building surface panel 100 may have a height of at least about 100 mm, such as at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the building surface panel 100 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the building surface panel 100 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the building surface panel 100 may be any value between any of the minimum and maximum values noted above.

[0161] According to yet other embodiments, the outer element 110 may have a particular height. For example, the outer element 110 may have a height of at least about 100 mm, such as at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the outer element 110 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the outer element 110 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the outer element 110 may be any value between any of the minimum and maximum values noted above. In an embodiment, the height of the outer element 110 may be substantially the same as that of the building surface panel 100. In another embodiment, the height of the outer element 110 may be less than that of the building surface panel 100.

[0162] According to yet other embodiments, the backing component 120 may have a particular height. For example, the backing component 120 may have a height of at least about 10 mm, such as at least about 25 mm or at least about 50 mm or at least about 75 mm or at least about 100 mm or at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the backing component 120 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the backing component 120 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the backing component 120 may be any value between any of the minimum and maximum values noted above. In an embodiment, the height of the backing component 120 may be substantially the same as that of the building surface panel 100. In another embodiment, the height of the backing component 120 may be less than that of the outer element 110. In yet another embodiment, the height of the backing component 120 may be more than that of the outer element 110.

[0163] According to still other embodiments, the building surface panel 100 may have a particular length. For example the building surface panel 100 may have a length of at least about 1 meter, such as at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the building surface panel 100 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the building surface panel 100 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the building surface panel 100 may be any value between any of the minimum and maximum values noted above.

[0164] According to still other embodiments, the outer element 110 may have a particular length. For example the outer element 110 may have a length of at least about 1 meter, such as at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the outer element 110 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the outer element 110 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the outer element 110 may be any value between any of the minimum and maximum values noted above. In an embodiment, the length of the outer element 110 is substantially the same as that of the building surface panel 100.

[0165] According to still other embodiments, the backing component 120 may have a particular length. For example the backing component 120 may have a length of at least about 0.5 meters, such as at least about 1.0 meters or at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the backing component 120 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the backing component 120 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the backing component 120 may be any value between any of the minimum and maximum values noted above. In another embodiment, the length of the backing component 120 is less than that of the outer element 110 and the building surface panel 100 for horizontally oriented building surface panels 100. In another embodiment, the length of the backing component 120 is substantially the same as that of the outer element 110 and the building surface panel 100 for vertically oriented building surface panels 100.

[0166] It will be appreciated that the outer element 110 of the building surface panel 100 may have any desirable shape, in horizontal or vertical orientation, including, but not limited to clapboard, dutchlap, board & batten, beaded, beveled edge, or v-groove. According to certain embodiments, and as shown in FIG. 1, the outer element 110 may have a rectangular or flat face shape. According to other embodiments, the outer element 110 may have a cylindrical or curved face shape. According to other embodiments, the outer element 110 may have a flat face shape with beveled edges. or a flat face shape with beveled edges and one or more longitudinal grooves. In an embodiment, the outer element 110 of the building surface panel 100 may have a shape, as disclosed in U.S. Pat. No. 11,920,356, incorporated by reference herein in its entirety. In an embodiment, the outer element 110 of the building surface panel 100 may have a decorative outer element, as disclosed in US Patent Publication No. 2024 / 0218670, incorporated by reference herein in its entirety.

[0167] It will be further appreciated that the backing component 120 of the building surface panel 100 may have any desirable shape. According to certain embodiments, and as shown in FIG. 1, the backing component 120 may have a rectangular or flat face shape. According to other embodiments, the backing component 120 may have a cylindrical or curved face shape.

[0168] According to certain embodiments, the shape of the outer element 110 will match the shape of the backing component 120. According to yet other embodiments, the shape of the outer element 110 will be different than the shape of the backing component 120. It will be appreciated that when the shape of the outer element 110 does not match the shape of the backing component 120, the backing component 120 may not completely contact the outer element 110 when attached. For example, portions of the backing component 120 may contact the outer element 110 when attached, but other portions of the backing component 120 may not contact the outer element, leaving voids between the two components.

[0169] According to certain embodiments, the outer element 110 of the building surface panel 100 may have any desirable profile. For example, the outer element 110 may have a flat profile. According to still other embodiments, the outer element 110 may have a contoured profile.

[0170] According to certain embodiments, the backing component 120 of the building surface panel 100 may have any desirable profile. For example, the backing component 120 may have a flat profile. According to still other embodiments, the backing component 120 may have a contoured profile.

[0171] According to certain embodiments, the backing component 120 may have a particular profile that matches the profile of the outer element 110. For example, the backing component 120 may have a flat profile that matches a flat profile of the outer element 110. According to still other embodiments, the backing component 120 may have a contoured profile that matches a contoured profile of the outer element 110.

[0172] According to still other embodiments, the backing component 120 may have a particular profile that does not match the profile of the outer element 110. It will be appreciated that when the profile of the outer element 110 does not match the profile of the backing component 120, the backing component 120 may not completely contact the outer element 110 when attached. For example, portions of the backing component 120 may contact the outer element 110 when attached, but other portions of the backing component 120 may not contact the outer element, leaving voids between the two components.

[0173] According to still other embodiments, the building surface panel 100 may be a siding panel and includes a fastener hem, an upper lock, a panel body, and a lower lock. As used herein, the term “tongue” is used interchangeably with lock or upper lock and the term “groove” is used interchangeably with butt leg, locking leg or lower leg. In an embodiment, the backing component 120 comprises a groove, and wherein the groove is adapted to receive a tongue of another building surface panel. In an embodiment, the outer element comprises a tongue that is proximate the fastener hem, and wherein the tongue is adapted to engage a groove of another building surface panel. In an embodiment, outer element 110 comprises the tongue and the backing component comprises the groove. In other embodiments, the backing component 120 comprises both the tongue and the groove. In a number of embodiments, the groove may be a longitudinally extending groove. In a number of embodiments, the tongue may be a longitudinally extending tongue.

[0174] According to yet another embodiment, a method of manufacturing a building surface panel may include providing an outer element 110 having a front side 112 and a rear side 114, and attaching a backing component 120 to the rear side 114 of the outer element 110. It will be appreciated that the building surface panel, the outer element, and the backing component described in reference to the method may have any of the characteristics or properties described in reference to the building surface panel 100, the outer element 110 or the backing component 120 described.

[0175] FIG. 3 is a representative perspective view of a portion of a building 30 covered by building surface panels 100 (e.g., building surface panels 100a, 100b, 100c, 100d) attached to a building surface 32 (or underlying support structure), in accordance with certain embodiments. The building surface panel 100 (e.g., building surface panel 100a) can have a longitudinal length L and a height H. The building surface panels 100 are shown as having a flat face profile, but the profile of the building surface panels 100 can be any of the profiles or shapes described herein. Although, FIGS. 4-11 illustrates some embodiments of the invention, the profiles are not limiting, and the invention is applicable to various profiles known in the art (not shown here), including those described in U.S. Pat. No. 11,920,356 and US Patent Publication No. 20240218670, incorporated by reference herein in their entirety.

[0176] FIG. 4A is a representative full view of a building surface panel 100 formed as a unitary body 106 with an outer element 110 and a backing component 120 formed together, prior to folding, in accordance with certain embodiments. The lower portion of the unitary body 106 can be seen as the outer element 110 with a front side 112, a rear side 114 (not shown, see FIG. 4B), a left side 132, a right side 134, and a bottom flange 138. When the building surface panel 100 is formed with a reinforced outer element 110 and attached to the building surface 32, the front side 112 of the outer element 110 can provide an aesthetic appearance, while covering a portion of the building surface 32, as shown in FIG. 3.

[0177] A tongue 130 can be formed at the top of the outer element 110 portion as well as a plurality of openings 118. The tongue 130 of one building surface panel 100 can be used to engage a groove 140 of another building surface panel 100, when multiple building surface panels 100 are attached to the building surface 32. The openings 118 can be used to receive fasteners when attaching the building surface panel 100 to a building surface 32.

[0178] The groove 140 can be formed at the top of the unitary body 106, which can be positioned at the bottom of the building surface panel 100 when the unitary body 106 is folded into a configuration where the backing component 120 is positioned behind the outer element 110 and attached to the rear side 114 of the outer element 110. The upper portion of the unitary body 106 can be seen as the backing component 120 portion with a front side 122 (not shown, see FIG. 4B), a rear side 124, a left side 102, a right side 104, and a groove 140. The groove 140 can be formed to mate and interlock with the tongue 130 of an adjacent building surface panel 100.

[0179] Openings 128 can be formed in the backing component 120 portion near the folding feature 150, such that when the unitary body 106 is folded into a configuration where the backing component 120 is positioned behind the outer element 110, the openings 128 can align with the openings 118, such that fasteners can be received in the aligned openings 118, 128. However, it is not a requirement to have the openings 128. The openings 118 can provide guidance for installation of fasteners, without having corresponding openings 128 in the backing component. The backing component 120 portion can include one or more longitudinally extending reinforcement elements, such as one or more longitudinally extending protrusions or longitudinally extending ribs 126 for enhanced, strength, rigidity, or stability of the building surface panel 100. The ribs 126 can be formed longitudinally along the backing component 120, and at a height that provides increased rigidity, strength, or stability while not interfering with attachment of the building surface panel 100 to a building surface 32.

[0180] A plurality of relief holes 136 can be provided in the backing component 120 portion to reduce weight of the building surface panel 100 while still providing sufficient rigidity and strength to the building surface panel 100. Any of the backing component 120 embodiments can include relief holes 136, which can preferably be located outside of the reinforcement elements 126. Foam generally used in foam backed siding can have a density that is much lower than a density of the outer element of the foam backed siding. For example, a density of a foam used in foam back siding can generally range from 0.15 grams / cm3 up to 0.32 grams / cm3, wherein material used to form the backing component 120 of this disclosure can range from 0.40 grams / cm3 up to 2.0 grams / cm3.

[0181] The density of either the outer element 110 or the backing component 120 of the building surface panels 100 can have a density that is greater than about 0.40 grams / cm3, or greater than about 0.50 grams / cm3, or greater than about 0.60 grams / cm3, or greater than about 0.70 grams / cm3, greater than about 0.80 grams / cm3, or greater than about 0.85 grams / cm3, or greater than about 0.90 grams / cm3, or greater than about 0.95 grams / cm3, or greater than about 1.00 grams / cm3, or greater than about 1.10 grams / cm3, or greater than about 1.20 grams / cm3, or greater than about 1.30 grams / cm3, or greater than about 1.40 grams / cm3, or greater than about 1.50 grams / cm3, or greater than about 1.55 grams / cm3, or greater than about 1.75 grams / cm3, or greater than about 1.85 grams / cm3, or greater than about 1.95 grams / cm3.

[0182] The density of either the outer element 110 or the backing component 120 of the building surface panels 100 can have a density that is less than about 2.00 grams / cm3, or less than about 1.95 grams / cm3, or less than about 1.90 grams / cm3, or less than about 1.85 grams / cm3, or less than about 1.80 grams / cm3, or less than about 1.75 grams / cm3, or less than about 1.70 grams / cm3, or less than about 1.60 grams / cm3, or less than about 1.50 grams / cm3, or less than about 1.40 grams / cm3, or less than about 1.30 grams / cm3. It will be appreciated that the density of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the density of the building surface panel 100 may be any value between any of the values noted above.

[0183] Providing relief holes 136 in the backing component 120 of the building surface panel 100 of this disclosure can provide significant weight reduction, while maintaining sufficient structural stability of the backing component 120. Additionally, the thickness of the backing component 120 can be adjusted to improve structural stability without significantly impacting the overall size of the building surface panel 100.

[0184] However, it is not required to have relief holes 136 in the backing component 120. A folding feature 150 can be formed in the unitary body 106 to enable folding of the backing component 120 to engage a rear side 114 of the outer element 110. The folding feature 150 can form a longitudinal peak in the unitary body 106 which can allow for deformation of the peak while allowing for alignment of the openings 118, 128 when the unitary body 106 is folded to form the building surface panel 100.

[0185] The folding feature 150 can also include holes 146 that can further assist in allowing the unitary body 106 to be folded about the axis 90. Additionally, or alternatively, the folding feature 150 can include a thinner or more pliable material to assist in folding the unitary body 106 along the folding feature 150. Additionally, or alternatively, the folding feature 150 can include a separate material than the outer element 110 or the backing component 120, with this separate material being a more resilient material than either the outer element 110 or the backing component 120, thereby minimizing forces needed to fold the unitary body 106 along the folding feature 150.

[0186] Since the building surface panels 100 can be assembled onto a building surface 32 with horizontally adjacent building surface panels 100 butted together, it can be desirable that the right side 134 of one building surface panel 100 overlaps the left side 132 of an adjacent building surface panel 100 to further protect the building surface 32 from environmental conditions. Therefore, to allow for this overlap, the tongue 130 and the backing component 120 portion can be cut-back from the left and right sides 132, 134 of the outer element 110 by a distance LI to form a cutback 116 in the unitary body 106. It should be understood that the cutback 116 can be desirable, but is not required.

[0187] FIG. 4B is a representative perspective view of a building surface panel 100 formed as a unitary body 106 with an outer element 110 and a backing component 120 formed together, in accordance with certain embodiments. After being formed as the unitary body 106, the backing component 120 portion can be rotated or folded (arrows 92) about the axis 90 relative to the outer element 110 portion, such that the front side 122 of the backing component 120 engages with the rear side 114 of the outer element 110. The outer element 110 can be attached to the backing component 120 through a particular means as described above. When the outer element 110 is attached to the backing component 120, the folded unitary body 106 can form the building surface panel 100, which includes the tongue 130 formed along the top of the building surface panel 100 and a groove 140 formed at the bottom of the building surface panel 100, as shown in FIG. 4C. The bottom flange 138 can be positioned just below the groove 140 for aesthetic purposes.

[0188] FIG. 5A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. The unitary body 106 has been folded at the folding feature 150 to engage the backing component 120 with the outer element 110. The openings 118 can be aligned with the openings 128 to form a fastener hem 170, which can receive fasteners when attaching the building surface panel 100 to a building surface 32 via fasteners (e.g., fasteners 34 shown in FIG. 6B). The tongue 130 can extend along the outer element 110, with the cutbacks 116 at each end. The front side 112 of the outer element 110 is shown as an angled flat face profile. However, the front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein. The one or more reinforcement elements such as ribs 126 can extend longitudinally along the backing component 120 to provide reinforcement and rigidity to the outer element 110 when the backing component 120 is attached to the outer element 110.

[0189] FIG. 5B is a representative partial cross-sectional view 5B-5B, as indicated in FIG. 5A, of a building surface panel 100, in accordance with certain embodiments. The unitary body 106 has been folded at the folding feature 150 and the backing component 120 has been attached by a particular means to the rear side 114 of the outer element 110. The outer element 110 can provide a flat-face appearance that is angled relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. When the openings 118 align with the openings 128, the building surface panel 100 can form a fastener hem 170 that is a double thickness of the material used to form that unitary body 106. The tongue 130 can be formed just below the fastener hem 170 and adapted to complimentarily mate with a groove 140 of an adjacent building surface panel 100. The bottom flange 138 can be formed to overlay the groove 140 to provide a more aesthetic look when the building surface panels 100 are installed on a building surface 32.

[0190] FIG. 5C is a representative detail view of the detail region 5C, as indicated in FIG. 5B, of a building surface panel 100, in accordance with certain embodiments. The front side 112 of the outer element 110 can provide an aesthetic look for the building surface panel 100. The front side 122 of the backing component 120 can be attached to the rear side 114 of the outer element 110. An adhesive or adhesive layer 144 can be used to attach the backing component 120 to the outer element 110. The rear side 124 of the backing component 120 faces the building surface 32 when the building surface panel 100 is installed on the building surface 32. The groove 140 can form a longitudinal channel 142 into which a tongue 130 of an adjacent building surface panel 100 can be received.

[0191] The bottom of the longitudinal channel 142 can be inclined relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. A plurality of weep holes 162 can be formed through the groove 140 to allow any trapped fluid to drain away from the longitudinal channel 142. The bottom flange 138 can also be inclined relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. The incline of the bottom flange 138 preferably matches the incline of the bottom of the longitudinal channel 142 but is not required to do so. A plurality of weep holes 160 can be formed through the bottom flange 138 to allow any trapped fluid to drain away from the bottom flange 138 to an external environment (e.g., a front side 112 of an adjacent building surface panel positioned below the current building surface panel 100), where the fluid can be evaporated or otherwise managed to prevent fluid from being trapped in the building surface panel 100.

[0192] FIG. 6A is a representative perspective view of multiple building surface panels 100 with a reinforced outer element 110 assembled together, in accordance with certain embodiments. The building surface panels 100 can be assembled on the building surface 32 horizontally aligned with other building surface panels 100 (e.g., building surface panels 100b, 100c, with the right side of the building surface panel 100b overlapping the left side of the building surface panel 100c). The cutback 116 can allow the right side of one building surface panel 100 to overlap the left side of an adjacent building surface panel 100 up to a distance that can be substantially equal to the distance L1.

[0193] FIG. 6B is a representative partial cross-sectional view 6B-6B, as indicated in FIG. 6A, of multiple building surface panels 100 assembled together on a building surface 32, in accordance with certain embodiments. The building surface panels 100 can be assembled on the building surface 32 vertically aligned with each other. For example, when assembled vertically, the upper building surface panel 100a can be positioned across an overlap of lower building surface panels 100b, 100c (see FIG. 6A). The groove 140 of the upper building surface panel 100a can engage a portion of the tongue 130′ of each of the building surface panels 100b, 100c. When the building surface panel 100a is engaged with the tongues 130′ and when fasteners 34 attach the fastener hem 170 of the building surface panel 100a to the building surface 32, then the engagement of the tongues 130′ of the building surface panels 100b, 100c with the groove 140 of the building surface panel 100a will secure the building surface panel 100a to the building surface 32, since the tongues 130′ are secured to the building surface 32 via the fasteners 34′.

[0194] The bottom flange 138 overlays the groove 140, which receives the tongue 130′. The building surface panel 100b can include the outer element 110′ and the backing component 120′ attached to the rear side of the building surface panel 100b. In a non-limiting embodiment, the building surface panels 100 assembled on the building surface 32 can form a surface (which can include the front sides 112, 112′) that covers the building surface 32 and forms a shiplap type look. It should be understood that many other finished surfaces are possible with this reinforced building surface panel 100.

[0195] Referring to FIGS. 7A-7B, FIG. 7A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 7B is a representative partial cross-sectional view 7B-7B, as indicated in FIG. 7A, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. Where the previously described building surface panel 100 forms a shiplap type look, the building surface panel 100 of FIGS. 7A-7B forms a beveled edge look, where there is an angled groove formed between adjacent building surface panels 100, with a flat-face surface between angled grooves. The beveled edge building surface panels 100 can form a flat-face with longitudinal V-shaped grooves evenly spaced apart in a vertical direction. The building surface panels 100 can also form other aesthetic looks such as clapboard, dutchlap, board & batten, tongue & groove.

[0196] It should be understood that the building surface panels 100 can be assembled on the building surface 32 in any orientation from horizontal to vertical. They are not limited to a horizontal orientation indicated in the figures. The building surface panel 100 is formed from a unitary body 106 folded at the folding feature 150 to engage the backing component 120 with the outer element 110, as discussed above. However, the shape of the outer element 110 and the backing component 120 are different than the shiplap type building surface panels 100. The folded unitary body 106 still forms the fastener hem 170 with the openings 118, 128 being aligned. The tongue 130 can be similar to the previous embodiments, such that it is formed to engage with a groove 140 of an adjacent building surface panel 100.

[0197] The front side 112 of the outer element 110 can form a flat face surface that can be substantially parallel with a building surface 32 when the building surface panel 100 is attached to the building surface 32. At the top of the front side 112 can be an angled portion 158, that is inclined from an upper portion of the building surface panel 100 to the front side 112. At the bottom of the front side 112, the bottom flange 138 can be formed as an angled portion that can engage (or at least be positioned proximate) an angled portion 158′ of an adjacent building surface panel 100b positioned below the current building surface panel 100a (see FIG. 8B).

[0198] The backing component 120 can include a complimentarily shaped angled portion 168 that can engage the angled portion 158 when the backing component 120 is attached to the outer element 110. The backing component 120 can also include one or more ribs 126 that provide additional stability for the backing component 120 and thus for the outer element 110, when the backing component 120 is attached to the outer element 110. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein. The front side 112 can also include one or more longitudinal recesses of various shapes, e.g., V-shaped, circularly shaped, rectangularly shaped, curve shaped, etc.

[0199] Referring to FIGS. 8A-8B, FIG. 8A is a representative perspective view of multiple building surface panels 100 with a reinforced outer element 110 assembled together, in accordance with certain embodiments. FIG. 8B is a representative partial cross-sectional view 8B-8B, as indicated in FIG. 8A, of multiple building surface panels 100 assembled together on a building surface 32, in accordance with certain embodiments.

[0200] As can be seen, the edge of the groove 140 of the upper building surface panel 100a can be received into the tongue 130′ of the lower building surface panel 100b. This can securely couple the groove 140 of the upper building surface panel 100a to the building surface 32 via the fasteners 34′ that can be used to secure the fastener hem 170 of the lower building surface panel 100b to the building surface 32. Fasteners 34 can be used to securely couple the fastener hem 170 of the upper building surface panel 100a to the building surface 32 in preparation for installing another building surface panel 100 above the upper building surface panel 100a. The lower building surface panel 100b can include an outer element 110′ with an angled portion 158′ and a bottom flange 138′, and a backing component 120′ with an angled portion 168′ and a groove 140′.

[0201] Referring to FIGS. 9A-9B, FIG. 9A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 9B is a representative partial cross-sectional view 9B-9B, as indicated in FIG. 9A, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments.

[0202] The building surface panel 100 is similar to the building surface panel 100 shown in FIGS. 7A-8B, except that this building surface panel 100 can have one or more additional longitudinal recesses formed in the front side 112 of the building surface panel 100. The building surface panel 100 of FIGS. 9A-9B forms a beveled edge look with a center longitudinal recess 117, where there is an angled groove formed between adjacent building surface panels 100, with a flat-face surface between angled grooves, and with one or more longitudinal recesses 117 being formed in the front side 112.

[0203] The beveled edge building surface panels 100 can form a flat-face with longitudinal V-shaped grooves evenly spaced apart in a vertical direction as well as the one or more longitudinal recesses 117 positioned between the V-shaped grooves. It should be understood that the one or more longitudinal recesses 117 can also be V-shaped as well as many other shapes.

[0204] It should be understood that the building surface panels 100 can be assembled on the building surface 32 in any orientation from horizontal to vertical. They are not limited to a horizontal orientation indicated in the figures. The building surface panel 100 is formed from a unitary body 106 folded at the folding feature 150 to engage the backing component 120 with the outer element 110, as discussed above. However, the shape of the outer element 110 and the backing component 120 are different than the shiplap type building surface panels 100. The folded unitary body 106 still forms the fastener hem 170 with the openings 118, 128 being aligned. The tongue 130 can be very similar to the previous embodiments, such that it is formed to engage with a groove 140 of an adjacent building surface panel 100.

[0205] The front side 112 of the outer element 110 can form a flat face surface that can be substantially parallel with a building surface 32 when the building surface panel 100 is attached to the building surface 32. At the top of the front side 112 can be an angled portion 158, that is inclined from an upper portion of the building surface panel 100 to the front side 112. At the bottom of the front side 112, the bottom flange 138 can be formed as an angled portion that can engage (or at least be positioned proximate) an angled portion 158 of an adjacent building surface panel 100 positioned below the current building surface panel 100. The front side 112 can include the one or more longitudinal recesses 117.

[0206] The backing component 120 can include a complimentarily shaped angled portion 168 that can engage the angled portion 158 when the backing component 120 is attached to the outer element 110. The backing component 120 can also include one or more ribs 126 that provide additional stability for the backing component 120 and thus for the outer element 110, when the backing component 120 is attached to the outer element 110. The backing component 120 can also include a complimentarily shaped one or more longitudinal recess 127 that can engage respective ones of the one or more longitudinal recess 117 when the backing component 120 is attached to the outer element 110.

[0207] It should be understood that many other shapes of a building surface panel 100 are envisioned that utilize the novel approach of forming a building surface panel 100 by forming a unitary body 106 and then folding the backing component 120 to engage the outer element 110. However, a novel building surface panel 100 can also be formed from two separately formed portions that are attached together to form the building surface panel 100.

[0208] Referring to FIGS. 10A-10D, FIG. 10A is a representative perspective view of an outer element 110 of a building surface panel 100, and FIG. 10B is a representative perspective view of a backing component 120 of the building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 10C is a representative perspective view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. FIG. 10D is a representative partial cross-sectional view 10D-10D, as indicated in FIG. 10C, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments.

[0209] The outer element 110 shown in FIG. 10A can include the front side 112, that forms a flat face, and a bottom flange 138 angled back and adapted to cover the groove 140 of the backing component 120 when the outer element 110 is attached to the backing component 120 to form the building surface panel 100. The outer element 110 can include a left side 132, a right side 134, and a top side 152. The length L2 can represent a distance from the left side 132 to the right side 134 of the outer element 110. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein.

[0210] The backing component 120 can be formed as a unitary body 108 with an upper portion containing the tongue 130 and the openings 118 with the upper portion being folded relative to the lower portion at the folding feature 150. This aligns the openings 118 with the openings 128 to form a double-thickness fastener hem 170 at the top of the building surface panel 100. The backing component 120 can include one or more ribs 126 that can provide reinforcement for the building surface panel 100 when the backing component 120 is attached to the outer element 110. The interaction of the tongue 130 with the groove 140 can be different than the previously described embodiments. The tongue 130 can be formed to provide a restricted clearance between the tongue and the body of the backing component 120. The groove 140 can include a bump feature that can be forced past the restricted clearance of the tongue 130 and held within the tongue 130 when an upper building surface panel 100 is engaged with the current building surface panel 100.

[0211] The length L3 can represent a distance from the left side 102 to the right side 104 of the backing component 120. It can be preferrable that the length L2 of the outer element 110 is larger than the length L3 of the backing component 120. This allows the top side 152 of the outer element 110 to form a cutback 116 of the building surface panel 100 (see FIG. 10C) formed when the backing component 120 is attached to the outer element 110. Because the backing component 120 is formed as a unitary body 106, alignment of the openings 118 with the openings 128 is built into the unitary body 106 so when the top portion if folded at the folding feature 150, the openings 118, 128 are aligned. Alignment of the outer element 110 with the backing component 120 can have loose tolerances, since precise alignment is not needed.

[0212] Referring to FIGS. 11A-11D, FIG. 11A is a representative perspective view of an outer element 110 of a building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 11B is a representative perspective view of a backing component 120 of a building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 11C is a representative perspective view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. FIG. 11D is a representative partial cross-sectional view 11D-11D, as indicated in FIG. 11C, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 11E is a representative perspective rear view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments.

[0213] The outer element 110 shown in FIG. 11A can include the front side 112, that forms a flat face, and a bottom flange 138 angled back and adapted to cover the groove 140 of the backing component 120 when the outer element 110 is attached to the backing component 120 to form the building surface panel 100. The outer element 110 can include a left side 132, a right side 134, and a top side 152. An upper portion of the outer element 110 can include a tongue 130 and openings 118. In this non-limiting embodiment, the fastener hem 170 can be a single thickness and includes openings 118 for receiving fasteners 34 to attach the building surface panel 100 to a building surface 32. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein.

[0214] The backing component 120 can include one or more ribs 126 that can provide reinforcement for the building surface panel 100 when the backing component 120 is attached to the outer element 110. The backing component 120 can include a left side 102, a right side 104, and a top side 154. The tongue 130 can be formed with the outer element 110 to provide a restricted clearance between the tongue and the body of the backing component 120. The groove 140 can be formed with the backing component 120 and can include a bump feature that can be forced past the restricted clearance of the tongue 130 and held by the tongue 130 when an upper building surface panel 100 is engaged with the current building surface panel 100.

[0215] The outer element 110 can have cutbacks 116 on the left side 132 and the right side 134 proximate the tongue 130. The width L4 can represent a distance from the left side 132 to the right side 134 of the outer element 110. The width L5 can represent a distance from the left side 102 to the right side 104 of the backing component 120. It can be preferrable that the width L4 of the outer element 110 is larger than the width L5 of the backing component 120. The width L5 can be substantially equal to the width L7 of the fastener hem 170 and tongue 130.

[0216] In a number of embodiments, the width L4 (representing a distance from the left side 132 to the right side 134 of the outer element 110) may be a first width and a width L5 (representing a distance from the left side 102 to the right side 104 of the backing component 120) may be a second width. In a number of embodiments, the first width L4 may be wider than the second width L5. In a number of embodiments, the first width L4 may be 1.5 times wider than the second width L5. In a number of embodiments, the first width L4 may be 2 times wider than the second width L5. In a number of embodiments, the first width L4 may be 2.5 times wider than the second width L5. In a number of embodiments, the first width L4 may be 3 times wider than the second width L5. In a number of embodiments, the first width L4 may be 4 times wider than the second width L5. In a number of embodiments, the first width L4 may be 5 times wider than the second width L5. In a number of embodiments, the first width L4 may be no greater than 25 times wider than the second width L5. In a number of embodiments, the first width L4 may be no greater than 20 times wider than the second width L5. In a number of embodiments, the first width L4 may be no greater than 15 times wider than the second width L5. It will be appreciated that the ratio of L4 to L5 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the ratio of L4 to L5 may be any value between any of the minimum and maximum values noted above.

[0217] When the backing component 120 is attached to the rear side 114 of the outer element 110, the backing component 120 can be aligned with the fastener hem 170 and the tongue 130 of the outer element 110, such that a distance approximately equal to the distance L1 of the cutback 116 can be provided between the left and right sides 132, 134 of the outer element 110 and the left and right sides 102, 104 of the backing component 120. As described previously, the cutback 116 allows overlap of the left and right sides of horizontally adjacent building surface panels 100 when installed onto the building surface 32.

[0218] Since features on either of the outer element 110 or the backing component 120 do not require precise alignment when they are being attached together, alignment of the outer element 110 with the backing component 120 can have loose tolerances.

[0219] The width L7 of the fastener hem 170 and tongue 130 can be substantially equal to the width L5 of the backing component 120, such that a cutback 116 can be formed on both sides of the building surface panel 100, such that the tongue 130 and the groove 140 are setback by a distance L6 (which can be substantially equal to distance L1) from both sides 132, 134 of the outer element 110 (or outer element 110) to allow overlapping the left and right sides 132, 134 of horizontally adjacent building surface panels 100.

[0220] FIGS. 12A-12D are representative partial cross-sectional views 12-12, as indicated in FIG. 11E, of reinforcement elements 126 of a backing component 120 to reinforce an outer element 110 of a building surface panel 100, in accordance with certain embodiments. The reinforcement elements 126 can extend longitudinally along the backing component as seen in FIG. 11E. However, it should be understood that the reinforcement elements 126 can extend longitudinally along the backing component 120 and can be substantially in parallel with the top side 152 of the outer element 110 or the top side 154 of the backing component 120. It should also be understood that the reinforcement elements 126 can extend longitudinally along the backing component 120 and can be angled relative to the top side 152 of the outer element 110 (or outer element) or the top side 154 of the backing component 120.

[0221] It should also be understood that the reinforcement elements 126 can extend axially across the backing component 120 and can be generally perpendicular to the top side 152 of the outer element 110 (or outer element) or the top side 154 of the backing component 120. In some embodiments, the reinforcement elements 126 comprises multiple reinforcement elements, such as ribs, arranged in a staggered manner to each other, each extending longitudinally such that each rib does not extend all the way along the backing component (not shown). In yet another embodiment, the backing component 120 comprises reinforcement elements that are embossed into the backing component 120, forming a plurality of dimples and / or protrusions, where the dimples bend inwards towards the rear side 114 of the outer element and may or may not be in contact with the outer element.

[0222] The reinforcement elements 126 can be seen as ribs 126 as shown in FIGS. 11E and 12A where the reinforcement element 126 is generally the same thickness as the other portions of the backing component but form a profile that protrudes from the rear side 124 and is spaced away from the front side 122. The reinforcement element 126 can form a hollow portion bounded by the outer element 110 and the reinforcement element 126. The profile of the reinforcement element 126 can provide increased rigidity for the backing component 120 and for the outer element 110 when it is attached to the backing component 120. A particular profile is shown for the reinforcement element 126 in FIG. 12A, but it should be understood that any other suitable profile can be used to provide increased rigidity to the building surface panel 100 when the backing component 120 is attached to the outer element 110 (or outer element 110). In an embodiment, the reinforcement element 126 is narrow, such that there is substantially no space in between the two side walls of the reinforcement element 126. The height and width of each reinforcing element 126 can be tailored to provide desired rigidity for a particular building panel having a particular profile of the outer element 110.

[0223] Alternatively, or in addition to, the reinforcement element 126 can be a separate piece that is adhered to the rear side 124 of the backing component 120 to provide increased rigidity to the building surface panel 100 or the reinforcement elements 126 can be formed with the backing component 120. FIGS. 12B-12D illustrate various cross-sectional shapes of elongated reinforcement elements 126 that can be adhered to the rear side 124 of (or formed with) the backing component 120. In these non-limiting embodiments, the backing component 120 can be formed without a reinforcement profile and a separate reinforcement element 126 can be adhered to the backing component 120. Also, the reinforcement element 126 can be formed with the backing component 120 and can have any suitable profile or cross-section shape.

[0224] FIG. 12B shows a reinforcement element 126 having a rectangular cross-section, where the thickness and width of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100. FIG. 12C shows a reinforcement element 126 having a triangular cross-section, where the legs of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100. FIG. 12D shows a reinforcement element 126 having a C-shaped cross-section, where the thickness and width of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100.

[0225] It should be understood that any of the reinforcement elements 126 (e.g., ribs 126) described in this disclosure can be used for any of the embodiments of the reinforcement elements 126 (e.g., ribs 126) disclosed herein.

[0226] FIG. 21 is a representative cross-sectional view of another building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. The building surface panel 100 can form a board and batten type siding configuration which can be installed on a building surface 32 in any orientation. However, a vertical orientation can be preferred. The ribs 126 of the backing component 120 can extend toward a building surface 32 and can contact the building surface 32 for additional support. However, it can be preferred that the ribs 126 extend enough to leave a gap between the ribs 126 and the building surface 32 when the building surface panel 100 is in an installed position on the building surface 32 and is in a steady state configuration, where the steady state configuration is where no outside forces are acting on the building surface panel 100.

[0227] The ribs 126 can also provide a more rigid feel when handling the building surface panel 100. For example, when the building surface panel 100 is installed on the building surface 32, when a user pushes on the outer element 110, the ribs 126 can engage the building surface 32 and resist further movement, thus giving the feel of the building surface panel 100 being more rigid.

[0228] The outer element 110 can include the tongue 130, the top side 152, the folding feature 150, and openings 118 that can receive fasteners in the fastener hem 170. The outer element 110 can also include the groove 140, which can engage a tongue 130 of an adjacent building surface panel 100. The outer element 110 can form the exterior shape of the building surface panel 100 that can be visible when it is installed on the building surface 32.

[0229] FIG. 22 is a representative cross-sectional view of another building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. The building surface panel 100 can form a shiplap type siding configuration which can be installed on a building surface 32 in any orientation. However, a horizontal orientation can be preferred. The ribs 126 of the backing component 120 can extend toward a building surface 32 and can contact the building surface 32 for additional support. However, it can be preferred that the ribs 126 extend enough to leave a gap between the ribs 126 and the building surface 32 when the building surface panel 100 is in an installed position on the building surface 32 and is in a steady state configuration.

[0230] The ribs 126 can include one or more weep holes 162 extending through a respective rib 126 to allow for fluid (e.g., water) to not be trapped between the building surface panel 100 and the building surface 32. Therefore, if the gap between the ribs 126 and the building surface 32 is substantially “0” zero, then the fluid can bypass the rib 126 and not get trapped by flowing through the weep holes 162. The groove 140 can also include one or more weep holes 160 to prevent fluid from collecting in the groove 140 when the building surface panel 100 is in an installed position on the building surface 32. As stated above with regard to FIG. 20, the ribs 126 can also provide a more rigid feel when handling the building surface panel 100.

[0231] The outer element 110 can include the tongue 130, the top side 152, the folding feature 150, and openings 118 that can receive fasteners in the fastener hem 170. The outer element 110 can also include the groove 140, which can engage a tongue 130 of an adjacent building surface panel 100. The outer element 110 can form the exterior shape of the building surface panel 100 that can be visible when it is installed on the building surface 32. The weep holes 160, 162 provide enhanced fluid flow management for the building surface panel 100.

[0232] The impact resistance of the building surface panel 100 can be measured according to ASTM D 4226 and can be greater than 60 mean failure energy (MFE) in-lbs. (6.78 Nm), or greater than 70 MFE in-lbs. (7.91 Nm), or greater than 80 MFE in-lbs. (9.4 Nm), or greater than 90 MFE in-lbs. (10.17 Nm), or greater than 100 MFE in-lbs. (11.30 Nm), or greater than 110 MFE in-lbs. (12.43 Nm), or greater than 120 MFE in-lbs. (13.56 Nm), or greater than 130 MFE in-lbs. (14.69 Nm), or greater than 140 MFE in-lbs. (15.82 Nm), or greater than 150 MFE in-lbs. (16.95 Nm), or greater than 155 MFE in-lbs. (17.5 Nm), or greater than 160 MFE in-lbs. (18.8 Nm), or greater than 165 MFE in-lbs. (18.64 Nm), or greater than 170 MFE in-lbs. (19.21 Nm), or greater than 175 MFE in-lbs. (19.77 Nm). The damage impact of the building surface panel 100 can be less than 190 MFE in-lbs. (21.47 Nm), or less than 185 MFE in-lbs. (20.90 Nm), or less than 180 MFE in-lbs. (20.34 Nm), or less than 175 MFE in-lbs. (19.77 Nm), or less than 170 MFE in-lbs. (19.21 Nm), or less than 165 MFE in-lbs. (18.64 Nm). It will be appreciated that the damage impact of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the damage impact of the building surface panel 100 may be any value between any of the values noted above.

[0233] The standard static test pressure rating of the building surface panel 100 can be measured according to testing requirements given in the ASTM D7445, which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding with Foam Plastic backing (Backed Vinyl Siding). The building surface panel 100 according to various embodiments of the present inventions are able to withstand a sustained static pressure of greater than 22.5 pounds per square foot (1.77 kPa), or greater than 25 pounds per square foot (1.20 kPa), or greater than 30 pounds per square foot (1.44 kPa), or greater than 35 pounds per square foot (1.68 kPa), or greater than 40 pounds per square foot (1.92 kPa), or greater than 45 pounds per square foot (2.16 kPa), or greater than 50 pounds per square foot (2.39 kPa), or greater than 55 pounds per square foot (2.63 kPa), or greater than 60 pounds per square foot (2.87 kPa), or greater than 64 pounds per square foot (3.6 kPa), or greater than 70 pounds per square foot (3.35 kPa), or greater than 75 pounds per square foot (3.59 kPa), or greater than 80 pounds per square foot (3.83 kPa), or greater than 85 pounds per square foot (4.7 kPa), or greater than 90 pounds per square foot (4.31 kPa), or greater than 95 pounds per square foot (4.55 kPa), or greater than 100 pounds per square foot (4.79 kPa). The standard design wind pressure rating of the building surface panel 100 can be less than 115 pounds per square foot (5.51 kPa), or less than 110 pounds per square foot (5.27 kPa), or less than 105 pounds per square foot (5.3 kPa), or less than 100 pounds per square foot (4.79 kPa), or less than 95 pounds per square foot (4.55 kPa), or less than 90 pounds per square foot (4.31 kPa). It will be appreciated that the standard design sustained static pressure rating of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the standard design wind pressure rating of the building surface panel 100 may be any value between any of the values noted above.

[0234] The standard design wind pressure rating of the building surface panel 100 can be measured according to testing requirements given in the ASTM D3679, which specifies a standard test procedure given in ASTM D5206, which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding. The building surface panel 100 according to various embodiments of the present inventions are able to withstand a standard design wind pressure rating of greater than 22.5 pounds per square foot (1.77 kPa), or greater than 25 pounds per square foot (1.20 kPa), or greater than 30 pounds per square foot (1.44 kPa), or greater than 35 pounds per square foot (1.68 kPa), or greater than 40 pounds per square foot (1.92 kPa), or greater than 45 pounds per square foot (2.16 kPa), or greater than 50 pounds per square foot (2.39 kPa), or greater than 55 pounds per square foot (2.63 kPa), or greater than 60 pounds per square foot (2.87 kPa), or greater than 64 pounds per square foot (3.6 kPa), or greater than 70 pounds per square foot (3.35 kPa), or greater than 75 pounds per square foot (3.59 kPa), or greater than 80 pounds per square foot (3.83 kPa), or greater than 85 pounds per square foot (4.7 kPa), or greater than 90 pounds per square foot (4.31 kPa), or greater than 95 pounds per square foot (4.55 kPa), or greater than 100 pounds per square foot (4.79 kPa). The standard design wind pressure rating of the building surface panel 100 can be less than 115 pounds per square foot (5.51 kPa), or less than 110 pounds per square foot (5.27 kPa), or less than 105 pounds per square foot (5.3 kPa), or less than 100 pounds per square foot (4.79 kPa), or less than 95 pounds per square foot (4.55 kPa), or less than 90 pounds per square foot (4.31 kPa). It will be appreciated that the standard design wind pressure rating of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the standard design wind pressure rating of the building surface panel 100 may be any value between any of the values noted above.

[0235] While there may be other backing systems for building surface panels that are known to have a backing component coupled to an outer element in a non-permanent manner, these are not necessarily subject to the same design constraints and issues when you fixedly or permanently attach the outer element to the backing component, such as problems (e.g., bulking, oil canning, etc.) that can occur due to CTE mismatches between the outer element and the backing component.

[0236] It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

[0237] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.VARIOUS EMBODIMENTSEmbodiment 1. A building surface panel comprising:

[0239] an outer element; and

[0240] a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel,

[0241] wherein the building surface panel further comprises one of:

[0242] a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%,

[0243] a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel,

[0244] a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element,

[0245] a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3, and

[0246] a combination thereof.

[0247] Embodiment 2. The building surface panel of embodiment 1, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0248] Embodiment 3. The building surface panel of embodiment 2, wherein a first adhesive attaches the first backing layer to the first element layer.

[0249] Embodiment 4. The building surface panel of embodiment 3, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0250] Embodiment 5. The building surface panel of embodiment 2, wherein the first backing composition is the same as the first element composition.

[0251] Embodiment 6. The building surface panel of embodiment 2, wherein the first backing composition is the same as the second backing composition.

[0252] Embodiment 7. The building surface panel of embodiment 1, wherein the first backing composition is different from the second backing composition.

[0253] Embodiment 8. The building surface panel of embodiment 1, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0254] Embodiment 9. The building surface panel of embodiment 8, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0255] Embodiment 10. The building surface panel of embodiment 2, wherein the first element composition is the same as the second element composition.

[0256] Embodiment 11. The building surface panel of embodiment 2, wherein the first element composition is different than the second element composition.

[0257] Embodiment 12. The building surface panel of embodiment 2, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0258] Embodiment 13. The building surface panel of embodiment 12, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0259] Embodiment 14. The building surface panel of embodiment 2, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0260] Embodiment 15. The building surface panel of embodiment 2, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0261] Embodiment 16. The building surface panel of embodiment 15, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0262] Embodiment 17. The building surface panel of embodiment 15, wherein the third element composition is different from either of the first element composition or the second element composition.

[0263] Embodiment 18. The building surface panel of embodiment 15, wherein the third element composition is ASA.

[0264] Embodiment 19. The building surface panel of embodiment 15, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0265] Embodiment 20. The building surface panel of embodiment 19, wherein the third element layer has a desired color.

[0266] Embodiment 21. The building surface panel of embodiment 15, wherein the first, second, and third element layers are of the same color or different colors.

[0267] Embodiment 22. The building surface panel of embodiment 15, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0268] Embodiment 23. The building surface panel of embodiment 1, wherein the backing component comprises one or more longitudinally extending reinforcement elements.

[0269] Embodiment 24. The building surface panel of embodiment 1, wherein the outer element further comprises a groove, and wherein the groove is adapted to receive a tongue of another building surface panel.

[0270] Embodiment 25. The building surface panel of embodiment 1, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0271] Embodiment 26. The building surface panel of embodiment 25, wherein the first, second, and third backing layers are of the same color or different colors.

[0272] Embodiment 27. The building surface panel of embodiment 25, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0273] Embodiment 28. The building surface panel of embodiment 25, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0274] Embodiment 29. The building surface panel of embodiment 25, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0275] Embodiment 30. The building surface panel of embodiment 25, wherein the third backing composition comprises ASA.

[0276] Embodiment 31. The building surface panel of embodiment 1, wherein the outer element comprises a tongue that is adapted to engage a groove of another building surface panel.

[0277] Embodiment 32. The building surface panel of embodiment 1, wherein the outer element comprises a fastener hem that is adapted to receive fasteners that secure the fastener hem to a building surface.

[0278] Embodiment 33. The building surface panel of embodiment 1, wherein the outer element is formed having a first width as measured from a first left side to a first right side of the outer element, and wherein the first width is wider than a second width of the backing component as measured from a second left side to a second right side of the backing component.

[0279] Embodiment 34. A building surface panel comprising:

[0280] an outer element; and a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel, and wherein the backing component further comprises one or more longitudinally extending ribs that protrude from the backing component.

[0281] Embodiment 35. The building surface panel of embodiment 34, wherein one or more of the longitudinally extending ribs comprises one or more weep holes formed therethrough.

[0282] Embodiment 36. The building surface panel of embodiment 34, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0283] Embodiment 37. The building surface panel of embodiment 36, wherein a first adhesive attaches the first backing layer to the first element layer.

[0284] Embodiment 38. The building surface panel of embodiment 37, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0285] Embodiment 39. The building surface panel of embodiment 36, wherein the first backing composition is the same as the first element composition.

[0286] Embodiment 40. The building surface panel of embodiment 36, wherein the first backing composition is the same as the second backing composition.

[0287] Embodiment 41. The building surface panel of embodiment 34, wherein the first backing composition is different from the second backing composition.

[0288] Embodiment 42. The building surface panel of embodiment 34, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0289] Embodiment 43. The building surface panel of embodiment 42, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0290] Embodiment 44. The building surface panel of embodiment 36, wherein the first element composition is the same as the second element composition.

[0291] Embodiment 45. The building surface panel of embodiment 36, wherein the first element composition is different than the second element composition.

[0292] Embodiment 46. The building surface panel of embodiment 36, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0293] Embodiment 47. The building surface panel of embodiment 46, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0294] Embodiment 48. The building surface panel of embodiment 36, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0295] Embodiment 49. The building surface panel of embodiment 36, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0296] Embodiment 50. The building surface panel of embodiment 49, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0297] Embodiment 51. The building surface panel of embodiment 49, wherein the third element composition is different than either of the first element composition or the second element composition.

[0298] Embodiment 52. The building surface panel of embodiment 49, wherein the third element composition comprises ASA.

[0299] Embodiment 53. The building surface panel of embodiment 49, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0300] Embodiment 54. The building surface panel of embodiment 53, wherein the third element layer has a desired color.

[0301] Embodiment 55. The building surface panel of embodiment 49, wherein the first, second, and third element layers are of the same color or different colors.

[0302] Embodiment 56. The building surface panel of embodiment 49, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0303] Embodiment 57. The building surface panel of embodiment 34, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0304] Embodiment 58. The building surface panel of embodiment 57, wherein the first, second, and third backing layers are of the same color or different colors.

[0305] Embodiment 59. The building surface panel of embodiment 57, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0306] Embodiment 60. The building surface panel of embodiment 57, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0307] Embodiment 61. The building surface panel of embodiment 57, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0308] Embodiment 62. The building surface panel of embodiment 57, wherein the third backing composition comprises ASA.

[0309] Embodiment 63. A building surface panel comprising:

[0310] an outer element; and

[0311] a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel, and

[0312] wherein the backing component comprises at least one of:

[0313] a longitudinally extending groove;

[0314] a longitudinally extending tongue; and

[0315] a density that is at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3.

[0316] Embodiment 64. The building surface panel of embodiment 63, wherein the longitudinally extending groove comprises one or more weep holes formed therethrough.

[0317] Embodiment 65. The building surface panel of embodiment 63, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0318] Embodiment 66. The building surface panel of embodiment 65, wherein a first adhesive attaches the first backing layer to the first element layer.

[0319] Embodiment 67. The building surface panel of embodiment 66, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0320] Embodiment 68. The building surface panel of embodiment 65, wherein the first backing composition is the same as the first element composition.

[0321] Embodiment 69. The building surface panel of embodiment 65, wherein the first backing composition is the same as the second backing composition.

[0322] Embodiment 70. The building surface panel of embodiment 63, wherein the first backing composition is different from the second backing composition.

[0323] Embodiment 71. The building surface panel of embodiment 63, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0324] Embodiment 72. The building surface panel of embodiment 71, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0325] Embodiment 73. The building surface panel of embodiment 65, wherein the first element composition is the same as the second element composition.

[0326] Embodiment 74. The building surface panel of embodiment 65, wherein the first element composition is different than the second element composition.

[0327] Embodiment 75. The building surface panel of embodiment 65, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0328] Embodiment 76. The building surface panel of embodiment 75, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0329] Embodiment 77. The building surface panel of embodiment 65, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0330] Embodiment 78. The building surface panel of embodiment 65, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0331] Embodiment 79. The building surface panel of embodiment 78, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0332] Embodiment 80. The building surface panel of embodiment 78, wherein the third element composition is different than either of the first element composition or the second element composition.

[0333] Embodiment 81. The building surface panel of embodiment 78, wherein the third element composition comprises ASA.

[0334] Embodiment 82. The building surface panel of embodiment 78, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0335] Embodiment 83. The building surface panel of embodiment 82, wherein the third element layer has a desired color.

[0336] Embodiment 84. The building surface panel of embodiment 78, wherein the first, second, and third element layers are of the same color or different colors.

[0337] Embodiment 85. The building surface panel of embodiment 78, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0338] Embodiment 86. The building surface panel of embodiment 63, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0339] Embodiment 87. The building surface panel of embodiment 86, wherein the first, second, and third backing layers are of the same color or different colors.

[0340] Embodiment 88. The building surface panel of embodiment 86, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0341] Embodiment 89. The building surface panel of embodiment 86, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0342] Embodiment 90. The building surface panel of embodiment 86, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0343] Embodiment 91. The building surface panel of embodiment 86, wherein the third backing composition comprises ASA.

[0344] Embodiment 92. A building surface panel comprising:

[0345] an outer element; and

[0346] a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel, and

[0347] wherein the outer element has a first front side, a first rear side, and a first thickness as measured between the first front side and the first rear side; and the backing component has a second front side, a second rear side, and a second thickness as measured between the second front side and the second rear side, wherein the second front side of the backing component is attached to the first rear side of the outer element, wherein the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

[0348] Embodiment 93. The building surface panel of embodiment 92, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

[0349] Embodiment 94. The building surface panel of embodiment 93, wherein a first adhesive attaches the first backing layer to the first element layer.

[0350] Embodiment 95. The building surface panel of embodiment 94, wherein the first adhesive in a cured state provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

[0351] Embodiment 96. The building surface panel of embodiment 93, wherein the first backing composition is the same as the first element composition.

[0352] Embodiment 97. The building surface panel of embodiment 93, wherein the first backing composition is the same as the second backing composition.

[0353] Embodiment 98. The building surface panel of embodiment 92, wherein the first backing composition is different from the second backing composition.

[0354] Embodiment 99. The building surface panel of embodiment 92, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

[0355] Embodiment 100. The building surface panel of embodiment 99, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

[0356] Embodiment 101. The building surface panel of embodiment 93, wherein the first element composition is the same as the second element composition.

[0357] Embodiment 102. The building surface panel of embodiment 93, wherein the first element composition is different than the second element composition.

[0358] Embodiment 103. The building surface panel of embodiment 93, wherein the first element composition comprises acrylonitrile styrene acrylate (ASA) and the second element composition comprises polyvinyl chloride (PVC).

[0359] Embodiment 104. The building surface panel of embodiment 103, wherein the second element composition comprises at least 10% by weight of recycled PVC.

[0360] Embodiment 105. The building surface panel of embodiment 93, wherein both the first element composition and the second element composition comprise polyvinyl chloride (PVC), and differ from one another in an amount and / or chemical composition of one or more additives.

[0361] Embodiment 106. The building surface panel of embodiment 93, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

[0362] Embodiment 107. The building surface panel of embodiment 106, wherein the third element composition is the same as either of the first element composition or the second element composition.

[0363] Embodiment 108. The building surface panel of embodiment 106, wherein the third element composition is different than either of the first element composition or the second element composition.

[0364] Embodiment 109. The building surface panel of embodiment 106, wherein the third element composition comprises ASA.

[0365] Embodiment 110. The building surface panel of embodiment 106, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0366] Embodiment 111. The building surface panel of embodiment 110, wherein the third element layer has a desired color.

[0367] Embodiment 112. The building surface panel of embodiment 106, wherein the first, second, and third element layers are of the same color or different colors.

[0368] Embodiment 113. The building surface panel of embodiment 106, wherein any of the first element composition, the second element composition, or the third element composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0369] Embodiment 114. The building surface panel of embodiment 92, wherein a standard design wind pressure rating of the building surface panel exceeds 62 pounds per square foot (2969 Pa) as determined by testing requirements given in the American Society for Testing and Materials (ASTM) specification D3679, test procedure D5206 which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding.

[0370] Embodiment 115. The building surface panel of embodiment 92, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

[0371] Embodiment 116. The building surface panel of embodiment 115, wherein the first, second, and third backing layers are of the same color or different colors.

[0372] Embodiment 117. The building surface panel of embodiment 115, wherein any of the first backing composition, the second backing composition, or the third backing composition comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, or any combination thereof.

[0373] Embodiment 118. The building surface panel of embodiment 115, wherein the third backing composition is the same as either of the first backing composition or the second backing composition.

[0374] Embodiment 119. The building surface panel of embodiment 115, wherein the third backing composition is different than either of the first backing composition or the second backing composition.

[0375] Embodiment 120. The building surface panel of embodiment 115, wherein the third backing composition comprises ASA.

[0376] Embodiment 121. A building surface panel comprising:

[0377] an outer element with a first element layer that comprises acrylonitrile styrene acrylate (ASA) that is attached to a second element layer that comprises polyvinyl chloride (PVC); and

[0378] a backing component with a first backing layer that comprises ASA that is attached to a second backing layer that comprises PVC, wherein the first element layer is attached to the first backing layer to form the building surface panel.

[0379] Embodiment 122. The building surface panel of embodiment 121, wherein the outer element further comprises a third element layer that comprises ASA that is attached to an opposite side of the second element layer from the first element layer.

[0380] Embodiment 123. The building surface panel of embodiment 122, wherein the third element layer forms a front side of the outer element and provides an aesthetic look for the building surface panel when the building surface panel is in an installed position on a building.

[0381] Embodiment 124. The building surface panel of embodiment 123, wherein the third element layer has a desired color.

[0382] Embodiment 125. The building surface panel of embodiment 122, wherein the first, second, and third element layers are of the same color or different colors.

[0383] Embodiment 126. The building surface panel of embodiment 121, wherein the backing component further comprises a third backing layer that comprises ASA that is attached to an opposite side of the second backing layer from the first backing layer.

[0384] Embodiment 127. The building surface panel of embodiment 126, wherein the first, second, and third backing layers are of the same color or different colors.

[0385] Embodiment 128. The building surface panel of embodiment 121, wherein a first adhesive attaches the first element layer to the first backing layer.

[0386] Embodiment 129. The building surface panel of embodiment 128, wherein the first adhesive in a cured state provides a bond shear strength between the first element layer and the first backing layer of at least about 0.10 MPa at room temperature.

[0387] Note that not all of the activities described above in the general description, or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

[0388] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0389] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Examples

embodiment 1

A building surface panel comprising:[0239]an outer element; and[0240]a backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel,[0241]wherein the building surface panel further comprises one of:[0242]a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%,[0243]a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel,[0244]a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element,[0245]a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3, and[0246]a combination thereof.[0247]Embodiment 2. The buildi...

Claims

1-129. (canceled)130. A building surface panel comprising:an outer element; anda backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel,wherein the building surface panel further comprises one or more of:a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%,a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel,a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element,a density of the backing component being at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3,one or more longitudinally extending ribs that protrude from the backing component,a longitudinally extending groove formed in either the outer element or the backing component,a longitudinally extending tongue formed in either the outer element or the backing component, andeither the outer element or the backing component comprises a density of at least 0.4 grams / cm3 but not greater than 2.0 grams / cm3.

131. The building surface panel of claim 130, wherein the outer element comprises a first element layer having a first element composition that is attached to a second element layer having a second element composition.

132. The building surface panel of claim 131, wherein the first backing layer is attached to the first element layer to form the building surface panel, and wherein the attachment provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

133. The building surface panel of claim 132, wherein an adhesive attaches the first backing layer to the first element layer.

134. The building surface panel of claim 131, wherein the outer element further comprises a third element layer having a third element composition that is attached to an opposite side of the second element layer from the first element layer.

135. The building surface panel of claim 134, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

136. The building surface panel of claim 135, wherein any of the first backing composition, the second backing composition, the third backing composition, the first element composition, the second element composition, or the third element composition comprise a polymeric material selected from polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), cross linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, and recycled versions and / or recycled blends thereof.

137. The building surface panel of claim 135, wherein each of the first element layer, second element layer, third element layer, first backing layer, second backing layer, or third backing layer, are of the same color or different colors.

138. The building surface panel of claim 135, wherein at least one of:(a) the first backing composition is the same as the first element composition;(b) the first backing composition is the same as the second backing composition;(c) the first backing composition is different from the second backing composition;(d) the first element composition is the same as the second element composition;(e) the first element composition is different from the second element composition;(f) the third backing composition is the same as either the first backing composition or the second backing composition;(g) the third backing composition is different from the first backing composition or the second backing composition;(h) the third element composition is the same as either the first element composition or the second element composition;(i) the third element composition is different from the first element composition or the second element composition; or(j) combinations thereof.

139. The building surface panel of claim 135, wherein the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC).

140. The building surface panel of claim 139, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

141. The building surface panel of claim 131, wherein the backing component further comprises a third backing layer having a third backing composition, the third backing layer being attached to an opposite side of the second backing layer from the first backing layer.

142. The building surface panel of claim 141, wherein at least one of:(a) the first backing composition is the same as the first element composition;(b) the first backing composition is the same as the second backing composition;(c) the first backing composition is different from the second backing composition;(d) the first element composition is the same as the second element composition;(e) the first element composition is different from the second element composition;(f) the third backing composition is the same as either the first backing composition or the second backing composition;(g) the third backing composition is different from the first backing composition or the second backing composition; or(h) combinations thereof.

143. The building surface panel of claim 141, wherein the first backing layer is attached to the first element layer to form the building surface panel.

144. The building surface panel of claim 143, wherein the attachment provides a bond shear strength between the first backing layer and the first element layer of at least about 0.10 MPa at room temperature.

145. The building surface panel of claim 144, wherein an adhesive attaches the first backing layer to the first element layer.

146. The building surface panel of claim 143, wherein at least one of:(a) the first backing composition comprises acrylonitrile styrene acrylate (ASA) and the second backing composition comprises polyvinyl chloride (PVC);(b) the first element composition comprises ASA and the second element composition comprises PVC;(c) both the first element composition and the second element composition comprise PVC and differ from one another in an amount and / or chemical composition of one or more additives;(d) both the first backing composition and the second backing composition comprise PVC and differ from one another in an amount and / or chemical composition of one or more additives; or(e) the third backing composition comprises ASA.

147. The building surface panel of claim 146, wherein the second backing composition comprises at least 10% by weight of recycled PVC.

148. The building surface panel of claim 146, wherein the third backing composition comprises acrylonitrile styrene acrylate (ASA), the first element composition comprises acrylonitrile styrene acrylate (ASA), and the second element composition comprises polyvinyl chloride (PVC).

149. The building surface panel of claim 130, wherein one or more of the longitudinally extending ribs comprises one or more weep holes formed therethrough.

150. A building surface panel comprising:an outer element; anda backing component comprising a first backing layer having a first backing composition that is attached to a second backing layer having a second backing composition, wherein the first backing layer is attached to the outer element to form the building surface panel,wherein the outer element has a first front side, a first rear side, and a first thickness as measured between the first front side and the first rear side,wherein the backing component has a second front side, a second rear side, and a second thickness as measured between the second front side and the second rear side,wherein the second front side of the backing component is attached to the first rear side of the outer element, andwherein the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

Images