Methods of making insulated siding sheets, and insulated sheets formed therefrom

Abstract

Methods of making insulated sheets can include: applying an exterior finish material to a mold comprising a profile design; applying an integrated insulation material against a back of the exterior finish material within the mold; curing the integrated insulation material for a pre-determined time in the mold to allow the integrated insulation material to rise to a desired thickness and density against the back of the exterior finish material in the mold; and releasing a formed insulated siding sheet from the mold, wherein the insulated siding sheet comprises the cured integrated insulation material attached to a backside of a plank siding formed from the exterior finish material. An insulated siding sheet and siding sheet system is also included, as well as certain molds used therein.

Description

METHODS OF MAKING INSULATED SIDING SHEETS, AND INSULATED SHEETS FORMED THEREFROMNOTICE OF GOVERNMENT SUPPORT

[0001] This invention was made with Government support under Contract No. DE-SC- 0022616 awarded by the Department of Energy.CROSS REFERENCE TO RELATED APPLICATION

[0002] This application claim priority to United States Provisional Application No. 63 / 557,816 filed February 26, 2024, the disclosure of which is hereby incorporated by reference in its entirety.BACKGROUNDTechnical Field

[0003] The present disclosure is generally directed to methods of making insulated siding sheets, and insulated siding sheets formed therefrom.Technical Description

[0004] In the existing home market, re-roofing, new windows, HVAC replacement, and replacing the siding on the exterior of a home are the dominant retrofit activities. As to the siding on the exterior of a home, the primary reasons for replacing the siding are storm damage or improving aesthetics due to aging. While retrofit siding options are available, continuous insulation is typically not included or even offered in a re-siding retrofit, nor is any type of rainscreen offered to provide better bulk water drainage. Moreover, methods of preparing such insulated sidings are not available. Thus, it is desirable to provide methods of forming insulated siding sheets for retrofit and new constructions applications and providing such siding sheets with these methods.SUMMARY

[0005] In some non-limiting embodiments, provided are methods of forming an insulated siding sheet.

[0006] In some non-limiting embodiments, the method can include: applying an exterior finish material to a mold comprising a profile design; applying an integrated insulation material against a back of the exterior finish material to a desired thickness within the mold; curing the integrated insulation material for a pre-determined time in the mold to allow the insulationmaterial to rise to a desired thickness and density against the back of the exterior finish material in the mold; and releasing a formed insulated siding sheet from the mold, in which the insulated siding sheet comprises the cured integrated insulation material attached to a backside of a plank siding formed from the exterior finish material.

[0007] In certain non-limiting embodiments, the exterior finish material is a capstock finish surface material. The capstock finish surface material can be poured or sprayed into the mold and at least partially cured prior to applying the integrated insulation material. The capstock finish surface material can comprise a plastic material, a cementitious material, or a combination thereof.

[0008] In certain non-limiting embodiments, the exterior finish material forms an exterior skin of the insulated siding sheet. In some non-limiting embodiments, the exterior skin has a thickness of 1 inch or less. In some non-limiting embodiments, the mold further includes vent holes.

[0009] In certain non-limiting embodiments, the integrated insulation material has a minimum insulation R- value of R-5. In such embodiments, the integrated insulation material can be formed from a material selected from the group consisting of a R-5 extruded polystyrene, a R-6.5 polyisocyanurate, a R-5 graphite polystyrene, spray foam, poured foam, and any combination thereof. The integrated insulation material can also be poured or sprayed against the back of the exterior finish material.

[0010] As indicated, the formed insulated siding sheet comprises the cured integrated insulation material attached to a backside of a plank siding formed from the exterior finish material. In certain non-limiting embodiments, the final plank siding comprises wood, plastic composite, wood fiber, metal, cement fiber, or any combination.

[0011] In certain non-limiting embodiments, the method is a linear process. In some nonlimiting embodiments, the method applies a continuous pour of the integrated insulation material, and the mold receives the continuous pour of the integrated insulation material.

[0012] In certain non-limiting embodiments, the method further includes applying a fastening system to the mold prior to the curing when the mold is in a closed position and removing the fastening system after curing prior to opening the mold and removing the formed insulated siding sheet.

[0013] In some non-limiting embodiments, the mold comprises a mold body having a cavity, a front attached to the mold body by a hinge that allows the front to move between a closed position that secures materials placed in the cavity and an open position that releases the materials, and a lid that attaches to and encases a top portion of the mold body in a closedposition. In such embodiments, the method can include: applying the exterior finish material into the cavity of the mold body when the front and lid are in the open position; closing the front by moving a portion of the front onto the exterior finish material positioned within the cavity of the mold body; applying the integrated insulation material against the back of the exterior finish material; closing the lid over the mold body to encase the portion of the mold; curing the integrated insulation material for a pre-determined time; and opening the lid and front to remove the formed insulated siding sheet.

[0014] In certain non-limiting embodiments, the present disclosure also includes an insulated siding sheet formed from any of the previously described methods and features. An insulated siding sheet system comprising two or more of such insulated siding sheets is also included.

[0015] In certain non-limiting embodiments, the present disclosure further includes a mold forming an insulated siding sheet that includes: a mold body having a cavity; a lid attached to the mold body and which between moves from an open position to expose the cavity of the mold body and a closed position that encases a top portion of the mold body; and a front attached to the mold body by a hinge that moves between an open position to allow materials to be inserted in the cavity and a closed position to hold the materials within the cavity. The inside portion of the lid can comprise a profile design.

[0016] Further non-limiting embodiments or aspects are set forth and described in the following clauses.

[0017] Clause 1: A method of forming an insulated siding sheet comprising: applying an exterior finish material to a mold comprising a profile design; applying an integrated insulation material against a back of the exterior finish material within the mold; curing the integrated insulation material for a pre-determined time in the mold to allow the integrated insulation material to rise to a desired thickness and density against the back of the exterior finish material in the mold; and releasing a formed insulated siding sheet from the mold, wherein the insulated siding sheet comprises the cured integrated insulation material attached to a backside of a plank siding formed from the exterior finish material.

[0018] Clause 2: The method of clause 1, wherein the exterior finish material is a capstock finish surface material.

[0019] Clause 3: The method of clause 2, wherein the capstock finish surface material is poured or sprayed into the mold and at least partially cured prior to applying the integrated insulation material.

[0020] Clause 4: The method of any one of clauses 1-3, wherein the capstock finish surface material comprises a plastic material, a cementitious material, or a combination thereof.

[0021] Clause 5: The method of clause 1, wherein the exterior finish material is a premanufactured plank siding material.

[0022] Clause 6: The method of any one of clauses 1-5, wherein the exterior finish material forms an exterior skin of the insulated siding sheet.

[0023] Clause 7: The method of clause 6, wherein the exterior skin has a thickness of 1 inch or less.

[0024] Clause 8: The method of any one of clauses 1-7, wherein the mold further comprises vent holes.

[0025] Clause 9: The method of any one of clauses 1-8, wherein the integrated insulation material has a minimum insulation R- value of R-5.

[0026] Clause 10: The method of clause 9, wherein the integrated insulation material is formed from a material selected from the group consisting of a R-5 extruded polystyrene, a R- 6.5 polyisocyanurate, a R-5 graphite polystyrene, spray foam, poured foam, and any combination thereof.

[0027] Clause 11: The method of any one of clauses 1-10, wherein the integrated insulation material is poured or sprayed against the back of the exterior finish material.

[0028] Clause 12: The method of any one of clauses 1-11, wherein the plank siding comprises wood, plastic composite, wood fiber, metal, cement fiber, or any combination.

[0029] Clause 13: The method of any one of clauses 1-12, wherein the method is a linear process.

[0030] Clause 14: The method of any one of clauses 1-13, wherein the method applies a continuous pour of the integrated insulation material, and the mold receives the continuous pour of the integrated insulation material.

[0031] Clause 15: The method of any one of clauses 1-14, further comprising applying a fastening system to the mold prior to the curing when the mold is in a closed position and removing the fastening system after curing prior to opening the mold and removing the formed insulated siding sheet.

[0032] Clause 16: The method of any one of clauses 1-15, wherein the mold comprises a mold body having a cavity, a front attached to the mold body by a hinge that moves between a closed position that secures materials placed in the cavity and an open position that releases the materials, and a lid that attaches to and encases a top portion of the mold body in the closed position.

[0033] Clause 17: The method of clause 16, wherein the method comprises: applying the exterior finish material into the cavity of the mold body when the front and lid are in the open position; closing the front by moving a portion of the front onto the exterior finish material positioned within the cavity of the mold body; applying the integrated insulation material against the back of the exterior finish material; closing the lid over the mold body to encase the portion of the mold; curing the integrated insulation material; and opening the front and lid to remove the formed insulated siding sheet.

[0034] Clause 18: An insulated siding sheet formed from a method according to any one of clauses 1-17.

[0035] Clause 19: An insulated siding sheet system comprising two or more insulated siding sheets according to clause 18.

[0036] Clause 20: A mold for forming an insulated siding sheet comprising: a mold body having a cavity; a lid attached to the mold body and which moves between an open position to expose the cavity of the mold body and a closed position that encases a top portion of the mold body; and a front attached to the mold body by a hinge that allows the front to move between an open position to allow materials to be inserted in the cavity and a closed position to hold the materials placed within the cavity, wherein an inside portion of the lid comprise a profile design.BRIEF DESCRIPTION OF THE DRAWINGS

[0037] FIG. 1 is a side view of non-limiting embodiments of an insulated siding sheet according to the principles of the present disclosure;

[0038] FIG. 2 is a top view of non-limiting embodiments of an insulated siding sheet according to the principles of the present disclosure;

[0039] FIG. 3 is a side view of non-limiting embodiments of an insulated siding sheet system according to the principles of the present disclosure;

[0040] FIG. 4 is a back cross-sectional view of non-limiting embodiments of a rainscreen formed from an insulated siding sheet system according to the principles of the present disclosure;

[0041] FIG. 5A is a cross-sectional view of non-limiting embodiments of an insulated siding sheet formed from methods with an exterior plank siding skin formed from aluminum with a poured polyurethane foam molded thereto according to the principles of the present disclosure;

[0042] FIG. 5B is a cross-sectional view of non-limiting embodiments of an insulated siding sheet formed from methods with an exterior plank siding skin formed from polyurethanecapstock with a poured polyurethane foam molded thereto according to the principles of the present disclosure;

[0043] FIG. 6 is a perspective view of non-limiting embodiments of an insulated siding sheet formed from methods according to the principles of the present disclosure;

[0044] FIG. 7 is a perspective view of non-limiting embodiments of an insulated siding sheet formed from methods according to the principles of the present disclosure;

[0045] FIG. 8 is a perspective view of non-limiting embodiments of an insulated siding sheet formed from methods according to the principles of the present disclosure;

[0046] FIG. 9 is a perspective view of non-limiting embodiments of a backside of insulated siding sheet and rainscreen formed from methods according to the principles of the present disclosure;

[0047] FIG. 10 is a top view of non-limiting embodiments of an insulated siding sheet system formed from methods according to the principles of the present disclosure;

[0048] FIG. 11 is a side view of non-limiting embodiments of an insulated siding sheet system formed from methods according to the principles of the present disclosure;

[0049] FIG. 12A is a perspective view of a hinged mold according to the principles of the present disclosure with an open front and lid;

[0050] FIG. 12B is a perspective view of an exterior finish material placed into the cavity of the hinged mold according to the principles of the present disclosure;

[0051] FIG. 12C is a perspective view of the front being closed according to the principles of the present disclosure;

[0052] FIG. 12D is a perspective view of integrated insulation material being placed into the cavity above the exterior finish material according to the principles of the present disclosure;

[0053] FIG. 12E is a perspective view of the hinged mold with the lid in the closed position according to the principles of the present disclosure;

[0054] FIG. 12F is a perspective view of the hinged mold with the lid in the open position after the curing process according to the principles of the present disclosure;

[0055] FIG. 12G is a perspective view of the hinged mold with the front in the open position after the curing process according to the principles of the present disclosure;

[0056] FIG. 12H is a perspective view of the hinged mold with the formed integrated insulation material being removed according to the principles of the present disclosure;

[0057] FIG. 13A is a side cross-sectional view of a hinged mold of FIG. 12A;

[0058] FIG. 13B is a side cross-sectional view of a hinged mold of FIG. 12B;

[0059] FIG. 13C is a side cross-sectional view of a hinged mold of FIG. 12C;

[0060] FIG. 13D is a side cross-sectional view of a hinged mold of FIG. 12D;

[0061] FIG. 13E is a side cross-sectional view of a hinged mold of FIG. 12E;

[0062] FIG. 13F is a side cross-sectional view of a hinged mold of FIG. 12F;

[0063] FIG. 13G is a side cross-sectional view of a hinged mold of FIG. 12G; and

[0064] FIG. 13H is a side view of a hinged mold of FIG. 12H.DETAILED DESCRIPTION

[0065] For purposes of the following detailed description, it is to be understood that the disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0066] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

[0067] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0068] Further, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the disclosure as it is oriented in the drawing figures. However, it is to be understood that the disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the specification, are simply exemplary embodiments or aspects ofthe present disclosure. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.

[0069] In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, in this application, the use of “or” means “and / or” unless specifically stated otherwise, even though “and / or” may be explicitly used in certain instances. It will also be appreciated that the dimensions and sizes provided in the drawings are only non-limiting examples. Therefore, different dimensions and sizes can be used.

[0070] Referring to FIGS. 1-4, and in some non-limiting embodiments, the present disclosure is directed to methods of forming insulated siding sheets 10. The insulated siding sheets 10 include an integrated insulation material 12 and a plank siding 14. Such insulated siding sheets 10 are described in U.S. Application Publication No. 2024 / 0271417, which is incorporated herein by reference in its entirety.

[0071] As used herein, an “integrated insulation material” refers to insulation made of blocks of polymeric foam or other rigid insulated foam. In certain non-limiting embodiments, the integrated insulation material 12 is made of a material that has a minimum insulation R-value of R-5. For example, the integrated insulation material 12 can be formed from a R-5 extruded polystyrene, a R-6.5 polyisocyanurate, a R-5 graphite polystyrene, spray foam, poured foam, or any combination thereof.

[0072] The “R-value”, as used herein, refers to a material’s insulating properties and its ability to impede heat flow. The greater the ability to impede heat flow, the higher the R-value. Calculating R-value involves measurements of heat energy transfer through different insulation materials and determining the R-value of insulation based on how quickly (or slowly) the heat flows through the material.

[0073] Referring to FIG. 5-11, the methods of forming the insulated siding sheets 10 include applying an integrated insulation material 12 (e.g., polymer foam, such as polyurethane) to an exterior finish material 6 in order to achieve the minimum R5 value.

[0074] In certain non-limiting embodiments, the methods of forming the insulated siding sheets 10 can first include applying an exterior finish material 6 to a mold comprising a profile design. As used herein, an “exterior finish material” refers to a material on the exterior or outer side of the insulated siding sheets 10 that faces the environment and protects the integrated insulation material 12 from conditions in the environment (e.g., protection from exposure to sun, rain, heat, cold, and the like). Non-limiting examples of exterior finish materials 6 include a capstock finish surface material and a pre-manufactured plank siding material.

[0075] As used herein, a “capstock finish surface material” refers to a material added to a mold and cured to form an exterior protective layer of the final product for better weatherability, durability, mechanical resistance, and the like. The capstock finish surface material can be selected from a high density continuous poured solution. Non-limiting examples of suitable capstock finish surface materials include plastic materials (e.g., PVC, polyurethane, and the like), cementitious materials, and combinations thereof.

[0076] In such embodiments when the exterior finish material 6 is a capstock finish surface material, the capstock finish surface material can be poured or sprayed into the mold and at least partially, or completely, cured. The capstock finish surface material can be cured over time at atmospheric temperatures, by applying heat, and / or through other known means.

[0077] As indicated, the exterior finish materials 6 can also include a pre-manufactured plank siding material. A “pre-manufactured plank siding material” refers to a material that is manufactured and formed, such as at a separate facility from where the insulated siding sheets 10 are formed. The pre-manufactured plank siding material can be prepared from various methods other than a molding process and, therefore, can include various materials. Nonlimiting examples of suitable pre-manufactured plank siding materials include wood, plastic composite, wood fiber, metal, cement fiber, and combinations thereof. The wood can be natural or engineered wood.

[0078] In certain non-limiting embodiments, after applying the exterior finish material 6 to the mold according to any one of the previously described steps, the method further includes applying an integrated insulation material 12 against a back of the exterior finish material 6, such as at a desired thickness within the mold. In some non-limiting embodiments, the integrated insulation material 12 can be poured or sprayed against the back of the exterior finish material 6 positioned in the mold.

[0079] In certain non-limiting embodiments, the integrated insulation material 12 is cured for a pre-determined time in the mold to allow the integrated insulation material 12 to rise to a desired thickness and density against the back of the exterior finish material 6 in the mold. The integrated insulation material 12 can be cured over time at atmospheric temperatures, by applying heat, and / or through other known means. In some non-limiting embodiments, the integrated insulation material 12 is set and cured in the mold to a thickness and density that provides the desired minimum R-value, the size and shape for the end use of the final insulated siding sheet 10 (e.g., based on the type of building the sheet 10 is intended to be placed, the geographical location of the building, and other related factors), and the like. For example, incertain non-limiting embodiments, the thickness of the integrated insulated material 12 is within a range of from 0.5 to 2 inches, or within a range of from 1 to 1.5 inches.

[0080] After curing the integrated insulation material 12 to rise to a desired thickness and density against the back of the exterior finish material 6 in the mold, the formed insulated siding sheet 10 is released from the mold. The resulting insulated siding sheet 10 can be packaged, stored, and delivered to the installation site, such as a residential or commercial building site.

[0081] Referring to FIGS. 5A-B, the exterior finish material 6 forms an exterior plank siding skin 8. The skin 8 can have a thickness of 1 inch or less. The thickness can be selected based on various factors including, but limited to, the type of building the sheet 10 is intended to be placed, the geographical location of the building, and the like. In certain non-limiting embodiments, when the exterior finish material 6 is formed from a capstock finish surface material, the skin 8 formed therefrom can have a thickness of 1 / 8 inch or less. In some nonlimiting embodiments, when the exterior finish material 6 is formed from a pre-manufactured plank siding material, the skin 8 formed therefrom can have a thickness within a range of 1 mm and 1 inch.

[0082] The skin 8 can also have various outer surfaces, such as for example a woodgrain effect or smooth painted effect. For instance, FIG. 5A illustrates an exterior plank siding skin 8 formed from aluminum with a poured polyurethane foam molded thereto, and FIG. 5B illustrates an exterior plank siding skin 8 formed from polyurethane capstock with a poured polyurethane foam molded thereto.

[0083] Referring again to FIGS. 5A-B, it is appreciated that the resulting insulated siding sheet 10 comprises the cured integrated insulation material 10 attached to a backside of a plank siding 14 formed from the exterior finish material 6 having exterior plank siding skin 8. The plank siding 14 can be formed from the any of the previously described materials including, but not limited to, wood, plastic composite, wood fiber, metal, cement fiber, and any combination thereof.

[0084] As previously described, the mold can have a desired profile design. As a result, the previously described methods using such molds can form the insulated siding sheets 10 shown in FIGS. 6-9, which include various profile designs. For instance, the method can use distinct molds with profile designs to create a siding sheet 10 that will fit into a manufacturer’s existing siding. It is appreciated that the profile designs in the molds can also provide the designs of the integrated insulation material 12 including the grooves 40 as shown in FIG. 9.

[0085] In some non-limiting embodiments, the mold is a five-sided or six-sided mold that encases the integrated insulation material 12 and exterior finish material 6 for a pre-determined time to allow the integrated insulation material 12 to rise to the proper thickness and density.

[0086] In certain non-limiting embodiments, referring to FIGS. 12A-H and 13A-H, a hinged mold 100 is used. As shown in FIGS. 12A and 13A, the hinged mold 100 can include a mold body 102 having a cavity 104. The mold body 102 and cavity 104 are sized and shaped to receive any of the previously described exterior finish materials 6 and integrated insulation materials 12, and which are designed to provide the desired size and shape of the final insulated siding sheet 10.

[0087] As further shown in FIGS. 12A-H and 13A-H, a lid 108 attaches to and encases a top portion 106 of the mold body 102. In some non-limiting embodiments, the lid 108 is attached to a back 110 of the mold body 102 with a hinge. It is appreciated that the lid 108 can move between an open position (see FIGS. 12A-D, 12F-H, 13A-D, and 13F-H) to expose the cavity 104 of the mold body 102 and a closed position (see FIGS. 12E and 13E) that encases the top portion 106 of the mold body 102 and seals the cavity 104 from the outside environment. In some non-limiting embodiments, the inside 112 of the lid 108 can have a design profile that provides the desired profile design.

[0088] In certain non-limiting embodiments, a front 114 of the mold body 102 can be attached with a hinge 120 to allow the front 114 to move between an open position and closed position. In the open position, the front 114 can fold or snap out and downwards from the mold body 102. This exposes the cavity 104 and allows materials to be placed inside. For instance, as shown in FIGS. 12B and 13B, the front 114 is in the open position and the exterior finish material 6 is positioned within the cavity 104.

[0089] Referring to FIGS. 12C and 13C, the front 114 is in the closed position and secures the exterior finish material 6 placed in the cavity 104. It is appreciated that the front 114 can fold or snap up and inwards onto the mold body 102. The front 114 can also be inserted or otherwise attached to the sides 116 of the mold body 102, such as to hold and / or secure the exterior finish material 6 within cavity 104. For example, the front 114 and sides 116 can be shaped to have a mating engagement.

[0090] Referring to FIG. 12D, the integrated insulation material 12 is placed into the cavity 104 above the exterior finish material 6. As shown in FIGS. 12E and 13E, the lid 108 can then be closed to encase the integrated insulation material 12 and the exterior finish material 6. After all the materials are formed within the mold body 102 (e.g., through at least partial or complete curing) and provided with a desired profile design as previously described, the lid 108 is opened(FIGS. 12F and 13F) followed by opening the front 114 (FIGS. 12G and 13G) and then removing the formed insulated sheet 10 (FIGS. 12H and 13H).

[0091] In certain non-limiting embodiments, as shown in FIGS. 12E and 13E, a fastening system 140 is used to fast and secure the mold 100 in the closed positioned. The fastening system 140 can include, but is not limited to, clamps, a mechanical press, and combinations thereof.

[0092] The hinged mold 100 can be made from various materials. For instance, the hinged mold 100 can be made from a metal or non-stick material. Non-limiting examples of suitable materials include a metal such as aluminum. It is appreciated that the mold 100 can be shaped and sized for various types of uses including, but not limited to, forming the siding of a building (residential or commercial), or trim around a window or door.

[0093] The hinged mold 100 can also include other features. In certain non-limiting embodiments, the mold 100 further includes holes 150. The holes 150 can act as vent holes that help control the pressure and flow of materials placed in the mold 100, such as during curing.

[0094] In such embodiments when the hinged mold 100 is used, the method can include, for example: applying the exterior finish material 6 into the cavity of the mold body 102 when the front 114 and lid 108 are in the open position; closing the front 114 by moving a portion of the front 114 over the exterior finish material 6 positioned within the cavity 104 of the mold body 102; applying the integrated insulation material 12 against the back of the exterior finish material 6; closing the lid 108 over the mold body 102; curing the integrated insulation material 12; and opening the lid 108 and front 114 to remove the formed insulated siding sheet 10.

[0095] The method can also include other steps. In certain non-limiting examples, the method can further include applying a release agent to the inside surfaces of the mold 100 prior to inserting any of the previously described materials. As used herein, a “release agent” refers to a material that helps prevent the formed insulated siding sheet 10 from adhering to the mold 100 without affecting or altering the mold 100 and formed insulated siding sheet 10 when removing the final product. Non-limiting examples of a release agent include waxes, silicon solutions, and combinations thereof.

[0096] It is appreciated that the hinged mold 100 can be used with any of the previously described materials and parameters. It was found that the hinged mold 100 allows easy opening and closing of the mold 100, as well as quick removal of the final product without imperfections and material waste.

[0097] The methods described herein can also use a linear process where the molding steps are conducted along a conveyor or similar line until the finished siding sheet 10 moves downand off the conveyance for packaging, storage, and delivery. This process can be replicated where multiple siding sheets 10 (e.g., using multicavity molds) are created simultaneously on the fabrication line. The pieces are then removed from the line for packaging. It is appreciated that the method can also include a batch process where multiple molds and steps can be used.

[0098] In certain non-limiting embodiments, the methods of forming the insulated siding sheets 10 can include a continuous pour of the integrated insulation material 12. For instance, the mold can be a moving mold, such as moving along a conveyor or similar line, that receives a continuous pour of the integrated insulation material 12.

[0099] FIG. 9 illustrates a non-limiting embodiment of the back side of an insulated siding sheet 10 that can be formed from any of the previously described methods. FIGS. 10 and 11 illustrate non-limiting embodiments of an insulated siding sheet system 80 comprising two or more insulated siding sheets 10 that can be formed from any of the previously described methods.

[0100] It will be appreciated that the previously described methods can be automated with robotics and pouring heads for the insulation material 12.

[0101] The present disclosure also includes the insulated siding sheets 10 formed from any of the previously described methods. In some non-limiting embodiments, referring to FIG. 1, the integrated insulation material 12 comprises a back side 16, a front side 18 opposite the back side 16, a top horizontal edge 20 having a 45 degree angle, and a bottom horizontal edge 22 having a 45 degree angle. As shown in FIG. 1, the 45 degree angle of the top horizontal edge 20 and the bottom horizontal edge 22 can be formed in the same direction. That is, in such embodiments, the configuration of the integrated insulation material 12 can be such that the top horizontal edge 20 comprises a 45 degree angle that is cut / formed from the front top edge 24 downward to the back top edge 26, and the bottom horizontal edge 22 comprises a 45 degree angle that is cut / formed from the front bottom edge 28 downward to the back bottom edge 30. It will be appreciated that an opposite configuration can also be used where the top horizontal edge 20 comprises a 45 degree angle that is cut / formed from the back top edge 26 downward to the front top edge 24, and the bottom horizontal edge 22 comprises a 45 degree angle that is cut / formed from the back bottom edge 30 downward to the front bottom edge 28.

[0102] As further shown in FIG. 2, the back side 16 of the integrated insulation material 12 comprises vertical grooves 40 that extend from the top horizontal edge 20 to the bottom horizontal edge 22. In certain non-limiting embodiments, the vertical grooves 40 can have a depth of a 1 / 4 inch or less, or 1 / 5 inch or less, or 1 / 8 inch or less. It is appreciated that the vertical grooves 40 have a depth that extends from the back side 16 of the integrated insulationmaterial 12 toward the front side 18 of the integrated insulation material 12. The vertical grooves 40 can also have a width selected within a range of from 1 / 8 inch to 1 / 4 inch, or within a range of from 1 / 5 inch to 1 / 4 inch. Each vertical groove 40 can further be spaced apart horizontally at a desired distance such as by at least 1 / 2 inch, or by at least 3 / 4 inch, or by at least 1 inch. The vertical grooves 40 can also have various shapes, such as a rounded shape, a square shape, or a triangular shape.

[0103] The vertical grooves 40 can have any combination of the previously described configurations. It was found that the vertical grooves 40 allow rain water, as well as other liquids, to drain through the integrated insulation material 12. As such, the vertical grooves 40 act as a rainscreen to provide bulk water drainage through the insulated siding sheet 10.

[0104] As indicated, the insulated siding sheet 10 also comprises a plank siding 14. Referring to FIG. 1, the plank siding 14 is attached, such as being bonded for example, to the front side 18 of the integrated insulation material 12. The plank siding 14 can be formed from various materials used as siding materials on buildings. For example, the plank siding 14 can be selected from wood, plastic composite, wood fiber, metal, cement fiber, or any combination thereof. If the material is wood, the wood can be engineered wood or natural wood.

[0105] In certain non-limiting embodiments, the plank siding 14 comprises a top horizontal edge 50 and a bottom horizontal edge 52 that both have cut-away portions 51 and 53 to overlap with cut-away portions 51 and 53 of the horizontal edges 50 and 52 of adjacent insulated siding sheets 10. It is appreciated that the cut-away portions 51 and 53 of the plank siding 14 have a thickness that is less than the thickness of the remaining portions of the plank siding 14. In certain non-limiting embodiments, the cut-away portions 51 and 53 have a thickness that is 75 % or less than the thickness of the remaining portions of the plank siding 14, or a thickness that is 50 % or less (z.e., half or less) than the thickness of the remaining portions of the plank siding 14. For example, the cut-away portions 51 and 53 can have a thickness that is about a 1 / 2 inch, while the remaining portions of the plank siding 14 have a thickness of about 1 inch.

[0106] As further shown in FIG. 1, the cut-away portion 51 at the top horizontal edge 50 can be taken from a different side of the plank siding 14 as compared to the cut-away portion 53 at the bottom horizontal edge 52. For instance, the cut-away portion 51 at the top horizontal edge 50 can be taken from the front side 56 of the plank siding 14 and the cut-away portion 53 at the bottom horizontal edge 52 can be taken from the back side 58 of the plank siding 14.

[0107] In some non-limiting embodiments, as shown in FIG. 3, the present disclosure is also directed to an insulated siding sheet system 80 comprising two or more insulated siding sheets 10 as previously described. The insulated siding sheets 10 are attached to each otherwith a lapped configuration 82, as shown in FIGS. 1 and 3. The lapped configuration 82 comprises overlapping cut-away portions 51 and 53 of the plank sidings 14 from adjacent insulated siding sheets 10. In certain non-limiting embodiments, the lapped configuration 82 forms an outer barrier of plank sidings 14 that are substantially even or flush across the front sides 56. FIG. 3 also illustrates a gap in the lapped configuration. However, such a gap can be removed and the plank sidings 14 can abut each other.

[0108] In some non-limiting embodiments, referring to FIGS. 1 and 3, the bottom horizontal edge 22 of the integrated insulation material 12 of a first insulated siding sheet 10 engages and forms a mating alignment 90 onto the top horizontal edge 20 of the integrated insulated material 12 of a second insulated siding sheet 10. This arrangement has been found to provide an easy alignment 90 between adjacent integrated insulation materials 12.

[0109] Referring to FIG. 4, the vertical grooves 40 from the various insulated siding sheets 10 that make-up the insulated siding sheet system 80 form a rainscreen 94. As further shown in FIG. 4, water 96 is drained through at least some of the grooves 40 of the insulated siding sheet system 80 to provide improved drying capabilities. It is noted that the shading has been adjusted for clarity in FIG. 4.

[0110] It is appreciated that the previously described methods can provide the various features of the insulated siding sheets 10.

[0111] Whereas particular embodiments or aspects of this disclosure have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from the disclosure as defined in the appended claims.

Claims

What is claimed is:

1. A method of forming an insulated siding sheet comprising: applying an exterior finish material to a mold comprising a profile design; applying an integrated insulation material against a back of the exterior finish material within the mold; curing the integrated insulation material for a pre-determined time in the mold to allow the insulation material to rise to a desired thickness and density against the back of the exterior finish material in the mold; and removing a formed insulated siding sheet from the mold, wherein the insulated siding sheet comprises the cured integrated insulation material attached to a backside of a plank siding formed from the exterior finish material.

2. The method of claim 1, wherein the exterior finish material is a capstock finish surface material.

3. The method of claim 2, wherein the capstock finish surface material is poured or sprayed into the mold and at least partially cured prior at applying the integrated insulation material.

4. The method of claim 2, wherein the capstock finish surface material comprises a plastic material, a cementitious material, or a combination thereof.

5. The method of claim 1, wherein the exterior finish material is a premanufactured plank siding material.

6. The method of claim 1, wherein the exterior finish material forms an exterior skin of the insulated siding sheet.

7. The method of claim 6, wherein the exterior skin has a thickness of 1 inch or less.

8. The method of claim 1, wherein the mold further comprises vent holes.

9. The method of claim 1, wherein the integrated insulation material has a minimum insulation R- value of R-5.

10. The method of claim 9, wherein the integrated insulation material is formed from a material selected from the group consisting of a R-5 extruded polystyrene, a R- 6.5 polyisocyanurate, a R-5 graphite polystyrene, spray foam, poured foam, and any combination thereof.

11. The method of claims 1, wherein the integrated insulation material is poured or sprayed against the back of the exterior finish material.

12. The method of claim 1, wherein the plank siding comprises wood, plastic composite, wood fiber, metal, cement fiber, or any combination.

13. The method of claim 1, wherein the method is a linear process.

14. The method of claim 1, wherein the method applies a continuous pour of the integrated insulation material, and the mold receives the continuous pour of the integrated insulation material.

15. The method of claim 1, further comprising applying a fastening system to the mold prior to the curing when the mold is in a closed position and removing the fastening system after curing prior to opening the mold and removing the formed insulated siding sheet.

16. The method of claim 15, wherein the mold comprises a mold body having a cavity, a front attached to the mold body by a hinge that allows the front to move between a closed position that secures materials placed in the cavity and an open position that releases the materials, and a lid that attaches to and encases a top portion of the mold body in a closed position.

17. The method of claim 16, wherein the method comprises: applying the exterior finish material into the cavity of the mold body when the front and lid are in the open position;closing the front by moving a portion of the front over the exterior finish material positioned within the cavity of the mold body; applying the integrated insulation material against the back of the exterior finish material; closing the lid over the mold body; curing the integrated insulation material; and opening the front and lid to remove the formed insulated siding sheet.

18. An insulated siding sheet formed from a method according to claim 1.

19. An insulated siding sheet system comprising two or more insulated siding sheets according to claim 18.

20. A mold for forming an insulated siding sheet comprising: a mold body having a cavity; a lid attached to the mold body and which between moves from an open position to expose the cavity of the mold body and a closed position that encases a top portion of the mold body; and a front attached to the mold body by a hinge that allows the front to move between an open position to allow materials to be inserted in the cavity and a closed position to hold the materials within the cavity, wherein an inside portion of the lid comprise a profile design.

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