US 20050262791 A1
A building product includes a pultruded panel including a first wall and a second wall separated by a space, the pultruded panel is configured to provide a stucco-like exterior surface when mounted to a building.
1. A building product comprising:
a pultruded panel including a first wall and a second wall separated by a space, the pultruded panel configured to provide a stucco-like exterior surface when mounted to a building.
2. The building product of
3. The building product of
4. The building product of
5. A building system:
two or more panels mounted adjacent to each other on an outer surface of a structure, each panel including a first wall and a second wall separated by a space, with each space of each panel is oriented in a vertical direction to allow water to flow down the space of the panel.
6. The building system of
7. The building system of
8. The building system of
9. The building system of
10. The building system of
11. The building system of
12. A method comprising:
fastening two or more panels adjacent to each other on an outer surface of a structure, each panel including a first wall and a second wall separated by a space, with each space of each panel being oriented in a vertical direction to allow water to flow down the space of the panel.
13. The method of
14. The method of
This application claims the benefit under 35 U.S.C. 119 (e) of U.S. Provisional Application No. 60/571,969 filed on May 17, 2004, which is hereby incorporated by reference in its entirety.
This application relates generally to building products and more specifically to a siding system.
Stucco sidings on homes provide an aesthetically pleasing and weather resistant surface. More modern synthetic stucco systems like Drivet and EFIS have largely replaced traditional stucco to reduce material and labor costs. Modern synthetic stucco systems have encountered severe product liability issues related to water trapped in the wall cavity that cannot dry out before rot sets in. What is needed is an alternative to stucco and synthetic stucco systems that improves on the cost disadvantages of traditional stucco and the trapped water disadvantages of synthetic stucco. What is needed is a system that provides the exterior look of stucco but is less expensive and allows water in the wall cavity to escape before rot sets in.
A building product includes a pultruded panel including a first wall and a second wall separated by a space, the pultruded panel configured to provide a stucco-like exterior surface when mounted to a building.
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that the embodiments may be combined or that other embodiments may be utilized and that structural changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
Panel 100 mates with other panels at its ends. In this example, one end of panel 100 includes a first finger 103 and a second finger 104 that define a U-shaped mounting area 105 therebetween. The other end of the panel includes a curved finger 106 including a shoulder 107 and a cut-out area 108.
As discussed, each panel can include one or more hollow spaces 140 to channel bulk water away from the building wall cavity. In some embodiments, the panel wall 102, facing the studs, can include a plurality of small holes 163 such as micro-perforations or micro-pores to allow for moisture vapor to pass through the wall, allowing the building wall cavity to release moisture.
In one embodiment, the panels 100 and 110 are constant cross-section profiles formed by pultrusion. This is advantageous because pultrusion can be produced with structural strength to match or exceed traditional wood sheathing. This allows panels 100 to take the place of traditional sheathing and siding, thus greatly simplifying the construction process. Also, pultruded products are also less susceptible to mold and mildew growth than wood products. Pultrusion also does not rot when exposed to moisture in the manner that wood products can. Moreover, since the pultruded members have a relatively high insulative property, they help the insulating value of a structure wall.
Members 100 and 110 can be formed by pultrusion and can include a coating or a film for additional protection from elements or ultraviolet protection. For example, the pultrusion and coating can be as described in commonly assigned U.S. Pat. No. 6,197,412, which is incorporated herein by reference in its entirety. Panels 100 and 110 can be various lengths, for example, from a few inches to 30 feet or longer. The members can also have various widths, from a few inches to 4 feet or wider.
In some embodiments, panels 100 and 110 can be pultruded and formed as composite parts. For example, glass, or other reinforcing fibers, are impregnated with resin and pulled through a forming guide and a heated die. The forming guide orients the fibers to be properly placed in the heated die to insure that the pultruded part has uniform reinforcement across its shape. The heated die cures and/or solidifies the resin around the reinforcing fibers, thus forming the composite part. The composite part, having a profile shape, is continuously pulled out of the heated die by a puller. The puller can be a clamp and stroke action from a reciprocating puller, or a smooth action from a caterpillar puller.
Reinforcing fibers used in the example pultrusions can be glass, carbon fiber, kevlar, and other organic and inorganic filaments and fibers. Reinforcement fibers can take the form of filament and strand bundles, called rovings. They also take the form of yarns, texturized yarns, chopped strand mats, continuous strand mats, knitted mats, woven mats, surfacing veils, and many hybrid combinations of rovings, yarns, mats, and veils.
Resin used in example pultrusions can be thermosetting resins like unsaturated polyesters in a styrene solution, or polyurethanes, phenolics, epoxides, thermosetting blends, and other thermosetting resins. Other resins used in pultrusion can be thermoplastic resins based on polyurethanes, acrylics, polyethylenes, and other thermoplastic resins. Resin used in pultrusion can also be thermoplastic resins that are embedded in rovings that melt and form the part inside the pultrusion die.
Resin mixtures in pultrusion can also contain organic, polymeric, and inorganic additives for such properties as shrink control, mold lubrication, colorants, fillers and other specially additives.
In some embodiments, the interlock seam 160 can be covered with sealant to match the color and texture of a weather-resistant coating 170 on the pultruded panels 100 and 110. This embodiment eliminates the appearance of the seam and produces a surface appearance similar to stucco or synthetic stucco. For example, coating 170 can be applied in-line during pultrusion at a low gloss, and can include some texture that from a distance, looks like synthetic stucco. In such an embodiment, there is no “stucco material,” . it just looks like there is. In another embodiment, the panels 100, 110 can be painted or coated with a smooth or textured finish. In general, the outer surface of panels 100, 110 has a stucco-like appearance having a generally flat, non-seamed appearance.
The above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.