Search Images Maps Play YouTube News Gmail Drive More »
Sign in
Screen reader users: click this link for accessible mode. Accessible mode has the same essential features but works better with your reader.

Patents

  1. Advanced Patent Search
Publication numberUS20050262791 A1
Publication typeApplication
Application numberUS 11/130,828
Publication dateDec 1, 2005
Filing dateMay 17, 2005
Priority dateMay 17, 2004
Also published asCA2507701A1
Publication number11130828, 130828, US 2005/0262791 A1, US 2005/262791 A1, US 20050262791 A1, US 20050262791A1, US 2005262791 A1, US 2005262791A1, US-A1-20050262791, US-A1-2005262791, US2005/0262791A1, US2005/262791A1, US20050262791 A1, US20050262791A1, US2005262791 A1, US2005262791A1
InventorsTodd Pringle, John Jambois
Original AssigneeTodd Pringle, John Jambois
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Siding and building product
US 20050262791 A1
Abstract
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.
Images(4)
Previous page
Next page
Claims(14)
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 claim 1, wherein the pultruded panel includes mating features at each end of the panel to couple to an adjacent pultruded panel having similar mating features.
3. The building product of claim 1, wherein the second wall includes a plurality of holes to allow moisture to escape through the second wall.
4. The building product of claim 1, wherein the pultruded panel includes a constant cross-section profile.
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 claim 5, wherein each panel includes a pultruded composite panel having a constant cross-section profile.
7. The building system of claim 5, wherein each panel is configured to have a stucco-like exterior surface.
8. The building system of claim 5, wherein a seam between two of the adjacent panels is covered with sealant or coating.
9. The building system of claim 5, wherein an outer surface of each of the panels includes a weather resistant coating.
10. The building system of claim 5, wherein there is a joint between each adjacent panel including a finger of a first panel located within a gap of a second panel.
11. The building system of claim 5, wherein each panel includes a pultruded panel and the panels are mounted directly to studs of the structure.
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 claim 12, wherein each panel includes a pultruded composite panel having a constant cross-section profile.
14. The method of claim 12, wherein the two or more panels are configured to have a stucco-like exterior surface.
Description
    CROSS-REFERENCE TO RELATED APPLICATION
  • [0001]
    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.
  • FIELD
  • [0002]
    This application relates generally to building products and more specifically to a siding system.
  • BACKGROUND
  • [0003]
    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.
  • SUMMARY
  • [0004]
    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.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • [0005]
    FIG. 1 shows a cross-section view of a panel, in accordance with one embodiment.
  • [0006]
    FIG. 2 shows a cross-section view of an assembled panel system, in accordance with one embodiment.
  • [0007]
    FIG. 3 shows a enlarged cross-section view of the interlock of two panels and the stud attachment of FIG. 2.
  • [0008]
    FIG. 4 shows a cross-section view of an assembled panel system, in accordance with one embodiment.
  • DETAILED DESCRIPTION
  • [0009]
    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.
  • [0010]
    FIG. 1 shows a profile, cross-section view of a panel 100, in accordance with one embodiment. Panel 100 is used as part of a siding system for a building. A plurality of panels 100 can be vertically or horizontally mounted to a building and interlock with one another. These panels 100 resist moisture and wind intrusion into the building wall cavity. In some embodiments, panel 100 includes two panel walls 101 and 102 and a hollow space 140 between the panel walls. In some examples there can be more than one hollow space 140 in a panel. In some hollow panel embodiments, the panel wall 102 facing the studs (and the building wall cavity) has micro-perforations to allow for moisture to escape. In some hollow panel embodiments, the panels 100 are mounted vertically to channel intruding bulk water, such as rain, down the hollow space and away from the building wall cavity. Vertically mounted panels are panels in which the space 140 runs vertically up and down the building.
  • [0011]
    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.
  • [0012]
    FIGS. 2 and 3 show a cross-section, top profile view, of an assembled panel system according to one embodiment. A panel 110 is equivalent to panel 100, as described above. In this example, panels 100 and 110 are mounted vertically (such that space 140 runs vertically up and down the building) and attached to building studs 120 with nails or screws 130. Cut-out area 108 provides a gap for the head of the nail or screw. In other examples, panels 100 and 110 can be nailed over sheathing, instead of being mounted directly to the studs. The two panels 100, 110 are connected at a seam 160. The panels mate such that finger 106 is positioned between fingers 103 and 104 with shoulder 107 abutting the end of finger 103. In mounting the panels, finger 106 of a first panel is inserted into the gap 105 of a second panel and the first panel is then placed flush against the structure and nailed or otherwise fastened through its finger 104 to the structure.
  • [0013]
    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.
  • [0014]
    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.
  • [0015]
    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.
  • [0016]
    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.
  • [0017]
    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.
  • [0018]
    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.
  • [0019]
    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.
  • [0020]
    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.
  • [0021]
    Referring to FIG. 4, in another embodiment the panels 100, 110 can be covered with a thick, plaster-like coating 180 used on synthetic stucco. In a further embodiment, these synthetic stucco coatings can be shaped into decorative patterns. In a further embodiment, the members can be covered in stucco, with and without decorative patterns. In each of these embodiments involving stucco or synthetic stucco coatings, the hollow panel wall still allows for bulk water management and moisture movement, thus maintaining the advantages over traditional stucco or synthetic stucco.
  • [0022]
    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.
Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US3230995 *Dec 29, 1960Jan 25, 1966Owens Corning Fiberglass CorpStructural panel and method for producing same
US4100710 *Dec 23, 1975Jul 18, 1978Hoesch Werke AktiengesellschaftTongue-groove connection
US4184301 *Aug 9, 1978Jan 22, 1980H. H. Robertson CompanyFastening device for wall panel joints
US4391068 *Apr 24, 1981Jul 5, 1983Kosar Walter FWater deflector
US4637191 *Dec 3, 1984Jan 20, 1987Smith Robert LStarter shingle
US4788088 *Oct 2, 1986Nov 29, 1988Kohl John OApparatus and method of making a reinforced plastic laminate structure and products resulting therefrom
US5131200 *Aug 23, 1989Jul 21, 1992Mckinnon GordonRoof system
US5617687 *Oct 24, 1995Apr 8, 1997Bussey, Jr.; HarryInsulation barrier
US5732520 *Dec 10, 1996Mar 31, 1998Multicoat CorporationSynthetic stucco system
US5800651 *Mar 13, 1997Sep 1, 1998Smartdoor Fiberglass Systems, Inc.Process for manufacturing a glass reinforced plastic door panel
US6128879 *Mar 2, 1998Oct 10, 2000Cpi Packaging, Inc.Insulation barrier
US6311456 *Nov 23, 1999Nov 6, 2001Isover Saint-GobainHigh-density glass wool rigid panel
US6314704 *May 11, 2000Nov 13, 2001American Structural Composites, Inc.Composite structural building panels and connections systems
US6355333 *Jun 9, 1999Mar 12, 2002E. I. Du Pont De Nemours And CompanyConstruction membrane
US6401428 *Oct 7, 1999Jun 11, 2002Bowmead Holding Inc.Fenestration sealed frame, insulating glazing panels
US6415574 *Jan 10, 2001Jul 9, 2002Certainteed Corp.Reinforced exterior siding
US6470638 *Aug 24, 2000Oct 29, 2002Plastics Components, Inc.Moisture management system
US6515062 *Mar 13, 2001Feb 4, 2003Icote Usa, Inc.Decorative synthetic stucco compositions
US6591567 *Dec 10, 2001Jul 15, 2003West Virginia UniversityLightweight fiber reinforced polymer composite modular panel
US6594965 *Aug 21, 2001Jul 22, 2003Benjamin Obdyke IncorporatedSpacer for providing drainage passageways within building structures
US6637163 *Jul 25, 2001Oct 28, 2003Gt Plastics Inc.Decking
US6871600 *May 22, 2003Mar 29, 2005Trn Business TrustPultruded panel
US6926785 *May 28, 2003Aug 9, 2005Louisiana Pacific CorporationLow emissivity products and methods for making same
US7114304 *Jun 23, 2003Oct 3, 2006Hitachi, Ltd.Friction stir welding member
US7127865 *Oct 10, 2003Oct 31, 2006Douglas Robert BModular structure for building panels and methods of making and using same
US20010004816 *Feb 27, 2001Jun 28, 2001Keith BoyerComposite joinery
US20020123288 *Dec 11, 2001Sep 5, 2002Pella CorporationPultruded part with reinforcing mat
US20020148382 *Feb 8, 2002Oct 17, 2002Trn Business TrustPultruded panel
US20030019175 *Jul 24, 2001Jan 30, 2003Kremers Dennis H.Concrete footing and wall system
US20030136072 *Nov 27, 2002Jul 24, 2003Weiling PengPanelized wall system utilizing adhesive-edge building panels
US20040182028 *Oct 21, 2003Sep 23, 2004Belleau Michael R.Stucco wall building arrangement
US20060000170 *May 17, 2005Jan 5, 2006Todd PringlePultruded building product and system
US20060096217 *Nov 5, 2004May 11, 2006Lance Philip ACladding
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US7520099May 17, 2005Apr 21, 2009Tecton ProductsPultruded building product and system
US7698865Jan 10, 2005Apr 20, 2010Tecton Products, LlcPultruded building product
US7856790Oct 10, 2007Dec 28, 2010Tecton Products, LlcPultruded building product
US7905067Sep 13, 2007Mar 15, 2011Composite Panel Systems, LlcSupport pads and support brackets, and structures supported thereby
US7926233Sep 13, 2007Apr 19, 2011Composite Panel Systems, LlcBuildings, building walls and other structures
US7926241Apr 19, 2011Composite Panel Systems, LlcBuilding panels
US7930861Apr 26, 2011Composite Panel Systems LlcBuilding, building walls and other structures
US8012301Sep 13, 2007Sep 6, 2011Composite Panel Systems, LlcMethods of manufacturing building panels
US8082711Sep 13, 2007Dec 27, 2011Composite Panel Systems, LlcWalls and wall sections
US8117801Nov 22, 2010Feb 21, 2012Tecton Products, LlcPultruded building product
US8266867Mar 11, 2011Sep 18, 2012Composite Panel Systems, LlcBuilding panels
US8297020 *Oct 30, 2012Top Down Siding LLCTop down trap lock two-ply shingle system for roofs
US8322097Sep 13, 2007Dec 4, 2012Composite Panel Systems, LlcMethods of constructing buildings and building appurtenances
US8322098Apr 26, 2011Dec 4, 2012Composite Panel Systems, LlcBuildings, building walls and other structures
US8393123Mar 11, 2011Mar 12, 2013Composite Panel Systems, LlcBuildings, building walls and other structures
US8534028Oct 11, 2011Sep 17, 2013Composite Panel Systems, LlcBuilding panels
US8607531Oct 11, 2011Dec 17, 2013Composite Panel Systems, LlcBuilding panel assemblies and methods of use in wall structures
US8793966Oct 11, 2011Aug 5, 2014Composite Panel Systems, LlcBuilding panels and methods of making
US8904737Dec 17, 2013Dec 9, 2014Composite Panel Systems, LlcBuilding panel assemblies and methods of use in wall structures
US20050252139 *Jan 10, 2005Nov 17, 2005Todd PringlePultruded building product
US20060000170 *May 17, 2005Jan 5, 2006Todd PringlePultruded building product and system
US20080127584 *Sep 13, 2007Jun 5, 2008Custom Components Of Eagle River, Inc.Support pads and support brackets, and structures supported thereby
US20090094914 *Oct 10, 2007Apr 16, 2009Tecton Products, LlcPultruded building product
US20110061327 *Nov 22, 2010Mar 17, 2011Tecton Products, LlcPultruded building product
EP2642036A1 *Mar 22, 2012Sep 25, 2013Bayer MaterialScience AGUse of fibre-reinforced polyurethane for forming a rail for a fitting assembly
EP2642037A1 *Mar 18, 2013Sep 25, 2013Bayer Intellectual Property GmbHUse of fibre-reinforced polyurethane for forming a rail for a fitting assembly
Classifications
U.S. Classification52/540
International ClassificationE04F13/08, E04F13/04, E04F13/18, E04C1/00
Cooperative ClassificationE04F13/18, E04F13/045, E04F2203/04
European ClassificationE04F13/18, E04F13/04B
Legal Events
DateCodeEventDescription
Aug 9, 2005ASAssignment
Owner name: TECTON PRODUCTS, NORTH DAKOTA
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:PRINGLE, TODD;JAMBOIS, JOHN;REEL/FRAME:016623/0501
Effective date: 20050805