The present disclosure is generally directed to an insulated siding sheet, an insulated sheet system formed with multiple insulated siding sheets, and buildings with the insulated sheet system positioned over one or more sides.
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. For instance, homes in the cold and mixed humid regions are typically outfitted with some type of vinyl, aluminum, steel, or wood siding product. However, these homes are commonly exposed to air infiltration through the exterior envelope, which may lead to excessive energy loss, comfort issues, and durability issues to the siding and structure of the home.
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. Thus, it is desirable to provide an insulated siding system that can be retrofitted onto a building and which does not exhibit the various known drawbacks.
In some non-limiting embodiments, provided is an insulated siding sheet. The insulated siding sheet includes an integrated insulation material and a plank siding. The integrated insulation material includes: (i) a back side; (ii) a front side opposite the back side; (iii) a top horizontal edge having a 45 degree angle; and (iv) a bottom horizontal edge having a 45 degree angle, in which the back side of the integrated insulation material comprises vertical grooves that extend from the top horizontal edge to the bottom horizontal edge. The plank siding is attached to the front side of the integrated insulation material, where the plank siding comprises a top horizontal edge and a bottom horizontal edge that both have a cut-away portion of the plank siding to overlap with horizontal edges of adjacent insulated siding sheets.
In certain non-limiting embodiments, the integrated insulation material has a minimum insulation R-value of R-5. For example, 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. In some non-limiting embodiments, the integrated insulation material has a thickness within a range of from 1 inch to 4 inches.
In certain non-limiting embodiments, the vertical grooves have a depth of ¼ inch or less, and/or a width within a range of from ⅛ inch to ¼ inch. The vertical grooves can also be spaced apart horizontally by at least 0.5 inch. The vertical grooves can have various shapes, such as a rounded shape for example.
In certain non-limiting embodiments, the plank siding comprises wood, plastic composite, wood fiber, metal, cement fiber, or any combination. In some non-limiting embodiments, a front portion of the top horizontal edge of the plank siding is cut-away and a back portion of the bottom horizontal edge of the plank siding is cut-away.
In some non-limiting embodiments, the present disclosure also includes an insulated siding sheet system comprising two or more of the previously described insulated siding sheets in which the insulated siding sheets are attached to each other with a lapped configuration. The lapped configuration can comprise overlapping cut-away portions of the plank siding of adjacent insulated siding sheets. In certain non-limiting embodiments, the bottom horizontal edge of the integrated insulated material of a first insulated siding sheet engages and mates onto the top horizontal edge of the integrated insulated material of a second insulated siding sheet.
In some non-limiting embodiments, the present disclosure includes a building comprising the previously described insulated siding sheet system that is formed over at least a portion of one side of the building. In certain non-limiting embodiments, the insulated siding sheet system is formed over each side of the building. The building can include a residential building for example.
In certain non-limiting embodiments, the building further includes at least one window and at least one door, in which the at least one window and the at least one door each independently comprise metal trim that extends around the at least one window and the at least one door. The metal trim can form a channel that receives insulated siding sheets extending around the at least one window and the at least one door.
In certain non-limiting embodiments, the building further includes a starter strip positioned at the bottom of each side of the building. The starter strip can include a channel that receives insulated siding sheets extending down toward a bottom of the sides of the building.
In some non-limiting embodiments, the present disclosure further includes a method of retrofitting an insulated siding sheet system onto a building. The method includes attaching the insulated siding sheet system previously described onto one or more sides of a building. In certain non-limiting embodiments, attaching the insulated siding sheet system onto one or more sides of the building includes laminating the integrated insulation material onto the one or more sides of the building.
The present disclosure also includes the following aspects.
Aspect 1: An insulated siding sheet comprising: an integrated insulation material comprising (i) a back side, (ii) a front side opposite the back side, (iii) a top horizontal edge having a 45 degree angle; and (iv) a bottom horizontal edge having a 45 degree angle, wherein the back side of the integrated insulation material comprises vertical grooves that extend from the top horizontal edge to the bottom horizontal edge; and a plank siding attached to the front side of the integrated insulation material, wherein the plank siding comprises a top horizontal edge and a bottom horizontal edge that both have a cut-away portion to overlap with horizontal edges of adjacent insulated siding sheets.
Aspect 2: The insulated siding sheet of aspect 1, wherein the integrated insulation material has a minimum insulation R-value of R-5.
Aspect 3: The insulated siding sheet of aspect 1 or 2, 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.
Aspect 4: The insulated siding sheet of any one of aspects 1-3, wherein the integrated insulation material has a thickness within a range of from 1 inch to 4 inches.
Aspect 5: The insulated siding sheet of any one of aspects 1-4, wherein the vertical grooves have a depth of ¼ inch or less.
Aspect 6: The insulated siding sheet of any one of aspects 1-5, wherein the vertical grooves have a width within a range of from ⅛ inch to ¼ inch.
Aspect 7: The insulated siding sheet of any one of aspects 1-6, wherein the vertical grooves are each spaced apart horizontally by at least ½ inch.
Aspect 8: The insulated siding sheet of any one of aspects 1-7, wherein the vertical grooves have a rounded shape.
Aspect 9: The insulated siding sheet of any one of aspects 1-8, wherein the plank siding comprises wood, plastic composite, wood fiber, metal, cement fiber, or any combination.
Aspect 10: The insulated siding sheet of any one of aspects 1-9, wherein a front portion of the top horizontal edge of the plank siding is cut-away to form a first cut-away portion and a back portion of the bottom horizontal edge of the plank siding is cut-away to form a second cut-away portion.
Aspect 11: An insulated siding sheet system comprising two or more insulated siding sheets according to any one of aspects 1-10, wherein the insulated siding sheets are attached to each other with a lapped configuration.
Aspect 12: The insulated siding sheet system of aspect 11, wherein the lapped configuration comprises overlapping cut-away portions of the plank siding of adjacent insulated siding sheets.
Aspect 13: The insulated siding sheet system of aspect 11 or 12, wherein the bottom horizontal edge of the integrated insulated material a first insulated siding sheet engages and mates onto the top horizontal edge of the integrated insulated material a second insulated siding sheet.
Aspect 14: A building comprising the insulated siding sheet system according to any one of aspects 11-13 formed over at least a portion of one side of the building.
Aspect 15: The building of aspect 14, wherein the insulated siding sheet system is formed over each side of the building.
Aspect 16: The building of aspects 14 or 15, wherein the building is a residential building.
Aspect 17: The building of any one of aspects 14-16, further comprising at least one window and at least one door, wherein the at least one window and the at least one door each independently comprise metal trim that extends around the at least one window and the at least one door, and wherein the metal trim forms a channel that receives insulated siding sheets extending around the at least one window and the at least one door.
Aspect 18: The building according to any one of aspects 14-17, further comprising a starter strip positioned at the bottom of each side of the building, wherein the starter strip comprises a channel that receives insulated siding sheets extending down toward a bottom of the sides of the building.
Aspect 19: A method of retrofitting an insulated siding sheet system onto a building, the method comprising attaching the insulated siding sheet system according to any one of aspects 14-18 onto one or more sides of a building.
Aspect 20: The method of aspect 19, wherein attaching the insulated siding sheet system onto one or more sides of the building comprises laminating the integrated insulation material onto the one or more sides of the building.
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.
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.
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.
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 of the present disclosure. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.
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.
Referring to
As used herein, an “integrated insulation material” refers to concrete forms of 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.
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) this heat flows through the material.
In some non-limiting embodiments, referring to
The integrated insulation material 12 can also be prepared to have a desired thickness. For instance, the integrated insulation material 12 can have a thickness of at least 1 inch, or at least 1 and half inches. The integrated insulation material 12 can also have a thickness of up to 4 inches or up to 3 inches. The thickness of the integrated insulation material 12 can be selected within a range of from 1 inch to 4 inches, or within a range of from 1 inch to 3 inches, or within a range of from 1 inch to 2 inches.
As further shown in
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 act as a rainscreen to provide bulk water drainage through the insulated siding sheet 10.
As indicated, the insulated siding sheet 10 also comprises a plank siding 14. Referring to
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 (i.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 ½ inch, while the remaining portions of the plank siding 14 have a thickness of about 1 inch.
As further shown in
In some non-limiting embodiments, as shown in
In some non-limiting embodiments, referring to
Referring to
It was found that the insulated siding sheet system 80 provides a durable exterior siding with robust sturdiness due to the combination of plank siding 14 and rigid integrated insulation material 12. The integrated insulation material 12 further provides a minimum insulation R-value of R-5, along with a continuous rainscreen 94 formed from the vertical grooves 40 that provides drying capabilities. The angled integrated insulation materials 12 with the mating alignment 90 and lapped configuration 82 between plank sidings 14 further allows for an easy installation due to the stacking interlock between plank sidings 14.
In certain non-limiting embodiments, referring to
In some non-limiting embodiments, referring again to
As shown in
The building 100 can also include various other components associated with the insulated siding sheet system 80. For example, as shown in
The present disclosure further includes a method of retrofitting an insulated siding sheet system 80 onto a building 100. The method can include attaching the insulated siding sheet system 80 as previously described onto one or more sides 102 of the building 100. The step of attaching the insulated siding sheet system 80 onto one or more sides 102 of the building 100 can include laminating the integrated insulation material 12 onto the one or more sides 102 of the building 100. The method can include other steps, such as removing previously existing siding prior to attaching the insulated siding sheet system 80 onto the sides 102 of the building 100. It is appreciated that the insulated siding sheet system 80 can be attached by overlapping cut-away portions 51 and 53 of the plank sidings 14 from adjacent insulated siding sheets 10.
Referring to
It was found that the insulated siding sheet system 80 can be easily installed and retrofitted to provide a minimum insulation R-value of R-5, along with a continuous rainscreen 94 system.
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.
The present application claims priority to U.S. Provisional Patent Application No. 63/444,731, filed Feb. 10, 2023, the content of which is incorporated herein by reference in its entirety.
This invention was made with Government support under Contract No. DE-SC-0022616 awarded by the Department of Energy.
Number | Date | Country | |
---|---|---|---|
63444731 | Feb 2023 | US |