US2006068188A1PendingUtilityA1

Foam backed fiber cement

59
Individually held — no corporate assignee on recordPriority: Sep 30, 2004Filed: Sep 30, 2004Published: Mar 30, 2006
Est. expirySep 30, 2024(expired)· nominal 20-yr term from priority
Inventors:Rick MorseRobert ShawGregory F. Jacobs
B32B 5/18E04F 13/077Y10T428/249953E04F 13/141B32B 2419/04B32B 2266/08B32B 2307/7265B32B 13/045E04F 13/0871B32B 2607/00E04F 13/0864B32B 2250/02B32B 13/12B32B 2262/04Y10T428/249982B32B 2307/712B32B 2266/0278B32B 13/02E04F 13/0866E04F 13/185E04F 13/0869B32B 2419/06B32B 2266/025Y10T428/249976
59
PatentIndex Score
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Claims

Abstract

A product comprises a fiber cement substrate, and a porous, closed cell foam joined to a substantial portion of a major surface of the fiber cement substrate.

Claims

exact text as granted — not AI-modified
1 . A product comprising: 
 a fiber cement substrate; and    a porous, closed cell foam joined to a substantial portion of a major surface of the fiber cement substrate.    
   
   
       2 . The product of  claim 1 , wherein the substrate is shaped as a section of siding, a shake, a soffit, a roofing tile or shingle, a panel, or a trim piece.  
   
   
       3 . The product of  claim 1 , wherein: 
 the substrate is shaped as a section of siding or a shake; and    the foam covers a surface of the siding or shake, except in a region where the section of siding or shake is to overlap an adjacent section of siding or shake.    
   
   
       4 . The product of  claim 1 , wherein: 
 the substrate is shaped as a section of siding or a shake; and    the foam covers a major surface of the section of siding or shake, except in a relatively narrow region adjacent to a first edge of the substrate.    
   
   
       5 . The product of  claim 4 , wherein the foam is tapered from a relatively large thickness adjacent the narrow region to a relatively small or zero thickness at a second edge of the substrate opposite the first edge.  
   
   
       6 . The product of  claim 1 , wherein: 
 the substrate is a soffit or a panel; and    the foam covers an entire rear major surface of the soffit or panel.    
   
   
       7 . The product of  claim 1 , wherein the foam comprises polypropylene, polyethylene, polyurethane, or polystyrene.  
   
   
       8 . The product of  claim 1 , further comprising an adhesive for bonding the foam to the substrate.  
   
   
       9 . The product of  claim 1 , wherein the foam is bonded to the substrate without an adhesive therebetween.  
   
   
       10 . The product of  claim 9 , wherein the foam is attached to the substrate by fusing, or forming the foam on the substrate.  
   
   
       11 . The product of  claim 9 , wherein the foam is attached to the substrate by mechanical fastening.  
   
   
       12 . The product of  claim 11 , wherein the foam is attached to the substrate using staples, flanges or prongs  
   
   
       13 . The product of  claim 1 , wherein the fiber cement substrate comprises cellulosic fiber.  
   
   
       14 . The product of  claim 1 , wherein the foam comprises polyurethane.  
   
   
       15 . A product comprising: 
 a fiber cement substrate; and    a closed cell foam joined to a substantial portion of a major surface of the fiber cement substrate, at least one major surface of the foam having a plurality of grooves therein.    
   
   
       16 . The product of  claim 15 , wherein the substrate is shaped as a section of siding, a shake, a soffit, a shingle, a roofing tile or shingle, a panel, or a trim piece.  
   
   
       17 . The product of  claim 16 , wherein the grooves are oriented relative to the substrate in a direction that has a vertical component when the siding, shake, soffit, roofing tile or shingle, panel, or trim piece is installed.  
   
   
       18 . The product of  claim 15 , wherein the grooves are located on the major surface of the foam facing away from the fiber cement substrate.  
   
   
       19 . The product of  claim 15 , wherein the grooves have a substantially semi-circular cross-section.  
   
   
       20 . The product of  claim 15 , wherein the foam comprises polypropylene, polyethylene polyurethane, or polystyrene.  
   
   
       21 . The product of  claim 15 , wherein the fiber cement substrate comprises cellulosic fiber.  
   
   
       22 . The product of  claim 15 , wherein the grooves are oriented in a direction that is not parallel or perpendicular to side edges of the panel.  
   
   
       23 . A method comprising: 
 providing a fiber cement substrate; and    joining a porous, closed cell foam to a substantial portion of a major surface of the fiber cement substrate.    
   
   
       24 . The method of  claim 23 , wherein the substrate is shaped as a section of siding, a shake, a soffit, roofing tile or shingle, a panel, or a trim piece.  
   
   
       25 . The method of  claim 23 , wherein: 
 the substrate is shaped as a section of siding, a shingle or a shake; and    the joining step includes covering a surface of the siding, shingle or shake with the foam, except in a region where the section of siding, shingle or shake is to overlap a neighboring section of siding, shingle or shake.    
   
   
       26 . The method of  claim 23 , wherein: 
 the substrate is shaped as a section of siding, a shingle or a shake; and    the bonding step includes covering a major surface of the siding, shingle or shake with the foam, except in a relatively narrow region adjacent to a first edge of the substrate.    
   
   
       27 . The method of  claim 26 , wherein the foam is tapered from a relatively large thickness adjacent the narrow region to a relatively small or zero thickness at a second edge opposite the first edge.  
   
   
       28 . The method of  claim 23 , wherein: 
 the substrate is a soffit or a panel; and    the bonding step includes covering an entire rear major surface of the soffit or panel.    
   
   
       29 . The method of  claim 23 , wherein the foam is made of polypropylene or polyethylene.  
   
   
       30 . The method of  claim 23 , wherein the joining step comprises: 
 providing the foam in the form of a sheet; and    bonding the foam to the substrate with an adhesive.    
   
   
       31 . The method of  claim 23 , wherein the foam is bonded to the substrate without an adhesive therebetween.  
   
   
       32 . The method of  claim 31 , wherein the foam is attached to the substrate by mechanical fastening.  
   
   
       33 . The method of  claim 32 , wherein the foam is attached to the substrate using staples, flanges or prongs  
   
   
       34 . The method of  claim 31 , wherein the foam is attached to the substrate by fusing, or forming the foam on the substrate.  
   
   
       35 . The method of  claim 34 , wherein the bonding step includes pouring the foam onto the substrate, and allowing the foam to solidify.  
   
   
       36 . The method of  claim 23 , wherein the foam comprises polyurethane.  
   
   
       37 . A method comprising: 
 providing a unitary panel, section of siding, roofing tile or shingle, shake, soffit or trim piece including a fiber cement substrate and a porous, closed cell foam bonded to a substantial portion of a major surface of the fiber cement substrate; and    mounting the panel, section of siding, roofing tile or shingle, shake, soffit or trim piece on a building surface.    
   
   
       38 . The method of  claim 37 , further comprising permitting moisture to drain from between the substrate and the building surface by way of interstices between cells of the foam.  
   
   
       39 . The method of  claim 37 , wherein the foam is tapered from a relatively large thickness adjacent a narrow region along a first edge of the substrate to a relatively small or zero thickness at a second edge of the substrate opposite the first edge, the method further comprising: 
 overlapping a second section of siding, shingle or shake with the first section of siding, shingle or shake, so that a rear surface of the foam on each of the first and second sections of siding, shingles or shakes contacts the building surface.    
   
   
       40 . The method of  claim 37 , wherein the foam covers a major surface of the siding, shingle or shake, except in a region where the section of siding, shingle or shake is to overlap a neighboring section of siding, shingle or shake.  
   
   
       41 . The method of  claim 40 , wherein the mounting step includes: 
 positioning the section of siding, shingle or shake so that a major surface of the foam contacts the building surface and acts as a spacer to position the region of the section of siding, shingle or shake at a non-zero distance from the building surface.    
   
   
       42 . The method of  claim 40 , wherein the mounting step includes: 
 positioning the section of siding, shingle or shake so that a major surface of the foam faces away from the building surface and acts as a spacer to position a bottom portion of an adjacent second section of siding, shingle or shake at a non-zero distance from the building surface.    
   
   
       43 . The method of  claim 37 , wherein: 
 the foam covers a rear surface of the siding, shingle or shake, except in a region where the section of siding, shingle or shake is to overlap a neighboring section of siding, shingle or shake, and the mounting step includes:    positioning the section of siding, shingle or shake so that a bottom edge of the foam rests on a top edge of an adjacent section of siding, shingle or shake.    
   
   
       44 . A method comprising: 
 providing a fiber cement substrate;    forming a plurality of grooves in a surface of a layer of closed cell foam; and    joining the closed cell foam to a substantial portion of a major surface of the fiber cement substrate.    
   
   
       45 . The method of  claim 44 , wherein the substrate is shaped as a section of siding, a shake, a soffit, roofing tile or shingle, a panel, or a trim piece.  
   
   
       46 . The method of  claim 45 , wherein the grooves are oriented so that they have a direction with a substantial vertical component when the siding, shake, soffit, roofing tile or shingle, panel, or trim piece is installed.  
   
   
       47 . The method of  claim 44 , wherein the grooves are located on the major surface of the foam facing away from the fiber cement substrate.  
   
   
       48 . The method of  claim 44 , wherein the grooves have a substantially semi-circular cross-section.

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