Foam backed fiber cement

Abstract

A method comprises: 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.

1 . 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.    
   
   
       2 . The method of  claim 1 , wherein the substrate is shaped as a section of siding, a shake, a soffit, roofing tile or shingle, a panel, or a trim piece.  
   
   
       3 . The method of  claim 1 , 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.    
   
   
       4 . The method of  claim 1 , 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.    
   
   
       5 . The method 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 opposite the first edge.  
   
   
       6 . The method of  claim 1 , 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.    
   
   
       7 . The method of  claim 1 , wherein the foam is made of polypropylene or polyethylene.  
   
   
       8 . The method of  claim 1 , wherein the joining step comprises: 
 providing the foam in the form of a sheet; and    bonding the foam to the substrate with an adhesive.    
   
   
       9 . The method of  claim 1 , wherein the foam is bonded to the substrate without an adhesive therebetween.  
   
   
       10 . The method of  claim 9 , wherein the foam is attached to the substrate by mechanical fastening.  
   
   
       11 . The method of  claim 10 , wherein the foam is attached to the substrate using staples, flanges or prongs  
   
   
       12 . The method of  claim 9 , wherein the foam is attached to the substrate by fusing, or forming the foam on the substrate.  
   
   
       13 . The method of  claim 12 , wherein the bonding step includes pouring the foam onto the substrate, and allowing the foam to solidify.  
   
   
       14 . The method of  claim 1 , wherein the foam comprises polyurethane.  
   
   
       15 . 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.    
   
   
       16 . The method of  claim 15 , further comprising permitting moisture to drain from between the substrate and the building surface by way of interstices between cells of the foam.  
   
   
       17 . The method of  claim 15 , 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.    
   
   
       18 . The method of  claim 15 , 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.  
   
   
       19 . The method of  claim 18 , 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.    
   
   
       20 . The method of  claim 18 , 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.    
   
   
       21 . The method of  claim 15 , 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.    
   
   
       22 . 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.    
   
   
       23 . The method of  claim 22 , wherein the substrate is shaped as a section of siding, a shake, a soffit, roofing tile or shingle, a panel, or a trim piece.  
   
   
       24 . The method of  claim 23 , 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.  
   
   
       25 . The method of  claim 22 , wherein the grooves are located on the major surface of the foam facing away from the fiber cement substrate.