BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/627,527, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Ashley A. SCHULTZ et al., filed Jan. 31, 2024, and also claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/710,660, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Greg Thomas HOLLAND, filed Oct. 23, 2024, both of which applications are assigned to the current assignee hereof and the entire disclosures of these applications are incorporated herein by reference in their entireties.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to a building surface panel for covering a building surface. The present disclosure relates more particularly to a backed or reinforced building surface panel for covering a building surface.

BACKGROUND

Building surface panels, such as cladding or siding, are visible elements that cover an underlying support structure. Siding panels are typically used in the construction of homes, businesses, and other buildings on exterior walls. These siding panels can provide protection to the underlying support structure from weather and other elements.

There is a wide variety of distinct types of building surface panels that may be used to cover exterior walls. Such surface panels may exhibit heat distortion and/or buckling while installed on a building surface, due to environmental conditions and changing conditions. Therefore, improvements in building surface panels are continually needed.

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

One general aspect includes a building surface panel that can include an outer element having a first front side, and a first rear side; and a backing component having a second front side and a second rear side, where the second front side is attached to the first rear side of the outer element, where the building surface panel may further include at least one of: a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%; a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel; a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element; a density of the backing component being at least 0.4 grams/cm³ but not greater than 2.0 grams/cm³; and a combination thereof.

Another aspect includes a building surface panel that can include an outer element having a first front side and a first rear side; and a backing component having a second front side and a second rear side, where the second front side of the backing component is attached to the first rear side of the outer element, where the backing component may include one or more longitudinally extending reinforcement elements, and where the one or more reinforcement elements may include a protrusion that protrudes from the second rear side.

Another aspect includes a building surface panel that can include an outer element having a first front side and a first rear side; and a backing component having a second front side and a second rear side, where the second front side of the backing component is attached to the first rear side of the outer element, where the backing component may include at least one of: a longitudinally extending groove; a longitudinally extending tongue; a plurality of relief holes; and a density that is at least 0.4 grams/cm³ but not greater than 2.0 grams/cm³.

Yet another aspect includes a building surface panel that can include an outer element having a first front side, a first rear side, and a first thickness as measured between the first front side and the first rear side; and a backing component having a second front side, a second rear side, and a second thickness as measured between the second front side and the second rear side, where the second front side of the backing component is attached to the first rear side of the outer element, where the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited to the accompanying figures. These and other features, aspects, and advantages of present embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is a schematic depiction of side-view of a portion of a building surface panel according to an embodiment described herein;

FIG. 2 is a schematic depiction of a front-view of a portion of a building surface panel according to an embodiment described herein;

FIG. 3 is a representative perspective view of a portion of a building covered by building surface panels, in accordance with certain embodiments;

FIG. 4A is a representative full view of a building surface panel formed as a unitary body with an outer element and a backing component formed together, prior to folding, in accordance with certain embodiments;

FIG. 4B is a representative perspective view of a building surface panel formed as a unitary body with an outer element and a backing component formed together, prior to folding, in accordance with certain embodiments;

FIG. 4C is a representative perspective view of a building surface panel formed as a unitary body with an outer element and a backing component formed together and the backing component folded to engage the outer element, in accordance with certain embodiments;

FIG. 5A is a representative perspective view of a unitary body formed with an outer element and a backing component, and the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

FIG. 5B is a representative partial cross-sectional view 5B-5B, as indicated in FIG. 5A, of a building surface panel, in accordance with certain embodiments;

FIG. 5C is a representative detail view of the detail region 5C, as indicated in FIG. 5B, of a building surface panel, in accordance with certain embodiments;

FIG. 6A is a representative perspective view of multiple building surface panels with a reinforced outer element assembled together, in accordance with certain embodiments;

FIG. 6B is a representative partial cross-sectional view 6B-6B, as indicated in FIG. 6A, of multiple building surface panels assembled together on a building surface, in accordance with certain embodiments;

FIG. 7A is a representative perspective view of a unitary body formed with an outer element and a backing component, with the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

FIG. 7B is a representative partial cross-sectional view 7B-7B, as indicated in FIG. 7A, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

FIG. 8A is a representative perspective view of multiple building surface panels with a reinforced outer element assembled together, in accordance with certain embodiments;

FIG. 8B is a representative partial cross-sectional view 8B-8B, as indicated in FIG. 8A, of multiple building surface panels assembled together on a building surface, in accordance with certain embodiments;

FIG. 9A is a representative perspective view of a unitary body formed with an outer element and a backing component, with the backing component folded to engage the outer element to form a building surface panel with a reinforced outer element, in accordance with certain embodiments;

FIG. 9B is a representative partial cross-sectional view 9B-9B, as indicated in FIG. 9A, of a building surface panel with a reinforced outer element, in accordance with certain embodiments;

FIG. 10A is a representative perspective view of an outer element of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

FIG. 10B is a representative perspective view of a backing component of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

FIG. 10C is a representative perspective view of a building surface panel formed from a two-piece construction by attaching the backing component to the outer element, in accordance with certain embodiments;

FIG. 10D is a representative partial cross-sectional view 10D-10D, as indicated in FIG. 10C, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

FIG. 11A is a representative perspective view of an outer element of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

FIG. 11B is a representative perspective view of a backing component of a building surface panel, which is formed from a two-piece construction, in accordance with certain embodiments;

FIG. 11C is a representative perspective view of a building surface panel formed from a two-piece construction by attaching the backing component to the outer element, in accordance with certain embodiments;

FIG. 11D is a representative partial cross-sectional view 11D-11D, as indicated in FIG. 11C, of the building surface panel with a reinforced outer element, in accordance with certain embodiments;

FIG. 11E is a representative perspective rear view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments; and

FIGS. 12A-12D are representative partial cross-sectional views 12-12, as indicated in FIG. 11E, of reinforcement elements in a backing component to reinforce an outer element of a building surface panel, in accordance with certain embodiments.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.

DETAILED DESCRIPTION

The following discussion will focus on specific implementations and embodiments of the teachings. The detailed description is provided to assist in describing certain embodiments and should not be interpreted as a limitation on the scope or applicability of the disclosure or teachings. It will be appreciated that other embodiments can be used based on the disclosure and teachings as provided herein.

The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present), and B is false (or not present), A is false (or not present), and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one or the singular as also including the plural or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

The use of the word “about”, “approximately”, “generally”, or “substantially” is intended to mean that a value of a parameter is close to a stated value or position. However, minor differences may prevent the values or positions from being exactly as stated. Thus, differences of up to ten percent (10%) for the value are reasonable differences from the ideal goal of exactly as described. A significant difference can be when the difference is greater than ten percent (10%).

Embodiments described herein are generally directed to a building surface panel that may include an outer element and a backing component. As used herein, the term “outer element” is used interchangeably with “outer shell,” “outer layer,” “exterior layer,” “cladding face,” or “siding.” The outer element can be formed separately from the backing component and attached to the backing component by any suitable means, or the outer element and the backing component can be formed together as a unitary body and folded to attach the backing component to the outer element to form the backed or reinforced building surface panel. As used herein, the term “building surface panel” refers to a backed or reinforced building surface panel unless specified otherwise.

For purposes of illustration, FIG. 1 shows a schematic side-view of a portion of a building surface panel 100 according to embodiments described herein. As shown in FIG. 1, the building surface panel 100 may include an outer element 110 and a backing component 120. As also shown in FIG. 1, the outer element 110 may have a front side 112 and a rear side 114. As further shown in FIG. 1, the backing component 120 may be attached to rear side 114 of the outer element 110.

For purposes of further illustration, FIG. 2 shows a schematic front view of a portion of the building surface panel 100 according to embodiments described herein. Components of embodiments described herein may be described as having a length, height, and width (or thickness). It is noted that, for purposes of embodiments described herein and as shown in FIG. 2, “length” refers to the length (L2) in an X-direction along a longitudinal axis of the component oriented as it would be installed on a building, “height” refers to the height (H) in a Y-direction along a lateral axis of the component oriented as it would be installed on a building, and “width” refers to the width (W) in a Z-direction along a transversal axis of the component oriented as it would be installed on a building. As used herein, the longitudinal axis corresponds to the extrusion direction.

Foams can be adhered to the back of building surface panels to form a backing component that can reinforce the building surface panels. However, the insulative properties of foam can lead to issues with heat buildup and temperature differential across the panel. This can lead to differences in thermal expansion between the backing component and the outer element, thus creating distortions at the overlap between building surface panels or distortions anywhere on the face of the outer element that can lead to aesthetic defects in the panel. A building surface panel that includes a backing (or support) component that provides mechanical support while reducing temperature differential between the backing component and the outer element (which can also be referred to as an outer element) can minimize these issues.

Referring back to FIG. 1, it will be appreciated that for purposes of embodiments described herein, the outer element 110 may be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the outer element 110 may be formed of multiple layers that are formed together, such as through extrusion or molding, or formed separately and attached together by any suitable means, including, but not limited to chemical, plasma, thermal, or ultrasonic bonding, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. For example, the outer element 110 may be formed of two layers that are coextruded or extruded separately and then bonded together.

It will be appreciated that for purposes of embodiments described herein, the backing component 120 may be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the backing component 120 may be formed of multiple layers that are formed together such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, thermal, or ultrasonic bonding, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. For example, the backing component 120 may be formed of two layers that are coextruded or extruded separately and then bonded together. In an embodiment, the backing component may comprise one or more longitudinally extending reinforcement elements. The one or more reinforcement elements may comprise one or more longitudinally extending protrusions or longitudinally extending ribs, longitudinal corrugation, honeycomb pattern, embossed features, or an elongated piece that is adhered to the backing component. The elongated piece may be continuous, solid piece, corrugated, honeycomb, or a geometric pattern. In a non-limiting embodiment, the front side 122 and/or the back side 124 of the backing component 120 can be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc. In another embodiment, only the front side 122 of the backing component can be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc, such that the back side 124 is substantially smooth and uniform, and without any embossed feature.

It will be appreciated that for purposes of embodiments described herein, the outer element 110 and the backing component 120 may be a unitary body that is a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. As used herein, “unitary body” refers to a body that includes multiple components that are formed together as one piece with the components being integral to each other.

According to certain embodiments the building surface panel 100 may have a particular CTE mismatch measured between the outer element 110 and the backing component 120. It will be appreciated that the CTE mismatch described herein is equal to the absolute value of the difference between the CTE of the outer element 110 and the CTE of the backing component 120 divided by the average of the CTE of the outer element 110 and the CTE of the backing component 120, where the CTE of each element is measured according to American Society for Testing and Materials (ASTM) D696 at a temperature 25° C. According to particular embodiments, the building surface panel 100 may have a CTE mismatch of not greater than about 20%, such as not greater than about 19% or not greater than about 18% or not greater than about 17% or not greater than about 16% or not greater than about 15% or not greater than about 14% or not greater than about 13 percent or not greater than about 12% or not greater than about 11% or not greater than about 10% or not greater than about 9% or not greater than about 8% or not greater than about 7% or not greater than about 6% or even not greater than about 5% or even not greater than about 2% or even not greater than about 1% or even not greater than about 0.5% or even not greater than about 0.1%. It will be appreciated that the CTE mismatch of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the CTE mismatch of the building surface panel 100 may be any value between any of the values noted above. In another embodiment, the outer element 110 and the backing component 120 may have substantially the same CTE.

According to still other embodiments, the building surface panel 100 may have a particular deflection measurement if subjected to a curvature test at least 90 days after formation of the building surface panel 100. For purposes of embodiments described herein, the curvature test is performed at a temperature of 25° C., ambient humidity, according to the following steps: 1) remove a substantially flat strip of the layered structure from the building surface panel to be tested, the strip extending parallel to the length of the building surface panel and having a length of 33 inches and a width of 4.5 inches (any nail hem may be cut away), 2) define a first end point of the strip at a position on the front side of the outer element that is 1.5 inches from a first end of the strip and centered across the width of the strip, and define a second end point of the strip at a position on the front side of the outer element that is that is 1.5 inches from the second end of the strip and centered across the width of the strip, 3) position the strip such that the width is oriented vertically, the front side of the outer element faces a fixed reference plane, and a line that passes through the first and second end points is parallel to the reference plane, and 4) measure, using a laser position gage, the deflection measurement as equal to a difference between a first distance from the end points to the reference plane and a second distance from a peak on the front side of the outer element to the reference plane. According to particular embodiments, the building surface panel 100 may have a deflection measurement of not greater than about 10 mm, such as not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm. Additionally, the building surface panel 100 according to various embodiments of the present invention exhibits deflection measurement of not greater than 10 mm not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm, in a curvature test when exposed to 1000 W/m². It will be appreciated that the deflection measurement of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the deflection measurement of the building surface panel 100 may be any value between any of the values noted above.

According to yet other embodiments, the building surface panel 100 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the building surface panel 100 may have an R-value of not greater than about 0.60° F.·ft²·hr/BTU, such as not greater than about 0.57° F.·ft²·hr/BTU or not greater than about 0.55° F.·ft²·hr/BTU or not greater than about 0.53° F.·ft²·hr/BTU or not greater than about 0.50° F.·ft²·hr/BTU or not greater than about 0.47° F.·ft²·hr/BTU or not greater than about 0.45° F.·ft²·hr/BTU or not greater than about 0.43° F.·ft²·hr/BTU or not greater than about 0.40° F.·ft²·hr/BTU or not greater than about 0.37° F.·ft²·hr/BTU or not greater than about 0.35° F.·ft²·hr/BTU or not greater than about 0.33° F.·ft²·hr/BTU or not greater than about 0.30° F.·ft²·hr/BTU or not greater than about 0.27° F.·ft²·hr/BTU or not greater than about 0.25° F.·ft²·hr/BTU or not greater than about 0.23° F.·ft²·hr/BTU or not greater than about 0.20° F.·ft²·hr/BTU or not greater than about 0.17° F.·ft²·hr/BTU or not greater than about 0.15° F.·ft²·hr/BTU or not greater than about 0.13° F.·ft²·hr/BTU or even not greater than about 0.10° F.·ft²·hr/BTU. It will be appreciated that the R-value of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the R-value of the building surface panel 100 may be any value between any of the values noted above.

According to yet other embodiments, the outer element 110 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the outer element 110 may have an R-value of not greater than about 0.40° F.·ft²·hr/BTU, such as not greater than about 0.37° F.·ft²·hr/BTU or not greater than about 0.35° F.·ft²·hr/BTU or not greater than about 0.33° F.·ft²·hr/BTU or not greater than about 0.30° F.·ft²·hr/BTU or not greater than about 0.27° F.·ft²·hr/BTU or not greater than about 0.25° F.·ft²·hr/BTU or not greater than about 0.23° F.·ft²·hr/BTU or not greater than about 0.20° F.·ft²·hr/BTU or not greater than about 0.17° F.·ft²·hr/BTU or not greater than about 0.15° F.·ft²·hr/BTU or not greater than about 0.13° F.·ft²·hr/BTU or even not greater than about 0.10° F.·ft²·hr/BTU. It will be appreciated that the R-value of the outer element 110 may be between any of the values noted above. It will be further appreciated that the R-value of the outer element 110 may be any value between any of the values noted above.

According to yet other embodiments, the backing component 120 may have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal conductivity of the article as measured according to ASTM C518. According to certain embodiments, the backing component 120 may have an R-value of not greater than about 0.40° F.·ft²·hr/BTU, such as not greater than about 0.37° F.··ft²·hr/BTU or not greater than about 0.35° F.·ft²·hr/BTU or not greater than about 0.33° F.·ft²·hr/BTU or not greater than about 0.30° F.·ft²·hr/BTU or not greater than about 0.27° F.·ft²·hr/BTU or not greater than about 0.25° F.·ft²·hr/BTU or not greater than about 0.23° F.·ft²·hr/BTU or not greater than about 0.20° F.·ft²·hr/BTU or not greater than about 0.17° F.·ft²·hr/BTU or not greater than about 0.15° F.·ft²·hr/BTU or not greater than about 0.13° F.··ft²·hr/BTU or even not greater than about 0.10° F.·ft²·hr/BTU. It will be appreciated that the R-value of the backing component 120 may be between any of the values noted above. It will be further appreciated that the R-value of the backing component 120 may be any value between any of the values noted above.

According to still other embodiments, the building surface panel 100 may pass a surface distortion test as measured according to ASTM 7745, where the foam backer is replaced with the backing component 120 of the present invention. In particular, the building surface panel 100 may pass a surface distortion test as measured according to ASTM 7745 at a temperature of 150° F. (66° C.) by being free of bulges, waves, and ripples. In various embodiments, the building surface panels of the present invention are substantially free of surface distortion, which can also be referred to as oil-canning effect.

According to other embodiments, the building surface panel 100 may have a particular vertical face radius of curvature as measured at room temperature along the vertical face (i.e., along the y-axis) of the building surface panel 100. For example, the building surface panel 100 may have a vertical face radius of curvature of at least about 500 mm, such as at least about 550 mm or at least about 600 mm or at least about 650 mm or at least about 700 mm or at least about 750 mm or at least about 800 mm or at least about 850 mm or at least about 900 mm or at least about 950 mm or at least about 1000 mm or at least about 1050 mm or at least about 1100 mm or at least about 1150 mm or at least about 1200 mm or at least about 1250 mm or at least about 1300 mm or at least about 1350 mm or at least about 1400 mm or at least about 1450 mm or at least about 1500 mm or at least about 1550 mm or at least about 1600 mm or at least about 1650 mm or at least about 1700 mm or at least about 1750 mm or at least about 1800 mm or at least about 1850 mm or at least about 1900 mm or at least about 1950 mm or at least about 2000 mm or at least about 2050 mm or at least about 2100 mm or at least about 2150 mm or at least about 2200 mm or at least about 2250 mm or at least about 2300 mm or at least about 2350 mm or at least about 2400 mm or at least about 2450 mm or at least about 2500 mm or at least about 2550 mm or even at least about 2600 mm. It will be appreciated that the vertical face radius of curvature of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the vertical face radius of curvature of the building surface panel 100 may be any value between any of the values noted above.

According to still other embodiments, the outer element 110 of the building surface panel 100 may include a particular material. For example, the outer element 110 may include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic resin, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, polymer composite, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, and combinations thereof comprising a combination of one of the above virgin (new/non-recycled) material and one of the above recycled material. As used herein, the term “recycled material” refers to post-industrial recycled material including scrap and regrind material, post-consumer recycled material, and a combination thereof.

According to yet other embodiments the outer element 110 of the building surface panel 100 may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

According to still other embodiments, the outer element 110 of the building surface panel 100 may have a particular CTE as measured according to ASTM D696. For example, the outer element 110 may have a CTE of not greater than about 200 μm/(m·° C.), such as not greater than about 195 μm/(m·° C.) or not greater than about 190 μm/(m·° C.) or not greater than about 185 μm/(m·° C.) or not greater than about 180 μm/(m·° C.) or even not greater than about 175 μm/(m·° C.). It will be appreciated that the CTE of the outer element 110 may be within a range between any of the values noted above. It will be further appreciated that the CTE of the outer element 110 may be any value between any of the minimum and maximum values noted above.

According to other embodiments, the backing component 120 of the building surface panel 100 may include a particular material. For example the backing component may include polyvinyl chloride (PVC), cellular PVC, chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof and combinations thereof comprising a combination of one of the above virgin (new/non-recycled) material and one of the above recycled material. In an embodiment, the backing component comprises recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC in an amount greater than that present in the capstock layer and/or the support layer of the outer element 110.

In yet another embodiment, the backing component 120 comprises post-industrial recycled PVC or post-consumer recycled PVC in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the backing component 120. In yet another embodiment, the backing component 120 comprises recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, the backing component 120 comprises recycled PVC that includes portions of recycled PVC having different colors.

The backing component 120, as opposed to the outer element 110 can include recycled PVC with minimal contents of impurities from the group including adhesive, metal, different colored PVC, various other polymers, etc. These impurities can arise from the reclamation process for collecting used or not newly manufactured PVC (e.g., from a job site, from factory PVC waste material, etc.), and blending the recycled PVC into manufacturing processes to make a product, such as a backing component 120.

The various impurities that can be present in the recycled PVC can include, but are not limited to, at least one of polyvinylidene flouride (PVDF), acrylonitrile styrene acrylate (ASA), chlorinated PVC (CPVC), polyurethane, acrylic, silicone, rubber, chlorinated polyethylene, calcium carbonate, titanium dioxide, talc, and combinations thereof. The various polymers can account for less than 20%, or less than 15%, or less than 10%; or less than 5% by weight of the backing component 120. The metal can comprise aluminum or steel and can account for less than 1% by weight of the backing component 120.

In an embodiment of the building surface panel 100, the amount of recycled PVC in the backing component 120, is substantially greater than that of the outer element 110. In some embodiments of the building surface panel 100, the outer element 110 and the backing component 120 have substantially the same color. In other embodiments of the building surface panel 100, the outer element 110 and the backing component 120 have substantially different colors.

According to yet other embodiments, the backing component 120 of the building surface panel 100 may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof. For example, the backing component 120 may include one or more additives and a polymer including polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof.

In all embodiments in this disclosure, the outer element 110 can include a capstock disposed over a support layer, with the capstock forming the front side 112 and the backing component 120 being disposed over the outer element 110 on a side opposite the capstock, the rear side 114 of the outer element 110, as shown in FIG. 1. The capstock and backer material can be any of the materials disclosed below for the outer element 110. However, it can be preferrable that the capstock be made from a material that is more resistant to damage or degradation by environmental elements. Therefore, the capstock can be laminated to the outer element or coextruded with the support layer or tri-extruded with the support layer and the backer material or printed/painted on those surfaces of the outer element 110 that would be exposed to the elements when installed on a building.

Any suitable polymer can be used for capstock including, but not limited to, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof. The capstock may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

In a non-limiting embodiment, the capstock comprises a virgin polymer, such as acrylonitrile styrene acrylate (ASA), and the support layer or the backing component 120 comprises a suitable polymer such as polyvinyl chloride (PVC), or chlorinated polyvinyl chloride (CPVC), recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC or blends thereof.

In a non-limiting embodiment, the support layer of the outer element 110 and the backing component 120 comprises substantially the same polymeric composition (polymer and one or more additives). In a non-limiting embodiment, the outer element 110 comprising the capstock and the support layer forming the front side 112, comprises two different polymeric compositions, and the backing component 120 is formed of another polymeric composition different from that of the capstock and the support layer. The polymeric compositions of the capstock, the support layer, and the backing component 120 can differ in the amounts of one or more additives and/or the chemical composition of the polymers. In a non-limiting embodiment, the capstock, the support layer and the backing component 120 are all co-extruded or tri-extruded. In a non-limiting embodiment, capstock is laminated over the support layer. In yet another embodiment, capstock is painted, printed, spray coated, or roll coated over the support layer.

According to still other embodiments, the backing component 120 of the building surface panel 100 may have a particular CTE as measured according to ASTM D696. For example, the backing component 120 may have a CTE of not greater than about 200 μm/(m·° C.), such as not greater than about 195 μm/(m·° C.) or not greater than about 190 μm/(m·° C.) or not greater than about 185 μm/(m·° C.) or not greater than about 180 μm/(m·° C.) or even not greater than about 175 μm/(m·° C.). It will be appreciated that the CTE of the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the CTE of the backing component 120 may be any value between any of the minimum and maximum values noted above.

According to yet other embodiments, the outer element 110 may have a particular thickness. As used herein, “thickness” of the outer element 110 refers to the distance between the front side 112 and the rear side 114 as shown in at least FIG. 1. For example, the outer element 110 may have a thickness of at least about 0.1 mm, such as at least about 0.5 mm or at least about 1 mm or at least about 1.5 mm or at least about 2 mm or at least about 2.5 mm or at least about 3 mm or at least about 3.5 mm or at least about 4 mm or at least about 4.5 mm or even at least about 5 mm. According to still other embodiments, the outer element 110 may have a thickness of not greater than about 10 mm, such as not greater than about 9.5 mm or not greater than about 9.0 mm or not greater than about 8.5 mm or not greater than about 8 mm or even not greater than about 7.5 mm. It will be appreciated that the thickness of the outer element 110 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the outer element 110 may be any value between any of the minimum and maximum values noted above.

According to still other embodiments, the backing component 120 may have a particular thickness. As used herein, “thickness” of the backing component 120 refers to the distance between the front side 122 to the rear side 124 of the portions of the backing component 120 that are outside the reinforcement elements 126 as shown in at least FIGS. 12A-12D. As used herein, “thickness” of the outer element 110 refers to the distance between the front side 112 to the rear side 114 of the outer element 110 as shown in at least FIGS. 12A-12D. For example, the backing component 120 may have a thickness of at least about 0.02 mm, such as at least about 0.05 mm or at least about 0.1 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the backing component 120 may have a thickness of not greater than about 50 mm, such as not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm or not greater than about 15.0 mm or not greater than about 10 mm or not greater than about 5 mm or not greater than about 4 mm or not greater than about 3 mm. It will be appreciated that the thickness of the backing component 120 may be within a range between any of the minimum and maximum values noted above here it will be further appreciated that the thickness of the backing component 120 may be any value between any of the minimum and maximum values noted above.

According to still other embodiments, the building surface panel 100 may have a particular thickness or multiple thicknesses along the height (Y axis). For example, the building surface panel 100 may have a thickness of at least about 0.12 mm, such as at least about 0.13 mm or at least about 0.14 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the building surface panel 100 may have a thickness of not greater than about 60 mm, such as not greater than about 57.5 mm were not greater than about 55 mm were not greater than about 52.5 mm were not greater than about 50 mm were not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm. It will be appreciated that the thickness of the building surface panel 100 may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the building surface panel 100 may be any value between any of the minimum and maximum values noted above. In some embodiments, the building surface panel 100 can have multiple thicknesses, along the height (Y axis), within a range between any of the minimum and maximum values noted above due to portions of the building surface panel 100 where the outer element 110 is attached to the backing component 120, and other portions of the building surface panel 100 where the outer element 110 has no backing component 120 attached to it.

In an embodiment, a first thickness of the backing component 120 can be greater than about 0.5 times, or greater than about 1.0 times, or greater than about 1.2 times, or greater than about 1.5 times, or greater than about 2.0 times, or greater than about 2.5 times, or greater than about 3.0 times or greater than about 3.5 times a second thickness of the outer element 110. The first thickness of the backing component 120 can be less than about 5.0 times, or less than about 4.75 times, or less than about 4.25 times, or than about 3.75 times, or less than about 3.25 times, or less than about 2.75 times, or less than about 2.25 times, or less than about 1.75 times, or less than about 1.25 times, or less than about 0.75 times a second thickness of the outer element 110. It will be appreciated that the first thickness of the backing component 120 may be within a range between any of the minimum and maximum values noted above times the second thickness of the outer element 110.

As noted above, the outer element 110 can be attached to the backing component 120 or vice versa. Any suitable means could be used for attaching the outer element 110 and the backing component 120, including but not limited to, chemical, plasma, thermal, or ultrasonic bonding, adhesive, mechanically or a combination thereof. According to certain embodiments, the outer element 110 can be attached to the backing component 120 through a particular means. For example, according to certain embodiments, the outer element 110 can be fused to the backing component 120, for example, through an ultrasonic weld. According to yet other embodiments, the outer element 110 can be mechanically attached to the backing component 120, for example, through a clip, nail, screw, or any other mechanical attachment component.

According to yet other embodiments, the backing component 120 can be fixedly attached to any portion of the outer element 110. According to still other embodiments, the outer element 110 can be adhered to any portion of the backing component 120, for example, with an adhesive. According to still other embodiments, the outer element 110 can be bonded to the backing component 120, for example, through chemical, plasma, or thermal bonding.

According to still other embodiments, the building surface panel 100 may further include an adhesive layer (not shown in FIG. 1) between the outer element 110 and the backing component 120.

According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the outer element 110 and the backing component 120. For example, the shear strength between the outer element 110 and the backing component 120 may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C. It will be appreciated that the shear strength as measured between the outer element 110 and the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the outer element 110 and the backing component 120 may be any value between any of the values noted above.

According to still other embodiments, the adhesive layer may include a particular material. For example, the adhesive layer may include a solvent-based adhesive, a polyvinyl chloride (PVC) adhesive, an acrylic adhesive, a modified acrylic adhesive, a silicone adhesive, a one or two-component polyurethane adhesive, heat or moisture cured adhesive of these materials thereof, or any tape form of these materials thereof.

According to still other embodiments, the adhesive layer may consist essentially of a particular material. For example, the adhesive layer may consist essentially of a polyvinyl chloride (PVC) adhesive, an acrylic adhesive, a modified acrylic adhesive, a silicone adhesive, a one or two-component polyurethane adhesive, heat or moisture cured adhesive of these materials thereof, or any tape form of these materials thereof. The adhesives of this disclosure can be a low surface energy type of adhesive that can be used to adhere the outer element 110 to the backing component 120. The adhesive of the present disclosure can have a surface energy of greater than 15 dynes/cm or greater than 20 dynes/cm or greater than 25 dynes/cm or greater than 30 dynes/cm or greater than 35 dynes/cm or greater than 40 dynes/cm or greater than 45 dynes/cm and less than 55 dynes/cm or less than 50 dynes/cm or less than 45 dynes/cm or less than 40 dynes/cm or less than 35 dynes/cm or less than 30 dynes/cm or less than 30 dynes/cm or less than 25 dynes/cm or less than 23 dynes/cm. In an embodiment, the adhesive of the present disclosure can have a surface energy in the range of 30 to 45 dynes/cm. The adhesives of this disclosure can remain flexible throughout the life of the building surface panel 100.

The adhesives of this disclosure can have a shear modulus, when cured, of between about 1 MPa to about 900 MPa. The disclosed adhesives can have a shear modulus of greater than 1 MPa, or greater than 2 MPa, or greater than 3 MPa, or greater than 4 MPa, or greater than 5 MPa, or greater than 6 MPa, or greater than 7 MPa, or greater than 8 MPa, or greater than 9 MPa, or greater than 10 MPa or greater than 15 MPa, or greater than 20 MPa, or greater than 30 MPa, or greater than 35 MPa, or greater than 40 MPa, or greater than 60 MPa, or greater than 80 MPa, or greater than 100 MPa, or greater than 200 MPa, or greater than 300 MPa, or greater than 400 MPa.

The adhesives of this disclosure can have a shear modulus when cured of less than 900 MPa, or less than 890 MPa, or less than 880 MPa, or less than 870 MPa, or less than 850 MPa, or less than 800 MPa, or less than 700 MPa, or less than 600 MPa, or less than 500 MPa, or less than 400 MPa, or less than 300 MPa, or less than 200 MPa, or less than 100 MPa. It will be appreciated that the shear modulus of the adhesives disclosed herein may be within a range between any of the values noted above. It will be further appreciated that the shear modulus of the adhesives disclosed herein may be any value between any of the minimum and maximum values noted above.

According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the outer element 110 and the adhesive layer. For example, the bond shear strength between the outer element 110 and the adhesive layer may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C. . . . It will be appreciated that the bond shear strength as measured between the outer element 110 and the adhesive layer may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the outer element 110 and the adhesive layer may be any value between any of the values noted above.

According to particular embodiments, the building surface panel 100 may have a particular bond shear strength as measured between the adhesive layer and the backing component 120. For example, the bond shear strength between the adhesive layer and the backing component 120 may be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa. It will be appreciated that the bond shear strength as measured between the adhesive layer and the backing component 120 may be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the adhesive layer and the backing component 120 may be any value between any of the values noted above.

According to yet other embodiments the adhesive layer may have a particular R-value. For purposes of embodiments described here in the R-value may be equal to the thickness of the article divided by the thermal conductivity of the article as measured according to ASTM C518. According to certain embodiments the adhesive layer may have an R-value of not greater than about 0.40° F.·ft²·hr/BTU, such as not greater than about 0.37° F.·ft²·hr/BTU or not greater than about 0.35° F.·ft²·hr/BTU or not greater than about 0.33° F.·ft²·hr/BTU or not greater than about 0.30° F.··ft²·hr/BTU or not greater than about 0.27° F.·ft²·hr/BTU or not greater than about 0.25° F.·· ft²·hr/BTU or not greater than about 0.23° F.·ft²·hr/BTU or not greater than about 0.20° F.·ft²·hr/BTU or not greater than about 0.17° F.·ft²·hr/BTU or not greater than about 0.15° F.·ft²·hr/BTU or not greater than about 0.13° F.·ft²·hr/BTU or even not greater than about 0.10° F.·ft²·hr/BTU. It will be appreciated that R-value of the adhesive layer may be between any of the values noted above. It will be further appreciated that the R-value of the building adhesive layer may be any value between any of the values noted above.

According to yet other embodiments, the building surface panel 100 may have a particular height. For example, the building surface panel 100 may have a height of at least about 100 mm, such as at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the building surface panel 100 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the building surface panel 100 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the building surface panel 100 may be any value between any of the minimum and maximum values noted above.

According to yet other embodiments, the outer element 110 may have a particular height. For example, the outer element 110 may have a height of at least about 100 mm, such as at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the outer element 110 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the outer element 110 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the outer element 110 may be any value between any of the minimum and maximum values noted above. In an embodiment, the height of the outer element 110 may be substantially the same as that of the building surface panel 100. In another embodiment, the height of the outer element 110 may be less than that of the building surface panel 100.

According to yet other embodiments, the backing component 120 may have a particular height. For example, the backing component 120 may have a height of at least about 10 mm, such as at least about 25 mm or at least about 50 mm or at least about 75 mm or at least about 100 mm or at least about 125 mm or at least about 150 mm or at least about 175 mm or at least about 200 mm or at least about 225 mm or at least about 250 mm or at least about 275 mm or at least about 300 mm or at least about 325 mm or at least about 350 mm or at least about 375 mm or at least about 400 mm or at least about 425 mm or at least about 450 mm or at least about 475 mm or even at least about 500 mm. According to still other embodiments, the backing component 120 may have a height of not greater than about 1000 mm, such as not greater than about 900 mm or not greater than about 800 mm or not greater than about 700 mm or even not greater than about 600 mm. It will be appreciated that the height of the backing component 120 may be between any of the minimum and maximum values noted above. It will be further appreciated that the height of the backing component 120 may be any value between any of the minimum and maximum values noted above. In an embodiment, the height of the backing component 120 may be substantially the same as that of the building surface panel 100. In another embodiment, the height of the backing component 120 may be less than that of the outer element 110. In yet another embodiment, the height of the backing component 120 may be more than that of the outer element 110.

According to still other embodiments, the building surface panel 100 may have a particular length. For example the building surface panel 100 may have a length of at least about 1 meter, such as at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the building surface panel 100 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the building surface panel 100 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the building surface panel 100 may be any value between any of the minimum and maximum values noted above.

According to still other embodiments, the outer element 110 may have a particular length. For example the outer element 110 may have a length of at least about 1 meter, such as at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the outer element 110 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the outer element 110 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the outer element 110 may be any value between any of the minimum and maximum values noted above. In an embodiment, the length of the outer element 110 is substantially the same as that of the building surface panel 100.

According to still other embodiments, the backing component 120 may have a particular length. For example the backing component 120 may have a length of at least about 0.5 meters, such as at least about 1.0 meters or at least about 1.5 meters or at least about 2.0 meters or at least about 2.5 meters or at least about 3.0 meters or at least about 3.5 meters or at least about 4.0 meters or at least about 4.5 meters or at least about 5.0 meters or at least about 5.5 meters or at least about 6.0 meters or at least about 6.5 meters or at least about 7.0 meters or at least about 7.5 meters or at least about 8.0 meters or at least about 8.5 meters or at least about 9.0 meters or at least about 9.5 meters or even at least about 10 meters. According to still other embodiments, the backing component 120 may have a length of not greater than about 20 meters, such as not greater than about 19 meters or not greater than about 18 meters or not greater than about 17 meters or not greater than about 16 meters or not greater than about 15 meters or not greater than about 14 meters or not greater than about 13 meters or not greater than about 12 meters or even not greater than about 11 meters. It will be appreciated that the length of the backing component 120 may be between any of the minimum and maximum values noted above. It will be further appreciated that the length of the backing component 120 may be any value between any of the minimum and maximum values noted above. In another embodiment, the length of the backing component 120 is less than that of the outer element 110 and the building surface panel 100 for horizontally oriented building surface panels 100. In another embodiment, the length of the backing component 120 is substantially the same as that of the outer element 110 and the building surface panel 100 for vertically oriented building surface panels 100.

It will be appreciated that the outer element 110 of the building surface panel 100 may have any desirable shape, in horizontal or vertical orientation, including, but not limited to clapboard, dutchlap, board & batten, beaded, beveled edge, or v-groove. According to certain embodiments, and as shown in FIG. 1, the outer element 110 may have a rectangular or flat face shape. According to other embodiments, the outer element 110 may have a cylindrical or curved face shape. According to other embodiments, the outer element 110 may have a flat face shape with beveled edges. or a flat face shape with beveled edges and one or more longitudinal grooves. In an embodiment, the outer element 110 of the building surface panel 100 may have a shape, as disclosed in U.S. Pat. No. 11,920,356, incorporated by reference herein in its entirety. In an embodiment, the outer element 110 of the building surface panel 100 may have a decorative outer element, as disclosed in US Patent Publication No. 2024/0218670, incorporated by reference herein in its entirety.

It will be further appreciated that the backing component 120 of the building surface panel 100 may have any desirable shape. According to certain embodiments, and as shown in FIG. 1, the backing component 120 may have a rectangular or flat face shape. According to other embodiments, the backing component 120 may have a cylindrical or curved face shape.

According to certain embodiments, the shape of the outer element 110 will match the shape of the backing component 120. According to yet other embodiments, the shape of the outer element 110 will be different than the shape of the backing component 120. It will be appreciated that when the shape of the outer element 110 does not match the shape of the backing component 120, the backing component 120 may not completely contact the outer element 110 when attached. For example, portions of the backing component 120 may contact the outer element 110 when attached, but other portions of the backing component 120 may not contact the outer element, leaving voids between the two components.

According to certain embodiments, the outer element 110 of the building surface panel 100 may have any desirable profile. For example, the outer element 110 may have a flat profile. According to still other embodiments, the outer element 110 may have a contoured profile.

According to certain embodiments, the backing component 120 of the building surface panel 100 may have any desirable profile. For example, the backing component 120 may have a flat profile. According to still other embodiments, the backing component 120 may have a contoured profile.

According to certain embodiments, the backing component 120 may have a particular profile that matches the profile of the outer element 110. For example, the backing component 120 may have a flat profile that matches a flat profile of the outer element 110. According to still other embodiments, the backing component 120 may have a contoured profile that matches a contoured profile of the outer element 110.

According to still other embodiments, the backing component 120 may have a particular profile that does not match the profile of the outer element 110. It will be appreciated that when the profile of the outer element 110 does not match the profile of the backing component 120, the backing component 120 may not completely contact the outer element 110 when attached. For example, portions of the backing component 120 may contact the outer element 110 when attached, but other portions of the backing component 120 may not contact the outer element, leaving voids between the two components.

According to still other embodiments, the building surface panel 100 may be a siding panel and includes a fastener hem, an upper lock, a panel body, and a lower lock. As used herein, the term “tongue” is used interchangeably with lock or upper lock and the term “groove” is used interchangeably with butt leg, locking leg or lower leg. In an embodiment, the backing component 120 comprises a groove, and wherein the groove is configured to receive a tongue of another building surface panel. In an embodiment, the outer element comprises a tongue that is proximate the fastener hem, and wherein the tongue is configured to engage a groove of another building surface panel. In an embodiment, outer element 110 comprises the tongue and the backing component comprises the groove. In other embodiments, the backing component 120 comprises both the tongue and the groove.

According to yet another embodiment, a method of manufacturing a building surface panel may include providing an outer element 110 having a front side 112 and a rear side 114, and attaching a backing component 120 to the rear side 114 of the outer element 110. It will be appreciated that the building surface panel, the outer element, and the backing component described in reference to the method may have any of the characteristics or properties described in reference to the building surface panel 100, the outer element 110 or the backing component 120 described.

FIG. 3 is a representative perspective view of a portion of a building 30 covered by building surface panels 100 (e.g., building surface panels 100a, 100b, 100c, 100d) attached to a building surface 32 (or underlying support structure), in accordance with certain embodiments. The building surface panel 100 (e.g., building surface panel 100a) can have a longitudinal length L and a height H. The building surface panels 100 are shown as having a flat face profile, but the profile of the building surface panels 100 can be any of the profiles or shapes described herein. Although, FIGS. 4-11 illustrates some embodiments of the invention, the profiles are not limiting, and the invention is applicable to various profiles known in the art (not shown here), including those described in U.S. Pat. No. 11,920,356 and US Patent Publication No. 20240218670, incorporated by reference herein in their entirety.

FIG. 4A is a representative full view of a building surface panel 100 formed as a unitary body 106 with an outer element 110 and a backing component 120 formed together, prior to folding, in accordance with certain embodiments. The lower portion of the unitary body 106 can be seen as the outer element 110 with a front side 112, a rear side 114 (not shown, see FIG. 4B), a left side 132, a right side 134, and a bottom flange 138. When the building surface panel 100 is formed with a reinforced outer element 110 and attached to the building surface 32, the front side 112 of the outer element 110 can provide an aesthetic appearance, while covering a portion of the building surface 32, as shown in FIG. 3.

A tongue 130 can be formed at the top of the outer element 110 portion as well as a plurality of openings 118. The tongue 130 of one building surface panel 100 can be used to engage a groove 140 of another building surface panel 100, when multiple building surface panels 100 are attached to the building surface 32. The openings 118 can be used to receive fasteners when attaching the building surface panel 100 to a building surface 32.

The groove 140 can be formed at the top of the unitary body 106, which can be positioned at the bottom of the building surface panel 100 when the unitary body 106 is folded into a configuration where the backing component 120 is positioned behind the outer element 110 and attached to the rear side 114 of the outer element 110. The upper portion of the unitary body 106 can be seen as the backing component 120 portion with a front side 122 (not shown, see FIG. 4B), a rear side 124, a left side 102, a right side 104, and a groove 140. The groove 140 can be formed to mate and interlock with the tongue 130 of an adjacent building surface panel 100.

Openings 128 can be formed in the backing component 120 portion near the folding feature 150, such that when the unitary body 106 is folded into a configuration where the backing component 120 is positioned behind the outer element 110, the openings 128 can align with the openings 118, such that fasteners can be received in the aligned openings 118, 128. However, it is not a requirement to have the openings 128. The openings 118 can provide guidance for installation of fasteners, without having corresponding openings 128 in the backing component. The backing component 120 portion can include one or more longitudinally extending reinforcement elements, such as one or more longitudinally extending protrusions or longitudinally extending ribs 126 for enhanced, strength, rigidity, or stability of the building surface panel 100. The ribs 126 can be formed longitudinally along the backing component 120, and at a height that provides increased rigidity, strength, or stability while not interfering with attachment of the building surface panel 100 to a building surface 32.

A plurality of relief holes 136 can be provided in the backing component 120 portion to reduce weight of the building surface panel 100 while still providing sufficient rigidity and strength to the building surface panel 100. Any of the backing component 120 embodiments can include relief holes 136, which can preferably be located outside of the reinforcement elements 126. Foam generally used in foam backed siding can have a density that is much lower than a density of the outer element of the foam backed siding. For example, a density of a foam used in foam back siding can generally range from 0.015 grams/cm³ up to 0.032 grams/cm³, wherein material used to form the backing component 120 of this disclosure can range from 0.40 grams/cm³ up to 2.0 grams/cm³.

The density of either the outer element 110 or the backing component 120 of the building surface panels 100 can have a density that is greater than about 0.40 grams/cm³, or greater than about 0.50 grams/cm³, or greater than about 0.60 grams/cm³, or greater than about 0.70 grams/cm³, greater than about 0.80 grams/cm³, or greater than about 0.85 grams/cm³, or greater than about 0.90 grams/cm³, or greater than about 0.95 grams/cm³, or greater than about 1.00 grams/cm³, or greater than about 1.10 grams/cm³, or greater than about 1.20 grams/cm³, or greater than about 1.30 grams/cm³, or greater than about 1.40 grams/cm³, or greater than about 1.50 grams/cm³, or greater than about 1.55 grams/cm³, or greater than about 1.75 grams/cm³, or greater than about 1.85 grams/cm³, or greater than about 1.95 grams/cm³.

The density of either the outer element 110 or the backing component 120 of the building surface panels 100 can have a density that is less than about 2.00 grams/cm³, or less than about 1.95 grams/cm³, or less than about 1.90 grams/cm³, or less than about 1.85 grams/cm³, or less than about 1.80 grams/cm³, or less than about 1.75 grams/cm³, or less than about 1.70 grams/cm³, or less than about 1.60 grams/cm³, or less than about 1.50 grams/cm³, or less than about 1.40 grams/cm³, or less than about 1.30 grams/cm³. It will be appreciated that the density of the building surface panel 100 may be between any of the values noted above. It will be further appreciated that the density of the building surface panel 100 may be any value between any of the values noted above.

Providing relief holes 136 in the backing component 120 of the building surface panel 100 of this disclosure can provide significant weight reduction, while maintaining sufficient structural stability of the backing component 120. Additionally, the thickness of the backing component 120 can be adjusted to improve structural stability without significantly impacting the overall size of the building surface panel 100.

However, it is not required to have relief holes 136 in the backing component 120. A folding feature 150 can be formed in the unitary body 106 to enable folding of the backing component 120 to engage a rear side 114 of the outer element 110. The folding feature 150 can form a longitudinal peak in the unitary body 106 which can allow for deformation of the peak while allowing for alignment of the openings 118, 128 when the unitary body 106 is folded to form the building surface panel 100.

The folding feature 150 can also include holes 146 that can further assist in allowing the unitary body 106 to be folded about the axis 90. Additionally, or alternatively, the folding feature 150 can include a thinner or more pliable material to assist in folding the unitary body 106 along the folding feature 150. Additionally, or alternatively, the folding feature 150 can include a separate material than the outer element 110 or the backing component 120, with this separate material being a more resilient material than either the outer element 110 or the backing component 120, thereby minimizing forces needed to fold the unitary body 106 along the folding feature 150.

Since the building surface panels 100 can be assembled onto a building surface 32 with horizontally adjacent building surface panels 100 butted together, it can be desirable that the right side 134 of one building surface panel 100 overlaps the left side 132 of an adjacent building surface panel 100 to further protect the building surface 32 from environmental conditions. Therefore, to allow for this overlap, the tongue 130 and the backing component 120 portion can be cut-back from the left and right sides 132, 134 of the outer element 110 by a distance L1 to form a cutback 116 in the unitary body 106. It should be understood that the cutback 116 can be desirable, but is not required.

FIG. 4B is a representative perspective view of a building surface panel 100 formed as a unitary body 106 with an outer element 110 and a backing component 120 formed together, in accordance with certain embodiments. After being formed as the unitary body 106, the backing component 120 portion can be rotated or folded (arrows 92) about the axis 90 relative to the outer element 110 portion, such that the front side 122 of the backing component 120 engages with the rear side 114 of the outer element 110. The outer element 110 can be attached to the backing component 120 through a particular means as described above. When the outer element 110 is attached to the backing component 120, the folded unitary body 106 can form the building surface panel 100, which includes the tongue 130 formed along the top of the building surface panel 100 and a groove 140 formed at the bottom of the building surface panel 100, as shown in FIG. 4C. The bottom flange 138 can be positioned just below the groove 140 for aesthetic purposes.

FIG. 5A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. The unitary body 106 has been folded at the folding feature 150 to engage the backing component 120 with the outer element 110. The openings 118 can be aligned with the openings 128 to form a fastener hem 170, which can receive fasteners when attaching the building surface panel 100 to a building surface 32 via fasteners (e.g., fasteners 34 shown in FIG. 6B). The tongue 130 can extend along the outer element 110, with the cutbacks 116 at each end. The front side 112 of the outer element 110 is shown as an angled flat face profile. However, the front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein. The one or more reinforcement elements such as ribs 126 can extend longitudinally along the backing component 120 to provide reinforcement and rigidity to the outer element 110 when the backing component 120 is attached to the outer element 110.

FIG. 5B is a representative partial cross-sectional view 5B-5B, as indicated in FIG. 5A, of a building surface panel 100, in accordance with certain embodiments. The unitary body 106 has been folded at the folding feature 150 and the backing component 120 has been attached by a particular means to the rear side 114 of the outer element 110. The outer element 110 can provide a flat-face appearance that is angled relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. When the openings 118 align with the openings 128, the building surface panel 100 can form a fastener hem 170 that is a double thickness of the material used to form that unitary body 106. The tongue 130 can be formed just below the fastener hem 170 and configured to complimentarily mate with a groove 140 of an adjacent building surface panel 100. The bottom flange 138 can be formed to overlay the groove 140 to provide a more aesthetic look when the building surface panels 100 are installed on a building surface 32.

FIG. 5C is a representative detail view of the detail region 5C, as indicated in FIG. 5B, of a building surface panel 100, in accordance with certain embodiments. The front side 112 of the outer element 110 can provide an aesthetic look for the building surface panel 100. The front side 122 of the backing component 120 can be attached to the rear side 114 of the outer element 110. An adhesive or adhesive layer 144 can be used to attach the backing component 120 to the outer element 110. The rear side 124 of the backing component 120 faces the building surface 32 when the building surface panel 100 is installed on the building surface 32. The groove 140 can form a longitudinal channel 142 into which a tongue 130 of an adjacent building surface panel 100 can be received.

The bottom of the longitudinal channel 142 can be inclined relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. A plurality of weep holes 162 can be formed through the groove 140 to allow any trapped fluid to drain away from the longitudinal channel 142. The bottom flange 138 can also be inclined relative to the building surface 32 when the building surface panel 100 is installed on the building surface 32. The incline of the bottom flange 138 preferably matches the incline of the bottom of the longitudinal channel 142 but is not required to do so. A plurality of weep holes 160 can be formed through the bottom flange 138 to allow any trapped fluid to drain away from the bottom flange 138 to an external environment (e.g., a front side 112 of an adjacent building surface panel positioned below the current building surface panel 100), where the fluid can be evaporated or otherwise managed to prevent fluid from being trapped in the building surface panel 100.

FIG. 6A is a representative perspective view of multiple building surface panels 100 with a reinforced outer element 110 assembled together, in accordance with certain embodiments. The building surface panels 100 can be assembled on the building surface 32 horizontally aligned with other building surface panels 100 (e.g., building surface panels 100b, 100c, with the right side of the building surface panel 100b overlapping the left side of the building surface panel 100c). The cutback 116 can allow the right side of one building surface panel 100 to overlap the left side of an adjacent building surface panel 100 up to a distance that can be substantially equal to the distance L1.

FIG. 6B is a representative partial cross-sectional view 6B-6B, as indicated in FIG. 6A, of multiple building surface panels 100 assembled together on a building surface 32, in accordance with certain embodiments. The building surface panels 100 can be assembled on the building surface 32 vertically aligned with each other. For example, when assembled vertically, the upper building surface panel 100a can be positioned across an overlap of lower building surface panels 100b, 100c (see FIG. 6A). The groove 140 of the upper building surface panel 100a can engage a portion of the tongue 130′ of each of the building surface panels 100b, 100c. When the building surface panel 100a is engaged with the tongues 130′ and when fasteners 34 attach the fastener hem 170 of the building surface panel 100a to the building surface 32, then the engagement of the tongues 130′ of the building surface panels 100b, 100c with the groove 140 of the building surface panel 100a will secure the building surface panel 100a to the building surface 32, since the tongues 130′ are secured to the building surface 32 via the fasteners 34′.

The bottom flange 138 overlays the groove 140, which receives the tongue 130′. The building surface panel 100b can include the outer element 110′ and the backing component 120′ attached to the rear side of the building surface panel 100b. In a non-limiting embodiment, the building surface panels 100 assembled on the building surface 32 can form a surface (which can include the front sides 112, 112′) that covers the building surface 32 and forms a shiplap type look. It should be understood that many other finished surfaces are possible with this reinforced building surface panel 100.

Referring to FIGS. 7A-7B, FIG. 7A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 7B is a representative partial cross-sectional view 7B-7B, as indicated in FIG. 7A, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. Where the previously described building surface panel 100 forms a shiplap type look, the building surface panel 100 of FIGS. 7A-7B forms a beveled edge look, where there is an angled groove formed between adjacent building surface panels 100, with a flat-face surface between angled grooves. The beveled edge building surface panels 100 can form a flat-face with longitudinal V-shaped grooves evenly spaced apart in a vertical direction. The building surface panels 100 can also form other aesthetic looks such as clapboard, dutchlap, board & batten, tongue & groove.

It should be understood that the building surface panels 100 can be assembled on the building surface 32 in any orientation from horizontal to vertical. They are not limited to a horizontal orientation indicated in the figures. The building surface panel 100 is formed from a unitary body 106 folded at the folding feature 150 to engage the backing component 120 with the outer element 110, as discussed above. However, the shape of the outer element 110 and the backing component 120 are different than the shiplap type building surface panels 100. The folded unitary body 106 still forms the fastener hem 170 with the openings 118, 128 being aligned. The tongue 130 can be similar to the previous embodiments, such that it is formed to engage with a groove 140 of an adjacent building surface panel 100.

The front side 112 of the outer element 110 can form a flat face surface that can be substantially parallel with a building surface 32 when the building surface panel 100 is attached to the building surface 32. At the top of the front side 112 can be an angled portion 158, that is inclined from an upper portion of the building surface panel 100 to the front side 112. At the bottom of the front side 112, the bottom flange 138 can be formed as an angled portion that can engage (or at least be positioned proximate) an angled portion 158′ of an adjacent building surface panel 100b positioned below the current building surface panel 100a (see FIG. 8B).

The backing component 120 can include a complimentarily shaped angled portion 168 that can engage the angled portion 158 when the backing component 120 is attached to the outer element 110. The backing component 120 can also include one or more ribs 126 that provide additional stability for the backing component 120 and thus for the outer element 110, when the backing component 120 is attached to the outer element 110. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein. The front side 112 can also include one or more longitudinal recesses of various shapes, e.g., V-shaped, circularly shaped, rectangularly shaped, curve shaped, etc.

Referring to FIGS. 8A-8B, FIG. 8A is a representative perspective view of multiple building surface panels 100 with a reinforced outer element 110 assembled together, in accordance with certain embodiments. FIG. 8B is a representative partial cross-sectional view 8B-8B, as indicated in FIG. 8A, of multiple building surface panels 100 assembled together on a building surface 32, in accordance with certain embodiments.

As can be seen, the edge of the groove 140 of the upper building surface panel 100a can be received into the tongue 130′ of the lower building surface panel 100b. This can securely couple the groove 140 of the upper building surface panel 100a to the building surface 32 via the fasteners 34′ that can be used to secure the fastener hem 170 of the lower building surface panel 100b to the building surface 32. Fasteners 34 can be used to securely couple the fastener hem 170 of the upper building surface panel 100a to the building surface 32 in preparation for installing another building surface panel 100 above the upper building surface panel 100a. The lower building surface panel 100b can include an outer element 110′ with an angled portion 158′ and a bottom flange 138′, and a backing component 120′ with an angled portion 168′ and a groove 140′.

Referring to FIGS. 9A-9B, FIG. 9A is a representative perspective view of a unitary body 106 formed with an outer element 110 and a backing component 120, with the backing component 120 folded to engage the outer element 110 to form a building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 9B is a representative partial cross-sectional view 9B-9B, as indicated in FIG. 9A, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments.

The building surface panel 100 is similar to the building surface panel 100 shown in FIGS. 7A-8B, except that this building surface panel 100 can have one or more additional longitudinal recesses formed in the front side 112 of the building surface panel 100. The building surface panel 100 of FIGS. 9A-9B forms a beveled edge look with a center longitudinal recess 117, where there is an angled groove formed between adjacent building surface panels 100, with a flat-face surface between angled grooves, and with one or more longitudinal recesses 117 being formed in the front side 112.

The beveled edge building surface panels 100 can form a flat-face with longitudinal V-shaped grooves evenly spaced apart in a vertical direction as well as the one or more longitudinal recesses 117 positioned between the V-shaped grooves. It should be understood that the one or more longitudinal recesses 117 can also be V-shaped as well as many other shapes.

It should be understood that the building surface panels 100 can be assembled on the building surface 32 in any orientation from horizontal to vertical. They are not limited to a horizontal orientation indicated in the figures. The building surface panel 100 is formed from a unitary body 106 folded at the folding feature 150 to engage the backing component 120 with the outer element 110, as discussed above. However, the shape of the outer element 110 and the backing component 120 are different than the shiplap type building surface panels 100. The folded unitary body 106 still forms the fastener hem 170 with the openings 118, 128 being aligned. The tongue 130 can be very similar to the previous embodiments, such that it is formed to engage with a groove 140 of an adjacent building surface panel 100.

The front side 112 of the outer element 110 can form a flat face surface that can be substantially parallel with a building surface 32 when the building surface panel 100 is attached to the building surface 32. At the top of the front side 112 can be an angled portion 158, that is inclined from an upper portion of the building surface panel 100 to the front side 112. At the bottom of the front side 112, the bottom flange 138 can be formed as an angled portion that can engage (or at least be positioned proximate) an angled portion 158 of an adjacent building surface panel 100 positioned below the current building surface panel 100. The front side 112 can include the one or more longitudinal recesses 117.

The backing component 120 can include a complimentarily shaped angled portion 168 that can engage the angled portion 158 when the backing component 120 is attached to the outer element 110. The backing component 120 can also include one or more ribs 126 that provide additional stability for the backing component 120 and thus for the outer element 110, when the backing component 120 is attached to the outer element 110. The backing component 120 can also include a complimentarily shaped one or more longitudinal recess 127 that can engage respective ones of the one or more longitudinal recess 117 when the backing component 120 is attached to the outer element 110.

It should be understood that many other shapes of a building surface panel 100 are envisioned that utilize the novel approach of forming a building surface panel 100 by forming a unitary body 106 and then folding the backing component 120 to engage the outer element 110. However, a novel building surface panel 100 can also be formed from two separately formed portions that are attached together to form the building surface panel 100.

Referring to FIGS. 10A-10D, FIG. 10A is a representative perspective view of an outer element 110 of a building surface panel 100, and FIG. 10B is a representative perspective view of a backing component 120 of the building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 10C is a representative perspective view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. FIG. 10D is a representative partial cross-sectional view 10D-10D, as indicated in FIG. 10C, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments.

The outer element 110 shown in FIG. 10A can include the front side 112, that forms a flat face, and a bottom flange 138 angled back and configured to cover the groove 140 of the backing component 120 when the outer element 110 is attached to the backing component 120 to form the building surface panel 100. The outer element 110 can include a left side 132, a right side 134, and a top side 152. The length L2 can represent a distance from the left side 132 to the right side 134 of the outer element 110. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein.

The backing component 120 can be formed as a unitary body 108 with an upper portion containing the tongue 130 and the openings 118 with the upper portion being folded relative to the lower portion at the folding feature 150. This aligns the openings 118 with the openings 128 to form a double-thickness fastener hem 170 at the top of the building surface panel 100. The backing component 120 can include one or more ribs 126 that can provide reinforcement for the building surface panel 100 when the backing component 120 is attached to the outer element 110. The interaction of the tongue 130 with the groove 140 can be different than the previously described embodiments. The tongue 130 can be formed to provide a restricted clearance between the tongue and the body of the backing component 120. The groove 140 can include a bump feature that can be forced past the restricted clearance of the tongue 130 and held within the tongue 130 when an upper building surface panel 100 is engaged with the current building surface panel 100.

The length L3 can represent a distance from the left side 102 to the right side 104 of the backing component 120. It can be preferrable that the length L2 of the outer element 110 is larger than the length L3 of the backing component 120. This allows the top side 152 of the outer element 110 to form a cutback 116 of the building surface panel 100 (see FIG. 10C) formed when the backing component 120 is attached to the outer element 110. Because the backing component 120 is formed as a unitary body 106, alignment of the openings 118 with the openings 128 is built into the unitary body 106 so when the top portion if folded at the folding feature 150, the openings 118, 128 are aligned. Alignment of the outer element 110 with the backing component 120 can have loose tolerances, since precise alignment is not needed.

Referring to FIGS. 11A-11D, FIG. 11A is a representative perspective view of an outer element 110 of a building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 11B is a representative perspective view of a backing component 120 of a building surface panel 100, which is formed from a two-piece construction, in accordance with certain embodiments. FIG. 11C is a representative perspective view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments. FIG. 11D is a representative partial cross-sectional view 11D-11D, as indicated in FIG. 11C, of the building surface panel 100 with a reinforced outer element 110, in accordance with certain embodiments. FIG. 11E is a representative perspective rear view of a building surface panel 100 formed from a two-piece construction by attaching the backing component 120 to the outer element 110, in accordance with certain embodiments.

The outer element 110 shown in FIG. 11A can include the front side 112, that forms a flat face, and a bottom flange 138 angled back and configured to cover the groove 140 of the backing component 120 when the outer element 110 is attached to the backing component 120 to form the building surface panel 100. The outer element 110 can include a left side 132, a right side 134, and a top side 152. An upper portion of the outer element 110 can include a tongue 130 and openings 118. In this non-limiting embodiment, the fastener hem 170 can be a single thickness and includes openings 118 for receiving fasteners 34 to attach the building surface panel 100 to a building surface 32. The front side 112 can be other shapes as desired, such as a curved face. The front side 112 can be any of the profiles or shapes described herein.

The backing component 120 can include one or more ribs 126 that can provide reinforcement for the building surface panel 100 when the backing component 120 is attached to the outer element 110. The backing component 120 can include a left side 102, a right side 104, and a top side 154. The tongue 130 can be formed with the outer element 110 to provide a restricted clearance between the tongue and the body of the backing component 120. The groove 140 can be formed with the backing component 120 and can include a bump feature that can be forced past the restricted clearance of the tongue 130 and held by the tongue 130 when an upper building surface panel 100 is engaged with the current building surface panel 100.

The outer element 110 can have cutbacks 116 on the left side 132 and the right side 134 proximate the tongue 130. The width LA can represent a distance from the left side 132 to the right side 134 of the outer element 110. The width L5 can represent a distance from the left side 102 to the right side 104 of the backing component 120. It can be preferrable that the width LA of the outer element 110 is larger than the width L5 of the backing component 120. The width L5 can be substantially equal to the width L7 of the fastener hem 170 and tongue 130.

When the backing component 120 is attached to the rear side 114 of the outer element 110, the backing component 120 can be aligned with the fastener hem 170 and the tongue 130 of the outer element 110, such that a distance approximately equal to the distance L1 of the cutback 116 can be provided between the left and right sides 132, 134 of the outer element 110 and the left and right sides 102, 104 of the backing component 120. As described previously, the cutback 116 allows overlap of the left and right sides of horizontally adjacent building surface panels 100 when installed onto the building surface 32.

Since features on either of the outer element 110 or the backing component 120 do not require precise alignment when they are being attached together, alignment of the outer element 110 with the backing component 120 can have loose tolerances.

The width L7 of the fastener hem 170 and tongue 130 can be substantially equal to the width L5 of the backing component 120, such that a cutback 116 can be formed on both sides of the building surface panel 100, such that the tongue 130 and the groove 140 are setback by a distance L6 (which can be substantially equal to distance L1) from both sides 132, 134 of the outer element 110 (or outer element 110) to allow overlapping the left and right sides 132, 134 of horizontally adjacent building surface panels 100.

FIGS. 12A-12D are representative partial cross-sectional views 12-12, as indicated in FIG. 11E, of reinforcement elements 126 of a backing component 120 to reinforce an outer element 110 of a building surface panel 100, in accordance with certain embodiments. The reinforcement elements 126 can extend longitudinally along the backing component as seen in FIG. 11E. However, it should be understood that the reinforcement elements 126 can extend longitudinally along the backing component 120 and can be substantially in parallel with the top side 152 of the outer element 110 or the top side 154 of the backing component 120. It should also be understood that the reinforcement elements 126 can extend longitudinally along the backing component 120 and can be angled relative to the top side 152 of the outer element 110 (or outer element) or the top side 154 of the backing component 120.

It should also be understood that the reinforcement elements 126 can extend axially across the backing component 120 and can be generally perpendicular to the top side 152 of the outer element 110 (or outer element) or the top side 154 of the backing component 120. In some embodiments, the reinforcement elements 126 comprises multiple reinforcement elements, such as ribs, arranged in a staggered manner to each other, each extending longitudinally such that each rib does not extend all the way along the backing component (not shown). In yet another embodiment, the backing component 120 comprises reinforcement elements that are embossed into the backing component 120, forming a plurality of dimples and/or protrusions, where the dimples bend inwards towards the rear side 114 of the outer element and may or may not be in contact with the outer element.

The reinforcement elements 126 can be seen as ribs 126 as shown in FIGS. 11E and 12A where the reinforcement element 126 is generally the same thickness as the other portions of the backing component but form a profile that protrudes from the rear side 124 and is spaced away from the front side 122. The reinforcement element 126 can form a hollow portion bounded by the outer element 110 and the reinforcement element 126. The profile of the reinforcement element 126 can provide increased rigidity for the backing component 120 and for the outer element 110 when it is attached to the backing component 120. A particular profile is shown for the reinforcement element 126 in FIG. 12A, but it should be understood that any other suitable profile can be used to provide increased rigidity to the building surface panel 100 when the backing component 120 is attached to the outer element 110 (or outer element 110). In an embodiment, the reinforcement element 126 is narrow, such that there is substantially no space in between the two side walls of the reinforcement element 126. The height and width of each reinforcing element 126 can be tailored to provide desired rigidity for a particular building panel having a particular profile of the outer element 110.

Alternatively, or in addition to, the reinforcement element 126 can be a separate piece that is adhered to the rear side 124 of the backing component 120 to provide increased rigidity to the building surface panel 100 or the reinforcement elements 126 can be formed with the backing component 120. FIGS. 12B-12D illustrate various cross-sectional shapes of elongated reinforcement elements 126 that can be adhered to the rear side 124 of (or formed with) the backing component 120. In these non-limiting embodiments, the backing component 120 can be formed without a reinforcement profile and a separate reinforcement element 126 can be adhered to the backing component 120. Also, the reinforcement element 126 can be formed with the backing component 120 and can have any suitable profile or cross-section shape.

FIG. 12B shows a reinforcement element 126 having a rectangular cross-section, where the thickness and width of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100. FIG. 12C shows a reinforcement element 126 having a triangular cross-section, where the legs of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100. FIG. 12D shows a reinforcement element 126 having a C-shaped cross-section, where the thickness and width of the reinforcement element 126 can be varied to adjust rigidity of the building surface panel 100.

It should be understood that any of the reinforcement elements 126 (e.g., ribs 126) described in this disclosure can be used for any of the embodiments of the reinforcement elements 126 (e.g., ribs 126) disclosed herein.

The impact resistance of the building surface panel 100 can be measured according to ASTM D 4226 and can be greater than 60 mean failure energy (MFE) in-lbs. (6.78 Nm), or greater than 70 MFE in-lbs. (7.91 Nm), or greater than 80 MFE in-lbs. (9.04 Nm), or greater than 90 MFE in-lbs. (10.17 Nm), or greater than 100 MFE in-lbs. (11.30 Nm), or greater than 110 MFE in-lbs. (12.43 Nm), or greater than 120 MFE in-lbs. (13.56 Nm), or greater than 130 MFE in-lbs. (14.69 Nm), or greater than 140 MFE in-lbs. (15.82 Nm), or greater than 150 MFE in-lbs. (16.95 Nm), or greater than 155 MFE in-lbs. (17.5 Nm), or greater than 160 MFE in-lbs. (18.08 Nm), or greater than 165 MFE in-lbs. (18.64 Nm), or greater than 170 MFE in-lbs. (19.21 Nm), or greater than 175 MFE in-lbs. (19.77 Nm). The damage impact of the building surface panel 100 can be less than 190 MFE in-lbs. (21.47 Nm), or less than 185 MFE in-lbs. (20.90 Nm), or less than 180 MFE in-lbs. (20.34 Nm), or less than 175 MFE in-lbs. (19.77 Nm), or less than 170 MFE in-lbs. (19.21 Nm), or less than 165 MFE in-lbs. (18.64 Nm). It will be appreciated that the damage impact of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the damage impact of the building surface panel 100 may be any value between any of the values noted above.

The standard static test pressure rating of the building surface panel 100 can be measured according to testing requirements given in the ASTM D7445, which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding with Foam Plastic backing (Backed Vinyl Siding). The building surface panel 100 according to various embodiments of the present inventions are able to withstand a sustained static pressure of greater than 22.5 pounds per square foot (1.077 kPa), or greater than 25 pounds per square foot (1.20 kPa), or greater than 30 pounds per square foot (1.44 kPa), or greater than 35 pounds per square foot (1.68 kPa), or greater than 40 pounds per square foot (1.92 kPa), or greater than 45 pounds per square foot (2.16 kPa), or greater than 50 pounds per square foot (2.39 kPa), or greater than 55 pounds per square foot (2.63 kPa), or greater than 60 pounds per square foot (2.87 kPa), or greater than 64 pounds per square foot (3.06 kPa), or greater than 70 pounds per square foot (3.35 kPa), or greater than 75 pounds per square foot (3.59 kPa), or greater than 80 pounds per square foot (3.83 kPa), or greater than 85 pounds per square foot (4.07 kPa), or greater than 90 pounds per square foot (4.31 kPa), or greater than 95 pounds per square foot (4.55 kPa), or greater than 100 pounds per square foot (4.79 kPa). The standard design wind pressure rating of the building surface panel 100 can be less than 115 pounds per square foot (5.51 kPa), or less than 110 pounds per square foot (5.27 kPa), or less than 105 pounds per square foot (5.03 kPa), or less than 100 pounds per square foot (4.79 kPa), or less than 95 pounds per square foot (4.55 kPa), or less than 90 pounds per square foot (4.31 kPa). It will be appreciated that the standard design sustained static pressure rating of the building surface panel 100 may be within a range between any of the values noted above. It will be further appreciated that the standard design wind pressure rating of the building surface panel 100 may be any value between any of the values noted above.

While there may be other backing systems for building surface panels that are known to have a backing component coupled to an outer element in a non-permanent manner, these are not necessarily subject to the same design constraints and issues when you fixedly or permanently attach the outer element to the backing component, such as problems (e.g., bulking, oil canning, etc.) that can occur due to CTE mismatches between the outer element and the backing component.

It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.

VARIOUS EMBODIMENTS

Embodiment 1. A building surface panel comprising:

• • an outer element having a first front side, and a first rear side; and
  • a backing component having a second front side and a second rear side, wherein the second front side is attached to the first rear side of the outer element,
  • wherein the building surface panel further comprises at least one of:
  • a room temperature coefficient of thermal expansion (CTE) mismatch between the outer element and the backing component of not greater than about 20%,
  • a deflection measurement of not greater than about 10 mm if subjected to a curvature test at least 90 days after formation of the building surface panel,
  • a first thickness of the backing component being 0.5 to 5.0 times a second thickness of the outer element,
  • a density of the backing component being at least 0.4 grams/cm³ but not greater than 2.0 grams/cm³, and
  • a combination thereof.

Embodiment 2. The building surface panel of embodiment 1, wherein the outer element and/or the backing component comprise polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof.

Embodiment 3. The building surface panel of embodiment 1, further comprising an adhesive layer between the outer element and the backing component, wherein the adhesive layer comprises a polyvinyl chloride (PVC) adhesive, an acrylic adhesive, a modified acrylic adhesive, a silicone adhesive, a one or two-component polyurethane adhesive, heat or moisture cured adhesive of these materials thereof, or any tape form of these materials thereof.

Embodiment 4. The building surface panel of embodiment 1, wherein the outer element and the backing component form a unitary body further comprising a folding feature that joins the outer element to the backing component.

Embodiment 5. The building surface panel of embodiment 4, wherein the unitary body is folded along the folding feature to engage the outer element with the backing component to form the building surface panel.

Embodiment 6. The building surface panel of embodiment 4, wherein the backing component comprises one or more longitudinally extending reinforcement elements.

Embodiment 7. The building surface panel of embodiment 6, wherein the one or more reinforcement elements comprise one or more longitudinally extending protrusions, longitudinally extending ribs, longitudinal corrugation, honeycomb pattern, embossed features, or an elongated piece, and wherein the one or more reinforcement elements protrude from the second rear side.

Embodiment 8. The building surface panel of embodiment 6, wherein the one or more reinforcement elements comprise an increased thickness of the backing component along a longitudinal portion of the backing component.

Embodiment 9. The building surface panel of embodiment 6, wherein the one or more reinforcement elements comprise an elongated piece that is adhered to the second rear side of the backing component.

Embodiment 10. The building surface panel of embodiment 4, wherein the backing component further comprises a groove, and wherein the groove is configured to receive a tongue of another building surface panel.

Embodiment 11. The building surface panel of embodiment 10, wherein the outer element comprises a bottom flange, and wherein the groove engages the bottom flange.

Embodiment 12. The building surface panel of embodiment 4, wherein the outer element comprises a tongue that is proximate a fastener hem, and wherein the tongue is configured to engage a groove of another building surface panel.

Embodiment 13. The building surface panel of embodiment 1, wherein the outer element forms a first unitary body, wherein the backing component forms a second unitary body with a groove at a bottom of the backing component, and wherein the outer element is attached to the backing component to form the building surface panel.

Embodiment 14. The building surface panel of embodiment 13, wherein the outer element comprises a bottom flange, and wherein the bottom flange engages the groove.

Embodiment 15. The building surface panel of embodiment 13, wherein the outer element or the backing component comprises a tongue that is configured to engage a second groove of another building surface panel.

Embodiment 16. The building surface panel of embodiment 13, wherein the outer element or the backing component comprises a fastener hem that is configured to receive fasteners that secure the fastener hem to a building surface.

Embodiment 17. The building surface panel of embodiment 13, wherein the backing component comprises one or more longitudinally extending reinforcement elements.

Embodiment 18. The building surface panel of embodiment 17, wherein the one or more reinforcement elements comprise one or more longitudinally extending protrusions or longitudinally extending ribs, and wherein the one or more reinforcement elements protrude from the second rear side.

Embodiment 19. The building surface panel of embodiment 17, wherein the one or more reinforcement elements comprise an increased thickness of the backing component along a longitudinal portion of the backing component.

Embodiment 20. The building surface panel of embodiment 17, wherein the one or more reinforcement elements comprise an elongated piece that is adhered to the second rear side of the backing component.

Embodiment 21. The building surface panel of embodiment 13, wherein the outer element is formed having a first width as measured from a first left side to a first right side of the outer element, and wherein the first width is wider than a second width of the backing component as measured from a second left side to a second right side of the backing component.

Embodiment 22. The building surface panel of embodiment 21, wherein the outer element extends past the second left side and the second right side of the backing component when the outer element is attached to the backing component to form the building surface panel.

Embodiment 23. The building surface panel of embodiment 1, wherein a bond shear strength, as measured between the outer element and the backing component, is at least 0.10 MPa.

Embodiment 24. The building surface panel of embodiment 1, wherein a damage impact of the building surface panel is greater than 150 MFE in-lbs. (16.95 Nm).

Embodiment 25. The building surface panel of embodiment 1, wherein a standard design wind pressure rating of the building surface panel exceeds 62 pounds per square foot (2969 Pa) as determined by testing requirements given in the American Society for Testing and Materials (ASTM) specification D3679, test procedure D5206 which specifies a standard test method for Rigid Polyvinyl Chloride (PVC) Siding.

Embodiment 26. A building surface panel comprising:

• • an outer element having a first front side and a first rear side; and
  • a backing component having a second front side and a second rear side, wherein the second front side of the backing component is attached to the first rear side of the outer element, wherein the backing component comprises one or more longitudinally extending reinforcement elements, and wherein the one or more reinforcement elements comprise a protrusion that protrudes from the second rear side.

Embodiment 27. The building surface panel of embodiment 26, wherein the one or more reinforcement elements comprise a longitudinally extending rib.

Embodiment 28. The building surface panel of embodiment 26, wherein the one or more reinforcement elements comprise an increased thickness of the backing component along a longitudinal portion of the backing component.

Embodiment 29. The building surface panel of embodiment 26, wherein the one or more reinforcement elements comprise an elongated piece that is attached to the second rear side of the backing component.

Embodiment 30. The building surface panel of embodiment 26, wherein the backing component comprises a groove along a bottom of the backing component which is configured to receive a tongue of another building surface panel.

Embodiment 31. The building surface panel of embodiment 30, wherein the outer element comprises a bottom flange which engages the groove when the outer element is attached to the backing component.

Embodiment 32. The building surface panel of embodiment 26, wherein the backing component comprises a fastener hem along a top of the backing component which is configured to receive fasteners that secure the building surface panel to a building surface.

Embodiment 33. The building surface panel of embodiment 26, wherein the backing component comprises a tongue proximate a top of the backing component which is configured to engage a groove of another building surface panel.

Embodiment 34. The building surface panel of embodiment 26, wherein the outer element and the backing component form a unitary body further comprising a folding feature that joins the outer element to the backing component.

Embodiment 35. The building surface panel of embodiment 26, wherein the outer element forms a first unitary body, wherein the backing component forms a second unitary body, and wherein the outer element is attached to the backing component to form the building surface panel.

Embodiment 36. A building surface panel comprising:

• • an outer element having a first front side, a first rear side, and a first thickness as measured between the first front side and the first rear side; and
  • a backing component having a second front side, a second rear side, and a second thickness as measured between the second front side and the second rear side, wherein the second front side of the backing component is attached to the first rear side of the outer element, wherein the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

Embodiment 37. A building surface panel comprising:

• • an outer element having a first front side and a first rear side; and
  • a backing component having a second front side and a second rear side, wherein the second front side of the backing component is attached to the first rear side of the outer element, wherein the backing component comprises at least one of:
  • a longitudinally extending groove;
  • a longitudinally extending tongue;
  • a plurality of relief holes;
  • a density that is at least 0.4 grams/cm³ but not greater than 2.0 grams/cm³; and
  • recycled PVC.

Embodiment 38. The building surface panel of embodiment 37, wherein the backing component comprises at least 10% by weight of the recycled PVC.

Embodiment 39. The building surface panel of embodiment 38, wherein the recycled PVC comprises impurities that comprise at least one of an adhesive, a metal, different colored PVC, various other polymers, or combinations thereof.

Embodiment 40. The building surface panel of any one of embodiments 36 to 37, further comprising any of the features of any one of embodiments 1 to 35.

Embodiment 41. The building surface panel of any one of embodiments 1 to 36, wherein the backing component further comprises recycled PVC.

Embodiment 42. The building surface panel of embodiment 41, wherein the backing component comprises at least 10% by weight of the recycled PVC.

Embodiment 43. The building surface panel of embodiment 42, wherein the recycled PVC comprises minimal contents of impurities from at least one of an adhesive, a metal, different colored PVC, various other polymers, and combinations thereof.

Embodiment 44. The building surface panel of embodiment 43, wherein the impurities of the recycled PVC comprise less than 20% adhesive by weight, or less than 15% adhesive by weight, or less than 10% adhesive by weight; or less than 5% adhesive by weight.

Embodiment 45. The building surface panel of embodiment 44, wherein the adhesive has a shear modulus that is within a range from about 1 MPa to about 900 MPa.

Embodiment 46. The building surface panel of embodiment 45, wherein the adhesive remains flexible when cured.

Embodiment 47. The building surface panel of embodiment 45, wherein the adhesive is a low surface energy type adhesive.

Embodiment 48. The building surface panel of embodiment 43, wherein the impurities of the recycled PVC comprise less than 1% metal by weight.

Embodiment 49. The building surface panel of embodiment 43, wherein the impurities of the recycled PVC comprise less than 20% of the various other polymers by weight, or less than 15% of the various other polymers by weight, or less than 10% of the various other polymers by weight; or less than 5% of the various other polymers by weight.

Note that not all of the activities described above in the general description, or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.