Process for manufacturing insulated siding

Abstract

A siding panel assembly includes an ornamental facing and a first insulation layer made from fibrous insulating material. That fibrous insulating material is selected from glass fibers, polymer fibers, natural fibers and mixtures thereof having a compressive strength of between about 14 to about 220 pounds of force and a wet and dry recovery of at least 98%. A method for making the siding panel assembly includes the steps of molding a first surface of a sheet of fibrous insulating material to match in profile a concavity in an ornamental facing and engaging the molded sheet of fibrous insulating material in that concavity.

1 . A siding panel assembly, comprising: 
 an ornamental facing; and    a first insulation layer made from fibrous insulating material.    
   
   
       2 . The assembly of  claim 1 , wherein said fibrous insulating material is selected from a group of materials consisting of glass fibers, polymer fibers, natural fibers and mixtures thereof providing a compressive strength of between about 14 and about 220 pounds of force and a wet and dry recovery of at least 98%.  
   
   
       3 . The assembly of  claim 1 , wherein said fibrous insulating material is selected from a group of materials consisting of glass fibers, polyolefin fibers, polyester fibers, polypropylene fibers, polyethylene fibers, polyethylene terephthalate fibers, polybutylene terephthalate fibers cotton fibers, hemp fibers, jute fibers, kenaf fibers, rayon fibers, nylon fibers, acrylic fibers, copolyester fibers and mixtures thereof.  
   
   
       4 . The assembly of  claim 2 , wherein said first insulation layer is a nonwoven mat or veil.  
   
   
       5 . The assembly of  claim 4 , wherein said fibers in said mat or veil are continuous and have a diameter of between about 2.0 and about 60.0 microns.  
   
   
       6 . The assembly of  claim 4 , wherein said fibers in said mat or veil are chopped to a length of between about 0.635 to about 7.62 cm and have a diameter of between about 2.0 and about 60.0 microns.  
   
   
       7 . The assembly of  claim 1 , wherein said first insulation layer comprises by weight percent between about 10 to about 70% glass fibers and about 90 to about 30% polymer binder fibers.  
   
   
       8 . The assembly of  claim 7 , wherein said glass fibers have a length of between about 0.635 to about 7.62 cm and a diameter of between about 2.0 to about 25.0 microns and said polymer binder fibers have a length of between about 1.20 to about 7.62 cm and a diameter of between about 8.0 to about  60 . 0  microns.  
   
   
       9 . The assembly of  claim 1 , wherein said first insulation layer comprises 100% polyester fibers having a length of between about 1.20 to about 7.62 cm and a diameter of between about 8.0 to about 60.0 microns.  
   
   
       10 . The assembly of  claim 1 , wherein said first insulation layer has a density of between about 0.7 Lbs/cubic foot and about 3 Lbs/cubic foot.  
   
   
       11 . The assembly of  claim 10 , wherein said first insulation layer comprises 100% polyester fibers having a length of between about 1.20 to about 7.62 cm and a diameter of between about 8.0 to about 60.0 microns.  
   
   
       12 . The assembly of  claim 11 , wherein said first insulation layer is adhered to the ornamental facing using a rigid adhesive.  
   
   
       13 . The assembly of  claim 1 , further including a second insulation layer, said first insulation layer being sandwiched between said ornamental facing and said second insulation layer.  
   
   
       14 . The assembly of  claim 1  or  13 , further including a film backing.  
   
   
       15 . The assembly of  claim 14 , wherein said film backing is breathable.  
   
   
       16 . The assembly of  claim 13 , wherein said film backing is made from a material selected from a group consisting of polypropylene, polyethylene, polyolefin and mixtures thereof.  
   
   
       18 . The assembly of  claim 14 , said second insulation layer is constructed from a material selected from a group consisting of glass fibers, polymer fibers, natural fibers, EVA, foam and mixtures thereof.  
   
   
       19 . The assembly of  claim 1 , wherein said ornamental facing is constructed from a material selected from a group consisting of fiberglass, vinyl, polyvinyl chloride, aluminum, steel, ABS and mixtures thereof.  
   
   
       20 . The assembly of  claim 1 , wherein said ornamental facing includes a concavity having a contoured face and said first insulation layer has a first face substantially matching and engaging said contoured face and a second, flat face.  
   
   
       21 . The assembly of  claim 20 , wherein said assembly has a total thickness of about 1.905 cm.  
   
   
       22 . The assembly of  claim 1 , further including a fiberglass rod, strand or roving running along at least one of said ornamental facing and said first insulation layer.  
   
   
       23 . A method of making a siding panel assembly, comprising: 
 molding a first surface of a sheet of fibrous insulating material to match in profile a concavity in a sheet of ornamental facing; and    engaging said molded sheet of fibrous insulating material in said concavity of said sheet of ornamental facing.    
   
   
       24 . The method of  claim 23 , further including a step of cutting a channel in said first surface of said sheet of fibrous material before molding.  
   
   
       25 . The method of  claim 24 , wherein said molding step includes heating and shaping said fibrous insulating material with one of rollers, mechanical forming shoes, belts, a press, and a combination thereof.  
   
   
       26 . The method of  claim 23 , further including feeding said fibrous insulating material from a roll.  
   
   
       27 . The method of  claim 23 , further including fastening said sheet of fibrous insulating material to said sheet of ornamental facing with one of an adhesive, chemical welding, ultrasonic welding, mechanical entrapment, mechanical fasteners, melting, vibration welding, or a combination thereof.  
   
   
       28 . A siding panel assembly, comprising: 
 an ornamental facing;    a fiberglass rod, strand or roving running along said ornamental facing; and    a resin securing said fiberglass rod, strand or roving to said ornamental facing.    
   
   
       29 . An insulation backing for a siding panel assembly, comprising: an insulation layer; and 
 a reinforcing member running along a portion of said insulation layer;.    
   
   
       30 . An insulation backing according to  claim 29 , wherein the reinforcing member comprises a fiberglass rod, strand or roving running along said insulation layer; and a resin securing said fiberglass rod, strand or roving to said insulation layer.  
   
   
       31 . The assembly of  claim 13 , further including a film backing.  
   
   
       32 . The assembly of  claim 31 , wherein said film backing is breathable.