Building surface panels and method of forming the same

Abstract

A building surface panel can include an outer element attached to a backing component and comprises at least one of: a CTE mismatch between outer element and 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; a first thickness of backing component being 0.5 to 5.0 times a second thickness of outer element; or a density of backing component being at least 0.4 grams/cm3 but not greater than 2.0 grams/cm3; the backing component comprising recycled PVC; or the backing component comprising at least one of: one or more reinforcement elements that protrude from backing component; a longitudinally extending groove; a longitudinally extending tongue; or a plurality of relief holes.

1 - 49 . (canceled) 
     
     
         50 . 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 fixedly 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/cm 3  but not greater than 2.0 grams/cm 3 , and 
 a combination thereof. 
   
     
     
         51 . The building surface panel of  claim 50 , 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. 
     
     
         52 . The building surface panel of  claim 51 , 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. 
     
     
         53 . The building surface panel of  claim 51 , wherein the backing component comprises one or more longitudinally extending reinforcement elements. 
     
     
         54 . The building surface panel of  claim 51 , wherein the backing component further comprises a groove, and wherein the groove is configured to receive a tongue of another building surface panel. 
     
     
         55 . The building surface panel of  claim 54 , wherein the outer element comprises a bottom flange, and wherein the groove engages the bottom flange. 
     
     
         56 . The building surface panel of  claim 51 , 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. 
     
     
         57 . The building surface panel of  claim 50 , 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. 
     
     
         58 . The building surface panel of  claim 57 , wherein the outer element comprises a bottom flange, and wherein the bottom flange engages the groove. 
     
     
         59 . The building surface panel of  claim 57 , wherein the outer element or the backing component comprises a tongue that is configured to engage the groove of another building surface panel. 
     
     
         60 . The building surface panel of  claim 57 , 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. 
     
     
         61 . The building surface panel of  claim 57 , wherein the backing component comprises one or more longitudinally extending reinforcement elements. 
     
     
         62 . The building surface panel of  claim 57 , 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. 
     
     
         63 . 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 fixedly 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 longitudinally extending reinforcement elements comprise a protrusion that protrudes from the second rear side.   
     
     
         64 . The building surface panel of  claim 63 , wherein the one or more longitudinally extending reinforcement elements comprise at least one of:
 a longitudinally extending rib;   an increased thickness of the backing component along a longitudinal portion of the backing component; and   an elongated piece that is attached to the second rear side of the backing component.   
     
     
         65 . 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/cm 3  but not greater than 2.0 grams/cm 3 ; and   recycled PVC.   
     
     
         66 . The building surface panel of  claim 65 , wherein the outer element comprises a first thickness as measured between the first front side and the first rear side, and the backing component comprises a second thickness as measured between the second front side and the second rear side, and wherein the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness. 
     
     
         67 . The building surface panel of  claim 65 , wherein the backing component comprises at least 10% by weight of the recycled PVC. 
     
     
         68 . The building surface panel of  claim 67 , 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. 
     
     
         69 . The building surface panel of  claim 68 , wherein the impurities of the recycled PVC comprise at least one of the following:
 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;   less than 1% metal by weight; and   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.   
     
     
         70 . 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.   
     
     
         71 . The building surface panel of  claim 70 , 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. 
     
     
         72 . The building surface panel of  claim 70 , 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.