Simulated bark siding and method of manufacturing same
A synthetic composition panel having a surface which resembles a tree bark is provided. The synthetic composition panel defines a series of irregular grooves and indentations which extend varied distances into the thickness of the panel. The irregular pattern of the grooves, the angles of the grooves, and the depth of the grooves contribute to a panel having an appearance of a tree bark product. The panel has sufficient strength to be used as a roofing product, interior siding, exterior siding, and can be fashioned into decorative trim items such as door moldings, window moldings, and door frame moldings.
This application claims the benefit of U.S. application Ser. No. 60/920,876 filed on Mar. 30, 2007, U.S. application Ser. No. 29/285,512 filed on Mar. 30, 2007, and U.S. application Ser. No. 61/066,558 filed on Feb. 21, 2008, all of which are incorporated herein by reference.
FIELD OF THE INVENTIONThis invention relates to the field of siding and roofing materials, in particular, to decorative roofing and siding panels.
BACKGROUND OF THE INVENTIONSiding is frequently used to cover the exterior surfaces of homes, office buildings, and other dwellings, for instance when the exterior surfaces of dwellings lack aesthetic appeal or are not able to protect the dwellings from the elements. Structural roofs are also covered with sheets of material to protect the roof from rain. Aluminum sheets and wood or wood fiber planks are common siding materials. Asphalt shingles and shake shingles are among the choices of sheet material that can be used to cover and protect a roof. In some locales, for instance those in rustic, heavily wooded areas, tree bark such as poplar tree bark is a favored siding material. However, tree bark, including poplar tree bark, is expensive both to harvest and to form into sheets of siding. Further, natural tree bark siding is not suitable as a roofing material. Manufactured siding and roofing material that retains many of the advantages of tree bark while reducing or eliminating many of the disadvantages of tree bark would be desirable. A synthetic tree bark building material would be useful for exterior use as siding or roofing material or for use as a material for interior walls and similar locations.
Accordingly, there remains room for improvement and variation within the art.
SUMMARY OF THE INVENTIONIt is one aspect of at least one of the present embodiments to provide a synthetic composition panel having a surface which resembles tree bark comprising: a panel having an upper surface and a lower surface, the panel having a height of at least about 0.25 inches to about 0.75 inches; the upper panel further defining a plurality of irregular grooves and indentations interspersed between a plurality of intervening ridge regions, the upper surface having a surface area at least about 50 percent greater than said lower surface.
It is another aspect of at least one of the present embodiments to provide a synthetic composition panel with a tree bark simulated surface wherein the plurality of irregular grooves include grooves which extend a depth of at least about 50 percent of the panel height and in another aspect of the invention the irregular grooves extend a depth of at least about 75 percent of the panel height.
Further, the synthetic composition panel provides a plurality of the irregular grooves and indentations which define an included angle of at least about 45 degrees. In some embodiments, the synthetic composition panel's irregular grooves and indentations may extend in a substantially parallel fashion and are discontinuous from one edge of the panel relative to an opposite edge of the panel. In other embodiments, substantially all of the irregular grooves and indentations are continuous from one edge of a panel to an opposite edge of the panel, thereby facilitating drainage of water from the upper surface.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims.
A fully enabling disclosure of the present invention, including the best mode thereof to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings.
Reference will now be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present invention are disclosed in the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.
In describing the various figures herein, the same reference numbers are used throughout to describe the same material, apparatus, or process pathway. To avoid redundancy, detailed descriptions of much of the apparatus once described in relation to a figure is not repeated in the descriptions of subsequent figures, although such apparatus or process is labeled with the same reference numbers.
Simulated bark siding according to an embodiment of the invention is shown broadly in
A single sheet 12 of the siding 10 is shown in
The siding sheet 12 may be fabricated from any material known by those of ordinary skill in the art as being capable of being formed to define the plurality of grooves and indentations 21 and the plurality of ridges 22 and capable of weathering the conditions and elements to which the siding sheet 12 may be exposed. As known by those of ordinary skill in the art, such materials may include, without limitation, wood fiber and/or concrete, and may be formed to define the plurality of grooves and indentations 21 and the plurality of ridges 22 using processes such as, without limitation; molding, injection molding, vacuum molding, foam molding, extrusion with embossing, and/or stamping. The overall process used to manufacture the siding sheet 12 comprises selecting a fabrication material, selecting a fabrication method, selecting or designing a fabrication design or pattern that simulates the appearance of an outward-facing surface of tree bark, obtaining a portion of the selected fabrication material that may be formed to define the selected or designed fabrication design or pattern through use of the selected fabrication method, and practicing the selected fabrication method on the formable portion of the selected fabrication material to form the selected or designed fabrication design or pattern on the selected fabrication material.
Any desired synthetic wood compositions, polymers, or foamed polymer compositions may be used in the present invention. For instance, the materials used to make the siding sheet of the present invention may be virgin or recycled materials including, but not limited to, cellulosic fillers, polymers, plastics, thermoplastics, rubber, inorganic fillers, cross-linking agents, lubricants, process aids, stabilizers, accelerators, inhibitors, enhancers, compatibilizers, blowing agents, foaming agents, thermosetting materials, and other similar, suitable, or conventional materials.
Examples of cellulosic fillers include sawdust, newspapers, alfalfa, wheat pulp, wood chips, wood fibers, wood particles, ground wood, wood flour, wood flakes, wood veneers, wood laminates, paper, cardboard, straw, cotton, rice hulls, coconut shells, peanut shells, bagass, plant fibers, bamboo fiber, palm fiber, kenaf, and other similar, suitable, or conventional materials.
Examples of polymers include multilayer films, high density polyethylene (HDPE), polypropylene, polyvinyl chloride (PVC), low density polyethylene (LDPE), chlorinated polyvinyl chloride (CPVC), acrylonitrile butadiene styrene (ABS), ethyl-vinyl acetate (EVA), polystyrene, other similar copolymers, other similar, suitable, or conventional plastic materials, and formulations that incorporate any of the aforementioned polymers.
Examples of inorganic fillers include talc, calcium carbonate, kaolin clay, magnesium oxide, titanium dioxide, silica, mica, barium sulfate, acrylics, and other similar, suitable, or conventional materials.
Examples of thermosetting materials include polyurethanes, such as isocyanates, phenolic resins, unsaturated polyesters, epoxy resins, and other similar, suitable, or conventional materials. Combinations of the aforementioned materials are also examples of thermosetting materials.
Examples of lubricants include zinc stearate, calcium stearate, esters, amide wax, paraffin wax, ethylene bis-stearamide, and other similar, suitable, or conventional materials.
Examples of stabilizers include tin stabilizers, lead and metal soaps such as barium, calcium, and zinc, and other similar, suitable, or conventional materials. UV protectant stabilizers and biocides may also be incorporated into the molding or extruding materials. In addition, examples of process aids include acrylic modifiers and other similar, suitable, or conventional materials.
Examples of synthetic wood compositions include, but are not limited to, plastic/cellulosic filler compositions, polymer/cellulosic filler compositions, thermosetting/cellulosic filler compositions, thermoplastic/cellulosic filler compositions, rubber/cellulosic filler compositions, foamed synthetic wood compositions, inorganic-filled plastic compositions, and other synthetic wood compositions that are known now or in the future.
Where the synthetic compositions used to form a siding sheet 12 utilize flow molding or similar techniques, it is possible for much of the interior of the synthetic panel to define a significant number of voids or air space within the interior of the panel. The presence of the hollow voids within the panel can be beneficial depending upon the end application of the siding sheets 12. For instance, where weight is a concern, such as when used as a roofing material, it may be advantageous to maximize the amount of air space so as to reduce the weight of the panels. It is also possible to fill the voids with an insulating foam so as to improve the resistance (R) value to provide an increased measure of thermal insulation to structures which incorporate the panels. Similarly, it is envisioned that the interior of the panels could be maintained at a negative air pressure, i.e., a partial vacuum, which also increases the R value of the siding sheet 12.
In one aspect of the present invention of the present invention, a siding sheet 12 can be provided in which the ornamental bark surface is pigmented using colors and color variations to mimic a natural tree bark product. One way of accomplishing the desired coloration is to use pigments in the molding or formation stage such that the color is inherent in the material mixed throughout the thickness of the material. In this manner, any scratches or surface flaws that may result do not show an obvious color variation. The process of formulating multi-color materials such as plastics are well known in the art. For instance, when using meltable resins, it is well known to incorporate a base pigment along with additional color pigments, the additional color pigments being in the form of pellets having a different melting temperature than a base material. By partially melting the different melting point pigments and with appropriate mixing, desirable streaks of pigment can result at which time the material can be appropriately molded, extruded, or otherwise formed into the desired siding sheet 12. In this manner, a siding sheet 12 can be provided having multiple gradations of a realistic mark coloration which, depending upon the bark species, may include multiple variations of gray, brown, and with streaks or patches of black and white. While multiple color combinations are possible, it is believed preferred to closely mimic the natural appearance of the appropriate bark species.
It is also envisioned that the siding sheet 12 may be formed of a single color in which paints may thereafter be supplied. For instance, in a brown or gray tone simulated bark pattern, the original siding sheet 12 may be formed using a dark brown pigment. Thereafter, a short nap roller can be used to apply a complimentary but contrasting color to portions of the panel surface. By using a short napped roller, the deeper recesses of the molded, ornamental product will not receive any applied paint. The resulting painted product has a contrast between the painted color and the original molded color which is visible in the deeper recesses and edges of the molded product.
The siding sheet 12 may be installed on the exterior surfaces 11 of the dwelling “D” using fasteners, adhesive, and/or other installation materials known to those of ordinary skill in the art. When used as an interior or exterior siding material, the siding sheets 12 may be secured using nails, screws, or similar fasteners. Depending on the nature of the molded material used to fashion the siding sheets 12, the siding sheets 12 can be nailed in place similar to a natural bark siding product. For molded siding panels that may be too strong or brittle for conventional nailing, the siding sheet 12 may be installed by drilled pilot holes which are then used to insert a nail or a screw. Alternatively, the panels may define predetermined apertures in which nails or other fasteners may be used to attach the product to a structural support. Additionally, it is possible to use an appropriate architectural grade adhesive to apply the panels directly to the dwelling's interior or exterior walls.
Further, the siding sheets 12 may be adhered to a backing material such as a rigid, structural backing material 30 as seen in
As best seen in reference to
The use of a sealant material as a coating layer 30′ facilitates sealing of areas in proximity to any nails or screws used to attach the siding sheet panels. Suitable adhesives which may be used as the backing layer 30′ may be found in reference to U.S. patent application publication US 2007/0199276 A1 which is incorporated herein by reference.
The sealable adhesive backing layer 30′ and optional paper backing layer 32 could also be applied to the lower surface of the siding sheet 12 as seen in
As seen in
If desired, the backing material 30 may overlap additional edges as well. By having backing material which extends beyond the boundaries of the decorative portion of siding sheet 12 or roofing panel 12′ facilitates the placement of a complete moisture barrier by installation of the panels by having overlapping backing areas. The presence of the backing material also allows for slight gaps to be maintained, without loss of moisture barrier properties, the gaps being needed to allow for thermal expansion and contraction of the panels which in exterior environments may be exposed to a temperature range of over 150° F. variation. The necessity and extent of possible gaps for thermal expansion depend greatly upon the nature of the material used to make the molded product. For interior use, placement of panels is not dependent upon allowances for thermal expansion. If desired, the backing material 30 may be integral with and an extension of the molded material used to form the siding sheet 12.
As best seen in reference to
The various indentations and grooves 21 and ridges 22, as illustrated in
The synthetic bark surface, because of the deep grooves and indentations patterns, offers a three-dimensional product face which simulates the aesthetic appearance of a natural bark siding product. The bark facing of the present invention offers a textured surface which creates a series of shadows and areas of contrast which can be seen in all types of lighting. The number, placement, and extent of the grooves and indentations 21 achieve a realistic bark appearance. As best seen in reference to
In one embodiment of the present invention, the siding sheet 12, as best seen in cross section in
As seen in an end view such as in
As best seen in reference to
For instance, the increased surface area allows for a greater radiant cooling effect such that the siding more quickly radiates heat away from the underlying structure. With respect to both an exterior wall siding and a roofing product, the ability to radiate heat prevents excessive heat accumulation and transfer to the adjacent dwelling. The increase in surface area of the ornamental surface also helps to prevent build up of undesired heat. But for brief intervals when the sun is directly opposite a surface of the panel, the extensive grooves and indentations 21 and the 45 degree or greater wall angles defined by many of the grooves and indentations 21 provide some element of shade/shadow to at least portions of the exposed surfaces of the panels. The shaded portions help maintain an overall cooler surface as opposed to a completely flat surface.
One of the attributes of a natural bark siding product favored by many consumers is the actual “weathered” look which increases over time for the natural bark siding. In areas of adequate moisture and shade, algae, moss, and similar plants may colonize the natural bark product and contribute to the overall aesthetic appeal of the siding. By providing a series of grooves and indentations, the synthetic siding sheets 12 facilitate a similar weathering process. If desired, the molded siding sheets 12 will facilitate the accumulation and colonization by algae, moss, and similar plants which enhance the aesthetic appearance of the molded product. While such growth on a conventional flat siding material designed to simulate finished wood or a painted wood product is considered unsightly, the texture and appearance of the siding sheet 12 can be enhanced by such natural colonization. However, if such growth is either excessive or considered unsightly, the durable nature of the simulated bark siding sheets 12 can be easily cleaned using conventional pressure cleaning and/or bleaching techniques. Such techniques are potentially harmful to and shorten the life of natural wood siding or many conventional roofing products such as a wooden shake roof, asphalt roof, or composite shingle roofing materials.
As best seen in reference to
The shape and size of the decorative simulated bark siding sheet 12 or roofing panel 12′ may be varied and adapted to achieve a number of different construction products. For instance, where a rustic look of a bark appearance is desired, the sheets 12 or panels 12′ can be manufactured in a size and dimension for use as decorative door molding, window moldings, chair rails, crown molding, as well as used as exterior covering on exposed ceiling beams, porch or deck railings, and similar structures.
Simulated bark siding and a method of manufacturing the same are described above. Although preferred embodiments of the invention have been described using specific terms, devices, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention which is set forth in the following claims. In addition, it should be understood that aspects of the various embodiments may be interchanged, both in whole, or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein.
Claims
1. A synthetic composition panel having a surface which resembles tree bark comprising:
- a panel having an upper surface and a lower surface, said panel having a height of at least about 0.25 inches to about 0.75 inches;
- said upper panel further defining a plurality of irregular grooves and indentations interspersed between a plurality of intervening ridge regions, said upper surface having a surface area at least about 50 percent greater than said lower surface.
2. The synthetic composition panel according to claim 1 wherein said plurality of grooves include grooves which extend a depth of at least about 50 percent of the panel height.
3. The synthetic composition panel according to claim 1 wherein said plurality of grooves include grooves which extend a depth of at least about 75 percent of the panel height.
4. The synthetic composition panel according to claim 1 wherein a plurality of said irregular grooves and indentations define an included angle of at least about 45 degrees.
5. The synthetic composition panel according to claim 1 wherein said irregular grooves and indentations extend in substantially parallel fashion and are discontinuous from one edge of the panel to an opposite edge of the panel.
6. The synthetic composition panel according to claim 1 wherein substantially all of said irregular grooves and indentations are continuous from one edge of a panel to an opposite edge of said panel, thereby facilitating drainage of water from said upper surface.
7. The synthetic composition panel according to claim 1 wherein said ridge regions further define a simulated wood grain.
8. A synthetic composition panel having a surface which resembles tree bark comprising:
- a panel having an upper surface and a lower surface, said panel having a height of at least about 0.25 inches to about 0.75 inches;
- said panel further defining a plurality of irregular grooves and indentations interspersed between a plurality of intervening ridge regions, said upper panel surface having a surface area having a surface area of at least about 50 percent greater than said lower surface;
- an adhesive seal layer applied to a lower surface of said panel, said adhesive seal layer comprising a sealable mixture adapted for providing a water tight seal around a nail used to install the synthetic composition panel.
9. The synthetic composition panel according to claim 8 wherein said adhesive seal layer comprises a mixture of an asphalt and an adhesive sealant selected from the group consisting of styrene-butadiene-styrene, polybutane, polybutalene and mixtures thereof.
Type: Application
Filed: Mar 31, 2008
Publication Date: Oct 2, 2008
Inventor: Phillip Daniel Heatherly (Canton, NC)
Application Number: 12/079,997
International Classification: E04F 13/08 (20060101);