Abstract: The present invention provides exterior building products, such as roofing and siding, shake, shingles, siding, sheathing, panels, planks, vertical siding, soffit panels, fencing, decking, fascia, corner posts, column corners and trim boards in which a plurality of cementitious layers are provided with an improved interlaminar bond by employing a resinous bond promoter, a rheological agent, mechanical means to distribute fibers in a direction which is perpendicular to the machine direction so as to bridge between layers in the product, or a combination thereof. These techniques help to increase interlaminar bond strength to improve the mechanical properties of the product. When certain resinous bond promoters are used, the additional benefits of water absorption resistance and pigmentation throughout the product can be provided with minimal expense. Improvements in interlaminar bond strength of about 10–46% were observed with a percent elongation improvement of about 7%.

Abstract: A process of simultaneously molding either a plurality of shingles or double walled shingles or other substantially planar exterior building products is provided, such that a blow moldable thermoplastic material is provided, of a composite parison that is then blow molded in a hollow mold, to produce novel shingles according to the process. Ventilation and/or insulation can be provided to a hollow interior between spaced apart walls of a double walled shingle.

Abstract: A process of simultaneously molding either a plurality of composite shingles or double walled shingles or other substantially planar exterior building products is provided, each being comprised of two or more layers of thermoplastic shingle material, such that a weatherable capstock material is provided outside a core material, in the form of a composite parison that is then blow molded in a hollow mold, to produce novel shingles according to the process. Ventilation and/or insulation can be provided to a hollow interior between spaced apart walls of a double walled shingle.

Abstract: A wind-resistant shingle and a method of making it is provided in which the rear surface of the shingle is provided with an attached reinforcement layer, which resists upwardly wind-applied bending torque when the shingle is installed on a roof, such that the failure of the shingle when it is bent beyond its elastic limit, is resisted until the shingle has absorbed a high percentage of applied torque.

Abstract: A generally rectangular siding panel having a front and rear faces is provided. The siding panel has at least one protrusion disposed along at least one of the faces, wherein the at least one protrusion provides an air gap between the siding panel and a face of a second siding panel when the siding panels are installed in a siding panel assembly. A generally rectangular siding panel having a front and rear faces is also provider where the siding panel has at least one recess or cut spaced along at least one of the faces, wherein the at least one recess or cut provides an air flow path between the siding panel and a face of a second siding panel when the siding panels are installed in a siding panel assembly.

Abstract: A filament-wound composite coupling for use in assembling a restrained joint between large diameter pipes with complementary retaining grooves, such as 16 inch or larger outer diameter polyvinyl chloride pipes. The coupling has first and second ends and ported retaining grooves associated with each end. Preferably, the coupling also includes O-ring seals and a pipe stop to index the pipes to be coupled. The composite coupling has a cylindrical composite body with a plurality of concentrically arranged layers of wound filaments in a thermoset plastic matrix. Each of the layers is characterized by a winding angle opposing the winding angle of the adjoining layers.

Abstract: This invention relates to methods and apparatus for manufacturing shaped polymeric articles by substantially continuous vacuum forming. The method includes providing a sheet of hot polymeric material which is disposed onto a rotating belt having a mold impression. Vacuum pressure is applied to the polymeric material through the belt so as to draw the hot polymeric material into intimate contact with the mold impression to form a patterned sheet portion and a remaining sheet portion. This method thereafter cools at least the patterned sheet portion below a heat deflection temperature of the polymeric material, forms the remaining sheet portion, and then cools the remaining sheet portion below the heat deflection temperature so that features other than the central pattern, such as nail and butt edges, can be mechanically worked into the polymeric sheet.

Abstract: A method for adhering together lanes of a compressible product includes inserting a wedge device between two separate lanes of a compressible product to split apart at least a portion of the lanes of product, advancing either the wedge device or the separate lanes of the compressible product to move the wedge device and lanes relative to one another, applying an adhesive onto an inside wall of one or both of the lanes of compressible product while at least a portion of the lanes are split, and contacting the inside walls of the lanes to form a single adhered product.

Abstract: A composite fabric for use in reinforcement, particularly tensile reinforcement, of cementitious boards and similar prefabricated building wall panels. The fabric is constructed as a mesh of continuously coated, high modulus of elasticity strands. The high modulus strands are preferably bundled glass fibers encapsulated by alkali and water resistant thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The fabric provides long-lasting, high strength tensile reinforcement of the panels or boards regardless of their spatial orientation during handling. The reinforcement also enhances the impact resistance of the boards after installation. Included as part of the invention are methods for making the reinforcement, cementitious boards and panels including the reinforcement, and methods for manufacturing such boards and panels.

Abstract: A sizer assembly for providing a shaped polymeric article in an extrusion process comprises a sizer body having a product profile channel corresponding to the shaped polymeric article formed therethrough. The sizer body comprises a plurality of cooling liquid inlet slots forming an opening substantially around the product profile channel and a plurality of vacuum slots forming an opening substantially around the product profile channel for removing cooling liquid expelled from said cooling liquid inlet slots.

Abstract: Cementitious exterior sheathing products are provided which include a rigid support member affixed to a cementitious layer. The rigid support member includes at least one nailing flange disposed along one of its lateral sides for allowing the sheathing product to be affixed to an exterior wall of a building. Preferred mechanical and adhesive bonding techniques are suggested for combining the cementitious layer and rigid support member together to form an integrated product. Such products are lighter in weight and are more crack resistant than currently available fiber cement trim boards.

Abstract: An adornment for a post is provided, wherein the adornment is any two of a cap adapted to be disposed at the upper end of a post, a base ring adapted to be disposed around a lower end of a post, and a cap ring adapted for disposition around an upper end of the post below and against the cap, as a modular combination of at least two adornment units.