CELLULAR PVC SIDING, TRIM, AND ARCHITECTURAL ASSEMBLIES
Cellular PVC siding, trim, and architectural assemblies are provided which use cellular PVC as an exterior building material due to its stable weatherproof qualities, but which is combined with a substrate to improve the handling and usability of the cellular PVC material. Embodiments of the invention include modular exterior siding assemblies, trim board assemblies, corner trim assemblies, and cylindrical trim assemblies.
The present invention relates to exterior siding, trim, and rigid structure architectural assemblies for buildings.
BACKGROUND OF THE INVENTIONTraditional exterior systems for wood frame construction homes involve plywood or oriented strandboard (OSB) sheets nailed to wood framing, covered with a vapor barrier, and covered with a siding material such as wood shingles, wooden clapboard siding, vinyl siding, or fiber-cement composite siding.
Cellular polyvinylchloride (“PVC”) materials have been used in the housing industry for at least 20 years for use in trim applications. It is a material that is easy to cut. It is more durable than wood, and does not succumb to rotting or other weather related problems. However, cellular PVC is very expensive compared to wood. Because of its expense, cellular PVC has had a very limited use in building exterior systems, typically only for building trim such as window trim. Furthermore, it is also not as rigid as wood and is more difficult to maneuver and position than wood products, which limits its suitability even for trim applications if the cellular PVC piece is so long that it becomes unmanageable.
SUMMARY OF THE INVENTIONCellular PVC siding, trim, and architectural assemblies are provided which use cellular PVC as an exterior building material due to its stable weatherproof qualities, but which is combined with a substrate to improve the handling and usability of the cellular PVC material.
In one embodiment, a modular exterior siding assembly comprising a rectangular backer panel having a cellular PVC boards affixed to its outer surface, optionally having an insulating rigid foam affixed to the inner surface of the backer panel. In another embodiment, a cellular PVC board is affixed to a wood material substrate and used as trim. In another embodiment, two cellular PVC casing components enclose and are affixed to a cylindrical or tubular substrate to form spindles. In another embodiment, a corner trim assembly formed from two cellular PVC boards having 45 degree edge cuts located adjacent each other, and held together by removable adhesive tape.
The above described invention is shown in the accompanying Figures and is further described in connection with the figures as follows.
The present invention and its preferred embodiments of the present invention may be further understood with reference to the following description and the related appended drawings, wherein like elements are provided with the same reference numerals. The described embodiments of the present invention relate to the use of cellular PVC as traditional siding, as trim, and as an architectural element. The invention allows a contractor to replace traditional siding, wood trim, and wood structure, with cellular PVC or a composite of cellular PVC and a substrate. The exemplary embodiments of the present invention may be easily implemented into an existing home or into new construction. The exemplary embodiments are described with reference to specific examples of siding, trim, and architectural structures, but those skilled in the art will understand that the present invention may be implemented in any form of siding, trim, or rigid structure.
House 100 also has multiple trim elements in accordance with the invention. Window trim 140 is made out of cellular PVC mounted to a wood substrate and is used in place of an all wood or all cellular PVC window trim. Corner trim 150 is fabricated from two separate pieces of cellular PVC, which are adhered together.
House 100 also has multiple architectural structures in accordance with the invention. These include stair and porch railings 160 including balusters 162. Rails 160 are designed to replace an all wood railing maintaining the structure and stability of wood with the added benefits of being weather resistant. Finally, house 100 has a pergola structure 190. Pergola 190 is made up of multiple vertical posts supporting multiple beams 170. In a standard pergola, the beams would be fashioned out of wood. In the present case, the beams are replaced with a cellular PVC beam which is cellular PVC affixed to multiple tubes to provide the rigidity and strength of wood. The cellular PVC is weather resistant and lasts significantly longer than its wood alternative.
In general, the cellular PVC siding, trim, and architectural assemblies of the present invention incorporate a substrate combined with a cellular PVC board material which has been milled to a particular shape. In general, the substrate is a wooden material such as plywood, oriented strand board (“OSB”), pressboard, or particle board. However, in some cases, the substrate is a composite material such as a Kevlar® material or a tubular PVC material.
The cellular PVC material used in the present invention is preferably a free-foam cellular extrusion PVC board material such as the PVC board material sold under the brand KLEER by Kleer Lumber, Westfield, Mass. Cellular PVC extrusion boards are consistent in thickness, density, color and cell structure form. The product looks and works like wood but is moisture resistant, and does not rot, warp, splinter or decay and is impervious to insects. Surface textures may be applied to the boards during the manufacturing process to give the appearance of wood grains. Cellular PVC board materials are typically sold by the manufacturer in the form of rectangular boards. The material thickness is in the range of 0.375 inch thick to 1.0625 inch thick. Preferably, a 0.75 inch thick board is used and is sawed to a desired thickness. Thus, in most of the embodiments of the present invention a 0.75 inch board is used as a starting material and is sawed to a 0.375 inch nominal thickness. However any thickness PVC may be used depending on the desired ruggedness of the assembly and the strength of any supporting substrate. Cellular PVC boards are easily milled in the same way as wood, so the boards can be presented with a variety of shapes milled into them. For example, the panels may have the appearance of shingles or shakes by milling or cutting grooves in the outer surface of the boards; or they may have the appearance of traditional clapboards. Other shapes, textures, patterns, designs, may be cut into the panels using a CNC milling machine. The present invention provides a significant ability to easily replicate traditional architectural elements such as Victorian shingle patterns, but also provides an almost unlimited ability to create new architectural exterior surfaces, such as exterior surfaces which look like tiles, or planks, and can be milled to create patterns such as “bulls eye” or fish scale patterns, or to replicate the look of masonry such as bricks or stone.
Referring now to
In a preferred embodiment, an insulating layer of rigid foam insulation 430 is adhered to the inner surface of the backer panel to provide an additional insulation layer to the building. The insulating layer desirably covers the entire backer layer and is sized and shaped to fit tightly against the insulating layers of adjacent panels so that the installed siding assembly provides a significant additional insulation to the structure. The addition of a one inch thick layer of rigid insulating foam over wall sheathing as seen in
The modular exterior siding assemblies of the invention can be manufactured in any size, however, the following standard sizes are the preferred embodiments of the invention: (1) a standard size which is easily lifted, placed and installed by a single worker (for example a 4 foot wide by 1.5 foot high assembly); (2) a standard size which is easily stored in existing lumberyards (for example 4 foot by 8 foot or 4 foot by 4 foot sections). The 4 foot by 1.5 foot section is a preferred embodiment because it is easily installed by a single worker.
The modular exterior siding assemblies of the invention can be installed over existing wall sheathing such as plywood, OSB, or particle board materials, or may be installed in new construction as a nonstructural sheathing fastened directly to the wall framing members. The typical installation will be by nailing, screwing, and/or gluing the modular exterior siding assemblies to the wall.
Preferably the backer panels 220, 320, and 420 of modular exterior siding assemblies 200, 300, and 400 connect to adjacent backer panels with a half lap joint such as the half lap joints 240, 340, and 440 in backer panels 220, 320, and 420. In a preferred embodiment, each backer panel 220, 320, 420 mates with adjacent backer panels with a half lap joint along all four edges and the seams along four edges are all covered by the cellular PVC sheet material. This design provides a more secure mounting of each exterior siding assembly and minimizes water penetration.
The backer panels 220, 320, and 420 of modular exterior siding assemblies 200, 300, and 400 preferably have their upper and left side edges free of the cellular PVC siding material so that the two edges may act as a nailing flange for mounting the backer panel to the building framing or wall. For example, in
Preferably, the top edge of the backer panels 220, 320, and 420 are slotted at regular intervals, providing gaps in the edges called weep holes, to provide drainage holes for water that may infiltrate the wall system. For example, in
The modular exterior siding assemblies 200, 300, and 400 provide a stronger and more rigid product compared to cellular PVC lumber boards. The modular exterior siding assemblies 200, 300, and 400 provide a less expensive product compared to solid cellular PVC lumber boards. The use of cellular PVC allows the assembly to be significantly lighter than prior art fiber cement laminar siding systems. The lighter weight makes the assembly of the present invention safer to work with than many products. The assemblies of the present invention can be installed very rapidly and at a considerable labor savings compared with traditional shingle siding.
The specific application of the exterior trim assembly shown in
The specific application of the exterior trim assembly shown in
Traditional cellular PVC trim pieces have been made from cellular PVC boards, but without any substrate as provided herein. The exterior trim assemblies of the present invention are an improvement over such known trim pieces because thinner sheets of the cellular PVC material can be used. Since they require less of the expensive cellular PVC material; they are less expensive than the known products. Also, the exterior trim assemblies of the present invention are more rigid and stable than the known products due to the inclusion of the substrate. By combining cellular PVC trim 510 with substrate 520, the exterior trim assemblies 500 are more stable and cheaper, while being equally weather resistant.
The exterior corner trim assembly 600 is suitable for transportation in a laid-out, flat position, then can be assembled to a fixed right angle position for installation in a building by the following steps. A suitable PVC adhesive is spread in the angle 630. One or both panels 610 and 670 are moved to put the 45 degree edge of the first long side 616 against the 45 degree edge of the second long side 676 as seen at 650 in
Architectural assembly 700 has greater structural integrity than cellular PVC boards without the substrate and can bear more tension and compression forces, allowing it to be used in handrails or other similar structures. Architectural assembly 700 is lighter than wood making for easier and cheaper transport. The cellular PVC casing components are weatherproof and will not rot. The casing components of architectural assembly 700 can be milled to create intricate contours for the assembly.
The cellular PVC pieces provide durability and weather resistance while combining with the interior cylindrical substrate to provide stability and rigidity. While the exemplary embodiment in
It will be apparent to those skilled in the art that various modifications may be made in the present invention, without departing from the spirit or the scope of the invention. Thus, it is intended that the present invention cover modifications and variations of this invention provided they come within the scope of the appended claimed and their equivalents.
Claims
1. A modular exterior siding assembly comprising
- a rectangular backer panel having an outer surface and an inner surface;
- cellular PVC siding material affixed to the outer surface of the backer panel.
2. The modular exterior siding assembly of claim 1, further comprising insulating rigid foam affixed to the inner surface of the backer panel.
3. The modular exterior siding assembly of claim 1, wherein the cellular PVC siding material comprises two or more boards.
4. The modular exterior siding assembly of claim 1, wherein the cellular PVC siding material is milled to provide the appearance of wooden shingles.
5. The modular exterior siding assembly of claim 1, wherein the cellular PVC siding material is milled to provide the appearance of clapboard siding.
6. The modular exterior siding assembly of claim 1 wherein the backer panel comprises one or more of plywood, OSB, pressboard, or particle board.
7. The modular exterior siding assembly of claim 1, where the assembly has a size and weight selected so that the assembly can be lifted, placed, and installed by a single worker.
8. The modular exterior siding assembly of claim 1, wherein the cellular PVC siding material is affixed to the outer surface of the backer panel by an adhesive.
9. The modular exterior siding assembly of claim 1, wherein the cellular PVC siding material is affixed to the outer surface of the backer panel in an offset pattern with one end of the cellular PVC siding material extending over one edge of the backer panel and another end of the cellular PVC siding material being located inwardly of another edge of the backer panel, whereby a plurality of said modular exterior siding assemblies may be mounted to a building frame with seams between adjacent backer panels covered by cellular PVC siding material.
10. An exterior trim assembly comprising:
- a wood material substrate having an outer surface and an inner surface;
- a cellular PVC trim material affixed to the outer surface of the substrate.
11. The exterior trim assembly of claim 10 wherein the wood material substrate comprises one or more of plywood, OSB, pressboard, or particle board.
12. The exterior trim assembly of claim 10 wherein the exterior trim assembly comprises a door trim, window trim, corner trim, fascia board, or a stair riser.
13. The exterior trim assembly of claim 10 wherein the cellular PVC trim material is milled to provide the appearance of wooden trim.
14. An architectural assembly comprising:
- a cylindrical substrate having an outer surface;
- two cellular PVC casing components, having channels provided therein to receive the cylindrical substrate, being affixed to and enclosing some or all of the outer surface of the cylindrical substrate.
15. The architectural assembly of claim 14 wherein the cylindrical substrate comprises a tubular material.
16. The architectural assembly of claim 15 wherein the tubular material comprises a PVC conduit.
17. The architectural assembly of claim 14 wherein the architectural assembly comprises a dowel, baluster, column, newel post, handrail, beam, or outdoor furniture.
18. The architectural assembly of claim 14 wherein the two cellular PVC casing components are milled.
19. An exterior corner trim assembly comprising:
- a first rectangular cellular PVC panel having an inner surface and an outer surface, and having first and second long sides, the first long side of the first rectangular cellular PVC panel having a 45 degree edge from the outer surface to the inner surface thereof;
- a second rectangular cellular PVC panel having an inner surface and an outer surface, and having third and fourth long sides, the third long side of the second rectangular cellular PVC panel having a 45 degree edge from the outer surface to the inner surface thereof;
- said first long side and said third long side being located adjacent each other with the 45 degree edges positioned together to form a 90 degree angle;
- a removable adhesive tape retaining the first rectangular cellular PVC panel to the second rectangular cellular PVC panel, said tape being adhered along the outer surfaces of the first long side of the first rectangular cellular PVC panel and the third long side of the second rectangular cellular PVC panel.
20. The exterior corner trim assembly of claim 19, further comprising: a wood material substrate affixed to one or both inner surfaces of the first rectangular cellular PVC panel and the second rectangular cellular PVC panel.
21. The exterior corner trim assembly of claim 19, further comprising: a third rectangular cellular PVC panel having an inner surface and an outer surface, and having fifth and sixth long sides, the fifth long side of the second rectangular cellular PVC panel having a 45 degree edge from the outer surface to the inner surface thereof; and the second long side of the first rectangular cellular PVC panel having a 45 degree edge from the outer surface to the inner surface thereof; said fifth long side and said second long side being located adjacent each other with the 45 degree edges positioned together to form a 90 degree angle; and a removable adhesive tape retaining the third rectangular cellular PVC panel to the first rectangular cellular PVC panel, said tape being adhered along the outer surfaces of the fifth long side of the third rectangular cellular PVC panel and the second long side of the first rectangular cellular PVC panel.
22. The modular exterior siding assembly of claim 1, having a sheet of foam insulation affixed to the inner surface of the rectangular backer panel.
Type: Application
Filed: Sep 10, 2009
Publication Date: Mar 11, 2010
Inventor: Robert Mannion (Danbury, CT)
Application Number: 12/557,491
International Classification: E04F 13/073 (20060101); E04C 2/20 (20060101); E04F 13/00 (20060101);