US 12,442,194 B2
Building surface panels with aged foam backing and method of manufacture
Jay M. Tudor, Goodrich, MI (US); David J. Stucky, Grass Lake, MI (US); Ashley A. Schultz, Jackson, MI (US); Eishaan Gakhar, Ann Arbor, MI (US); and Dev B. Barpanda, Northville, MI (US)
Assigned to CERTAINTEED LLC, Malvern, PA (US)
Filed by CertainTeed LLC, Malvern, PA (US)
Filed on Jan. 21, 2022, as Appl. No. 17/581,533.
Claims priority of provisional application 63/140,637, filed on Jan. 22, 2021.
Prior Publication US 2024/0110386 A1, Apr. 4, 2024
Int. Cl. E04F 13/00 (2006.01); B29C 44/00 (2006.01); B29C 44/34 (2006.01); B32B 27/00 (2006.01); B32B 27/06 (2006.01); B32B 27/30 (2006.01); B32B 37/12 (2006.01); B32B 38/00 (2006.01); E04F 13/08 (2006.01)
CPC E04F 13/0876 (2013.01) [B29C 44/354 (2013.01); B32B 27/065 (2013.01); B32B 27/302 (2013.01); B32B 27/304 (2013.01); B32B 37/12 (2013.01); B32B 38/0004 (2013.01); B32B 2038/0084 (2013.01); B32B 2266/0228 (2013.01); B32B 2305/022 (2013.01); B32B 2307/558 (2013.01); B32B 2307/734 (2013.01); B32B 2309/025 (2013.01); B32B 2327/06 (2013.01); B32B 2355/00 (2013.01); B32B 2419/00 (2013.01); B32B 2607/00 (2013.01)] 37 Claims
OG exemplary drawing
 
1. A method of manufacturing a building surface panel, the method comprising:
providing a foam piece;
aging the foam piece for at least 1 day or at a pressure of no more than 0.85 atmospheres so as to form an aged foam piece, wherein the aged foam piece has at least one of a 30 day/23° C. residual shrinkage of no more than 0.2% or a 150 day/23° C. residual shrinkage of no more than 0.25%; and
attaching the aged foam piece to a rear side of an outer shell so as to form the building surface panel, wherein the building surface panel further comprises a fastening strip along a top of the building surface panel,
wherein the outer shell comprises polyvinyl chloride.