Building Surface Panels and Method of Forming the Same

This application claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/627,527, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Ashley A. SCHULTZ et al., filed Jan. 31, 2024, and also claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/710,660, entitled “BUILDING SURFACE PANELS AND METHOD OF FORMING THE SAME,” by Greg Thomas HOLLAND, filed Oct. 23, 2024, both of which applications are assigned to the current assignee hereof and the entire disclosures of these applications are incorporated herein by reference in their entireties.

The present disclosure relates generally to a building surface panel for covering a building surface. The present disclosure relates more particularly to a backed or reinforced building surface panel for covering a building surface.

Building surface panels, such as cladding or siding, are visible elements that cover an underlying support structure. Siding panels are typically used in the construction of homes, businesses, and other buildings on exterior walls. These siding panels can provide protection to the underlying support structure from weather and other elements.

There is a wide variety of distinct types of building surface panels that may be used to cover exterior walls. Such surface panels may exhibit heat distortion and/or buckling while installed on a building surface, due to environmental conditions and changing conditions. Therefore, improvements in building surface panels are continually needed.

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

One general aspect includes a building surface panel that can include 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, where the second front side is attached to the first rear side of the outer element, where the building surface panel may further include 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/cmbut not greater than 2.0 grams/cm; and a combination thereof.

Another aspect includes a building surface panel that can include 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, where the second front side of the backing component is attached to the first rear side of the outer element, where the backing component may include one or more longitudinally extending reinforcement elements, and where the one or more reinforcement elements may include a protrusion that protrudes from the second rear side.

Another aspect includes a building surface panel that can include 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, where the second front side of the backing component is attached to the first rear side of the outer element, where the backing component may include at least one of: a longitudinally extending groove; a longitudinally extending tongue; a plurality of relief holes; and a density that is at least 0.4 grams/cmbut not greater than 2.0 grams/cm.

Yet another aspect includes a building surface panel that can include 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, where the second front side of the backing component is attached to the first rear side of the outer element, where the second thickness is greater than or equal to 0.5 times the first thickness up to 5.0 times the first thickness.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.

The following discussion will focus on specific implementations and embodiments of the teachings. The detailed description is provided to assist in describing certain embodiments and should not be interpreted as a limitation on the scope or applicability of the disclosure or teachings. It will be appreciated that other embodiments can be used based on the disclosure and teachings as provided herein.

The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present), and B is false (or not present), A is false (or not present), and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one or the singular as also including the plural or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

The use of the word “about”, “approximately”, “generally”, or “substantially” is intended to mean that a value of a parameter is close to a stated value or position. However, minor differences may prevent the values or positions from being exactly as stated. Thus, differences of up to ten percent (10%) for the value are reasonable differences from the ideal goal of exactly as described. A significant difference can be when the difference is greater than ten percent (10%).

Embodiments described herein are generally directed to a building surface panel that may include an outer element and a backing component. As used herein, the term “outer element” is used interchangeably with “outer shell,” “outer layer,” “exterior layer,” “cladding face,” or “siding.” The outer element can be formed separately from the backing component and attached to the backing component by any suitable means, or the outer element and the backing component can be formed together as a unitary body and folded to attach the backing component to the outer element to form the backed or reinforced building surface panel. As used herein, the term “building surface panel” refers to a backed or reinforced building surface panel unless specified otherwise.

For purposes of illustration,shows a schematic side-view of a portion of a building surface panelaccording to embodiments described herein. As shown in, the building surface panelmay include an outer elementand a backing component. As also shown in, the outer elementmay have a front sideand a rear side. As further shown in, the backing componentmay be attached to rear sideof the outer element.

For purposes of further illustration,shows a schematic front view of a portion of the building surface panelaccording to embodiments described herein. Components of embodiments described herein may be described as having a length, height, and width (or thickness). It is noted that, for purposes of embodiments described herein and as shown in, “length” refers to the length (L) in an X-direction along a longitudinal axis of the component oriented as it would be installed on a building, “height” refers to the height (H) in a Y-direction along a lateral axis of the component oriented as it would be installed on a building, and “width” refers to the width (W) in a Z-direction along a transversal axis of the component oriented as it would be installed on a building. As used herein, the longitudinal axis corresponds to the extrusion direction.

Foams can be adhered to the back of building surface panels to form a backing component that can reinforce the building surface panels. However, the insulative properties of foam can lead to issues with heat buildup and temperature differential across the panel. This can lead to differences in thermal expansion between the backing component and the outer element, thus creating distortions at the overlap between building surface panels or distortions anywhere on the face of the outer element that can lead to aesthetic defects in the panel. A building surface panel that includes a backing (or support) component that provides mechanical support while reducing temperature differential between the backing component and the outer element (which can also be referred to as an outer element) can minimize these issues.

Referring back to, it will be appreciated that for purposes of embodiments described herein, the outer elementmay be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the outer elementmay be formed of multiple layers that are formed together, such as through extrusion or molding, or formed separately and attached together by any suitable means, including, but not limited to chemical, plasma, thermal, or ultrasonic bonding, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. For example, the outer elementmay be formed of two layers that are coextruded or extruded separately and then bonded together.

It will be appreciated that for purposes of embodiments described herein, the backing componentmay be a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. It will be further appreciated that the backing componentmay be formed of multiple layers that are formed together such as through extrusion or molding or formed separately and attached together through any suitable means including, but not limited to chemical, plasma, thermal, or ultrasonic bonding, adhesive, spray or roll-on coating, heat shrink film, adhesive film, or a combination thereof. For example, the backing componentmay be formed of two layers that are coextruded or extruded separately and then bonded together. In an embodiment, the backing component may comprise one or more longitudinally extending reinforcement elements. The one or more reinforcement elements may comprise one or more longitudinally extending protrusions or longitudinally extending ribs, longitudinal corrugation, honeycomb pattern, embossed features, or an elongated piece that is adhered to the backing component. The elongated piece may be continuous, solid piece, corrugated, honeycomb, or a geometric pattern. In a non-limiting embodiment, the front sideand/or the back sideof the backing componentcan be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc. In another embodiment, only the front sideof the backing component can be embossed with a woodgrain pattern, a corrugated pattern, a honeycomb pattern, a geometric pattern, a plurality of protrusions, etc, such that the back sideis substantially smooth and uniform, and without any embossed feature.

It will be appreciated that for purposes of embodiments described herein, the outer elementand the backing componentmay be a unitary body that is a single layered component formed according to any desirable forming process including, but not limited to molding or extrusion. As used herein, “unitary body” refers to a body that includes multiple components that are formed together as one piece with the components being integral to each other.

According to certain embodiments the building surface panelmay have a particular CTE mismatch measured between the outer elementand the backing component. It will be appreciated that the CTE mismatch described herein is equal to the absolute value of the difference between the CTE of the outer elementand the CTE of the backing componentdivided by the average of the CTE of the outer elementand the CTE of the backing component, where the CTE of each element is measured according to American Society for Testing and Materials (ASTM) D696 at a temperature 25° C. According to particular embodiments, the building surface panelmay have a CTE mismatch of not greater than about 20%, such as not greater than about 19% or not greater than about 18% or not greater than about 17% or not greater than about 16% or not greater than about 15% or not greater than about 14% or not greater than about 13 percent or not greater than about 12% or not greater than about 11% or not greater than about 10% or not greater than about 9% or not greater than about 8% or not greater than about 7% or not greater than about 6% or even not greater than about 5% or even not greater than about 2% or even not greater than about 1% or even not greater than about 0.5% or even not greater than about 0.1%. It will be appreciated that the CTE mismatch of the building surface panelmay be within a range between any of the values noted above. It will be further appreciated that the CTE mismatch of the building surface panelmay be any value between any of the values noted above. In another embodiment, the outer elementand the backing componentmay have substantially the same CTE.

According to still other embodiments, the building surface panelmay have a particular deflection measurement if subjected to a curvature test at least 90 days after formation of the building surface panel. For purposes of embodiments described herein, the curvature test is performed at a temperature of 25° C., ambient humidity, according to the following steps: 1) remove a substantially flat strip of the layered structure from the building surface panel to be tested, the strip extending parallel to the length of the building surface panel and having a length of 33 inches and a width of 4.5 inches (any nail hem may be cut away), 2) define a first end point of the strip at a position on the front side of the outer element that is 1.5 inches from a first end of the strip and centered across the width of the strip, and define a second end point of the strip at a position on the front side of the outer element that is that is 1.5 inches from the second end of the strip and centered across the width of the strip, 3) position the strip such that the width is oriented vertically, the front side of the outer element faces a fixed reference plane, and a line that passes through the first and second end points is parallel to the reference plane, and 4) measure, using a laser position gage, the deflection measurement as equal to a difference between a first distance from the end points to the reference plane and a second distance from a peak on the front side of the outer element to the reference plane. According to particular embodiments, the building surface panelmay have a deflection measurement of not greater than about 10 mm, such as not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm. Additionally, the building surface panelaccording to various embodiments of the present invention exhibits deflection measurement of not greater than 10 mm not greater than about 9 mm or not greater than about 8 mm or not greater than about 7 mm or not greater than about 6 mm or even not greater than about 5 mm, in a curvature test when exposed to 1000 W/m. It will be appreciated that the deflection measurement of the building surface panelmay be between any of the values noted above. It will be further appreciated that the deflection measurement of the building surface panelmay be any value between any of the values noted above.

According to yet other embodiments, the building surface panelmay have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the building surface panelmay have an R-value of not greater than about 0.60° F.·ft·hr/BTU, such as not greater than about 0.57° F.·ft·hr/BTU or not greater than about 0.55° F.·ft·hr/BTU or not greater than about 0.53° F.·ft·hr/BTU or not greater than about 0.50° F.·ft·hr/BTU or not greater than about 0.47° F.·ft·hr/BTU or not greater than about 0.45° F.·ft·hr/BTU or not greater than about 0.43° F.·ft·hr/BTU or not greater than about 0.40° F.·ft·hr/BTU or not greater than about 0.37° F.·ft·hr/BTU or not greater than about 0.35° F.·ft·hr/BTU or not greater than about 0.33° F.·ft·hr/BTU or not greater than about 0.30° F.·ft·hr/BTU or not greater than about 0.27° F.·ft·hr/BTU or not greater than about 0.25° F.·ft·hr/BTU or not greater than about 0.23° F.·ft·hr/BTU or not greater than about 0.20° F.·ft·hr/BTU or not greater than about 0.17° F.·ft·hr/BTU or not greater than about 0.15° F.·ft·hr/BTU or not greater than about 0.13° F.·ft·hr/BTU or even not greater than about 0.10° F.·ft·hr/BTU. It will be appreciated that the R-value of the building surface panelmay be between any of the values noted above. It will be further appreciated that the R-value of the building surface panelmay be any value between any of the values noted above.

According to yet other embodiments, the outer elementmay have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal-conductivity of the article as measured according to ASTM C518. According to certain embodiments, the outer elementmay have an R-value of not greater than about 0.40° F.·ft·hr/BTU, such as not greater than about 0.37° F.·ft·hr/BTU or not greater than about 0.35° F.·ft·hr/BTU or not greater than about 0.33° F.·ft·hr/BTU or not greater than about 0.30° F.·ft·hr/BTU or not greater than about 0.27° F.·ft·hr/BTU or not greater than about 0.25° F.·ft·hr/BTU or not greater than about 0.23° F.·ft·hr/BTU or not greater than about 0.20° F.·ft·hr/BTU or not greater than about 0.17° F.·ft·hr/BTU or not greater than about 0.15° F.·ft·hr/BTU or not greater than about 0.13° F.·ft·hr/BTU or even not greater than about 0.10° F.·ft·hr/BTU. It will be appreciated that the R-value of the outer elementmay be between any of the values noted above. It will be further appreciated that the R-value of the outer elementmay be any value between any of the values noted above.

According to yet other embodiments, the backing componentmay have a particular R-value. For purposes of embodiments described herein the R-value is equal to the thickness of the article divided by the thermal conductivity of the article as measured according to ASTM C518. According to certain embodiments, the backing componentmay have an R-value of not greater than about 0.40° F.·ft·hr/BTU, such as not greater than about 0.37° F.··ft·hr/BTU or not greater than about 0.35° F.·ft·hr/BTU or not greater than about 0.33° F.·ft·hr/BTU or not greater than about 0.30° F.·ft·hr/BTU or not greater than about 0.27° F.·ft·hr/BTU or not greater than about 0.25° F.·ft·hr/BTU or not greater than about 0.23° F.·ft·hr/BTU or not greater than about 0.20° F.·ft·hr/BTU or not greater than about 0.17° F.·ft·hr/BTU or not greater than about 0.15° F.·ft·hr/BTU or not greater than about 0.13° F.··ft·hr/BTU or even not greater than about 0.10° F.·ft·hr/BTU. It will be appreciated that the R-value of the backing componentmay be between any of the values noted above. It will be further appreciated that the R-value of the backing componentmay be any value between any of the values noted above.

According to still other embodiments, the building surface panelmay pass a surface distortion test as measured according to ASTM 7745, where the foam backer is replaced with the backing componentof the present invention. In particular, the building surface panelmay pass a surface distortion test as measured according to ASTM 7745 at a temperature of 150° F. (66° C.) by being free of bulges, waves, and ripples. In various embodiments, the building surface panels of the present invention are substantially free of surface distortion, which can also be referred to as oil-canning effect.

According to other embodiments, the building surface panelmay have a particular vertical face radius of curvature as measured at room temperature along the vertical face (i.e., along the y-axis) of the building surface panel. For example, the building surface panelmay have a vertical face radius of curvature of at least about 500 mm, such as at least about 550 mm or at least about 600 mm or at least about 650 mm or at least about 700 mm or at least about 750 mm or at least about 800 mm or at least about 850 mm or at least about 900 mm or at least about 950 mm or at least about 1000 mm or at least about 1050 mm or at least about 1100 mm or at least about 1150 mm or at least about 1200 mm or at least about 1250 mm or at least about 1300 mm or at least about 1350 mm or at least about 1400 mm or at least about 1450 mm or at least about 1500 mm or at least about 1550 mm or at least about 1600 mm or at least about 1650 mm or at least about 1700 mm or at least about 1750 mm or at least about 1800 mm or at least about 1850 mm or at least about 1900 mm or at least about 1950 mm or at least about 2000 mm or at least about 2050 mm or at least about 2100 mm or at least about 2150 mm or at least about 2200 mm or at least about 2250 mm or at least about 2300 mm or at least about 2350 mm or at least about 2400 mm or at least about 2450 mm or at least about 2500 mm or at least about 2550 mm or even at least about 2600 mm. It will be appreciated that the vertical face radius of curvature of the building surface panelmay be between any of the values noted above. It will be further appreciated that the vertical face radius of curvature of the building surface panelmay be any value between any of the values noted above.

According to still other embodiments, the outer elementof the building surface panelmay include a particular material. For example, the outer elementmay include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic resin, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, polymer composite, any combination thereof, any recycled versions of these materials thereof, or any recycled blends of these materials thereof, and combinations thereof comprising a combination of one of the above virgin (new/non-recycled) material and one of the above recycled material. As used herein, the term “recycled material” refers to post-industrial recycled material including scrap and regrind material, post-consumer recycled material, and a combination thereof.

According to yet other embodiments the outer elementof the building surface panelmay also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

According to still other embodiments, the outer elementof the building surface panelmay have a particular CTE as measured according to ASTM D696. For example, the outer elementmay have a CTE of not greater than about 200 μm/(m·° C.), such as not greater than about 195 μm/(m·° C.) or not greater than about 190 μm/(m·° C.) or not greater than about 185 μm/(m·° C.) or not greater than about 180 μm/(m·° C.) or even not greater than about 175 μm/(m·° C.). It will be appreciated that the CTE of the outer elementmay be within a range between any of the values noted above. It will be further appreciated that the CTE of the outer elementmay be any value between any of the minimum and maximum values noted above.

According to other embodiments, the backing componentof the building surface panelmay include a particular material. For example the backing component may include polyvinyl chloride (PVC), cellular 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 and combinations thereof comprising a combination of one of the above virgin (new/non-recycled) material and one of the above recycled material. In an embodiment, the backing component comprises recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC in an amount greater than that present in the capstock layer and/or the support layer of the outer element.

In yet another embodiment, the backing componentcomprises post-industrial recycled PVC or post-consumer recycled PVC in an amount of greater than 1%, or greater than 5%, or greater than 10%, or greater than 20%, or greater than 30%, or greater than 40%, or greater than 50%, or greater than 60%, or greater than 70%, or greater than 80%, or greater than 90%, or greater than 95%, or greater than 99%, and up to 100%, by weight, based on the total weight of the backing component. In yet another embodiment, the backing componentcomprises recycled PVC with impurities that can include portions having different colors; small amounts of adhesive (e.g., less than 20% adhesive, or less than 15% adhesive, or less than 10% adhesive; or less than 5% adhesive); various other polymers; or a small amounts of metal (e.g., less than 1%). In another embodiment, the backing componentcomprises recycled PVC that includes portions of recycled PVC having different colors.

The backing component, as opposed to the outer elementcan include recycled PVC with minimal contents of impurities from the group including adhesive, metal, different colored PVC, various other polymers, etc. These impurities can arise from the reclamation process for collecting used or not newly manufactured PVC (e.g., from a job site, from factory PVC waste material, etc.), and blending the recycled PVC into manufacturing processes to make a product, such as a backing component.

The various impurities that can be present in the recycled PVC can include, but are not limited to, at least one of polyvinylidene flouride (PVDF), acrylonitrile styrene acrylate (ASA), chlorinated PVC (CPVC), polyurethane, acrylic, silicone, rubber, chlorinated polyethylene, calcium carbonate, titanium dioxide, talc, and combinations thereof. The various polymers can account for less than 20%, or less than 15%, or less than 10%; or less than 5% by weight of the backing component. The metal can comprise aluminum or steel and can account for less than 1% by weight of the backing component.

In an embodiment of the building surface panel, the amount of recycled PVC in the backing component, is substantially greater than that of the outer element. In some embodiments of the building surface panel, the outer elementand the backing componenthave substantially the same color. In other embodiments of the building surface panel, the outer elementand the backing componenthave substantially different colors.

According to yet other embodiments, the backing componentof the building surface panelmay also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof. For example, the backing componentmay include one or more additives and a polymer including 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.

In all embodiments in this disclosure, the outer elementcan include a capstock disposed over a support layer, with the capstock forming the front sideand the backing componentbeing disposed over the outer elementon a side opposite the capstock, the rear sideof the outer element, as shown in. The capstock and backer material can be any of the materials disclosed below for the outer element. However, it can be preferrable that the capstock be made from a material that is more resistant to damage or degradation by environmental elements. Therefore, the capstock can be laminated to the outer element or coextruded with the support layer or tri-extruded with the support layer and the backer material or printed/painted on those surfaces of the outer elementthat would be exposed to the elements when installed on a building.

Any suitable polymer can be used for capstock including, but not limited to, 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. The capstock may also comprise one or more additives. Non-limiting examples of suitable one or more additives include, but not limited to, oxidative and thermal stabilizers, impact modifiers, lubricants, release agents, flame-retarding agents, oxidation inhibitors, oxidation scavengers, neutralizers, antiblock agents, dyes, pigments and other coloring agents, ultraviolet light absorbers and stabilizers, organic or inorganic fillers, reinforcing agents, nucleators, plasticizers, waxes, and combinations thereof.

In a non-limiting embodiment, the capstock comprises a virgin polymer, such as acrylonitrile styrene acrylate (ASA), and the support layer or the backing componentcomprises a suitable polymer such as polyvinyl chloride (PVC), or chlorinated polyvinyl chloride (CPVC), recycled PVC, post-industrial recycled PVC or post-consumer recycled PVC or blends thereof.

In a non-limiting embodiment, the support layer of the outer elementand the backing componentcomprises substantially the same polymeric composition (polymer and one or more additives). In a non-limiting embodiment, the outer elementcomprising the capstock and the support layer forming the front side, comprises two different polymeric compositions, and the backing componentis formed of another polymeric composition different from that of the capstock and the support layer. The polymeric compositions of the capstock, the support layer, and the backing componentcan differ in the amounts of one or more additives and/or the chemical composition of the polymers. In a non-limiting embodiment, the capstock, the support layer and the backing componentare all co-extruded or tri-extruded. In a non-limiting embodiment, capstock is laminated over the support layer. In yet another embodiment, capstock is painted, printed, spray coated, or roll coated over the support layer.

According to still other embodiments, the backing componentof the building surface panelmay have a particular CTE as measured according to ASTM D696. For example, the backing componentmay have a CTE of not greater than about 200 μm/(m·° C.), such as not greater than about 195 μm/(m·° C.) or not greater than about 190 μm/(m·° C.) or not greater than about 185 μm/(m·° C.) or not greater than about 180 μm/(m·° C.) or even not greater than about 175 μm/(m·° C.). It will be appreciated that the CTE of the backing componentmay be within a range between any of the values noted above. It will be further appreciated that the CTE of the backing componentmay be any value between any of the minimum and maximum values noted above.

According to yet other embodiments, the outer elementmay have a particular thickness. As used herein, “thickness” of the outer elementrefers to the distance between the front sideand the rear sideas shown in at least. For example, the outer elementmay have a thickness of at least about 0.1 mm, such as at least about 0.5 mm or at least about 1 mm or at least about 1.5 mm or at least about 2 mm or at least about 2.5 mm or at least about 3 mm or at least about 3.5 mm or at least about 4 mm or at least about 4.5 mm or even at least about 5 mm. According to still other embodiments, the outer elementmay have a thickness of not greater than about 10 mm, such as not greater than about 9.5 mm or not greater than about 9.0 mm or not greater than about 8.5 mm or not greater than about 8 mm or even not greater than about 7.5 mm. It will be appreciated that the thickness of the outer elementmay be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the outer elementmay be any value between any of the minimum and maximum values noted above.

According to still other embodiments, the backing componentmay have a particular thickness. As used herein, “thickness” of the backing componentrefers to the distance between the front sideto the rear sideof the portions of the backing componentthat are outside the reinforcement elementsas shown in at least. As used herein, “thickness” of the outer elementrefers to the distance between the front sideto the rear sideof the outer elementas shown in at least. For example, the backing componentmay have a thickness of at least about 0.02 mm, such as at least about 0.05 mm or at least about 0.1 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the backing componentmay have a thickness of not greater than about 50 mm, such as not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm or not greater than about 15.0 mm or not greater than about 10 mm or not greater than about 5 mm or not greater than about 4 mm or not greater than about 3 mm. It will be appreciated that the thickness of the backing componentmay be within a range between any of the minimum and maximum values noted above here it will be further appreciated that the thickness of the backing componentmay be any value between any of the minimum and maximum values noted above.

According to still other embodiments, the building surface panelmay have a particular thickness or multiple thicknesses along the height (Y axis). For example, the building surface panelmay have a thickness of at least about 0.12 mm, such as at least about 0.13 mm or at least about 0.14 millimeters or at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or at least about 0.35 mm or at least about 0.4 mm or at least about 0.45 mm or at least about 0.5 mm or at least about 1.0 mm or at least about 2.5 mm or at least about 5.0 mm or at least about 7.5 mm or at least about 10.0 mm or at least about 12.5 mm or at least about 15.0 mm or at least about 17.5 mm or even at least about 20 mm. According to still other embodiments, the building surface panelmay have a thickness of not greater than about 60 mm, such as not greater than about 57.5 mm were not greater than about 55 mm were not greater than about 52.5 mm were not greater than about 50 mm were not greater than about 47.5 mm were not greater than about 45 mm or not greater than about 42.5 mm or not greater than about 40 millimeters are not greater than about 37.5 mm or not greater than about 35 mm or not greater than about 32.5 mm or not greater than about 30 mm or not greater than about 27.5 mm or even not greater than about 25 mm. It will be appreciated that the thickness of the building surface panelmay be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the building surface panelmay be any value between any of the minimum and maximum values noted above. In some embodiments, the building surface panelcan have multiple thicknesses, along the height (Y axis), within a range between any of the minimum and maximum values noted above due to portions of the building surface panelwhere the outer elementis attached to the backing component, and other portions of the building surface panelwhere the outer elementhas no backing componentattached to it.

In an embodiment, a first thickness of the backing componentcan be greater than about 0.5 times, or greater than about 1.0 times, or greater than about 1.2 times, or greater than about 1.5 times, or greater than about 2.0 times, or greater than about 2.5 times, or greater than about 3.0 times or greater than about 3.5 times a second thickness of the outer element. The first thickness of the backing componentcan be less than about 5.0 times, or less than about 4.75 times, or less than about 4.25 times, or than about 3.75 times, or less than about 3.25 times, or less than about 2.75 times, or less than about 2.25 times, or less than about 1.75 times, or less than about 1.25 times, or less than about 0.75 times a second thickness of the outer element. It will be appreciated that the first thickness of the backing componentmay be within a range between any of the minimum and maximum values noted above times the second thickness of the outer element.

As noted above, the outer elementcan be attached to the backing componentor vice versa. Any suitable means could be used for attaching the outer elementand the backing component, including but not limited to, chemical, plasma, thermal, or ultrasonic bonding, adhesive, mechanically or a combination thereof. According to certain embodiments, the outer elementcan be attached to the backing componentthrough a particular means. For example, according to certain embodiments, the outer elementcan be fused to the backing component, for example, through an ultrasonic weld. According to yet other embodiments, the outer elementcan be mechanically attached to the backing component, for example, through a clip, nail, screw, or any other mechanical attachment component.

According to yet other embodiments, the backing componentcan be fixedly attached to any portion of the outer element. According to still other embodiments, the outer elementcan be adhered to any portion of the backing component, for example, with an adhesive. According to still other embodiments, the outer elementcan be bonded to the backing component, for example, through chemical, plasma, or thermal bonding.

According to still other embodiments, the building surface panelmay further include an adhesive layer (not shown in) between the outer elementand the backing component.

According to particular embodiments, the building surface panelmay have a particular bond shear strength as measured between the outer elementand the backing component. For example, the shear strength between the outer elementand the backing componentmay be at least about 0.10 MPa, such as at least about 0.15 MPa or at least about 0.20 MPa or at least about 0.25 MPa or at least about 0.30 MPa or at least about 0.35 MPa or at least about 0.40 MPa or at least about 0.45 MPa or at least about 0.50 MPa or at least about 0.55 MPa or at least about 0.60 MPa or at least about 0.65 MPa or even at least about 0.70 MPa or even at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 3.0 MPa or even at least about 4.0 MPa or even at least about 5.0 MPa or even at least about 6.0 MPa or even at least about 7.5 MPa at room temperature and at least about 1.0 MPa or even at least about 2.0 MPa or even at least about 4 MPa or at least about 7.5 MPa or even at least about 10 MPa or even at least about 12 MPa or even at least about 15 MPa at a temperature of about −40° C. It will be appreciated that the shear strength as measured between the outer elementand the backing componentmay be within a range between any of the values noted above. It will be further appreciated that the bond shear strength as measured between the outer elementand the backing componentmay be any value between any of the values noted above.