IP Library › Granted Patent US 11,649,639

Granted Patent B2

US 11,649,639 · App. 17/713,655 · Granted May 16, 2023

Assembly for improved insulation

Inventors: Patrick Olvey (Columbus, OH); Chris J. Johnson (Columbus, OH)

Assignee: Westlake Royal Building Products (USA) Inc.

E04F13/0875 B32B3/30 B32B5/18 E04C2/284 B32B2266/0228 B32B2305/022 B32B2307/304 B32B2607/00

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Quick Facts

Patent No.: US 11,649,639
App. No.: 17/713,655
Granted: May 16, 2023
Kind: B2

External Links

USPTO Patent Center↗ Full Patent PDF↗

Abstract

An insulated panel assembly having improved insulative R-value. The insulated panel assembly comprises a cover panel, a first insulation layer, and at least one additional insulation layer, wherein the at least one additional insulation layer has a higher R-value than the first insulation layer. The first insulation layer is secured to the cover panel. The first insulation layer further forms at least one recessed portion. The at least one additional insulation layer is positioned in the at least one recessed portion of the first insulation layer. Examples of the at least one additional insulation layer may include vacuum insulated panels and modified atmosphere insulation panels.

Claims (55)

1. An insulated panel assembly comprising:

a first cover layer;

a first insulation layer secured to the first cover layer, the first insulation layer comprising a front face, a rear face, a first end, a second end, and at least one recessed portion in the front face, the rear face, the first end, or the second end; and

at least one additional insulation layer positioned in the at least one recessed portion of the first insulation layer and secured to the first cover layer or the first insulation layer by a means of connection selected from the group consisting of tape, mechanical fasteners, and adhesives, or by being interlocked with the first cover layer or the first insulation layer;

wherein the at least one additional insulation layer has freedom of movement within the at least one recessed portion to allow for differences in expansion and contraction rates between the at least one additional insulation layer and the first insulation layer; and

wherein the at least one additional insulation layer has a higher R-value than the first insulation layer.

2. The insulated panel assembly of claim 1 wherein the at least one additional insulation layer is a vacuum insulated panel.

3. The insulated panel assembly of claim 1 wherein the at least one additional insulation layer is a MAI panel.

4. The insulated panel assembly of claim 1 wherein the first cover layer is a siding panel.

5. The insulated panel assembly of claim 1 wherein the first insulation layer is comprised of expanded polystyrene foam.

6. The insulated panel assembly of claim 1 or 5 further comprising:

a back cover secured to the first cover layer or the first insulation layer to assist with retaining the at least one additional insulation layer in the at least one recessed portion of the first insulation layer.

7. The insulated panel assembly of claim 6 wherein the back cover is comprised of a same material as the first insulation layer.

8. The insulated panel assembly of claim 6 wherein the back cover is secured to the first cover layer or the first insulation layer by tape such that the tape is adapted to be removed to facilitate removal of the back cover.

9. The insulated panel assembly of claim 1 wherein the at least one recessed portion is in the front face of the first insulation layer.

10. The insulated panel assembly of claim 9 wherein:

the front face of the first insulation panel has a portion set at an inclined angle; and

the at least one recessed portion is positioned in the portion set at inclined angle.

11. The insulated panel assembly of claim 1 wherein the at least one recessed portion is in the rear face of the first insulation layer.

12. The insulated panel assembly of claim 1 wherein the at least one recessed portion is in at least one of the first end and the second end of the first insulation layer.

13. The insulated panel assembly of claim 1 wherein the at least one additional insulation layer is removable from the at least one recessed portion of the first insulation layer.

14. The insulated panel assembly of claim 13 wherein the at least one additional insulation layer is secured in the at least one recessed portion by tape such that the tape is adapted to be removed to facilitate removal of the at least one additional insulation layer from the at least one recessed portion of the first insulation layer.

15. The insulated panel assembly of claim 1 wherein the at least one additional insulation layer is permanently secured in the at least one recessed portion of the first insulation layer.

16. The insulated panel assembly of claim 1 wherein the at least one additional insulation layer is secured to the first cover layer or the first insulation layer by at least one mechanical fastener selected from the group consisting of nuts and bolts, screws, nails, staples, and hook and loop fasteners.

17. The insulated panel assembly of claim 1 wherein the at least one additional insulation layer is secured to the first cover layer or the first insulation layer by at least one adhesive selected from the group consisting of glues and resins.

18. The insulated panel assembly of claim 1 wherein:

the first cover layer is a vinyl siding panel;

the first insulation layer is comprised of expanded polystyrene foam; and

the at least one additional insulation layer is selected from the group consisting of vacuum insulated panels and MAI panels.

19. A siding panel assembly comprising:

a siding panel;

an expanded polystyrene foam layer secured to the siding panel, the expanded polystyrene foam layer comprising a front face, a rear face, a first end, a second end, and at least one recessed portion in the front face, the rear face, the first end, or the second end; and

at least one additional insulation layer positioned in the at least one recessed portion of the expanded polystyrene foam layer and secured to the siding panel or the expanded polystyrene foam layer by a means of connection selected from the group consisting of tape, mechanical fasteners, and adhesives, or by being interlocked with the siding panel or the expanded polystyrene foam layer;

wherein the at least one additional insulation layer has a higher R-value than the expanded polystyrene foam layer.

20. The siding panel assembly of claim 19 wherein the at least one additional insulation layer is a vacuum insulated panel.

21. The siding panel assembly of claim 19 wherein the at least one additional insulation layer is a MAI panel.

22. The siding panel assembly of claim 19 further comprising:

a back cover secured to the siding panel or the expanded polystyrene foam layer to assist with retaining the at least one additional insulation layer in the at least one recessed portion of the expanded polystyrene foam layer.

23. The siding panel assembly of claim 22 wherein the back cover is comprised of expanded polystyrene foam.

24. The siding panel assembly of claim 22 wherein the back cover is secured to the siding panel or the expanded polystyrene foam layer by tape such that the tape is adapted to be removed to facilitate removal of the back cover.

25. The siding panel assembly of claim 19 wherein the at least one recessed portion is in the front face of the expanded polystyrene foam layer.

26. The siding panel assembly of claim 25 wherein:

the front face of the expanded polystyrene foam layer has a portion set at an inclined angle; and

the at least one recessed portion is positioned in the portion set at inclined angle.

27. The siding panel assembly of claim 19 wherein the at least one recessed portion is in the rear face of the expanded polystyrene foam layer.

28. The siding panel assembly of claim 19 wherein the at least one recessed portion is in at least one of the first end and the second end of the expanded polystyrene foam layer.

29. The siding panel assembly of claim 19 wherein the at least one additional insulation layer is removable from the at least one recessed portion of the expanded polystyrene foam layer.

30. The siding panel assembly of claim 29 wherein the at least one additional insulation layer is secured in the at least one recessed portion by tape such that the tape is adapted to be removed to facilitate removal of the at least one additional insulation layer from the at least one recessed portion of the expanded polystyrene foam layer.

31. The siding panel assembly of claim 19 wherein the at least one additional insulation layer is permanently secured in the at least one recessed portion of the expanded polystyrene foam layer.

32. The siding panel assembly of claim 19 wherein the at least one additional insulation layer is secured to the siding panel or the expanded polystyrene foam layer by at least one mechanical fastener selected from the group consisting of nuts and bolts, screws, nails, staples, and hook and loop fasteners.

33. The siding panel assembly of claim 19 wherein the at least one additional insulation layer is secured to the siding panel or the expanded polystyrene foam layer by at least one adhesive selected from the group consisting of glues and resins.

34. The siding panel assembly of claim 19 wherein:

the siding panel is a vinyl siding panel; and

the at least one additional insulation layer is selected from the group consisting of vacuum insulated panels and MAI panels.

Assignments (2)

CHANGE OF NAME Recorded Feb 17, 2023

From: ROYAL BUILDING PRODUCTS (USA) INC.

To: WESTLAKE ROYAL BUILDING PRODUCTS (USA) INC.

Reel/Frame 062797/0496 →

ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 5, 2022

From: OLVEY, PATRICK; JOHNSON, CHRIS J.

To: ROYAL BUILDING PRODUCTS (USA) INC.

Reel/Frame 059505/0406 →