System, method and article for siding corner

Patent metadata

Field	Value
Publication number	US-11007690-B2
Application number	US-201715854266-A
Country	US
Kind code	B2
Filing date	Dec 26, 2017
Priority date	Mar 15, 2013
Publication date	May 18, 2021
Grant date	May 18, 2021

Abstract

A method of injection molding a building product includes providing an injection mold with a plurality of gates located adjacent a perimeter of the injection mold. The method further includes commingling a first material and a second material into a flow, the second material comprising a color that contrasts with a color of the first material and injecting the commingled flow into the plurality of gates to form a building product. Thereafter, the method includes removing the building product from the injection mold. The second material extends through an interior of the building product and appears as contrasting streaks on an exterior of the building product to form a variegated grain appearance. The method also includes notching a portion of the building product, such that the building product has a substantially linear grain in an exposed portion thereof.

First claim

What is claimed is:

1. A method of injection molding a building product, comprising:
(a) providing an injection mold with a plurality of gates located adjacent a perimeter of the injection mold;
(b) commingling a first material and a second material into a flow, forming a commingled flow, the second material comprising a color that contrasts with a color of the first material;
(c) injecting the commingled flow into the plurality of gates to form the building product, wherein the building product comprises a corner shingle comprising two tiles that are substantially orthogonal and resembling a single course of tiles that differ in size, wherein each tile comprises a headlap and an exposed portion below the headlap, the headlap further comprising a pair of flow runners that intersect at an injection molded vestige at the perimeter of the injection mold;
(d) removing the building product from the injection mold, wherein the second material extends through an interior of the building product and appears as contrasting streaks on an exterior of the building product, and wherein the contrasting streaks are substantially parallel to a wood grain direction of the building product to form a variegated wood grain appearance; and
(e) notching a portion of the building product, forming a notched portion, such that the building product has a substantially linear grain in an exposed portion thereof.

2. The method of claim 1 , wherein the notched portion comprises a plurality of notched portions.

3. The method of claim 2 , wherein the notched portions comprise upper outer corners of the building product.

4. The method of claim 2 , wherein the notched portions are positions at upper outer corners of the tiles in the headlap above the exposed portion.

5. The method of claim 1 , wherein the building product comprises corner tiles that differ in size by horizontal width.

6. The method of claim 1 , wherein a melting point of the first material is about 20° F. to about 70° F. less than the melting point of the second material.

7. The method of claim 1 , wherein the injection mold comprises a cavity located within the perimeter of the injection mold, the cavity is generally in a shape of a corner panel.

8. The method of claim 7 , wherein the step (c) comprises a substantially linear commingled flow through the corner panel of the cavity away from the gates.

9. The method of claim 1 , wherein the step (c) comprises dividing the commingled flow into separate flow runners for each gate.

10. The method of claim 1 , wherein the step (c) comprises forming different textures on different tiles of the building product.

11. The method of claim 1 , wherein the step (c) comprises forming the building product with a front or cavity side, and a back or core side, and texturing both the front and the back.

12. The method of claim 11 , wherein the step (c) comprises contouring the back to follow and be complementary in shape to the texture on the front.

13. A method of injection molding a building product, comprising:
(a) providing an injection mold with a plurality of gates located adjacent a perimeter of the injection mold;
(b) commingling a first material and a second material into a flow, forming a commingled flow, the second material comprising a color that contrasts with a color of the first material;
(c) injecting the commingled flow into the plurality of gates to form an injection molded building product, wherein the injection molded building product comprises a corner shingle comprising two tiles that are substantially orthogonal and resembling a single course of tiles that differ in size, wherein each tile comprises a headlap and an exposed portion below the headlap, the headlap further comprising a pair of flow runners that intersect at an injection molded vestige at the perimeter of the injection mold; and
(d) removing the injection molded building product from the injection mold;
wherein the second material extends through an interior of the injection molded building product and appears as contrasting streaks on an exterior of the injection molded building product, and wherein the contrasting streaks are substantially parallel to a wood grain direction of the injection molded building product to form a variegated wood grain appearance.

14. The method of claim 13 , wherein both the first and second materials are an amorphous or semi-crystalline thermoplastic, or a thermoset material.

15. The method of claim 13 , wherein the first material is a solid at room temperature and the second material is a liquid at room temperature, or both materials are solid at room temperature.

16. The method of claim 13 , wherein the first material has a melting point that is less than a melting point of the second material.

17. The method of claim 13 , wherein the melting point of the first material is about 20° F. to about 70° F. less than the melting point of the second material.

18. A method of injection molding a building product, comprising:
(a) providing an injection mold with a first gate and a second gate, wherein each of the first and second gates is located adjacent a perimeter of the injection mold;
(b) injecting a first material into the first gate;
(c) injecting a second material into the second gate at about a same time as the step (b), such that the first and the second materials are substantially simultaneously co-injected into the injection mold, forming a commingled flow, and the second material comprises a color that contrasts with a color of the first material; and
(d) removing the building product from the injection mold;
wherein the building product comprises a corner shingle comprising two tiles that are substantially orthogonal and resembling a single course of tiles that differ in size, wherein each tile comprises a headlap and an exposed portion below the headlap, the headlap further comprising a pair of flow runners that intersect at an injection molded vestige at the perimeter of the injection mold, wherein the second material extends through an interior of the building product and appears as contrasting streaks on an exterior of the building product, and wherein the contrasting streaks are substantially parallel to a wood grain direction of the building product to form a variegated wood grain appearance.

19. The method of claim 18 , wherein the first material comprises about 85 wt. % to about 97 wt. % of a base resin.

20. The method of claim 18 , wherein the first material comprises a base resin, and the second material comprises a colorant that has a melting point similar to that of the base resin.

Assignees

• Certain Teed Corp

Inventors

• Steffes Stephen W
• Kirn Brian W

Classifications

• B29C45/1816

  Feeding auxiliary material, e.g. colouring material · CPC title

• B29L2031/104

  Tiles · CPC title

• E04D3/32

  of plastics, fibrous materials, or asbestos cement · CPC title

• B29K2995/0021

  Multi-coloured · CPC title

• B29C45/0055

  Shaping · CPC title