Panel for attachment to a mounting surface of a building structure and method of making the same

A panel configured for attachment to a mounting surface of a building structure, the panel comprising:

• a first end surface and a second end surface spaced from each other along a longitudinal axis;
• a top edge surface and a bottom edge surface spaced from each other and offset from the longitudinal axis;
• and
• an inner surface and an outer surface opposed to each other and extending from the first end surface and the second end surface,
• wherein the inner surface comprises,
• a contact portion disposed on a reference plane,
• a first contour portion and a second contour portion, each contoured toward the outer surface, away from the reference plane, such that the first contour portion defines a first channel and the second contour portion defines a second channel, wherein the first and second channels each extend along a length of the panel between the first end surface and the second end surface;
• a first notched portion and a second notched portion, each contoured toward the outer surface, away from the reference plane, such that the first notched portion defines a first plurality of turbulence-inducing elements and the second notched portion defines a second plurality of turbulence-inducing elements, wherein each of the first plurality of turbulence-inducing elements extend along the panel between the top edge surface and the first channel and each of the second plurality of turbulence-inducing elements extend along the panel between the bottom edge surface and the second channel;
• and
• an undulating portion extending between the first end surface and the second end surface, such that the undulling portion is disposed between the first contour portion and the second contour portion, the first contour portion is disposed between the first notched portion and the undulating portion, and the second contour portion is disposed between the second notched portion and the undulating portion;
• wherein the undulating portion is contoured toward the outer surface in an undulating fashion, away from the reference plane, wherein the undulating portion comprises a first undulating portion defining a first plurality of curves and a second undulating portion defining a second plurality of curves, and wherein each of the first plurality of curves extends in offset relationship to each of the second plurality of curves.

A method of making a panel configured for attachment to a mounting surface of a building structure, the method comprising:

• molding a polymer in a mold cavity of a continuous mold formed at least in part by opposing surfaces of two opposed belts;
• wherein the panel comprises a first end surface and a second end surface spaced from each other along a longitudinal axis and comprises:
• a top edge surface and a bottom edge surface spaced from each other and offset from the longitudinal axis;
• and
• an inner surface and an outer surface opposed to each other and extending from the first end surface and the second end surface;
• wherein the inner surface comprises:
• a contact portion disposed on a reference plane;
• and
• a contour portion contoured toward the outer surface, away from the reference plane, such that the contour portion defines a channel extending lengthwise along at least a portion of the panel between the first end surface and the second end surface;
• a notched portion contoured toward the outer surface, away from the reference plane, such that the notched portion defines a turbulence-inducing element, and
• an undulating portion extending between the first end surface and the second end surface, such that the contour portion is disposed between the notched portion and the undulating portion, wherein the undulating portion is contoured toward the outer surface in an undulating fashion, away from the reference plane, wherein the undulating portion comprises a first undulating portion and a second undulating portion each defining a plurality of curves, and wherein each of the plurality of curves of the first undulating portion extends in offset relationship to each of the plurality of curves of the second undulating portion;
• and
• wherein at least one of the two opposed belts comprises:
• a contact portion-forming section;
• and
• a contour portion-forming section.