Continuous production of plastic siding panels with separate shingle appearance

A method of continuously producing elongated siding panels, each panel having an upper edge portion, an intermediate portion having an aesthetic pattern, and a lower edge portion having a lower leg extending substantially perpendicular from the intermediate portion defining a horizontal plane, said method comprising the steps of:

• extruding a sheet of material having a temperature sufficient for vacuum forming the sheet of material;
• directing the sheet of material onto a plurality of mold plates carried by a conveyor, each of the mold plates having an upper edge portion, a lower edge portion, and an intermediate portion having an aesthetic pattern disposed therebetween;
• progressively applying a vacuum to the mold plates as the mold plates travel along the conveyor;
• drawing the sheet of material into the mold plates when the vacuum is applied;
• forming the upper edge portion, the intermediate portion, and the lower edge portion while the entire sheet of material has the sufficient temperature for vacuum forming;
• and
• forming a projection portion between the lower edge portion and the intermediate portion simultaneously with the forming of the lower edge portion and the intermediate portion wherein the projection portion extends beyond the horizontal plane to impart a jagged pattern to the intermediate portion.

An elongated siding panel formed of a sheet of material, said elongated siding panel comprising:

• an upper edge portion and a lower edge portion with an intermediate portion therebetween;
• said intermediate portion having an aesthetic pattern therein;
• said lower edge portion having a lower leg extending substantially perpendicular from said intermediate portion defining a horizontal plane and a cap leg extending upwardly from said horizontal plane such that said lower edge portion has a generally C-shape;
• and
• a projection portion between said lower edge portion and said intermediate portion extending beyond said horizontal plane for imparting a jagged pattern to said intermediate portion.