US20150128422A1 - Method of forming steel cladding construction for buildings - Google Patents
Method of forming steel cladding construction for buildings Download PDFInfo
- Publication number
- US20150128422A1 US20150128422A1 US14/079,367 US201314079367A US2015128422A1 US 20150128422 A1 US20150128422 A1 US 20150128422A1 US 201314079367 A US201314079367 A US 201314079367A US 2015128422 A1 US2015128422 A1 US 2015128422A1
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- United States
- Prior art keywords
- panel
- media
- cladding
- relief pattern
- predetermined
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- Abandoned
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/26—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles
- E04D1/265—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles the roofing elements being rigid, e.g. made of metal, wood or concrete
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
- B21C47/16—Unwinding or uncoiling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
- B21D11/18—Joggling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/26—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/28—Roofing elements comprising two or more layers, e.g. for insulation
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
- E04D3/30—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of metal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
- Y10T29/49623—Static structure, e.g., a building component
- Y10T29/49629—Panel
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Finishing Walls (AREA)
Abstract
A method for forming cladding panels includes providing a panel forming unit comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a panel media is moved through the panel forming unit, placing the panel media proximate the panel forming unit and feeding the panel media into the panel forming unit, embossing a texture defined by the panel media using the embossing unit, pressing guide lines and guide indents into the panel media using the punch press, stamping a relief pattern into the panel media using the stamping die such that the texture is defined within the relief pattern, cutting the panel media into panels using the shear press and forming at least one flange on an edge of each of the panels using the roll former, wherein the panels each include a flange, the texture and the relief pattern.
Description
- The present application generally relates to a method for making exterior cladding panels, more specifically, a method for making exterior cladding panels having a plurality of stamped patterns and applied finishes.
- In at least one respect, a method for forming roofing panels in a continuous assembly path includes the steps of providing a continuous panel forming unit comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a panel media is moved through the panel forming unit, placing the panel media proximate the panel forming unit and feeding an end of the panel media into the panel forming unit, embossing a predetermined texture defined by the panel media using the embossing unit, pressing guide lines and guide indents into a surface of the panel media using the punch press, stamping a predetermined relief pattern defined by the panel media using the stamping die such that the predetermined texture is at least partially defined within the relief pattern, cutting the panel media into roofing panels having a predetermined length using the shear press, and forming at least one flange on an edge of each of the roofing panels using the roll former, wherein the roofing panels each include the at least one flange, the predetermined texture and the predetermined relief pattern.
- In at least another respect, a method for forming building cladding panels in a continuous assembly path includes the steps of placing a rolled media into a continuous cladding panel assembly, embossing a predetermined texture within the rolled media, pressing guide lines and guide indents into a surface of rolled media, stamping a predetermined relief pattern within the rolled media, wherein the predetermined texture is at least partially defined within the relief pattern, and wherein the predetermined relief pattern includes a plurality of sub-sections, cutting the rolled media into cladding panels having a predetermined length, forming at least one flange on an edge of each cladding panel along at least one of the guide lines, and coating each of the plurality of subsections with at least one of a plurality of finishes.
- In at least another respect, a method for forming cladding panels in a continuous assembly path includes the steps of providing a continuous cladding panel assembly comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a rolled media is moved through the cladding panel assembly, and wherein the rolled media includes predetermined colored portions, each having at least one of a plurality of finishes, placing the rolled media on an uncoiling unit proximate the cladding panel assembly, wherein the uncoiling unit feeds the rolled media into the cladding panel assembly, embossing a predetermined first relief pattern onto the rolled media using the embossing unit to form a patterned media, wherein the first relief pattern has a first maximum depth, pressing guide lines and guide indents into a surface of the patterned media using the punch press, stamping a predetermined second relief pattern onto the patterned media using the stamping die, wherein the first relief pattern is at least partially defined within the second relief pattern, and wherein the second relief pattern has a second maximum depth that is greater than the first maximum depth, and wherein the predetermined second relief pattern aligns with the predetermined colored portions having the predetermined finishes, cutting the patterned media into cladding panels having a predetermined length using the shear press, and forming at least one flange on an edge of each of the cladding panels using the roll former, wherein the cladding panels each include the at least one flange, the first relief pattern and the second relief pattern.
- These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
- In the drawings:
-
FIG. 1 is a side elevation view of a panel forming unit utilizing one embodiment of the method; -
FIG. 2 is a top plan view of the panel forming unit ofFIG. 1 ; -
FIG. 3 is a top perspective view of one embodiment of a cladding panel having a slate tile texture and relief pattern formed thereon using one embodiment of the method; -
FIG. 4 is a top perspective view of another embodiment of a cladding panel having a wood shake texture and relief pattern formed thereon using an alternate embodiment of the method; -
FIG. 5 is a flow chart diagram showing an embodiment of the method for forming roofing panels in a continuous assembly path; -
FIG. 6 is another embodiment of the method for forming building cladding panels; and -
FIG. 7 is another embodiment of the method for forming building cladding panels. - For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
FIGS. 1 and 2 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. - As illustrated in
FIGS. 1-4 , thereference numeral 10 generally refers to apanel forming unit 10. Thepanel forming unit 10 includes anembossing unit 12, apunch press 14, astamping die 16, ashear press 18 and a roll former 20, wherein apanel media 22 is configured to be moved through thepanel forming unit 10. Theembossing unit 12 is configured to receive thepanel media 22 and press down upon thepanel media 22 to include apredetermined texture 30 within thepanel media 22. Thepredetermined texture 30 can be any one of a plurality oftextures 30 that can include, but is not limited to, a wood-grain texture, a wood shake texture, a slate tile texture, a thatch texture, a concrete tile texture, orother texture 30 of similar exterior cladding materials. Thepredetermined texture 30 placed in thepanel media 22 by theembossing unit 12 includes a substantially minimal profile that is configured to not interfere with the flow of water off from thecladding panel 32, ultimately formed out of thepanel media 22, after being installed on a structure. Typically, the profile of thepredetermined texture 30 applied by theembossing unit 12 will have a vertical profile of 1″ or less, although larger profiles are contemplated. - The
punch press 14 of thepanel forming unit 10 is configured to pressguide lines 40 and guideindents 42 into a surface of thepanel media 22. Theguide lines 40 are configured to define locations for definingdrain troughs 44,drain apertures 50,attachment flanges 46, connectingmembers 48 and other fastening portions of thecladding panels 32 that will be formed within thepanel media 22. These fastening portions of eachcladding panel 32 are configured to cooperate withadjacent cladding panels 32 to provide secure attachment points and substantially direct water down thedrain troughs 44 and throughdrain apertures 50, as well as preventing leakage between thecladding panels 32 once installed. Thepunch press 14 can include a poweredconveyor 52 andvarious rollers 54 to assist in moving thepanel media 22 through thepanel forming unit 10. Also, in various embodiments, theindividual punch press 14 mechanisms can include various types ofpresses 56, such as C-frame presses, portal-type presses, among other types ofpresses 56. - The
stamping die 16 of thepanel forming unit 10 is configured to stamp or press apredetermined relief pattern 70 within thepanel media 22. Thestamping die 16 is configured to define therelief pattern 70 within thepanel media 22 such that thepredetermined texture 30 formed by theembossing unit 12 remains at least partially defined within thepredetermined relief pattern 70 and the formedcladding panel 32. As described above with respect to thepredetermined texture 30 formed by theembossing unit 12, thepredetermined relief pattern 70 defined by thestamping die 16 can be of a pattern of any one of multiple cladding materials that can include, but is not limited to, wooden shake panels, slate panels, concrete panels, terra cotta tiles, thatched roof layers, and other cladding and roofing material patterns. Thestamping die 16, similar to thepunch press 14, can include afeeder 72, such as a servo feeder, or other mechanism configured to deliver thepanel media 22 through thepanel forming unit 10. It is contemplated that thestamping die 16 is able to stamp between about 15 to about 20 panels per minute, although more stamps per minute are also contemplated. - The
shear press 18 of thepanel forming unit 10 is configured to cut thepanel media 22 intoindividual cladding panels 32 that have a predetermined length. Theshear press 18 is configured to cut thepanel media 22, such that eachcladding panel 32 includes substantially thesame texture 30,relief pattern 70,guide lines 40 andguide indents 42. In this manner, as thecladding panels 32 are installed on a structure, substantial uniformity of thecladding panels 32 ensures a substantially tight fit between the fastening portions of each of thecladding panels 32, as described above. It is contemplated that thetexture 30 andrelief pattern 70 of thecladding panels 32 can vary amongcladding panels 32. Such variation can add to the natural aesthetic of thecladding panels 32 formed through the disclosed method. Theshear press 18 can be similar to a stationary shear or hydrex design or othersimilar shear press 18. - The roll former 20 of the
panel forming unit 10 is configured to form at least one flange, such as anattachment flange 46, of each of thecladding panels 32 to provide the fastening portions of each of thecladding panels 32. As illustrated inFIGS. 3 and 4 ,various cladding panels 32 can include fastening portions on each of the fourouter edges 140 of thecladding panel 32. In various embodiments, thepanel forming unit 10 can include anexit conveyor 80 for receiving each of the roofing panels that leave the roll former 20 of thepanel forming unit 10. In this manner, thecladding panels 32 can be easily collected and stacked for subsequent packaging and shipment. The roll former 20 used in various embodiments of the method can include various functions, such as start/stop, jog and auto functions, among others. The roll former 20 used can be one of various types that include, but are not limited to, rafted, duplex, single high, double high, and othersimilar roll formers 20. - It is contemplated that the
panel forming unit 10 can include additional mechanisms to assist in the delivery of thepanel media 22 through thepanel forming unit 10. These mechanisms include, but are not limited to,loop controls 82,feeders 72,conveyors 52,rollers 54, support tables 58, and the like. Theloop controls 82 of thepanel forming unit 10 are configured to limit the bunching and flexing movement of thepanel media 22 as thepanel media 22 is moved through thepanel forming unit 10. This bunching and flexing can occur due to thepanel media 22 being steadily fed into thepanel forming unit 10, while certain mechanisms, such as theshear press 18,punch press 14 and stampingdie 16 require thepanel media 22 to temporarily stop to perform the various pressing, punching and stamping functions. Theloop control 82 substantially maintains the position of thepanel media 22 so that it can be properly fed through thepanel forming unit 10. - The above-described panel forming unit (or cladding panel assembly) 10, can be operated according to the various methods described herein to create
various cladding panels 32 having a variety of finishes, shapes,textures 30 and configurations that include, but are not limited to, slatetile cladding panels 32, as shown inFIG. 3 , woodshake cladding panels 32 as shown inFIG. 4 , as well asother cladding panels 32 that represent a myriad of configurations. - Having generally described the
panel forming unit 10, and referring now toFIGS. 1-5 , a method 500 for formingcladding panels 32, such as roofing panels, is described herein. Afirst step 502 of the method 500 includes providing a continuouspanel forming unit 10 comprising theembossing unit 12, thepunch press 14, thestamping die 16, theshear press 18, and the roll former 20, wherein thepanel media 22 is moved through thepanel forming unit 10, as described above. The step of providing thepanel forming unit 10 can also include providing anuncoiling unit 90, wherein thepanel media 22 is in a roll form, and theuncoiling unit 90 unrolls thepanel media 22 to be formed through thepanel forming unit 10. According to this method, thepanel media 22 can include a plurality of colored sections, wherein each of the plurality of colored sections includes at least one of a plurality of colors. In various embodiments, the plurality of colors can be oriented upon thepanel media 22 in bands that run the length of thepanel media 22. These bands can correspond tocourses 100 defined within thepredetermined relief pattern 70, as will be more fully described below. In alternate embodiments, the plurality of colored sections can correspond toindividual relief sections 102 of thepredetermined relief pattern 70 defined within thepanel media 22, wherein therelief sections 102 make up thecourses 100 that run the length of thecladding panel 32. In such an embodiment, eachindividual relief section 102, when formed by thestamping die 16, will be aligned to cooperate with the various colored sections disposed upon thepanel media 22. In various embodiments of the method, thepanel forming unit 10 can include a painting, coloring, and/or finishing mechanism that is configured to apply a predetermined finish to thepanel media 22 as thepanel media 22 is moved through the panel forming assembly. -
Step 504 of the method 500 includes placing thepanel media 22 proximate thepanel forming unit 10 and feeding an end of thepanel media 22 into thepanel forming unit 10. In various embodiments, the uncoilingunit 90 can be configured to automatically feed thepanel media 22 into thepanel forming unit 10. It is contemplated that the speed at which thepanel media 22 is fed into thepanel forming unit 10 can vary depending upon various factors that include, but are not limited to, the complexity of thecladding panel 32 to be formed, the type ofpanel media 22 used, the size of thecladding panel 32, the number ofcourses 100 to be formed within thecladding panel 32, the number ofrelief sections 102 to be formed within thecourses 100 of thecladding panel 32, among other factors. The uncoilingunit 90 can be one of several units that include a single mandrel unit or a multiple mandrel unit. The uncoilingunit 90 can also include various features such as brake and drive controls, aloop control 82, as well as others features for delivering the rolledpanel media 22 to thepanel forming unit 10. - Step 506 of the method 500 includes embossing the
predetermined texture 30 to be defined within thepanel media 22 using theembossing unit 12. As discussed above, thepredetermined texture 30 can vary depending upon the desired material and finish that the formedcladding panel 32 is meant to show. The force necessary to include thetexture 30 defined within thepanel media 22 can depend upon thepanel media 22 used. Thepanel media 22 can include a steel sheet that is disposed in a rolled sheet coil, such as a rolled steel coil, and fed into thepanel forming unit 10. Other panel media can include, but are not limited to, vinyl, aluminum, plastic, and other substantially formable materials that can be used as cladding materials. One example of material that can be used as thepanel media 22 is G90 pre-galvanized steel, grade 37. - According to step 508, the method 500 also includes
pressing guide lines 40 and guideindents 42 into a surface of thepanel media 22, using thepunch press 14. As discussed above, the guide lines 40 are included to allow for easier bending and forming of the material during formation of thecladding panel 32. Various apertures, such as thedrain apertures 50, can also be formed during operation of thisstep 508. Additionally, the guide indents 42 formed upon thepanel media 22 provide attachment guides through which nails, screws, or other fasteners can be used to attach or otherwise fasten thecladding panel 32 to the structure. It is contemplated that thecladding panels 32 formed through this method can be roofing panels, wall panels, interior or exterior panels, as well as panels used in other building applications that can utilize a wide range of fasteners, thereby requiring varying configurations ofguide lines 40 and guide indents 42. - According to the method 500,
step 510 includes stamping thepredetermined relief pattern 70 defined within thepanel media 22 using the stamping die 16, such that thepredetermined texture 30 is at least partially defined within therelief pattern 70. As discussed above, thepredetermined relief pattern 70 can includeindividual relief sections 102 that can make upcourses 100 of thepredetermined relief pattern 70. In various embodiments, therelief sections 102 may not form intocourses 100 of thecladding panel 32, but rather may form alternate patterns upon thecladding panel 32, that include, but are not limited to, irregular patterns, alternating patterns, diagonal or vertical patterns, and arcuate patterns, among others. Theseindividual relief sections 102 can be defined within thepanel media 22 by stamping the shape of therelief sections 102 within thepanel media 22. Alternatively, therelief sections 102 can be formed by stampingrelief channels 110 that are disposed between therelief sections 102 such that as therelief channels 110 are formed, and therelief sections 102 are extruded between therelief channels 110. It is contemplated that two sets of forms can be used cooperatively to define both therelief sections 102 and therelief channels 110 betweenadjacent relief sections 102 to form a three-dimensional pattern within thepanel media 22. - As illustrated in
FIGS. 3 and 4 , typically, the relief panels are formed intocourses 100 disposed within thepanel media 22. The number ofcourses 100 included in thepanel media 22 varies depending upon the size of thecladding panel 32 and therelief pattern 70 to be defined within thepanel media 22. Thecourses 100 ofrelief sections 102 are typically separated byvertical risers 120, wherein thevertical risers 120 define anend surface 122 of theindividual relief sections 102. Therelief channels 110 disposed between therelief sections 102 extend through thevertical risers 120 and further define a separation between therelief sections 102 within eachcourse 100 at the vertical riser for thatcourse 100. It is further contemplated that, as discussed above, thepanel media 22 will include colored sections that correspond tocourses 100 ofrelief sections 102 defined within thepanel media 22, and alternatively, can correspond to theindividual relief sections 102 defined within thepanel media 22. The colored sections of thepanel media 22 can be configured to resemble the various cladding material that the panel is being formed into, such as rough edges resembling slate tiles (as shown inFIG. 3 ), a wood grain resembling wooden shakes (as shown inFIG. 4 ), individual fiber strands representing a thatched roof, as well as other similar materials. - According to step 510, as the stamping die 16 is used to form the
relief pattern 70 within thepanel media 22, the stamping die 16 is configured so as to not substantially press against thepredetermined texture 30 that has been defined within thepanel media 22 by theembossing unit 12, according tostep 506. In this manner, the stamping die 16 can include a rigid form at certain portions that are used to define theedges 124 of theindividual relief sections 102 andrelief channels 110 within thepanel media 22. Areas within these rigid portions of the stamping die 16 may include apertures, softer materials, cushion material or other features that prevent thepredetermined texture 30 from being pressed out of thepanel media 22 while thepredetermined relief pattern 70 is being formed. - According to step 512, the method 500 also includes cutting the
panel media 22 intocladding panels 32 having a predetermined length using theshear press 18. As discussed above, theshear press 18 is configured to cut the media panels such that each panel is substantially uniform and includes the guide lines 40 and guide intents in substantially the same location on each of thecladding panels 32. In various embodiments, the guide lines 40 defined within thepanel media 22 by thepunch press 14 can include aguide line 40 through which theshear press 18 is to cut each individual roofing panel. In such an embodiment, the force necessary to cut through thepanel media 22 can be lessened where the material of thepanel media 22 has already been weakened through the formation ofcorresponding guide lines 40 by thepunch press 14, according tostep 508. It is also contemplated that theshear press 18 can not only cut individual lengths ofpredetermined cladding panels 32, but also cut predetermined widths ofcladding panels 32, wherein horizontal and vertical cutting mechanisms of theshear press 18 can be used to cut outmultiple cladding panels 32 within each section of thepanel media 22. In various embodiments, where two ormore cladding panels 32 are configured to be narrower than a standard width of thepanel media 22,multiple cladding panels 32, and/or different types ofcladding panels 32 can be formed simultaneously in a side-by-side configuration so as to substantially limit waste of thepanel media 22. - According to the method 500,
step 514 includes forming at least one flange proximate anouter edge 140 of each of thecladding panels 32 using the roll former 20, wherein thecladding panels 32 each include at least one flange, thepredetermined texture 30 and thepredetermined relief pattern 70. As shown inFIGS. 3 and 4 , thecladding panel 32 can include anupper flange 142 and alower flange 144, wherein theupper flange 142 of one panel cooperates with thelower flange 144 of a verticallyadjacent cladding panel 32. Eachcladding panel 32 can also include aright flange 146 and aleft flange 148, wherein aright flange 146 of onecladding panel 32 cooperates with theleft flange 148 of a laterallyadjacent cladding panel 32. These various flanges can include theattachment flange 46 and/or at least onenail flange 150 where theattachment flanges 46 of thevarious cladding panels 32 cooperate to linkadjacent cladding panels 32 together. The nail flanges 150 are configured to provide a location into which fasteners, such as nails and screws, can be attached through thecladding panels 32 into the structure of the building. - According to step 516, the method 500 can also include collecting or receiving each
cladding panel 32 onto anexit conveyor 80 after thecladding panels 32 leave the roll former 20 of thepanel forming unit 10. Once on theexit conveyor 80, theindividual cladding panels 32 can be sorted based upon various characteristics, evaluated for quality control, sent to other areas or locations for packaging and shipment, among other functions. - Referring now to
FIG. 6 , analternate method 600 for forming building cladding materials includesstep 602 of preparing a rolledpanel media 22 having a plurality of colored courses, wherein the colored courses can correspond to thecourses 100 of thepredetermined relief pattern 70 to be defined within the rolledpanel media 22, at a later step of the process. According to step 604, themethod 600 also includes placing the rolledpanel media 22 onto a continuouscladding panel assembly 10 orpanel forming unit 10. As discussed above, thisstep 604 can be accomplished through the use of an uncoilingunit 90, whereby the rolledpanel media 22 is fed into thecladding panel assembly 10. In various embodiments, individual panels can be inserted into thecladding panel assembly 10. In such embodiments, the cutting steps of each of the disclosed methods may be used to separate individual pieces ofpanel media 22 intosmaller cladding panels 32. According to step 606, themethod 600 can also include embossing apredetermined texture 30 within the surface of the rolledpanel media 22. Thesepredetermined textures 30 can include, but are not limited to, a slate texture, wood-grain textures, or other building material textures.Step 608, of themethod 600, includespressing guide lines 40 and guideindents 42 into a surface of the rolledpanel media 22. Step 610 includes stamping apredetermined relief pattern 70 within the rolledpanel media 22, wherein thepredetermined texture 30 is at least partially defined within therelief pattern 70, and wherein thepredetermined relief pattern 70 includes a plurality of subsections, wherein each subsection can include one ormore relief sections 102. In various embodiments, the plurality of subsections can correspond to theindividual relief sections 102 of thepredetermined relief pattern 70, theindividual relief channels 110, or combinations ofrelief channels 110 andrelief sections 102 defined within the rolledpanel media 22. Additionally, in alternate embodiments, each of the plurality of subsections can be defined by the variouspredetermined textures 30 defined within thecladding panel 32 or within one ormore relief sections 102 and therelief channels 110 between therelief sections 102. It is also contemplated that the subsections can correspond to thevarious courses 100 ofrelief sections 102 that are defined within the rolledpanel media 22. As discussed above, the plurality of subsections can correspond to the plurality of colored sections or bands that are included within the rolledpanel media 22 before entering thecladding panel assembly 10, as described insteps method 600 can also include cutting the rolledpanel media 22 intocladding panels 32 having a predetermined length. After being cut, themethod 600 includesstep 614 of forming at least one flange on an edge of eachcladding panel 32 along at least one of the guide lines 40. As with previously discussed embodiments, the cutting and forming steps described above are configured to form thecladding panels 32 into substantiallyuniform cladding panels 32 that are configured to securely fit together upon the structure to prevent gaps between thecladding panels 32 and water leakage through any of thecladding panels 32, especially at the joints between the installedcladding panels 32. After being formed intoindividual cladding panels 32,step 616 of themethod 600 includes coating each of the plurality of subsections with at least one of a plurality of finishes. In various embodiments, the colored sections disposed upon the rolledpanel media 22 include colored bands that extend the length of the rolledpanel media 22 and correspond to thecourses 100 ofrelief sections 102 defined within each of thecladding panels 32. In such an embodiment, additional finishes and/or coatings can be added to one ormore relief sections 102 of thecladding panels 32 to differentiate therelief sections 102 disposed within acourse 100 of thecladding panel 32. These coating materials can include, but are not limited to, stone coatings, granule coatings, additional painted layers, adhered materials, baked on or cured layers, or other finishing materials that can help to differentiate theindividual relief sections 102 within acourse 100 of thecladding panel 32, or within thecladding panel 32 as a whole. - Referring now to
FIG. 7 , yet anothermethod 700 for formingcladding panels 32 includesstep 702 of providing a continuouscladding panel assembly 10 that includes theembossing unit 12, thepunch press 14, the stamping die 16, theshear press 18 and the roll former 20, wherein a rolledpanel media 22 is moved through thecladding panel assembly 10, and wherein the rolledpanel media 22 includes a plurality of finishes disposed on predetermined colored sections of the rolledpanel media 22. Step 704 includes placing the rolledpanel media 22 on anuncoiling unit 90 placed proximate thecladding panel assembly 10, wherein the uncoilingunit 90 feeds the rolledpanel media 22 into thecladding panel assembly 10. According to step 706, a predetermined first relief pattern is embossed onto the rolledpanel media 22 using theembossing unit 12 to form a patterned media, wherein the first relief pattern is typically apredetermined texture 30, as described above, having a first maximum depth. As discussed above, this first maximum depth can have a thickness of about 1″ or less. In alternate embodiments, the depth of the first relief pattern can exceed 1″. After being embossed,step 708 includespressing guide lines 40 and guideindents 42 into the surface of the patterned media using thepunch press 14. According to step 710 of themethod 700, a predetermined second relief pattern is stamped onto the patterned media using astamping die 16. In forming the second relief pattern, which is typically thepredetermined relief pattern 70 as described above, the first relief pattern remains at least partially defined within the second relief pattern. The second relief pattern is configured to have a second maximum depth that is greater than the first maximum depth. The second maximum depth can include various thicknesses that can range from ⅛″ or more. It is contemplated that in various embodiments, the thickness of the first relief pattern can exceed the thickness of the second relief pattern, depending upon the characteristics of the building material being formed within thecladding panel 32. It is contemplates that the thickness of thetexture 30 andrelief pattern 70 are determined, in part, by the slope of the surface that thecladding panels 32 will be installed upon. Thetexture 30 andrelief pattern 70, when installed, must maintain a sufficient slope such that water and other material properly drain off from thecladding panel 32 at a predetermined rate. It is also contemplated that the predetermined second relief pattern is configured to align with the predetermined colored portions that include the plurality of finishes placed upon the rolledpanel media 22 before entering thecladding panel assembly 10. As discussed above, the predetermined second relief pattern can correspond to the colored bands that are disposed upon the rolledpanel media 22, or can correspond to the colored sections of the rolledpanel media 22, wherein the colored sections correspond toindividual relief sections 102 defined within the rolledpanel media 22. - It is contemplated that in various embodiments, the first relief pattern can correspond to the
individual relief sections 102 andrelief channels 110 defined within thecladding panel 32 and the second relief pattern can correspond to thepredetermined texture 30 applied to thecladding panel 32. In such an embodiment, thetexture 30 applied by theembossing unit 12 to the surface of the rolledpanel media 22 is applied after the stamping die 16 has defined theindividual relief sections 102 andrelief channels 110 within the rolledpanel media 22. In this manner, theembossing unit 12 will be required to include a profile substantially similar to that of therelief pattern 70 created by the individual relief panels andrelief channels 110 disposed within the rolledpanel media 22 in order to properly dispose thetexture 30 within therelief sections 102 andrelief channels 110. - According to step 712 of the
method 700, the patterned media is then cut intocladding panels 32 using ashear press 18, wherein each of the panels is a predetermined length. According to step 714, thecladding panels 32 are formed using the roll former 20 to include at least one flange on an edge of each of thecladding panels 32, such that thecladding panels 32 each include at least one flange, the first relief pattern, and the second relief pattern. After being formed,step 716 of the method includes collecting thecladding panels 32 at anexit conveyor 80 configured to receive eachcladding panel 32 after exiting the roll former 20. - It is contemplated that in various embodiments, the steps described herein can be adjusted and performed in alternate orders. By way of explanation, and not limitation, the rolled
panel media 22 can be inserted into thecladding panel assembly 10 and immediately cut into individual panels and then formed into the desired panel configuration. In such an embodiment, once the rolledpanel media 22 is cut, each piece of rolledpanel media 22 can sent to one of a plurality ofconveyors 52, wherein eachconveyor 52 leads to acladding panel assembly 10 configured to form different types ofcladding panels 32, thereby allowing a number of assemblies to be disposed adjacent or parallel with one another, while allowing multiple panels to be formed, within a single location. - It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
- For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.
- It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired embodiment and other exemplary embodiments without departing from the spirit of the present innovations.
- It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
- It will also be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
Claims (20)
1. A method for forming roofing panels in a continuous assembly path, the method including the steps of:
providing a continuous panel forming unit comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a panel media is moved through the panel forming unit;
placing the panel media proximate the panel forming unit and feeding an end of the panel media into the panel forming unit;
embossing a predetermined texture defined by the panel media using the embossing unit;
pressing guide lines and guide indents into a surface of the panel media using the punch press;
stamping a predetermined relief pattern defined by the panel media using the stamping die such that the predetermined texture is at least partially defined within the relief pattern;
cutting the panel media into roofing panels having a predetermined length using the shear press; and
forming at least one flange on an edge of each of the roofing panels using the roll former, wherein the roofing panels each include the at least one flange, the predetermined texture and the predetermined relief pattern.
2. The method of claim 1 , wherein the panel forming unit includes an uncoiling unit, wherein the panel media is in roll form and the uncoiling unit unrolls the panel media to be moved through the panel forming unit, and wherein the panel media includes a plurality of colored sections, each of the plurality of colored sections including at least one of a plurality of colors.
3. The method of claim 2 , wherein the panel media is a steel sheet disposed on a rolled steel coil.
4. The method of claim 1 , wherein the predetermined texture is one of a slate texture and a wood-grain texture.
5. The method of claim 1 , wherein the relief pattern is a shake roof tile pattern.
6. The method of claim 1 , wherein the at least one flange includes at least one attachment flange and at least one nail flange.
7. The method of claim 1 , wherein the panel forming unit includes an exit conveyor for receiving each roofing panel after leaving the roll former of the panel forming unit.
8. A method for forming building cladding panels in a continuous assembly path, the method including the steps of:
placing a rolled media into a continuous cladding panel assembly;
embossing a predetermined texture within the rolled media;
pressing guide lines and guide indents into a surface of rolled media;
stamping a predetermined relief pattern within the rolled media, wherein the predetermined texture is at least partially defined within the relief pattern, and wherein the predetermined relief pattern includes a plurality of sub-sections;
cutting the rolled media into cladding panels having a predetermined length;
forming at least one flange on an edge of each cladding panel along at least one of the guide lines; and
coating each of the plurality of subsections with at least one of a plurality of finishes.
9. The method of claim 8 , wherein the cladding panels are roofing panels.
10. The method of claim 8 , wherein the cladding panel assembly includes an uncoiling unit, wherein an uncoiling unit supports the rolled media and delivers the rolled media to be formed by the cladding panel assembly.
11. The method of claim 10 , wherein the rolled media is a steel sheet disposed on a rolled steel coil, wherein the rolled media includes a plurality of colored courses, wherein each of the plurality of colored courses is configured to cooperate with a corresponding colored portion of the plurality of subsections.
12. The method of claim 8 , wherein the predetermined texture is one of a slate texture and a wood-grain texture.
13. The method of claim 8 , wherein the relief pattern is a shake roof tile pattern.
14. The method of claim 8 , wherein the at least one flange includes at least one attachment flange and at least one nail flange.
15. The method of claim 8 , wherein the cladding panel assembly includes an exit conveyor for receiving the formed cladding panels.
16. A method for forming cladding panels in a continuous assembly path, the method including the steps of:
providing a continuous cladding panel assembly comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a rolled media is moved through the cladding panel assembly, and wherein the rolled media includes a plurality of finishes each disposed on at least one of a plurality of predetermined colored sections of the rolled media;
placing the rolled media on an uncoiling unit proximate the cladding panel assembly, wherein the uncoiling unit feeds the rolled media into the cladding panel assembly;
embossing a predetermined first relief pattern onto the rolled media using the embossing unit to form a patterned media, wherein the first relief pattern has a first maximum depth;
pressing guide lines and guide indents into a surface of the patterned media using the punch press;
stamping a predetermined second relief pattern onto the patterned media using the stamping die, wherein the first relief pattern is at least partially defined within the second relief pattern, and wherein the second relief pattern has a second maximum depth that is greater than the first maximum depth, and wherein the predetermined second relief pattern aligns with the plurality of predetermined colored sections;
cutting the patterned media into cladding panels having a predetermined length using the shear press; and
forming at least one flange on an edge of each of the cladding panels using the roll former, wherein the cladding panels each include the at least one flange, the first relief pattern and the second relief pattern.
17. The method of claim 16 , wherein the first relief pattern is one of a slate texture and a wood-grain texture.
18. The method of claim 16 , wherein the second relief pattern is a shake tile pattern.
19. The method of claim 16 , wherein the at least one flange includes at least one attachment flange and at least one nail flange.
20. The method of claim 16 , wherein the cladding panel assembly includes an exit conveyor for receiving each of the cladding panels after leaving the roll former of the cladding panel assembly.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/079,367 US20150128422A1 (en) | 2013-11-13 | 2013-11-13 | Method of forming steel cladding construction for buildings |
CA2865141A CA2865141A1 (en) | 2013-11-13 | 2014-09-24 | Method of forming steel cladding construction for buildings |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/079,367 US20150128422A1 (en) | 2013-11-13 | 2013-11-13 | Method of forming steel cladding construction for buildings |
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US20150128422A1 true US20150128422A1 (en) | 2015-05-14 |
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Family Applications (1)
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US14/079,367 Abandoned US20150128422A1 (en) | 2013-11-13 | 2013-11-13 | Method of forming steel cladding construction for buildings |
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US (1) | US20150128422A1 (en) |
CA (1) | CA2865141A1 (en) |
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USD776833S1 (en) * | 2014-06-27 | 2017-01-17 | Certainteed Corporation | Metal roofing |
CN108284186A (en) * | 2018-01-30 | 2018-07-17 | 长沙市大川防火材料有限公司 | Flange cold rolling forming production line and its production technology |
CN108856478A (en) * | 2017-05-10 | 2018-11-23 | 姜立国 | Rack gear automatic moulding machine |
CN111496083A (en) * | 2020-04-27 | 2020-08-07 | 厦门市全新彩钢结构有限公司 | A roll-in former for producing various steel |
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GB2588713A (en) * | 2019-09-18 | 2021-05-05 | Quality Edge Inc | Plank siding |
CN112792618A (en) * | 2020-12-17 | 2021-05-14 | 贵州航天风华实业有限公司 | Short beam production system and short beam production and manufacturing method |
WO2021243961A1 (en) * | 2020-06-01 | 2021-12-09 | 山东鼎昌复合材料有限公司 | Expressway split type guardrail production line |
US11466459B1 (en) * | 2019-02-27 | 2022-10-11 | Christopher G. Tatasciore | Method for manufacturing a one-piece gutter guard article employing a wire mesh filter |
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