| Crowning panel assembly -> Monitor Keywords |
|
|
  Crowning panel assemblyThe Patent Description & Claims data below is from USPTO Patent Application 20070289233. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001]This patent application claims priority under 35 U.S.C. .sctn.119(e) to U.S. Provisional Patent Application Ser. No. 60/805,275, that was filed on Jun. 20, 2006, that is entitled "CROWNING PANEL ASSEMBLY," and the entire disclosure of which is hereby incorporated by reference in its entirety herein. FIELD OF THE INVENTION [0002]The present invention generally relates to building surfaces that are susceptible to oil canning or stress wrinkling and, more particularly, to reducing its visual impact on building surfaces. BACKGROUND OF THE INVENTION [0003]Metal panels are being increasingly used to define building surfaces such as roofs and sidewalls. One type of metal panel is a standing seam panel, where the edges of adjacent standing seam panels of the building surface are interconnected in a manner that defines a standing seam. Standing seam panels are expensive compared to other metal panels, and building surfaces defined by metal panels may be more costly than other types of building surface constructions. [0004]Standing seam metal panels for building surfaces are typically formed from relatively thin sheet metal stock. Sheet meal stock is cold-worked to define the desired profile for the panel, as well as to define its pair of oppositely disposed, standing seam-defining longitudinal edges. Generally, a piece of sheet metal is directed through a plurality of sets of forming rollers or forming stations to shape or form the sheet metal into the desired panel configuration (e.g., to define one or more ribs, as well the pair of standing-seam defining longitudinal edges). In any case, standing seam panels, as well as possibly other panels, may include a relatively large, planar or flat base section that may tend to exhibit waviness or other surface irregularities after the panel is installed. This is commonly referred to in the art as "oil canning." Although oil canning does not necessarily adversely affect the performance of the building surface defined by a plurality of metal panels, many owners and building designers find the aesthetics visually distracting and unacceptable, particularly in view of the premium cost associated with metal panel building surfaces. [0005]Oil canning of metal panels has been addressed by the industry in various ways. In some cases tension (or "stretch") leveling methods have been used to flatten and straighten the coil material prior to fabrication. This process is expensive, inconvenient, and increases material handling requirements. In other cases, heavier gauge thicknesses of metal are used to "stiffen" the flat area of the panels' profile. This method significantly increases material costs. Another method employed in fabrication is to reduce the width dimension of the panel, thereby reducing the area of the planar base section. This method also increases material costs and significantly changes the architectural effect. Often surface irregularities persist due to the fabrication and installation process, notwithstanding the added process, decreased panel width, or increased panel thickness. [0006]Metal panels have also been fabricated in a manner to address oil canning. One or more small structures have been formed/shaped into the base section(s) of a metal panel to address oil canning. These structures are commonly referred to as crests, minor ribs, intermediate ribs, pencil ribs, striations, fluting, or flutes. While these methods may in some cases reduce some degree of oil canning, often they are not effective. Additionally, some users find these alternative structures themselves aesthetically annoying and undesireable. [0007]Attempts have also been made to address oil canning of metal panels by their manner of installation. One approach has been to use a foam rope, strip, or backer rod centered beneath the flat area of the metal panel to force an "arch" into the flat, base portion of the panel, thus directing the surface undulations into a defined and consistent shape, and thereby reducing the visual distraction. One method of installation is to nail this material to a plywood deck over which the metal panels are installed. Another approach has been to apply backer rod to the under-side of a metal panel prior to being positioned over the plywood deck. This has been done by taping the backer rod to the panel, so that the backer rod is disposed between the tape and the metal panel. These types of installation techniques are cumbersome, time consuming, inconvenient, and subject to human error. Additionally, commonly used "backer rod" structures and materials may not be well-suited to this kind of use. SUMMARY OF THE INVENTION [0008]A first aspect of the present invention is directed to what may be characterized as a panel assembly. This panel assembly includes a metal panel having first and second primary panel surfaces that are oppositely disposed. The first primary panel surface projects toward a substrate when the metal panel is installed over the substrate, while the second primary surface projects away from the substrate when the metal panel is installed over the substrate. A first structure includes a first surface, and this first surface is disposed on and is chemically bonded to the first primary panel surface, which again projects toward or faces the substrate when the metal panel is installed over the substrate. That is, the interface between the first surface of the first structure and the first primary panel surface includes a chemical bond. Generally, this first structure produces a convexity on the second primary panel surface when the metal panel is installed over the substrate (the second primary panel surface again projecting away from the substrate when the metal panel is installed over the substrate). Stated another way, the first structure produces a "crown" or the like on the second primary panel surface when the metal panel is installed over the substrate. [0009]Various refinements exist of the features noted in relation to the first aspect of the present invention. Further features may also be incorporated in the first aspect of the present invention as well. These refinements and additional features may exist individually or in any combination. Generally, the first aspect may be characterized as a panel assembly that addresses oil canning or stress wrinkling by generally directing surface irregularities into a "crown." That is, the noted convexity in the metal panel provided by the first structure should desirably reduce the visual impact of oil canning or stress wrinkling of the metal panel. [0010]The metal panel used by the panel assembly of the first aspect may be of any appropriate size, shape, configuration, and/or type (e.g., of an at least generally rectangular profile in plan view; at least generally pie-shaped in plan view, for instance to define a silo on a roof). In one embodiment, the metal panel has first and second longitudinal edges configured to define a standing seam when appropriately interconnected with an adjacent panel (e.g., the metal panel may include a pair of laterally spaced standing seam sections of any appropriate configuration/type and which define the noted first and second longitudinal edges). However, the metal panel could be of other configurations, such as metal panels that are used to define what is at least sometimes referred to as a trapezoidal ribbed or lap-seam metal panel surface in the construction industry. It should be noted that the first aspect is directed to the panel assembly, and does not require the combination of a panel assembly and a substrate over which it may be installed. Therefore, the first aspect encompasses the panel assembly both prior to and after its installation. Moreover, this panel assembly may be used to define a roofing surface, a soffit surface, a siding surface, or any other appropriate building surface when installed over an appropriate substrate. It should also be appreciated that the panel assembly is applicable to both interior and exterior building surfaces. [0011]The first surface of the first structure may be chemically bonded directly to the metal panel in any appropriate manner in the case of the first aspect such that the interface between the first surface of the first structure and the first primary panel surface includes a chemical bond. In one embodiment, an adhesive may be appropriately disposed between the first surface of the first structure and the first primary panel surface (e.g., the adhesive could be disposed on the first primary panel surface, on the first surface of the first structure, or both). Another option would be to dispose double-sided tape or the like between the first primary panel surface and the first surface of the first structure. Another option would be to dispense an appropriate material (e.g., in a liquid-like or paste-like state or form; in the form of a "bead") on the metal panel in any appropriate manner, where this dispensation would both chemically bond the material to the first primary panel surface and at least eventually define the first structure (possibly after being allowed to air cure, possibly after some type of post-processing or the like (e.g., a heat treatment), or both). Another option would be to form the first structure (e.g., extrusion) and to thereafter position the first structure onto the metal panel while still in a "wet" or "uncured" state such that a chemical bond will exist/develop between the opposing surfaces of the first structure and the first primary panel surface. Yet another option would be to move the metal panel relative to a supply of the first structure (e.g., a "roll" of the first structure) while positioning or dispensing the first structure on the metal panel. In this case, an appropriate adhesive could be applied to the metal panel, an appropriate adhesive could be applied to the first structure before being positioned on the metal panel, or both. It also may be possible to have pre-applied adhesive to the first structure in some manner prior to being transferred to its supply position. It may also be possible to incorporate a material with an inborne adhesive or adhesive characteristic within the composition of the first structure. [0012]The first structure could be mounted to the metal panel at any appropriate time in the case of the first aspect, including without limitation in any of the above-noted manners. For instance, the first structure could be mounted to the metal panel at the job site. Another option would be to mount the first structure to the metal panel as part of the overall fabrication of the metal panel or at least in a "plant" environment. Consider the case where a piece of sheet metal is directed through one or more sets of rollers or the like to shape the sheet metal into the desired end configuration for the metal panel. The first structure could be formed/mounted on the first primary panel surface of the metal panel at any appropriate point in the fabrication process (e.g., prior to roll forming; in tandem with roll forming; subsequent to roll forming). For instance, an appropriate material could be dispensed in any appropriate manner (e.g., using a nozzle) onto the metal panel as the metal panel is being advanced relative to a supply of this material, again where this material will chemically bond to the first primary panel surface and at least eventually will define the first structure. Another option would be for an appropriate adhesive or the like to be dispensed onto the metal panel as the metal panel is being advanced relative to the adhesive source, and some time thereafter the first structure may be positioned over this adhesive (e.g., as the metal panel is being advanced relative to the first structure). Another option would be for the first structure, with pre-applied adhesive or the like or itself having adhesive-like characteristics (e.g., in the form of double-sided adhesive tape; with the first structure incorporating an inborne adhesive or the like within its composition; with the first structure being in a "wet" or "uncured" state, such that when it is disposed on the panel and thereafter cures, a chemical bond will develop/exist between the opposing surfaces of the first structure and the first primary panel surface), to be positioned on the metal panel as the metal panel is being advanced relative to the first structure. Yet another option would be to dispense an appropriate adhesive or the like onto the first structure, and to thereafter position this first structure on the metal panel as the metal panel is being advanced relative to the first structure. Once again, adhesive could be applied to both the metal panel and the first structure. [0013]Various characterizations may be made in relation to the first structure used by the panel assembly of the first aspect. One is that the first structure may be disposed between first and second protruding structures that are linearly extending and that protrude at least generally away from the substrate when the metal panel is installed over the substrate. In this case, the apex of the convexity on the second primary panel surface provided by the first structure may extend at least generally along a line that is disposed at least generally parallel with the noted first and second protruding structures of the metal panel. Each of the first and second protruding structures may be in the form of a standing seam section at one of the two longitudinal edges of the metal panel (a standing seam section being that structure of the metal panel that interconnects with a standing seam section of another metal panel to collectively define a standing seam), may be in the form of a rib, or may be any other appropriate protruding structure. The term "rib" encompasses a protruding structure of any size, shape, configuration, and/or type that is located somewhere between the two longitudinal edges of the metal panels, whether characterized as a crest, minor rib, intermediate rib, pencil rib, striation, fluting, or flute. The metal panel may include any appropriate number of ribs between its first and second longitudinal edges, regardless of whether the first and second longitudinal edges are associated with standing seam sections or not. [0014]The first structure may also be a linearly extending structure when installed on the first primary panel surface, and further may be disposed at least generally parallel with the above-noted first and second protruding structures in the case of the first aspect. In one embodiment, a center-to-center distance or spacing between the noted first and second protruding structures is at least about 12 inches, and the first structure is mounted to a flat base section that extends or spans the entire distance between these first and second protruding structures. For instance, the first structure may at least generally bisect this flat base section in a dimension corresponding with the spacing between the first and second protruding structures. [0015]Another characterization that may be made in relation to the metal panel used by the first aspect is that it may include first and second longitudinal edges that are laterally spaced, as well as first and second transverse or lateral edges that are longitudinally spaced and that each extend between and interconnect the first and second longitudinal edges, and where the first structure extends at least generally from the first transverse edge to at least generally the second transverse edge (e.g., the first structure could terminate at or within a few inches of the noted transverse edges). Yet another characterization is that the first structure may be disposed on a flat base section or the like of the metal panel (e.g., a flat region between an adjacent pair of raised ribs or the like that may be incorporated into the structure of the metal panel; between an adjacent pair of protruding structures (e.g., standing seam sections; ribs) that extend or protrude at least generally away from the substrate when the metal panel is installed over the substrate, including both where the adjacent pair of protruding structures are of a common type (e.g., a pair of standing seam sections; a pair of ribs) and where the adjacent pair of protruding structures are not a common type (e.g., a standing seam section and a rib). It may be desirable for the first structure to at least generally bisect this base section in the lateral dimension (e.g., a dimension extending from the above-noted first longitudinal edge to the above-noted second longitudinal edge of the metal panel). [0016]The first structure used by the panel assembly of the first aspect may be of any appropriate size, shape, configuration, and/or type, and may be formed from any appropriate material or combination of materials (e.g., a foam; plastic foam; rubber foam; synthetic foam; or any other flexible rope-like material). In one embodiment, the first structure is in the form of what is referred to as "backer rod" in the construction industry. Backer rod is generally intended for use as a caulking backer within a joint, but has been adapted to other purposes as well. The first structure may also be characterized as a compressible structure. Generally, the first structure should be sufficiently compressible so that the first structure will not bend or otherwise permanently deform the metal panel when under normal design loads. In this regard, there may be a gap between the metal panel and the substrate when the meal panel is installed over the substrate. The height or thickness of the first structure would then have to be greater than the height of this gap to produce the desired convexity on the second primary panel surface. In any case, it would be desirable for the first structure to at least temporarily compress if the metal panel experiences a normal design load (e.g., a person walking on the panel) so that the first structure would not bend or permanently deform the metal panel in this instance. Although the first structure could be elastic, such need not be the case. That is, after undergoing a compression, the first structure would not necessarily have to assume its original configuration once the load is removed (although an elastic first structure is of course encompassed by the first aspect), but preferably the first structure would at least move back toward its original configuration (e.g., by a subsequent expansion) upon experiencing a reduction in the applied load. [0017]In one embodiment of the first aspect, the first surface of the first structure is flat prior to being positioned on the first primary panel surface. Although the first structure could be fabricated in any appropriate manner to realize the desired shape/configuration, in one embodiment the first structure is an extrusion (e.g., compressible/expandable foam). The first structure also could include a second surface that is disposed oppositely of the first surface and that is also flat prior to interfacing with a substrate when the metal panel is installed over the substrate. A pair of opposing sidewalls extending between these flat first and second surfaces of the first structure could be flat or curved (e.g., convexly-shaped). The first structure also could be "solid" in cross-section, or the first structure could include one or more apertures that extend along its length dimension (e.g., the first structure could be in the form of a tube; the first structure could be hollow). [0018]In another embodiment of the first aspect, the first structure is positioned on the first primary panel surface while the first structure is in a "wet" or "uncured" state. This may provide for a suitable chemical bond between the opposing first structure and the first primary panel surface--that is, such that the interface between the first surface of the first structure and the first primary panel surface includes a chemical bond. This may also allow the first structure to deform to a certain extent by placing the first structure into contact with the metal panel (and possibly placing the same in compression to a degree) such that a flat surface is formed on the portion of the first structure that interfaces with the first primary panel surface. [0019]A second aspect of the present invention is directed to a panel assembly. This panel assembly includes a panel having first and second primary panel surfaces that are oppositely disposed. The first primary panel surface projects toward a substrate when the panel is installed over the substrate, while the second primary panel surface projects away from the substrate when the panel is installed over the substrate. The panel also includes at least two protruding structures that are linearly extending and that protrude at least generally away from the substrate when the panel is installed over the substrate. A first structure includes a first surface, and this first surface is disposed on and is chemically bonded to the first primary panel surface at a location that is somewhere between the first and second protruding structures. That is, the interface between the first surface of the first structure and the first primary panel surface includes a chemical bond. Again, the first primary panel surface projects toward or faces the substrate when the panel is installed over the substrate. Generally, this first structure produces a convexity on the second primary panel surface somewhere between the first and second protruding structures when the panel is installed over the substrate (again, where the second primary panel surface projects or faces away from the substrate when the panel is installed over the substrate). [0020]Various refinements exist of the features noted in relation to the second aspect of the present invention. Further features may also be incorporated in the second aspect of the present invention as well. These refinements and additional features may exist individually or in any combination. Generally, the second aspect may be characterized as a panel assembly that addresses oil canning or stress wrinkling. That is, the convexity in the standing seam panel provided by the first structure should desirably reduce the visual impact of oil canning or stress wrinkling of the panel by generally directing surface irregularities into a "crown." Continue reading... Full patent description for Crowning panel assembly Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Crowning panel assembly patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Crowning panel assembly or other areas of interest. ### Previous Patent Application: Composite decking board fastening system Next Patent Application: Finishing panel using marble Industry Class: Synthetic resins or natural rubbers -- part of the class 520 series ### FreshPatents.com Support Thank you for viewing the Crowning panel assembly patent info. IP-related news and info Results in 1.71281 seconds Other interesting Feshpatents.com categories: Medical: Surgery , Surgery(2) , Surgery(3) , Drug , Drug(2) , Prosthesis , Dentistry |
||
