U.S. patent application number 09/747367 was filed with the patent office on 2002-06-27 for seamless siding and method and apparatus for making a seamless siding panel.
Invention is credited to Bullinger, Michael J., Cooper, Russell L..
Application Number | 20020078650 09/747367 |
Document ID | / |
Family ID | 30444697 |
Filed Date | 2002-06-27 |
United States Patent
Application |
20020078650 |
Kind Code |
A1 |
Bullinger, Michael J. ; et
al. |
June 27, 2002 |
Seamless siding and method and apparatus for making a seamless
siding panel
Abstract
A siding system includes panels having a facing element with a
convex front face portion. A first connecting portion extending
along an upper edge and a second connecting portion at a lower edge
is adapted to engage the first connecting portion of an adjacent
lower siding panel. Mounting holes at a top edge of the facing
element provide for mounting the siding panel to a vertical
surface. A support element, such as foam insulation attaches to a
rear surface of the facing element. A machine for making the metal
siding panels has a feeder and multiple roller sets. First ones of
the rollers have a concave portion and complementary second ones of
the rollers have a convex portion. The concave portion first roller
set has a larger radius profile than the last roller set to roll
form the siding from a coil of blank material. Bending rollers form
the mounting structure of the panels. Embossing rollers forming an
embossed pattern on the face of the panels.
Inventors: |
Bullinger, Michael J.;
(Fargo, ND) ; Cooper, Russell L.; (Crewell,
OR) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Family ID: |
30444697 |
Appl. No.: |
09/747367 |
Filed: |
December 21, 2000 |
Current U.S.
Class: |
52/539 ;
52/520 |
Current CPC
Class: |
B21H 8/00 20130101; B21B
27/005 20130101; B21B 1/227 20130101; E04F 13/0864 20130101; B21H
8/005 20130101 |
Class at
Publication: |
52/539 ;
52/520 |
International
Class: |
E04D 001/00 |
Claims
What is claimed is:
1. A siding panel, comprising: a facing element, the facing element
comprising: a convex front face portion; a first connecting portion
extending along an upper edge of the front face portion, a second
connecting portion at a lower edge of the front face portion, and
adapted to engage a first connecting portion of an adjacent lower
siding panel; a mounting portion at a top edge of the facing
element adapted for mounting the siding panel to a vertical
surface; a support element having a convex first face and mounting
to a rear surface of the front face portion of the facing
element.
2. A siding panel according to claim 1, wherein the first and
second connecting portions comprise complementary hooks configured
for engaging one another.
3. A siding panel according to claim 1, wherein the second
connecting portion hook extends under and behind the support
element to retain the support element.
4. A siding panel according to claim 1, wherein the support element
comprises a molded expanded polystyrene element.
5. A siding panel according to claim 1, wherein facing element
comprises a roll formed metal element.
6. A siding panel according to claim 1, wherein the front face
portion comprises an embossed surface.
7. A siding panel according to claim 5, wherein the front face
portion comprises an embossed arcing surface.
8. A siding system, comprising: a plurality of siding panels, each
siding panel comprising: a facing element, the facing element
comprising: an embossed convex front face portion, a first
connecting portion extending along an upper edge of the front face
portion, a second connecting portion at a lower edge of the front
face portion, and adapted to engage a first connecting portion of
an adjacent lower siding panel, a mounting portion at a top edge of
the facing element adapted for mounting the siding panel to a
vertical surface; a support element having a convex first face and
mounting to a rear surface of the front face portion of the facing
element; wherein the siding panels are connected along their top
and bottom edges to adjacent siding panels to form extended
siding.
9. A siding system according to claim 8, wherein the panels are
predetermined lengths to seamless siding that abuts building
structure on each end.
10. A siding panel, comprising: a facing element, the facing
element comprising: an embossed convex front face portion, a first
connecting portion extending along an upper edge of the front face
portion, a second connecting portion at a lower edge of the front
face portion, and adapted to engage a first connecting portion of
an adjacent lower siding panel; a mounting portion at a top edge of
the facing element adapted for mounting the siding panel to a
vertical surface; a support element having a convex first face and
mounting to a rear surface of the front face portion of the facing
element.
11. A roll-formed siding facing element, comprising: an embossed
convex front face portion; a first connecting portion extending
along an upper edge of the front face portion; a second connecting
portion at a lower edge of the front face portion, and adapted to
engage a first connecting portion of an adjacent lower siding
panel; and a mounting portion at a top edge of the facing element
adapted for mounting the siding panel to a vertical surface.
12. A siding facing element according to claim 11, wherein the
mounting portion comprises a plurality of spaced apart holes.
13. An apparatus for making metal siding panels, comprising: a
feeder; a plurality of first roller sets, wherein first ones of the
rollers having a concave portion and complementary second ones of
the rollers have a convex portion, and wherein the concave portion
first roller set has a larger radius profile than a last roller
set; bending means adapted for forming a first flange proximate a
first end of the rollers; stamping means; embossing means adapted
for forming an embossed pattern.
14. An apparatus according to claim 13, further comprising a
plurality of intermediate roller sets, wherein each successive
roller set has a profile with a radius equal to or smaller than the
preceding roller profile.
15. An apparatus according to claim 13, wherein the bending means
is adapted for forming a second flange complementary to the first
flange.
16. An apparatus according to claim 13, wherein the embossing means
comprises opposed rollers having a patterned surface.
17. An apparatus according to claim 13, wherein the rollers are
aligned linearly, along a direction perpendicular to the axis of
each roller.
18. An apparatus according to claim 13, wherein the each successive
roller set has an axial profile radius no larger than a radius of a
preceding roller set.
19. An apparatus according to claim 13, further comprising means
for supporting a continuous coil of blank material.
20. A metal siding element from a blank material, made by the steps
of: providing a siding-forming device with a plurality of aligned
roller sets of first rollers and second complementary rollers,
wherein each of the first rollers has a concave profile, and
wherein rollers become successively more concave from a first end
to a second end, and a flange former, and a punching station;
feeding the material through the punching station, whereby the
flange has a plurality of mounting orifices formed therein; feeding
the blank material along the roller sets in engagement with the
first and second rollers, whereby a portion of the blank acquires
an arcing cross-section material past the flange formers, whereby
an edge of the blank has a flange formed thereon; cutting the
material at a predetermined length.
21. A siding element according to claim 20, wherein the siding
element is made by the further steps of providing an embossing
roller set and feeding the blank past the embossing roller, whereby
the blank acquires an embossed surface prior to engaging the
aligned roller sets.
22. A siding element according to claim 21, wherein the embossing
roller set comprises opposed rollers having a wood grain contoured
periphery.
23. A method of making a siding element, comprising the steps of:
providing a continuous coil of blank material; providing a siding
forming device with a plurality of aligned roller sets progressing
from a first end to a second end, wherein each of the roller sets
has a first roller having a concave profile, and wherein the first
rollers become successively more concave from the first end to the
second end, flange forming rollers, and a punching station; feeding
the blank through the punching station, whereby an edge of the
blank material has a plurality of spaced apart mounting orifices
formed therein; feeding the blank material along the rollers in
engagement with the rollers, whereby a portion of the blank
acquires an arcing cross-section; passing the blank past the flange
forming rollers, whereby an edge of the blank has a flange formed
thereon; cutting the blank at a predetermined length.
24. A method according to claim 23, wherein the blank material
comprises a length of metal.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a siding element having an
appearance of log construction, and in particular to a metal
seamless siding element, an apparatus for making the siding and a
method of making the siding.
[0003] 2. Description of the Prior Art
[0004] Various types of siding for houses and other structures have
been developed. Vinyl siding, aluminum siding and steel siding have
all been developed as low maintenance or maintenance free siding
options that do not require painting and other normal maintenance
tasks. Some types of siding provide the additional advantage of
being seamless, wherein siding elements are cut to a desired length
spanning the entire distance from a corner or interruption in the
siding to the next such occurrence. Seamless siding provides the
advantages of uninterrupted siding that is more aesthetically
pleasing. In addition, the lack of seams also provides greater
protection from the elements and improved insulating
properties.
[0005] In order to accommodate seamless siding, it is generally
necessary to cut the siding that typically comes off a spool in a
continuous coil of material at the site where the siding is being
hung. Cutting length at the job site therefore requires a
specialized cutting machine that is portable and that is typically
trailered to the job site. In addition to providing an arc on the
siding simulating log siding, such a device must also form the
flange or mounting structure onto the siding panels. It can be
appreciated that metal siding, which affords greater protection and
wears better than vinyl siding, has special requirements in forming
the siding due to its stiffness as opposed to vinyl siding that may
be easily extruded or formed.
[0006] Although textured sidings, such as vinyl siding are well
known, it is more difficult to form a textured harder siding
element, such as metal siding from a blank coil of material.
However, such formation improves the overall quality of the siding
on the house or other structure if it is seamless. Providing
texture to the siding encounters special problems when the siding
is a metal siding as the material is generally quite hard and more
difficult to emboss or texture than other siding materials. The
additional weight and special handling required for metal siding
from a spool requires additional considerations for forming such
panels from continuous metal material.
[0007] In order to create an appearance similar to log structures,
it is necessary to provide a textured and arcing profile to siding
elements. Providing an arc to the element for a seamless siding
system is especially difficult as the material must be formed by a
portable device at the job site. In addition, the material with its
arcing profile must be cut to length at the job site. In addition
to putting the arc in the siding elements, the flanges for
attaching to the structure and to the aligning and engaging
adjacent upper and lower edges of siding elements is also needed.
Providing flanges and texture and an arc all with a portable device
is a special challenge for seamless metal siding.
[0008] It can be seen that a new and improved metal siding system
is needed that provides the aesthetically pleasing appearance of a
log structure. In addition, such a system should provide a seamless
siding system wherein the siding elements are cut to the required
length needed for the structure at the job site. A feasible device
and method for making such siding elements is needed. In addition
to providing an arc and flange, such a device and system should
impart texture for improved strength and aesthetics. The present
invention addresses these as well as other problems associated with
seamless metal siding having the appearance of logs.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a seamless metal siding
panel, and in particular to a panel having the appearance of log
siding, as well as to a method and apparatus for making such
panels.
[0010] Each siding panel includes an arcing portion having an outer
surface with a diameter substantially that corresponding to a log
type home construction. In addition, the panel may be painted or
otherwise have a color pattern to simulate wood grain and may be
embossed with a wood grain texture. The panels preferably have a
hook type portion on the lower edge of the panel and a flange for
mounting and for engaging the hook type portion along an upper edge
of the panel. The flange preferably includes mounting holes or
other structure for mounting to the wall of a building. The panel
preferably includes Styrofoam or other insulation beneath the arc
portion, providing support to the arcing portion of the metal
panels as well as improved durability and protection. The panels
are seamless and cut to the desired length from a continuous coil
of blank material at the job site.
[0011] The device for forming the panels includes a rigid frame
with a series of roller sets receiving the blank material and
bending the material into the desired final shape. In addition, the
rollers are driven by a motor and connected by chain type drives on
sprockets about the ends of the shafts of the rollers to ensure
that the rollers are all driven at substantially the same speed and
to ensure alignment and proper feeding of the material.
[0012] The blank material is first fed through a punch station
wherein a roller includes a plurality of punches extending outward
from the periphery of the roller at one end to form spaced apart
holes along one edge of the blank material for mounting purposes.
Following punching on the mounting holes, the material is fed
through an embossing station wherein a pair of rollers engage the
material and press a contoured surface onto the blank coil of
metal. It has been found that embossing not only provides improved
texture for hiding imperfections and for improved aesthetics
resembling wood grain, but also provides unexpected improved
support as compared to arced panels that are not embossed.
[0013] The embossed blank passes through a series of roller pairs
having complementary arcing peripheries. The roller sets include
arc forming rollers that generally include upper rollers with a
concave periphery, or have portions that include a concave
periphery, and complementary lower rollers that have a
complementary convex periphery. In addition, one of the rollers may
include a periphery having an edge for bending the edge of the
material into the bottom hook portion. The opposite edge of the
rollers may include a periphery for forming the bend and a
complementary hook of the flange. The rollers have generally
successively smaller radiused arcing surfaces and generally have
their edges moving closer together from the initial roller to the
later encountered rollers. In a preferred embodiment, the last
three arcing roller sets have identical profiles to ensure that the
panels have the same profile. The contours of the flange forming
portion change from roller set to roller set. In addition,
intermediate the arc forming roller pairs are sets of rollers that
further aid in guiding and tensioning the continuous coil of
material and in forming the structure at the edges of the siding
panels. The edges of these alternating rollers on their edges and
their orientations change from roller to roller due to the changes
in shape of the material as it progresses along the roller sets
while aiding in gradually achieving the final structure of the
siding panels.
[0014] The panels are cut to length at a cutting station at the
exit end of the rollers. The cutting station is preferably mounted
on a sliding or other movable frame so that the desired length
required for each siding panel can be easily achieved for optimum
fit. The cutting station includes a die having an arcing upper edge
generally conforming to the inner periphery of the arcing section
of the siding panels. A pivoting blade includes a concave edge
substantially complementary to the panels to provide a cleaner cut
at the end of the panel sections.
[0015] These features of novelty and various other advantages that
characterize the invention are pointed out with particularity in
the claims annexed hereto and forming a part hereof. However, for a
better understanding of the invention, its advantages, and the
objects obtained by its use, reference should be made to the
drawings which form a further part hereof, and to the accompanying
descriptive matter, in which there is illustrated and described a
preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Referring now to the drawings, wherein like reference
letters and numerals indicate corresponding structure throughout
the several views:
[0017] FIG. 1 shows a perspective view of a siding panel element
according to the principles of the present invention;
[0018] FIG. 2 shows a front elevational view of the siding panel
shown in FIG. 1 cut to a predetermined length and abutting building
structures at each end;
[0019] FIG. 3 shows an end elevational view of siding panels shown
in FIG. 1 joined to form building siding;
[0020] FIG. 4 shows a side elevational view of an apparatus for
making the siding panels shown in FIG. 1 according to the
principles of the present invention;
[0021] FIG. 5 shows a side elevational view of the frame portion of
the apparatus shown in FIG. 4;
[0022] FIG. 6 shows a top plan view of the frame portion of the
apparatus shown in FIG. 4;
[0023] FIG. 7 shows a side elevational view of the drive motor and
reducer for the apparatus shown in FIG. 4;
[0024] FIG. 8 shows an end view of a cutting station for the
apparatus shown in FIG. 4;
[0025] FIG. 9 shows a side elevational view of a pair of embossing
rollers for the apparatus shown in FIG. 4;
[0026] FIG. 10 shows a side elevational view of a first set of
arcing rollers for the apparatus shown in FIG. 4;
[0027] FIG. 11 shows a side elevational view of a first set of
flange forming rollers for the apparatus shown in FIG. 4;
[0028] FIG. 12 shows a side elevational view of a second set of
arcing rollers for the apparatus shown in FIG. 4;
[0029] FIG. 13 shows a side elevational view of a second set of
flange forming rollers for the apparatus shown in FIG. 4;
[0030] FIG. 14 shows a side elevational view of a third set of
arcing rollers for the apparatus shown in FIG. 4;
[0031] FIG. 15 shows a side elevational view of a third set of
flange forming rollers for the apparatus shown in FIG. 4;
[0032] FIG. 16 shows a side elevational view of a fourth set of
arcing rollers for the apparatus shown in FIG. 4;
[0033] FIG. 17 shows a side elevational view of a fourth set of
flange forming rollers for the apparatus shown in FIG. 4;
[0034] FIG. 18 shows a side elevational view of a fifth set of
arcing rollers for the apparatus shown in FIG. 4;
[0035] FIG. 19 shows a side elevational view of a sixth set of
flange forming rollers for the apparatus shown in FIG. 4; and
[0036] FIG. 20 shows a side elevational view of a set of lower edge
forming rollers for the apparatus shown in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] Referring now to the drawings, wherein like reference
numerals and letters indicate corresponding structure throughout
the several views, in particular referring to FIG. 1, there is
shown a seamless siding panel, generally designated 100. The panel
100 includes an arcing outer surface 102 and a flange 104 along a
first edge, as also shown in FIGS. 2 and 3. The upper flange 104
has a hook portion 108 formed therein that engages a complementary
bottom hook 110 to join the panels 100 together to form extended
siding covering the side of the building, as shown in FIG. 3. The
bottom hook portion 110 may also include spaced apart weep holes
112 to allow water to drain from the panel 100. The flange 104
includes spaced apart mounting holes 106 for attaching the panels
100 to the side of a building.
[0038] Foam insulation, molded polystyrene, or other support
material 114 substantially follows the interior of the arcing
portion 102. Referring again to FIGS. 1 and 2, the exterior of the
arcing portion 102 preferably includes a wood grain type pattern
and is embossed, as explained hereinafter, to give the arcing
portion 102 the texture as well as the visual color pattern for log
siding. It can be appreciated that the panels 100 may also be made
without an embossed surface. In a preferred embodiment, the panels
100 are made from a continuous metal material 120, such as treated
steel or aluminum, or alloys, wound on a spool 280, as shown in
FIG. 4 and are cut to length to form a continuous, or seamless
siding extending between building corners or other structure, as
shown in FIG. 2 and as explained hereinafter. In this manner,
seamless siding with surprising durability is obtained. Where it is
impractical to cut the individual panels to required length, the
panels 100 may be cut to a standard length, such as twelve feet and
cut to the required length with shears at the job site. It has been
found that an embossed siding panel 100 provides improved strength
over panels just having an arc formed therein.
[0039] Referring now to FIGS. 4-6, there is shown a panel forming
apparatus, generally designated 200. The apparatus 200 supports a
spool 280 of the blank siding material 120 and feeds it through a
series of rollers to achieve the panel 100 shown in FIGS. 1-3 and
is cut to length at an exit end at a cutting station 240. The
siding forming apparatus 200 is preferably placed on a trailer or
is otherwise portable to the job sites, so that the siding panels
100 may be cut to the length that is required for each panel to
provide a seamless siding system. The continuous coil of blank
material 120 is fed to the siding forming apparatus 200 and through
a series of roll forming rollers, as explained hereinafter. The
roller sets 206, 208, 210, 212, 214, 216 and 218 bend the blank
material 120 gradually to the arced configuration shown in FIGS.
1-3. In addition, the flange 104 and other features of the panel
100, including the embossed surface, are accomplished as the blank
120 passes through the series of rollers. Upon exiting the series
of rollers, the material is passed through a cutting station 240
shown in FIG. 8. The cutting station 240 includes a blade 244 and
handle 246 with a die 248 having an upper surface substantially
conforming to the profile of the panel 100 providing improved
support along the entire arc. The cutting station 240 is slidably
mounted relative to the apparatus 200 on a framework 242 that
telescopes to move the cutting station 240 to a desired position so
that the siding may be cut to the length needed for the specific
placement of each particular siding panel 100. With this
arrangement, there is no overlap or seams in the siding and a
proper fit is obtained for each specific piece.
[0040] Referring again to FIGS. 4 and 5, the siding forming
apparatus 200 includes a framework 202. The framework 202 supports
bearing blocks 204, shown in FIGS. 10, 12, 14, 16 and 18. The
bearing blocks 204 support the shafts for the forming rollers, as
explained hereinafter. A motor 250 driving a reducer 252 by a belt
256, as also shown in FIG. 7, drives the rollers. A chain 254
engages a sprocket to drive all the roller sets. The various
rollers are connected by chains 260 at one end of the shafts to
ensure that the rollers are driven at the substantially same speed.
The various chains 260 also provide for driving all of the various
shafts off a single motor. To provide tension at the other ends of
the shafts, a chain 262 links two sets of rollers.
[0041] Referring to FIG. 4, intermediate the roller sets forming
the arcing surface, are roller sets 270, 272, 274, 276 and 278
along the hook edge of the rollers to maintain tension and to form
the hook portion. A tension roller 268 is placed at the other edge
of the panel 100 as it is being fed through the panel forming
apparatus 200. Other rollers 266 provide guidance along the
material path to ensure that the coil of blank material 120 does
not drift to the left or the right as it proceeds through the
various rollers. The tension of the chains 258 and 260 provide for
driving from a single motor 250 and also ensure that relative
timing and rotation of the various rollers is maintained so that
the blank material 120 is fed at a continuous, even rate and the
material does not veer to one side or the other. This avoids
jamming of the forming device 200 and malformed panels 100.
[0042] Referring to FIG. 6, the panel forming apparatus 200
includes arc forming roller sets 206, 208, 210, 212, 214, 216 and
218. The arc forming roller sets 206, 208, 210, 212, 214, 216 and
218 generally have a concave upper roller A and a complementary
convex lower roller B as explained hereinafter. Details of the
lower rollers are omitted from FIG. 6 for improved clarity. In the
early portion of the forming process, the upper rollers may be
spaced apart so that the designation A1 and A2 is utilized while
complementary lower rollers that are split apart are designated B1
and B2. In addition, the rollers may include a flange forming
portions designated 207, 209, 211, 213 and 215. The rollers are
generally mounted on shafts designated E with the number associated
with each roller set. The shafts E extend out to the associated
sprockets and are driven by the chains as explained above and shown
in FIG. 5.
[0043] In addition to the arc forming rollers, tensioning roller
sets 270, 272, 274, 276 and 278 are interposed along the hook edge
intermediate and alternating with the arc forming rollers. Along an
opposite edge, tension rollers 266 and 268 guide the material 120
and maintain proper tension so that the panels are formed
correctly. The roller sets 270, 272, 274, 276 and 278 and the
opposite roller 268 may be mounted about an angled axis of rotation
and may have angled edges in order to maintain contact and
facilitate proper tension. As explained hereinafter, as the blank
panel material 120 is fed through the various forming roller sets,
the edges of the material 120 are bent and manipulated so that a
horizontal roller may not be adequate to maintain proper pressure
and alignment of the material. As the material 120 is formed while
passing through each successive roller set, the angle and shape of
the support needed changes, as can be appreciated by those skilled
in the art.
[0044] Prior to engaging the arc forming rollers, the material is
first manipulated by passing through a punch station 220 having a
punch roller 222. The rollers 222 include a plurality of punch
members 224 projected radially outward and spaced about the
periphery of the roller 222 along one edge. As the material is fed
through the panel forming device 200, the punch roller 222 rotates
and the punch members 224 form the mounting holes 106, through the
material shown most clearly in FIGS. 1 and 2.
[0045] Referring now to FIG. 9, the panel material 120 proceeds to
a set of embossing rollers 230. The embossing roller set 230
includes an upper roller 230A and a lower roller 230B. The upper
roller 230A includes an embossing surface 232A while the lower
roller 230B has a complementary outer embossing surface 232B. As
the material passes between the rollers 230A and 230B, the
embossing surfaces 232A and 232B engage the panel and provide a
texture simulating that of wood grain. It has been found that such
embossing and additional texture provides added strength to the
panels and resistance to holes, dents, etc. In addition, the
embossed surface 120 of the panel aids in hiding such imperfections
from the ordinary observer.
[0046] Referring now to FIG. 10, after passing through the
embossing roller set, the material engages the first arc forming
rollers 206 on shafts 206E. The arc forming rollers 206 include
upper rollers 206A1 and 206A2 having concave surfaces, and
complementary lower rollers 206B1 and 206B2 having convex surfaces.
The upper rollers 206A1 and 206A2 are spaced apart as are the lower
rollers 206B1 and 206B2 to form the initial arc forming to the
arcing surface of the panel. In addition, at the one edge of the
material, a flange forming portion 207 abuts the rollers 206. The
flange forming portion 207 includes an upper flange forming roller
portion 207A and a lower roller portion 207B with complementary
surfaces 207C and 207D imparting initial bends to the material 120
towards achieving the flange and hook as shown in FIGS. 1-3.
[0047] Referring to FIG. 11, after passing through the roller set
230, the material is maintained in alignment by roller set 270
having an upper roller 270A and lower roller 270B engaging the edge
of the material 120 corresponding to the bottom edge of the panel
100. The rollers 270 form an initial bend in the material towards
achieving the hook portion 110.
[0048] Following passing through roller set 270, the blank material
engages roller set 208 on shafts 208E. Roller set 208 includes
upper rollers 208A1 and 208A2 and lower complementary rollers 208B1
and 208B2. The upper rollers 208A1 and 208A2 include a concave
arcing surface while the corresponding lower rollers 208B1 and
208B2 have a convex surface with a complementary arc. The roller
set 208 is slightly more arced than the roller set 206 shown in
FIG. 10 so that additional arcing is performed on the material 120.
In addition, roller 208A1 includes an outer flange that continues
to bend the lower edge and direct it downward for forming the lower
hook portion. At the opposite end of the rollers is an additional
flange forming portion 209 including an upper portion 209A on
roller 208A2 and a lower flange forming portion 209B on lower
roller 208B2. Surface 209C includes a slightly more exaggerated
channel with a complementary peak 209D extending into the channel
209C. This structure bends the flange to a greater degree than
continues from the surfaces shown as shown in FIG. 10.
[0049] Referring to FIG. 13, following passage through roller set
208, the edge of the material corresponding to the lower edge of
the panel engages roller set 272 including a complementary first
roller 272A and a complementary second roller 272B. The edges of
the rollers 272A and 272B engage an angled edge of the material
extending back inward to place a greater bend to the hook
portion.
[0050] Referring to FIG. 14, roller set 210 is engaged following
passage through roller set 272. Roller set 210 includes an upper
roller set 210A having rollers 210A1 on upper shaft 210E and 210A2
and lower roller set 210B including lower rollers 210B1 and 210B2
on lower shaft 210E. Rollers 210A1 and 210A2 have concave arcing
portions while rollers 210B1 and 210B2 have complementary convex
portions. In addition, the edge of rollers 210A1 and 210B1 are
arranged so that the partially formed hook portion 110 of the panel
is fed beyond the end of convex portion of roller 210B1 and
maintain the material in alignment. At the opposite ends of the
rollers on 210A2 and 210B2 is a flange forming portion 211. Flange
forming portion 211 includes an upper forming portion 211A on
roller 210A2 and a lower portion 211B on lower roller 210B2. The
portion 211A includes a forming surface 211C including a channel
with a nearly horizontal side and portion 211B includes a
complementary peak extending into the channel to continue forming
the flange portion of the material.
[0051] Referring to FIG. 15, following passage through roller set
210, the material engages roller set 274 including roller set 274A
and 274B. Roller set 274 includes an angled edge maintaining and
bending the lower edge of the material further forming the hook
portion.
[0052] Referring to FIG. 16, the material next engages a roller set
212 including upper rollers 212A and lower rollers 212B on shaft
212E. Upper rollers 212A include a first roller 212A1 and 212A2
while lower rollers 212 include complementary rollers 212B1 and
212B2. The upper rollers 212A have a concave forming surface while
the lower rollers 212B include a complementary convex forming
surface. In addition, roller 212B1 includes an outer edge providing
a space for the hook portion 110 of the panel. At the opposite end
of the rollers, is an additional flange forming station 213
including first portion 213A and second portion 213B. Forming
surfaces 213C and 213D provide realignment of the hook portion in
the flange of the material.
[0053] Following passage through roller set 212, the material
engages roller 276. Roller 276 includes an angled edge having an
upper and lower portion providing a triangular profile and added
bend to the hook portion of the material.
[0054] Referring now to FIG. 18, the material next engages roller
set 214. Roller set 214 includes upper concave rollers 214A and
lower complementary convex rollers 214B on shafts 214E. Upper
roller set 214A includes a first roller 214A1 and second roller
214A2 while lower roller set includes a first roller 214B1 and
lower roller 214B2. The upper rollers 214A1 and 214A2 abut one
another as do the lower rollers 214B1 and 214B2. The roller set 214
has a slightly greater arc than the preceding rollers 212. At a
lower edge of the material, the roller 214A1 extends beyond the
convex surface of roller 214B1 to provide space for the hook
portion 110 of the material. At the opposite edge, the flange
forming portion 215 includes an upper portion 215A on roller 214A2
while the lower portion 215B extends from roller 214B2. A forming
surface 215C includes a gap providing for the hook portion of the
flange while the lower surface 215D is substantially planar.
[0055] Referring to FIG. 19, the material then passes against
roller 278. Roller 278 includes an engaging surface having an
angled upper portion and a horizontal lower portion that engages
the lower edge of the material.
[0056] After passing roller 278, the material engages a roller set
216, as shown in FIG. 6. Roller set 216 has a configuration
substantially the same as roller set 214 as forming at this stage
is to maintain the shape and ensure that the proper arc is formed.
However, the opposite edge engages roller set 268 including upper
roller 268A and lower roller 268B engaging and providing final
positioning of the flange portion while maintaining the proper form
and alignment and fine. Following passage through roller set 216,
the final roller set 218 also has the same configuration and arcing
surface as roller sets 214 and 216. Tension rollers 266 maintain
the material in alignment and ensure the flange is properly
oriented.
[0057] When the panel has been formed into the blank with the
desired profile as shown in FIGS. 1-3, the panels are then cut to
the predetermined length at the cutting station 240 shown in FIG.
8. The cutting station 240 is mounted on the sliding frame, as
shown in FIG. 4. As shown in FIG. 8, the cutting station 240
includes die 248 substantially conforming to the arc of the panel.
The cutting station includes a pivoting blade 244 having an arcing
surface that slices through the panel at the predetermined length.
A handle 246 extends outward from the end of the blade 244 to
provide mechanical advantage during the cutting motion for easily
slicing through the panel material. The complementary arcing
surfaces that substantially conform to the arc of the panels
ensures that a clean cut is made. As the cutting station 240 is
slidably mounted, the desired length is obtained so that a proper
fit may be made to meet the needs for each siding panel.
[0058] It is to be understood, however, that even though numerous
characteristics and advantages of the present invention have been
set forth in the foregoing description, together with details of
the structure and function of the invention, the disclosure is
illustrative only, and changes may be made in detail, especially in
matters of shape, size and arrangement of parts within the
principles of the invention to the full extent indicated by the
broad general meaning of the terms in which the appended claims are
expressed.
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