U.S. patent application number 09/795644 was filed with the patent office on 2002-08-29 for roof panel and a method of manufacturing thereof.
Invention is credited to Baas, Nigel, Elzink, Toone, Hayman, Stuart, Miller, John, Richards, Peter, Sadosky, Lenard JR., Tanner, Natalie, Wilson, Joseph O..
Application Number | 20020116886 09/795644 |
Document ID | / |
Family ID | 25166072 |
Filed Date | 2002-08-29 |
United States Patent
Application |
20020116886 |
Kind Code |
A1 |
Sadosky, Lenard JR. ; et
al. |
August 29, 2002 |
Roof panel and a method of manufacturing thereof
Abstract
A single metal sheet roofing panel having a plurality of
alternatively raised and lowered patches longitudinally arranged in
three rows. The panel30 comprises a side clip connection system for
laterally connecting adjacent panels. The panel is coated with the
stone based coating and has a unique patterned appearance of
multiple colors and shades. A method for manufacturing of the
panel.
Inventors: |
Sadosky, Lenard JR.;
(Arlington, TX) ; Miller, John; (Corona, CA)
; Tanner, Natalie; (Anaheim, CA) ; Wilson, Joseph
O.; (Menifee Valley, CA) ; Baas, Nigel;
(Pakuranga, Auckland, NZ) ; Elzink, Toone;
(Manurewa ,Auckland, NZ) ; Hayman, Stuart;
(Remeura ,Auckland, NZ) ; Richards, Peter;
(Howick,Auckland, NZ) |
Correspondence
Address: |
LADAS & PARRY
Suite 2100
5670 Wilshire Boulevard
Los Angeles
CA
90036-5679
US
|
Family ID: |
25166072 |
Appl. No.: |
09/795644 |
Filed: |
February 28, 2001 |
Current U.S.
Class: |
52/314 |
Current CPC
Class: |
E04D 3/30 20130101; B44F
1/08 20130101; E04D 3/365 20130101; B44C 1/04 20130101; C04B 26/06
20130101; B44F 9/00 20130101; B32B 3/12 20130101; C04B 26/06
20130101; C04B 2111/00525 20130101; C04B 41/4574 20130101; C04B
24/2641 20130101; C04B 20/1055 20130101 |
Class at
Publication: |
52/314 |
International
Class: |
E04C 001/00; B44F
007/00; B44F 009/00 |
Claims
We claim:
1. A roof panel comprising a metal panel having a front surface and
a back surface, a lengthwise edge, a first lateral edge and a
second lateral edge, said panel further comprising: (a) a lap
including at least one claw, said lap being disposed along said
first lateral edge of said panel; and (b) at least one pocket
disposed on said back surface adjacent said second lateral edge,
whereby said at least one claw of a first panel are engagedly
connected with said at least one pocket of a second adjacent panel
to form a side clip connection when said first lateral edge of said
first panel and said second lateral edge of said second panel are
brought together to form an assembly.
2. The panel as claimed in claim 1, further comprising a plurality
of alternating raised and lowered sections, wherein said sections
are arranged longitudinally in a plurality of rows to mimic
individual non-metal shingles.
3. The panel as claimed in claim 1, wherein said metal panel has a
substantially rectangular shape.
4. The panel as claimed in claim 2, wherein said front surface of
said metal panel is coated with a stone-chip based coating in a
plurality of color mixes in selectable locations to form a pattern
of differently colored areas, said areas being coordinated with
said alternating raised and lowered sections.
5. The panel as claimed in claim 1, wherein a metal of said metal
panel comprises steel.
6. The panel as claimed in claim 1, further including a side lap
channel disposed adjacent said lap.
7. The panel as claimed in claim 2, wherein said plurality of rows
comprises three rows.
8. The panel as claimed in claim 3, wherein said metal panel has a
length of about 1.35 meters and a width of about 0.5 meters.
9. The panel as claimed in claim 4, wherein said stone-chip based
coating comprises a cured adhesive, stone granules held in place by
said adhesive, and a sealant.
10. The panel as claimed in claim 5, wherein said metal panel has a
thickness of between about 0.42 millimeters and about 0.46
millimeters.
11. The panel as claimed in claim 5, further comprising a
zinc-aluminum alloy applied on said surfaces of said metal
panel.
12. The panel as claimed in claim 9, wherein said adhesive
comprises an acrylic water-based composition.
13. The panel as claimed in claim 9, wherein said sealant comprises
a clear acrylic water-based glaze composition.
14. The panel as claimed in claim 9, wherein said stone granules
are made of ceramic coated stone.
15. The panel as claimed in claim 9, wherein said pattern of
differently colored areas is achieved by steps of: (a) providing
said granules having differing colors; (b) preparing mixtures of
said granules having differing ratios between said granules having
said differing colors; and (c) applying said mixtures to
pre-selected areas of said panel.
16. An assembly of a plurality of roof panels, said assembly
comprising: (a) a first metal panel having a plurality of claws;
and (b) a second metal panel having a plurality of pockets, whereby
said claws are engagedly connected with said pockets to form a side
clip connection when said first panel and said second panel are
laterally attached to form said assembly.
17. The assembly as claimed in claim 16, wherein said plurality of
said claws are located on a lap, said lap being disposed along a
lateral edge of said first panel, and said plurality of said
pockets are located on a back surface of said second panel.
18. The assembly as claimed in claim 16, wherein said first metal
panel and said second metal panel are substantially of a
rectangular shape.
19. The assembly as claimed in claim 16, wherein a metal of said
metal panel comprises steel.
20. The assembly as claimed in claim 18, wherein said metal panel
has a length of about 1.35 meters and a width of about 0.5
meters.
21. The assembly as claimed in claim 19, wherein said first metal
panel and said second metal panel have a thickness of between about
0.42 millimeters and about 0.46 millimeters.
22. A method for manufacturing a metal roof panel from a single
sheet of metal, said method comprising steps of: (a) providing said
sheet metal in an uncoiled form; (b) forming metal panels having a
front surface and a back surface, a lengthwise edge, first lateral
edge and a second lateral edge, said metal panels provided with a
plurality of alternating raised and lowered sections; and (c)
applying a stone-chip based coating on said front surface of said
metal panels, to form a pattern of differently colored areas, said
areas being coordinated with said alternating raised and lowered
sections.
23. The method as claimed in claim 22, wherein said step of forming
said metal panels comprises further steps of: (a) making said
plurality of said alternating raised and lowered sections on said
panels; (b) making a lap including a plurality of claws, said lap
disposed along said first lateral edge of said panel; (c) making a
side lap channel disposed adjacent said lap; and (d) making a
plurality of pockets disposed on said back panel; (d) applying a
sealant on top of said dispensed differently colored mixes of said
stone granules; and (e) curing said coating at an elevated
temperature.
29. The method as claimed in claim 23, wherein said metal panel has
a length of about 1.35 meters and a width of about 0.5 meters.
30. The method as claimed in claim 24, wherein said plurality of
rows comprises three rows.
31. The method as claimed in claim 27, further comprising a
zinc-aluminum alloy applied on said surfaces of said metal
panel.
32. The method as claimed in claim 28, wherein said stone granules
are made of ceramic coated stone.
33. The method as claimed in claim 28, wherein said adhesive
comprises an acrylic water-based composition.
34. The method as claimed in claim 28, wherein said sealant
comprises a clear acrylic water-based glaze composition.
35. A method of installing a roof using interlocking panels
comprising the steps of: (a) laying a first course of panels on
said roof, with adjacent panels being coupled to one another in
said first course by at least one claw on a panel mating with at
least one pocket of a laterally adjacent panel; and (b) laying a
second course of panel on said roof, with adjacent panels being
coupled to one another in said second course by at least one claw
one panel mating with at least one pocket of a laterally adjacent
panel, the panels in the sound course also mating with panel in the
first course with hooks one panels in one of said course mating
with clips associated with panels in the other course.
Description
I. BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of roofing products.
More particularly, it pertains to the multi-step dimensional metal
roof panels having a TAC-LOK.TM. side clip connection system and
stone-coated in a particular way so as to have a unique
multicolored, multi-shade appearance.
[0003] 2. Description of the Related Art
[0004] In the art of roof shingles, it is important to provide a
shingle which has good structural characteristics, ease of
installation, durability, and pleasant appearance. Even though
metal panels offer significant life time cost savings, service life
and flammability advantages over wood shingles, wood shingles are
still often preferred due to the pleasing aesthetic appearance of a
wood shingled roof. An important aesthetic advantage of such wood
shingles is due to their greater thickness as compared to steel
panels or composite shingles. The higher thickness of wood shingles
leads to a more pleasing, layered look for the finished roof.
[0005] Various composite shingles have been developed to provide an
appearance of thickness comparable to wood shingles. Examples of
such composite or asphalt shingles are shown in U.S. Pat. No.
5,232,530 to Malmquist, et. al. (asphalt-and-polymer composite);
U.S. Pat. No. 3,921,358 to Bettoli (asphalt composite); U.S. Pat.
No. 4,717,614 to Bondoc, et. al. (asphalt composite); and U.S.
Design Pat. No. D309,027 to Noone et. al. (asphalt). None of these
patents teaches a metal-based roof panel, and structural
characteristics of all these shingles are inferior to those of
metal-based roof panels.
[0006] Another group of patents includes two U.S. Patents to Weaver
et. al., U.S. Pat. Nos. 5,611,186 and 5,666,776. Both of these
patents claim to achieve the pleasing aesthetic appearance of the
wood shingles. However, the shingles described in these patents are
asphalt based laminated products, the structural strength of which
is inferior to that of metal-based panels. In addition, the
shingles described in these two patents are one-step shingles, the
process of installation of which is very time-consuming.
[0007] In view of the foregoing problems and disadvantages inherent
in the shingles taught in prior art, there exists, therefore, a
need for an improved roofing product which would have the following
improved characteristics:
[0008] (a) it is metal-based;
[0009] (b) it is a multiple-step product to improve the aesthetic
appearance and to facilitate its installation;
[0010] (c) it has a mechanism allowing secure lateral connection of
adjacent panels; and
[0011] (d) it has a pleasing, dimensional, layered look for the
finished roof comparable to the look provided by wood shingles.
[0012] There exists no known prior art roofing product having all
the advantages and benefits described above. Yet the need for such
is acute. The present invention discloses such roofing product, its
assembly and a method for manufacturing thereof.
II. SUMMARY OF THE INVENTION
[0013] This invention is applicable to metal-based roof panels. In
general terms, the present invention uses a multiple-step,
preferably, a three-step, metal panel, having a side clip system
for connecting adjacent panels. The panel is coated in a special
way to have multi-colored, multi-shade appearance. This appearance
is similar to that of a wood shingle in that the panel appears to
have a significant depth.
[0014] According to a first aspect of this invention, a roof panel
is provided, the panel comprising a single-piece metal panel having
a front surface and a back surface, a lengthwise edge and a lateral
edge, the panel comprising a plurality of alternating raised and
lowered sections, a lap including a plurality of claws, the lap
disposed along the lateral edge of the panel, a side lap channel
disposed adjacent the lap, and a plurality of pockets disposed on
the back surface, whereby the claws of a first panel are engagedly
connected with the pockets of a second panel to form a side clip
connection when the lateral edge of the first panel and the lateral
edge of the second panel are attached to form an assembly.
[0015] According to a second aspect of this invention, an assembly
of a plurality of roof panels is provided, the assembly comprising
a first metal panel having a plurality of claws, and a second metal
panel having a plurality of pockets, whereby the claws are
engagedly connected with the pockets to form a side clip connection
when the first panel and the second panel are laterally attached to
form the assembly.
[0016] According to a third aspect of this invention, a method for
manufacturing a metal roof panel from a single sheet of metal is
provided, the method comprising steps of providing the sheet metal
in an uncoiled form, forming metal panels having a front surface
and a back surface, a lengthwise edge and a lateral edge, the metal
panels provided with a plurality of alternating raised and lowered
sections, and applying a stone-chip based coating on the front
surface of the metal panels, to form a pattern of differently
colored areas, the areas being coordinated with the alternating
raised and lowered sections.
[0017] According to a fourth aspect of this invention, such pattern
of differently colored areas is achieved by providing stone
granules having differing colors, preparing mixtures of the
granules having differing ratios between the granules having the
differing colors, and applying the mixtures to pre-selected areas
of the panel.
III. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The features and advantages of the present invention will
become better understood with regard to the following description,
appended claims, and accompanying drawings where
[0019] FIG. 1 is a schematic diagram showing a plan view of a
preferred embodiment of the panel of this invention.
[0020] FIG. 1a is a schematic diagram showing a perspective view of
a preferred embodiment of the panel of this invention.
[0021] FIG. 2a is a schematic diagram showing a side view of the
left side lap of the panel of this invention.
[0022] FIG. 2b is a schematic diagram showing a side view of the
right flange of the panel of this invention.
[0023] FIG. 3 is a schematic diagram showing a side view of a
raised section of the panel of this invention.
[0024] FIG. 4a is a schematic diagram showing a side view of the
pocket of the panel of this invention.
[0025] FIG. 4b is a schematic diagram showing a side view of the
claw of the panel of this invention.
[0026] FIGS. 4c and 4d are schematic diagrams showing a side view
of the assembled side clip connection system of the panel of this
invention.
[0027] FIG. 4e is a schematic diagram showing a plan view of the
assembly of the panels of this invention, the panels being
laterally connected.
[0028] FIG. 4f is a schematic diagram showing a cross section of
the assembled side clip connection system of the panel of this
invention.
[0029] FIG. 4g is a plan view showing four panels being joined
together.
[0030] FIG. 5a is a schematic diagram showing an end view of a
preferred embodiment of the panel of this invention.
[0031] FIGS. 5b and 5c are schematic diagrams showing a more
detailed side view of a rolled edge of a preferred embodiment of
the panel of this invention.
[0032] FIG. 5d is a schematic diagram showing a more detailed side
view of the claw of the panel of this invention.
[0033] FIGS. 6a, 6b, and 6c are schematic diagrams showing the
steps of a preferred method of manufacturing of the panel of this
invention.
IV. DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 shows a plan view of a preferred embodiment of the
panel 100 of this invention, as viewed when looked at it when the
panel is laid down, with the front side 1 (coated) up. FIG. 1a
shows the same preferred embodiment of the panel 100 of this
invention in a perspective view.
[0035] In accordance with the present invention, the panel 100 is
made preferably of a single sheet of a material, preferably metal,
and more preferably, steel. The kind of steel used to manufacture
the panel of this invention is preferably zinc-aluminum coated
steel of grade 37 according to the classification adopted by the
American Society for Testing of Materials, ASTM A792.
[0036] Such steel has a thickness within a range of between about
0.31 millimeters and about 0.55 millimeters, preferably within a
range of between about 0.42 millimeters and 0.46 millimeters, and
more preferably, about 0.44 millimeters. The zinc-aluminum coating
is preferably grade AZ-50 coating, according to the ASTM's
classification. The front side of the sheets of steel used to
manufacture the panels of this invention is typically pre-coated
with a water-based acrylic primer by the manufacturer of the steel
sheet, which is preferably Steelscape, Inc. of Kalama, Wash.
[0037] Other metals having similar properties can be used instead
of steel described hereinabove. It should be borne in mind that
those reasonably skilled in the art of making roof panels will know
what those metals are and how they can be used to replace this kind
of steel.
[0038] The total dimensions of the sheet of metal used to fabricate
the panels of this invention is preferably about 1.35 meters in
length L (as shown on FIG. 1) by about 0.5 meters in width W. (as
shown on FIG. 1 also).
[0039] The panel comprises multiple, and preferably three,
longitudinal rows 2', 2" and 2'" of alternatively raised and
lowered sections 2. These sections 2', 2" and 2'" mimic non-metal
shingles in order to give a roof covered with panels 100 a natural
shingled appearance. The width x (shown on FIG. 1) of a row the
raised and lowered sections 2 is preferably about 16 cm. The height
d of these sections 2 (shown on a side view of the patch 2, in FIG.
3) is preferably within a range of between about 2 millimeters and
about 10 millimeters, and more preferably, within a range of
between about 3 millimeters and about 5 millimeters.
[0040] The panel 100 further comprises a notch 7, having a length
of between about 1 millimeter and about 3 millimeters, preferably,
about 2 millimeters, and a side lap 3 having a width, a, within a
range of between about 29 millimeters and about 31 millimeters,
preferably, about 30 millimeters, as shown on FIG. 2a. The side lap
3, in turn, includes a plurality of claws 8, to be discussed
subsequently. Between the side lap 3 and the body of the panel 100
is preferably provided a side lap channel 10 (FIG. 2a), the purpose
of which is to provide for the removal of water which may
accumulate on the front side 1 of the panel 100 when the panel is
installed on a roof and the weather is inclement. The side lap
channel 10 runs along a majority of the width W of the panel 100
and preferably has a depth, b (See FIG. 2a), within a range of
between about 3.21 millimeters and about 5.21 millimeters.
[0041] On the side 4 of the panel 100 opposite to the side where
the side lap 3 is located, there is a curved flange 41, preferably
having a tip with a width, c, up to about 1 millimeter.
[0042] Turning now to FIG. 5a showing an end view of a preferred
embodiment of the panel 100 of this invention when viewed in a
direction 5-5 (See FIG. 1), one can see claws 8 along the side lap
3 and a clip 9' disposed along a bottom edge 5 of panel 100 and a
hook 9 disposed along its top edge 11. FIGS. 5b and 5c show clip 9
(FIG. 5b) and hook 9' (FIG. 5c) in more detail, revealing the
length, h, which is preferably within a range of between about 2
millimeters and about 4 millimeters, more preferably, about 3
millimeters. The back clip 9 and the front hook 9' are used for
connecting adjacent panels 100 along their as known by those
skilled in the art of roof installation.
[0043] In order to provide for lateral connecting of adjacent
panels 100, a side clip connection system is provided. The side
clip connection system comprises: (i) a plurality of claws 8,
located on side lap 3, as mentioned above and on the side of the
panel 100 opposing the side where the claws 8 are located (ii)
pockets 6 formed by indentations formed in the back side (the
uncoated side opposite front side 1) of the panel 100 in the risers
8' between adjacent rows of the alternatively raised and lowered
sections 2.
[0044] Turning to FIG. 4a, the outer sides 6' of the pockets 6 are
preferably located in risers 8' at a distance within a range of
between about 45.5 millimeters and about 49.5 millimeters, more
preferably, about 47.5 millimeters from the edge 4 of the panel
100. The pockets 6 preferably have a length, f, within a range of
about 47 millimeters and about 43 millimeters, more preferably,
about 45 millimeters, a width, e, within a range of between about 6
millimeters and about 4 millimeters, preferably, about 5
millimeters, and a depth (not shown) preferably, of at least about
2 millimeters.
[0045] The claws 8 are disposed at the tops of risers 8'
immediately adjacent the exposed edge of side lap 3 at an small
angle, g, of preferably less than 5.degree. (FIG. 4b) from the
plane of the side lap 3. The claws 8 are preferably formed by
cutting into the side lap 3 by a distance of about 2 cm when the
panels 100 are formed so that the claws 8 project from the panel
100 instead of being bent around to follow the normal course of the
riser 8'. The cut begins at a distance, y, which is preferably
within a range of between about 3 millimeters and about 4
millimeters, from the bend 13 at the tops of the risers 81 and then
proceeds toward that bend 13. (FIG. 5a). A more detailed view of a
claw 8 is shown on FIGS. 4d, 4f and 5d.
[0046] Turning to FIGS. 4c-4f, these figures show two panels 100'
and 100" being joined along their edges. In FIG. 4c they are still
spaced apart, but the risers 8' of the two panel are aligned in
preparation for mating the two panels together. When a side having
claws 8 of the first panel 100" is laterally attached to a side of
a second panel having pockets 6 the claws 8 penetrate into the
pockets 6, forming a side clip connection and thus holding the
first and the second panels together, as shown by FIGS. 4d and 4e.
In FIGS. 4c and 4d, only small portions of the two panels 100' and
100" are shown to emphasize the connection being made between the
claw 8 and the pocket 6.
[0047] Obviously, the first panel 100" will then have free pockets
6 facing outwardly adjacent its remote edge 4, to which claws 8 of
another third, panel can be attached; the second panel 1001 will
have free claws 8 facing outwardly, which can be inserted into
pockets 6 of yet another, fourth, panel, and so on, thus forming an
assembly of panels 100. A portion of such assembly is schematically
shown on FIG. 4e, it being understood the still further panels
would be arranged at edges 5' and 11 and using the previously
described side clip connection. FIG. 4f shows a cross section of
the side clip connection system with the claw 8 already inside the
pocket 6. The depth of the pocket 6 is exaggerated somewhat in FIG.
4f for ease of illustration.
[0048] The claws 8 are conveniently protected due to the fact that
the end 4 of panel 100" overlies panel 100'. The curved flange at
end 4 helps keep water from getting underneath the panels. And
water which does get underneath the end 4 is conveyed by channel 10
to the face of a panel in the lower course.
[0049] FIG. 4g shows four panels connected together as they may be
when installed on a roof, for example. The lower row which includes
panels 100' and 100" would be laid down first and laterally secured
with the aforedescribed side clip connection system. Then the next
row including panels 100'" and 100"" would be laid down with the
clip 9' of the next row fastening to the hook 9 of the lower
row.
[0050] The panel 100 described hereinabove is preferably
manufactured according to the following process. The process
comprises three principal stages: the roll-forming stage, the
pressing stage, and the coating stage schematically shown on FIGS.
6a, 6b, and 6c. The purpose of the roll-forming and pressing stages
is to convert sheet metal into pressed panels 100. The roll-forming
and pressing lines are slaved to the speed of the coating line,
which controls the overall speed of the process.
[0051] The roll-forming stage (FIG. 6c) begins from loading a steel
coil, preferably about 620 millimeters wide, onto the uncoiler 12
whence the sheet is directed to the roll former 13. Other widths of
the steel coil are possible, depending on a particular design of
the metal panel 100. In the roll former 13, the three horizontal
creases are formed, later to become three longitudinal rows 2', 2"
and 2'" of alternatively raised and lowered sections, or patches 2,
shown on FIG. 1. The metal sheet is also notched in the roll former
13 and individual pieces (or "panels") later to become panels 100
are formed.
[0052] These panels then go through the drop station unit 14 and
the lowering elevator 15, and through the return conveyor 16 and
the return conveyor door unit 17 and are directed to the in-feed
conveyor 18.
[0053] The panels then pass the press 19 (FIG. 6b) and the press
tool 20, where they are pressed into their final form (FIG. 1a). At
this stage the alternating raised and lowered sections or pads 2,
the side lap 3, the side lap channel 10, the claws 8 and the
pockets 6 are formed, among other things. The panels are then
extracted, flipped over and directed to the out-feed conveyor 21,
the transfer conveyor 22 and the transfer conveyor door unit 23
onto the coating conveyor, front side 1 up.
[0054] During the coating stage, the panel 100 is finished. The
panels are automatically loaded onto the coating conveyor and are
carried through the coating application process by pushers fitted
to the conveyor chain. The coating conveyor transports the product
through the basecoat spray booth 24, the chip patching booth 25,
the chip booth 26f and the glaze spray booth 27 (FIG. 6a)
[0055] Basecoat is sprayed onto the bare metal panel in the
basecoat spray booth 24. It features two on/off spray guns (not
shown) to stop spraying if no product is present in the line. The
scrubber unit (not shown), keeps a negative pressure in the booth
24 to extract any over-spray. Acrylic water-based glue, known to
those skilled in the art, is used as a preferred basecoat. The
preferred thickness of the basecoat is about 12 mils (about 305
micrometers).
[0056] The color patching booth 25 puts chip patches and shadow
strips on the product to match and highlight the form in the
panels. The stone chips are dropped onto the panels, while the
panels are still wet with the basecoat. The patching unit contains
three sets of three rollers (not shown), the first set for the
shadow and the other two sets for the patch.
[0057] The color patch part of the system includes three pairs of
servomotors (not shown), controlled by a Programmable Logic
Controller (PLC), driving three pairs of grooved rollers which
carry premixed stone granules from two different hoppers and apply
them in patches to the metal panels. The paired rollers meter and
blend two contrasting mixes of granules and precisely drop them as
color patches on the panels.
[0058] The use of a PLC to control the servomotors that drive the
grooved rollers allows not only precise patch size, through
starting and stopping the motors at precisely the right moment as
the panel travels under the rollers, but also different shading or
shadowing of the mixes of stone through controlling the
servomotors' speed of rotation.
[0059] This second part of the system, to provide shadow and
highlight, comprises three PLC controlled servomotor-driven grooved
rollers that apply narrow bands of stone granules at the rear and
front of each step in the metal panel. This system is located
immediately before the granule patching system described above and
it works in tandem with the granule patching equipment to discharge
granules on panel locations with or without the contrasting color
patches. Two hoppers (not shown) feed granules through three
grooved rollers.
[0060] The quantity of granules delivered, and therefore the
intensity of the color, can be controlled by varying the speed of
rotation of the servomotors. The width of the bands of color can be
adjusted by moving divider plates in the delivery hoppers above the
grooved rollers. The divider plates can be set at an angle to
achieve a flared shadow effect with one edge of the shadow band
being heavier (containing more stone granules) than the other
edge.
[0061] The chip booth 26 coats the product evenly with its base, or
background, color. In the chip booth 26 all the gaps between the
patches, shadows and highlights already on the panel are filled
with a mixed blend of stone granules and then all excess loose
granules are removed. The chips are dropped via two drops of chips
with blow on nozzles to help chip coverage. The excessive amount of
the stone chip is blown off by air.
[0062] As a result of the process of application of the stone
chips, the surface is provided with a "patterned" surface having
differing colors and shades in different areas. The colors of
particular areas is determined by the ratio of differently colored
stone granules, to create a variety of colors and shades,
preferably, a fawn grey, a canyon brown and a vintage slate colored
panels. Four mixes of the granules are preferably used: one very
light, one dark, and two in between.
[0063] The color and shades are coordinated with the raised and
lowered patches so that the appearance of depth of the panel is
enhanced by creating shadows with darker colors. Preferably,
granules of a dark color are delivered adjacent and immediately
below the risers 8' so as to give the impression of a shadow caused
by the riser. The "fake" shadow gives the impression that the riser
is higher than it really is. This has an ornamental advantage of
being attractive without weakening the panel or using additional
metal in its manufacture.
[0064] The stone granules used in this process are preferably grade
14 ceramic coated stone granules supplied by the Minnesota Mining
and Manufacturing Company of Saint Paul, Minn. Other sizes of the
stone granules can be used. Those skilled in the art will use such
other grades by first adjusting the viscosity of the basecoat,
according to commonly used practices.
[0065] The method of the application of the stones is unique. It
allows to precisely place patches of different color mixes of stone
granules on the metal panel.
[0066] Finally, the glaze spray booth 27 coats the product with its
glaze layer, or a sealant layer. A water-based acrylic adhesive is
preferably used as a glaze, or a sealant, to achieve a wet
thickness of about 1 mil (about 25 micrometers). The glaze spray
booth 27 features two on/off spray guns (not shown) to stop spray
if no product is present in the line. The scrubber unit keeps a
negative pressure in the booth to extract any over-spray. The
basecoat is so thick and viscous that the stone granules stick to
the panels in the positions in which they are dropped onto the
panels by the patching, shadowing, highlighting and stone granule
applicator systems.
[0067] Fully coated panels are then transferred into an oven 28
where the basecoat and glaze are cured at a preferred initial
temperature of about 60.degree. C., which temperature is gradually
raised up to about 100.degree. C. The curing time is preferably
within a range of between about 65 minutes to about 75 minutes,
more preferably, about 70 minutes.
[0068] A complete engineering drawing of the panel of this
invention is attached herewith as Appendix A.
[0069] Having described the invention in connection with several
embodiments thereof, modification will now suggest itself to those
skilled in the art. As such, the invention is not to be limited to
the described embodiments except as required by the appended
claims.
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