U.S. patent application number 11/425338 was filed with the patent office on 2007-12-20 for crowning panel assembly.
Invention is credited to ROBERT M.M. HADDOCK.
Application Number | 20070289233 11/425338 |
Document ID | / |
Family ID | 38834268 |
Filed Date | 2007-12-20 |
United States Patent
Application |
20070289233 |
Kind Code |
A1 |
HADDOCK; ROBERT M.M. |
December 20, 2007 |
CROWNING PANEL ASSEMBLY
Abstract
A panel assembly (40) that addresses oil canning when installed
over a substrate or deck (72) is disclosed. The panel assembly (40)
includes a panel (42). The panel (42) includes a first primary
panel surface (44) that faces the substrate (72) in the installed
configuration, as well as a second primary panel surface (46) that
faces away from the substrate (72) in the installed configuration.
Another component of the panel assembly (40) is a first structure
(60) that is disposed between the panel (42) and the substrate
(72). Typically, either a first surface (62) of the first structure
(60) is chemically bonded directly to the first primary panel
surface (44) such that an interface between the first surface (62)
and the first primary panel surface (44) includes a chemical bond,
or a second surface (64) is chemically bonded directly to the
substrate (72) such that an interface between the second surface
(64) and the substrate (72) includes a chemical bond. In any case,
the first structure (60) produces a convexity on the second primary
panel surface (46) to address oil-canning effects or stress
wrinkling of the panel (42).
Inventors: |
HADDOCK; ROBERT M.M.;
(Colorado Springs, CO) |
Correspondence
Address: |
MARSH, FISCHMANN & BREYFOGLE LLP
3151 SOUTH VAUGHN WAY, SUITE 411
AURORA
CO
80014
US
|
Family ID: |
38834268 |
Appl. No.: |
11/425338 |
Filed: |
June 20, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60805275 |
Jun 20, 2006 |
|
|
|
Current U.S.
Class: |
52/309.4 |
Current CPC
Class: |
E04D 3/363 20130101;
E04D 3/364 20130101; E04C 2/08 20130101; E04D 3/366 20130101; E04D
3/30 20130101 |
Class at
Publication: |
52/309.4 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. A panel assembly, comprising: a metal panel, comprising: first
and second primary panel surfaces that are oppositely disposed,
wherein said first primary panel surface projects toward a
substrate when said metal panel is installed over the substrate,
and wherein said second primary panel surface projects away from
the substrate when said metal panel is installed over the
substrate; and a first structure comprising a first surface,
wherein said first surface is chemically bonded directly to said
first primary panel surface such that an interface between said
first surface of said first structure and said first primary panel
surface comprises a chemical bond, wherein said first structure
produces a convexity on said second primary panel surface when said
metal panel is installed over the substrate.
2. The panel assembly of claim 1, wherein said first surface of
said first structure is chemically bonded directly to said metal
panel by an adhesive.
3. The panel assembly of claim 1, wherein said first structure
comprises foam.
4. The panel assembly of claim 1, wherein said first structure is
an extrusion.
5. The panel assembly of claim 1, wherein said first surface of
said first structure is flat prior to said first structure being
chemically bonded to said first primary panel surface.
6. The panel assembly of claim 1, wherein said first structure
comprises a second surface that is flat prior to said metal panel
being installed over the substrate, that is disposed opposite of
said first surface, and that faces the substrate when said metal
panel is installed over the substrate.
7. The panel assembly of claim 1, wherein said first structure is
hollow.
8. The panel assembly of claim 1, wherein said first surface of
said first structure is flat prior to said first structure being
chemically bonded to said first primary panel surface, wherein said
first structure comprises a pair of curved sidewalls that are
convex, as well as a second surface that is flat prior to said
metal panel being installed over the substrate, that is disposed
opposite of said first surface, and that faces the substrate when
said metal panel is installed over the substrate.
9. The panel assembly of claim 1, wherein said metal panel further
comprises first and second longitudinal edges, wherein said first
and second longitudinal edges are each configured to interconnect
with a longitudinal edge of another metal panel to define a
standing seam.
10. The panel assembly of claim 1, wherein said metal panel further
comprises first and second protruding structures that are linearly
extending and that protrude at least generally away from the
substrate when said metal panel is installed over the
substrate.
11. The panel assembly of claim 10, wherein each of said first and
second protruding structures is selected from the group consisting
of a standing seam section and a rib.
12. The panel assembly of claim 10, wherein said first structure is
linearly extending and is disposed at least generally parallel with
said first and second protruding structures.
13. The panel assembly of claim 10, wherein said metal panel
further comprises first and second longitudinal edges that are
laterally spaced, as well as first and second transverse edges that
are longitudinally spaced and that each extend between and
interconnect said first and second longitudinal edges, wherein said
first structure extends at least generally from said first
transverse edge to at least generally said second transverse
edge.
14. The panel assembly of claim 10, wherein said metal panel
further comprises a flat base section that extends between said
first and second protruding structures, and wherein said first
structure is chemically bonded to said first primary panel surface
within said base section, wherein a center-to-center distance
between said first and second protruding structures is at least
about 12 inches.
15. The panel assembly of claim 14, wherein said first structure at
least generally bisects said base section in a lateral dimension
that coincides with a spacing between said first and second
protruding structures.
16. The panel assembly of claim 1, wherein said metal panel further
comprises a flat first base section, wherein said first structure
is chemically bonded to said first primary panel surface within
said first base section.
17. A panel assembly, comprising: a panel, comprising: first and
second primary panel surfaces that are oppositely disposed, wherein
said first primary panel surface projects toward a substrate when
said panel is installed over the substrate, and wherein said second
primary panel surface projects away from the substrate when said
panel is installed over the substrate; and first and second
protruding structures that are linearly extending and that protrude
at least generally away from the substrate when said panel is
installed over the substrate; and a first structure comprising a
first surface that is chemically bonded directly to said first
primary panel surface such that an interface between said first
surface of said first structure and said first primary panel
surface comprises a chemical bond, wherein said first structure
produces a convexity on said second primary panel surface somewhere
between said first and second protruding structures when said panel
is installed over the substrate.
18. A panel assembly, comprising: a panel, comprising: first and
second primary panel surfaces that are oppositely disposed, wherein
said first primary panel surface projects toward a substrate when
said panel is installed over the substrate, and wherein said second
primary panel surface projects away from the substrate when said
panel is installed over the substrate; and first and second
protruding structures that are linearly extending and that protrude
at least generally away from the substrate when said panel is
installed over the substrate; and a first structure that is hollow
and that produces a convexity on said second primary panel surface
somewhere between said first and second protruding structures when
said panel is installed over the substrate and by said first
structure interacting with said first primary panel surface.
19. A building surface, comprising: a substrate; a panel,
comprising: first and second primary panel surfaces that are
oppositely disposed, wherein said first primary panel surface
projects toward said substrate, and wherein said second primary
panel surface projects away from said substrate; and first and
second protruding structures that are linearly extending and that
protrude at least generally away from said substrate; and a first
structure that comprises a first surface that is flat prior to said
first structure being disposed to interact with one of said
substrate and said first primary panel surface, wherein said first
structure exerts a force on said first primary panel surface to
produce a convexity on said second primary panel surface somewhere
between said first and second protruding structures.
20. A building surface, comprising: a substrate; a panel,
comprising: first and second primary panel surfaces that are
oppositely disposed, wherein said first primary panel surface
projects toward said substrate, and wherein said second primary
panel surface projects away from said substrate; and a first
structure comprising a first surface chemically bonded directly to
one of said first primary panel surface and said substrate such
that an interface between said first surface of said first
structure and said one of said first primary panel surface and said
substrate comprises a chemical bond, wherein said first structure
produces a convexity on said second primary panel surface.
21. The building surface of claim 20, wherein said substrate is
flat.
22. The building surface of claim 20, wherein said first structure
is chemically bonded directly to only one of said first primary
panel surface and said substrate, and is in contact with and
movable relative to the other of said first primary panel surface
and said substrate.
23. A building surface, comprising: a substrate; a panel,
comprising: first and second primary panel surfaces that are
oppositely disposed, wherein said first primary panel surface
projects toward said substrate, and wherein said second primary
panel surface projects away from said substrate; and first and
second protruding structures that are linearly extending and that
protrude at least generally away from said substrate; and a first
structure that is hollow and that produces a convexity on said
second primary panel surface somewhere between said first and
second protruding structures by said first structure interacting
with said first primary panel surface.
24. A method of installing a panel over a substrate, wherein said
panel comprises first and second primary panel surfaces that are
oppositely disposed, wherein said method comprises the steps of:
disposing said panel over said substrate such that said first
primary panel surface faces said substrate, such that said second
primary panel surface faces away from said substrate, and such that
a first structure is disposed between said first primary panel
surface and said substrate; providing a chemical bond directly
between a first surface of said first structure and one of said
first primary panel surface and said substrate such that an
interface between said first surface of said first structure and
said one of said first primary panel surface and said substrate
comprises a chemical bond; and producing a convexity on said second
primary surface of said panel by said first structure being
disposed between said first primary panel surface and said
substrate.
25. The method of claim 24, wherein said substrate is flat.
26. The method of claim 24, wherein said providing a chemical bond
step comprises providing a chemical bond between said first
structure and only one of said first primary panel surface and said
substrate.
Description
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."
[0021] The various features discussed above in relation to the
first aspect may be used by this second aspect as well,
individually or in any combination. Each of the noted first and
second protruding structures may be of any appropriate size, shape,
configuration, and/or form. For instance, one or both of these
first and second protruding structures could be in the form of a
standing seam section at one of the two longitudinal edges of the
panel. One or both of these first and second protruding structures
also could be in the form of a rib (as defined above in relation to
the first aspect) that is somewhere between the two longitudinal
edges of the panel (regardless of whether in the form of a standing
seam section or not). Typically, the two longitudinal edges of the
panel, any rib located between these two longitudinal edges, and
the first structure will be disposed in at least substantially
parallel relation to each other.
[0022] A third aspect of the present invention is generally
directed to a panel assembly having a panel and a first structure.
The panel includes first and second primary panel surfaces that are
disposed opposite of each other (e.g., on opposite "sides" of the
panel). 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
first and second protruding structures that are linearly extending
and that protrude at least generally away from the substrate when
the panel is installed over the substrate. The noted first
structure is hollow and interfaces with the first primary panel
surface at least when the panel is installed over the substrate so
as to produce a convexity on the second primary panel surface
somewhere between the first and second protruding structures. The
various features discussed above in relation to the first aspect
may also be used by this third aspect, individually or in any
combination. However, the first structure may be integrated with
the panel or substrate in any appropriate manner (e.g., a chemical
bond is not required between the opposing surfaces of the first
structure and the panel in the case of the third aspect, or stated
another way, the interface between the first surface of the first
structure and the first primary panel surface need not include a
chemical bond in the case of the third aspect).
[0023] The first through the third aspects encompass a panel
assembly prior to being installed over a substrate, as well as a
panel assembly after it has been installed over a substrate.
Representative examples of panel assemblies used in combination
with a substrate will now be presented. The panel assemblies of the
first through the third aspects may be used with the types of
substrates that will now be discussed in relation to any of the
fourth through the sixth aspects, and further otherwise may be used
in accordance with any of the fourth through the sixth aspects
where appropriate.
[0024] A fourth aspect of the present invention is embodied by a
building or other appropriate surface (e.g., roof; siding; soffit;
interiorly disposed; exteriorly disposed) that includes a
substrate, a panel, and a first structure, and thereby encompasses
the resulting building surface as well as the method of defining
this building surface. The panel includes first and second primary
panel surfaces that are disposed opposite of each other (e.g., on
opposite "sides" of the panel). The first primary panel surface
projects toward the 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 first and second protruding structures that
are linearly extending and that protrude at least generally away
from the substrate when the panel is installed over the substrate.
The noted first structure includes a first surface that is flat
prior to the first structure being disposed in interfacing or
opposing relation with either the substrate or the first primary
panel surface. Another portion of the first structure engages the
other of the substrate and the first primary panel surface so that
the first structure produces a convexity on the second primary
panel surface somewhere between the first and second protruding
structures. The various features discussed above in relation to the
first aspect may also be used by this fourth aspect, individually
or in any combination. The various features that will now be
discussed in relation to a fifth aspect of the present invention
also may be used by this fourth aspect, individually or in any
combination. However, it should be appreciated that the first
structure may be integrated with the panel or substrate in any
appropriate manner in the case of the fourth aspect (e.g., a
chemical bond is not required between opposing surfaces of the
first structure and either of the panel or substrate in the case of
the fourth aspect, or stated another way, the interface between the
first surface of the first structure and either the first primary
panel surface or the substrate need not include a chemical bond in
the case of the fourth aspect).
[0025] A fifth aspect of the present invention is embodied by a
building or other appropriate surface (e.g., roof; siding; soffit;
interiorly disposed; exteriorly disposed) that includes a
substrate, a panel, and a first structure, and thereby encompasses
the resulting building surface as well as the method of defining
this building surface. The panel includes first and second primary
panel surfaces that are oppositely disposed, where the first
primary panel surface projects toward or faces the substrate, and
where the second primary panel surface projects away from the
substrate. The first structure includes a first surface, and this
first surface is disposed on and is chemically bonded to one of the
first primary panel surface and the substrate, again where the
first primary panel surface projects toward or faces the substrate.
That is, the interface between the first surface of the first
structure and either the first primary panel surface or the
substrate includes a chemical bond. Generally, this first structure
produces a convexity on the second primary panel surface (again,
where the second primary panel projects away from the
substrate).
[0026] Various refinements exist of the features noted in relation
to the fifth aspect of the present invention. Further features may
also be incorporated in the fifth aspect of the present invention
as well. These refinements and additional features may exist
individually or in any combination. Generally, the fifth aspect may
be characterized as addressing oil canning or stress wrinkling.
That is, the convexity in the 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." In any case, the various features
discussed above in relation to the first aspect may also be used by
this fifth aspect where appropriate, individually or in any
combination.
[0027] The substrate in the case of the fifth aspect may be of any
appropriate size, shape, configuration, and/or type, and further
may be formed from any appropriate material or combination of
materials. The substrate may be in the form of a plywood deck or
the like, a metal deck or the like, a deck defined by one or more
foam boards or the like, as well as a deck defined by wood,
concrete, or any other appropriate material/structure. A membrane
or the like may be disposed between the above-noted types of
structures and the panel, and thereby may be characterized as the
substrate for purposes of this fifth aspect. In any case, the
substrate will typically be in the form of a flat surface.
Generally, the substrate may be characterized as that structure
that is disposed directly underneath the panel, or that structure
that, in combination with the panel, "sandwiches" the first
structure therebetween.
[0028] The building surface of the fifth aspect may be in any
appropriate location in relation to the building. For instance, the
building surface of the fifth aspect encompasses both interior and
exterior surfaces. Moreover, this building surface may define any
appropriate surface, such as an interior wall or ceiling, exterior
siding, a roof, or a soffit. In one embodiment, the roof has a
pitch and the panel is installed such that its first and second
longitudinal edges run at least generally up/down the pitch of the
roof (e.g., the first and second longitudinal edges may be disposed
at least generally perpendicularly to a peak of the roof). Another
way to characterize the positioning of the first and second
longitudinal edges of the panel on the roof is that they may be
disposed in a vertical reference plane, they may be oriented such
that the elevation of the first and second longitudinal edges
progressively changes proceeding along their length dimension, or
both.
[0029] The first surface of the first structure may be chemically
bonded directly to the relevant structure prior to disposing the
panel over the substrate. One embodiment has the first surface of
the first structure being chemically bonded directly to the
substrate prior to disposing the panel over the substrate such that
the interface between the first surface of the first structure and
the substrate includes a chemical bond. In this case, the panel
would be in contact with the first structure, but preferably would
be movable relative to the first structure (e.g., preferably the
first structure is not bonded to both the panel and the substrate).
Another embodiment has the first surface of the first structure
being chemically bonded directly to the first primary panel surface
prior to disposing the panel over the substrate such that the
interface between the first surface of the first structure and the
first primary panel surface includes a chemical bond. In this case,
the panel would be in contact with the substrate, but would be
movable relative to the substrate. The first surface of the first
structure may be chemically bonded directly to the relevant
structure at least generally in any of the manners discussed above
in relation to the first aspect.
[0030] A sixth aspect of the present invention is embodied by a
building or other appropriate surface (e.g., roof; siding; soffit;
interiorly disposed; exteriorly disposed) that includes a
substrate, a panel, and a first structure, and thereby encompasses
the resulting building surface as well as the method of defining
this building surface. The panel includes first and second primary
panel surfaces that are oppositely disposed, where the first
primary panel surface projects toward or faces the substrate, and
where the second primary panel surface projects away from the
substrate. The first structure is disposed between the panel and
the substrate so as to produce a convexity on the second primary
panel surface. In a first embodiment of the sixth aspect, the first
structure includes a flat first surface prior to this first surface
being disposed in interfacing or opposing relation with either the
panel or substrate. The first surface of the first structure could
be chemically bonded directly to the panel or the substrate in
accordance with the fifth aspect such that the interface between
the first surface of the first structure and either the panel or
the substrate includes a chemical bond, although the first
structure could be mounted to the panel and/or substrate in any
appropriate manner in the case of the first embodiment of the sixth
aspect. In a second embodiment of the sixth aspect, the first
structure is hollow. The first surface of the first structure could
be chemically bonded directly to the panel or the substrate in
accordance with the fifth aspect such that the interface between
the first surface of the first structure and either the panel or
the substrate includes a chemical bond, although the first
structure could be mounted to the panel and/or substrate in any
appropriate manner in the case of the second embodiment of the
sixth aspect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a perspective view of a conventional standing seam
roof.
[0032] FIG. 2 is a cross-sectional schematic of one of the standing
seams of FIG. 1.
[0033] FIG. 3 is a schematic of a standing seam panel installed
over a deck using a first structure to address oil canning or
stress wrinkling of the panel.
[0034] FIG. 4 is a top view of the standing seam panel of FIG. 3,
and without illustrating the underlying deck.
[0035] FIG. 5A is an end view of the first structure illustrated in
FIG. 3.
[0036] FIG. 5B is an end view of an alternative configuration for
the first structure of FIG. 5A.
[0037] FIG. 5C is an end view of another alternative configuration
for the first structure of FIG. 5A.
[0038] FIG. 6A is an alternative configuration for a standing seam
panel (two base sections) that may be used in combination with any
of the first structures of FIGS. 5A-C to address oil canning or
stress wrinkling of the panel.
[0039] FIG. 6B is an alternative configuration for a standing seam
panel (three base sections) that may be used in combination with
any of the first structures of FIGS. 5A-C to address oil canning or
stress wrinkling of the panel.
[0040] FIG. 7A is a schematic of a standing seam defined by the
interconnection of a pair of standing seam sections of the type
used by the standing seam panel of FIG. 3.
[0041] FIGS. 7B-G are various alternative standing seam
profiles/configurations for standing seam panels that may be used
in combination with a first structure to address oil canning or
stress wrinkling.
DETAILED DESCRIPTION
[0042] FIG. 1 illustrates a representative roof 12 of a building.
The roof 12 may be of any pitch, but at least generally slopes
downwardly from a peak 14 of the roof 12 to an eave 16 of the roof
12. Multiple panels 22 (e.g., metal) are interconnected to define
the roof 12. The interconnection of adjacent panels 22 defines a
standing seam 18. The length dimension of each standing seam 18
extends from the peak 14 of the roof 12 to the eave 16 of the roof
12, and furthermore the elevation of the various standing seams 18
progressively changes proceeding along their respective length
dimensions. Each panel 22 includes a flat, planar base 20 that is
disposed between each adjacent pair of standing seams 18. The
standing seams 18 may be further characterized as extending at
least generally away from the bases 20 that are disposed on each
side of the relevant standing seam 18 (FIG. 2, where an upper end
19 of the standing seam 18 is vertically spaced from the adjacent
bases 20 of the panels 22). The panels 22 may be of any appropriate
configuration, the standing seams 18 may be of any appropriate
configuration, and the standing seams 18 may be disposed in any
appropriate orientation relative to the adjacent bases 20.
[0043] FIG. 3 illustrates one embodiment of a building or any other
appropriate surface 70. The building surface 70 is applicable to
both interior and exterior surfaces. Moreover, the building surface
70 may be incorporated at any appropriate location, such as an
interior wall or ceiling, a roof, siding, or a soffit. In any case,
the building surface 70 is defined by a plurality of what may be
characterized as panel assemblies 40 (only one being illustrated in
FIG. 3 and in the form of a panel 42 and a first structure 60,
where multiple panels 42 would be at least generally interconnected
in the manner discussed above in relation to the roof 12) that are
installed over an appropriate substrate or deck 72. Portions of the
substrate 72 are removed in FIG. 3 to highlight the illustration of
at least certain portions of the panel assembly 40. The substrate
72 is a flat or planar structure, and may be formed/constructed in
any appropriate manner. Typically the substrate 72 will be in the
form of plywood sheets that are nailed to the rafters or other
underlying supports of the building surface 70. However, the
substrate 72 could be in the form of a metal deck or the like, a
deck defined by one or more foam boards or the like, as well as a
deck defined by wood, concrete, or any other appropriate
material/structure. Moreover, a membrane or the like may be
disposed between the above-noted types of structures and the panel
42 of the panel assembly 40, and thereby itself may be
characterized as the substrate 72. Generally, the substrate 72 may
be characterized as that structure that is disposed directly
underneath the panel 42, or that structure that, in combination
with the panel 42, "sandwiches" the first structure 60 of the panel
assembly 40 therebetween.
[0044] The panel assembly 40 includes a panel 42, which is
illustrated in both FIG. 3 and FIG. 4. The illustrated panel 42 is
in the form of what is commonly referred to as a standing seam
panel 42 based upon the manner in which it is interconnected with
adjacent panels 42 to define the building surface 70. However, the
panel 42 may be of any appropriate configuration in relation to the
manner in which it is assembled to define a building surface.
Although the panel 42 could be formed from any appropriate
material, typically the panel 42 will be formed from an appropriate
metal. In any case, the panel 42 includes a first primary panel
surface 44 that projects toward or faces the substrate 72 when the
panel assembly 40 is installed over the substrate 72. A second
primary panel surface 46 is disposed oppositely of the first
primary panel surface 44, and thereby faces or projects at least
generally away from the substrate 72 when the panel assembly 40 is
installed over the substrate 72.
[0045] The panel 42 includes a pair of longitudinal edges 48a, 48b
that extend in what may be characterized as a longitudinal
dimension. In the illustrated embodiment, the longitudinal edges
48a, 48b are in the form of standing seam sections 48a, 48b. The
standing seam sections 48a, 48b each may be of any appropriate
configuration (e.g., FIGS. 7A-G), and may be disposed in any
appropriate orientation so as to be able to interconnect with an
adjacent panel 42 when the panels 42 are installed over the
substrate 72 and that will define a standing seam (e.g., standing
seams 49a-g of FIGS. 7A-G, respectively). However and in accordance
with the foregoing, the longitudinal edges 48a, 48b need not be in
the form of standing seam sections.
[0046] In the case where the building surface 70 of FIG. 3 is in
the form of a roof, the roof may have a pitch and the panel 42 will
typically be installed such that its longitudinal edges 48a, 48b
run at least generally up/down the pitch of the roof (e.g., the
longitudinal edges 48a, 48b may be disposed at least generally
perpendicularly to a peak of the roof; the longitudinal edges 48a,
48b may extend from a peak of the roof to an eave of the roof).
Another way to characterize the positioning/orientation of the
longitudinal edges 48a, 48b of the panel 42 on the building surface
70 in the form of a roof is that they may be disposed in a vertical
reference plane, the longitudinal edges 48a, 48b may be oriented
such that the elevation of the longitudinal edges 48a, 48b
progressively changes proceeding along their respective length
dimensions, or both.
[0047] Extending between and interconnecting the longitudinal edges
or standing seam sections 48a, 48b of the panel 42 is a pair of
transverse or lateral edges 50. The longitudinal edges or standing
seam sections 48a, 48b may be characterized as being longitudinally
extending and spaced in a lateral dimension. The transverse edges
50 thereby may be characterized as being laterally extending and
spaced in a longitudinal dimension. In the illustrated embodiment,
the longitudinal edges or standing seam sections 48a, 48b are
parallel to each other, as are the transverse edges 50, although
such may not be required in all instances.
[0048] A base section 54 is disposed between the longitudinal edges
or standing seam sections 48a, 48b in the case of the panel 42, and
is a flat or planar structure. The width dimension of the base
section 54 coincides with the dimension in which the longitudinal
edges or standing seam sections 48a, 48b of the panel 42 are spaced
from each other in the illustrated embodiment (again, where the
longitudinal edges or standing seam sections 48a, 48b each define a
standing seam 49a in the illustrated embodiment when appropriately
interconnected with an adjacent panel 42 and as illustrated in FIG.
7A), and corresponds with the dimension "W" in FIG. 3. The base
section 54 of the panel 42 is particularly susceptible to oil
canning or stress wrinkling. It should be appreciated that the
panel 42 could be configured to include more than one base section
54 (not shown in FIG. 3, but see FIGS. 6A-B to be discussed below)
by including one or more "ribs" (discussed below) between the
longitudinal edges or standing seam sections 48a, 48b.
[0049] The panel assembly 40 further includes an associated first
structure 60 that is disposed between the substrate 72 and first
primary panel surface 44 of the associated panel 42. In one
embodiment, the first structure 60 is at least generally in the
form of a foam (e.g., a material of the type that is typically used
to define backer rod). Although the first structure 60 may be
fabricated in any appropriate manner, in one embodiment the first
structure 60 is extruded, such that it may be referred to as an
extrusion.
[0050] The first structure 60 may be formed from any appropriate
material or combination of materials, may be of any appropriate
size, shape, configuration, and cross-sectional profile, or both,
so long as the first structure 60 provides a desired convexity for
the second primary panel surface 46 in a manner that will be
discussed in more detail below. However, generally it would be
desirable for the first structure 60 to be sufficiently
compressible so that the first structure 60 will not bend or
otherwise permanently deform the panel 42 when under normal design
loads. It would be desirable for the first structure 60 to at least
temporarily compress if the panel 42 experiences a normal design
load (e.g., a person walking on the panel 42) so that the first
structure 60 would not bend or permanently deform the panel 42 in
this instance. Although the first structure 60 could be elastic,
such need not be the case. That is, after undergoing a compression
by the panel 42 being exposed to a load, the first structure 60
would not necessarily have to assume its original configuration
once the load is removed or reduced (although the first structure
60 could in fact be elastic), but preferably the first structure 60
would at least move back toward its original configuration (e.g.,
by a subsequent expansion) upon experiencing a removal/reduction of
the applied load.
[0051] Referring now to FIGS. 3, 4, and 5A, a first surface 62 of
the first structure 60 faces and may be in direct contact with the
first primary panel surface 44 (such that the first surface 62 and
the first primary panel surface 44 are in opposing relation), while
an oppositely disposed second surface 64 faces and may be in direct
contact with the substrate 72 (such that the second surface 64 and
the first primary panel surface 44 are in opposing relation). The
interface between the first surface 62 and the first primary panel
surface 44, the interface between the second surface 62 and the
substrate 72, or both, may include an adhesive (e.g., such that
there may not be direct contact between the first structure 60 and
the relevant structure). In any case, both the first surface 62 and
the second surface 64 are flat in the illustrated embodiment prior
to being disposed in opposing relation with the corresponding
structure, or with the first structure 60 being in an uncompressed
state. The sidewalls 63 that interconnect the surfaces 62 and 64
are also flat, although other configurations may be appropriate.
Typically either the first surface 62 will be chemically bonded to
the first primary panel surface 44 such that the interface between
the first surface 62 and the first primary panel surface 44
includes a chemical bond, or the second surface 64 of the first
structure 60 will be chemically bonded to the substrate 72 such
that the interface between the second surface 64 and the substrate
72 includes a chemical bond. That is, typically the first structure
60 will be chemically bonded directly to only one of the panel 42
and the substrate 72. However, the first structure 60 could
possibly be chemically bonded directly to each of the panel 42 and
substrate 72, although this may in fact be disadvantageous in one
or more respects. The first structure 60 may be a solid structure,
or may be hollow by including one or more apertures 66 that extend
along its length dimension (illustrated by dashed lines in FIG.
5A). Each aperture 66 may be of any appropriate cross-sectional
profile, and multiple apertures 66 used by the first structure 60
may be disposed in any appropriate arrangement. When the first
structure 60 includes a single aperture of the type shown in FIG.
5A, the first structure 60 may be characterized as a tube or at
least as being tube-like.
[0052] Any appropriate way of providing a chemical bond between
opposing surfaces of the first structure 60 and the panel
42/substrate 72 may be utilized. One appropriate way to provide the
noted chemical bond would be via an appropriate adhesive. This
adhesive could be applied by the manufacturer of the panel 42 (in
which case the first surface 62 of the first structure 60 would be
chemically bonded directly to the panel 42), could be applied by a
contractor at the job site (in which case the first surface 62 of
the first structure 60 could be chemically bonded directly to the
panel 42, the substrate 72, or both), or at any other appropriate
time. Another appropriate way to provide the noted chemical bond
would be to use double-sided tape and in any appropriate manner
(e.g., the first surface 62 of the first structure 60 could be
chemically bonded directly to the panel 42 prior to arriving at the
job site and including being attached by the manufacturer of the
panel 42; the first surface 62 of the first structure 60 could be
chemically bonded directly to the panel 42 at the job site; the
second surface 64 of the first structure 60 could be chemically
bonded to the substrate 72 at the job site). It also may be such
that the first structure 60 could be formed on the first primary
panel surface 44 as part of its overall fabrication process, such
as by dispensing an appropriate material onto the first primary
panel surface 44 as a piece of sheet metal moves relative to the
dispenser (e.g., prior to the sheet metal passing through a roll
forming station or the like, where such a roll forming station may
utilize a plurality of forming rollers or the like that
shape/define the longitudinal edges or standing seam sections 48a,
48b; as the sheet metal passes through a roll forming station or
the like; after the sheet metal has passed through a roll forming
station or the like). This dispensed material may be in the form of
a liquid or a paste that may be deposited directly on the panel 42.
In any case, it may be such that this deposition would both
chemically bond the material to the first primary panel surface 44
and at least eventually define the first structure 60 (possibly
after being allowed to air cure, possibly after some type of
post-processing or the like (e.g., a heat treatment), or both). Yet
another option would be to form the first structure 60 (e.g., by
extrusion) and to thereafter position the first structure 60 onto
the first primary panel surface 44 while in a "wet" or "uncured"
state such that a chemical bond will develop/exist between the
interfacing surfaces of the first structure 60 and the first
primary panel surface 44.
[0053] Any way of mounting the first structure 60 to the panel 42
as part of its overall fabrication process may be utilized as well
(e.g., in a roll forming line; in a separate line from the roll
forming line). For instance: 1) an appropriate adhesive or the like
could be dispensed onto the panel 42 as the panel 42 is being
advanced relative to the adhesive source, and at some time
thereafter the first structure 60 could be positioned over this
adhesive as the panel 42 is being advanced relative to the first
structure 60; 2) the first structure 60, with pre-applied adhesive
or the like (e.g., in the form of double-sided adhesive tape; an
inborne adhesive or adhesive characteristic may be part of the
composition of the first structure 60), could be positioned on the
panel 42 as the panel 42 is being advanced relative to the first
structure 60; 3) an appropriate adhesive or the like could be
dispensed onto the first structure 60, and thereafter the first
structure 60 could be positioned on the panel 42 as the panel 42 is
being advanced relative to the first structure 60; 4) an
appropriate adhesive or the like could be dispensed onto the panel
42 as the panel 42 is being advanced relative to the adhesive
source, an appropriate adhesive or the like could be dispensed onto
the first structure 60, and thereafter the first structure 60 could
be positioned on the panel 42 as the panel 42 is being advanced
relative to the first structure 60; and 5) the first structure 60
could be formed (e.g., extruded), and while the first structure 60
is still in a "wet" or an "uncured" state, the first structure 60
may be positioned on the first primary panel surface 44 such that a
chemical bond will develop/exist between the interfacing surfaces
of the first structure 60 and the first primary panel surface 44,
and which may also result in a "flattening" of the interfacing
surface of the first structure 60 (the surface thereof that
interfaces with the first primary panel surface 44)--possibly after
placing the first structure 60 in compression to enhance the
mounting of the first structure 60 to the panel 42.
[0054] The first structure 60 is installed so as to produce a
convexity on the second primary panel surface 46 on the base
section 54 of the panel 42 and as illustrated in FIG. 3. This
desirably addresses oil canning or stress wrinkling of the base
section 54. That is, the panel assembly 40 should reduce the visual
impact of oil canning or stress wrinkling of the panel 42 when the
panel assembly 40 is installed over the substrate 72. In this
regard, the first surface 62 of the first structure 60 engages or
faces the first primary panel surface 44 (again, the interface may
be in the form of an adhesive layer or film), while the second
surface 64 of the first structure 60 engages or faces the substrate
72 (again, the interface may be in the form of an adhesive layer or
film). Typically the first structure 60 is installed at the lateral
midpoint of the base section 54, although other positionings may be
appropriate. More than one first structure 60 could be installed on
the base section 54 as well. Moreover, typically the first
structure 60 extends from at least generally one transverse edge 50
to at least generally the other transverse edge 50 (e.g., to or
within a few inches of each transverse edge 50), and furthermore at
least in generally parallel relation with the longitudinal edges or
standing seam sections 48a, 48b that again each define a standing
seam 49a (FIG. 7A) when appropriately interconnected with an
adjacent panel 42. Other installed positions may be
appropriate.
[0055] As noted, the first structure 60 may be of any appropriate
cross-sectional configuration. For instance, the first structure 60
could be cylindrical, for instance when the first structure 60 is
in a "wet" or "uncured" state when initially disposed on the first
primary panel surface 44 and as discussed above. FIGS. 5B and 5C
illustrate other representative alternative cross-sectional
profiles for the first structure 60. Other than having different
cross-sectional profiles, the discussion presented above with
regard to the first structure 60 is equally applicable to the first
structures 60' and 60'' of FIGS. 5B and 5C, respectively.
[0056] FIG. 5B illustrates that the first structure 60' includes a
single flat first surface 62' (flat before being disposed in
interfacing relation with the relevant structure or with the first
structure 60' being in an uncompressed state) and an oppositely
disposed convex or curved second surface 64', as well as convex or
curved sidewalls 63'. Generally, the first structure 60' may be
characterized as a cylindrical rod with a single flat (first
surface 62') formed on its exterior surface. In the illustrated
embodiment, the first structure 60' is semicircular. In any case
and in accordance with the first structure 60, the first structure
60' may include one or more optional apertures 66' (illustrated by
dashed lines). The first surface 62' could be chemically bonded to
the relevant structure (either the first primary panel surface 44
of the panel 42 or the substrate 72). The configuration shown in
FIG. 5B may also be realized after a "wet" or "uncured" first
structure 60 is disposed on the first primary panel surface 44 in
the above-noted manner.
[0057] FIG. 5C illustrates that the first structure 60'' includes a
flat first surface 62'' (flat before being disposed in interfacing
relation with the relevant structure or with the first structure
60'' being in an uncompressed state) and an oppositely disposed
flat second surface 64'' (flat before being disposed in interfacing
relation with the relevant structure or with the first structure
60'' being in an uncompressed state). Generally, the first
structure 60'' may be characterized as a cylindrical rod with a
pair of opposing flats (first surface 62'' and second surface 64'')
formed on its exterior surface. In this regard, a pair of convex or
curved sidewalls 63'' extend between and interconnect the surfaces
62'' and 64''. In accordance with the first structure 60, the first
structure 60'' may include one or more optional apertures 66''.
Generally, one of the surfaces 62'', 64'' would be disposed in
interfacing relation with the first primary panel surface 44 of the
panel 42, while the other of the surfaces 62'', 64'' would be
disposed in interfacing relation with the substrate 72.
[0058] The panel 42 may be installed in any appropriate manner
relative to the substrate 72. For instance, the entire first
primary panel surface 44 may be disposed in spaced relation to the
substrate 72. In this case, the height or thickness of the first
structure 60 (including the variations thereof addressed herein)
would of course need to be greater than the size of this gap to
provide the desired convexity on the second primary panel surface
46. Alternatively and in the absence of the first structure 60
(including the variations thereof addressed herein), the panel 42
may be installed such that the base section 54 of the panel 42 is
disposed on the substrate 72. However, the first structure 60
(including the variations thereof addressed herein) will of course
dispose at least a portion of the base section 54 in spaced
relation to the substrate 72.
[0059] The first structure 60 (including the variations thereof
addressed herein) may be used with a panel of any appropriate
configuration. Representative alternative standing seam panel
configurations are illustrated in FIGS. 6A-B. The panel 42.sup.i of
FIG. 6A includes a pair of longitudinal edges 48a.sup.i, 48b.sup.i
in the form of standing seam sections, and a single rib 53 (a "rib"
again being a protruding structure of any appropriate size, shape,
and/or configuration that is located between the longitudinal edges
of a panel, including without limitation a crest, minor rib,
intermediate rib, pencil rib, striation, fluting, or flute) that is
disposed midway between these longitudinal edges or standing seam
sections 48a.sup.i, 48b.sup.i. The panel 42.sup.i thereby includes
two base sections 54.sup.i--one between the rib 53 and each of the
two longitudinal edges or standing seam sections 48a.sup.i,
48b.sup.i. One or more first structures 60 (or any of the
variations thereof addressed herein) may be disposed so as to
interface with the first primary panel surface 44.sup.i in each of
the base sections 54.sup.i to produce a convexity on the second
primary panel surface 46.sup.i at least generally in accordance
with the foregoing.
[0060] The panel 42.sup.ii of FIG. 6B includes a pair of
longitudinal edges 48a.sup.ii, 48b.sup.ii in the form of standing
seam sections, and two or more ribs 53 (of any appropriate size,
shape, and/or configuration) that are typically equally spaced
between these longitudinal edges or standing seam sections
48a.sup.ii, 48b.sup.ii. The panel 42.sup.ii thereby includes at
least three base sections 54.sup.ii--one between each rib 53 and
the adjacent longitudinal edge or standing seam section 48a.sup.ii,
48.sup.ii, and another between each adjacent pair of ribs 53. One
or more first structures 60 (or any of the variations thereof
addressed herein) may be disposed so as to interface with the first
primary panel surface 44.sup.ii in each of the base sections
54.sup.ii to produce a convexity on the second primary panel
surface 46.sup.ii at least generally in accordance with the
foregoing.
[0061] As noted above, longitudinal edges in the form of standing
seam sections 48a, 48b each may be of any appropriate size, shape,
and/or configuration. FIG. 7A illustrates a pair of standing seam
panels that are of the type illustrated in FIG. 3 and that are
interconnected to define a standing seam 49a. FIGS. 7B-7G
illustrate representative, alternative standing seams 49b-g defined
by the interconnection of the standing seam sections of a pair of
adjacent standing seam panels. The standing seam section
configurations illustrated in FIGS. 7A-G may be used in relation to
any of the panels described herein, where a first structure is used
in combination with this panel to provide a convexity on its second
primary panel surface to address oil canning.
[0062] Summarizing the foregoing, a first structure is disposed in
opposing relation with a first primary panel surface of a panel
somewhere between an adjacent pair of protruding structures (e.g.,
a standing seam section; a rib) to produce a convexity on the
second primary panel surface, where each protruding structure is
both linearly extending and protrudes at least generally away from
the substrate when the panel is installed over the substrate.
Therefore, the longitudinal edges or standing seam sections 48a,
48b (as well as the variations thereof addressed herein) and the
ribs 53 would each be such a protruding structure. A first
structure could be disposed between an adjacent pair of protruding
structures of a common type, or between protruding structures of
different types. Typically, the first structure will be disposed on
a flat base section between an adjacent pair of protruding
structures, where the center-to-center spacing between these
protruding structures is at least about 12 inches. Although these
protruding structures may be associated with a standing seam panel
to address oil canning, the first structure may be used in relation
to any panel having at least two protruding structures of the type
discussed herein to address oil canning as well.
[0063] The foregoing description of the present invention has been
presented for purposes of illustration and description.
Furthermore, the description is not intended to limit the invention
to the form disclosed herein. Consequently, variations and
modifications commensurate with the above teachings, and skill and
knowledge of the relevant art, are within the scope of the present
invention. The embodiments described hereinabove are further
intended to explain best modes known of practicing the invention
and to enable others skilled in the art to utilize the invention in
such, or other embodiments and with various modifications required
by the particular application(s) or use(s) of the present
invention. It is intended that the appended claims be construed to
include alternative embodiments to the extent permitted by the
prior art.
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