U.S. patent application number 12/827692 was filed with the patent office on 2010-11-11 for method of continuously producing elongated plastic siding panels.
This patent application is currently assigned to TAPCO INTERNATIONAL CORPORATION. Invention is credited to Daniel W. King.
Application Number | 20100283190 12/827692 |
Document ID | / |
Family ID | 34714516 |
Filed Date | 2010-11-11 |
United States Patent
Application |
20100283190 |
Kind Code |
A1 |
King; Daniel W. |
November 11, 2010 |
METHOD OF CONTINUOUSLY PRODUCING ELONGATED PLASTIC SIDING
PANELS
Abstract
A method and an apparatus for continuously producing elongated
siding panels is disclosed. The apparatus includes a conveyor, a
plurality of mold plates, and a die for extruding a sheet of
material onto the mold plates. The mold plates are formed of a
rigid material and positioned adjacent one another and supported by
the conveyor for forming the elongated siding panels. Each of the
mold plates has an upper edge portion and a lower edge portion with
an intermediate portion therebetween. The intermediate portion has
an aesthetic pattern for imparting the pattern to the sheet of
material with the adjacent mold plates having different aesthetic
patterns. The lower edge portion has a lower leg extending
substantially perpendicular from the intermediate portion defining
a horizontal plane and a projection portion between the lower edge
portion and the intermediate portion extends beyond the horizontal
plane for imparting a jagged pattern to the intermediate
portion.
Inventors: |
King; Daniel W.; (Copely,
OH) |
Correspondence
Address: |
HOWARD & HOWARD ATTORNEYS PLLC
450 West Fourth Street
Royal Oak
MI
48067
US
|
Assignee: |
TAPCO INTERNATIONAL
CORPORATION
Wixom
MI
|
Family ID: |
34714516 |
Appl. No.: |
12/827692 |
Filed: |
June 30, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11942502 |
Nov 19, 2007 |
7775008 |
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12827692 |
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10999559 |
Nov 30, 2004 |
7296989 |
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11942502 |
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|
10689137 |
Oct 20, 2003 |
7008213 |
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10999559 |
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|
09919136 |
Jul 31, 2001 |
6635218 |
|
|
10689137 |
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09315317 |
May 20, 1999 |
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09919136 |
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60086378 |
May 22, 1998 |
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Current U.S.
Class: |
264/554 |
Current CPC
Class: |
B29C 53/02 20130101;
B29C 51/24 20130101; B29C 48/07 20190201; E04F 13/0864 20130101;
B29C 2791/001 20130101; B29C 2791/006 20130101; B29C 51/34
20130101; B29C 48/0022 20190201; B29C 48/001 20190201; B29C 2793/00
20130101; B29C 48/00 20190201; B29L 2031/108 20130101; E04D 1/265
20130101; B29C 48/13 20190201; B29C 2793/009 20130101; B29C 48/0017
20190201; E04F 13/185 20130101; B29C 51/10 20130101; B29K 2905/02
20130101; B29K 2995/0072 20130101 |
Class at
Publication: |
264/554 |
International
Class: |
B29C 43/10 20060101
B29C043/10 |
Claims
1-23. (canceled)
24. A method of continuously producing elongated siding panels,
each panel having an upper edge portion, an intermediate portion
having an aesthetic pattern, and a lower edge portion having a
lower leg extending substantially perpendicular from the
intermediate portion defining a horizontal plane, said method
comprising the steps of: extruding a sheet of material having a
temperature sufficient for vacuum forming the sheet of material;
directing the sheet of material onto a plurality of mold plates
carried by a conveyor, each of the mold plates having an upper edge
portion, a lower edge portion, and an intermediate portion having
an aesthetic pattern disposed therebetween; progressively applying
a vacuum to the mold plates as the mold plates travel along the
conveyor; drawing the sheet of material into the mold plates when
the vacuum is applied; forming the upper edge portion, the
intermediate portion, and the lower edge portion while the entire
sheet of material has the sufficient temperature for vacuum
forming; and forming a projection portion between the lower edge
portion and the intermediate portion simultaneously with the
forming of the lower edge portion and the intermediate portion
wherein the projection portion extends beyond the horizontal plane
to impart a jagged pattern to the intermediate portion.
25. A method as set forth in claim 24 further comprising the step
of forming the projection portion angled upwardly at an angle of
less than ninety degrees from the intermediate portion toward the
lower leg.
26. A method as set forth in claim 25 wherein the step of forming
the projection portion is further defined as varying a depth of the
projection portion between adjacent molds for increasing the
jaggedness of the panel.
27. A method as set forth in claim 25 further comprising the step
of forming a locking channel in the lower edge portion while the
entire sheet of material has the sufficient temperature for vacuum
forming.
28. A method as set forth in claim 27 further comprising the step
of forming a mounting flange having a locking groove in the upper
edge portion simultaneously with the formation of the locking
channel.
29. A method as set forth in claim 28 wherein the step of forming
the mounting flange is further defined as forming an interlock
having two corners with one of the corners having a substantially
right angle.
30. A method as set forth in claim 28 further comprising the step
of cooling the entire sheet of material below the temperature
sufficient for vacuum forming after the sheet of material has been
vacuum-formed.
31. A method as set forth in claim 30 further comprising the step
of heating a line spaced inward from a terminal edge of the upper
edge portion dividing the upper edge portion into a first part
spaced inward from the line and a second part spaced outward from
the line such that the first part and the second part remain at a
temperature below a temperature of the line.
32. A method as set forth in claim 31 further comprising the step
of bending the second part relative to the first part to define an
interlock of said upper edge portion.
33. A method as set forth in claim 32 further comprising the step
of trimming excess material from the upper and the lower edge
portions prior to heating the line.
34. A method as set forth in claim 33 further comprising the step
of cutting the sheet of material at longitudinally spaced intervals
to produce the succession of separate elongated siding panels.
35. A method as set forth in claim 34 further comprising the step
of detecting a micro-switch cam in one of the upper and lower edge
portions and cutting the sheet of material in response to detecting
the micro-switch cam.
36. A method as set forth in claim 24 further comprising the step
of urging the sheet of material into the projection portion with a
plug-assist.
37. A method as set forth in claim 36 wherein the step of urging
the sheet of material is further defined as rotating a plurality of
mold inserts into engagement with adjacent mold plates as the
conveyor is operated.
38-66. (canceled)
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 11/942,502, filed Nov. 19, 2007, which is a divisional of
U.S. patent application Ser. No. 10/999,559, filed Nov. 30, 2004,
now U.S. Pat. No. 7,296,989, issued on Nov. 20, 2007, which is a
continuation-in-part of U.S. patent application Ser. No.
10/689,137, filed on Oct. 20, 2003, now U.S. Pat. No. 7,008,213,
issued on Mar. 7, 2006, which is a divisional of U.S. Pat. No.
6,635,218, issued on Oct. 21, 2002, which is a continuation-in-part
of abandoned U.S. patent application Ser. No. 09/315,317, filed May
20, 1999, which claims the benefit of U.S. Provisional Patent
Application Ser. No. 60/086,378 filed on May 22, 1998.
BACKGROUND OF THE INVENTION
[0002] In the production of vinyl siding panels having the
appearance of rough-sawn cedar shake shingles, for example, as
disclosed in U.S. Pat. Nos. 3,593,479 and 5,455,099, it is known to
injection mold the panel or vacuum-form a precut sheet and then
trim and punch and form the edge portions of the sheet, to form a
hook-shaped lower portion along the panel and an upper portion
which defines a groove and forms a nailing flange. It is also known
to extrude or form a flat sheet of plastics material and then
direct the sheet onto the upper run of an endless flexible belt
conveyor for vacuum-forming the sheet, for example, as disclosed in
U.S. Pat. Nos. 3,982,868 and 5,314,325. The endless flexible belt
is constructed of a porous material and defines cavities into which
the hot plastic sheet is sucked by a vacuum source under the upper
run of the endless belt. The door sheet is then cooled and cut at
longitudinally spaced intervals to produce vacuum-formed garage
door panels or other articles. It has been found that the endless
flexible conveyor belts for producing vacuum-formed articles are
expensive to construct, have a relatively short service life and do
not conduct heat rapidly away from the vacuum-form sheet.
SUMMARY OF THE INVENTION
[0003] The subject invention provides a method and an apparatus for
continuously producing elongated siding panels. The apparatus
comprises a conveyor, a plurality of mold plates, and a die for
extruding a sheet of material onto the mold plates. The mold plates
are formed of a rigid material and positioned adjacent one another
and supported by the conveyor for forming the elongated siding
panels. Each of the mold plates has an upper edge portion and a
lower edge portion with an intermediate portion therebetween. A
plurality of vacuum passages are disposed within each of the
intermediate portion, the upper edge portion, and the lower edge
portion for vacuum-forming the sheet onto the mold plates. The
intermediate portion has an aesthetic pattern for imparting the
pattern to the sheet of material with the adjacent mold plates
having different aesthetic patterns. The lower edge portion has a
lower leg extending substantially perpendicular from the
intermediate portion defining a horizontal plane and a projection
portion between the lower edge portion and the intermediate portion
extends beyond the horizontal plane for imparting a jagged pattern
to the intermediate portion.
[0004] One advantage of the subject invention is that the siding
panel has a realistic appearance that is enhanced by the projection
portion extending at different amounts beyond the horizontal plane.
The projection portion gives the siding panel a jagged appearance
which is more similar to actual shake siding. Another advantage of
the projection portion is that when the siding panels are fastened
to a structure, moisture is not able to get behind the siding
panels because the moisture is not able to follow the projection
portion. Whereas the moisture does travel along the generally flat
bottom of the prior art siding panels and damages the structure.
Therefore, it is advantageous that the subject invention does not
allow the moisture to travel along the projection portion and
behind the siding panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a fragmentary perspective view of two overlapping
siding panels produced in accordance with one embodiment of the
invention;
[0006] FIG. 2 is a fragmentary section taken generally on the line
2-2 of FIG. 1;
[0007] FIG. 3 is a vertical section through the upper run of an
endless vacuum-forming conveyor constructed in accordance with the
invention;
[0008] FIG. 4 is a perspective view of a plastic sheet being
vacuum-formed in accordance with one embodiment of the invention
and illustrating the progressive steps for successively producing
the panels;
[0009] FIG. 5 is a fragmentary perspective view of portions of two
siding panels constructed in accordance with another embodiment of
the invention;
[0010] FIG. 6 is a perspective view of portions of the siding
panels shown in FIG. 5 and illustrating the connection of adjacent
overlapping panels;
[0011] FIGS. 7 and 8 are fragmentary sections showing the assembly
of the siding panels shown in FIGS. 5 and 6;
[0012] FIG. 9 is a fragmentary perspective view of vacuum-forming
apparatus constructed in accordance with the invention for
continuously forming the siding panels shown in FIGS. 5-8;
[0013] FIGS. 10-14 are fragmentary perspective views of different
interchangeable siding panels produced with apparatus constructed
as shown in FIG. 9;
[0014] FIG. 15 is a schematic view of one embodiment of an assembly
having for forming elongated siding panel;
[0015] FIG. 16 is a perspective view of a forming station including
an extruder extruding a sheet of material directed onto mold plates
carried by a conveyor for vacuum-forming;
[0016] FIG. 17A is a cross-sectional view of one embodiment of the
mold plates having the sheet of material disposed thereon;
[0017] FIG. 17B is a cross-sectional view of siding panels shown in
FIG. 17A and illustrating the connection of adjacent overlapping
panels;
[0018] FIG. 17C is a front view of the siding panels shown in FIG.
17A;
[0019] FIG. 17D is a rear view of the siding panels shown in FIG.
17A;
[0020] FIG. 18A is a cross-sectional view of another embodiment of
the mold plates having the sheet of material disposed thereon;
[0021] FIG. 18B is a cross-sectional view of siding panels shown in
FIG. 18A and illustrating the connection of adjacent overlapping
panels;
[0022] FIG. 19 is a close-up view of a lower edge portion of the
mold plates having a pivotable cap for removing the sheet of
material from the mold plates;
[0023] FIG. 20 is a perspective view of a bending station having a
heater for heating a line along the siding panel;
[0024] FIG. 21 is another perspective view of the heater
illustrated in FIG. 20;
[0025] FIG. 22 is a perspective view of a finishing station having
a cutting mechanism for sectioning the elongated siding panel;
[0026] FIG. 23 is a perspective view of another embodiment of the
forming station having a plug assist urging the sheet of material
into the mold plates;
[0027] FIG. 24 is a close-up perspective view of the plug assist
illustrated in FIG. 23; and
[0028] FIG. 25 is a perspective view of yet another embodiment of
the forming station having another embodiment of the plug
assist.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 1 illustrates portions of two elongated siding panels
10 connected together as shown in FIG. 2, and each siding panel has
a length of about five feet. Each siding panel is formed from a
sheet of rigid plastics material such as polyvinylchloride or
"vinyl" and includes a series of ten generally rectangular shingle
panels 12 each having a different and distinct wood grain
appearance. The shingle panels 12 are integrally connected by flat
recessed strip portions 14 defining grooves, and each panel 10 has
a longitudinally extending hook-shaped lower portion 16 (FIG. 2).
Each panel 10 also has a longitudinally extending upper flange
portion 18 which extends from a step or shoulder portion 19 and is
integrally connected to a folded-over flange portion 22.
[0030] The folded-over flange portion 22 cooperates with the flange
portion 18 to form a double wall nailing flange 24 and a slot or
groove 26 for receiving and retaining the hook-shaped lower edge
portion 16 of the above overlapping panel 10. The folded-over
flange portion 22 has a bottom lip 28 which is spaced above the
shoulder portion 19 to facilitate inserting the hook-shaped lower
edge portion 16 into the groove 26. As also shown in FIGS. 1 and 2,
the upper nailing flange 24 of each panel 10 has a series of
longitudinally spaced slots 31 for receiving longitudinally spaced
nails which attach the panel 10 to a vertical wall surface 34.
[0031] Referring to FIGS. 3 and 4, the siding panels 10 are
continuously produced from a flat sheet S of plastics material or
polyvinylchloride which has a substantially uniform thickness and
which is produced by a flat sheet die on a plastics extruder (not
shown), as well known in the art. The hot vinyl sheet S from the
extruder is directed onto the top or upper run of an endless
vacuum-forming machine or conveyor 50 (FIG. 3). The conveyor
includes a pair of endless flexible length chains 52 which carry a
continuous series of separate aluminum carrier plates or slats 54,
with one carrier slat corresponding to one of the shingle panels
12. The opposite end portions of each carrier slat 54 are guided
along the upper run of the endless conveyor by a pair of opposing
guide tracks or rails 56 each constructed of a set of strips of
solid low friction plastics materials.
[0032] Each of the rectangular carrier slats 54 has a center hole
58, and the slats are supported for horizontal sliding movement
along a set of stationary elongated support plates 62 each
constructed of a low friction solid plastics material. As the
continuous series of carrier slats 54 move along the top surface of
the support plates 62, the holes 58 align with longitudinally
extending slots 66 within the support plates 62. The slots 66
connect with corresponding slots 67 within the top wall of a
longitudinally extending suction or vacuum manifold 70 connected by
longitudinally spaced tube 72 to a vacuum source or pump.
[0033] Each of the carrier slats 54 has a width equal to the width
of the corresponding shingle panel 12 plus one of the separator
strip portions 14. A shingle mold plate 75 has the same width as
its corresponding carrier slat 54 and is secured to its carrier
slat 54 by a set of screws (not shown) extending through the slat
54 and threaded into the mold plate 75. Each mold plate 75 includes
a rectangular intermediate section 78 defining a recessed cavity 81
having a wood grain surface texture corresponding to the desired
wood grain appearance on the corresponding shingle 12. The
intermediate section 78 of each mold plate 75 has a bottom vacuum
cavity 83 which connects the center vacuum hole or passage 58 to
narrow vacuum slots 84 and 86 at opposite ends of the mold section
78 and to a top mold section 88 and a bottom mold section 92. The
top mold section 88 has a stepped top surface 94 and three rows of
small holes or passages 96 which extend from steps in the top
surface to a vacuum cavity or passage 99 formed in the bottom of
the mold section 88 and connected to the vacuum passage 83.
[0034] The bottom section 92 of each mold plate 75 has a set of
longitudinally spaced holes 102 which connect a vacuum passage 104
extending from the vacuum passage 83 to a vacuum passage 106 under
a cap plate 108. Thus, the suction or partial vacuum within the
manifold 70 creates a vacuum within the passages 83, 84, 86, 99,
104 and 106 and the holes 96 and 102 within each mold plate 75 as
the mold plate and its supporting carrier slat 54 move along the
stationary support plates 62.
[0035] Referring to FIG. 4, as the hot extruded sheet S
progressively contacts the succession of mold plates 75 which move
along the upper run of the endless conveyor 50 at a speed
corresponding to the extrusion rate for the sheet S, the
longitudinal center portion of the sheet is progressively sucked
into the cavities 81 to form the shingle panels 12, and the lower
and upper portions of the sheet S are progressively sucked into the
undercut cavities defined by the bottom mold sections 92 and cap
members 108 and onto the stepped surfaces 94 of the top sections 88
of the mold plates 75 to provide the sheet with a cross-sectional
configuration as shown in FIG. 3.
[0036] After the sheet S is vacuum-formed within the mold plates 75
and is cooled as the sheet moves along the top run of the conveyor
with the aid of air blowers and/or water streams directed against
the moving carrier slats 54, the opposite edge portions 116 and 118
of the sheet are trimmed from the vacuum-formed sheet by cutting or
slitting the sheet at the corners 121 and 122 (FIG. 3). The
separated portions or trim of the edge portions 116 and 118 are
directed into a suitable scrap chopper (not shown) for reducing the
trim into fine particles which are conveyed back to the material
supply hopper for the extruder.
[0037] After the trimming operation, the vacuum-formed sheet is
reheated along a line or the step 124, and the outer stepped flange
portion 118 of the sheet is progressively folded back onto the
flange portion 18 to form the cross-sectional configuration for the
upper edge portion of the panel, as shown in FIG. 2. The double
wall nailing flange 24 is then progressively punched with the
longitudinally spaced slots 31. As the vacuum-formed strip or sheet
continues to move horizontally after the slots 31 are punched, the
sheet is cut laterally at longitudinally spaced intervals, for
example, intervals of 5 feet, for successively producing the siding
panels 10 which are ready for installation.
[0038] Referring to FIGS. 5-8, siding panels 130 are continuously
produced by vacuum-forming endless conveyor apparatus in accordance
with the invention, and each siding panel 130 includes a series of
integrally connected shingle panels 132 separated by grooves formed
by strip portions 134. Each shingle panel 132 has a wood grain
pattern and a hook-shaped bottom portion 136 connecting tapering
hook-shaped inclined portions 138 to provide each shingle panel 132
with generally a partial octagonal configuration. Each siding panel
130 also includes an upper portion having a series of
longitudinally spaced and outwardly projecting tabs or projections
142 which are vertically aligned with the strip portions 134 and
define corresponding undercut grooves 143 (FIG. 7) for receiving
the hook-shaped bottom portions 136 of the shingle panels 132 of an
overlapping siding panel 130. As shown in FIG. 6, the hook-shaped
bottom portion 136 of each shingle panel 132 has a straight upper
edge 144 and each projecting tab 142 has a straight horizontal edge
147 at the upper end of the corresponding groove 143. This provides
for a positive and accurate connection of vertically adjacent
overlapping siding panels 130, as shown in FIG. 8. The upper
portion of each siding panel 130 also has a longitudinally
extending continuous nailing flange 152 having longitudinally
spaced slots 153 for receiving fasteners, such as the nails 156
(FIG. 8), for attaching each siding panel 132 to a vertical wall
158. At opposite ends of each panel 130, the projections 142 are
half size, and a flange 159 projects from one end of each panel
130.
[0039] Referring to FIG. 9, a series of the siding panels 130 are
continuously produced by a vacuum-forming endless conveyor machine
or apparatus 160 which is generally constructed as described above
in connection with FIG. 3 for continuously producing the siding
panels 10. The machine 160 includes a pair of endless conveyor
chains 162 which are constructed the same as the conveyor chains 52
and are directed about a corresponding set of sprockets 164 mounted
on parallel spaced shafts (not shown) located at opposite ends of
the machine 160. A series of rectangular aluminum slats 166 are
constructed the same as the slats 54 and are attached to the
conveyor chains 162, and the opposite end portions of the slats 166
are guided by an opposing set of parallel spaced guide tracks or
rails 168 which are constructed the same as the guide rails 56
shown in FIG. 3. As also described above in connection with FIG. 3,
the conveyor slats 166 are supported along the upper run of the
conveyor by the support plate 62 having longitudinally spaced slots
66 which connect with the vacuum manifold 70. Each of the slats 166
has a center hole 58 which aligns with the slots 66 as the slats
166 slide horizontally on top of the support plate 62 for creating
a continuous vacuum above each conveyor slat 166.
[0040] A series of aluminum mold plates 175 are attached to
corresponding conveyor slats 166 in the same manner as the mold
plates 75 are attached to the conveyor slats 54 described above in
connection with FIG. 3. Each mold plate 175 has a shingle forming
cavity 178 with the impression of a wood grain shingle and a border
rib 181 which mates with the border rib 181 of the adjacent mold
plate 175 to form the groove defining strip portions 134 between
the shingle panels 132. Each of the mold plates 175 also has an
undercut cavity 183 configured to form the bottom hook portions 136
and 138 of each shingle panel 132. As also shown in FIG. 9, each
adjacent pair of abutting mold plates 175 cooperate to define
another undercut cavity 186 which is configured to form the
projecting tab 142 and undercut groove 143 in vertical alignment
with each strip portion 134, as shown in FIG. 5. Each mold plate
175 has small vacuum passages (not shown) which connect the
cavities 178, 183 and 186 to a vacuum cavity 188 formed within the
bottom of each mold plate in the same manner and for the same
purpose as the vacuum cavity or chamber 83 described above in
connection with FIG. 3.
[0041] As shown in FIG. 9, a generally flat sheet S1 of
thermoplastic material or PVC is continuously extruded from an
extruder head 200 onto the mold plates 175 which form the upper
linear run of the endless conveyor vacuum-forming machine 160, and
the vacuum created within the cavities 178, 183 and 186 immediately
sucks the hot sheet S1 into the cavities. As the hot sheet S1 is
sucked into the vacuum mold plates 175, a set of vacuum-forming
assist members or plugs 202 and 204 are quickly extended or
inserted into the corresponding cavities 183 and 186 and then
quickly retracted to assure that the plastic sheet S1 completely
fills the cavities to form the portions 136 and 142 of each single
panel 132. Each of the vacuum assist plugs 202 and 204 is supported
for reciprocating movement on an incline by a corresponding piston
rod 206 extending from a fluid or air cylinder 208 and by a
corresponding guide rod 210 which reciprocates in a guide block 211
mounted on the outer end of the corresponding cylinder 208.
[0042] Each of the air cylinders 208 is supported by a
corresponding plate or bracket 214 projecting upwardly from a
carriage member or platform 216. The carriage platform 216 is
supported for horizontal reciprocating movement by a pair of slides
or guide rods 218 extending between a pair of support plates 219
mounted on a stationary support plate 222. A fluid or air cylinder
224 is also mounted on the plate 222 and has a piston rod 226
connected to an arm 228 projecting laterally from the carriage
platform 216. An L-shaped locking or actuator arm or lever 232 is
pivotally supported by the carriage platform 216 and is pivoted by
a fluid or air cylinder 234. The locking or actuating lever 232
releasably and successively engages a series of actuating pins 236
projecting laterally or horizontally from the mold plates 175.
[0043] In operation of the endless conveyor vacuum-forming machine
160 for continuously producing the siding panels 130, the
continuously extruded sheet S1 of PVC is directed under a guide
roller 242 and onto the continuously moving mold plates 175 forming
the upper run of the endless conveyor or machine 160. The speed of
the conveyor machine is controlled to match the speed of the sheet
S1, and the intermediate portion of the sheet is progressively
sucked into the shingle cavities 178 and into the undercut cavities
183 and 186 of the mold plates. The vacuum assist plugs 202 and 204
are quickly and simultaneously extended by actuation of the
cylinders 208 and press the portions of the hot sheet within the
undercut cavities 183 and 186 further into the cavities. Thus, the
plugs assist the vacuum within the cavities for forming the
undercut U-shaped portions 136 and 138 of the siding panels within
the lower portion of the sheet and also form the projecting tabs
142 and the undercut grooves 143 within the upper portion of the
sheet.
[0044] The plugs 202 and 204 travel with the vacuum-formed sheet 51
by movement of the carriage platform 216 in response to actuation
of the air cylinder 234 to tilt the lever 232 for engaging a moving
pin 236 on the conveyor. As soon as the vacuum assist plugs 202 and
204 are retracted, the tilting lever 218 disengages with the pin
236, and the carriage platform 216 returns to the right in FIG. 9
to its home position by the biasing force exerted by the air
cylinder 224 to extend its piston rod 226. The timing of the
actuation of the cylinders 208 and the cylinder 234 is controlled
by electrically actuated valves (not shown) in time relation with
the linear movement of the mold plates 175 on the endless conveyor
chains 162.
[0045] As also shown in FIG. 9, as the intermediate portion of the
sheet 51 is progressively vacuum formed into the mold plate
cavities, the lower edge portion of the sheet is held against the
top surfaces of the mold plates by a series of hold-down rollers
246 supported by a horizontally adjustable bar 248. After the
continuously moving vacuum-formed sheet 51 is somewhat cooled on
the conveyor mold plates 175 by conducting heat from the mold
plates and is stripped from the mold plates, as shown in FIG. 9,
the upper edge portion of the continuously moving vacuum-formed
sheet is progressively punched by conventional punch and die
machine 252 to form the longitudinally spaced slots 153, after
which the upper portion of the sheet is trimmed by a rotating
vertical saw blade 256. Simultaneously, the lower portion of the
strip is trimmed by a horizontal circular saw blade 258 which is
positioned to form the hook-shaped lower edge portions 136 and 138,
thereby completing the continuous forming of the siding panels 130.
Downstream of the saws 256 and 258, the continuous strip of
integrally connected siding panels 130 is cut transversely at
longitudinally spaced predetermined intervals, such as five feet,
by a traveling reciprocating circular saw for successively
producing the separate siding panels 130.
[0046] Referring to FIGS. 10-14, by interchanging the mold plates
175 on the conveyor slats 188, siding panels having shingle panels
with different bottom contours or configurations and different wood
grain patterns may be continuously produced on the vacuum-forming
machine 160 in place of the siding panels 130. For example, a
siding panel 270 (FIG. 10) having shingle panels with a partial
hexagon bottom configuration, a siding panel 272 (FIG. 11) having
shingle panels with mitered bottom corners, a siding panel 274
(FIG. 12) having shingle panels with a rounded bottom
configuration, a siding panel 276 having shingle panels with a half
cove bottom configuration or a siding panel 278 (FIG. 14) having
shingle panels with a square bottom configuration may each be
continuously produced on the apparatus or machine 160 simply by
selecting the corresponding interchangeable mold plates 175. In
each of the siding panels, the lower hook-shaped bottom portion of
each shingle panel has a straight edge 144, and each projecting tab
has a straight edge 147 defining an undercut groove, in the same
location and with the same spacing therebetween as the straight
edges 144 and 147 described above in connection with the siding
panels 130. As a result, all of the siding panels 130, 270, 272,
274, 276 and 278 are interchangeable which permits various
combinations of the siding panels to be attached to a vertical wall
surface.
[0047] From the drawings and the above description, it is apparent
that the continuous production of vacuum-formed siding panels in
accordance with the invention, provides desirable features and
advantages. For example, the continuous forming of the extruded
flat sheet S or S1 with the continuous succession of mold plates 75
or 175 on the endless conveyor 50 or 160, provides for efficiently
and economically producing the siding panels with different shingle
panels each having sharp detail and one or more undercut portions.
The close fitting aluminum mold plates along the upper run of the
conveyor also efficiently and precisely form the lower and upper
portions of each siding panel. The separate aluminum mold plates
further provide the conveyor or machine with a long service life
for producing a large volume of siding panels, and the mold plates
may be rapidly cooled by cooling water or air during the continuous
production of the siding panels. The vacuum-forming assist plugs
202 and 210 which travel with the sheet S1, also help in producing
precision shingle panels with precision undercut portions.
[0048] Referring to FIG. 15, another embodiment of an apparatus for
continuously producing elongated siding panels 310 is illustrated
generally at 300. The apparatus 300 includes a forming station 302,
a trimming station 304, a bending station 306, and a finishing
station 308. The forming station 302 is shown generally in FIG. 16
and includes a conveyor 360, a plurality of mold plates 376, and an
extruder die 400 for extruding a sheet of material S3 onto the mold
plates 376. A guide roller 342 directs the sheet of material S3
onto the plates 376 and material rollers 346 ensure that the
material S3 is in contact with the mold plates 376. The conveyor
360 is preferably an endless conveyor belt; however, other types of
conveyors may accommodate the subject invention.
[0049] After the sheet of material S3 has been vacuum formed and
while still traveling on the conveyor 360, a plurality of coolers
320 cool the entire sheet of material S3 below the temperature for
vacuum forming. A lower edge portion 392 and an upper edge portion
388 are both formed while the sheet of material S3 is above the
temperature for vacuum forming. Preferably, the entire lower edge
portion 392 is formed prior to being removed from the conveyor 360
and while the sheet of material S3 is above the temperature for
vacuum forming. At the end of the conveyor 360, the sheet of
material S3 is removed from the mold plates 376 and is below the
temperature for vacuum forming.
[0050] After the sheet of material S3 has been removed, the
trimming station 304 trims excess material S3 from both the lower
edge portion 392 and the upper edge portion 388, if necessary. The
lower edge portion 392 may be formed without excess material S3 so
the lower edge portion 392 may not require trimming. The trimming
station 304 may include circular-type saws, knives, slicers, or the
like. The trimming station 304 includes a horizontal blade 358 for
trimming the lower edge portion 392 and a vertical blade 356 for
trimming the upper edge portion 388. Depending upon the orientation
of the sheet of material S3, those skilled in the art appreciate
that the blades may be positioned differently while still
practicing the subject invention.
[0051] The mold plates 376 are formed of a rigid material and are
positioned adjacent one another. In one embodiment, the mold plates
376 are cast of aluminum. The mold plates 376 are supported by the
conveyor 360 and form the elongated siding panels 310 from the
extruded sheet of material S3.
[0052] Referring to the formation of the upper and the lower edge
portions 388, 392, FIGS. 17A and 18A show cross-sectional views of
the mold plates 376 having the sheet of material S3 disposed
thereon. Each of the mold plates 376 has the upper edge portion 388
and the lower edge portion 392 with an intermediate portion 378
therebetween. A plurality of vacuum passages 382 are disposed
within each of the intermediate portion 378, the upper edge portion
388, and the lower edge portion 392 for vacuum-forming the sheet of
material S3 onto the mold plates 376.
[0053] The intermediate portion 378 has an aesthetic pattern 381
for imparting the pattern to the sheet of material S3. The mold
plates 376 are arranged on the conveyor 360 so that the mold plates
376 adjacent one another have different aesthetic patterns 381.
This allows the siding panels 310 to achieve a realistic appearance
while in use. For example, the conveyor 360 may carry eighty mold
plates 376, but when the elongated siding panel 310 is sectioned
into desired lengths, only eight mold plates 376 form the sectioned
panel, such as for a five-foot panel. Therefore, the eight mold
plates 376 adjacent one another have different aesthetic patterns
381 to improve the realistic appearance of the sectioned panel.
[0054] The lower edge portion 392 has a lower leg 336 extending
substantially perpendicular from the intermediate portion 378
defining a horizontal plane. The lower leg 336 is collinear along
each of the adjacent mold plates 376 to allow for alignment between
adjacent siding panels 310. A projection portion 340 between the
lower edge portion 392 and the intermediate portion 378 extends
beyond the horizontal plane and imparts a jagged pattern to the
intermediate portion 378. The jagged pattern also enhances the
realistic appearance of the siding panel 310. Another advantage of
the projection portion 340 is that when the siding panels 310 are
fastened to a structure 350, moisture is not able to get behind the
siding panels 310. Said another way, moisture is not able to follow
the projection portion 340 because of the angle, whereas the
moisture does travel along the generally flat bottom of the prior
art siding panels 310. Any moisture that is trapped behind the
siding panels 310 may damage the structure 350, therefore, it is
advantageous that the subject invention does not allow the moisture
to travel behind the siding panels 310.
[0055] Referring to FIG. 17B, the projection portion 340 is
illustrated as angling upwardly at an angle of less than ninety
degrees from the intermediate portion 378 toward the lower leg 336.
The projection portion 340 is also illustrated as having a rounded
nose 354; however, the projection portion 340 may terminate in a
point to further decrease the likelihood of the moisture traveling
behind the siding panels 310.
[0056] With reference to FIGS. 17C and 17D, the realistic
appearance of the siding panels 310 can be further enhanced by
extending the projection portion 340 a different amount beyond the
horizontal plane within one of the mold plates 376. If each of the
mold plates 376 has the projection portion 340 extending at
different amounts within each mold plate 376, the siding panel 310
will have increased jaggedness. One example of the siding panel 310
having the projection portion 340 extending at different amounts in
a single mold plate 376 is shown in FIG. 17C. Referring to the
right-most panel, the projection portion 340 extends further on the
right-hand side than it does on the left-hand side. The center-most
panel has the projection portion 340 extending generally the same
amount with smaller variations within the single mold plate 376.
FIG. 17D is a rear view of the siding panel 310 illustrating the
projection portion 340 extending beyond the lower leg 336.
[0057] The realistic appearance is further enhanced by the
projection portion 340 of the adjacent mold plates 376 extending a
different amount beyond the horizontal plane relative to the next
adjacent mold plate 376. The difference between adjacent mold
plates 376 further increases the jaggedness of the siding panel
310, thereby increasing the realistic appearance of the panel. It
has been determined that if the projection portion 340 extends too
far down and out from the intermediate portion 378 and the lower
leg 336, the material S3 becomes too thin at the projection portion
340. Therefore, the projection portion 340 should extend at most
0.5 inches laterally beyond the horizontal plane and at most 0.5
inches vertically beyond the intermediate portion 378. Referring
again to FIG. 17D, the lower edge portion 392 may also have the
aesthetic pattern 381 thereon for imparting the pattern to the
sheet of material S3.
[0058] Referring back to FIGS. 17A and 17B, one embodiment of the
upper edge portion 388 is illustrated. The upper edge portion 388
defines a mounting flange 362 which may include having a locking
groove 364 for mating with the lower edge portion 392 of a
vertically overlapping panel. The mounting flange 362 also includes
slots 314 for receiving fasteners to secure to the structure 350.
Referring to FIGS. 18A and 18B, another embodiment of the upper
edge portion 388 is illustrated. The upper edge portion 388
includes an L-shaped projection 366 extending from the upper edge
portion 388 for forming an interlock 368. The interlock 368 has two
corners 370 with one of the corners 370 having a substantially
right angle 372 for mating with the lower edge portion 392 of a
vertically overlapping panel. The interlock 368 creates a more
secure connection between adjacent siding panels 310 because the
corner 370 having the right angle 372 is more difficult to unlock
from the lower edge portion 392. Further, the interlock 368 allows
the siding panel 310 to withstand higher winds without becoming
unfastened from adjacent panels or the structure 350.
[0059] Referring to FIG. 19, the apparatus 300 includes a cap 309
extending from the lower leg 336 forming a cap leg 311 and the
lower edge portion 392 having a generally C-shape. The cap leg 311
extends upwardly from the horizontal plane for engaging adjacent
panels 310. The generally C-shaped lower edge portion 392 mates
with the upper edge portion 388 of adjacent siding panels 310 when
secured to the structure 350. The cap 309 includes a locking
channel 374 for forming into the sheet of material S3 to secure to
the upper edge portion 388 of a vertically overlapping panel. More
specifically, the locking groove 364 co-acts with the locking
channel 374 to secure adjacent panels to the structure 350. It is
to be appreciated that the siding panels may be formed with or
without the locking groove 364, while still securing fastened to
adjacent panels. Further, the locking channel 374 may be removed
and a locking leg 363 may be used to engage the locking groove 364.
The locking leg 363 biases the cap leg 311 outwardly.
[0060] The cap 309 also includes a connector 380 pivotally
connecting the cap 309 to the lower leg 336. The cap 309 is
moveable between an open position and a closed position for
allowing removal of the elongated siding panel 310. Application of
the vacuum through the vacuum passages 382 seals the cap 309
against the lower leg 336. When the sheet of material S3 reaches
the end of the conveyor 360, the sheet of material S3 is removed
from the mold plates 376 and forces the cap 309 to the open
position. A biasing device 384 biases the cap 309 from the open
position to the closed position so that after the material S3 is
removed, the biasing device 384 forces the cap 309 back to the
closed position. The biasing device 384 is illustrated as a spring
interconnecting the cap 309 to the lower leg 336, however, the
biasing device 384 may include other devices, such as, but not
limited to, actuated cylinders to move the cap 309.
[0061] With reference to FIG. 20, the bending station 306 is
illustrated. The bending station 306 includes a heater 390
positioned downstream from the extruder 400 for heating the sheet
of material S3 after the sheet of material S3 has been removed from
the mold plates 376 and after the entire sheet of material S3 has
been cooled. The heater 390 further includes a manifold 393
defining a plurality of apertures 394 disposed in a straight line
as illustrated in FIG. 21. The heater 390 heats a line 324 spaced
inward from a terminal edge of either one of the upper and the
lower edge portions 388, 392. The line 324 divides the edge portion
into a first part 414 spaced inward from the line 324 and a second
part 416 spaced outward from the line 324. In one preferred
embodiment, only a single heater 390 is required since the lower
edge portion 392 is formed while the entire sheet of material S3 is
above the temperature for vacuum forming and does not require
additional bending. However, both edge portions may be heated and
bent to form final profiles of the edge portions.
[0062] Once the line 324 is heated along the edge portion, the
bending station 306 bends the second part 416 relative to the first
part 414 for finishing the edge portion. For example, referring
back to FIGS. 17A and 17B, the details of the upper edge portion
388, such as the locking groove or the interlock, are formed
substantially simultaneously with the remainder of the siding panel
310. However, the upper edge portion 388 needs to be finished after
it has been removed from the mold plates 376. Therefore, after the
heater 390 heats the line 324, the bending station 306 bends the
second part 416 relative to the first part 414 to form the profile
shown in FIG. 17B.
[0063] Referring to FIG. 22, a micro-switch cam 420 is disposed in
one of the upper edge portion 388 and the lower edge portion 392 at
longitudinally spaced intervals for activating a cutting mechanism
422 to cut the sheet of material S3 into a succession of separate
elongated siding panels 310. As the micro-switch cam 420 approaches
the cutting mechanism 422, a micro-switch 423 detects the
micro-switch cam 420 and activates the cutting mechanism 422. The
cutting mechanism 422 secures the sheet of material S3 by slowing
or stopping the material S3 and then the material S3 is cut. The
micro-switch cam 420 is formed into the sheet of material S3 by the
mold plates 376 while the sheet of material S3 is above the
temperature for vacuum forming.
[0064] Referring to the example described above having eight mold
plates 376 forming one siding panel 310, the micro-switch cam 420
may be located every eighth mold plates 376. Those skilled in the
art recognize that if the siding panel 310 is to be cut into ten
foot sections, then sixteen mold plates 376 may form one siding
panel 310 and the micro-switch cam 420 would be located every
sixteenth mold plate 376. The mold plate 376 that divides the
lengths of the siding panels 310 may be further defined as a
divider plate 421 that is substantially flat and that only includes
the micro-switch cam 420 and does not have an aesthetic pattern 381
disposed thereon. The cutting mechanism 422 does not cut the siding
panel 310 in the aesthetic pattern 381 but only where the siding
panel 310 does not have the aesthetic pattern 381. The
substantially flat section would be hidden by adjacent siding
panels 310 during use. In FIG. 15, the finishing station also
includes a punch 312 for punching slots 314 into the mounting
flange 362.
[0065] Another embodiment of the apparatus 300 is shown in FIG. 23
and includes a plug assist 402 adjacent the conveyor 360. The plug
assist 402 urges the sheet of material S3 into at least one of the
intermediate portion 378, the upper edge portion 388, and the lower
edge portion 392 as the sheet of material S3 is vacuum formed. The
plug assist 402 preferably includes a plurality of mold inserts 404
rotatably engaging adjacent mold plates 376 as the conveyor 360 is
operated. Other prior art plug assists limit the rate of speed that
the conveyor 360 is able to operate because the plug assist 402 has
to be reset each time. The plug assist 402 according to the subject
invention moves at the same speed of the conveyor 360 and therefore
the conveyor 360 can be operated at maximum speeds. In the
embodiment shown in FIG. 23, the plug assist 402 is a wheel having
mold inserts 404 about the circumference of the wheel.
[0066] Referring to FIG. 24, the plug assist 402 is illustrated in
more detail. The plug assist 402 includes a shaft 406 fixed
relative to the conveyor 360 that supports the plurality of mold
inserts 404 substantially horizontally for rotation about the shaft
406. In one embodiment, a common drive 408 connects to the conveyor
360 and the shaft 406 for driving the conveyor 360 and the shaft
406 simultaneously. Alternatively, the shaft 406 may be driven by a
drive separate from the conveyor 360.
[0067] Another embodiment shown in FIG. 25 includes a plurality of
separate and distinct mold inserts 410 that travel along with the
conveyor 360. The mold inserts 410 are urged into contact with the
sheet of material S3 by following a track 418. The mold inserts 410
travel with the sheet of material S3 at the speed of the conveyor
360. At a predetermined point, the mold inserts 410 separate from
the sheet of material S3 and cycle back to the beginning. The track
418 may be a chain drive 419 as illustrated in FIG. 25. The
separate mold inserts 410 would travel back toward the start of the
conveyor 360 in a clockwise or counterclockwise direction. At least
one mold insert engages the sheet of material S3 as it travels
along the conveyor 360. Preferably, there would be at least eight
mold inserts 410 spaced from one another that travel with the
conveyor 360.
[0068] The subject invention further provides a method of
continuously producing elongated siding panels 310. Each of the
panels 310 have the upper edge portion 388, the intermediate
portion 378 having the aesthetic pattern 381, and the lower edge
portion 392. The lower leg 336 extends substantially perpendicular
from the intermediate portion 378 defining the horizontal plane and
the cap leg 311 extends upwardly from the horizontal plane such the
lower edge portion 392 is substantially C-shaped. The method
includes the steps of extruding the sheet of material S3 having the
temperature sufficient for vacuum forming and directing the sheet
of material S3 onto the plurality of mold plates 376 carried by the
conveyor 360.
[0069] Next, a vacuum is progressively applied to the mold plates
376 as the mold plates 376 travel along the conveyor 360 and the
sheet of material S3 is drawn into the mold plates 376 when the
vacuum is applied. The upper edge portion 388, the intermediate
portion 378, and the lower edge portion 392 are formed while the
entire sheet of material S3 has the sufficient temperature for
vacuum forming. The projection portion 340 between the lower edge
portion 392 and the intermediate portion 378 is also formed
simultaneously with the forming of the lower edge portion 392 and
the intermediate portion 378. Likewise, the cap 309 is sealed
against the lower leg 336 and the locking channel 374 in the lower
edge portion 392 is formed while the entire sheet of material S3 is
above the temperature for vacuum forming and the locking groove
364, if present, in the upper edge portion 388 is also formed
simultaneously with the formation of the locking channel 374.
[0070] After forming, the entire sheet of material S3 is cooled
below the temperature sufficient for vacuum forming. If necessary,
the excess material S3 is trimmed from the upper and the lower edge
portions 388, 392 prior to finishing. The subject invention heats
the line 324 spaced inward from a terminal edge of the upper edge
portion 388. The line 324 divides the upper edge portion 388 into
the first part 414 spaced inward from the line 324 and the second
part 416 spaced outward from the line 324. The first part 414 and
the second part 416 remain at a temperature below the temperature
of the line 324 even though the line 324 has been re-heated. The
second part 416 is bent relative to the first part 414 to define
the interlock 368 of the upper edge portion 388.
[0071] After the upper edge portion 388 is complete, the siding
panel 310 reaches the finishing station 308. The slots 314 are
punched into the mounting flange 362 and then the micro-switch cam
420 is detected and the sheet of material S3 is cut at
longitudinally spaced intervals to produce the succession of
separate elongated siding panels 310 in response to detecting the
micro-switch cam 420.
[0072] While the methods and forms of apparatus and the siding
panels herein described constitute preferred embodiments of the
invention, it is to be understood that the invention is not limited
to the precise methods and forms of apparatus and siding panels
described, and that changes may be made therein without departing
from the scope and spirit of the invention as defined in the
appended claims. For example, it is within the scope of the
invention to produce siding panels with a single elongated mold
plate for each elongated siding panel and attach forward end
portions of the mold plates to one pair of endless conveyor chains
and the rearward end portions of the mold plates to another pair of
endless conveyor chains so that the mold plates always remain
horizontal as they travel with the endless conveyor chains.
* * * * *