METHOD OF FORMING STEEL CLADDING CONSTRUCTION FOR BUILDINGS

Abstract

A method for forming cladding panels includes providing a panel forming unit comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a panel media is moved through the panel forming unit, placing the panel media proximate the panel forming unit and feeding the panel media into the panel forming unit, embossing a texture defined by the panel media using the embossing unit, pressing guide lines and guide indents into the panel media using the punch press, stamping a relief pattern into the panel media using the stamping die such that the texture is defined within the relief pattern, cutting the panel media into panels using the shear press and forming at least one flange on an edge of each of the panels using the roll former, wherein the panels each include a flange, the texture and the relief pattern.

Description

BACKGROUND OF THE INVENTION

The present application generally relates to a method for making exterior cladding panels, more specifically, a method for making exterior cladding panels having a plurality of stamped patterns and applied finishes.

SUMMARY OF THE PRESENT INVENTION

In at least one respect, a method for forming roofing panels in a continuous assembly path includes the steps of providing a continuous panel forming unit comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a panel media is moved through the panel forming unit, placing the panel media proximate the panel forming unit and feeding an end of the panel media into the panel forming unit, embossing a predetermined texture defined by the panel media using the embossing unit, pressing guide lines and guide indents into a surface of the panel media using the punch press, stamping a predetermined relief pattern defined by the panel media using the stamping die such that the predetermined texture is at least partially defined within the relief pattern, cutting the panel media into roofing panels having a predetermined length using the shear press, and forming at least one flange on an edge of each of the roofing panels using the roll former, wherein the roofing panels each include the at least one flange, the predetermined texture and the predetermined relief pattern.

In at least another respect, a method for forming building cladding panels in a continuous assembly path includes the steps of placing a rolled media into a continuous cladding panel assembly, embossing a predetermined texture within the rolled media, pressing guide lines and guide indents into a surface of rolled media, stamping a predetermined relief pattern within the rolled media, wherein the predetermined texture is at least partially defined within the relief pattern, and wherein the predetermined relief pattern includes a plurality of sub-sections, cutting the rolled media into cladding panels having a predetermined length, forming at least one flange on an edge of each cladding panel along at least one of the guide lines, and coating each of the plurality of subsections with at least one of a plurality of finishes.

In at least another respect, a method for forming cladding panels in a continuous assembly path includes the steps of providing a continuous cladding panel assembly comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a rolled media is moved through the cladding panel assembly, and wherein the rolled media includes predetermined colored portions, each having at least one of a plurality of finishes, placing the rolled media on an uncoiling unit proximate the cladding panel assembly, wherein the uncoiling unit feeds the rolled media into the cladding panel assembly, embossing a predetermined first relief pattern onto the rolled media using the embossing unit to form a patterned media, wherein the first relief pattern has a first maximum depth, pressing guide lines and guide indents into a surface of the patterned media using the punch press, stamping a predetermined second relief pattern onto the patterned media using the stamping die, wherein the first relief pattern is at least partially defined within the second relief pattern, and wherein the second relief pattern has a second maximum depth that is greater than the first maximum depth, and wherein the predetermined second relief pattern aligns with the predetermined colored portions having the predetermined finishes, cutting the patterned media into cladding panels having a predetermined length using the shear press, and forming at least one flange on an edge of each of the cladding panels using the roll former, wherein the cladding panels each include the at least one flange, the first relief pattern and the second relief pattern.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a side elevation view of a panel forming unit utilizing one embodiment of the method;

FIG. 2 is a top plan view of the panel forming unit of FIG. 1;

FIG. 3 is a top perspective view of one embodiment of a cladding panel having a slate tile texture and relief pattern formed thereon using one embodiment of the method;

FIG. 4 is a top perspective view of another embodiment of a cladding panel having a wood shake texture and relief pattern formed thereon using an alternate embodiment of the method;

FIG. 5 is a flow chart diagram showing an embodiment of the method for forming roofing panels in a continuous assembly path;

FIG. 6 is another embodiment of the method for forming building cladding panels; and

FIG. 7 is another embodiment of the method for forming building cladding panels.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIGS. 1 and 2. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

As illustrated in FIGS. 1-4, the reference numeral 10 generally refers to a panel forming unit 10. The panel forming unit 10 includes an embossing unit 12, a punch press 14, a stamping die 16, a shear press 18 and a roll former 20, wherein a panel media 22 is configured to be moved through the panel forming unit 10. The embossing unit 12 is configured to receive the panel media 22 and press down upon the panel media 22 to include a predetermined texture 30 within the panel media 22. The predetermined texture 30 can be any one of a plurality of textures 30 that can include, but is not limited to, a wood-grain texture, a wood shake texture, a slate tile texture, a thatch texture, a concrete tile texture, or other texture 30 of similar exterior cladding materials. The predetermined texture 30 placed in the panel media 22 by the embossing unit 12 includes a substantially minimal profile that is configured to not interfere with the flow of water off from the cladding panel 32, ultimately formed out of the panel media 22, after being installed on a structure. Typically, the profile of the predetermined texture 30 applied by the embossing unit 12 will have a vertical profile of 1″ or less, although larger profiles are contemplated.

The punch press 14 of the panel forming unit 10 is configured to press guide lines 40 and guide indents 42 into a surface of the panel media 22. The guide lines 40 are configured to define locations for defining drain troughs 44, drain apertures 50, attachment flanges 46, connecting members 48 and other fastening portions of the cladding panels 32 that will be formed within the panel media 22. These fastening portions of each cladding panel 32 are configured to cooperate with adjacent cladding panels 32 to provide secure attachment points and substantially direct water down the drain troughs 44 and through drain apertures 50, as well as preventing leakage between the cladding panels 32 once installed. The punch press 14 can include a powered conveyor 52 and various rollers 54 to assist in moving the panel media 22 through the panel forming unit 10. Also, in various embodiments, the individual punch press 14 mechanisms can include various types of presses 56, such as C-frame presses, portal-type presses, among other types of presses 56.

The stamping die 16 of the panel forming unit 10 is configured to stamp or press a predetermined relief pattern 70 within the panel media 22. The stamping die 16 is configured to define the relief pattern 70 within the panel media 22 such that the predetermined texture 30 formed by the embossing unit 12 remains at least partially defined within the predetermined relief pattern 70 and the formed cladding panel 32. As described above with respect to the predetermined texture 30 formed by the embossing unit 12, the predetermined relief pattern 70 defined by the stamping die 16 can be of a pattern of any one of multiple cladding materials that can include, but is not limited to, wooden shake panels, slate panels, concrete panels, terra cotta tiles, thatched roof layers, and other cladding and roofing material patterns. The stamping die 16, similar to the punch press 14, can include a feeder 72, such as a servo feeder, or other mechanism configured to deliver the panel media 22 through the panel forming unit 10. It is contemplated that the stamping die 16 is able to stamp between about 15 to about 20 panels per minute, although more stamps per minute are also contemplated.

The shear press 18 of the panel forming unit 10 is configured to cut the panel media 22 into individual cladding panels 32 that have a predetermined length. The shear press 18 is configured to cut the panel media 22, such that each cladding panel 32 includes substantially the same texture 30, relief pattern 70, guide lines 40 and guide indents 42. In this manner, as the cladding panels 32 are installed on a structure, substantial uniformity of the cladding panels 32 ensures a substantially tight fit between the fastening portions of each of the cladding panels 32, as described above. It is contemplated that the texture 30 and relief pattern 70 of the cladding panels 32 can vary among cladding panels 32. Such variation can add to the natural aesthetic of the cladding panels 32 formed through the disclosed method. The shear press 18 can be similar to a stationary shear or hydrex design or other similar shear press 18.

The roll former 20 of the panel forming unit 10 is configured to form at least one flange, such as an attachment flange 46, of each of the cladding panels 32 to provide the fastening portions of each of the cladding panels 32. As illustrated in FIGS. 3 and 4, various cladding panels 32 can include fastening portions on each of the four outer edges 140 of the cladding panel 32. In various embodiments, the panel forming unit 10 can include an exit conveyor 80 for receiving each of the roofing panels that leave the roll former 20 of the panel forming unit 10. In this manner, the cladding panels 32 can be easily collected and stacked for subsequent packaging and shipment. The roll former 20 used in various embodiments of the method can include various functions, such as start/stop, jog and auto functions, among others. The roll former 20 used can be one of various types that include, but are not limited to, rafted, duplex, single high, double high, and other similar roll formers 20.

It is contemplated that the panel forming unit 10 can include additional mechanisms to assist in the delivery of the panel media 22 through the panel forming unit 10. These mechanisms include, but are not limited to, loop controls 82, feeders 72, conveyors 52, rollers 54, support tables 58, and the like. The loop controls 82 of the panel forming unit 10 are configured to limit the bunching and flexing movement of the panel media 22 as the panel media 22 is moved through the panel forming unit 10. This bunching and flexing can occur due to the panel media 22 being steadily fed into the panel forming unit 10, while certain mechanisms, such as the shear press 18, punch press 14 and stamping die 16 require the panel media 22 to temporarily stop to perform the various pressing, punching and stamping functions. The loop control 82 substantially maintains the position of the panel media 22 so that it can be properly fed through the panel forming unit 10.

The above-described panel forming unit (or cladding panel assembly) 10, can be operated according to the various methods described herein to create various cladding panels 32 having a variety of finishes, shapes, textures 30 and configurations that include, but are not limited to, slate tile cladding panels 32, as shown in FIG. 3, wood shake cladding panels 32 as shown in FIG. 4, as well as other cladding panels 32 that represent a myriad of configurations.

Having generally described the panel forming unit 10, and referring now to FIGS. 1-5, a method 500 for forming cladding panels 32, such as roofing panels, is described herein. A first step 502 of the method 500 includes providing a continuous panel forming unit 10 comprising the embossing unit 12, the punch press 14, the stamping die 16, the shear press 18, and the roll former 20, wherein the panel media 22 is moved through the panel forming unit 10, as described above. The step of providing the panel forming unit 10 can also include providing an uncoiling unit 90, wherein the panel media 22 is in a roll form, and the uncoiling unit 90 unrolls the panel media 22 to be formed through the panel forming unit 10. According to this method, the panel media 22 can include a plurality of colored sections, wherein each of the plurality of colored sections includes at least one of a plurality of colors. In various embodiments, the plurality of colors can be oriented upon the panel media 22 in bands that run the length of the panel media 22. These bands can correspond to courses 100 defined within the predetermined relief pattern 70, as will be more fully described below. In alternate embodiments, the plurality of colored sections can correspond to individual relief sections 102 of the predetermined relief pattern 70 defined within the panel media 22, wherein the relief sections 102 make up the courses 100 that run the length of the cladding panel 32. In such an embodiment, each individual relief section 102, when formed by the stamping die 16, will be aligned to cooperate with the various colored sections disposed upon the panel media 22. In various embodiments of the method, the panel forming unit 10 can include a painting, coloring, and/or finishing mechanism that is configured to apply a predetermined finish to the panel media 22 as the panel media 22 is moved through the panel forming assembly.

Step 504 of the method 500 includes placing the panel media 22 proximate the panel forming unit 10 and feeding an end of the panel media 22 into the panel forming unit 10. In various embodiments, the uncoiling unit 90 can be configured to automatically feed the panel media 22 into the panel forming unit 10. It is contemplated that the speed at which the panel media 22 is fed into the panel forming unit 10 can vary depending upon various factors that include, but are not limited to, the complexity of the cladding panel 32 to be formed, the type of panel media 22 used, the size of the cladding panel 32, the number of courses 100 to be formed within the cladding panel 32, the number of relief sections 102 to be formed within the courses 100 of the cladding panel 32, among other factors. The uncoiling unit 90 can be one of several units that include a single mandrel unit or a multiple mandrel unit. The uncoiling unit 90 can also include various features such as brake and drive controls, a loop control 82, as well as others features for delivering the rolled panel media 22 to the panel forming unit 10.

Step 506 of the method 500 includes embossing the predetermined texture 30 to be defined within the panel media 22 using the embossing unit 12. As discussed above, the predetermined texture 30 can vary depending upon the desired material and finish that the formed cladding panel 32 is meant to show. The force necessary to include the texture 30 defined within the panel media 22 can depend upon the panel media 22 used. The panel media 22 can include a steel sheet that is disposed in a rolled sheet coil, such as a rolled steel coil, and fed into the panel forming unit 10. Other panel media can include, but are not limited to, vinyl, aluminum, plastic, and other substantially formable materials that can be used as cladding materials. One example of material that can be used as the panel media 22 is G90 pre-galvanized steel, grade 37.

According to step 508, the method 500 also includes pressing guide lines 40 and guide indents 42 into a surface of the panel media 22, using the punch press 14. As discussed above, the guide lines 40 are included to allow for easier bending and forming of the material during formation of the cladding panel 32. Various apertures, such as the drain apertures 50, can also be formed during operation of this step 508. Additionally, the guide indents 42 formed upon the panel media 22 provide attachment guides through which nails, screws, or other fasteners can be used to attach or otherwise fasten the cladding panel 32 to the structure. It is contemplated that the cladding panels 32 formed through this method can be roofing panels, wall panels, interior or exterior panels, as well as panels used in other building applications that can utilize a wide range of fasteners, thereby requiring varying configurations of guide lines 40 and guide indents 42.

According to the method 500, step 510 includes stamping the predetermined relief pattern 70 defined within the panel media 22 using the stamping die 16, such that the predetermined texture 30 is at least partially defined within the relief pattern 70. As discussed above, the predetermined relief pattern 70 can include individual relief sections 102 that can make up courses 100 of the predetermined relief pattern 70. In various embodiments, the relief sections 102 may not form into courses 100 of the cladding panel 32, but rather may form alternate patterns upon the cladding panel 32, that include, but are not limited to, irregular patterns, alternating patterns, diagonal or vertical patterns, and arcuate patterns, among others. These individual relief sections 102 can be defined within the panel media 22 by stamping the shape of the relief sections 102 within the panel media 22. Alternatively, the relief sections 102 can be formed by stamping relief channels 110 that are disposed between the relief sections 102 such that as the relief channels 110 are formed, and the relief sections 102 are extruded between the relief channels 110. It is contemplated that two sets of forms can be used cooperatively to define both the relief sections 102 and the relief channels 110 between adjacent relief sections 102 to form a three-dimensional pattern within the panel media 22.

As illustrated in FIGS. 3 and 4, typically, the relief panels are formed into courses 100 disposed within the panel media 22. The number of courses 100 included in the panel media 22 varies depending upon the size of the cladding panel 32 and the relief pattern 70 to be defined within the panel media 22. The courses 100 of relief sections 102 are typically separated by vertical risers 120, wherein the vertical risers 120 define an end surface 122 of the individual relief sections 102. The relief channels 110 disposed between the relief sections 102 extend through the vertical risers 120 and further define a separation between the relief sections 102 within each course 100 at the vertical riser for that course 100. It is further contemplated that, as discussed above, the panel media 22 will include colored sections that correspond to courses 100 of relief sections 102 defined within the panel media 22, and alternatively, can correspond to the individual relief sections 102 defined within the panel media 22. The colored sections of the panel media 22 can be configured to resemble the various cladding material that the panel is being formed into, such as rough edges resembling slate tiles (as shown in FIG. 3), a wood grain resembling wooden shakes (as shown in FIG. 4), individual fiber strands representing a thatched roof, as well as other similar materials.

According to step 510, as the stamping die 16 is used to form the relief pattern 70 within the panel media 22, the stamping die 16 is configured so as to not substantially press against the predetermined texture 30 that has been defined within the panel media 22 by the embossing unit 12, according to step 506. In this manner, the stamping die 16 can include a rigid form at certain portions that are used to define the edges 124 of the individual relief sections 102 and relief channels 110 within the panel media 22. Areas within these rigid portions of the stamping die 16 may include apertures, softer materials, cushion material or other features that prevent the predetermined texture 30 from being pressed out of the panel media 22 while the predetermined relief pattern 70 is being formed.

According to step 512, the method 500 also includes cutting the panel media 22 into cladding panels 32 having a predetermined length using the shear press 18. As discussed above, the shear press 18 is configured to cut the media panels such that each panel is substantially uniform and includes the guide lines 40 and guide intents in substantially the same location on each of the cladding panels 32. In various embodiments, the guide lines 40 defined within the panel media 22 by the punch press 14 can include a guide line 40 through which the shear press 18 is to cut each individual roofing panel. In such an embodiment, the force necessary to cut through the panel media 22 can be lessened where the material of the panel media 22 has already been weakened through the formation of corresponding guide lines 40 by the punch press 14, according to step 508. It is also contemplated that the shear press 18 can not only cut individual lengths of predetermined cladding panels 32, but also cut predetermined widths of cladding panels 32, wherein horizontal and vertical cutting mechanisms of the shear press 18 can be used to cut out multiple cladding panels 32 within each section of the panel media 22. In various embodiments, where two or more cladding panels 32 are configured to be narrower than a standard width of the panel media 22, multiple cladding panels 32, and/or different types of cladding panels 32 can be formed simultaneously in a side-by-side configuration so as to substantially limit waste of the panel media 22.

According to the method 500, step 514 includes forming at least one flange proximate an outer edge 140 of each of the cladding panels 32 using the roll former 20, wherein the cladding panels 32 each include at least one flange, the predetermined texture 30 and the predetermined relief pattern 70. As shown in FIGS. 3 and 4, the cladding panel 32 can include an upper flange 142 and a lower flange 144, wherein the upper flange 142 of one panel cooperates with the lower flange 144 of a vertically adjacent cladding panel 32. Each cladding panel 32 can also include a right flange 146 and a left flange 148, wherein a right flange 146 of one cladding panel 32 cooperates with the left flange 148 of a laterally adjacent cladding panel 32. These various flanges can include the attachment flange 46 and/or at least one nail flange 150 where the attachment flanges 46 of the various cladding panels 32 cooperate to link adjacent cladding panels 32 together. The nail flanges 150 are configured to provide a location into which fasteners, such as nails and screws, can be attached through the cladding panels 32 into the structure of the building.

According to step 516, the method 500 can also include collecting or receiving each cladding panel 32 onto an exit conveyor 80 after the cladding panels 32 leave the roll former 20 of the panel forming unit 10. Once on the exit conveyor 80, the individual cladding panels 32 can be sorted based upon various characteristics, evaluated for quality control, sent to other areas or locations for packaging and shipment, among other functions.

Referring now to FIG. 6, an alternate method 600 for forming building cladding materials includes step 602 of preparing a rolled panel media 22 having a plurality of colored courses, wherein the colored courses can correspond to the courses 100 of the predetermined relief pattern 70 to be defined within the rolled panel media 22, at a later step of the process. According to step 604, the method 600 also includes placing the rolled panel media 22 onto a continuous cladding panel assembly 10 or panel forming unit 10. As discussed above, this step 604 can be accomplished through the use of an uncoiling unit 90, whereby the rolled panel media 22 is fed into the cladding panel assembly 10. In various embodiments, individual panels can be inserted into the cladding panel assembly 10. In such embodiments, the cutting steps of each of the disclosed methods may be used to separate individual pieces of panel media 22 into smaller cladding panels 32. According to step 606, the method 600 can also include embossing a predetermined texture 30 within the surface of the rolled panel media 22. These predetermined textures 30 can include, but are not limited to, a slate texture, wood-grain textures, or other building material textures. Step 608, of the method 600, includes pressing guide lines 40 and guide indents 42 into a surface of the rolled panel media 22. Step 610 includes stamping a predetermined relief pattern 70 within the rolled panel media 22, wherein the predetermined texture 30 is at least partially defined within the relief pattern 70, and wherein the predetermined relief pattern 70 includes a plurality of subsections, wherein each subsection can include one or more relief sections 102. In various embodiments, the plurality of subsections can correspond to the individual relief sections 102 of the predetermined relief pattern 70, the individual relief channels 110, or combinations of relief channels 110 and relief sections 102 defined within the rolled panel media 22. Additionally, in alternate embodiments, each of the plurality of subsections can be defined by the various predetermined textures 30 defined within the cladding panel 32 or within one or more relief sections 102 and the relief channels 110 between the relief sections 102. It is also contemplated that the subsections can correspond to the various courses 100 of relief sections 102 that are defined within the rolled panel media 22. As discussed above, the plurality of subsections can correspond to the plurality of colored sections or bands that are included within the rolled panel media 22 before entering the cladding panel assembly 10, as described in steps 602 and 604 of the method. According to step 612, the method 600 can also include cutting the rolled panel media 22 into cladding panels 32 having a predetermined length. After being cut, the method 600 includes step 614 of forming at least one flange on an edge of each cladding panel 32 along at least one of the guide lines 40. As with previously discussed embodiments, the cutting and forming steps described above are configured to form the cladding panels 32 into substantially uniform cladding panels 32 that are configured to securely fit together upon the structure to prevent gaps between the cladding panels 32 and water leakage through any of the cladding panels 32, especially at the joints between the installed cladding panels 32. After being formed into individual cladding panels 32, step 616 of the method 600 includes coating each of the plurality of subsections with at least one of a plurality of finishes. In various embodiments, the colored sections disposed upon the rolled panel media 22 include colored bands that extend the length of the rolled panel media 22 and correspond to the courses 100 of relief sections 102 defined within each of the cladding panels 32. In such an embodiment, additional finishes and/or coatings can be added to one or more relief sections 102 of the cladding panels 32 to differentiate the relief sections 102 disposed within a course 100 of the cladding panel 32. These coating materials can include, but are not limited to, stone coatings, granule coatings, additional painted layers, adhered materials, baked on or cured layers, or other finishing materials that can help to differentiate the individual relief sections 102 within a course 100 of the cladding panel 32, or within the cladding panel 32 as a whole.

Referring now to FIG. 7, yet another method 700 for forming cladding panels 32 includes step 702 of providing a continuous cladding panel assembly 10 that includes the embossing unit 12, the punch press 14, the stamping die 16, the shear press 18 and the roll former 20, wherein a rolled panel media 22 is moved through the cladding panel assembly 10, and wherein the rolled panel media 22 includes a plurality of finishes disposed on predetermined colored sections of the rolled panel media 22. Step 704 includes placing the rolled panel media 22 on an uncoiling unit 90 placed proximate the cladding panel assembly 10, wherein the uncoiling unit 90 feeds the rolled panel media 22 into the cladding panel assembly 10. According to step 706, a predetermined first relief pattern is embossed onto the rolled panel media 22 using the embossing unit 12 to form a patterned media, wherein the first relief pattern is typically a predetermined texture 30, as described above, having a first maximum depth. As discussed above, this first maximum depth can have a thickness of about 1″ or less. In alternate embodiments, the depth of the first relief pattern can exceed 1″. After being embossed, step 708 includes pressing guide lines 40 and guide indents 42 into the surface of the patterned media using the punch press 14. According to step 710 of the method 700, a predetermined second relief pattern is stamped onto the patterned media using a stamping die 16. In forming the second relief pattern, which is typically the predetermined relief pattern 70 as described above, the first relief pattern remains at least partially defined within the second relief pattern. The second relief pattern is configured to have a second maximum depth that is greater than the first maximum depth. The second maximum depth can include various thicknesses that can range from ⅛″ or more. It is contemplated that in various embodiments, the thickness of the first relief pattern can exceed the thickness of the second relief pattern, depending upon the characteristics of the building material being formed within the cladding panel 32. It is contemplates that the thickness of the texture 30 and relief pattern 70 are determined, in part, by the slope of the surface that the cladding panels 32 will be installed upon. The texture 30 and relief pattern 70, when installed, must maintain a sufficient slope such that water and other material properly drain off from the cladding panel 32 at a predetermined rate. It is also contemplated that the predetermined second relief pattern is configured to align with the predetermined colored portions that include the plurality of finishes placed upon the rolled panel media 22 before entering the cladding panel assembly 10. As discussed above, the predetermined second relief pattern can correspond to the colored bands that are disposed upon the rolled panel media 22, or can correspond to the colored sections of the rolled panel media 22, wherein the colored sections correspond to individual relief sections 102 defined within the rolled panel media 22.

It is contemplated that in various embodiments, the first relief pattern can correspond to the individual relief sections 102 and relief channels 110 defined within the cladding panel 32 and the second relief pattern can correspond to the predetermined texture 30 applied to the cladding panel 32. In such an embodiment, the texture 30 applied by the embossing unit 12 to the surface of the rolled panel media 22 is applied after the stamping die 16 has defined the individual relief sections 102 and relief channels 110 within the rolled panel media 22. In this manner, the embossing unit 12 will be required to include a profile substantially similar to that of the relief pattern 70 created by the individual relief panels and relief channels 110 disposed within the rolled panel media 22 in order to properly dispose the texture 30 within the relief sections 102 and relief channels 110.

According to step 712 of the method 700, the patterned media is then cut into cladding panels 32 using a shear press 18, wherein each of the panels is a predetermined length. According to step 714, the cladding panels 32 are formed using the roll former 20 to include at least one flange on an edge of each of the cladding panels 32, such that the cladding panels 32 each include at least one flange, the first relief pattern, and the second relief pattern. After being formed, step 716 of the method includes collecting the cladding panels 32 at an exit conveyor 80 configured to receive each cladding panel 32 after exiting the roll former 20.

It is contemplated that in various embodiments, the steps described herein can be adjusted and performed in alternate orders. By way of explanation, and not limitation, the rolled panel media 22 can be inserted into the cladding panel assembly 10 and immediately cut into individual panels and then formed into the desired panel configuration. In such an embodiment, once the rolled panel media 22 is cut, each piece of rolled panel media 22 can sent to one of a plurality of conveyors 52, wherein each conveyor 52 leads to a cladding panel assembly 10 configured to form different types of cladding panels 32, thereby allowing a number of assemblies to be disposed adjacent or parallel with one another, while allowing multiple panels to be formed, within a single location.

It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired embodiment and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It will also be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Claims

1. A method for forming roofing panels in a continuous assembly path, the method including the steps of:

providing a continuous panel forming unit comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a panel media is moved through the panel forming unit;

placing the panel media proximate the panel forming unit and feeding an end of the panel media into the panel forming unit;

embossing a predetermined texture defined by the panel media using the embossing unit;

pressing guide lines and guide indents into a surface of the panel media using the punch press;

stamping a predetermined relief pattern defined by the panel media using the stamping die such that the predetermined texture is at least partially defined within the relief pattern;

cutting the panel media into roofing panels having a predetermined length using the shear press; and

forming at least one flange on an edge of each of the roofing panels using the roll former, wherein the roofing panels each include the at least one flange, the predetermined texture and the predetermined relief pattern.

2. The method of claim 1, wherein the panel forming unit includes an uncoiling unit, wherein the panel media is in roll form and the uncoiling unit unrolls the panel media to be moved through the panel forming unit, and wherein the panel media includes a plurality of colored sections, each of the plurality of colored sections including at least one of a plurality of colors.

3. The method of claim 2, wherein the panel media is a steel sheet disposed on a rolled steel coil.

4. The method of claim 1, wherein the predetermined texture is one of a slate texture and a wood-grain texture.

5. The method of claim 1, wherein the relief pattern is a shake roof tile pattern.

6. The method of claim 1, wherein the at least one flange includes at least one attachment flange and at least one nail flange.

7. The method of claim 1, wherein the panel forming unit includes an exit conveyor for receiving each roofing panel after leaving the roll former of the panel forming unit.

8. A method for forming building cladding panels in a continuous assembly path, the method including the steps of:

placing a rolled media into a continuous cladding panel assembly;

embossing a predetermined texture within the rolled media;

pressing guide lines and guide indents into a surface of rolled media;

stamping a predetermined relief pattern within the rolled media, wherein the predetermined texture is at least partially defined within the relief pattern, and wherein the predetermined relief pattern includes a plurality of sub-sections;

cutting the rolled media into cladding panels having a predetermined length;

forming at least one flange on an edge of each cladding panel along at least one of the guide lines; and

coating each of the plurality of subsections with at least one of a plurality of finishes.

9. The method of claim 8, wherein the cladding panels are roofing panels.

10. The method of claim 8, wherein the cladding panel assembly includes an uncoiling unit, wherein an uncoiling unit supports the rolled media and delivers the rolled media to be formed by the cladding panel assembly.

11. The method of claim 10, wherein the rolled media is a steel sheet disposed on a rolled steel coil, wherein the rolled media includes a plurality of colored courses, wherein each of the plurality of colored courses is configured to cooperate with a corresponding colored portion of the plurality of subsections.

12. The method of claim 8, wherein the predetermined texture is one of a slate texture and a wood-grain texture.

13. The method of claim 8, wherein the relief pattern is a shake roof tile pattern.

14. The method of claim 8, wherein the at least one flange includes at least one attachment flange and at least one nail flange.

15. The method of claim 8, wherein the cladding panel assembly includes an exit conveyor for receiving the formed cladding panels.

16. A method for forming cladding panels in a continuous assembly path, the method including the steps of:

providing a continuous cladding panel assembly comprising an embossing unit, a punch press, a stamping die, a shear press and a roll former, wherein a rolled media is moved through the cladding panel assembly, and wherein the rolled media includes a plurality of finishes each disposed on at least one of a plurality of predetermined colored sections of the rolled media;

placing the rolled media on an uncoiling unit proximate the cladding panel assembly, wherein the uncoiling unit feeds the rolled media into the cladding panel assembly;

embossing a predetermined first relief pattern onto the rolled media using the embossing unit to form a patterned media, wherein the first relief pattern has a first maximum depth;

pressing guide lines and guide indents into a surface of the patterned media using the punch press;

stamping a predetermined second relief pattern onto the patterned media using the stamping die, wherein the first relief pattern is at least partially defined within the second relief pattern, and wherein the second relief pattern has a second maximum depth that is greater than the first maximum depth, and wherein the predetermined second relief pattern aligns with the plurality of predetermined colored sections;

cutting the patterned media into cladding panels having a predetermined length using the shear press; and

forming at least one flange on an edge of each of the cladding panels using the roll former, wherein the cladding panels each include the at least one flange, the first relief pattern and the second relief pattern.

17. The method of claim 16, wherein the first relief pattern is one of a slate texture and a wood-grain texture.

18. The method of claim 16, wherein the second relief pattern is a shake tile pattern.

19. The method of claim 16, wherein the at least one flange includes at least one attachment flange and at least one nail flange.

20. The method of claim 16, wherein the cladding panel assembly includes an exit conveyor for receiving each of the cladding panels after leaving the roll former of the cladding panel assembly.