BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a conventional standing seam roof.
FIG. 2 is a cross-sectional schematic of one of the standing seams of FIG. 1.
FIG. 3 is a schematic of a standing seam panel installed over a deck using a first structure to address oil canning or stress wrinkling of the panel.
FIG. 4 is a top view of the standing seam panel of FIG. 3, and without illustrating the underlying deck.
FIG. 5A is an end view of the first structure illustrated in FIG. 3.
FIG. 5B is an end view of an alternative configuration for the first structure of FIG. 5A.
FIG. 5C is an end view of another alternative configuration for the first structure of FIG. 5A.
FIG. 6A is an alternative configuration for a standing seam panel (two base sections) that may be used in combination with any of the first structures of FIGS. 5A-C to address oil canning or stress wrinkling of the panel.
FIG. 6B is an alternative configuration for a standing seam panel (three base sections) that may be used in combination with any of the first structures of FIGS. 5A-C to address oil canning or stress wrinkling of the panel.
FIG. 7A is a schematic of a standing seam defined by the interconnection of a pair of standing seam sections of the type used by the standing seam panel of FIG. 3.
FIGS. 7B-G are various alternative standing seam profiles/configurations for standing seam panels that may be used in combination with a first structure to address oil canning or stress wrinkling.
DETAILED DESCRIPTION
FIG. 1 illustrates a representative roof 12 of a building. The roof 12 may be of any pitch, but at least generally slopes downwardly from a peak 14 of the roof 12 to an eave 16 of the roof 12. Multiple panels 22 (e.g., metal) are interconnected to define the roof 12. The interconnection of adjacent panels 22 defines a standing seam 18. The length dimension of each standing seam 18 extends from the peak 14 of the roof 12 to the eave 16 of the roof 12, and furthermore the elevation of the various standing seams 18 progressively changes proceeding along their respective length dimensions. Each panel 22 includes a flat, planar base 20 that is disposed between each adjacent pair of standing seams 18. The standing seams 18 may be further characterized as extending at least generally away from the bases 20 that are disposed on each side of the relevant standing seam 18 (FIG. 2, where an upper end 19 of the standing seam 18 is vertically spaced from the adjacent bases 20 of the panels 22). The panels 22 may be of any appropriate configuration, the standing seams 18 may be of any appropriate configuration, and the standing seams 18 may be disposed in any appropriate orientation relative to the adjacent bases 20.
FIG. 3 illustrates one embodiment of a building or any other appropriate surface 70. The building surface 70 is applicable to both interior and exterior surfaces. Moreover, the building surface 70 may be incorporated at any appropriate location, such as an interior wall or ceiling, a roof, siding, or a soffit. In any case, the building surface 70 is defined by a plurality of what may be characterized as panel assemblies 40 (only one being illustrated in FIG. 3 and in the form of a panel 42 and a first structure 60, where multiple panels 42 would be at least generally interconnected in the manner discussed above in relation to the roof 12) that are installed over an appropriate substrate or deck 72. Portions of the substrate 72 are removed in FIG. 3 to highlight the illustration of at least certain portions of the panel assembly 40. The substrate 72 is a flat or planar structure, and may be formed/constructed in any appropriate manner. Typically the substrate 72 will be in the form of plywood sheets that are nailed to the rafters or other underlying supports of the building surface 70. However, the substrate 72 could be in the form of a metal deck or the like, a deck defined by one or more foam boards or the like, as well as a deck defined by wood, concrete, or any other appropriate material/structure. Moreover, a membrane or the like may be disposed between the above-noted types of structures and the panel 42 of the panel assembly 40, and thereby itself may be characterized as the substrate 72. Generally, the substrate 72 may be characterized as that structure that is disposed directly underneath the panel 42, or that structure that, in combination with the panel 42, “sandwiches” the first structure 60 of the panel assembly 40 therebetween.
The panel assembly 40 includes a panel 42, which is illustrated in both FIG. 3 and FIG. 4. The illustrated panel 42 is in the form of what is commonly referred to as a standing seam panel 42 based upon the manner in which it is interconnected with adjacent panels 42 to define the building surface 70. However, the panel 42 may be of any appropriate configuration in relation to the manner in which it is assembled to define a building surface. Although the panel 42 could be formed from any appropriate material, typically the panel 42 will be formed from an appropriate metal. In any case, the panel 42 includes a first primary panel surface 44 that projects toward or faces the substrate 72 when the panel assembly 40 is installed over the substrate 72. A second primary panel surface 46 is disposed oppositely of the first primary panel surface 44, and thereby faces or projects at least generally away from the substrate 72 when the panel assembly 40 is installed over the substrate 72.
The panel 42 includes a pair of longitudinal edges 48a, 48b that extend in what may be characterized as a longitudinal dimension. In the illustrated embodiment, the longitudinal edges 48a, 48b are in the form of standing seam sections 48a, 48b. The standing seam sections 48a, 48b each may be of any appropriate configuration (e.g., FIGS. 7A-G), and may be disposed in any appropriate orientation so as to be able to interconnect with an adjacent panel 42 when the panels 42 are installed over the substrate 72 and that will define a standing seam (e.g., standing seams 49a-g of FIGS. 7A-G, respectively). However and in accordance with the foregoing, the longitudinal edges 48a, 48b need not be in the form of standing seam sections.
In the case where the building surface 70 of FIG. 3 is in the form of a roof, the roof may have a pitch and the panel 42 will typically be installed such that its longitudinal edges 48a, 48b run at least generally up/down the pitch of the roof (e.g., the longitudinal edges 48a, 48b may be disposed at least generally perpendicularly to a peak of the roof; the longitudinal edges 48a, 48b may extend from a peak of the roof to an eave of the roof). Another way to characterize the positioning/orientation of the longitudinal edges 48a, 48b of the panel 42 on the building surface 70 in the form of a roof is that they may be disposed in a vertical reference plane, the longitudinal edges 48a, 48b may be oriented such that the elevation of the longitudinal edges 48a, 48b progressively changes proceeding along their respective length dimensions, or both.
Extending between and interconnecting the longitudinal edges or standing seam sections 48a, 48b of the panel 42 is a pair of transverse or lateral edges 50. The longitudinal edges or standing seam sections 48a, 48b may be characterized as being longitudinally extending and spaced in a lateral dimension. The transverse edges 50 thereby may be characterized as being laterally extending and spaced in a longitudinal dimension. In the illustrated embodiment, the longitudinal edges or standing seam sections 48a, 48b are parallel to each other, as are the transverse edges 50, although such may not be required in all instances.
A base section 54 is disposed between the longitudinal edges or standing seam sections 48a, 48b in the case of the panel 42, and is a flat or planar structure. The width dimension of the base section 54 coincides with the dimension in which the longitudinal edges or standing seam sections 48a, 48b of the panel 42 are spaced from each other in the illustrated embodiment (again, where the longitudinal edges or standing seam sections 48a, 48b each define a standing seam 49a in the illustrated embodiment when appropriately interconnected with an adjacent panel 42 and as illustrated in FIG. 7A), and corresponds with the dimension “W” in FIG. 3. The base section 54 of the panel 42 is particularly susceptible to oil canning or stress wrinkling. It should be appreciated that the panel 42 could be configured to include more than one base section 54 (not shown in FIG. 3, but see FIGS. 6A-B to be discussed below) by including one or more “ribs” (discussed below) between the longitudinal edges or standing seam sections 48a, 48b.
The panel assembly 40 further includes an associated first structure 60 that is disposed between the substrate 72 and first primary panel surface 44 of the associated panel 42. In one embodiment, the first structure 60 is at least generally in the form of a foam (e.g., a material of the type that is typically used to define backer rod). Although the first structure 60 may be fabricated in any appropriate manner, in one embodiment the first structure 60 is extruded, such that it may be referred to as an extrusion.
The first structure 60 may be formed from any appropriate material or combination of materials, may be of any appropriate size, shape, configuration, and cross-sectional profile, or both, so long as the first structure 60 provides a desired convexity for the second primary panel surface 46 in a manner that will be discussed in more detail below. However, generally it would be desirable for the first structure 60 to be sufficiently compressible so that the first structure 60 will not bend or otherwise permanently deform the panel 42 when under normal design loads. It would be desirable for the first structure 60 to at least temporarily compress if the panel 42 experiences a normal design load (e.g., a person walking on the panel 42) so that the first structure 60 would not bend or permanently deform the panel 42 in this instance. Although the first structure 60 could be elastic, such need not be the case. That is, after undergoing a compression by the panel 42 being exposed to a load, the first structure 60 would not necessarily have to assume its original configuration once the load is removed or reduced (although the first structure 60 could in fact be elastic), but preferably the first structure 60 would at least move back toward its original configuration (e.g., by a subsequent expansion) upon experiencing a removal/reduction of the applied load.
Referring now to FIGS. 3, 4, and 5A, a first surface 62 of the first structure 60 faces and may be in direct contact with the first primary panel surface 44 (such that the first surface 62 and the first primary panel surface 44 are in opposing relation), while an oppositely disposed second surface 64 faces and may be in direct contact with the substrate 72 (such that the second surface 64 and the first primary panel surface 44 are in opposing relation). The interface between the first surface 62 and the first primary panel surface 44, the interface between the second surface 62 and the substrate 72, or both, may include an adhesive (e.g., such that there may not be direct contact between the first structure 60 and the relevant structure). In any case, both the first surface 62 and the second surface 64 are flat in the illustrated embodiment prior to being disposed in opposing relation with the corresponding structure, or with the first structure 60 being in an uncompressed state. The sidewalls 63 that interconnect the surfaces 62 and 64 are also flat, although other configurations may be appropriate. Typically either the first surface 62 will be chemically bonded to the first primary panel surface 44 such that the interface between the first surface 62 and the first primary panel surface 44 includes a chemical bond, or the second surface 64 of the first structure 60 will be chemically bonded to the substrate 72 such that the interface between the second surface 64 and the substrate 72 includes a chemical bond. That is, typically the first structure 60 will be chemically bonded directly to only one of the panel 42 and the substrate 72. However, the first structure 60 could possibly be chemically bonded directly to each of the panel 42 and substrate 72, although this may in fact be disadvantageous in one or more respects. The first structure 60 may be a solid structure, or may be hollow by including one or more apertures 66 that extend along its length dimension (illustrated by dashed lines in FIG. 5A). Each aperture 66 may be of any appropriate cross-sectional profile, and multiple apertures 66 used by the first structure 60 may be disposed in any appropriate arrangement. When the first structure 60 includes a single aperture of the type shown in FIG. 5A, the first structure 60 may be characterized as a tube or at least as being tube-like.
Any appropriate way of providing a chemical bond between opposing surfaces of the first structure 60 and the panel 42/substrate 72 may be utilized. One appropriate way to provide the noted chemical bond would be via an appropriate adhesive. This adhesive could be applied by the manufacturer of the panel 42 (in which case the first surface 62 of the first structure 60 would be chemically bonded directly to the panel 42), could be applied by a contractor at the job site (in which case the first surface 62 of the first structure 60 could be chemically bonded directly to the panel 42, the substrate 72, or both), or at any other appropriate time. Another appropriate way to provide the noted chemical bond would be to use double-sided tape and in any appropriate manner (e.g., the first surface 62 of the first structure 60 could be chemically bonded directly to the panel 42 prior to arriving at the job site and including being attached by the manufacturer of the panel 42; the first surface 62 of the first structure 60 could be chemically bonded directly to the panel 42 at the job site; the second surface 64 of the first structure 60 could be chemically bonded to the substrate 72 at the job site). It also may be such that the first structure 60 could be formed on the first primary panel surface 44 as part of its overall fabrication process, such as by dispensing an appropriate material onto the first primary panel surface 44 as a piece of sheet metal moves relative to the dispenser (e.g., prior to the sheet metal passing through a roll forming station or the like, where such a roll forming station may utilize a plurality of forming rollers or the like that shape/define the longitudinal edges or standing seam sections 48a, 48b; as the sheet metal passes through a roll forming station or the like; after the sheet metal has passed through a roll forming station or the like). This dispensed material may be in the form of a liquid or a paste that may be deposited directly on the panel 42. In any case, it may be such that this deposition would both chemically bond the material to the first primary panel surface 44 and at least eventually define the first structure 60 (possibly after being allowed to air cure, possibly after some type of post-processing or the like (e.g., a heat treatment), or both). Yet another option would be to form the first structure 60 (e.g., by extrusion) and to thereafter position the first structure 60 onto the first primary panel surface 44 while in a “wet” or “uncured” state such that a chemical bond will develop/exist between the interfacing surfaces of the first structure 60 and the first primary panel surface 44.
Any way of mounting the first structure 60 to the panel 42 as part of its overall fabrication process may be utilized as well (e.g., in a roll forming line; in a separate line from the roll forming line). For instance: 1) an appropriate adhesive or the like could be dispensed onto the panel 42 as the panel 42 is being advanced relative to the adhesive source, and at some time thereafter the first structure 60 could be positioned over this adhesive as the panel 42 is being advanced relative to the first structure 60; 2) the first structure 60, with pre-applied adhesive or the like (e.g., in the form of double-sided adhesive tape; an inborne adhesive or adhesive characteristic may be part of the composition of the first structure 60), could be positioned on the panel 42 as the panel 42 is being advanced relative to the first structure 60; 3) an appropriate adhesive or the like could be dispensed onto the first structure 60, and thereafter the first structure 60 could be positioned on the panel 42 as the panel 42 is being advanced relative to the first structure 60; 4) an appropriate adhesive or the like could be dispensed onto the panel 42 as the panel 42 is being advanced relative to the adhesive source, an appropriate adhesive or the like could be dispensed onto the first structure 60, and thereafter the first structure 60 could be positioned on the panel 42 as the panel 42 is being advanced relative to the first structure 60; and 5) the first structure 60 could be formed (e.g., extruded), and while the first structure 60 is still in a “wet” or an “uncured” state, the first structure 60 may be positioned on the first primary panel surface 44 such that a chemical bond will develop/exist between the interfacing surfaces of the first structure 60 and the first primary panel surface 44, and which may also result in a “flattening” of the interfacing surface of the first structure 60 (the surface thereof that interfaces with the first primary panel surface 44)—possibly after placing the first structure 60 in compression to enhance the mounting of the first structure 60 to the panel 42.
The first structure 60 is installed so as to produce a convexity on the second primary panel surface 46 on the base section 54 of the panel 42 and as illustrated in FIG. 3. This desirably addresses oil canning or stress wrinkling of the base section 54. That is, the panel assembly 40 should reduce the visual impact of oil canning or stress wrinkling of the panel 42 when the panel assembly 40 is installed over the substrate 72. In this regard, the first surface 62 of the first structure 60 engages or faces the first primary panel surface 44 (again, the interface may be in the form of an adhesive layer or film), while the second surface 64 of the first structure 60 engages or faces the substrate 72 (again, the interface may be in the form of an adhesive layer or film). Typically the first structure 60 is installed at the lateral midpoint of the base section 54, although other positionings may be appropriate. More than one first structure 60 could be installed on the base section 54 as well. Moreover, typically the first structure 60 extends from at least generally one transverse edge 50 to at least generally the other transverse edge 50 (e.g., to or within a few inches of each transverse edge 50), and furthermore at least in generally parallel relation with the longitudinal edges or standing seam sections 48a, 48b that again each define a standing seam 49a (FIG. 7A) when appropriately interconnected with an adjacent panel 42. Other installed positions may be appropriate.
As noted, the first structure 60 may be of any appropriate cross-sectional configuration. For instance, the first structure 60 could be cylindrical, for instance when the first structure 60 is in a “wet” or “uncured” state when initially disposed on the first primary panel surface 44 and as discussed above. FIGS. 5B and 5C illustrate other representative alternative cross-sectional profiles for the first structure 60. Other than having different cross-sectional profiles, the discussion presented above with regard to the first structure 60 is equally applicable to the first structures 60′ and 60″ of FIGS. 5B and 5C, respectively.
FIG. 5B illustrates that the first structure 60′ includes a single flat first surface 62′ (flat before being disposed in interfacing relation with the relevant structure or with the first structure 60′ being in an uncompressed state) and an oppositely disposed convex or curved second surface 64′, as well as convex or curved sidewalls 63′. Generally, the first structure 60′ may be characterized as a cylindrical rod with a single flat (first surface 62′) formed on its exterior surface. In the illustrated embodiment, the first structure 60′ is semicircular. In any case and in accordance with the first structure 60, the first structure 60′ may include one or more optional apertures 66′ (illustrated by dashed lines). The first surface 62′ could be chemically bonded to the relevant structure (either the first primary panel surface 44 of the panel 42 or the substrate 72). The configuration shown in FIG. 5B may also be realized after a “wet” or “uncured” first structure 60 is disposed on the first primary panel surface 44 in the above-noted manner.
FIG. 5C illustrates that the first structure 60″ includes a flat first surface 62″ (flat before being disposed in interfacing relation with the relevant structure or with the first structure 60″ being in an uncompressed state) and an oppositely disposed flat second surface 64″ (flat before being disposed in interfacing relation with the relevant structure or with the first structure 60″ being in an uncompressed state). Generally, the first structure 60″ may be characterized as a cylindrical rod with a pair of opposing flats (first surface 62″ and second surface 64″) formed on its exterior surface. In this regard, a pair of convex or curved sidewalls 63″ extend between and interconnect the surfaces 62″ and 64″. In accordance with the first structure 60, the first structure 60″ may include one or more optional apertures 66″. Generally, one of the surfaces 62″, 64″ would be disposed in interfacing relation with the first primary panel surface 44 of the panel 42, while the other of the surfaces 62″, 64″ would be disposed in interfacing relation with the substrate 72.
The panel 42 may be installed in any appropriate manner relative to the substrate 72. For instance, the entire first primary panel surface 44 may be disposed in spaced relation to the substrate 72. In this case, the height or thickness of the first structure 60 (including the variations thereof addressed herein) would of course need to be greater than the size of this gap to provide the desired convexity on the second primary panel surface 46. Alternatively and in the absence of the first structure 60 (including the variations thereof addressed herein), the panel 42 may be installed such that the base section 54 of the panel 42 is disposed on the substrate 72. However, the first structure 60 (including the variations thereof addressed herein) will of course dispose at least a portion of the base section 54 in spaced relation to the substrate 72.
The first structure 60 (including the variations thereof addressed herein) may be used with a panel of any appropriate configuration. Representative alternative standing seam panel configurations are illustrated in FIGS. 6A-B. The panel 42i of FIG. 6A includes a pair of longitudinal edges 48ai, 48bi in the form of standing seam sections, and a single rib 53 (a “rib” again being a protruding structure of any appropriate size, shape, and/or configuration that is located between the longitudinal edges of a panel, including without limitation a crest, minor rib, intermediate rib, pencil rib, striation, fluting, or flute) that is disposed midway between these longitudinal edges or standing seam sections 48ai, 48bi. The panel 42i thereby includes two base sections 54i—one between the rib 53 and each of the two longitudinal edges or standing seam sections 48ai, 48bi. One or more first structures 60 (or any of the variations thereof addressed herein) may be disposed so as to interface with the first primary panel surface 44i in each of the base sections 54i to produce a convexity on the second primary panel surface 46i at least generally in accordance with the foregoing.
The panel 42ii of FIG. 6B includes a pair of longitudinal edges 48aii, 48bii in the form of standing seam sections, and two or more ribs 53 (of any appropriate size, shape, and/or configuration) that are typically equally spaced between these longitudinal edges or standing seam sections 48aii, 48bii. The panel 42ii thereby includes at least three base sections 54ii—one between each rib 53 and the adjacent longitudinal edge or standing seam section 48aii, 48ii, and another between each adjacent pair of ribs 53. One or more first structures 60 (or any of the variations thereof addressed herein) may be disposed so as to interface with the first primary panel surface 44ii in each of the base sections 54ii to produce a convexity on the second primary panel surface 46ii at least generally in accordance with the foregoing.
As noted above, longitudinal edges in the form of standing seam sections 48a, 48b each may be of any appropriate size, shape, and/or configuration. FIG. 7A illustrates a pair of standing seam panels that are of the type illustrated in FIG. 3 and that are interconnected to define a standing seam 49a. FIGS. 7B-7G illustrate representative, alternative standing seams 49b-g defined by the interconnection of the standing seam sections of a pair of adjacent standing seam panels. The standing seam section configurations illustrated in FIGS. 7A-G may be used in relation to any of the panels described herein, where a first structure is used in combination with this panel to provide a convexity on its second primary panel surface to address oil canning.
Summarizing the foregoing, a first structure is disposed in opposing relation with a first primary panel surface of a panel somewhere between an adjacent pair of protruding structures (e.g., a standing seam section; a rib) to produce a convexity on the second primary panel surface, where each protruding structure is both linearly extending and protrudes at least generally away from the substrate when the panel is installed over the substrate. Therefore, the longitudinal edges or standing seam sections 48a, 48b (as well as the variations thereof addressed herein) and the ribs 53 would each be such a protruding structure. A first structure could be disposed between an adjacent pair of protruding structures of a common type, or between protruding structures of different types. Typically, the first structure will be disposed on a flat base section between an adjacent pair of protruding structures, where the center-to-center spacing between these protruding structures is at least about 12 inches. Although these protruding structures may be associated with a standing seam panel to address oil canning, the first structure may be used in relation to any panel having at least two protruding structures of the type discussed herein to address oil canning as well.
The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the present invention. The embodiments described hereinabove are further intended to explain best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
Patent Application
20070289233
