Crowning panel assembly

Abstract

A panel assembly (40) that addresses oil canning when installed over a substrate or deck (72) is disclosed. The panel assembly (40) includes a panel (42). The panel (42) includes a first primary panel surface (44) that faces the substrate (72) in the installed configuration, as well as a second primary panel surface (46) that faces away from the substrate (72) in the installed configuration. Another component of the panel assembly (40) is a first structure (60) that is disposed between the panel (42) and the substrate (72). Typically, either a first surface (62) of the first structure (60) is chemically bonded directly to the first primary panel surface (44) such that an interface between the first surface (62) and the first primary panel surface (44) includes a chemical bond, or a second surface (64) is chemically bonded directly to the substrate (72) such that an interface between the second surface (64) and the substrate (72) includes a chemical bond. In any case, the first structure (60) produces a convexity on the second primary panel surface (46) to address oil-canning effects or stress wrinkling of the panel (42).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This patent application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 60 / 805,275, that was filed on Jun. 20, 2006, that is entitled “CROWNING PANEL ASSEMBLY,” and the entire disclosure of which is hereby incorporated by reference in its entirety herein.FIELD OF THE INVENTION[0002]The present invention generally relates to building surfaces that are susceptible to oil canning or stress wrinkling and, more particularly, to reducing its visual impact on building surfaces.BACKGROUND OF THE INVENTION[0003]Metal panels are being increasingly used to define building surfaces such as roofs and sidewalls. One type of metal panel is a standing seam panel, where the edges of adjacent standing seam panels of the building surface are interconnected in a manner that defines a standing seam. Standing seam panels are expensive compared to other metal panels, and building surfaces defined by metal panels may be mo...

AI Technical Summary

Benefits of technology

[0009]Various refinements exist of the features noted in relation to the first aspect of the present invention. Further features may also be incorporated in the first aspect of the present invention as well. These refinements and additional features may exist individually or in any combination. Generally, the first aspect may be characterized as a panel assembly that addresses oil canning or stress wrinkling by generally directing surface irregularities into a “crown.” That is, the noted convexity in the metal panel provided by the first structure should desirably reduce the visual impact of oil canning or stress wrinkling of the metal panel.

[0018]In another embodiment of the first aspect, the first structure is positioned on the first primary panel surface while the first structure is in a “wet” or “uncured” state. This may provide for a suitable chemical bond between the opposing first structure and the first primary panel surface—that is, such that the interface between the first surface of the first structure and the first primary panel surface includes a chemical bond. This may also allow the first structure to deform to a certain extent by placing the first structure into contact with the metal panel (and possibly placing the same in compression to a degree) such that a flat surface is formed on the portion of the first structure that interfaces with the first primary panel surface.

[0020]Various refinements exist of the features noted in relation to the second aspect of the present invention. Further features may also be incorporated in the second aspect of the present invention as well. These refinements and additional features may exist individually or in any combination. Generally, the second aspect may be characterized as a panel assembly that addresses oil canning or stress wrinkling. That is, the convexity in the standing seam panel provided by the first structure should desirably reduce the visual impact of oil canning or stress wrinkling of the panel by generally directing surface irregularities into a “crown.”

[0026]Various refinements exist of the features noted in relation to the fifth aspect of the present invention. Further features may also be incorporated in the fifth aspect of the present invention as well. These refinements and additional features may exist individually or in any combination. Generally, the fifth aspect may be characterized as addressing oil canning or stress wrinkling. That is, the convexity in the panel provided by the first structure should desirably reduce the visual impact of oil canning or stress wrinkling of the panel by generally directing surface irregularities into a “crown.” In any case, the various features discussed above in relation to the first aspect may also be used by this fifth aspect where appropriate, individually or in any combination.

Problems solved by technology

Standing seam panels are expensive compared to other metal panels, and building surfaces defined by metal panels may be more costly than other types of building surface constructions.

In any case, standing seam panels, as well as possibly other panels, may include a relatively large, planar or flat base section that may tend to exhibit waviness or other surface irregularities after the panel is installed.

This is commonly referred to in the art as “oil canning.” Although oil canning does not necessarily adversely affect the performance of the building surface defined by a plurality of metal panels, many owners and building designers find the aesthetics visually distracting and unacceptable, particularly in view of the premium cost associated with metal panel building surfaces.

This process is expensive, inconvenient, and increases material handling requirements.

This method significantly increases material costs.

This method also increases material costs and significantly changes the architectural effect.

Often surface irregularities persist due to the fabrication and installation process, notwithstanding the added process, decreased panel width, or increased panel thickness.

While these methods may in some cases reduce some degree of oil canning, often they are not effective.

Additionally, some users find these alternative structures themselves aesthetically annoying and undesireable.

These types of installation techniques are cumbersome, time consuming, inconvenient, and subject to human error.

Additionally, commonly used “backer rod” structures and materials may not be well-suited to this kind of use.

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