METAL ROOF PANEL WITH DEFORMATION RESISTANT RIB AND METHOD OF MAKING THE SAME

Abstract

A metal roof panel includes a rib with a unique shape. The rib is bilateral with upwardly angled sides that each transition into an indentation, with both indentations transitioning into a central flat apex. Between each rib is a channel, preferably including at least one raised surface. The lower surface of the channel between the raised surfaces, and the top of the raised surfaces, are substantially planar and parallel to the flat surface of the apex of the panel. A unique method of manufacturing the roof panel employs a roll machine configured to shape a piece of sheet metal into the roof panel by modifying the shape in many small increments, which allows the final product to have a fairly intricate bend pattern.

Claims

1) A method of manufacturing a metal roof panel including the steps of: A. inserting a panel of sheet metal into a roll machine; B. passing said sheet metal through a first roller set of said roll machine to form sheet metal post-first roller; C. passing said sheet metal post-first roller through a second roller set of said roll machine to form sheet metal post-second roller; D. passing said sheet metal post-second roller through a third roller set of said roll machine to form sheet metal post-third roller; and E. passing said sheet metal post-third roller through at least one subsequent roller of said roll machine wherein said panel of sheet metal is transformed into a metal roof panel having a profile including: i. a plurality of bilateral ribs having upwardly angled sides that each transition into an indentation, with both indentations transitioning into a central flat apex extending from one of said indentations to the other of said indentations and having a width of approximately , wherein said ribs run substantially parallel to the slope of the roof, and wherein the angle formed between one of said upwardly angled sides and said central flat apex is approximately 126; and ii. a plurality of channels each positioned between two of said ribs, each channel including at least one raised surface and at least one lower surface, said raised surface having a height of approximately , wherein the angle formed between one of said upwardly angled sides and said central flat apex is approximately 54, and wherein said at least one raised surface and at least one lower surface are each substantially planar and parallel to said central flat apex.

2) The method of claim 1 wherein said step of passing said sheet metal post-third roller through subsequent rollers includes forming a profile having exactly two raised surfaces and exactly three lower surfaces.

3) The method of claim 1 wherein said step of inserting a panel of sheet metal into a roll machine includes the step of inserting a panel of 29 gauge GALVALUME sheet metal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a roof having known metal roof panels installed, with a panel attached at the channel and at the rib shown in an enlarged view;

[0015] FIG. 2 is a roof having known metal roof panels with rounded ribs installed, with a panel attached at the rib shown in an enlarged view;

[0016] FIG. 3 depicts a roof panel attached at the rib and at a channel side-by-side, with wind forces shown on the panel attached at the rib;

[0017] FIG. 4 is a perspective view of a roof panel of the present invention;

[0018] FIG. 5 is a side profile view of a section of a roof panel of the present invention;

[0019] FIG. 6 is a perspective view of a roll machine;

[0020] FIGS. 7-12 depict the manufacturing process with rollers forming sheet metal into a roof panel in gradual stages; and

[0021] FIG. 13 is a roof having roof panels of the present invention secured along ribs.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but rather it illustrates the general principles of the invention, with the scope of the invention set forth in the appended claims.

[0023] The following structure numbers shall apply to the following structures among the various figures: [0024] 10roof panel; [0025] 15substrate; [0026] 20channel; [0027] 22lower surface; [0028] 24raised surface; [0029] 30rib; [0030] 32apex; [0031] 34side; [0032] 35shoulder; [0033] 36indentation; [0034] 37side-apex angle; [0035] 38side-shoulder angle; [0036] 39lower surface-side angle; [0037] 40screw; [0038] 45washer; [0039] 50water; [0040] 55leaked water; [0041] 60sheet metal; [0042] 60asheet metal post-first roller; [0043] 60bsheet metal post-second roller; [0044] 60csheet metal post-third roller; [0045] 60dsheet metal post-forth roller; [0046] 60esheet metal post-fifth roller; [0047] 60fsheet metal post-sixth roller; [0048] 60gsheet metal post-seventh roller; [0049] 60hsheet metal post-eighth roller; [0050] 60isheet metal post-ninth roller; [0051] 60jsheet metal post-tenth roller; and [0052] 60ksheet metal post-eleventh roller; [0053] 62roller set; [0054] 62afirst roller set; [0055] 62bsecond roller set; [0056] 62cthird roller set; [0057] 62dforth roller set; [0058] 62efifth roller set; [0059] 62fsixth roller set; [0060] 62gseventh roller set; [0061] 62heighth roller set; [0062] 62ininth roller set; [0063] 62jtenth roller set; and [0064] 62keleventh roller set; [0065] 64controller; and [0066] 80roll machine.

[0067] Referring to FIG. 4, preferred roof panel 10 preferably has a plurality of ribs 30, preferably 5, separated by a plurality of channels 20. In a preferred embodiment the roof panel can be a variety of lengths, is approximately 37 wide, the distance between adjacent apices 32 is approximately 9, and the height of each rib 30 is approximately , as measured from lower surface 22 (FIG. 5) to apex 32. The width of each apex 32 is preferably , which accommodates a standard screw and a standard washer. Roof panel 10 can be constructed of a variety of metals including steel, aluminum, copper, zinc, titanium, or composites including these metals. In a preferred embodiment, roof panel 10 is constructed of 29 gauge bare or pre-painted GALVALUME coil from, for example CRACO Metal Supply in York, S.C.

[0068] A profile view of a section of a roof panel is depicted in FIG. 5. Each rib 30 is bilateral and preferably includes two sides 34 sloping upwardly from channels 20, one substantially flat apex 32 at the height of each rib, and a transitional indentation 36 between each side and the apex. Indentation 36 includes shoulder 35 at interface with side 34.

[0069] The rib strength of the present invention is significantly better than relevant competitors. This is an important property because it allows roof panel 10 to be screwed down tight without risking deformation. The superior rib strength of the present invention is attributed to the unique shape of the rib including indentations 36, and angles formed by intersecting planes of structures. More specifically, as shown in FIG. 5, side-apex angle 37 should be approximately 126, side-shoulder angle 38 should be approximately 168, and lower surface-side angle 39 should be approximately 54.

[0070] Another benefit of the novel roof panel shape is that indentations 36 act as a water passage to the bottom of the panel and off the roof. This further eliminates standing water, likelihood of leakage, and prevents deterioration.

[0071] The unique shape of the rib is possible through novel manufacturing techniques. Referring to FIG. 6, roll machine 80 preferably includes eleven set of rollers 62, with 62a being the first roller set, 62b being the second roller set, 62c being third roller set, and so forth. Sheet metal 60 passes through first roller set 62a and emerges as sheet metal post-first roller 60a, then passes through second roller set 62b and emerges as sheet metal post-second roller 60b, and so forth. Programmable controller 64 dictates production parameters such as roller speed, force of rollers, symmetry, and accuracy so as to keep sheet metal straight in the rollers to ensure an even run of each panel.

[0072] Referring to FIG. 7, first roller set 62a pulls sheet 60 from a coil of sheet metal into the machine past first roller set 62a, which pulls slightly to the left so that the straight edge lines up on the rollers correctly. Similarly, in FIGS. 8-12 each set of rollers are different die-cuts for gradually bending the sheet to achieve the desired profile at the end.

[0073] In use, roof panels are installed in the conventional manner, except screws are used to secure the panel primarily along the ribs, and not along the lower surface 22 of channels 20. However, a minimal number of screws 40 are employed at lower surface 22 at panel bottom edges to prevent uplift.

[0074] Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. It should be understood that many modifications and improvements have been omitted for the sake of conciseness and readability but are properly within the scope of the following claims. Unless stated otherwise, or contrary to common sense, all ranges include stated endpoints as well as all increments there between, however small. Also, unless stated otherwise, or contrary to common sense, all values are +/10%. It should also be understood that significantly and similar terms shall mean generally true, but allowing exceptions due to manufacturing and material variations, user variations, and so forth. By way of example, a significantly planar surface may have irregularities or contours.