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BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to a siding element having an appearance of log construction, and in particular to a metal seamless siding element, an apparatus for making the siding and a method of making the siding.  
           [0003]    2. Description of the Prior Art  
           [0004]    Various types of siding for houses and other structures have been developed. Vinyl siding, aluminum siding and steel siding have all been developed as low maintenance or maintenance free siding options that do not require painting and other normal maintenance tasks. Some types of siding provide the additional advantage of being seamless, wherein siding elements are cut to a desired length spanning the entire distance from a corner or interruption in the siding to the next such occurrence. Seamless siding provides the advantages of uninterrupted siding that is more aesthetically pleasing. In addition, the lack of seams also provides greater protection from the elements and improved insulating properties.  
           [0005]    In order to accommodate seamless siding, it is generally necessary to cut the siding that typically comes off a spool in a continuous coil of material at the site where the siding is being hung. Cutting length at the job site therefore requires a specialized cutting machine that is portable and that is typically trailered to the job site. In addition to providing an arc on the siding simulating log siding, such a device must also form the flange or mounting structure onto the siding panels. It can be appreciated that metal siding, which affords greater protection and wears better than vinyl siding, has special requirements in forming the siding due to its stiffness as opposed to vinyl siding that may be easily extruded or formed.  
           [0006]    Although textured sidings, such as vinyl siding are well known, it is more difficult to form a textured harder siding element, such as metal siding from a blank coil of material. However, such formation improves the overall quality of the siding on the house or other structure if it is seamless. Providing texture to the siding encounters special problems when the siding is a metal siding as the material is generally quite hard and more difficult to emboss or texture than other siding materials. The additional weight and special handling required for metal siding from a spool requires additional considerations for forming such panels from continuous metal material.  
           [0007]    In order to create an appearance similar to log structures, it is necessary to provide a textured and arcing profile to siding elements. Providing an arc to the element for a seamless siding system is especially difficult as the material must be formed by a portable device at the job site. In addition, the material with its arcing profile must be cut to length at the job site. In addition to putting the arc in the siding elements, the flanges for attaching to the structure and to the aligning and engaging adjacent upper and lower edges of siding elements is also needed. Providing flanges and texture and an arc all with a portable device is a special challenge for seamless metal siding.  
           [0008]    It can be seen that a new and improved metal siding system is needed that provides the aesthetically pleasing appearance of a log structure. In addition, such a system should provide a seamless siding system wherein the siding elements are cut to the required length needed for the structure at the job site. A feasible device and method for making such siding elements is needed. In addition to providing an arc and flange, such a device and system should impart texture for improved strength and aesthetics. The present invention addresses these as well as other problems associated with seamless metal siding having the appearance of logs.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention is directed to a seamless metal siding panel, and in particular to a panel having the appearance of log siding, as well as to a method and apparatus for making such panels.  
           [0010]    Each siding panel includes an arcing portion having an outer surface with a diameter substantially that corresponding to a log type home construction. In addition, the panel may be painted or otherwise have a color pattern to simulate wood grain and may be embossed with a wood grain texture. The panels preferably have a hook type portion on the lower edge of the panel and a flange for mounting and for engaging the hook type portion along an upper edge of the panel. The flange preferably includes mounting holes or other structure for mounting to the wall of a building. The panel preferably includes Styrofoam or other insulation beneath the arc portion, providing support to the arcing portion of the metal panels as well as improved durability and protection. The panels are seamless and cut to the desired length from a continuous coil of blank material at the job site.  
           [0011]    The device for forming the panels includes a rigid frame with a series of roller sets receiving the blank material and bending the material into the desired final shape. In addition, the rollers are driven by a motor and connected by chain type drives on sprockets about the ends of the shafts of the rollers to ensure that the rollers are all driven at substantially the same speed and to ensure alignment and proper feeding of the material.  
           [0012]    The blank material is first fed through a punch station wherein a roller includes a plurality of punches extending outward from the periphery of the roller at one end to form spaced apart holes along one edge of the blank material for mounting purposes. Following punching on the mounting holes, the material is fed through an embossing station wherein a pair of rollers engage the material and press a contoured surface onto the blank coil of metal. It has been found that embossing not only provides improved texture for hiding imperfections and for improved aesthetics resembling wood grain, but also provides unexpected improved support as compared to arced panels that are not embossed.  
           [0013]    The embossed blank passes through a series of roller pairs having complementary arcing peripheries. The roller sets include arc forming rollers that generally include upper rollers with a concave periphery, or have portions that include a concave periphery, and complementary lower rollers that have a complementary convex periphery. In addition, one of the rollers may include a periphery having an edge for bending the edge of the material into the bottom hook portion. The opposite edge of the rollers may include a periphery for forming the bend and a complementary hook of the flange. The rollers have generally successively smaller radiused arcing surfaces and generally have their edges moving closer together from the initial roller to the later encountered rollers. In a preferred embodiment, the last three arcing roller sets have identical profiles to ensure that the panels have the same profile. The contours of the flange forming portion change from roller set to roller set. In addition, intermediate the arc forming roller pairs are sets of rollers that further aid in guiding and tensioning the continuous coil of material and in forming the structure at the edges of the siding panels. The edges of these alternating rollers on their edges and their orientations change from roller to roller due to the changes in shape of the material as it progresses along the roller sets while aiding in gradually achieving the final structure of the siding panels.  
           [0014]    The panels are cut to length at a cutting station at the exit end of the rollers. The cutting station is preferably mounted on a sliding or other movable frame so that the desired length required for each siding panel can be easily achieved for optimum fit. The cutting station includes a die having an arcing upper edge generally conforming to the inner periphery of the arcing section of the siding panels. A pivoting blade includes a concave edge substantially complementary to the panels to provide a cleaner cut at the end of the panel sections.  
           [0015]    These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views:  
         [0017]    [0017]FIG. 1 shows a perspective view of a siding panel element according to the principles of the present invention;  
         [0018]    [0018]FIG. 2 shows a front elevational view of the siding panel shown in FIG. 1 cut to a predetermined length and abutting building structures at each end;  
         [0019]    [0019]FIG. 3 shows an end elevational view of siding panels shown in FIG. 1 joined to form building siding;  
         [0020]    [0020]FIG. 4 shows a side elevational view of an apparatus for making the siding panels shown in FIG. 1 according to the principles of the present invention;  
         [0021]    [0021]FIG. 5 shows a side elevational view of the frame portion of the apparatus shown in FIG. 4;  
         [0022]    [0022]FIG. 6 shows a top plan view of the frame portion of the apparatus shown in FIG. 4;  
         [0023]    [0023]FIG. 7 shows a side elevational view of the drive motor and reducer for the apparatus shown in FIG. 4;  
         [0024]    [0024]FIG. 8 shows an end view of a cutting station for the apparatus shown in FIG. 4;  
         [0025]    [0025]FIG. 9 shows a side elevational view of a pair of embossing rollers for the apparatus shown in FIG. 4;  
         [0026]    [0026]FIG. 10 shows a side elevational view of a first set of arcing rollers for the apparatus shown in FIG. 4;  
         [0027]    [0027]FIG. 11 shows a side elevational view of a first set of flange forming rollers for the apparatus shown in FIG. 4;  
         [0028]    [0028]FIG. 12 shows a side elevational view of a second set of arcing rollers for the apparatus shown in FIG. 4;  
         [0029]    [0029]FIG. 13 shows a side elevational view of a second set of flange forming rollers for the apparatus shown in FIG. 4;  
         [0030]    [0030]FIG. 14 shows a side elevational view of a third set of arcing rollers for the apparatus shown in FIG. 4;  
         [0031]    [0031]FIG. 15 shows a side elevational view of a third set of flange forming rollers for the apparatus shown in FIG. 4;  
         [0032]    [0032]FIG. 16 shows a side elevational view of a fourth set of arcing rollers for the apparatus shown in FIG. 4;  
         [0033]    [0033]FIG. 17 shows a side elevational view of a fourth set of flange forming rollers for the apparatus shown in FIG. 4;  
         [0034]    [0034]FIG. 18 shows a side elevational view of a fifth set of arcing rollers for the apparatus shown in FIG. 4;  
         [0035]    [0035]FIG. 19 shows a side elevational view of a sixth set of flange forming rollers for the apparatus shown in FIG. 4; and  
         [0036]    [0036]FIG. 20 shows a side elevational view of a set of lower edge forming rollers for the apparatus shown in FIG. 4.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0037]    Referring now to the drawings, wherein like reference numerals and letters indicate corresponding structure throughout the several views, in particular referring to FIG. 1, there is shown a seamless siding panel, generally designated  100 . The panel  100  includes an arcing outer surface  102  and a flange  104  along a first edge, as also shown in FIGS. 2 and 3. The upper flange  104  has a hook portion  108  formed therein that engages a complementary bottom hook  110  to join the panels  100  together to form extended siding covering the side of the building, as shown in FIG. 3. The bottom hook portion  110  may also include spaced apart weep holes  112  to allow water to drain from the panel  100 . The flange  104  includes spaced apart mounting holes  106  for attaching the panels  100  to the side of a building.  
         [0038]    Foam insulation, molded polystyrene, or other support material  114  substantially follows the interior of the arcing portion  102 . Referring again to FIGS. 1 and 2, the exterior of the arcing portion  102  preferably includes a wood grain type pattern and is embossed, as explained hereinafter, to give the arcing portion  102  the texture as well as the visual color pattern for log siding. It can be appreciated that the panels  100  may also be made without an embossed surface. In a preferred embodiment, the panels  100  are made from a continuous metal material  120 , such as treated steel or aluminum, or alloys, wound on a spool  280 , as shown in FIG. 4 and are cut to length to form a continuous, or seamless siding extending between building corners or other structure, as shown in FIG. 2 and as explained hereinafter. In this manner, seamless siding with surprising durability is obtained. Where it is impractical to cut the individual panels to required length, the panels  100  may be cut to a standard length, such as twelve feet and cut to the required length with shears at the job site. It has been found that an embossed siding panel  100  provides improved strength over panels just having an arc formed therein.  
         [0039]    Referring now to FIGS.  4 - 6 , there is shown a panel forming apparatus, generally designated  200 . The apparatus  200  supports a spool  280  of the blank siding material  120  and feeds it through a series of rollers to achieve the panel  100  shown in FIGS.  1 - 3  and is cut to length at an exit end at a cutting station  240 . The siding forming apparatus  200  is preferably placed on a trailer or is otherwise portable to the job sites, so that the siding panels  100  may be cut to the length that is required for each panel to provide a seamless siding system. The continuous coil of blank material  120  is fed to the siding forming apparatus  200  and through a series of roll forming rollers, as explained hereinafter. The roller sets  206 ,  208 ,  210 ,  212 ,  214 ,  216  and  218  bend the blank material  120  gradually to the arced configuration shown in FIGS.  1 - 3 . In addition, the flange  104  and other features of the panel  100 , including the embossed surface, are accomplished as the blank  120  passes through the series of rollers. Upon exiting the series of rollers, the material is passed through a cutting station  240  shown in FIG. 8. The cutting station  240  includes a blade  244  and handle  246  with a die  248  having an upper surface substantially conforming to the profile of the panel  100  providing improved support along the entire arc. The cutting station  240  is slidably mounted relative to the apparatus  200  on a framework  242  that telescopes to move the cutting station  240  to a desired position so that the siding may be cut to the length needed for the specific placement of each particular siding panel  100 . With this arrangement, there is no overlap or seams in the siding and a proper fit is obtained for each specific piece.  
         [0040]    Referring again to FIGS. 4 and 5, the siding forming apparatus  200  includes a framework  202 . The framework  202  supports bearing blocks  204 , shown in FIGS. 10, 12,  14 ,  16  and  18 . The bearing blocks  204  support the shafts for the forming rollers, as explained hereinafter. A motor  250  driving a reducer  252  by a belt  256 , as also shown in FIG. 7, drives the rollers. A chain  254  engages a sprocket to drive all the roller sets. The various rollers are connected by chains  260  at one end of the shafts to ensure that the rollers are driven at the substantially same speed. The various chains  260  also provide for driving all of the various shafts off a single motor. To provide tension at the other ends of the shafts, a chain  262  links two sets of rollers.  
         [0041]    Referring to FIG. 4, intermediate the roller sets forming the arcing surface, are roller sets  270 ,  272 ,  274 ,  276  and  278  along the hook edge of the rollers to maintain tension and to form the hook portion. A tension roller  268  is placed at the other edge of the panel  100  as it is being fed through the panel forming apparatus  200 . Other rollers  266  provide guidance along the material path to ensure that the coil of blank material  120  does not drift to the left or the right as it proceeds through the various rollers. The tension of the chains  258  and  260  provide for driving from a single motor  250  and also ensure that relative timing and rotation of the various rollers is maintained so that the blank material  120  is fed at a continuous, even rate and the material does not veer to one side or the other. This avoids jamming of the forming device  200  and malformed panels  100 .  
         [0042]    Referring to FIG. 6, the panel forming apparatus  200  includes arc forming roller sets  206 ,  208 ,  210 ,  212 ,  214 ,  216  and  218 . The arc forming roller sets  206 ,  208 ,  210 ,  212 ,  214 ,  216  and  218  generally have a concave upper roller A and a complementary convex lower roller B as explained hereinafter. Details of the lower rollers are omitted from FIG. 6 for improved clarity. In the early portion of the forming process, the upper rollers may be spaced apart so that the designation A 1  and A 2  is utilized while complementary lower rollers that are split apart are designated B 1  and B 2 . In addition, the rollers may include a flange forming portions designated  207 ,  209 ,  211 ,  213  and  215 . The rollers are generally mounted on shafts designated E with the number associated with each roller set. The shafts E extend out to the associated sprockets and are driven by the chains as explained above and shown in FIG. 5.  
         [0043]    In addition to the arc forming rollers, tensioning roller sets  270 ,  272 ,  274 ,  276  and  278  are interposed along the hook edge intermediate and alternating with the arc forming rollers. Along an opposite edge, tension rollers  266  and  268  guide the material  120  and maintain proper tension so that the panels are formed correctly. The roller sets  270 ,  272 ,  274 ,  276  and  278  and the opposite roller  268  may be mounted about an angled axis of rotation and may have angled edges in order to maintain contact and facilitate proper tension. As explained hereinafter, as the blank panel material  120  is fed through the various forming roller sets, the edges of the material  120  are bent and manipulated so that a horizontal roller may not be adequate to maintain proper pressure and alignment of the material. As the material  120  is formed while passing through each successive roller set, the angle and shape of the support needed changes, as can be appreciated by those skilled in the art.  
         [0044]    Prior to engaging the arc forming rollers, the material is first manipulated by passing through a punch station  220  having a punch roller  222 . The rollers  222  include a plurality of punch members  224  projected radially outward and spaced about the periphery of the roller  222  along one edge. As the material is fed through the panel forming device  200 , the punch roller  222  rotates and the punch members  224  form the mounting holes  106 , through the material shown most clearly in FIGS. 1 and 2.  
         [0045]    Referring now to FIG. 9, the panel material  120  proceeds to a set of embossing rollers  230 . The embossing roller set  230  includes an upper roller  230 A and a lower roller  230 B. The upper roller  230 A includes an embossing surface  232 A while the lower roller  230 B has a complementary outer embossing surface  232 B. As the material passes between the rollers  230 A and  230 B, the embossing surfaces  232 A and  232 B engage the panel and provide a texture simulating that of wood grain. It has been found that such embossing and additional texture provides added strength to the panels and resistance to holes, dents, etc. In addition, the embossed surface  120  of the panel aids in hiding such imperfections from the ordinary observer.  
         [0046]    Referring now to FIG. 10, after passing through the embossing roller set, the material engages the first arc forming rollers  206  on shafts  206 E. The arc forming rollers  206  include upper rollers  206 A 1  and  206 A 2  having concave surfaces, and complementary lower rollers  206 B 1  and  206 B 2  having convex surfaces. The upper rollers  206 A 1  and  206 A 2  are spaced apart as are the lower rollers  206 B 1  and  206 B 2  to form the initial arc forming to the arcing surface of the panel. In addition, at the one edge of the material, a flange forming portion  207  abuts the rollers  206 . The flange forming portion  207  includes an upper flange forming roller portion  207 A and a lower roller portion  207 B with complementary surfaces  207 C and  207 D imparting initial bends to the material  120  towards achieving the flange and hook as shown in FIGS.  1 - 3 .  
         [0047]    Referring to FIG. 11, after passing through the roller set  230 , the material is maintained in alignment by roller set  270  having an upper roller  270 A and lower roller  270 B engaging the edge of the material  120  corresponding to the bottom edge of the panel  100 . The rollers  270  form an initial bend in the material towards achieving the hook portion  110 .  
         [0048]    Following passing through roller set  270 , the blank material engages roller set  208  on shafts  208 E. Roller set  208  includes upper rollers  208 A 1  and  208 A 2  and lower complementary rollers  208 B 1  and  208 B 2 . The upper rollers  208 A 1  and  208 A 2  include a concave arcing surface while the corresponding lower rollers  208 B 1  and  208 B 2  have a convex surface with a complementary arc. The roller set  208  is slightly more arced than the roller set  206  shown in FIG. 10 so that additional arcing is performed on the material  120 . In addition, roller  208 A 1  includes an outer flange that continues to bend the lower edge and direct it downward for forming the lower hook portion. At the opposite end of the rollers is an additional flange forming portion  209  including an upper portion  209 A on roller  208 A 2  and a lower flange forming portion  209 B on lower roller  208 B 2 . Surface  209 C includes a slightly more exaggerated channel with a complementary peak  209 D extending into the channel  209 C. This structure bends the flange to a greater degree than continues from the surfaces shown as shown in FIG. 10.  
         [0049]    Referring to FIG. 13, following passage through roller set  208 , the edge of the material corresponding to the lower edge of the panel engages roller set  272  including a complementary first roller  272 A and a complementary second roller  272 B. The edges of the rollers  272 A and  272 B engage an angled edge of the material extending back inward to place a greater bend to the hook portion.  
         [0050]    Referring to FIG. 14, roller set  210  is engaged following passage through roller set  272 . Roller set  210  includes an upper roller set  210 A having rollers  210 A 1  on upper shaft  210 E and  210 A 2  and lower roller set  210 B including lower rollers  210 B 1  and  210 B 2  on lower shaft  210 E. Rollers  210 A 1  and  210 A 2  have concave arcing portions while rollers  210 B 1  and  210 B 2  have complementary convex portions. In addition, the edge of rollers  210 A 1  and  210 B 1  are arranged so that the partially formed hook portion  110  of the panel is fed beyond the end of convex portion of roller  210 B 1  and maintain the material in alignment. At the opposite ends of the rollers on  210 A 2  and  210 B 2  is a flange forming portion  211 . Flange forming portion  211  includes an upper forming portion  211 A on roller  210 A 2  and a lower portion  211 B on lower roller  210 B 2 . The portion  211 A includes a forming surface  211 C including a channel with a nearly horizontal side and portion  211 B includes a complementary peak extending into the channel to continue forming the flange portion of the material.  
         [0051]    Referring to FIG. 15, following passage through roller set  210 , the material engages roller set  274  including roller set  274 A and  274 B. Roller set  274  includes an angled edge maintaining and bending the lower edge of the material further forming the hook portion.  
         [0052]    Referring to FIG. 16, the material next engages a roller set  212  including upper rollers  212 A and lower rollers  212 B on shaft  212 E. Upper rollers  212 A include a first roller  212 A 1  and  212 A 2  while lower rollers  212  include complementary rollers  212 B 1  and  212 B 2 . The upper rollers  212 A have a concave forming surface while the lower rollers  212 B include a complementary convex forming surface. In addition, roller  212 B 1  includes an outer edge providing a space for the hook portion  110  of the panel. At the opposite end of the rollers, is an additional flange forming station  213  including first portion  213 A and second portion  213 B. Forming surfaces  213 C and  213 D provide realignment of the hook portion in the flange of the material.  
         [0053]    Following passage through roller set  212 , the material engages roller  276 . Roller  276  includes an angled edge having an upper and lower portion providing a triangular profile and added bend to the hook portion of the material.  
         [0054]    Referring now to FIG. 18, the material next engages roller set  214 . Roller set  214  includes upper concave rollers  214 A and lower complementary convex rollers  214 B on shafts  214 E. Upper roller set  214 A includes a first roller  214 A 1  and second roller  214 A 2  while lower roller set includes a first roller  214 B 1  and lower roller  214 B 2 . The upper rollers  214 A 1  and  214 A 2  abut one another as do the lower rollers  214 B 1  and  214 B 2 . The roller set  214  has a slightly greater arc than the preceding rollers  212 . At a lower edge of the material, the roller  214 A 1  extends beyond the convex surface of roller  214 B 1  to provide space for the hook portion  110  of the material. At the opposite edge, the flange forming portion  215  includes an upper portion  215 A on roller  214 A 2  while the lower portion  215 B extends from roller  214 B 2 . A forming surface  215 C includes a gap providing for the hook portion of the flange while the lower surface  215 D is substantially planar.  
         [0055]    Referring to FIG. 19, the material then passes against roller  278 . Roller  278  includes an engaging surface having an angled upper portion and a horizontal lower portion that engages the lower edge of the material.  
         [0056]    After passing roller  278 , the material engages a roller set  216 , as shown in FIG. 6. Roller set  216  has a configuration substantially the same as roller set  214  as forming at this stage is to maintain the shape and ensure that the proper arc is formed. However, the opposite edge engages roller set  268  including upper roller  268 A and lower roller  268 B engaging and providing final positioning of the flange portion while maintaining the proper form and alignment and fine. Following passage through roller set  216 , the final roller set  218  also has the same configuration and arcing surface as roller sets  214  and  216 . Tension rollers  266  maintain the material in alignment and ensure the flange is properly oriented.  
         [0057]    When the panel has been formed into the blank with the desired profile as shown in FIGS.  1 - 3 , the panels are then cut to the predetermined length at the cutting station  240  shown in FIG. 8. The cutting station  240  is mounted on the sliding frame, as shown in FIG. 4. As shown in FIG. 8, the cutting station  240  includes die  248  substantially conforming to the arc of the panel. The cutting station includes a pivoting blade  244  having an arcing surface that slices through the panel at the predetermined length. A handle  246  extends outward from the end of the blade  244  to provide mechanical advantage during the cutting motion for easily slicing through the panel material. The complementary arcing surfaces that substantially conform to the arc of the panels ensures that a clean cut is made. As the cutting station  240  is slidably mounted, the desired length is obtained so that a proper fit may be made to meet the needs for each siding panel.  
         [0058]    It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Summary:
A siding system includes panels having a facing element with a convex front face portion. A first connecting portion extending along an upper edge and a second connecting portion at a lower edge is adapted to engage the first connecting portion of an adjacent lower siding panel. Mounting holes at a top edge of the facing element provide for mounting the siding panel to a vertical surface. A support element, such as foam insulation attaches to a rear surface of the facing element. A machine for making the metal siding panels has a feeder and multiple roller sets. First ones of the rollers have a concave portion and complementary second ones of the rollers have a convex portion. The concave portion first roller set has a larger radius profile than the last roller set to roll form the siding from a coil of blank material. Bending rollers form the mounting structure of the panels. Embossing rollers forming an embossed pattern on the face of the panels.