Patent Publication Number: US-2023138257-A1

Title: Frame for a wall panel, wall panel, and method of manufacture

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 17/150362, filed Jan. 15, 2021, which is a continuation of U.S. patent application Ser. No. 16/368161, filed Mar. 28, 2019, which claims the benefit of priority of U.S. Provisional Patent Application no. 62/650383, filed Mar. 30, 2018, each of which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     1. Field of the Disclosure 
     The present disclosure relates generally to siding, for example, suitable for covering a wall surface. The present disclosure relates more particularly to a support frame for a wall panel. 
     2. Technical Background 
     There are many ways to cover the exterior façade or interior walls of building structures, such as houses. While wall coverings of natural products were often traditionally used, many modern structures are covered using a manufactured product that is polymer or ceramic based. These manufactured siding products can be made to replicate natural products (or other manufactured products, such as brick), while offering advantages over their natural counterparts. In particular, manufactured siding products can provide advantages in performance and cost in comparison with other methods of covering exterior walls. Further, manufactured siding products can be designed for ease of installation. 
     A wide variety of different manufactured siding products are available for covering walls. Often these products include an exterior face intended to be viewable and an attachment structure for securing the product to a wall substrate. In some cases, the siding products are made in a single piece where the same material forms both the visible exterior face and the attachment structure. In other cases, the structure that forms the visible face is of a different material than the attachment structure. For example, some products include a frame that extends about the perimeter of the structure forming the visible face and holds the visible face against the substrate wall. 
     The present inventors have recognized that the frames used in such siding products are often manufactured using an excess of material. In particular, the inventors have unexpectedly determined that portions of the frame that greatly add to the material needed for manufacturing are unnecessary or add little to the function of the frame. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect, the present disclosure provides a frame for a wall panel, the frame comprising:
         a support strip extending in a lateral direction, the support strip including a first end and a second end; and   a row of columns extending in a first direction from the support strip, each column including a proximal end attached to the support strip and a free distal end, the row of columns including:
           a first column disposed at a first end of the row of columns and laterally offset from the first end of the support strip, and   a second column disposed at a second end of the row of columns and laterally offset from the second end of the support strip.   
               

     In another aspect, the disclosure provides a wall panel comprising:
         a panel body; and   a frame partially embedded in the panel body, the frame comprising:
           a support strip extending in a lateral direction, the support strip including a first end and a second end; and   a row of columns extending in a first direction from the support strip, each column including a proximal end attached to the support strip and a free distal end, the row of columns including:
               a first column disposed at a first end of the row of columns and laterally offset from the first end of the support strip, and   a second column disposed at a second end of the row of columns and laterally offset from the second end of the support strip.   
               
               

     In another aspect, the disclosure provides a method of manufacturing a frame for a wall panel, the method comprising:
         positioning a first section of a metal sheet in a stamping press;   conducting a first stamping operation using the stamping press to form a first frame segment in the first section of the metal sheet, the first frame segment including a portion of a support strip and a column extending from the support strip;   pitching the metal sheet forward so as to position a second section of the metal sheet in the stamping press;   conducting a second stamping operation using the stamping press to form a second frame segment in the second section of the metal sheet, the second frame segment including another portion of the support strip and another column extending from the support strip, wherein the second frame segment is adjacent to the first frame segment so as to form a line of columns extending from the support strip; and   cutting the frame segments from the metal sheet so as to form a frame according to the disclosure.       

     Additional aspects of the disclosure will be evident from the disclosure herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure. 
         FIG.  1    is a schematic perspective view of a frame in accordance with an embodiment of the disclosure; 
         FIG.  2    is a schematic back view of a section of the frame of  FIG.  1   ; 
         FIG.  3    is a schematic top perspective view of a section of the frame of  FIG.  1   ; 
         FIG.  4    is a schematic side perspective view of a section of the frame of  FIG.  1   ; 
         FIG.  5    is a schematic perspective view of a frame in accordance with another embodiment of the disclosure; 
         FIG.  6    is a schematic perspective view of a frame in accordance with another embodiment of the disclosure; 
         FIG.  7    is a schematic perspective view of a frame in accordance with another embodiment of the disclosure; 
         FIG.  8    is a schematic perspective view of a wall panel in accordance with an embodiment of the disclosure; 
         FIG.  9    is a schematic side view of the wall panel of  FIG.  8    rotated onto its front face; 
         FIG.  10    is a schematic perspective rear view of the wall panel of  FIG.  8   ; 
         FIG.  11    is a schematic top view of a fabrication method according to an embodiment of the disclosure; 
         FIG.  12    is a schematic top view of a fabrication method according to another embodiment of the disclosure; 
         FIG.  13    is a perspective view of a frame according to an embodiment of the disclosure; 
         FIG.  14    is a front view of the frame of  FIG.  13   ; 
         FIG.  15    is a back view of the frame of  FIG.  13   ; 
         FIG.  16    is a right side view of the frame of  FIG.  13   ; 
         FIG.  17    is a left side view of the frame of  FIG.  13   ; 
         FIG.  18    is a top view of the frame of  FIG.  13   ; 
         FIG.  19    is a bottom view of the frame of  FIG.  13   ; 
         FIG.  20    is a perspective view of a frame according to another embodiment of the disclosure; 
         FIG.  21    is a front view of the frame of  FIG.  20   ; 
         FIG.  22    is a back view of the frame of  FIG.  20   ; 
         FIG.  23    is a right side view of the frame of  FIG.  20   ; 
         FIG.  24    is a left side view of the frame of  FIG.  20   ; 
         FIG.  25    is a top view of the frame of  FIG.  20   ; 
         FIG.  26    is a bottom view of the frame of  FIG.  20   ; 
         FIG.  27    is a perspective view of a frame according to another embodiment of the disclosure; 
         FIG.  28    is a front view of the frame of  FIG.  27   ; 
         FIG.  29    is a back view of the frame of  FIG.  27   ; 
         FIG.  30    is a right side view of the frame of  FIG.  27   ; 
         FIG.  31    is a left side view of the frame of  FIG.  27   ; 
         FIG.  32    is a top view of the frame of  FIG.  27   ; 
         FIG.  33    is a bottom view of the frame of  FIG.  27   ; 
         FIG.  34    is a perspective view of a frame according to another embodiment of the disclosure; 
         FIG.  35    is a front view of the frame of  FIG.  34   ; 
         FIG.  36    is a back view of the frame of  FIG.  34   ; 
         FIG.  37    is a right side view of the frame of  FIG.  34   ; 
         FIG.  38    is a left side view of the frame of  FIG.  34   ; 
         FIG.  39    is a top view of the frame of  FIG.  34   ; 
         FIG.  40    is a bottom view of the frame of  FIG.  34   ; 
         FIG.  41    is a perspective view of sections of a frame according to another embodiment of the disclosure; 
         FIG.  42    is a front view of the frame sections of  FIG.  41   ; 
         FIG.  43    is a back view of the frame sections of  FIG.  41   ; 
         FIG.  44    is a right side view of the frame sections of  FIG.  41   ; 
         FIG.  45    is a left side view of the frame sections of  FIG.  41   ; 
         FIG.  46    is a top view of the frame sections of  FIG.  41   ; 
         FIG.  47    is a bottom view of the frame sections of  FIG.  41   ; 
         FIG.  48    is a perspective view of sections of a frame according to an embodiment of the disclosure; 
         FIG.  49    is a front view of the frame sections of  FIG.  48   ; 
         FIG.  50    is a back view of the frame sections of  FIG.  48   ; 
         FIG.  51    is a right side view of the frame sections of  FIG.  48   ; 
         FIG.  52    is a left side view of the frame sections of  FIG.  48   ; 
         FIG.  53    is a top view of the frame sections of  FIG.  48   ; 
         FIG.  54    is a bottom view of the frame sections of  FIG.  48   ; 
         FIG.  55    is a perspective view of a frame according to another embodiment of the disclosure; 
         FIG.  56    is a front view of the frame of  FIG.  55   ; 
         FIG.  57    is a back view of the frame of  FIG.  55   ; 
         FIG.  58    is a right side view of the frame of  FIG.  55   ; 
         FIG.  59    is a left side view of the frame of  FIG.  55   ; 
         FIG.  60    is a top view of the frame of  FIG.  55   ; 
         FIG.  61    is a bottom view of the frame of  FIG.  55   ; 
         FIG.  62    is a perspective view of a frame according to another embodiment of the disclosure; 
         FIG.  63    is a front view of the frame of  FIG.  62   ; 
         FIG.  64    is a back view of the frame of  FIG.  62   ; 
         FIG.  65    is a right side view of the frame of  FIG.  62   ; 
         FIG.  66    is a left side view of the frame of  FIG.  62   ; 
         FIG.  67    is a top view of the frame of  FIG.  62   ; 
         FIG.  68    is a bottom view of the frame of  FIG.  62   ; 
         FIG.  69    is a perspective view of a frame according to another embodiment of the disclosure; 
         FIG.  70    is a front view of the frame of  FIG.  69   ; 
         FIG.  71    is a back view of the frame of  FIG.  69   ; 
         FIG.  72    is a right side view of the frame of  FIG.  69   ; 
         FIG.  73    is a left side view of the frame of  FIG.  69   ; 
         FIG.  74    is a top view of the frame of  FIG.  69   ; 
         FIG.  75    is a bottom view of the frame of  FIG.  69   ; 
         FIG.  76    is a perspective view of a frame according to another embodiment of the disclosure; 
         FIG.  77    is a front view of the frame of  FIG.  76   ; 
         FIG.  78    is a back view of the frame of  FIG.  76   ; 
         FIG.  79    is a right side view of the frame of  FIG.  76   ; 
         FIG.  80    is a left side view of the frame of  FIG.  76   ; 
         FIG.  81    is a top view of the frame of  FIG.  76   ; and 
         FIG.  82    is a bottom view of the frame of  FIG.  76   . 
         FIG.  83    is a perspective view of sections of a frame according to another embodiment of the disclosure; 
         FIG.  84    is a front view of the frame sections of  FIG.  83   ; 
         FIG.  85    is a back view of the frame sections of  FIG.  83   ; 
         FIG.  86    is a right side view of the frame sections of  FIG.  83   ; 
         FIG.  87    is a left side view of the frame sections of  FIG.  83   ; 
         FIG.  88    is a top view of the frame sections of  FIG.  83   ; 
         FIG.  89    is a bottom view of the frame sections of  FIG.  83   ; 
         FIG.  90    is a perspective view of sections of a frame according to another embodiment of the disclosure; 
         FIG.  91    is a front view of the frame sections of  FIG.  90   ; 
         FIG.  92    is a back view of the frame sections of  FIG.  90   ; 
         FIG.  93    is a right side view of the frame sections of  FIG.  90   ; 
         FIG.  94    is a left side view of the frame sections of  FIG.  90   ; 
         FIG.  95    is a top view of the frame sections of  FIG.  90   ; and 
         FIG.  96    is a bottom view of the frame sections of  FIG.  90   . 
     
    
    
     DETAILED DESCRIPTION 
     As described above, the present inventors have recognized that frames used in certain siding products use are manufactured using an excess of material. Therefore, the present inventors have developed a frame that is produced from significantly less material without sacrificing performance. 
     Accordingly, one aspect of the disclosure is a frame for a wall panel. The frame comprises: a support strip extending in a lateral direction, the support strip including a first end and a second end; and a row of columns extending in a first direction from the support strip, each column including a proximal end attached to the support strip and a free distal end, the row of columns including: a first column disposed at a first end of the row of columns and laterally offset from the first end of the support strip, and a second column disposed at a second end of the row of columns and laterally offset from the second end of the support strip. 
     Such a frame is shown in perspective view in  FIG.  1   . Frame  110  includes a support strip  120  and a plurality of columns  140  extending in a first direction  142  from support strip  120 . Frame  110  is configured for use with a wall panel where support strip  120  is positioned to extend horizontally and columns  140  extend vertically. In other embodiments, the directions of extension of the support strip and columns differ. In some embodiments, the support strips and columns are not perpendicular. For example, in one embodiment the support strip is configured to be attached to a wall substrate at an angle to horizontal in order to match the top of a gable adjacent to the roof. Vertical columns extending from such a support strip are at a non-perpendicular angle to the support strip. 
     Each of columns  140  is attached to the support strip at an upper end  144  that is proximal to support strip  120 . In contrast, the distal lower end  146  of each column is free. Thus, each of the columns has a cantilevered attachment to the support strip, where the free end is left unsupported. The term free, as used herein, refers to the lack of any connection or cross support of the lower half of each column. Thus, frame  110  does not include a lower horizontally extending support structure providing structural support to any of the columns  140 . It should be understood that reference to the lower end of the columns being free is relative only to the frame itself, and that the columns may be secured with respect to one another by another structure, for example by virtue of being attached to a substrate or partially embedded in a panel body. 
     Support strip  120  provides a structural connection for columns  140  and is also configured for attaching the frame to a substrate, as explained in more detail below. Columns  140  are provided in a row that extends across a portion of support strip  120  with the ends of the support strip  120  extending further laterally than the respective column at the end of the row. Thus, column  148  at one end of the row of columns is inwardly laterally offset from the first end  122  of support strip  120 , and column  150  at the other end of the row is inwardly laterally offset from the second end  124  of support strip  120 . 
     Embodiments of the frame include a variety of different sizes. The size can vary depending upon the application, as will be understood by those of ordinary skill in the art. In certain embodiments as otherwise described herein, the width of the frame is in a range of 6 to 55 inches, e.g., 8 to 48 inches, e.g., about 10 inches, e.g., about 13 inches, e.g., about 23 inches, e.g., about 46 inches. The width of the frame is dependent upon the width of the columns, the space between the columns, and the number of columns. Thus, in certain systems of wall panels, frames having the same column width and column spacing have different sizes based on the number of columns used in the frame. In certain embodiments as otherwise described herein, a height of each column is in a range from 4 to 14 inches, e.g., from 5 to 12 inches, e.g., from 6 to 9 inches. 
     In certain embodiments as otherwise described herein, the frame is formed of a cut and shaped metal sheet. Thus, as explained in more detail below, embodiments of the frame can be produced by metal stamping, where a metal stamping press shapes the frame from a metal sheet and cuts the metal sheet to form the edges of the frame. The term metal sheet, as used herein, is not limited to any particular thickness and may include materials conventionally referred to as metal foil, sheet metal, metal plate or metal strips. 
     In certain embodiments as otherwise described herein, the frame consists of a plurality of identical segments in a line, each of the segments including one of the columns and a portion of the support strip. For example, frame  110  includes six identical segments  130  without any additional perimeter structure or variation from one segment to the next. This repeating pattern allows for efficient manufacture of the frame using a small machine, as explained in more detail below. A detailed view of three of the segments of frame  110  is shown in  FIG.  2   . 
     In certain embodiments as otherwise described herein, each of the segments includes a single column. Further, in some embodiments, each column is disposed at the lateral center of the respective segment. For example, segments  130  of frame  110  each include a single column  140  and a section  126  of support strip  120 . Each column  140  is centered on the corresponding segment  130 , such that a portion of support strip  120  extends past the column  140  within segment  130 . This extension beyond the column defines the spacing of the columns within frame  110  and also produces the corresponding offset at end columns  148  and  150  ( FIG.  1   ). With this configuration, the segments are in the form of a T-shape. In other embodiments, each segment has more than one column. 
     In certain embodiments as otherwise described herein, the width of each segment is in a range from 3 to 6 inches, e.g., from 3.5 to 5 inches. The width of the segment can, of course, depend on the number of columns in the particular segment. Thus, in some embodiments a segment with two columns of a particular size may be larger than a segment with only one column of the same size. For example, in some embodiments, each segment has two columns and a width in a range of 6 to 12 inches, e.g., 7 to 10 inches. 
     In certain embodiments as otherwise described herein, the support strip includes a contact surface that defines a first plane. For example, as illustrated in the detailed top perspective view of  FIG.  3   , the rear surface  128  of support strip  120  forms a contact surface for mounting the frame against a substrate wall. Contact surface  128  is substantially flat in order to match the contour of a wall, and thus surface  128  defines a plane that might coextend with the outer surface of a corresponding wall. 
     In certain embodiments as otherwise described herein, each column includes a column body extending away from the support strip. Further, in some embodiments, each column body lies in a second plane that is parallel to the first plane. For example, columns  140  each include a generally flat column body  152  extending downward and away from support strip  120 . The flat surface of column bodies  152  lie in a plane that is parallel to but offset from the plane defined by contact surface  128 . Indeed, because the column bodies are flat, they define the plane that is parallel and offset from the plane of the contact surface. 
     Embodiments of the frame include various features to improve the structural integrity of the components of the frame. As will be understood by a person of ordinary skill in the art, a variety of combinations of these features can be used to improve the stiffness of the parts of the frame. In certain embodiments as otherwise described herein, the lateral sides of each column body include stiffening side bends. For example, column bodies  152  include stiffening side bends  154  that run along the length of the body  152 . The stiffening side bends  154  are included on each side of column bodies  152 . In other embodiments, a side bend is included on only one side of the column body. The side bends can be effective in adding stiffness to the column bodies with only a limited depth. In some embodiments, the side bends extend no more than ¼ inch from the plane defined by the column body. 
     In certain embodiments as otherwise described herein, each column includes a connecting flange that couples the column body to the support strip, and the connecting flange extends in a direction that is at an angle to the first plane. For example, each of columns  140  includes connecting flange  156  that connects column body  152  to the support strip  120 . In frame  110 , connecting flange  156  is disposed perpendicular to the plane defined by contact surface  128 . Likewise, connecting flange  156  is also perpendicular to the plane of column bodies  156 . In other embodiments, the connecting flange is disposed at an angle that is shallower than perpendicular to the support strip. 
     Embodiments of the connecting flange are configured to rigidly hold the column body to the support strip without an excess amount of material. In certain embodiments as otherwise described herein, the connecting flange includes a proximal bend adjacent to the support strip, and a stiffening gusset is disposed in the proximal bend. Likewise, in certain embodiments, the connecting flange includes a distal bend adjacent to the respective column body, and a stiffening gusset is disposed in the distal bend. For example, connecting flange  156  of column  140  of frame  100  is coupled to support strip  120  by a bend  158  at the proximal end of the connecting flange. Likewise, connecting flange  156  is coupled to column body  152  by a bend  160  at the distal end of the connecting flange. The bends at the proximal and distal ends of connecting flange provide a simple connection between support strip  120 , connecting flange  156 , and column body  152  and allow the component to be fabricated from a single metal sheet. However, in some embodiments, as in frame  110 , the bends do not rigidly hold the column body to the support strip. Accordingly, proximal bend  158  includes a gusset  162  between connecting flange  156  and support strip  120 , and distal bend  160  includes two gussets  164  between column body  152  and connecting flange  156 . In other embodiments, the number and position of the gussets in each of the bends may differ, as will be appreciated by those of ordinary skill in the art. 
     In certain embodiments as otherwise described herein, the connecting flange includes at least one locating tab that extends toward the support strip. Such a locating tab may be configured to position the frame into a mold when a panel body is molded onto the frame. For example, the detailed perspective view of a portion of frame  110  in  FIG.  4    shows locating tabs  166  extending upward from each side of connecting flange  156 . Locating tabs  166  extend in a direction opposite to the direction of extension of the columns  140 , which places the column bodies  152  further toward the vertical center of a corresponding panel body when it is molded onto the frame. Further, the locating tabs  166  provide consistency in the placement of frame  110  within the mold so that each frame is. Accordingly, locating tabs  166  add stability to the panel as a whole and also provide consistency of the dimensions of two panels made with the same frame and in the same mold. 
     In certain embodiments as otherwise described herein, the locating tab is attached to a side of the connecting flange by a bend. For example, locating tabs  166  are formed from the same metal sheet as the rest of frame  110  and are bent upward from the adjacent connecting flange. As a result, locating tabs  166  lie in a plane that is perpendicular to both column body  152  and connecting flange  156 . 
     While frame  110  shows column bodies  152  being attached to the support strip by connecting flange  156 , in some embodiments the frame does not include a connecting flange. For example, in some embodiments, the column bodies are attached to the support strip directly. In certain embodiments as otherwise described herein, the support strip has a section that bends away from the contact surface and the columns are attached to this bent section. Accordingly, the columns can be offset from the support strip and lie in the second plane without the columns including a connecting flange. For example, in certain embodiments the support strip includes a cross bar disposed in a second plane, and each column is connected to the cross bar. 
     An example of such a frame is shown in  FIG.  5   . Frame  510  includes a support strip  520  that has a contact surface  528  defining a first plane and a cross bar  525  defining a second plane that is offset from the first plane. The cross bar  525  is connected to the contact surface  528  by a lateral section  527  of support strip  520 . Columns  540  extend down from cross bar  525  of support strip  520  at regular intervals. Locating tabs  566  extend up from cross bar  525 . In certain embodiments, the locating tabs extending from the cross bar are used to position the frame within a mold at the upper end of the mold. Accordingly, the locating tabs define the position of the upper edge of the panel body in such embodiments when the panel body is formed in a mold. 
     In certain embodiments as otherwise described herein, each column includes a positioning brace disposed at a distal end thereof. The positioning brace is configured to support the frame against a substrate wall and thereby allow portions of the frame to project away from the substrate wall. For example, each of the columns  140  in frame  110 , shown in  FIGS.  1 - 4    includes a positioning brace  168  disposed at the lower distal end of the column  140 . Positioning brace  168  provides support for frame  110 , so that sections of the frame, such as column bodies  152  can be offset from the substrate wall. 
     In certain embodiments as otherwise described herein, the support strip includes a contact surface that defines a first plane, and each positioning brace includes a foot that lies on the first plane. For example, the rear surface of support strip  120  includes contact surface  128 , as described in further detail above, which is configured to support the frame against the substrate wall when the frame is attached thereto. The contact surface  128  is configured to lie against the substrate wall and thereby defines a first plane where such a wall lies. Similarly, positioning brace  168  includes foot  169 , which lies on the first plane in order to also support the frame against the substrate wall. Specifically, foot  169  includes a flat contact surface that lies on the first plane. 
     In certain embodiments as otherwise described herein, each column includes a column body that lies in a second plane that is parallel to the first plane, and each positioning brace extends from a corresponding column body to the first plane. For example, as explained above, column bodies  152  are flat and lie in a second plane that is parallel to the first plane and offset therefrom. As a result, the column bodies  152  form a planar surface that is projected out from the first plane and any substrate wall on which the frame is supported. To provide the supporting characteristic of positioning brace  168 , it extends from the respective column body  152  back toward the first plane where foot  169  is located. 
     In certain embodiments as otherwise described herein, the positioning brace includes a locating shelf. The locating shelf is configured to orient the frame in a proper location when the frame is set in a mold for molding a panel body thereon. Thus, the locating shelf serves a similar function to the above-described locating tabs. In certain embodiments, the locating shelf is disposed between the foot of the positioning brace and the column body. For example, positioning brace  168  of each column includes locating shelf  170  disposed between foot  169  and column body  152  of the respective column. Accordingly, locating shelf  170  lies between the first and second planes and provides positioning of the frame toward the top of the corresponding mold when the panel body is molded to the frame, as described in more detail below. Like the other components of frame  110 , positioning brace is formed of bent metal sheet and is connected to column body  152  by a bend. 
     In certain embodiments as otherwise described herein, each column includes at least one stand-off leg disposed between the proximal and distal end thereof. Similar to the positioning brace, the standoff leg is configured to support the frame against a substrate wall allowing portions of the frame to project away from the substrate wall. For example, each column  140  of frame  110  includes three standoff legs  172 . In some embodiments, the frame includes up to four standoff legs, or more. As explained in more detail below, the combination of connecting flange  156 , positioning brace  168 , and standoff legs  172  provide a rain screen for the assembled siding panel. While in frame  110  the columns all include the same number of standoff legs  172 , in other embodiments different columns within the frame include different numbers of standoff legs. For example, in some embodiments, the end columns at the end of the row include three standoff legs, while the columns in the middle of the row include two. 
     In certain embodiments as otherwise described herein, each column includes an aperture corresponding to each respective stand-off leg. The aperture in the column body provides a strong connection between the frame and any panel body attached thereto. For example, a mold material of the panel body may pass through the aperture thereby locking the column in place once the material hardens. The aperture in the column also provides material for the standoff leg. Specifically, the standoff leg can be formed from material bent from the column, rather than adding a component to the column. For example, each of standoff legs  172  corresponds to an associated aperture  174 . Three sides of the aperture are cut from the column body  152  and the standoff legs are bent backward from the aperture. In other embodiments, the standoff legs are separate components that are attached to the respective columns. 
     In certain embodiments, one or more of the columns include an aperture that is not associated with a standoff leg. For example, in some embodiments, each column includes one to four apertures, a portion of which are associated with a corresponding standoff leg. In certain embodiments, the column includes fingers similar to the standoff legs that extend outward from the column body to a lesser extent than the standoff legs. In some embodiments, the fingers are configured to be entirely embedded within the panel body. The fingers may enhance the connection between the frame and the panel body. 
     In certain embodiments as otherwise described herein, each stand-off leg extends from a lower or upper edge of the corresponding aperture. Such a configuration allows the standoff leg to be bent from the column without the depth of the standoff leg and the width of the column being dependent upon one another. In contrast, in embodiments where the standoff legs are bent from a side edge of the apertures, the width of the columns is closely associated with the depth of the standoff legs, such that a wider column is needed for a longer standoff leg. With the standoff legs extending from the upper or lower edges of the aperture, the columns may be thinner allowing for adequate room between two columns for manufacturing a corresponding part, as explained in more detail below. For example, standoff legs  172  are bent from the lower edge  176  of aperture  174 . Accordingly, standoff legs  172  are of sufficient depth to reach the plane of the contact surface  128  of support strip  120 , and the distance between the columns  140  is wider than the width of each column. 
     In certain embodiments as otherwise described herein, the support strip includes a contact surface that defines a first plane, and each stand-off leg includes a foot that lies in the first plane. For example, the rear surface of support strip  120  includes contact surface  128  that supports the frame against a substrate wall, as described above. The contact surface defines a first plane and standoff legs  172  each include a foot  178  that lies on the first plane in order to also support the frame against the substrate wall. Specifically, foot  178  includes a flat contact surface that lies on the first plane. 
     In certain embodiments as otherwise described herein, each column includes a column body that lies in a second plane that is parallel to the first plane, and each stand-off leg extends from a corresponding column body to the first plane. For example, like positioning brace  168 , standoff legs  172  extend from the column body  152  at the second plane back toward the first plane where foot  178  lies. 
     In certain embodiments as otherwise described herein, the support strip includes a fastening band configured to attach the frame to a substrate. The fastening band, which may be configured as a nailing strip or fastening hem, as will be appreciated by those of ordinary skill in the art, is configured to attach the frame to the substrate wall. In some embodiments, the fastening band includes openings for receiving a mechanical fastening element, such as a screw or nail. For example, support strip  120  includes fastening strip  132  at the upper end of frame  110 . The fastening strip  132  includes a row of openings  136  for receiving mechanical fasteners. In some embodiments the fastening strip is integrally formed with the rest of the frame. For example, in some embodiments the fastening strip is part of a metal sheet that forms other components of the frame. In other embodiments, the fastening strip is attached at the upper end of the support strip. In such embodiments the fastening strip can be made of a different material than the other parts of the frame. 
     In certain embodiments as otherwise described herein, the support strip includes at least one stiffening rib. For example, support strip  120  includes a series of stiffening ribs  134  running across the width of the strip. In other embodiments, the support strip includes a single stiffening rib that runs across the width of the frame. 
     In certain embodiments as otherwise described herein, the frame includes indicia configured to assist in positioning the frame. For example, in some embodiments the support strip includes indicia to assist with installation or lateral spacing between frames in adjacent rows. In some embodiments, the indicia are correlated to the fastener openings. In some embodiments, the indicia are in the form of a ruler. For example, the indicia may be in the form of a ruler along a top edge of the support strip. 
     In certain embodiments as otherwise described herein, the frame includes at least two columns, e.g., at least 3 columns, e.g., 6 columns. For example, frame  110  includes 6 columns. Other arrangements are also possible. 
     In certain embodiments the ends of the support strip include chamfered corners. For example, the ends  122 ,  124  of support strip  120  of frame  110  include upper and lower chamfered corners. In other embodiments, the ends of the support strip of the frame include other configurations. For example, in some embodiments, the ends have rounded corners. Such an embodiment is shown in  FIG.  6   . In particular, frame  610  includes a support strip  620  that includes ends  622 ,  624  with rounded corners. In other embodiments, the ends of the support strip are cut straight. For example, frame  710 , shown in  FIG.  7    includes a support strip  720  with ends  722 ,  724  that are cut straight and have sharp corners. Still, in other embodiments the shape of the support strip may have other configurations. 
     Another aspect of the disclosure provides a wall panel comprising: a panel body; and a frame partially embedded in the panel body. The frame comprises a support strip extending in a lateral direction and a row of columns extending in a first direction from the support strip. The support strip includes a first end and a second end. Each column includes a proximal end attached to the support strip and a free distal end. The row of columns includes a first column disposed at a first end of the row of columns and laterally offset from the first end of the support strip and a second column disposed at a second end of the row of columns and laterally offset from the second end of the support strip. Such a wall panel is shown in  FIGS.  8  to  10   . Wall panel  100  includes a panel body  180  and frame  110  partially embedded in the panel body  180 . The panel body  180  includes a front face  182 , a rear face  184  (see  FIGS.  9  and  10   ), a top surface  186  and a bottom surface  188 . 
     In certain embodiments as otherwise described herein, portions of the frame protrude from a rear face of the panel body, and a front face of the panel body has a textured surface. In some embodiments, the textured surface replicates a masonry wall. For example, panel body  180  includes a front face  182  with a textured surface that replicates a stone wall. In other embodiments, the textured surface of the front face replicates other masonry walls, such as a brick wall. Still in other embodiments the front face replicates other natural siding products, such as wood. 
     In certain embodiments as otherwise described herein, each column includes an embedded portion disposed in the panel body. In certain embodiments as otherwise described herein, each column includes a column body extending away from the support strip and embedded in the panel body. For example, column bodies  152  of frame  110  are embedded in panel body  180  of wall panel  100 . The embedded column bodies  152  are schematically depicted in  FIG.  9   . 
     As set forth above, only a portion of the frame of the wall panel is embedded in the panel body. In embodiments of the wall panel various portions of the frame are external to the wall panel body. In certain embodiments as otherwise described herein, each column includes a connecting flange that couples the column body to the support strip, wherein the connecting flange protrudes out of the panel body. For example, support strip  120  of frame  110  is coupled to the column bodies  152  by connecting flange  156 . While column bodies  152  are embedded within panel body  180 , the connecting flange  156  is partially embedded in body  180  but also protrudes outward from rear face  184 . 
     In certain embodiments as otherwise described herein, the connecting flange includes at least one locating tab that defines an upper edge of the panel body. For example, connecting flange  156  includes locating tabs  166  disposed at the upper end of frame  110 . In certain embodiments, the locating tabs on the connecting flange are used to position the frame within a mold at the upper end of the mold. Accordingly, the locating tabs define the position of the upper edge of the panel body in such embodiments when the panel body is formed in a mold. 
     In certain embodiments as otherwise described herein, each column includes a positioning brace disposed at a distal end thereof, and wherein each positioning brace protrudes from the panel body. In certain embodiments as otherwise described herein, each positioning brace includes a locating shelf that defines a lower edge of the panel body. For example, wall panel  100  includes positioning brace  168  that protrudes out from the panel body  180  in order to engage a substrate wall. Positioning brace  168  has a locating shelf  170  between the column body  152  and the foot  169  of brace  168 . In certain embodiments, the locating shelf is used to position the frame within a mold at the lower end of the mold. Accordingly, the locating shelf defines the position of the lower edge of the panel body in such embodiments when the panel body is formed in a mold. 
     In certain embodiments as otherwise described herein, each column includes at least one stand-off leg disposed between the proximal and distal end thereof, and wherein each stand-off leg protrudes from the panel body. For example, each column of wall panel  100  includes three standoff legs  172  that extend rearward form the column body and protrude from rear face  184  of body  180 . 
     In certain embodiments as otherwise described herein, protruding components of the frame, such as the support strip, standoff legs, and positioning brace, extend back from the rear face of the panel body. As a result, these components can hold the wall panel at a distance from the substrate wall. This configuration provides a rain screen, which allows any water that migrates behind the wall panel to flow downward on the outside of the substrate wall, preventing damage to the substrate wall and the wall panels. 
     In certain embodiments as otherwise described herein, the support strip is external to the panel body. The external support strip is configured to support the wall panel directly against a substrate wall. For example, support strip  120  is external to panel body  180  and is configured for direct attachment to a substrate wall. In some embodiments, a portion of the panel body may extend around the support strip. For example, in some embodiments a thin coating of the panel body covers the support strip. 
     Another aspect of the disclosure provides a method of manufacturing a frame for a wall panel, the method comprising: positioning a first section of a metal sheet in a stamping press; conducting a first stamping operation using the stamping press to form a first frame segment in the first section of the metal sheet, the first frame segment including a portion of a support strip and a column extending from the support strip; pitching the metal sheet forward so as to position a second section of the metal sheet in the stamping press; conducting a second stamping operation using the stamping press to form a second frame segment in the second section of the metal sheet, the second frame segment including another portion of the support strip and another column extending from the support strip, wherein the second frame segment is adjacent to the first frame segment so as to form a line of columns extending from the support strip; and cutting the frame segments from the metal sheet so as to form a frame according to the disclosure. Such a method is depicted in  FIG.  11   . A metal sheet  1190  is fed into a stamping press  1192  so that a first section of the metal sheet is positioned inside the stamping press. Press  1192  then performs a first stamping operation to form a single frame segment in the first section of the metal sheet. Stamping press  1192  produces a frame segment with a portion of a support strip  1120  and a single column  1140 . A second section of metal sheet  1190  is fed into stamping press  1192  and a second frame segment is formed in the metal sheet. After six adjacent segments have been formed in the metal sheet, the segments are cut from the sheet to form frame  1110 . In other embodiments, the frame is cut from the metal sheet after only two or three frame segments have been formed, or after twelve segments have been formed. Still, in other embodiments, the frame is cut after another number of frame segments have been formed. 
     As explained above, the term metal sheet is not limited to any particular thickness or gauge. Further, the term stamping, as used herein, includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. 
     In certain embodiments as otherwise described herein, the stamped first frame segment is identical to the stamped second frame segment. For example, stamping press  1192  uses the same operation to form each segment  1130  of the frame such that all of the frame segments within frame  1110  are identical. In other embodiments, the first and second frame segments are not identical. 
     In certain embodiments as otherwise described herein, the method includes conducting at least one additional stamping operation to form another frame segment in the metal sheet before cutting the frame segments from the metal sheet. For example, as set forth above, stamping press  1192  includes four additional stamping operations before frame  1110  is cut from metal sheet  1190 , such that frame  1110  includes a total of six frame segments. 
     In certain embodiments as otherwise described herein, conducting the first stamping operation includes forming an opposing first frame segment in the first section of the metal sheet and conducting the second stamping operation includes forming an opposing second frame segment in the second section of the metal sheet. Further, the opposing frame segments include opposing columns extending from an opposing support strip. For example, stamping press  1192  includes stamping machinery to form a pair of frame segments simultaneously, as schematically depicted by dashed lines in  FIG.  11   . The opposing frame segment  1131  is identical to frame segment  1130  and includes an opposing column  1141  and portion of opposing support strip  1121 . In some embodiments, the frame and opposing frame are identical. For example, frame  1110  is identical to opposing frame  1111 . 
     In certain embodiments as otherwise described herein, at least one of the opposing columns is interposed between a pair of the columns in the line of columns. For example, opposing column  1141  is interposed between two columns of frame  1110 . In certain embodiments where the frames include several columns, the columns are interleaved as they are produced by the stamping press. The construction of each column having a free lower end and the frame not including a perimeter structure allows the columns to be interposed to one another as they are manufactured by the stamping press. This construction allows the frames to be manufactured using substantially less material. 
     In certain embodiments as otherwise described herein, the method includes cutting the opposing frame segments from the metal sheet so as to form an opposing frame according to the frame of the disclosure. For example, the method depicted in  FIG.  11    shows opposing frame  1111  also being cut from the metal sheet  1190 . 
     In certain embodiments as otherwise described herein, the method includes conducting at least one additional stamping operation between cutting the frame segments and cutting the opposing frame segments, such that the frame and the opposing frame include a different number of columns. For example, in some embodiments, the method includes cutting the stamped frame segments from the metal sheet every 6 cycles, and cutting the opposing frame segments from the metal sheet every 2 cycles. This method produces frames that have 6 columns and opposing frames that have 2 columns. It also results in fewer frames being produced than opposing frames. 
     In certain embodiments as otherwise described herein, each of the frame segments includes a single column. For example, stamping press  1192  produces frame segments with one column  1140 ,  1141  for each of the frames. However, in other embodiments, the stamping press produces two or more columns in each frame segment. 
     In certain embodiments as otherwise described herein, the first stamping operation occurs at a single station of the stamping press. In other embodiments, the first stamping operation includes a first stage performed at first station and a second stage performed at a second station. For example, in some embodiments, the bending and cutting required to make each frame segment occurs through a single cycle of the press at a single station. In other embodiments, certain bending processes occur at a different station than the cutting processes. 
     In certain embodiments as otherwise described herein, the pitching the metal sheet forward is carried out between the first stage and the second stage of the first stamping operation. For example, in some embodiments where the stamping operation is carried out in two stages, the metal sheet is pitched forward after the first stage has been performed on the first section of metal. Pitching the metal sheet forward moves the partially formed frame segments into the second station and the second section of metal sheet is moved into the first station. 
     In certain embodiments, the entire frame is stamped from a metal sheet in a single stamping operation. For example,  FIG.  12    shows such a method. A metal sheet  1290  is fed into a stamping press  1292  so that a section of the metal sheet is positioned inside the stamping press. Stamping press  1292  then performs a stamping operation to form the frame in the metal sheet. In some embodiments, the stamping press forms more than one frame at a time. For example, stamping press  1292  forms two frames  1210  that are interlaced. In other embodiments, the stamping press forms one frame in each stamping operation. 
     Additional aspects of the disclosure are provided by the following numbered embodiments, which can be combined and permuted in any number and in any fashion that is not logically or technically inconsistent. 
     Embodiment 1 
     A frame for a wall panel, the frame comprising:
         a support strip extending in a lateral direction, the support strip including a first end and a second end; and   a row of columns extending in a first direction from the support strip, each column including a proximal end attached to the support strip and a free distal end, the row of columns including:
           a first column disposed at a first end of the row of columns and laterally offset from the first end of the support strip, and   a second column disposed at a second end of the row of columns and laterally offset from the second end of the support strip.   
               

     Embodiment 2 
     The frame according to embodiment 1, wherein a width of the frame is in a range of 6 to 55 inches, e.g., 8 to 48 inches, e.g., about 10 inches, e.g., about 13 inches, e.g., about 23 inches, e.g., about 46 inches. 
     Embodiment 3 
     The frame according to embodiment 1 or embodiment 2, wherein a height of each column is in a range from 4 to 14 inches, e.g., from 5 to 12 inches, e.g., from 6 to 9 inches. 
     Embodiment 4 
     The frame according to any of embodiments 1 to 3, wherein the frame is formed of a cut and shaped metal sheet. 
     Embodiment 5 
     The frame according to any of embodiments 1 to 4, wherein the frame consists of a plurality of identical segments in a line, each of the segments including one of the columns and a portion of the support strip. 
     Embodiment 6 
     The frame according to embodiment 5, wherein each of the segments includes a single column. 
     Embodiment 7 
     The frame according to embodiment 6, wherein each column is disposed at the lateral center of the respective segment. 
     Embodiment 8 
     The frame according to any of embodiments 5 to 7, wherein the width of each segment is in a range from 3 to 6 inches, e.g., from 3.5 to 5 inches. 
     Embodiment 9 
     The frame according to any of embodiments 1 to 8, wherein the support strip includes a contact surface that defines a first plane. 
     Embodiment 10 
     The frame according to any of embodiments 1 to 9, wherein each column includes a column body extending away from the support strip. 
     Embodiment 11 
     The frame according to embodiment 10, wherein each column body lies in a second plane that is parallel to the first plane. 
     Embodiment 12 
     The frame according to embodiment 10 or embodiment 11, wherein the lateral sides of each column body include stiffening side bends. 
     Embodiment 13 
     The frame according to any of embodiments 10 to 12, wherein each column includes a connecting flange that couples the column body to the support strip, and
         wherein the connecting flange extends in a direction that is at an angle to the first plane.       

     Embodiment 14 
     The frame according to embodiment 13, wherein the connecting flange includes a proximal bend adjacent to the support strip, and
         wherein a stiffening gusset is disposed in the proximal bend.       

     Embodiment 15 
     The frame according to embodiment 13 or embodiment 14, wherein the connecting flange includes a distal bend adjacent to the respective column body, and
         wherein a stiffening gusset is disposed in the distal bend.       

     Embodiment 16 
     The frame according to any of embodiments 13 to 15, wherein the connecting flange includes at least one locating tab that extends toward the support strip. 
     Embodiment 17 
     The frame according to embodiment 16, wherein the locating tab is attached to a side of the connecting flange by a bend. 
     Embodiment 18 
     The frame according to any of embodiments 8 to 12, wherein the support strip includes a cross bar disposed in a second plane, and wherein each column is connected to the cross bar. 
     Embodiment 19 
     The frame according to any of embodiments 1 to 18, wherein each column includes a positioning brace disposed at a distal end thereof. 
     Embodiment 20 
     The frame according to embodiment 19, wherein the support strip includes a contact surface that defines a first plane, and wherein each positioning brace includes a foot that lies on the first plane. 
     Embodiment 21 
     The frame according to embodiment 20, wherein each column includes a column body that lies in a second plane that is parallel to the first plane, and
         wherein each positioning brace extends from a corresponding column body to the first plane.       

     Embodiment 22 
     The frame according to any of embodiments 19 to 21, wherein the positioning brace includes a locating shelf. 
     Embodiment 23 
     The frame according to any of embodiments 1 to 22, wherein each column includes at least one stand-off leg disposed between the proximal and distal end thereof. 
     Embodiment 24 
     The frame according to embodiment 23, wherein each column includes an aperture corresponding to each respective stand-off leg. 
     Embodiment 25 
     The frame according to embodiment 24, wherein each stand-off leg extends from a lower or upper edge of the corresponding aperture. 
     Embodiment 26 
     The frame according to any of embodiments 23 to 25, wherein the support strip includes a contact surface that defines a first plane, and
         wherein each stand-off leg includes a foot that lies in the first plane.       

     Embodiment 27 
     The frame according to embodiment 26, wherein each column includes a column body that lies in a second plane that is parallel to the first plane, and
         wherein each stand-off leg extends from a corresponding column body to the first plane.       

     Embodiment 28 
     The frame according to any of embodiments 1 to 27, wherein the support strip includes a fastening band configured to attach the frame to a substrate. 
     Embodiment 29 
     The frame according to any of embodiments 1 to 28, wherein the support strip includes at least one stiffening rib. 
     Embodiment 30 
     The frame according to any of embodiments 1 to 29, wherein the frame includes at least two columns, e.g., at least 3 columns, e.g., 6 columns, e.g., 12 columns. 
     Embodiment 31 
     A wall panel comprising:
         a panel body; and   a frame according to any of embodiments 1 to 30 partially embedded in the panel body.       

     Embodiment 32 
     The wall panel according to embodiment 31, wherein portions of the frame protrude from a rear face of the panel body, and
         wherein a front face of the panel body has a textured surface.       

     Embodiment 33 
     The wall panel according to embodiment 32, wherein the textured surface replicates a masonry wall. 
     Embodiment 34 
     The wall panel according to any of embodiments 31 to 33, wherein each column includes an embedded portion disposed in the panel body. 
     Embodiment 35 
     The wall panel according to any of embodiments 31 to 34, wherein each column includes a column body extending away from the support strip and embedded in the panel body. 
     Embodiment 36 
     The wall panel according to embodiment 35, wherein each column includes a connecting flange that couples the column body to the support strip, wherein the connecting flange protrudes out of the panel body. 
     Embodiment 37 
     The wall panel according to embodiment 36, wherein the connecting flange includes at least one locating tab that defines an upper edge of the panel body. 
     Embodiment 38 
     The wall panel according to any of embodiments 31 to 37, wherein each column includes a positioning brace disposed at a distal end thereof, and
         wherein each positioning brace protrudes from the panel body.       

     Embodiment 39 
     The wall panel according to embodiment 38, wherein each positioning brace includes a locating shelf that defines a lower edge of the panel body. 
     Embodiment 40 
     The wall panel according to any of embodiments 31 to 39, wherein each column includes at least one stand-off leg disposed between the proximal and distal end thereof, and
         wherein each stand-off leg protrudes from the panel body.       

     Embodiment 41 
     The wall panel according to any of embodiments 31 to 40, wherein the support strip is external to the panel body. 
     Embodiment 42 
     A method of manufacturing a frame for a wall panel, the method comprising:
         positioning a first section of a metal sheet in a stamping press;   conducting a first stamping operation using the stamping press to form a first frame segment in the first section of the metal sheet, the first frame segment including a portion of a support strip and a column extending from the support strip;   pitching the metal sheet forward so as to position a second section of the metal sheet in the stamping press;   conducting a second stamping operation using the stamping press to form a second frame segment in the second section of the metal sheet, the second frame segment including another portion of the support strip and another column extending from the support strip, wherein the second frame segment is adjacent to the first frame segment so as to form a line of columns extending from the support strip; and   cutting the frame segments from the metal sheet so as to form a frame according to any of embodiments 1 to 30.       

     Embodiment 43 
     The method according to embodiment 42, wherein the stamped first frame segment is identical to the stamped second frame segment. 
     Embodiment 44 
     The method according to embodiment 42 or embodiment 43, further comprising conducting at least one additional stamping operation to form another frame segment in the metal sheet before cutting the frame segments from the metal sheet. 
     Embodiment 45 
     The method according to any of embodiments 42 to 44, wherein conducting the first stamping operation includes forming an opposing first frame segment in the first section of the metal sheet and conducting the second stamping operation includes forming an opposing second frame segment in the second section of the metal sheet, and
         wherein the opposing frame segments include opposing columns extending from an opposing support strip.       

     Embodiment 46 
     The method according to embodiment 45, wherein at least one of the opposing columns is interposed between a pair of the columns in the line of columns. 
     Embodiment 47 
     The method according to embodiment 45 or embodiment 46, further comprising cutting the opposing frame segments from the metal sheet so as to form an opposing frame according to any of embodiments 1 to 30. 
     Embodiment 48 
     The method according to embodiment 47, further comprising conducting at least one additional stamping operation between cutting the frame segments and cutting the opposing frame segments, such that the frame and the opposing frame include a different number of columns. 
     Embodiment 49 
     The method according to any of embodiments 42 to 48, wherein each of the frame segments includes a single column. 
     Embodiment 50 
     The method according to any of embodiments 42 to 49, wherein the first stamping operation occurs at a single station of the stamping press. 
     Embodiment 51 
     The method according to any of embodiments 42 to 49, wherein the first stamping operation includes a first stage performed at first station and a second stage performed at a second station. 
     Embodiment 52 
     The method according to embodiment 51, wherein the pitching the metal sheet forward is carried out between the first stage and the second stage of the first stamping operation. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.