Patent Abstract:
An environmentally resilient building product of a vinyl laminated formed-sheet metallic substrate wherein the vinyl laminate is adhesively attached to the formed-sheet metallic substrate to provide a durable and attractive surface. Possible decorative and resilient surfaces include, but are not limited to solid colors, metallic finishes, and graphical images or patterns, all available in a variety of textures.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. utility application entitled, “Method of Manufacturing an Environmentally Resilient Structural Panel,” having Ser. No. 12/536,275, now U.S. Pat. No. 8,141,221 B2 filed Aug. 5, 2009, which is a divisional application of U.S. utility application entitled, “Environmentally Resilient Corrugated Building Products and Methods of Manufacture,” having Ser. No. 11/035,548, filed Jan. 13, 2005, which is allowed, and which are entirely incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure is generally related to building products and, more particularly, is related to products and manufacturing methods for environmentally resilient building products. 
     BACKGROUND 
     Many different products have utilized, and continue to utilize, sheet metal as a raw material for constructing various components. Sheet metal generally possesses a high tensile strength, but is often very flexible. For structural purposes, the flexibility can be reduced through the use of additional structure attached to the sheet metal, such as beams, purlins, bars, and posts, among others. Additional structural components, however, increase the cost for the additional materials and increase the size and weight of the assembled component. 
     One method for avoiding the requirement for additional structure is to break or bend the sheet along a line where the reduction in flexibility is desired. When done as a series of parallel bends to form channels or ridges, this is known as corrugating. Corrugating is known to produce metal sheet products with significantly reduced flexibility along at least one axis. Although the corrugation may be produced by performing a series of independent breaks on a metal sheet, corrugating machines also referred to as roll forming machines have been developed to provide corrugation to flat sheet metal in a continuous process. An example of the prior art relating to roll forming machines can be found in U.S. Pat. No. 4,269,055, which is hereby incorporated by reference in its entirety. 
     Metal sheets are often used in applications where specific aesthetic properties are desirable on at least one surface of the metal sheet. In some cases, the aesthetic property may constitute a specific color. Methods for applying a solid color to corrugated metallic products have previously been performed using spraying or coating processes  100 , as illustrated in  FIG. 1 . Referring to  FIG. 1 , the flat metallic product  110  is unrolled from a coil  102  and made proximate to, for example, spray nozzles  120 , which deliver a sprayed paint or coating  130  to the surface of the flat metallic product  110 . After coating or painting, the flat metallic product is dried or cured using, for example, a heater or oven  140  and then rolled into a coil  104 . Other cases may require specific graphical images or patterns in lieu of a solid color. Some methods of applying a graphical image or pattern to flat metallic product include immersion graphics methods where, for example, an inked film is applied to the flat metallic product, which is then immersed to dissolve the film, leaving the ink image or pattern on the flat metallic product. Like the painted coating products discussed above, the immersion graphics products may not provide a surface that is sufficiently resistant to scratching, abrasion, weathering, or fading due to outdoor exposure or mechanical impact associated with subsequent processing, assembly, or use. 
     One technique for providing mechanically resilient protection for metallic sheet products includes laminating. The laminating process  200  in this context, as illustrated in  FIG. 2 , includes adhesively bonding a graphic film  202  to at least one surface of a flat metallic sheet  201 . By way of example, the graphic film  202  may be applied using the pressure of a laminating roll  220 . Additionally, the laminating roll  220  may possess specific surface properties which are transferred or embossed into the surface of the graphic film  202  during application. The resulting laminated metallic sheet  210  includes a graphic film  202 , which may possess specific aesthetic properties including solid colors, metallic finishes, patterns, and graphical images. Additionally, if embossing was performed, the graphic film  202  may possess specific surface finish properties such as brushed, matte, or pebbled, among others. This process, however, has only been applicable to flat products because the manufacturing impracticality of continuously processing laminated corrugated products. For example, previous attempts to corrugate a laminated sheet have resulted in a graphic film that weakens and cracks during subsequent processing and is not resistant to damaging elements associated with an outdoor environment. 
     Thus, a heretofore-unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies. 
     SUMMARY 
     Embodiments of the present disclosure provide an environmentally resilient structural product, comprising: a vinyl laminate and a formed-sheet metallic substrate having a first side; wherein the vinyl laminate is adhesively attached to the first side. 
     Briefly described, other embodiments of the present disclosure provide an environmentally resilient outdoor building, comprising: at least one formed-sheet metallic panel, the panel comprising a vinyl layer, and a corrugated metallic substrate having a first side, wherein the vinyl layer is bonded to the first side. 
     Embodiments of the present disclosure can also be viewed as methods for providing a decorative, environmentally resilient, structurally significant panel. In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: bonding a first side of a vinyl layer to a first side of a flat metallic sheet; and deforming the flat metallic sheet to create a plurality of parallel ribs in the first side of the metallic sheet. 
     Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  is a side view of a coating/painting process for metal products as is known in the prior art. 
         FIG. 2  is a side view of a process of applying a laminate to flat metallic sheet as is known in the prior art. 
         FIG. 3  is an illustration of a side-elevational view of an exemplary roll former used in an embodiment, as disclosed herein. 
         FIG. 4  is an illustration of a partial top view of the exemplary roll former of  FIG. 3  used in an embodiment, as disclosed herein. 
         FIG. 5  is an illustration of a partial end view of a set of complementary rollers and a partial cross-sectional view of a vinyl laminated metallic sheet of the exemplary roll former of  FIG. 3  used in an embodiment, as disclosed herein. 
         FIG. 6  is a side cross-sectional view of a flat metallic sheet with a vinyl laminate. 
         FIG. 7  is an end cross-sectional view of a vinyl-laminated corrugated metal sheet, as disclosed herein. 
         FIG. 8  is an illustration of side-elevational view of an exemplary roll former used in an embodiment, as disclosed herein. 
         FIGS. 9A-9D  are end cross-sectional views of exemplary formed-sheet vinyl laminated metallic products, as disclosed herein. 
         FIG. 10  is a block diagram of an exemplary method of producing environmentally resilient products as disclosed herein. 
         FIG. 11  is a perspective view of an exemplary building constructed using environmentally resilient corrugated metallic products, as disclosed herein. 
     
    
    
     DETAILED DESCRIPTION 
     Reference is now made in detail to the description of the embodiments as illustrated in the drawings. While several embodiments are described in connection with these drawings, there is no intent to limit the invention to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents. 
     Reference is made to  FIG. 3 , which illustrates a side-elevational view of an exemplary roll former used in an embodiment, as disclosed herein. The roll former  300  begins with a vinyl laminated flat metallic sheet  305 , as manufactured in a device consistent with the prior art, as discussed in reference to  FIG. 2  addressed in the preceding Background section. The vinyl laminated flat metallic sheet  305  of  FIG. 3  retains a carrier film (not shown) associated with the vinyl laminating material. The vinyl laminated flat metallic sheet  305  is propelled in direction A and drawn between a first set of complementary forming rollers  322  and  323  to form a first set of channels/ridges, creating a partially formed sheet  306 . The partially formed sheet  306  is propelled from the first set of complementary forming rollers  322  and  323  and drawn between a second set of complementary rollers  324  and  325 . The second complementary forming rollers  324  and  325  form additional channels/ridges to create partially formed sheet  307 . Similarly, the partially formed sheet  307  proceeds through complementary forming rollers  326  and  327  to form a final set of channels/ridges such that the corrugated sheet  308  is created. The corrugated vinyl laminated metallic sheet  308  is then fed into a shear  340 , where the continuous sheet is cut into panels for subsequent packaging or manufacturing (not shown). 
     Reference is now made to  FIG. 4 , which illustrates a partial top view of the exemplary forming roller table of  FIG. 3 , as discussed above. The vinyl laminated flat metallic sheet  305  is propelled in a direction A between a first top forming roller  322  and a first bottom forming roller, which is not visible in this view. The partially formed sheet  306  produced by the first complementary forming rollers  322  and  323  (see  FIG. 3 ) has channels/ridges  316  corresponding to the profile of the gap between the first forming rollers  322  and  323  (see  FIG. 3 ). The partially formed sheet  306  is then drawn into the gap between a second top forming roller  324  and a second bottom forming roller, which is not visible in this view. The partially formed sheet  307  produced by the first and second complementary forming rollers  322 ,  323  (see  FIG. 3 ),  324 , and  325  (see  FIG. 3 ) has channels/ridges  317  corresponding to the cumulative profile of the gaps between the two sets of complementary forming rollers  322 ,  323 ,  324 , and  325 . 
     The partially formed sheet  307  is similarly drawn between a third top forming roller  326  and a complementary third bottom forming roller, which is not visible in this view. A final set of channels/ridges  318  is formed resulting in a corrugated vinyl laminated metallic sheet  308 . Note that as the vinyl laminated metallic sheet progresses through each of the sets of complementary forming rollers, the width of the sheet is reduced by the portion of the sheet profile which is deformed to create the depth and height of the channels/ridges, respectively. In other words, the final corrugated vinyl laminated metallic sheet  308  is not as wide as the vinyl laminated flat metallic sheet  305  that entered the forming roller table  320 . One of ordinary skill in the art knows, or will know, that the complementary forming roller configurations of  FIGS. 3 and 4  are merely exemplary and that a roll former  300  configured with any number, combination, or configuration of forming rollers is consistent with this disclosure. For example, an alternative roll former  300  may have four or more complementary sets of forming rollers, each configured to produce a single channel or ridge in a vinyl laminated metallic sheet. 
     Reference is briefly made to  FIG. 5 , which is an illustration of a partial end view of a set of complementary rollers with a partial cross-sectional view of a vinyl laminated metallic sheet. As discussed above, the top forming roller  322  has a complementary profile with the bottom-forming roller  323 . As the vinyl laminated metallic sheet  306  is drawn through the gap between the two forming rollers  322  and  323 , the channel/ridge  316  is formed. One of ordinary skill in the art knows or will know that the multiple channels/ridges  316  may be formed by multiple serially arranged forming roller sets configured at specific widths across the vinyl laminated metallic sheet and that the multiple channels/ridges may aggregate to form a corrugated sheet. Further, one of ordinary skill in the art will appreciate that the channels/ridges may have different depths, widths, and shape profiles. 
     Further, one of ordinary skill in the art will appreciate that a roll former is but one way to produce formed-sheet products. For example, in addition to roll forming, sheets can be formed using bends, breaks, or folds for introducing the additional dimensional characteristics associated with formed-sheet products. Additionally, one of ordinary skill in the art knows or will know that a formed-sheet product includes any sheet product subsequently processed to introduced additional dimensional characteristics including products with any number, configuration, or combination of bends, breaks, folds, curls, or rolls. 
     Reference is now made to  FIGS. 6 and 7 , which illustrate cross-sectional end views of a vinyl laminated flat metallic sheet and a vinyl-laminated corrugated metal sheet, respectively. The vinyl laminated flat metallic sheet  600  is formed by a laminating process, such as the process disclosed in the above discussion of  FIG. 2 , and includes a vinyl laminate  602 , which has a thickness of at least 0.0005 inches, bonded to at least one side of the flat metallic sheet  601 , which has an exemplary thickness ranging from 10 gauge to 35 gauge. The corrugated vinyl laminated metallic sheet  700  of  FIG. 7  includes the corrugated metallic substrate  701  and a vinyl layer  702  bonded to at least one side of the corrugated metallic substrate  701 . Additionally, the corrugated vinyl laminated metallic sheet  700  includes multiple parallel channels  710  and ridges  720 . 
     The metallic sheets or substrates as disclosed herein may be steel, aluminum, tin, copper, or brass, among others. 
     The bonding of the vinyl layer  602  to the metallic sheet  601  is performed on a flat metallic sheet, as previously discussed in reference to  FIG. 2 . The vinyl laminated flat metallic sheet may be processed using the methods herein to produce the corrugated vinyl laminated metallic sheet. Although the corrugated profile of the product  700  is illustrated as including three primary ribs  720  per section with two secondary ribs  710  between each of the primary ribs  720 , one of ordinary skill in the art knows or will know that the methods herein may be utilized to produce numerous combinations of ribs having various and varied geometric profiles and dimensional characteristics. The product  700  also includes a vinyl layer  702  bonded to one side of the metallic sheet  701 . The vinyl layer  702 , which has a thickness of at least 0.0005 inches, is UV-stabilized and provides an ultra-violet light resistant protective covering for the metallic sheet  701 . Additionally, the product  700  provides a vinyl layer  702  that is resistant to delamination. The vinyl layer  702  also provides a decorative finish for the product  700 . For example, the vinyl layer  702  may have solid color or some graphical representation. Exemplary graphical representations include, but are not limited to, metallic finishes such as gold or silver including different textures such as brushed, matte, pebbled, or gloss, among others. Other exemplary graphical representations include, but are not limited to, natural finishes such as wood grain or an outdoor environment blending pattern such as, for example, one sold under the registered trademark, REALTREE®. 
     Reference is now made to  FIG. 8 , which illustrates a side-elevational view of an exemplary roll former used in an embodiment, as disclosed herein. The roll former  800  begins with a vinyl laminated flat metallic sheet  805 , as manufactured in a device consistent with the prior art, as previously discussed in reference to  FIG. 2 . The vinyl layer  815  of the vinyl laminated flat metallic sheet  805  includes a carrier film  832 , that may be removed from the vinyl laminated flat metallic sheet  805  or it may be left in place during the forming operation. If the carrier film  832  is removed before the vinyl laminated flat metallic sheet  805  enters the forming roller table  820 , the carrier film is wound onto a separate roll  830 . Although, as illustrated, only one side of the vinyl laminated flat metallic sheet is shown as having a vinyl laminate, one of ordinary skill in the art will appreciate that both sides of the vinyl laminated flat metallic sheet may have a vinyl laminate applied. In an embodiment having two sides of vinyl laminate, the removal of a second carrier film may be performed prior to the roll forming process or the second carrier film may remain attached during subsequent processing. 
     After removing the carrier film  832 , the vinyl laminated flat metallic sheet  806  is drawn between a first set of complementary forming rollers  822  and  823  to form a first set of channels/ridges, creating a partially formed sheet  806 . The partially formed sheet  806  is propelled from the first set of complementary forming rollers  822  and  823  and drawn between a second set of complementary rollers  824  and  825 . The second set of complementary forming rollers  824  and  825  forms additional channels/ridges to create partially formed sheet  807 . Similarly, the partially formed sheet  807  proceeds through complementary forming rollers  826  and  827  to form another set of ridges/channels such that the corrugated sheet  808  is produced without the carrier film  832 . One of ordinary skill in the art knows or will know that the roll forming process may be performed by four or more sets of forming rollers, each configured to generate an element of the overall profile. The corrugated vinyl laminated metallic sheet  808  may then be fed into a shear  840 , where the continuous sheet is cut into panels for subsequent packaging or manufacturing (not shown). Additionally, excess vinyl laminate may be trimmed at one or more of numerous different stages of the manufacturing. For example, the vinyl laminate may be trimmed before or after the roll forming  820  or before, after, or during the shear function  840 . 
     Reference is now made to  FIGS. 9A-9D , which illustrate end cross-sectional views of exemplary formed-sheet vinyl laminated metallic products, as disclosed herein. The exemplary profile of  FIG. 9A  includes five primary ribs  902 , each separated by two wide, shallow ribs  904 . The exemplary profile of  FIG. 19B  similarly includes four primary ribs  912 , each separated by two wide, shallow ribs  914 . As is shown, the primary ribs  912  of  FIG. 9B  illustrate a different geometrical and dimensional profile than the primary ribs  902  of  FIG. 9A . The exemplary profile of  FIG. 9C  similarly includes four primary channels  922 , each separated by two wide, shallow channels  924 . The exemplary profile illustrated in  FIG. 9D  includes four wide, shallow channels  932 , one standing seam locking surface  934 , and one standing seam locking tab  936 . 
     Reference is now made to  FIG. 10 , which is a block diagram of an exemplary method of producing environmentally resilient products, as disclosed herein. The method  1000  first bonds a vinyl layer to a flat metallic sheet in step  1010 . Next, optional step  1020  constitutes removing the carrier film component of the vinyl layer. The vinyl laminated flat metallic sheet is deformed using, for example, a roll forming device, to produce channels/ridges in block  1030 . In block  1040  the excess vinyl material is trimmed from the edges of the metallic sheet, if present. This step may be optionally performed before or after the deforming step. 
     Reference is now made to  FIG. 11 , which illustrates a perspective view of an exemplary building constructed using environmentally resilient corrugated products, as disclosed herein. The building  1100  may be fully or partially constructed utilizing corrugated vinyl laminated metallic wall panels  1110  consistent with the disclosure herein. Corrugated vinyl laminated metallic wall panels  1110  may be produced from metallic substrate in the exemplary thickness range from 18 gauge to 30 gauge. As discussed above, the vinyl laminated panels are environmentally resilient. Additionally, or in the alternative, the building  1100  may also utilize one or more corrugated vinyl laminated metallic roof panels  1120  for all or part of the roof. Corrugated vinyl laminated metallic roof panels  1120  may be produced from metallic substrate in the exemplary thickness range from 18 gauge to 30 gauge. 
     It should be emphasized that the above-described embodiments of the present disclosure, particularly, any illustrated embodiments, are merely possible examples of implementations, merely to provide a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims.

Technology Classification (CPC): 8