# US 10,118,209 B1 · Variable pressure door facade forming > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,118,209 B1 - Document ID: US10118209B1 - Status: Granted - Kind: B1 - Application number: 15/615,283 - Filed: 2017-06-06 - Granted: 2018-11-06 - Earliest claimed: 2014-03-06 - Assignees: Overhead Door Corporation - Applicants: Overhead Door Corporation - Inventors: Charles Andrew Haba; Dwayne Joseph Kornish; Daniel Christian; Robert E. Dickerson - Web page: https://patentgrep.com/patent/US10118209B1 ## CPC - B21D 5/08: making use of forming-rollers (B21D5/12 takes precedence) - B21D 22/02: Stamping using rigid devices or tools - B21D 22/08: with die parts on rotating carriers - B44B 5/026: {Dies (B44B5/028 takes precedence)} - B44C 1/24: Pressing or stamping ornamental designs on surfaces - B21B 1/227: {Surface roughening or texturing} - B21B 2263/02: Profile, e.g. of plate, hot strip, sections - B21D 17/04: by rolling - B21D 43/02: Advancing work in relation to the stroke of the die or tool - B21H 8/005: {Embossing sheets or rolls} - B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F) - B44B: MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING (processes for producing decorative effects B44C; embossing leather C14B) - B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)} - B21B: ROLLING OF METAL (auxiliary operations used in connection with metal-working operations covered in B21, see B21C; bending by rolling B21D; manufacture of particular objects, e.g. screws, wheels, rings, barrels, balls, by rolling B21H; pressure welding by means of a rolling mill B23K20/04) - B21H: MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS (essentially from sheet metal B21D) ## Abstract This disclosure presents methods and/or processes for forming a garage door façade using variable pressure. The forming processes, different from common stamping processes, creates a shaded design in a garage door section such that a continuous pattern is realized in the length direction (i.e., the longest side of the garage door section). The forming processes also produces significantly deep and smooth impressions that deform the center of the design. The forming process may be preceded by a texturing process, for example, each garage door section may first be textured and then sent for forming the design. ## Claims ### Claim 1 A method for producing a design in a garage door section, the method comprising: receiving the garage door section at a pair of roller dies, the garage door section having a thickness and a width and a length, the width being shorter than the length; feeding the garage door section into the pair of roller dies along the length in a length direction; and rotating the pair of roller dies such that corresponding embossing patterns and recessed patterns of the pair of roller dies apply a variable pressure against the garage door section to form a deep out-of-plane deformation into the thickness of the garage door section and extending along the length of the garage door section, wherein a shape of the corresponding embossing patterns and recessed patterns of the pair of roller dies forms the deep out-of-plane deformation including a varying width perpendicular to the length direction and a depth of the out-of-plane deformation in a direction of the thickness of the garage door section is at least greater than the garage door section thickness. ### Claim 2 (depends on 1) The method of claim 1, wherein the depth of the deep out-of-plane deformation is at least 1.5 mm (0.06 in). ### Claim 3 (depends on 1) The method of claim 1, wherein the depth of the deep out-of-plane deformation is 3.175 mm (0.125 in). ### Claim 4 (depends on 1) The method of claim 1, wherein forming the deep out-of-plane deformation further comprises forming a plurality of areas of deep out-of-plane deformation, wherein the plurality areas having different depths including 1.5 mm (0.06 in) and 3.175 mm (0.125 in). ### Claim 5 (depends on 1) The method of claim 1, wherein feeding the garage door section into the pair of roller dies comprises feeding at a rate between 10 m/min (30 ft/min) and 20 m/min (60 ft/min). ### Claim 6 (depends on 1) The method of claim 1, further comprising pre-texturing the garage door section using a pair of texturing roller dies. ### Claim 7 (depends on 6) The method of claim 6, wherein the pair of texturing roller dies produces a texture of depth between 0.5 mm (0.02 in) and 1 mm (0.04 in). ### Claim 8 (depends on 1) The method of claim 1, wherein the garage door section is pre-textured with a stucco or faux woodgrain texture. ### Claim 9 (depends on 1) The method of claim 1, wherein the design in the garage door section expands substantially entirely across the length of the garage door section. ### Claim 10 (depends on 1) The method of claim 1, wherein the garage door section comprises a steel sheet having a low yield tensile strength. ### Claim 11 A method for producing a design in a garage door section, the method comprising: providing the garage door section having a thickness and a width and a length, the width being shorter than the length; providing a pair of roller dies; aligning the garage door section between the pair of roller dies; rotating the pair of roller dies to draw in the garage door section along the length in a length direction; and while rotating the pair of roller dies, corresponding embossing patterns and recessed patterns of the pair or roller apply a variable pressure against the garage door section to form a deep out-of-plane deformation into the thickness of the garage door section and extending along the length of the garage door section wherein a shape of the corresponding embossing patterns and recessed patterns of the pair of roller dies forms the deep out-of-plane deformation including a varying width perpendicular to the length direction and a depth of the deep out-of-plane deformation in a direction of the thickness of the garage door section is at least greater than the garage door section thickness. ### Claim 12 (depends on 11) The method of claim 11, wherein rotating the pair of rollers to draw in the garage door section comprises drawing in the garage door section along the garage door section length. ### Claim 13 (depends on 11) The method of claim 11, wherein providing the pair of roller dies comprises providing two roller dies, one roller die having the embossing patterns and the other roller die having the recess patterns corresponding to the embossing patterns. ### Claim 14 (depends on 11) The method of claim 11, wherein rotating the pair of roller dies comprises rotating the dies in opposite directions. ### Claim 15 (depends on 11) The method of claim 11, wherein drawing in the garage door section into the pair of roller dies comprises drawing in at a rate between 10 m/min (30 ft/min) and 20 m/min (60 ft/min). ### Claim 16 (depends on 11) The method of claim 11, further comprising pre-texturing the garage door section using a pair of texturing roller dies. ### Claim 17 (depends on 11) The method of claim 11, wherein forming the deep out-of-plane deformation comprises forming an out-of-plane portion at a depth of at least 1.5 mm (0.06 in). ### Claim 18 (depends on 11) The method of claim 11, wherein forming the deep out-of-plane deformation comprises forming an out-of-plane portion at a depth of 3.175 mm (0.125 in). ### Claim 19 (depends on 11) The method of claim 11, wherein providing the garage door section comprises providing the garage door section formed of a steel sheet having a low yield tensile strength.