# US 10,501,938 B2 · Metal roof panel with deformation resistant rib and method of making the same

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- Number: US 10,501,938 B2
- Document ID: US10501938B2
- Status: Granted
- Kind: B2
- Application number: 15/833,151
- Filed: 2017-12-06
- Published: 2019-06-06
- Granted: 2019-12-10
- Earliest claimed: 2017-12-06
- Applicants: Daniel Lawrence Jordan
- Inventors: Daniel Lawrence Jordan
- Web page: https://patentgrep.com/patent/US10501938B2

## CPC

- E04D 3/3606: {the fastening means being screws or nails}
- B21B 1/38: for rolling sheets of limited length, e.g. folded sheets, superimposed sheets, {pack rolling}(B21B1/40 takes precedence; folding sheets before, or separating layers after, rolling B21B47/00)
- B21D 5/08: making use of forming-rollers (B21D5/12 takes precedence)
- B21D 5/14: by passing between rollers (B21D5/06 takes precedence)
- B21D 13/045: {the corrugations being parallel to the feeding movement}
- E04C 2/08: of metal, e.g. sheet metal (E04C2/26 takes precedence)
- E04C 2/322: {with parallel corrugations}
- E04D 3/30: of metal
- E04D 3/3605: {of roof covering supported directly by the roof structure (E04D3/3607, E04D3/3608, E04D3/361 - E04D3/369 take precedence)}
- E04D 3/365: by simple overlapping of the marginal portions with use of separate connecting elements, e.g. hooks or bolts for corrugated sheets
- E04D 3/40: Slabs or sheets locally modified for auxiliary purposes, e.g. for resting on walls, for serving as guttering; Elements for particular purposes, e.g. ridge elements, specially designed for use in conjunction with slabs or sheets {(E04D13/15 and E04D13/174 take precedence; ridge sealing E04D1/36; solar collectors F24S20/67)}
- E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00)
- 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)
- 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)
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)

## Abstract

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

## Claims

### Claim 1

A roof panel positioned on a roof having a profile including:
A. a plurality of bilateral ribs having upwardly angled sides that each transition into an indentation, with both indentations transitioning into a central flat apex extending from one of said indentations to the other of said indentations and having a width of approximately ⅝″, wherein said ribs run substantially parallel to the slope of the roof, and wherein the angle formed between one of said upwardly angled sides and said central flat apex is approximately 126°;
B. a plurality of channels each positioned between two of said ribs, each channel including at least one raised surface and at least one lower surface, said raised surface having a height of approximately ⅛″, wherein the angle formed between one of said upwardly angled sides and said raised surface is approximately 54°, and wherein said at least one raised surface and at least one lower surface are each substantially planar and parallel to said central flat apex; and
C. a plurality of screws engaged with each central flat apex wherein the resulting flat apex and screw interface is substantially impermeable to water, wherein said roof panel is strong enough to withstand wind sway and rib deformation.

### Claim 2 (depends on 1)

The roof panel of claim 1 wherein each channel includes exactly two raised surfaces and exactly three lower surfaces.

### Claim 3 (depends on 1)

The roof panel of claim 1 wherein said raised surfaces are parallel to said lower surfaces.

### Claim 4 (depends on 3)

The roof panel of claim 3 wherein said central flat apex is parallel to said raised surfaces.