Seamless siding and method and apparatus for making a seamless siding panel

#1. Field of the Invention

#The present invention relates to a siding element having an appearance of log construction, and in particular to a metal seamless siding element, an apparatus for making the siding and a method of making the siding.

#2. Description of the Prior Art

#Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views:

#FIG. 1 shows a perspective view of a siding panel element according to the principles of the present invention;

#FIG. 2 shows a front elevational view of the siding panel shown in FIG. 1 cut to a predetermined length and abutting building structures at each end;

#Referring now to the drawings, wherein like reference numerals and letters indicate corresponding structure throughout the several views, in particular referring to FIG. 1, there is shown a seamless siding panel, generally designated 100. The panel 100 includes an arcing outer surface 102 and a flange 104 along a first edge, as also shown in FIGS. 2 and 3. The upper flange 104 has a hook portion 108 formed therein that engages a complementary bottom hook 110 to join the panels 100 together to form extended siding covering the side of the building, as shown in FIG. 3. The bottom hook portion 110 may also include spaced apart weep holes 112 to allow water to drain from the panel 100. The flange 104 includes spaced apart mounting holes 106 for attaching the panels 100 to the side of a building.

#Foam insulation, molded polystyrene, or other support material 114 substantially follows the interior of the arcing portion 102. Referring again to FIGS. 1 and 2, the exterior of the arcing portion 102 preferably includes a wood grain type pattern and is embossed, as explained hereinafter, to give the arcing portion 102 the texture as well as the visual color pattern for log siding. It can be appreciated that the panels 100 may also be made without an embossed surface. In a preferred embodiment, the panels 100 are made from a continuous metal material 120, such as treated steel or aluminum, or alloys, wound on a spool 280, as shown in FIG. 4 and are cut to length to form a continuous, or seamless siding extending between building corners or other structure, as shown in FIG. 2 and as explained hereinafter. In this manner, seamless siding with surprising durability is obtained. Where it is impractical to cut the individual panels to required length, the panels 100 may be cut to a standard length, such as twelve feet and cut to the required length with shears at the job site. It has been found that an embossed siding panel 100 provides improved strength over panels just having an arc formed therein.

#Referring now to FIGS. 4-6, there is shown a panel forming apparatus, generally designated 200. The apparatus 200 supports a spool 280 of the blank siding material 120 and feeds it through a series of rollers to achieve the panel 100 shown in FIGS. 1-3 and is cut to length at an exit end at a cutting station 240. The siding forming apparatus 200 is preferably placed on a trailer or is otherwise portable to the job sites, so that the siding panels 100 may be cut to the length that is required for each panel to provide a seamless siding system. The continuous coil of blank material 120 is fed to the siding forming apparatus 200 and through a series of roll forming rollers, as explained hereinafter. The roller sets 206, 208, 210, 212, 214, 216 and 218 bend the blank material 120 gradually to the arced configuration shown in FIGS. 1-3. In addition, the flange 104 and other features of the panel 100, including the embossed surface, are accomplished as the blank 120 passes through the series of rollers. Upon exiting the series of rollers, the material is passed through a cutting station 240 shown in FIG. 8. The cutting station 240 includes a blade 244 and handle 246 with a die 248 having an upper surface substantially conforming to the profile of the panel 100 providing improved support along the entire arc. The cutting station 240 is slidably mounted relative to the apparatus 200 on a framework 242 that telescopes to move the cutting station 240 to a desired position so that the siding may be cut to the length needed for the specific placement of each particular siding panel 100. With this arrangement, there is no overlap or seams in the siding and a proper fit is obtained for each specific piece.