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

Abstract

A siding system includes panels having a facing element with a convex front face portion. A first connecting portion extending along an upper edge and a second connecting portion at a lower edge is adapted to engage the first connecting portion of an adjacent lower siding panel. Mounting holes at a top edge of the facing element provide for mounting the siding panel to a vertical surface. A support element, such as foam insulation attaches to a rear surface of the facing element. A machine for making the metal siding panels has a feeder and multiple roller sets. First ones of the rollers have a concave portion and complementary second ones of the rollers have a convex portion. The concave portion first roller set has a larger radius profile than the last roller set to roll form the siding from a coil of blank material. Bending rollers form the mounting structure of the panels. Embossing rollers forming an embossed pattern on the face of the panels.

What is claimed is:  
     
         1 . A siding panel, comprising: 
 a facing element, the facing element comprising: 
 a convex front face portion;  
 a first connecting portion extending along an upper edge of the front face portion,  
 a second connecting portion at a lower edge of the front face portion, and adapted to engage a first connecting portion of an adjacent lower siding panel;  
 a mounting portion at a top edge of the facing element adapted for mounting the siding panel to a vertical surface;  
   a support element having a convex first face and mounting to a rear surface of the front face portion of the facing element.    
     
     
         2 . A siding panel according to  claim 1 , wherein the first and second connecting portions comprise complementary hooks configured for engaging one another.  
     
     
         3 . A siding panel according to  claim 1 , wherein the second connecting portion hook extends under and behind the support element to retain the support element.  
     
     
         4 . A siding panel according to  claim 1 , wherein the support element comprises a molded expanded polystyrene element.  
     
     
         5 . A siding panel according to  claim 1 , wherein facing element comprises a roll formed metal element.  
     
     
         6 . A siding panel according to  claim 1 , wherein the front face portion comprises an embossed surface.  
     
     
         7 . A siding panel according to  claim 5 , wherein the front face portion comprises an embossed arcing surface.  
     
     
         8 . A siding system, comprising: 
 a plurality of siding panels, each siding panel comprising: 
 a facing element, the facing element comprising: 
 an embossed convex front face portion,  
 a first connecting portion extending along an upper edge of the front face portion,  
 a second connecting portion at a lower edge of the front face portion, and adapted to engage a first connecting portion of an adjacent lower siding panel,  
 a mounting portion at a top edge of the facing element adapted for mounting the siding panel to a vertical surface;  
 
 a support element having a convex first face and mounting to a rear surface of the front face portion of the facing element;  
   wherein the siding panels are connected along their top and bottom edges to adjacent siding panels to form extended siding.    
     
     
         9 . A siding system according to  claim 8 , wherein the panels are predetermined lengths to seamless siding that abuts building structure on each end.  
     
     
         10 . A siding panel, comprising: 
 a facing element, the facing element comprising: 
 an embossed convex front face portion,  
 a first connecting portion extending along an upper edge of the front face portion,  
 a second connecting portion at a lower edge of the front face portion, and adapted to engage a first connecting portion of an adjacent lower siding panel;  
 a mounting portion at a top edge of the facing element adapted for mounting the siding panel to a vertical surface;  
   a support element having a convex first face and mounting to a rear surface of the front face portion of the facing element.    
     
     
         11 . A roll-formed siding facing element, comprising: 
 an embossed convex front face portion;    a first connecting portion extending along an upper edge of the front face portion;    a second connecting portion at a lower edge of the front face portion, and adapted to engage a first connecting portion of an adjacent lower siding panel; and    a mounting portion at a top edge of the facing element adapted for mounting the siding panel to a vertical surface.    
     
     
         12 . A siding facing element according to  claim 11 , wherein the mounting portion comprises a plurality of spaced apart holes.  
     
     
         13 . An apparatus for making metal siding panels, comprising: 
 a feeder;    a plurality of first roller sets, wherein first ones of the rollers having a concave portion and complementary second ones of the rollers have a convex portion, and wherein the concave portion first roller set has a larger radius profile than a last roller set; bending means adapted for forming a first flange proximate a first end of the rollers; stamping means;    embossing means adapted for forming an embossed pattern.    
     
     
         14 . An apparatus according to  claim 13 , further comprising a plurality of intermediate roller sets, wherein each successive roller set has a profile with a radius equal to or smaller than the preceding roller profile.  
     
     
         15 . An apparatus according to  claim 13 , wherein the bending means is adapted for forming a second flange complementary to the first flange.  
     
     
         16 . An apparatus according to  claim 13 , wherein the embossing means comprises opposed rollers having a patterned surface.  
     
     
         17 . An apparatus according to  claim 13 , wherein the rollers are aligned linearly, along a direction perpendicular to the axis of each roller.  
     
     
         18 . An apparatus according to  claim 13 , wherein the each successive roller set has an axial profile radius no larger than a radius of a preceding roller set.  
     
     
         19 . An apparatus according to  claim 13 , further comprising means for supporting a continuous coil of blank material.  
     
     
         20 . A metal siding element from a blank material, made by the steps of: 
 providing a siding-forming device with a plurality of aligned roller sets of first rollers and second complementary rollers, wherein each of the first rollers has a concave profile, and wherein rollers become successively more concave from a first end to a second end, and a flange former, and a punching station;    feeding the material through the punching station, whereby the flange has a plurality of mounting orifices formed therein;    feeding the blank material along the roller sets in engagement with the first and second rollers, whereby a portion of the blank acquires an arcing cross-section 
 material past the flange formers, whereby an edge of the blank has a flange formed thereon;  
   cutting the material at a predetermined length.    
     
     
         21 . A siding element according to  claim 20 , wherein the siding element is made by the further steps of providing an embossing roller set and feeding the blank past the embossing roller, whereby the blank acquires an embossed surface prior to engaging the aligned roller sets.  
     
     
         22 . A siding element according to  claim 21 , wherein the embossing roller set comprises opposed rollers having a wood grain contoured periphery.  
     
     
         23 . A method of making a siding element, comprising the steps of: 
 providing a continuous coil of blank material;    providing a siding forming device with a plurality of aligned roller sets progressing from a first end to a second end, wherein each of the roller sets has a first roller having a concave profile, and wherein the first rollers become successively more concave from the first end to the second end, flange forming rollers, and a punching station;    feeding the blank through the punching station, whereby an edge of the blank material has a plurality of spaced apart mounting orifices formed therein;    feeding the blank material along the rollers in engagement with the rollers, whereby a portion of the blank acquires an arcing cross-section;    passing the blank past the flange forming rollers, whereby an edge of the blank has a flange formed thereon;    cutting the blank at a predetermined length.    
     
     
         24 . A method according to  claim 23 , wherein the blank material comprises a length of metal.