Curved Building Panel, Building Structure, Panel Curving System and Methods for Making Curved Building Panels

Abstract

A building panel formed from sheet material extends in a longitudinal direction along its length and includes a curved center portion in cross section, a pair of side portions extending from the curved center portion, and a pair of connecting portions extending from the side portions. The curved center portion includes a plurality segments extending in the longitudinal direction. The panel is curved in the longitudinal direction without having transverse corrugations. A particular segment may have a depth greater than that of another segment to accommodate the longitudinal curve. A system for longitudinally curving the panel includes first and second curving assemblies, each of which includes multiple rollers arranged to contact the panel as it passes along, a positioning mechanism for changing a relative rotational orientation between the first and second curving assemblies, a drive system for moving the panel longitudinally, and a control system for controlling the positioning mechanism.

1 . A building panel formed from sheet material, the building panel extending in a longitudinal direction along its length and having a shape in cross section in a plane perpendicular to the longitudinal direction, the building panel comprising:
 a curved center portion in cross section;   a pair of side portions extending from the curved center portion in cross section; and   a pair of connecting portions extending from the side portions in cross section,   the curved center portion including a plurality of segments comprising multiple outwardly extending segments and multiple inwardly extending segments in cross section,   the plurality of segments extending in the longitudinal direction,   the building panel being curved in the longitudinal direction along its length without having transverse corrugations therein,   a particular segment of the plurality of segments having a depth greater than that of another segment to accommodate the longitudinal curve in the building panel.   
     
     
         2 . The building panel of  claim 1 , wherein the sheet of building material comprises sheet metal having a thickness between about 0.040 inches and about 0.060 inches. 
     
     
         3 . The building panel of  claim 1 , wherein one of the plurality of segments is positioned at a middle of the curved center portion. 
     
     
         4 . The building panel of  claim 1 , wherein one of the connecting portions comprises a hook portion and another of the connecting portions comprises a hem portion, the hook portion and the hem portion being complementary in shape for joining the building panel to adjacent building panels. 
     
     
         5 . A building structure comprising a plurality of interconnected building panels, each building panel formed from sheet material, each building panel extending in a longitudinal direction along its length and having a shape in cross section in a plane perpendicular to the longitudinal direction, each building panel comprising:
 a curved center portion in cross section;   a pair of side portions extending from the curved center portion in cross section; and   a pair of connecting portions extending from the side portions in cross section,   the curved center portion including a plurality segments comprising multiple outwardly extending segments and multiple inwardly extending segments in cross section, the plurality of segments extending in the longitudinal direction.   the building panel being curved in the longitudinal direction along its length without having transverse corrugations therein,   a particular segment of the plurality of segments having a depth greater than that of another segment to accommodate the longitudinal curve in the building panel, wherein one the connecting portions of one building panel is connected to one of the connecting portions of an adjacent building panel.   
     
     
         6 . The building structure of  claim 1 , wherein the sheet of building material comprises sheet metal having a thickness between about 0.040 inches and about 0.060 inches. 
     
     
         7 . The building structure of  claim 1 , wherein one of the plurality of longitudinal deformations is positioned at a middle of the curved center portion. 
     
     
         8 . The building structure of  claim 1 , wherein the sheet material comprises steel sheet metal of approximately 0.060 inches in thickness, the building structure comprising a self-supporting span having a width ranging from 110 feet to 155 feet. 
     
     
         9 . A building panel formed from sheet material, the building panel extending in a longitudinal direction along its length and having a shape in cross section in a plane perpendicular to the longitudinal direction, the building panel comprising:
 a curved center portion in cross section;   a pair of side portions extending from the curved center portion in cross section;   a pair of connecting portions extending from the side portions in cross section,   the curved center portion including a plurality segments comprising multiple outwardly extending segments and multiple inwardly extending segments in cross section,   the plurality of segments extending in the longitudinal direction,   the building panel being curved in the longitudinal direction along its length without having transverse corrugations therein.   a particular segment of the plurality of segments having a depth greater than that of another segment to accommodate the longitudinal curve in the building panel; and   wherein the sheet material comprises steel sheet metal having a thickness between about 0.060 inches and about 0.080 inches, and wherein the length of the building panel ranges from 110 feet to 155 feet, such that the building panel can be joined to adjacent building panels to form a building structure comprising a self-supporting span having a width ranging from 110 feet to 155 feet.   
     
     
         10 . The building panel of  claim 9 , wherein the sheet of building material comprises sheet metal having a thickness of about 0.060 inches. 
     
     
         11 . The building panel of  claim 9 , wherein one of the plurality of segments is positioned at a middle of the curved center portion. 
     
     
         12 . The building panel of  claim 9 , wherein one of the connecting portions comprises a hook portion and another of the connecting portions comprises a hem portion, the hook portion and the hem portion being complementary in shape for joining the building panel to adjacent building panels.