Crowning panel assembly

Abstract

A panel assembly ( 40 ) that addresses oil canning when installed over a substrate or deck ( 72 ) is disclosed. The panel assembly ( 40 ) includes a panel ( 42 ). The panel ( 42 ) includes a first primary panel surface ( 44 ) that faces the substrate ( 72 ) in the installed configuration, as well as a second primary panel surface ( 46 ) that faces away from the substrate ( 72 ) in the installed configuration. Another component of the panel assembly ( 40 ) is a first structure ( 60 ) that is disposed between the panel ( 42 ) and the substrate ( 72 ). Typically, either a first surface ( 62 ) of the first structure ( 60 ) is chemically bonded directly to the first primary panel surface ( 44 ) such that an interface between the first surface ( 62 ) and the first primary panel surface ( 44 ) includes a chemical bond, or a second surface ( 64 ) is chemically bonded directly to the substrate ( 72 ) such that an interface between the second surface ( 64 ) and the substrate ( 72 ) includes a chemical bond. In any case, the first structure ( 60 ) produces a convexity on the second primary panel surface ( 46 ) to address oil-canning effects or stress wrinkling of the panel ( 42 ).

1 . A panel assembly, comprising:
 a metal panel, comprising:
 first and second primary panel surfaces that are oppositely disposed, wherein said first primary panel surface projects toward a substrate when said metal panel is installed over the substrate, and wherein said second primary panel surface projects away from the substrate when said metal panel is installed over the substrate; and 
   a first structure comprising a first surface, wherein said first surface is chemically bonded directly to said first primary panel surface such that an interface between said first surface of said first structure and said first primary panel surface comprises a chemical bond, wherein said first structure produces a convexity on said second primary panel surface when said metal panel is installed over the substrate.   
   
   
       2 . The panel assembly of  claim 1 , wherein said first surface of said first structure is chemically bonded directly to said metal panel by an adhesive. 
   
   
       3 . The panel assembly of  claim 1 , wherein said first structure comprises foam. 
   
   
       4 . The panel assembly of  claim 1 , wherein said first structure is an extrusion. 
   
   
       5 . The panel assembly of  claim 1 , wherein said first surface of said first structure is flat prior to said first structure being chemically bonded to said first primary panel surface. 
   
   
       6 . The panel assembly of  claim 1 , wherein said first structure comprises a second surface that is flat prior to said metal panel being installed over the substrate, that is disposed opposite of said first surface, and that faces the substrate when said metal panel is installed over the substrate. 
   
   
       7 . The panel assembly of  claim 1 , wherein said first structure is hollow. 
   
   
       8 . The panel assembly of  claim 1 , wherein said first surface of said first structure is flat prior to said first structure being chemically bonded to said first primary panel surface, wherein said first structure comprises a pair of curved sidewalls that are convex, as well as a second surface that is flat prior to said metal panel being installed over the substrate, that is disposed opposite of said first surface, and that faces the substrate when said metal panel is installed over the substrate. 
   
   
       9 . The panel assembly of  claim 1 , wherein said metal panel further comprises first and second longitudinal edges, wherein said first and second longitudinal edges are each configured to interconnect with a longitudinal edge of another metal panel to define a standing seam. 
   
   
       10 . The panel assembly of  claim 1 , wherein said metal panel further comprises first and second protruding structures that are linearly extending and that protrude at least generally away from the substrate when said metal panel is installed over the substrate. 
   
   
       11 . The panel assembly of  claim 10 , wherein each of said first and second protruding structures is selected from the group consisting of a standing seam section and a rib. 
   
   
       12 . The panel assembly of  claim 10 , wherein said first structure is linearly extending and is disposed at least generally parallel with said first and second protruding structures. 
   
   
       13 . The panel assembly of  claim 10 , wherein said metal panel further comprises first and second longitudinal edges that are laterally spaced, as well as first and second transverse edges that are longitudinally spaced and that each extend between and interconnect said first and second longitudinal edges, wherein said first structure extends at least generally from said first transverse edge to at least generally said second transverse edge. 
   
   
       14 . The panel assembly of  claim 10 , wherein said metal panel further comprises a flat base section that extends between said first and second protruding structures, and wherein said first structure is chemically bonded to said first primary panel surface within said base section, wherein a center-to-center distance between said first and second protruding structures is at least about 12 inches. 
   
   
       15 . The panel assembly of  claim 14 , wherein said first structure at least generally bisects said base section in a lateral dimension that coincides with a spacing between said first and second protruding structures. 
   
   
       16 . The panel assembly of  claim 1 , wherein said metal panel further comprises a flat first base section, wherein said first structure is chemically bonded to said first primary panel surface within said first base section. 
   
   
       17 . A panel assembly, comprising:
 a panel, comprising:
 first and second primary panel surfaces that are oppositely disposed, wherein said first primary panel surface projects toward a substrate when said panel is installed over the substrate, and wherein said second primary panel surface projects away from the substrate when said panel is installed over the substrate; and 
 first and second protruding structures that are linearly extending and that protrude at least generally away from the substrate when said panel is installed over the substrate; and 
   a first structure comprising a first surface that is chemically bonded directly to said first primary panel surface such that an interface between said first surface of said first structure and said first primary panel surface comprises a chemical bond, wherein said first structure produces a convexity on said second primary panel surface somewhere between said first and second protruding structures when said panel is installed over the substrate.   
   
   
       18 . A panel assembly, comprising:
 a panel, comprising:
 first and second primary panel surfaces that are oppositely disposed, wherein said first primary panel surface projects toward a substrate when said panel is installed over the substrate, and wherein said second primary panel surface projects away from the substrate when said panel is installed over the substrate; and 
 first and second protruding structures that are linearly extending and that protrude at least generally away from the substrate when said panel is installed over the substrate; and 
   a first structure that is hollow and that produces a convexity on said second primary panel surface somewhere between said first and second protruding structures when said panel is installed over the substrate and by said first structure interacting with said first primary panel surface.   
   
   
       19 . A building surface, comprising:
 a substrate;   a panel, comprising:
 first and second primary panel surfaces that are oppositely disposed, wherein said first primary panel surface projects toward said substrate, and wherein said second primary panel surface projects away from said substrate; and 
 first and second protruding structures that are linearly extending and that protrude at least generally away from said substrate; and 
   a first structure that comprises a first surface that is flat prior to said first structure being disposed to interact with one of said substrate and said first primary panel surface, wherein said first structure exerts a force on said first primary panel surface to produce a convexity on said second primary panel surface somewhere between said first and second protruding structures.   
   
   
       20 . A building surface, comprising:
 a substrate;   a panel, comprising:
 first and second primary panel surfaces that are oppositely disposed, wherein said first primary panel surface projects toward said substrate, and wherein said second primary panel surface projects away from said substrate; and 
   a first structure comprising a first surface chemically bonded directly to one of said first primary panel surface and said substrate such that an interface between said first surface of said first structure and said one of said first primary panel surface and said substrate comprises a chemical bond, wherein said first structure produces a convexity on said second primary panel surface.   
   
   
       21 . The building surface of  claim 20 , wherein said substrate is flat. 
   
   
       22 . The building surface of  claim 20 , wherein said first structure is chemically bonded directly to only one of said first primary panel surface and said substrate, and is in contact with and movable relative to the other of said first primary panel surface and said substrate. 
   
   
       23 . A building surface, comprising:
 a substrate;   a panel, comprising:
 first and second primary panel surfaces that are oppositely disposed, wherein said first primary panel surface projects toward said substrate, and wherein said second primary panel surface projects away from said substrate; and 
 first and second protruding structures that are linearly extending and that protrude at least generally away from said substrate; and 
   a first structure that is hollow and that produces a convexity on said second primary panel surface somewhere between said first and second protruding structures by said first structure interacting with said first primary panel surface.   
   
   
       24 . A method of installing a panel over a substrate, wherein said panel comprises first and second primary panel surfaces that are oppositely disposed, wherein said method comprises the steps of:
 disposing said panel over said substrate such that said first primary panel surface faces said substrate, such that said second primary panel surface faces away from said substrate, and such that a first structure is disposed between said first primary panel surface and said substrate;   providing a chemical bond directly between a first surface of said first structure and one of said first primary panel surface and said substrate such that an interface between said first surface of said first structure and said one of said first primary panel surface and said substrate comprises a chemical bond; and   producing a convexity on said second primary surface of said panel by said first structure being disposed between said first primary panel surface and said substrate.   
   
   
       25 . The method of  claim 24 , wherein said substrate is flat. 
   
   
       26 . The method of  claim 24 , wherein said providing a chemical bond step comprises providing a chemical bond between said first structure and only one of said first primary panel surface and said substrate.