Note: Descriptions are shown in the official language in which they were submitted.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
ROOFING PANEL SYSTEM
Technical Field
The invention relates to the field of roofing and siding, and more
particularly to a system of interlocking panels that can be used for
roofing and/or siding applications.
Back round
Roofing and siding panels of various kinds are known. Such
panels are generally fabricated with raised decorative elements simulat-
ing classic roofing and siding materials such as, for example, shake,
tile, brick, stone, and slate. Such panels may be fabricated from they-
moplastic sheets, by injection molded plastics, fiberglass molding, and
metal, among other materials . In comparison to real wood shakes or
tiles, such panels are generally easier t~ install, require less care,
provide a reduced fire ha~ard% and provide greater durability.
Summary of Invention
A roofing system according to the present invention includes
high-profile panels made from recycled rubber tire crumb and recycled
industrial polymers such as polyethylene and polypropylene or other
virgin plastics.
The panels incorporate a longitudinal locking mechanism along
the length of their front and back edges that allows each panel to lock to
its neighbor to produce a weather-resistant closure. This longitudinal
locking mechanism allows the panels to be continuously staggered to
avoid any repetition of pattern that would be unappealing to the eye of
the beholder. The portion of the longitudinal locking mechanism along
the rear edge of a panel protrudes upward, while the portion of the
longitudinal locking mechanism along the front edge is a longitudinal
cavity within an indented region on the underside of the panel, into
which the rear edge of an adjacent panel can latch. This longitudinal
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-2-
locking mechanism allows the panels to expand and contract and tighten
with exterior forces, such as wind.
Fasteners, for example nails or screws, may be used to fasten
each panel to a substrate along its rear edge through a nailing flange in
marked preferred locations. All such fasteners are protected by the
longitudinal locking mechanism against exposure to the elements.
The panels also have transverse locking mechanisms on each side,
adapted so that adjacent panels can be locked together in a side-to-side
manner. This transverse locking mechanism may be a hook and lap
arrangement, which offers a tight lock and easy alignment of the panels
during installation.
When interlocked together, the panels offer protection against
wind, rain, and other elements of nature. wilt-in cavities along the
front edge of the panels and in front of the longitudinal locking mecha-
nism diffuse wind-driven rain pressures and resist the entry of rain
along the front edge of the panel. If rain were to get past these cavities,
it would be quickly diffused when it reached the longitudinal locking
mechanism and would drain naturally away.
Additionally, the panels have supports built into the under
surface that evenly distribute forces to the substrate when the panels are
walked upon.
The undersurface is also specially designed with an integrated
venting system that allows for continual air flow under the panel,
reducing the possibility for moisture build-up from underneath, which is
a common source of wood rot or mold.
The panels can be manufactured to look like wood cedar shakes,
concrete tile, Spanish tile, Italian tile, slate and other textures on their
top and/or front visible surfaces. Many other designs may be imparted
to the visible surfaces as may be required or desired. The panels can be
colored to numerous synthetic colors to emulate the colors of nature -
for example, greys, black, or browns.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-3-
The panels ° polymer and rubber matrix makes them flexible and
gives them a high coefficient of expansion and contraction. Being
composed of recycled materials, the panels may be an environmentally
friendly and cost-competitive alternative to natural products. Addition-
s ally, the panels are themselves recyclable; if ever a panel has to be
recycled, it can simply be re-ground and reprocessed. The durability
and resistance to ultra-violet radiation of the polymer matrix offer an
extended life expectancy of about 50 years.
The panel design allows for easy application, thus cutting labor
costs and installation times. Because each panel contains an assembly of
three to five pieces of textured decorative elements (for example,
simulated shakes or tiles), they are easy to handle and install. For
example, the panels can be made about 16 inches by 40 inches (40 cm.
by 100 cm.), with an exposed surface when installed of about three
square feet (300 square cm.) and a thickness of about 1.g in ches (4.5
cm.) at the thickest protrusion.
while the most common usage of the panels is for roof applica-
dons, they may be also used for other applications - for example as
siding.
Accessory caps may be used on roof applications in respect of
changes of direction on various types of roofs - for example, on
gables, ridges, hips, or valleys, otherwise to cover any change in
direction where there are exposed edges of panels. These accessory
caps incorporate similar design features as the panels.
Brief Description of Drawings
Figure 1 is a top plan view of a panel embodying aspects of the
present invention.
Figure 2 is a front elevational view of the panel of Figure 1.
Figure 3 is a bottom plan view of the panel of Figure 1.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-4-
Figure 4 is a top, left, front oblique view of a system of panels
formed by connecting together a plurality of the panels of Figure 1.
Figure 5 is a bottom, left, front, oblique view of the system of
panels of Figure 4.
Figure 6 is a top plan view of the system of panels of Figure 4.
Figure 7 is a bottom plan view of the system of panels of Figure
4.
Figure 8 is a cross-sectional side view of the panel of Figure 1
taken along lines 8-8 of Figure 1.
Figure 9 is an enlarged cross-sectional side view of the longitudi-
nal protrusion portion of the panel of Figure 8, which forms one half of
the longitudinal locking mechanism.
Figure 10 is an enlarged cross-sectional side view of the longitu-
dinal cavity portion of the panel of Figure 8, which forms the other half
of the longitudinal locking mechanism.
Figure 11 is a cross-sectional view of two interconnected panels
taken along lines 11-11 of Figure 6.
Figure 12 is an enlarged cross-sectional view of the longitudinal
locking mechanism connecting the two panels of Figure 11.
Figure 13 is a front elevational view of two adjacent panels
showing a transverse locking mechanism for interconnecting the two
panels:
Figure 14 is a top, right, front oblique view of a roof having
installed thereon a plurality of interlocked panels and accessory caps
embodying aspects of the invention.
Figure 15 is a top plan view of the roof of Figure 14.
Figure 16 is a right elevational view of the roof of Figure 14.
Figure 17 is a top, right, front oblique view of a ridge cap em
bodying aspects of the invention.
Figure 18 is a bottom, right, front oblique view of the ridge cap
of Figure 17.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-S-
Figure 19 is a front elevational view of the ridge cap of Figure
17.
Figure 20 is a top plan view of the ridge cap of Figure 17.
Figure 21 is a bottom plan view of the ridge cap of Figure 17.
Figure 22 is a cross-sectional side view of the ridge cap of Figure
17 taken along lines 22-22 of Figure 20.
Figure 23 is a top, right, front oblique view of a hip cap embody-
ing aspects of the invention.
Figure 24 is a bottom, right, front oblique view of the hip cap of
Figure 23.
Figure 25 is a front elevational view of the hip cap of Figure 23.
Figure 26 is a top plan view of the hip cap of Figure 23.
Figure 27 is a bottom plan view of the hip cap of Figure 23.
Figure 2~ is a cross-sectional side view of the hip cap of Figure
23 taken along lines 2~-2~ of Figure 26.
Description
'Throughout the following description specific details are set forth
in order to provide a more thorough understanding of the invention.
T-lowever, the irwention may be practised without these particulars. In
other instances, well known elements have not been shown or described
in detail to avoid unnecessarily obscuring the present invention. Ac-
cordingly, the specification and drawings are to be regarded in an
illustrative, rather than a restrictive, sense.
Figure 1 is a top plan view and Figure 2 is a front elevation view
of a panel 10 according to an embodiment of the invention. Each panel
10 is preferably manufactured from a blend of recycled rubber tire
crumb and recycled industrial polymers such as polyethylene and
polypropylene or other virgin plastics. Such a polymer and rubber
matrix makes the panel 10 flexible and gives it a high coefficient of
expansion and contraction; expansion and contraction will be minimal
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-6-
but the flexibility of the panel 10 makes it resistant to cracking or
breaking. The preferred material composition also makes the panel 10
essentially impervious to water absorption or penetration. Being com-
posed of recycled materials, a panel 10 with such a material composition
may be an environmentally friendly and cost-competitive alternative to
natural products. Additionally, such a material composition would
make the panel 10 itself recyclable. If ever a panel 10 needed to be
recycled, it can be simply re-ground and reprocessed. The durability
and resistance to ultra-violet radiation of a panel 10 with such a material
composition offer an extended life expectancy of about 50 years. A
panel 10 of such a material composition also has high insulation and
sound dampening qualities. It is also lightweight, reducing the stress
and structural pressures on any building on which the panel 10 is in-
stalled.
Even so, a panel 10 according to the present invention could
conceivably be manufactured from any type of material or blend of
materials, including rubber, plastic, fiberglass, metal, and/or other
natural or synthetic materials.
Although the most common usage of the panel i1is for roofing
applications, it may also be used for other applications, such as siding.
Referring to Figures 1 and 2, a panel 10 according to an embodi-
meat of the invention includes decorative elements 12, the top and
frontal visible surfaces of which may be characterized by simulated
textures of wood shakes (cedar or otherwise), slate, stone, brick,
concrete tile, Spanish tile, Italian tile, other tile patterns, or any other
effects. Many other designs may be imparted to the visible surfaces as
may be required. The panel 10 may be colored to numerous synthetic
colors to emulate natural colors - for example, greys, black, or
browns .
Although each panel 10 is a unitary member, the decorative
elements 12 are preferably separated by gaps 14 to give the appearance
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
_7_
of discrete shakes, tiles, or other natural materials affixed adjacently.
The decorative elements 12 are preferably staggered so that their frontal
faces 16 form an irregular pattern when viewed from the top. This
irregular pattern avoids the artificial appearance that the frontal faces 16
would present if they were perfectly aligned. As noted, the frontal
faces 16 may also have simulated textures imparted to them to provide
integrity and consistency with corresponding simulated textures im-
parted to the top surfaces 18 of the decorative elements 12.
Although each panel 10 could conceivably include just one
decorative element 12, the panel 10 preferably includes a plurality of
decorative elements 12. For example, each panel 10 can have a single
row of three to five decorative elements 12 in the form of simulated
511akeS or tiles. A typical panel 10 with a single row of about three to
five simulated shakes or tiles can be, for example, made about 16 in ches
by 40 inches (40 cm. by 100 cn~.), with an exposed surface when
installed of about three square feet (300 square cm.) and a thickness of
about 1.g inches (4.5 cm.) at the thicl~est protrusion. A panel 10 of this
approximate size, combined with the general lightweight nature of such
panels 10, make the panels 10 easy to carry, position, align, and install,
thereby cutting labor costs and installation times. It is possible for each
panel 10 to have a plurality of rows of decorative elements 12 rather
than just a single row. I~owever, if the overall size of the panel 1is to
be maintained at about 16 inches by 40 inches (40 cm. by 100 cm.),
each decorative element 12 would then need to be made smaller, which
might be desirable for some applications but the decorative elements 12
might then no longer simulate the sizes and proportions of actual shakes
and tiles commonly found in building applications. Alternatively, the
size of the panel 10 can be made larger, but this should be balanced
against having a panel 10 sized for optimal ease of carrying and installa-
tion.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
_g_
Referring to Figure 1, each panel 10 has a nailing flange 20 along
its rear edge. The nailing flange 20 has recessed indicators 22 to show
preferred locations where fasteners may be inserted to affix each panel
to an underlying substrate. Fasteners, for example nails or screws,
5 may be used to fasten a panel 10 to a substrate or structure at one or
more of each recessed indicator 22.
Figure 3 is a bottom plan view of a panel 10 according to an
embodiment of the invention. As shown in Figure 3, a panel 10 accord-
ing to this embodiment is not of solid construction, but is preferably
10 hollow other than a network of structural supports that run between the
outer edges of the panel 10. In particular, a network of longitudinal
supports 24 which run from one side of the panel 10 to the other side,
and transverse supports 26 which run from the front of the panel 10 to
the back, form an overall structure that allows for contact and support
of the panel 1~ to the substrate to which it is fastened w1t11out the need
for the panel 1to be completely solid. The structure formed by the
longitudinal supports 24 and the transverse supports 2~ distributes any
weight or forces of pressure that may be imparted to the top surface of
any panels ~ 0 and evenly dissipates those pressures to the substrate,
whether such pressures are caused by elemental forces such as wield or
by someone walking on the panel 10, all without causing damage to the
integrity of the panel for the substrate. The longitudinal supports 2
and transverse supports 2provide strength and integrity to each panel
1, but allow the panel 10 to be manufactured using less material, while
achieving a more lightweight panel 10 that is both easier to install and
easier for the substrate or underlying structure to support. The struc-
tural supports need not be in a grid pattern as shown in Figure 3; any
other pattern that similarly distributes weight and pressure will also be
effective, although a grid pattern allows for simpler and more cost-
effective manufacturing.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-9-
Referring to Figures 3, 5, and g, structural cavities 25 created by
the multiple intersections of longitudinal supports 24 and transverse
supports 26 also enhance the isolative qualities of the panel 10 by
encapsulating pockets of air which become part of the natural insulation
mechanism of the panel 10. Along with the thermal qualities of the
composition of the preferred materials used in the manufacture of the
panels 10 themselves, the air pockets within the plurality of structural
cavities 25 give the panels 10 further isolative qualities which assist in
cost savings in the heating and air conditioning of buildings on which
panels 10 are interconnected into roofing or siding systems in hot or
cold climatic areas.
As best shown in Figures 5 and ~, the longitudinal supports 24
and transverse supports 26 are preferably slightly recessed from the
bottom of the panel X10 relative to the outer edges of the panel 10 - in
1~ particular, the side edges; this permits movement of the air pockets
trapped under the panel 10. Accordingly, the slightly recessed longitu-
dinal supports 24 and slightly recessed transverse supports 2~ together
form a structure which both provides structural support to the panel 1
and assists in the dissipation of any built-up moisture underneath the
panel 10 that may be created by moisture vapor which may percolate
from the substrate or otherwise, thereby resisting damage caused by
moisture in the form of damp rot, fungus or mold which proliferate in
areas of dampness. In other words, the longitudinal supports 2and
transverse supports 2provide both an effective support structure as
well as an integrated venting system for the panels 10.
In addition, as shown in Figures 2, 3, and 5, a plurality of slots
27 in the bottom surface of each panel 10 near its front and rear edges
connect air pockets that may otherwise be trapped beneath each panel 10
to pass to adjacent panels 10 to which they are connected, thereby
creating a complete and integrated insulating air blanket under a system
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
- 10-
of interconnected panels 10 to further alleviate the chance of any mois-
ture or vapor build up under a system of interconnected panels 10.
Such systems of interconnected panels 10 are shown in Figures 4
to 7. As shown in Figures 4 to 7, a plurality of panels 10 can be con-
s nected together to form an interconnected system of panels, intercon-
nected both in a side-to-side manner and in a front-to-back manner.
With respect to the front-to-back connectivity, each panel 10 has an
element of a longitudinal locking mechanism along its length near each
of its front and rear edges that allows it to interlock with an adjacent
panel 10 in front of it or behind it. With respect to the side-to-side
connectivity, each panel 10 preferably also has a transverse locking
mechanism on its sides that allows it to interlock with an adjacent panel
10 to its side. both the longitudinal locking mechanism and the trans-
verse locking mechanism will be described in more detail below.
Deferring to the cross-sectional side views of tl~ae panel 10 in
Figures ~, 9, 11, and 12, a longitudinal protrusion 28 extends upwardly
from the panel 10 in front of the nailing flange 2~, and forwardly
toward the frontal faces 1. Referring to Figure 1, the longitudinal
protrusion 28 preferably runs the length of the panel 10 near the rear
edge of the panel 10 but in front of the nailing flange 20. Tllis longit~-
dinal protrusion 28 forms one half of a longitudinal locking mechanism
that permits a panel 10 to be longitudinally interlocked with an adjacent
panel 1. In particular, the longitudinal protrusion 28 of one panel 1
interfits and interlocks with a corresponding longitudinal cavity 30 near
the frontal faces 16 of an adjacent panel 1, as shown in Figures 11 and
12.
Referring to Figures 10 to 12, the underside of each panel 10 has
an indented region 32 proximate to the frontal faces 16 of the panel 10.
The indented region 32 of each panel 10 is adapted to receive and
encompass both the longitudinal protrusion 28 and the nailing flange 20
of the adjacent panel 10 in front of it. Each indented region 32 has
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-11-
within it a longitudinal cavity 30 which interfits with and interlocks, in a
latching manner, with the longitudinal protrusion 28 of the adjacent
panel 10 in front of it. During installation, after the frontmost of two
adjacent panels 10 is fastened through its nailing flange 20 to the under-
lying substrate, the indented region 32 of the rearmost of the two panels
can be placed over both the longitudinal protrusion 28 and nailing
flange 20 of the frontmost panel 10 and then pulled backwards until its
longitudinal cavity 30 has interfitted and interlocked with the longitudi-
nal protrusion 28 of the adjacent panel 10 in front of it. ~nce the
10 longitudinal cavity 30 of the rearmost panel 10 is interlocked in a
latching manner with the longitudinal protrusion 28 of the adjacent panel
10 in front of it, the resulting longitudinal locking mechansm prevents
the two interlocked panels 10 from moving perpendicularly away from
each other. 'I'he indented region ~2 also, when the panel il0 is viewed
from the side, encompasses and protects the nailing flange 20 of the
panel tin front of it against elements such as water, wind, or wind-
driven rain. Further, once the rearmost of the two panels 10 has also
been fastened to the underlying substrate along its nailing flange 1, the
1~ngitudinal loclging mechanism prevents both bacl~ward movement of
the panel 10 as well as upward movement that might otherwise be
caused by wind uplift and rain near its frontal faces 16, without the need
for additional fasteners near the front of the panel 1.
Deferring to Figures 3, 5, 7, ~, 10, and 12, further resistance to
elemental forces is preferably provided by a plurality of additional
cavities 3along the underside of the panel 1, running strategically
along the full length of the frontal faces 16 of the panel 10. Each such
cavity 34 creates a vacuum break which disrupts any wind-driven rain
or water that may pass along the underside of the panel 10, thereby
resisting the hazardous effect such elements could potentially cause, and
draining the water naturally away.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-12-
Referring to Figure 12, any wind-driven rain or water that some-
how penetrates under the panel 10 past the cavities 34 is then stopped by
the longitudinal locking mechanism formed by the longitudinal cavity 30
of the panel 10 interfitting and interlocking with the longitudinal protru-
sion 28 of the adjacent panel 10 in front of it, which together create a
water-resistant joint which provides further resistance from wind-driven
rain or other elements which might otherwise penetrate under the panel
10. This longitudinal locking mechanism also protects the nailing flange
20 of the front panel 10 and the fasteners used to secure that panel 10
through nailing flange 20 to the underlying substrate. For even further
protection, as shown in Figures 8, 11 and 12, each panel 10 can have a
water stop 36 along the full length of its rear edge behind its nailing
flange 20, to further prevent moisture from penetrating past the water
st~p 3to reach the underlying substrate. ~s shown in Figures 11 and
1 ~ 12, the longitudinal protrusion 28 of one panel interfits and interlocks
with the longitudinal cavity 30 of an adjacent panel in a manner that
adds strength to the system of interconnected panels 10 and that in-
creases in strength with any exterior force that causes lift, such as wind.
As shown in Figures 4 to 7, the configuration of the longitudinal
locl~ing mechanism, namely, a substantially continuous longitudinal
protrusion 28 to which a corresponding longitudinal cavity 30 of one or
more adjacent panels 10 can be latched at an indefinite number of points
along the length of the longitudinal protrusion 28, allows for a continu-
ous side-to-side adjustment of adjacent rows of interlocking panels 10 to
achieve a laterally staggered effect, and prevent the proliferation of any
ongoing noticeable repetitive design which may have a negative appeal
to the look of the visual elements of the panels 10 when used in a system
of such panels 10.
In addition to a longitudinal locking mechanism for allowing a
plurality of panels 10 to be interlocked together in a front-to-back
manner, a transverse locking mechanism is also desirable for allowing
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-13-
panels 10 to be interlocked together in a side-to-side manner. Having a
transverse locking mechanism to interlock panels 10 together in a side-
to-side manner is preferable to simply laying the panels 10 next to one
another since interlocking provides improved protection of the underly-
ing substrate from the elements. If desired, the transverse locking
mechanism of each panel 10 can take a similar latching arrangement as
the longitudinal locking mechanism described above. However, given
that the longitudinal locking mechanism already serves to prevent
upward movement of each of a system of interlocked panels 10, and
given that fasteners through the nailing flange 20 already serve to
restrain side-by-side movement, the transverse locking mechanism of
the panels 10 can take a simpler form than the longitudinal locking
mechanism if desired, and need not be a latching arrangement similar to
the longitudinal locking mechanism. For example, the transverse
1~ locking mechanism of the panels 10 can take the form of a simple hook
and lap arrangement.
Figures 1, 2, 3, and 13 show one possible embodiment of a
transverse locking mechanism. In the example in Figures 1, 3, and 13,
the transverse locking mechanism consists of a transverse protrusion
extending upwardly from a panel 1~ along its right edge and a corre-
sponding transverse cavity 40 on the underside of an adjacent panel 10
along its left edge. the transverse protrusion 3of one panel 1
interfits and interlocks with the transverse cavity of the adjacent
panel 1to form an interlocking joint that resists moisture penetration of
the system of interlocked panels 10. 'This transverse locking mecha~usm
provides yet further protection against damaging water or moisture
ingress into the underside of a system of interlocked panels 10.
Still further protection against the elements is preferably built into
each panel 10 in the form of a reservoir cavity system located where the
longitudinal locking mechanism of a panel 10 intersects the transverse
locking mechanism. Referring to Figure 1, a recessed water reservoir
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-14-
42 extends downwardly from the top of a panel 10 at its right, rear
corner. Referring to Figure 3, a corresponding reservoir protrusion 44
extends downwardly from the underside of a panel 10 at its left, rear
corner. The reservoir protrusion 44 of one panel 10 is adapted t~
interfit and interlock into the water reservoir 42 of an adjacent panel 10
to its left. The water reservoir 42 of one panel 10 cooperates with the
reservoir protrusion 44 of the adjacent panel 10 to allow for the draining
of any moisture that may penetrate or wick between the end of the
longitudinal protrusion 28 of the first panel 10 and the opposing end of
the longitudinal protrusion 28 of the adjacent panel 10. In particular,
any such moisture in the water reservoir 42 drains down into an adjacent
exposed drain gap 46 where it can simply run off the panel 10. The
reservoir protrusion 44 interfits and interlocks into the adjacent water
reservoir 42 to also create a tight bond and positioning mechanism,
which assists to keep the ends of two adjacent panels ~0 in tight contact
and position with respect to each other, especially in cooperation with
the transverse locking mechanisms of those panels 10. The interlocking
of the transverse protrusion ~8 and the transverse cavity 4also facili-
tates additional alignment and tightness of placement between two
adjacent panels ~~.
~f course, it will be realized that the transverse protrusion 38, the
water reservoir 42, and the drain gap 6 could similarly be located on
the left edge of the panel 1, in which case the corresponding transverse
cavity 4and reservoir protrusion 44 would be located on the right edge
of the panel 10. ~hs long as the transverse protrusion 38 is on an oppo-
site side edge to the transverse cavity 40, and the water reservoir 42 and
an adjacent drain gap 46 are on an opposite side edge to the reservoir
protrusion 44, these elements will function as intended.
To install a system of panels 10, one should first remove any pre-
existing cladding material from the underlying substrate or structure,
and then cover the substrate with a suitable underlayment. Beginning at
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-IS-
the lowest edge of the roof or other substrate, one should then install a
' starter strip (not shown) that replicates only the rearmost, normally not
visible, portion of a panel 10. In particular, such a starter strip includes
elements equivalent to the nailing flange 20, longitudinal protrusion 28,
and water stop 36 of a panel 10, but not the decorative elements 12.
The starter strip can be, but need not be, the same length as the panels
being used in the same installation; also, the starter strip can be, but
need not be, made of the same material as the panels 10. For example,
the starter strip may be made of metal and extruded in a greater length
10 than the panels 10 being used in the same installation, which may be
made, for example, of a blend of rubber and plastic. The starter strip
may also incorporate and integrate along its front edge a drip edge
element, which would be similar to drip edges or gutter aprons typically
installed along the eaves and/or gables of conventional roofs. ~s
required, a series of such starter strips should be installed, by inserting
one or more fasteners through the nailing flange of each starter strip,
along the length of the edge of the substrate with the longitudinal protru-
sion portion of each starter strip closest to tile edge of the substrate and
the water stop portion farthest away.
after installing one ore more starter strips, as required, along the
lowest edge of the substrate, a first row of panels 10 should then be
interlocked to the installed starter strips by placing the indented region
32 of each of the row of panels lover the longitudinal protrusion and
nailing flange portions of the starter strips and then pulling each of those
panels 10 backward so as to engage the longitudinal locking mechanism
by latching the longitudinal protrusions of the starter strips into the
longitudinal cavities 30 of the panels 10. Each panel 10 in the row
should also be transversely interlocked with any adjacent panel 10 in the
row by interlocking the transverse protrusion 38 of each panel 10 into
the transverse cavity 40 of the panel 10 to its right, and by interlocking
the reservoir protrusion 44 of each panel 10 into the water reservoir 42
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-16-
of the panel 10 to its left. Each of the panels 10 in the row should then
be fastened to the substrate by inserting suitable fasteners through one or
more of the recessed indicators 22 in the nailing flange 20. Once the
first row of panels 10 has been installed, a second row can be installed
by interfitting and interlocking the longitudinal cavities 30 of the panels
in the second row to the longitudinal protrusions 28 of the panels 10
in the first row, and by transversely interlocking those panels 10 within
the second row together in the same manner as the first row, preferably
in a manner where the decorative elements 12 of the second row are
10 staggered with respect to the decorative elements 12 of the first row,
and then fastening the second row of panels 10 to the substrate by
inserting suitable fasteners through one or more of the recessed indica-
tore in the nailing flanges 20 of the panels 10 in the second row. This
procedure should be repeated for subsequent rows of panels 1L0 until the
maderlying substrate has been covered. again, the panels 10 within
each row should preferably be adjusted relative t~ panels 10 in adjacent
rows to avoid any repeated patterns between adJacent rows that will
result in an artificial overall appearance.
Figures 14 to 16 show longitudinally ~~lterlocked rows of trans-
versely interlocked pan els 0 installed on a roof. Referring to Figures
14 to 16, wherever the underlying substrate or structure experiences a
change in direction, such as a gable, ridge, hip, or valley (not Shown),
which may result in any edges of panels 1being otherwise exposed,
accessory caps incorporating similar design features to the panels 10
may be used to cover. those exposed edges. Referring to Figures 14 to
2~, such accessory caps may, for example, include ridge caps 50 for use
along horizontal ridges of a roof, as well as on gables; hip caps 70 for
inclined hips of a roof; valley caps (not shown) for horizontal or in-
clined valleys of a roof; and edge caps (not shown) for edges of a roof
(especially if the starter strip selected does not include an integrated drip
edge). Such accessory caps, like the panels 10, may have simulated
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-17-
textures imparted to their visible surfaces if desired to provide the
appearance of natural materials.
Figures 17 to 22 show a ridge cap 50 for installation along a ridge
of a roof over systems of interlocked panels 10 on either side of the
ridge, to protect the edges of those panels 10. Such a ridge cap 50 may
also be used as a gable cap, to protect the edges of panels 10 where they
end at a gable or rake of a roof. In the same manner as the panels 10,
each ridge cap 50 has a nailing flange 52 with recessed indicators 54 to
show preferred locations through which fasteners may be inserted to
affix each ridge cap 50 to the underlying substrate. The nailing flange
52 is analogous to the nailing flange 20 of a panel 10. Deferring to
Figures 17, 20, and 22, each ridge cap 50 has a ridge cap protrusion 56
extending upwardly and forwardly from its top surface in the same
manner as the longitudinal protrusion 2~ of a panel ~0. Deferring to
Figure 229 a corresponding ridge cap cavity 5~ in the underside of the
ridge cap 50 is adapted to receive the ridge cap protrusion 56 of an
adjacent ridge cap 5~. The ridge cap protrusion 5~ of a ridge cap 50
interfits and interlocks, in a latching manner, with the ridge cap cavity
5~ of the ridge cap 50 behind it, in a manner that protects the nailing
flange 52 from the elements.
Similar to the panel 10, the ridge cap 50 is preferably not of solid
construction, but rather has a network of longitudinal supports and
transverse supports 62 which are slightly recessed from the bottom of
the ridge cap 50 relative to the outer edges of the ridge cap 50 (in
particular, the side edges). This provides both structural support and
improved insulation value by providing an integrated blanket of air
underneath a system of interlocked ridge caps 50 covering a ridge of the
roof and the systems of interlocked panels 10 on either side of the ridge;
where used as a gable cap, this provides an integrated blanket of air
underneath the system of interlocked ridge caps 50 covering the gable
and the system of interlocked panels 10 that end at that gable.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-Ig-
Figures 23 to 2~ show a hip cap 70 for installation along a hip of
a roof over systems of interlocked panels 10 on either side of the hip, to
protect the edges of those panels 10. Although each hip cap 70 has a
hip cap cavity 78 in its front underside in the same manner that the ridge
cap 50 has a ridge cap cavity 58 in its front underside, the hip cap 70
need not have a fixed, integrated corresponding protrusion near its rear
top surface for latching with the hip cap cavity 78. Unlike the ridge cap
50 which is intended for a horizontal ridge, the hip cap 70 is intended
for hips having a variety of possible pitches. Accordingly, a hip cap 70
which does not include an integrated latching protrusion near its rear
edge, allows greater flexibility f~r adjustment to a variety of ro~f
pitches. After each hip cap 70 has been adjusted to the particular pitch
of the hip and installed on that hip, a separate removable locking mecha-
nism (not shown) is installed near the rear edge of the hip cap 70, the
1 ~ separate removable locking mechanism having a protrusion adapted to
interfit and interlock with the hip cap cavity 78. A subsequent hip cap
70 CaI1 then be interlocked behind that first hip cap 70 by interfitting and
interlocking the hip cap cavity 78 ~f that subsequent hip cap 70 with the
separate removable locl~ing mechanism installed onto the first hip cap
70. In other words, lzip cap °~0 has a hip cap protrusion that
interfits
and interlocks with its hip cap cavity 78, but that hip cap protrusion
(unlike the ridge cap protrusion 5integrated into the ridge cap 50) is
both removable from and re-attachable to the hip cap 7, in order to
allow hip cap 70 to be easily adjusted to a wide variety of pitches of
hips. While is it possible to manufacture the ridge cap 50 in a similar
manner with a removable and re-attachable ridge cap protrusion 56, this
would add an additional step into the installation of the ridge cap 50 and
is typically unnecessary in respect of the installation of a ridge cap 50
onto a horizontal ridge or onto a gable.
Similar to the ridge cap 50 and the panel 10, the hip cap 70 is
preferably not of solid construction, but rather has a network of trans-
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-19-
verse supports 82 which are slightly recessed from the bottom of the hip
cap 70 relative to the outer edges of the hip cap 70 (in particular, the
side edges); if desired, the hip cap. 70 can also have longitudinal sup-
ports (not shown) similar to the ridge cap 50 and the panel 10. This
provides both structural support and improved insulation value by
providing an integrated blanket of air underneath the system of inter-
locked hip caps 70 covering the hip of the roof and the systems of
interlocked panels 10 on either side of the hip.
Like a panel 10, and for the same reasons set out above in respect
of the panels 10, accessory caps like the ridge cap 50 and the hip cap 70
are preferably manufactured from a blend of recycled rubber tire crumb
and recycled industrial polymers such as polyethylene and polypropy-
lene or other virgin plastics. Even so, such accessory caps could
conceivably be manufactured from any type of material or blend of
materials, including rubber, plastic, fiberglass, metal, and/or other
natural or synthetic materials.
The ridge cap 50 and hip cap 70 are preferably manufactured so
that they are easily adjustable to any roofing application. Eor example,
the ridge cap 50 is preferably formed in one piece, in the angles) most
prevalent on sloped roof structures, but each ridge cap 50 preferably has
a hinge ~4 along its longitudinal center for adjusting the ridge cap 50.
The hinge 64 is preferably simply a portion of the ridge cap 5along its
longitudinal center that has been deliberately formed of lesser thickness
than the "flaps" surrounding the hinge 64 on either side, in order to
allow the ridge cap 50 to flex and adjust to various degrees larger or
smaller than the prevalent angle(s). Preferably, the hinge 64 will permit
adjustment of about between 10 to 20 degrees or more, but not so much
that it degrades the strength of the ridge cap 50. The hip cap 70 prefer-
ably has an analogous hinge 84 for adjusting the hip cap 70 in a similar
manner as the ridge cap 50.
CA 02505679 2005-05-25
WO 2004/074594 PCT/CA2004/000223
-20-
In conventional roofing applications, valley flashing is typically
installed onto each valley of the roof or other substrate prior to installing
the exterior roofing material, but no other covering is applied onto a
valley after the exterior roofing material has been installed on either side
of the valley. In respect of the present invention, valley flashing would
similarly typically be installed onto a valley of the substrate prior to
installing systems of interlocked panels 10 on either side of the valley.
Optionally, a system of interlocked accessory caps could also be in-
stalled onto the valley after installing those systems of interlocked panels
10, to further protect the edges of the panels 10 that meet along the
valley. As will be apparent to those skilled in the art in light of the
descriptions above and drawings of the ridge cap 50 and the hip cap 70,
a valley cap can be created for horizontal valleys by inverting the design
of the ridge cap ~0 and for inclined valleys by inverting the design of
the hip cap ~~. similarly, accessory caps could be created using the
same principles for any edge of a roof, whether gabled or otherwise.
As will be further apparent to those skilled in the art in light of the
examples in Figures 14 to 2~, accessory caps embodying aspects of the
111ventl~n can tale an infinite number of forms to suit any change in
direction on the surface of a roof or other substr~.te or structure.
As will be apparent to those skilled in the art in the light of the
foregoing disclosure, many alterations and modifications are possible in
the practice of this invention without departing from the scope thereof.
Accordingly, the scope of the invention is to be construed in accordance
with the substance defined by the following claims.
