Note: Descriptions are shown in the official language in which they were submitted.
CA 02573544 2007-01-10
ROOFING PANELS AND ROOFING SYSTEM
EMPLOYING THE SAME
FIELD OF THE INVENTION
The present invention pertains to the field of roofing, and more particularly
to a
roofing system comprising a plurality of roofing panels, each roofing panel
having the
appearance of a plurality of individual shingles and adapted to be slidingly
engageable with
like roofing panels disposed horizontally and vertically adjacent thereto.
BACKGROUND
For years the task of roofing a dwelling or other structure has conventionally
been
undertaken using a plurality of individual shingles, whether of asphalt,
slate, tile, etc., These
individual shingles must be painstakingly laid one at a time in successive
horizontal rows
starting at a roof's lower edge and proceeding upwardly therefrom to the peak,
with each
individual shingle being fastened to the roofing substrate. This is a labor
intensive and time
consuming process. Moreover, the shingles of each successive row must be laid
so as to
slightly overlap those of the preceding row, an arrangement requiring
considerable care in
order to ensure that the rows of shingles are disposed in proper relative
position. Further
complicating this task is the fact that successive rows of shingles are often
staggered in
relation to preceding rows in order to provide a more aesthetically pleasing
appearance to the
finished roof. This requires an even greater degree of care to ensure that the
individual
shingles are properly aligned to convey the desired appearance.
Apart from the issue of time, roofing can also be expensive, particularly
where more
exotic roofing materials such as slate, tile, or wood are desired.
Accordingly, it is most
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common to employ as roofing comparatively inexpensive asphalt shingles.
However, others
have more recently developed polymeric roofing which resembles such exotic
roofing
materials. But despite this advance, little has been done heretofore to
facilitate the rapid
completion of the roofing task. At best, others have developed roofing panels
having the
appearance of just two or three individual shingles arranged side-by-side
horizontally in a
single row. While such roofing materials may speed up the process of laying
each successive
row of shingles, the improvement is only marginal over the conventional
roofing installation
methodology.
SUMMARY OF THE DISCLOSURE
The present invention addresses the foregoing problems of the prior art in the
provision of a roofing system a plurality of roofing panels each having a
bottom surface and
a top surface, opposite upper and lower edges and opposite lateral edges. The
top surface has
the appearance of a plurality of individual shingles. The roofing panels are
adapted for
sliding engagement with each other along their opposite upper and lower edges
and opposite
lateral edges when positioned vertically and horizontally adjacent.
In one embodiment of the present invention, the top surface of each roofing
panel has
the appearance of a plurality of individual shingles arranged in a plurality
of vertically
adjacent, horizontally extending rows. In one variation of this embodiment,
the top surface of
each roofing panel has the appearance of a plurality of individual shingles
arranged in a
plurality of vertically adjacent, horizontally extending rows with each
successive row
staggered relative to the preceding row. The lateral edges of each roofing
panel are stepped to
correspond to the staggered rows.
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According to one feature of the present invention, each roofing panel
comprises a
plurality of hooks disposed proximate one of the upper or lower edges and one
of the lateral
edges, and a plurality of tabs disposed proximate the other of the upper or
lower edges and
the other of the lateral edges. The tabs of each roofing panel are slidingly
receivable within
the hooks of vertically and horizontally adjacent roofing panels to thereby
permit sliding
engagement between roofing panels disposed horizontally and vertically
adjacent each other.
In another feature of this invention, at least the upper edge of each roofing
panel
comprises a plurality of laterally extending slots for receiving fastening
elements
therethrough. The slots are defined along vertically recessed portions of the
upper edge
intermediate the plurality of tabs or hooks provided on the upper edge.
According to still another feature of the present invention, the bottom
surface of each
roofing panel includes a plurality of ribs projecting downwardly therefrom.
Per yet another feature of the instant invention, the roofing system comprises
a
plurality of edging strips each having the appearance of the bottom portions
of a plurality of
individual shingles arranged in a horizontal row. Each edging strip is
slidingly engageable
with the bottom edge of at least one roofing panel disposed vertically
adjacent thereto.
In one embodiment, each edging strip comprises a plurality of hooks or tabs
disposed
proximate an upper edge of the edging strip, these hooks or tabs adapted to
engage with the
hooks or tabs provided on the bottom edge of a vertically adjacent roofing
panel to permit
sliding engagement therebetween. In another aspect of this embodiment, the
upper edge of
each edging strip further comprises a plurality of laterally extending slots
for receiving
fastening elements therethrough, the slots being defined along vertically
recessed portions of
the upper edge intermediate the plurality of tabs or hooks provided on said
upper edge.
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According to yet another feature of the present invention, each roofing panel
further
comprises indicia facilitating the selective horizontal spacing of each
roofing panel with a
horizontally adjacent roofing panel. In one embodiment thereof, these indicia
comprise a
plurality of temperature lines each indicating a predetermined horizontal
spacing between
horizontally adjacent roofing panels at a predetermined ambient temperature.
Per still another inventive feature, each edging strip of the presently
disclosed roofing
system further comprises indicia facilitating the selective horizontal spacing
of each edging
strip with a horizontally adjacent edging strip. In one embodiment thereof,
these indicia
comprise a plurality of temperature lines each indicating a predetermined
horizontal spacing
between horizontally adjacent edging strips at a predetermined ambient
temperature.
According to yet another inventive feature of the present invention, each
roofing
panel includes at least one flexible stop projecting from the bottom surface
thereof, the at
least one stop positioned for abutting contact with a lateral edge of another
roofing panel
positioned vertically adjacent thereto. In one embodiment thereof, each
roofing panel is
provided with a plurality of such flexible stops positioned proximate each of
the plurality of
hooks disposed proximate the upper or lower edges. Each such stop projects
from the bottom
surface of each roofing panel so as to be positioned for abutting contact with
a lateral edge of
another roofing panel positioned vertically adjacent thereto.
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BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood with reference to the written
description and drawings, of which:
FIG. 1A comprises a top plan view of a single roofing panel according to the
exemplary embodiment of the present invention;
FIG. 1B comprises a bottom plan view of the roofing panel of FIG. 1A;
FIG. 2A is a top plan view of a single edging strip according to the exemplary
embodiment of the present invention;
FIG. 2B comprises a bottom plan view of the edging strip of FIG. 2A;
FIG. 3A depicts in perspective an edging strip according to the present
invention, the
edging strip shown in an operation environment secured to the roof substrate
of a dwelling;
FIG. 3B is a cross-sectional view of the edging strip of FIG. 3A, taken along
lines
III;
FIGS. 4A and 4B are respectively a top plan view and a perspective view of the
opposing ends of adjacent edging strips;
FIG. 5 depicts in perspective the securement of a first roofing panel
according to the
exemplary embodiment of the present invention on to the roofing underlayment
or substrate
of a dwelling and into engagement with a previously installed edging strip;
FIG. 6 is a bottom plan view of a roofing panel and edging strip in engagement
with
each other;
FIGS. 7A and 7B illustrate in top plan-view the manner of engagement between a
single roofing panel and both a horizontally adjacent roofing panel and an
edging strip;
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FIG. 8 is a detailed top plan-view depicting the manner of engagement between
horizontally adjacent roofing panels; and
FIGS. 9, 9A, and 9B are detailed quartering perspectives of vertically
adjacent
roofing panels, depicting in detail the manner of engagement and subsequent
relative
movement between them.
DETAILED DESCRIPTION
Referring now to the drawings, wherein like numerals refer to like or
corresponding
parts among the several views, the present invention will be seen to most
generally comprise
a roofing system including a plurality of roofing panels adapted for sliding
engagement with
like roofing panels positioned vertically and horizontally adjacent thereto.
Turning to FIGS. 1A and 1B, each such roofing panel 10 is characterized by an
upper
surface ha (FIG. 1A) and a bottom surface lib (FIG. 1B), opposite upper 12a
and lower
12b edges and opposite lateral edges 13a, 13b.
With continuing reference to FIG. 1A, the upper surface ha of each individual
roofing panel 10 is formed to represent a plurality of vertically adjacent,
horizontally
extending rows of shingles 14. Still more particularly, the upper surface 11a
of the illustrated
embodiment is formed to create the appearance of a plurality of individual
shingles 14
arranged in a plurality of vertically adjacent, horizontally extending rows.
Further to this
particular embodiment, each successive row is staggered relative to the
preceding row, and
the lateral edges 13a, 13b of the roofing panel 10 are correspondingly stepped
to
accommodate the staggered rows.
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The roofing panels 10 of the present invention may be formed of any material
known
to be suited to use as a roofing material, with a polymeric material being
preferred but not
required. And while each roofing panel 10 as shown in the exemplary embodiment
is
monolithic, it will be understood that such construction is only preferred and
that each
roofing panel may, in the alternative, comprise an unitary element fashioned
from two or
more separate constituent components.
Referring particularly to FIG. 1B, sliding engagement between vertically and
horizontally adjacent roofing panels is accomplished, in the illustrated
embodiment, by the
provision of a plurality of hooks 15 disposed proximate one or more of the
upper 12a or
lower 12b edges and one or more of the lateral edges 13a, 13b, and the
provision of a
plurality of tabs regions 20 disposed proximate one or more of the upper 12a
or lower 12b
edges and one or more of the lateral edges 13a, 13b.
Referring also to FIGS. 9, 9A, and 9B, each hook 15 of this embodiment more
specifically comprises a generally J-shaped jaw 16 extending from the bottom
surface lib of
the panel 10 so as to define an intermediate opening 17 ¨ i.e., between the
jaw 16 and the
bottom surface lib -- dimensioned to slidingly receive therein a tab portion
20' of an
adjacent panel 10'.
Each of the tabs portions 20, 20' (in FIGS. 9, 9A, and 9B) in turn,
constitutes as
shown a generally planar portion of the roofing panel defined proximate one or
more of the
upper 12a (12a' in FIGS. 9, 9A, and 9B) or lower 12b edges and one or more of
the lateral
edges 13a, 13b as mentioned previously. As shown best in FIGS. 9, 9A, and 9B,
each tab
20' is further characterized by dimensions sufficient to permit relative
lateral sliding
movement of the hook 15 of another roofing panel therealong, thus facilitating
relative
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sliding movement of adjacent roofing panels due to thermal expansion and
contraction, all as
described further hereinbelow.
As will be appreciated with reference to this specification, the arrangement
of hooks
15 and tabs 20 may be reversed, or a combination of hooks 15 and tabs 20 may
be provided
on the edges 12a or 12b, 13a or 13b, as desired.
Referring now to FIGS. 1A, 1B, and 9, securement of each individual roofing
panel
to the roofing substrate or underlayment is facilitated by the provision of a
plurality of
laterally extending slots 21(21' in FIG. 9) positioned about the perimeter of
the roofing
panel, including at least along the upper edge 12a (12a' in FIG. 9). Each such
slot 21, 21' is
10 dimensioned to receive a fastening element, such as nail N or the like,
therethrough. As
shown, each slot 21, 21' is defined along a vertically recessed portion of the
panel edge 12a
(12a' in FIG. 9), with tabs 20, 20' being defined therebetween by vertically
raised portions
of the same edge.
Referring specifically to FIG. 1B, in order to reinforce the structure of each
roofing
panel 10, and further to aid in maintaining the upper surface ha at a desired
distance from
the roofing substrate so as to facilitate the circulation of air therethrough,
the bottom surface
lib of the each roofing panel 10 includes a plurality of ribs or stand-offs 22
projecting
downwardly therefrom.
Referring now to FIG. 8, each roofing panel 10 is optionally provided with
indicia
facilitating the selective horizontal spacing of each roofing panel with a
horizontally adjacent
roofing panel, thereby ensuring that subsequent expansion and contraction of
roofing panels
due to changes in ambient temperatures do not lead to unwanted separation or
buckling of
adjacent panels. More particularly according to the illustrated embodiment,
each roofing
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panel is provided with a plurality of horizontally staggered lines 25 or other
indicia each
representing a desired position of the extreme lateral edge (indicated at 13a'
in FIG. 8) of an
adjacent roofing panel 10' in relation thereto and, by association, the extent
of engagement
between the tabs 20 and hooks 15' of such adjacent panels. These lines 25,
which in the
illustrated embodiment are positioned proximate a lateral edge 13b of each
roofing panel 10,
are further associated with indicia 26 reflecting several ambient
temperatures, each such
temperature reflecting an approximate ambient temperature under which the
roofing panels
of the present invention may be installed.
Turning next to FIGS. 1B, 9, 9A and 9B, each roofing panel 10 is, in order to
facilitate the precise alignment of vertically adjacent roofing panels
relative to each other,
optionally provided with one or more flexible stops 30 projecting downwardly
from the
bottom surface lib proximate each of those hooks 15 disposed adjacent the
upper and/or
lower edges 12a, 12b. As best shown in FIGS. 9A and 9B, each such stop 30 is
positioned
intermediate the length of an adjacent hook 15, thereby defining a stop
surface for the upper
edge 12a' of an adjacent panel 10' before the corresponding tabs 20' are fully
received in the
openings 17 in hooks 15 so that the edge 12a' abuts against the end walls 18
of hooks 15.
Preferably, though not necessarily, one stop 30 is provided adjacent either
side of each hook
15 as shown. The specific position of the abutments 30 is predetermined as
that which will
permit subsequent expansion and contraction of adjacent panels 10, 10' ¨ and
the
corresponding relative movement of slidingly engaged hooks 15 and tabs 20' --
due to
changes in ambient temperatures without causing either unwanted separation of
the panels
occasioned by disengagement of the tabs 20' and hooks 15, or buckling of
adjacent panels
10, 10' occasioned by the force of edge 12a' acting against the end walls 18
of hooks 15.
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Preferably, though not necessarily, each abutment 30 is formed integrally with
the
panel 10, although it will be appreciated that the abutments 30 may be affixed
to the panels
subsequent to their formation.
As mentioned, each stop 30 serves to define a positive stop for the lateral
edge 12a'
5 of an adjacent panel 10' as the panel 10 is installed, thereby
identifying for the installer the
preferred relative positioning between the panels 10, 10'. To permit
subsequent relative
movement of the installed panels 10, 10' as a result of changes in ambient
temperatures, each
stop 30 is also sufficiently flexible so as to yield (FIG. 9B) under the
pressure of the lateral
edge 12a' of an adjacent panel 10' acting thereagainst as such panel 10'
expands in
10 consequence of increased ambient temperatures.
Referring next to FIGS. 2A, 2B, 4A and 4B, the roofing system of the present
invention further comprises a plurality of edging strips 40 each having a
bottom edge 41b
proximate which the edging strip is formed to represent the bottom edges of a
plurality of
individual shingles 43, an upper edge 41a, and opposite lateral edges 42a,
42b. As with the
roofing panels 10 (not shown in FIGS. 2A and 2B), each edging strip 40
includes a plurality
of slotted holes 44 for receiving fastening elements (such as nails or the
like) therethrough.
Also as with the roofing panels 10 described above, the plurality of slotted
holes 44 are
defined in vertically recessed portions of an upper edge 41a of the edging
strip, while the
vertically raised portions of the upper edge 41a positioned therebetween
define a plurality of
tab portions 45 slidingly engageable with hooks 15 of vertically adjacent
roofing panels in a
manner akin to that employed to slidingly engage the roofing members 10 with
each other.
To facilitate the installation of adjacent edging strips 40, 40', etc. at
desirable
distances so as to permit the subsequent temperature-induced expansion and
contraction of
CA 02573544 2007-01-10
these elements without unwanted buckling or disengagement, each edging strip
is optionally
provided with indicia facilitating the selective horizontal spacing of each
edging strip 40 with
a horizontally adjacent edging strip 40'. More particularly according to the
illustrated
embodiment, best shown in FIG. 4A, each edging strip 40 is provided with a
plurality of
horizontally staggered lines 46 or other indicia each representing a desired
position of the
extreme lateral edge (indicated at 42a' in FIG. 4A) of an adjacent edging
strip 40' in relation
thereto. These lines 46 are further associated with indicia 47 reflecting
several ambient
temperatures, each such temperature reflecting an approximate ambient
temperature under
which the edging strips of the present invention may be installed.
1() In
the illustrated embodiment, each edging strip 40 is formed of a suitable
polymeric
material such as is presently known in the art for the manufacture of roofing
materials.
However, it will be understood that other materials also known to those
skilled in the art may
be substituted. Also in the illustrated embodiment, each edging strip 40 is
characterized by an
overall length equivalent to the width of a single roofing panel 10. Again,
however, it will be
appreciated that this length may be varied, being either shorter or longer
than that particularly
illustrated.
Referring now to FIGS. 3A through 8, there is shown the exemplary installation
of a
roof according to the inventive system using the roofing panels 10 and edging
strips 40 as
heretofore described.
As with convention, the roofing system of the present invention is installed
on a
suitable substrate, such as wood panels adhered to the frame of a dwelling.
Also per
convention, it will be understood as desirable to have the substrate further
covered with a
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CA 02573544 2007-01-10
waterproof underlayment material, such as a polymeric liner, sandwiched
between the
substrate and the elements of the roofing system.
Turning first to FIGS. 3A and 3B, the first step in installation of a roof
according to
the instant invention is to preferably secure a plurality of edging strips 40
along the bottom
edge of the roof 50. Each strip 40 is laid successively, preferably beginning
at the farthest
lateral point along the bottom edge of the roof. When each edging strip 40 is
in the desired
position, fasteners such as nails or the like are inserted through one or more
of the slotted
holes 44 to secure the edging strip 40 to the roof substrate (e.g., wood
panels overlaid with a
water resistant sheathing).
Referring next to FIGS. 4A and 4B, installation of successive edging strips
40', etc.
is achieved by sliding such successive edging strip laterally into abutting
contact with the
preceding edging strip (e.g., 40) and thereafter securing the successive strip
40', etc. in place
in the same manner described previously.
To facilitate the installation of the successive edging strips 40' at a
distance relative to
the preceding edging strip 40 permitting the subsequent temperature-induced
expansion and
contraction of these edging strips relative to each other without producing
unwanted
separation or buckling, the successive edging strip 40', etc. is positioned so
that the terminal
end 42a' thereof is aligned with the positioning line 46 or other indicia on
the edging strip 40
which closest approximates the prevailing ambient temperature at the time of
installation.
Referring next to FIGS. 5 and 6, installation of a first roofing panel 10 onto
the roof
50 and into engagement with a previously installed edging strip 40 is
depicted. More
particularly, it will be seen that the roofing panel 10 is placed on the roof
substrate such that
the innermost lateral edge (denoted by 13a in FIGS. 5 and 6) is in alignment
with the farthest
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CA 02573544 2007-01-10
lateral edge of the roof 50. The roofing panel 10 is then moved vertically
downwards to bring
the hooks 15 positioned along the lower edge 12b thereof slidingly into
engagement with the
correspondingly positioned tabs 45 defined along the upper edge 41a of the
previously
installed edging strip 40, in exactly the same manner as that described
previously for
engagement of the tabs and hooks of vertically adjacent roofing panels in
reference to FIGS.
9, 9A and 9B. Thus, upon the first indication of abutting contact between the
upper edge 41a
and the stops 30 positioned adjacent each hook 15 ¨ thus identifying for the
installing user
that the relative position between the panel 10 and the upper edge 41a of the
edging strip 40
is that which will permit subsequent vertical expansion of the panel 10 due to
increases in the
ambient temperature without causing unwanted buckling -- the user preferably
ceases urging
the panel 10 further vertically downward into engagement with the edging strip
40.
With the roofing panel 10 so aligned relative to the edging strip 40,
fasteners are
inserted through the slotted holes 21 to fix the roofing panel 10 in position.
Any excess X of
the roofing panel 10 extending beyond the innermost lateral edge 13a of the
roof 50 is then
trimmed off to present a neat appearance therealong.
Turning now to FIGS. 7A and 7B, there is depicted the subsequent step of
installing a
second (or subsequent) roofing panel 10', etc. in position horizontally
adjacent the previously
installed roofing panel 10. More particularly, it will be seen that the
roofing panel 10' is
placed on the roof (not depicted) adjacent the previously installed roofing
panel 10. The
roofing panel 10' is then moved vertically downwards to bring the hooks 15
(not visible)
positioned along the lower edge 12b thereof slidingly into engagement with the
correspondingly positioned tabs 45 provided on the upper edge 41a' of the
previously
installed edging strip 40' in the same manner as described previously in
connection with the
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roofing panel 10 and edging strip 40. The roofing panel 10' may then be slid
horizontally
towards the previously installed roofing panel 10 to bring the hooks 15' (not
visible)
positioned along the lateral edge 13a' thereof slidingly into engagement with
the tabs 20
defined along stepped lateral edges 13b of the roofing panel 10.
To facilitate the installation of successive adjacent roofing panels 10, 10',
etc. at a
distance permitting the subsequent temperature-induced expansion and
contraction thereof
without causing unwanted separation or buckling of the panels, the installing
user positions
the outermost lateral edge 13a' of the panel 10' with the line 25 or other
indicia which
closest approximates the prevailing ambient temperature at the time of
installation, all as
described previously.
With the roofing panel 10' so positioned, fasteners are inserted through the
slotted
holes 15' to fix the roofing panel in position.
It will be understood from the foregoing that the installation of successive
roofing
panels in the same horizontal row of roofing panels 10, 10', etc. continues in
the manner
described until an entire row is installed across the roof. Thereafter,
subsequent vertical rows
of roofing panels are installed in similar fashion, with the hooks 15 provided
along the
bottom edge 12b of each such roofing panel being slidingly engaged with the
tabs 20
provided along the upper edges 12a of vertically lower roofing panels in
identical fashion to
the engagement between the hooks 15 of roofing panels and the tabs 45 of the
edging strips
40 already described hereinabove.
Upon complete installation of all rows of roofing panels on all surfaces of
the roof,
there is further installed a plurality of ridge panels (not shown)
characterized by an inverted
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CA 02573544 2013-04-24
V-shaped cross-section. However, such ridge panels constitute no part of the
current
invention.
Naturally, variations in the exemplary manner of installation heretofore
described are
possible, as will be apparent to those of ordinary skill in the art.
It will be appreciated from the foregoing disclosure that the present
invention
provides a roofing system of employment thereof, which facilitates the
inexpensive and rapid
installment of a roof having the appearance of comprising multiple individual
shingles.
Of course, the preceding specification is merely illustrative of the present
invention,
and those of ordinary skill in the art will appreciate that many additions and
modifications to
the present invention, as set out in this disclosure, are possible without
departing from the
spirit of this invention as defined in the appended claims.
