Static structures (e.g. – buildings) – Lapped multiplanar surfacing; e.g. – shingle type – Interfitted sections
Reexamination Certificate
2000-02-29
2001-09-04
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
Lapped multiplanar surfacing; e.g., shingle type
Interfitted sections
C052S302100, C052S520000, C052S526000, C052S547000, C052S555000, C052S591500
Reexamination Certificate
active
06282858
ABSTRACT:
BACKGROUND—FIELD OF INVENTION
This invention relates generally to rigid roof panels as they apply to “pitched” roofs. More specifically, to the design, manufacture and installation methodologies of a roof panel system intended for use on roof construction with a minimum pitch of 3:12. This invention is an injection molded, fiberglass reinforced thermoplastic compound roof panel system that is designed to be installed directly onto the subject building's roof trusses or rafters in a sealed, interlocking, overlapping and self-draining manner.
BACKGROUND—DESCRIPTION OF PRIOR ART
In the past, roof and roof panel construction generally required a plywood or similar sheathing surface as a means of structurally/mechanically attaching the components to the building structure. Specific references can be made to a plurality of common roofing media.
These include asphalt or fiberglass shingles of the type disclosed in U.S. Pat. No. 3,903,340 and wood shingles such as cedar shakes, slate, clay, cementious and plastic/composite tiles of the types disclosed in U.S. Pat. Nos. 5,711,126; 5,635,125; 4,949,522; 4,514,947; 3,852,934 and 3,579,940. There are numerous types of metal panel systems such as disclosed in U.S. Pat. Nos. 4,759,165 and 4,406,106 as well. Each of these roof types requires that one or more waterproof membranes (e.g., tar paper) be installed over the sheathing surface before the roof covering media is installed.
Additional references herein are made to a plurality of roof panel systems manufactured with composite materials as well as prefabricated panel systems that integrate the plywood or rigid laminate sheathing into the assembly of the roof panel.
Each of the individual roofing media types has distinct advantages and disadvantages. Some of these are performance and some appearance related. For instance, cedar shakes look attractive but have problems such as flammability, moisture retention, mold and rot. Wood shakes will dry out over time in dry/sunny conditions and split, warp or crack. Insects can infest the shakes by boroughing into the body of the shake and weakening it there by reducing the useful lifespan of the product. Slate, clay and cement tiles solve these problems but require a relatively high level of maintenance to keep them secured, they are brittle and crack easily when walked on and require heavier sheathing to support their relatively high weight per square (100 sq.ft.). Slate, clay and cement tiles are prohibitively costly to purchase and install for average size/cost structures.
There is a plurality of composite products currently on the market that simulate wood shakes, slate and clay tiles as well as conventional shingles but these products generally offer minimal cost or performance advantages over the products they are meant to replace. As a result, little incentive for using these products is realized.
In all of the prior art, however, a rigid sheathing material is required whether it is applied prior to the roof media or in conjunction with a prefabricated panel. The rigid sheathing is required to structurally secure the roof trusses or rafters together and support roof loads as well as provide a continuous rigid surface for attaching the loose roof covering components.
The majority of the prior art is secured to the roof structure by means of nails or staples and oft times requires additional wood strips be secured horizontally to build up the top edge of the roof components. Virtually all of the prior art is installed in a systematic manner that requires the installer to begin at a lower corner of the roof structure and proceed in a horizontal left-to-right or right-to-left fashion until the first coarse is complete. Only after the first course is complete can the second coarse be started. Each subsequent coarse is completed in such a same manner by overlapping the previous coarse. Roofs of this type are secured to the structure with the nails or staples being applied by hand or via use of pneumatic nail or staple guns.
The entire process of completing the roof structure beginning at the roof trusses or rafters requires several days of labor with specially trained workers for each phase of the job. Typically, carpenters will apply the sheathing to the trusses and a roofing contractor will then apply the felt paper and roofing media. Some of the specialty type media such as slate and the various tiles require further specialized installers and are cost prohibitive for wide spread use on median market homes and buildings.
Of the prior art sited herein, only one, U.S. Pat. No. 5,635,125, addresses the issue of recyclability. Historically the scrap generated at construction sites constitutes a large percentage of landfilled waste. Conventional roofing media is difficult to collect, segregate and recycle. Each step in the construction of the roof structure generates its own type of scrap or waste which is either burned or simply hauled away in a dumpster, adding to the already overwhelming environmental burdens placed on existing landfills.
A search of the prior art did not disclose any patents that read directly on the claims of the instant invention, however, the following U.S. patents were considered related:
U.S. Pat. No.
Inventor(s)
Filing Date
5048255
Gonzales
2/12/90
4932184
Waller
3/6/89
4856236
Parker
8/15/89
4777776
Morrell
4/26/82
4759165
Getoor; Pottinger
5/30/86
4406106
Dinges
4/13/81
4343126
Hoofe
11/14/80
4279106
Gleason; Greenleaf
11/5/79
4028450
Gould
4/19/74
3943677
Carothers, et. al.
8/5/74
3875715
Martin, et. al.
6/21/73
3775925
Keiich
12/4/73
SUMMARY OF THE INVENTION—OBJECTS AND ADVANTAGES
It is the object of the present invention to provide a rigid roof construction for pitched roofs by systematically positioning a plurality of differing standard roof panel shapes, sizes and configurations directly over the roof trusses or rafters, eliminating the need for plywood or other sheathing and secondary moisture barriers. The plurality of panels are installed sequentially in a manner that provides for overlapping, underlapping and interlocking seams that include an integral seal and channels for shedding water.
A primary object of the invention is that each panel configuration incorporates a unique water channeling system that lies beneath the exposed surface of the panels at each seam. Moisture that is driven between adjoining panels by strong winds is shed from the roof structure by means of the integral water channels that are located on the horizontal head-lap and one end of each panel. Each panel has an integral seal located on the shoulder adjacent to an outboard of the upward facing water channel.
An additional object of the invention is that when positioned in the proper sequence, the downward facing shoulder compresses the seal thereby creating a double edge seal on both underlapping and overlapping panels. The shapes and sizes of the upward facing water channels and the corresponding downward facing shoulders is such that a simple and accurate method of location is realized.
Another primary objects of the invention is that the panels will be secured in place with threaded, self-sealing fasteners. The fastener holes are located on a plane above the water channels and inboard of the seals. This method of installation provides a continuous, rigid roof surface, which seals out wind driven moisture, efficiently drains moisture off of the roof structure and is effective in withstanding high winds that would normally damage or destroy more conventionally installed roof structures.
Another object of the current invention is to provide a rigid roof panel system that by means of the design and method of manufacture, a fiberglass mesh sheet is encapsulated during the molding process there by adding strength and stiffness to the body of each panel. A significant object of the present invention is that the encapsulated fiberglass mesh sheet provides for a Class A fire barrier when tested according to ASTM test E108-93 ANSI/UL 790 for flame spread, burning brand and intermittent flame requires less time and relatively unskilled la
Glessner Brian E.
Stephan Beth A.
Swick Andrew C.
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