U.S. patent application number 10/107191 was filed with the patent office on 2003-10-02 for roofing shignle.
Invention is credited to Shirota, Muneyasu.
Application Number | 20030182887 10/107191 |
Document ID | / |
Family ID | 30117275 |
Filed Date | 2003-10-02 |
United States Patent
Application |
20030182887 |
Kind Code |
A1 |
Shirota, Muneyasu |
October 2, 2003 |
ROOFING SHIGNLE
Abstract
The present invention relates to a roofing shingle, which can
surely prevent water such as rainwater from leaking through a roof.
A roofing shingle has a rectangular plate (11) provided with first
through fourth seam portions (11a-11d). The first and second seam
portions (11a, 11b) are positioned in a pair along opposite side
edges of said plate and folded in opposite directions with respect
to a plane of said plate. The third and fourth seam portions (11c,
11d) are positioned in a pair along opposite end edges of said
plate and folded in opposite directions with respect to the plane
of said plate. The roofing shingle comprises a waterproofing sheet
member (20) having a sheet (21) with its configuration greater than
that of said plate and adhesive layers (22a, 22b) provided on both
sides of the sheet. The sheet member is positioned and adhered on
the plate (11) so that a gap or space formed between the seam
portion and a corresponding seam portion of an adjacent roofing
shingle is closed and filled with an edge portion (21a, 21d) of the
sheet.
Inventors: |
Shirota, Muneyasu;
(Urasoe-shi, JP) |
Correspondence
Address: |
David E. Dougherty
Dennison, Schultz & Dougherty
612 Crystal Square 4
1745 Jefferson Davis Highway
Arlington
VA
22202
US
|
Family ID: |
30117275 |
Appl. No.: |
10/107191 |
Filed: |
March 28, 2002 |
Current U.S.
Class: |
52/533 ; 52/519;
52/539; 52/545 |
Current CPC
Class: |
E04D 2001/3414 20130101;
E04D 1/28 20130101; E04D 1/18 20130101; E04D 3/362 20130101; E04D
1/365 20130101 |
Class at
Publication: |
52/533 ; 52/519;
52/539; 52/545 |
International
Class: |
E04D 001/00 |
Claims
What is claimed is:
1. A roofing shingle having a plate (11) provided with first and
second seam portions (11a, 11b) positioned in a pair along opposite
side edges of said plate and folded in opposite directions with
respect to a plane of said plate, and third and fourth seam
portions (11c, 11d) positioned in a pair along opposite end edges
of said plate and folded in opposite directions with respect to the
plane of said plate, comprising a waterproofing sheet member (20)
having a sheet (21) with its configuration greater than that of
said plate and adhesive layers (22a, 22b) provided on both of top
and back sides of the sheet, said sheet member being positioned and
adhered on said plate so as to make an extension area of the sheet,
and edge portions (21a, 21d) of said sheet being inserted into the
first and fourth seam portions (11a, 11d), whereby a gap formed
between said seam portion and a corresponding seam portion of an
adjacent roofing shingle is filled with said edge portion (21a,
21d) of said sheet and said extension area of the waterproofing
sheet member overlaps with a corresponding waterproofing sheet
member of another adjacent roofing shingle to adhere to each
other.
2. A roofing shingle according to claim 1, wherein a configuration
of a corner of said sheet adhered on said plate is coincident with
a configuration of a corner of said plate and the corner of said
sheet is overlaid on the corner of said plate.
3. A roofing shingle according to claim 2, wherein said plate (11)
is provided with an extending part (12) with an aperture (12a)
through which an anchoring member (31) extends.
4. A roofing shingle according to claim 1, further comprising a
release member applied to cover said adhesive layer in said
extension area of said sheet.
5. A roofing shingle according to claim 1, further comprising means
for cushioning the roofing shingle and venting a backside area of
the shingle, which is provided on a backside of said sheet.
6. A roofing shingle according to claim 1, wherein said plate is
made of a sheet metal.
7. A roofing shingle according to claim 3, wherein said sheet is
provided with a notch (25) in said extension area so that said
extending part (12) of an adjacent roofing shingle is uncovered
with said sheet.
8. A roofing shingle according to claim 1, wherein said seam
portion (11a, 11b, 11c, 11d) is adapted to be brought into
interlocking engagement with the corresponding seam portion of an
adjacent roofing shingle by relatively displacing one of the
roofing shingles, whereby said gap is filled with said edge portion
(21a, 21d) of said sheet (21).
9. A roofing shingle according to claim 1, wherein said edge
portion (21a, 21d) is inserted into said seam portion to an extent
that the overlapping distance (T) of a leading edge (27, 27') of
said edge portion (21a, 21d) and an apex (18, 18') of a seam
portion of said adjacent shingle is at least 10 mm.
10. A roofing shingle according to claim 1, wherein a leading edge
(27, 27') of said edge portion (21a, 21d) is inserted into said
seam portion to an extent that said leading edge is in close
proximity to a turning part (17, 17') of said seam portion (11a,
11d).
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a roofing shingle, and more
particularly, to such a roofing shingle which can surely prevent
water such as rainwater from leaking through a roof.
BACKGROUND OF THE INVENTION
[0002] FIG. 11 is a perspective view generally illustrating a
Dutch-lap roof with use of conventional roofing shingles, the
roofing shingles made of a sheet metal being successively laid on a
roof board.
[0003] As shown in FIG. 11, a Dutch-lap type of roof is constructed
on a house typically built in a conventional manner, and the
Dutch-lap roof has an asphaltic waterproofing material 102 and a
thermal insulating material (not shown) laid on a roof board 101. A
plurality of shingles 104, each being made of a metallic roofing
sheet, are installed on the waterproofing material 102. The
metallic roofing shingles 104 are successively arranged on the
waterproofing material 102, starting from a lowermost eaves plate
103, and the shingles 104 are secured to the roof board 101 at
clips 105 by nails 106, respectively. Reference numerals 107, 108
denote a sub-structural flashing board and a sub-structural verge
board, respectively.
[0004] Each of the roofing shingles 104 is formed in a rectangular
configuration. The shingle 104 has a first seaming edge portion
104a downwardly folded or turned toward its back or underneath side
along its longitudinal edge, and a second seaming edge portion 104b
upwardly folded or turned toward its top or upper side along
another longitudinal edge. Further, the roofing shingle 104 has a
third seaming edge portion 104c upwardly folded or turned toward
its top side in its transverse right-hand edge, and a fourth
seaming edge portion (not shown) downwardly folded or turned toward
its back side along its transverse left-hand edge.
[0005] These seaming portions allow "flat lock seams" (or pinching
lock seams) to be provided on the roof.
[0006] The conventional roof with use of such a roofing shingle
might be able to effect a satisfactory waterproofing performance,
so long as it is observed within a certain term of time after
construction.
[0007] However, as shown in FIG. 12, a clearance or gap may be
created between the shingle 104 and the asphaltic waterproofing
material 102 during a long-term of use, owing to a deterioration of
fixing means for the shingle, or the like. This results in a
condition in that a quantity of rainwater may leak into the
underside of roofing shingle through a passage of water as shown by
arrows A, B. This kind of water leakage tends to be observed
especially in a low-pitched part, a crest part or a curved part of
a roof, and so forth. Even if the waterproofing work is executed
prior to the roofing work, it is difficult to keep its
waterproofing performance in a perfect condition. This is because
the waterproofing material has to be partially broken by anchor
screws or nails used for at least temporarily anchoring the roofing
shingles in position of the substrate and the screws or nails in
contact with water gradually lose its anchoring force for their
rusting or deteriorating tendency.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is, therefore, to provide
a roofing shingle, which can surely prevent water such as rainwater
from penetrating therethrough.
[0009] To achieve this object of the invention, the present
invention provides a roofing shingle having a plate (11) provided
with first and second seam portions (11a, 11b) positioned in a pair
along opposite side edges of said plate and folded in opposite
directions with respect to a plane of said plate, and third and
fourth seam portions (11c, 11d) positioned in a pair along opposite
end edges of said plate and folded in opposite directions with
respect to the plane of said plate, comprising
[0010] a waterproofing sheet member (20) having a sheet (21) with
its configuration greater than that of said plate and adhesive
layers (22a, 22b) provided on both of top and back sides of the
sheet, said sheet member being positioned and adhered on said plate
so as to make an extension area of the sheet, and edge portions
(21a, 21d) of said sheet being inserted into the first and fourth
seam portions (11a, 11d),
[0011] whereby a gap formed between said seam portion and a
corresponding seam portion of an adjacent roofing shingle is filled
with said edge portion (21a, 21d) of said sheet and said extension
area of the waterproofing sheet member overlaps with a
corresponding waterproofing sheet member of another adjacent
roofing shingle to adhere to each other.
[0012] According to the present invention, the waterproofing sheet
member (20) has the sheet (21) acting as a waterproofing layer
(synthetic fiber/synthetic rubber layer) on a roof board (101) and
the adhesive layers (adhesive rubber layers) (22a, 22b) applied to
the top and back sides of the sheet (21), as shown in FIG. 4. The
sheet (21) is adhered to one side of the plate (sheet metal) (11)
by the adhesive layer, as shown in FIG. 1. The edge portion (21a,
21d) of the sheet (21) is inserted into the seam portion (11a,
11d), but the other edge portion of the sheet (21) extends over the
seam portion (11b, 11c) to make an outward extension area, which
overlaps with a corresponding sheet of a waterproofing sheet member
of another adjacent roofing shingle and which adheres thereon.
[0013] When installing the roofing shingles (YH) on the roof board,
the flat lock seam portions (11c, 11d; 11a, 11b) of the roofing
shingles (YH1, YH2; YH1, YH11) are engaged with each other and the
extension area of the sheet member adheres to the sheet member of
the adjacent shingle, as shown in FIG. 8. The edge portion (21a,
21d) of the sheet seals the upper and lower seam portions (11c,
11d; 11a, 11b) of the shingles (YH1, YH2; YH1, YH11) and the nail
or screw (31) is completely sealed by the overlapping sheet
members. Therefore, rainwater does not penetrate into the underside
of the shingles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other objects and advantages will become more
readily apparent when considered in relation to the preferred
embodiments as set forth in the specification and shown in the
drawings in which:
[0015] FIGS. 1A, 1B and 1C show a longitudinal side elevation, a
plan view and a transverse side elevation of a roofing shingle
according to a first embodiment of the present invention;
[0016] FIGS. 2A, 2B and 2C show a longitudinal side elevation, a
plan view and a transverse side elevation of a metal plate in the
first embodiment:
[0017] FIGS. 3A, 3B and 3C show a longitudinal side elevation, a
plan view and a transverse side elevation of a waterproofing sheet
member in the first embodiment;
[0018] FIG. 4 shows an enlarged cross-sectional view of the
waterproofing sheet member;
[0019] FIG. 5 shows a cross-section of the roof constructed with
use of the roofing shingle of the first embodiment;
[0020] FIGS. 6A and 6B illustrate the process of constructing the
roof with use of the roofing shingle of the first embodiment;
[0021] FIG. 7 illustrates the roofing process continuing the
process shown in FIG. 6;
[0022] FIGS. 8A and 8B illustrate an function of the roofing
shingle of the first embodiment which prevents water from
penetrating into the underside of the shingle, wherein FIG. 8A
shows an enlarged cross-sectional view of a portion indicated by an
arrow in FIG. 6B and FIG. 8B shows a cross-section taken along a
line VIIIB-VIIIB in FIG. 7;
[0023] FIGS. 9A, 9B and 9C show a longitudinal side elevation, a
plan view and a transverse side elevation of a roofing shingle
according to a second embodiment of the present invention;
[0024] FIG. 10 shows an enlarged cross-section of the waterproofing
sheet member according to the second embodiment;
[0025] FIG. 11 shows a perspective view, partially broken away, of
a roofing shingle of the prior art; and
[0026] FIG. 12 shows an enlarged cross-sectional view of the
conventional roofing shingle, in which a state of rainwater leakage
is illustrated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] I. First Embodiment
[0028] (1) Structure of Roofing Shingle
[0029] Referring to FIG. 1, a roofing shingle YH, which is a
roofing component, segment or module, is generally formed in a
rectangular configuration, wherein the shingle YH comprises a
metallic (copper) sheet-like member or plate 10 and a waterproofing
sheet member 20, each having a substantially rectangular
configuration. The member 20 is provided with an adhesive material
applied on the opposite sides thereof and release paper sheets
covered on the adhesive material.
[0030] Referring to FIG. 2, the metallic plate 10 is a panel formed
in a generally rectangular profile by a rectangle-shaped sheet
metal 11, which is substantially rigid but elastically deformable.
The sheet metal 11 has a first seam portion or flat lock seam
portion 11a which is downwardly folded or turned toward its back
side along its longitudinal edge, and a second seam portion 11b
which is upwardly folded or turned toward its top or front side
along another longitudinal edge. The sheet metal 11 also has a
third seam portion 11c upwardly folded or turned toward its top
side along its transverse edge and a fourth seam portion 11d
downwardly folded or turned toward its back or underneath side
along another transverse edge. These seam portions are formed to
have a U-shaped cross-section for "flat lock seam" (or pinching
lock seam).
[0031] The sheet metal 11 is provided with a nailing portion 12
outwardly extending therefrom at an upper-right corner. The nailing
portion 12 has a central aperture 12a, which is used for at least
temporarily fixing the roofing shingle on a roof board by a nail
(not shown). The nailing portion 12 is formed by an extension of
the sheet metal 11 and effects the same functions as in the clip
105 of the prior art (see FIG. 11). Since provision of the clip can
be omitted in the present embodiment, a saving in manufacturing
cost and a decrease in the number of parts to be installed can be
achieved.
[0032] As shown in FIGS. 3 and 4, the waterproofing sheet member 20
has an elastic waterproofing core layer 21 made from a synthetic
fiber and a synthetic rubber. The waterproofing sheet member 20 has
a generally rectangular profile greater than that of the sheet
metal 11 to make an extension extending across the third and fourth
seam portions 11b, 11c. The waterproofing sheet member 20 is
provided with a top adhesive rubber layer 22a on the top side
surface of member 20 and a top release paper sheet 23a over the
layer 22a. The waterproofing sheet member 20 is further provided
with a back adhesive rubber layer 22b on the underside of the
member 20 and a back release paper sheet 23b over the layer 22b. A
synthetic rubber sheet or rubber/asphalt sheet with adhesive
layers, e.g., Gamlon MG base B manufactured by TAJIMA ROOFING Co.
Ltd. is preferably employed as the waterproofing sheet member
20.
[0033] Referring now to FIG. 3, an exposed area 24 of the
waterproofing sheet member 20 is illustrated as a hatched rectangle
as indicated by zone-I, in which the top release paper sheet 23a is
preliminarily removed or peeled from the waterproofing sheet member
20, so that the top adhesive rubber layer 22a is uncovered therein.
In the area as indicated by zone II, the layer 22a remains covered
with the sheet 23a. The uncovered area 24 allows the waterproofing
sheet member 20 to be preliminarily adhered to the underside of the
sheet metal 11 as shown in FIG. 1. The member 20 and the sheet
metal 11 are positioned relatively to each other and integrally
combined with each other in such a manner that a notch 25 is formed
at the upper-left corner of the shingle YH. The notch 25 is used to
temporarily expose the nailing portion 12 of the adjacent sheet
metal 11 during the roofing work, as shown in FIG. 6B, and is
adapted to adjust or regulate the thickness of the roofing. The
lower-left corner of the plate 10 as seen in FIG. 2 has a
configuration identical with a configuration of the corresponding
corner of the member 20 as seen in FIG. 3, and the member 20 and
the plate 10 are aligned with each other along their edges as shown
in FIG. 1.
[0034] The left and lower edge portions of the sheet member 20 are
inserted into the U-shaped seam portions 11a, 11d to an extent that
the edges of the member 20 is in close proximity to the edges of
the seam portions 11a, 11d.
[0035] (2) Roofing Process
[0036] The process of roofing (Dutch-lap roofing) will be described
hereinafter with reference to FIGS. 5-8. In FIG. 5, a cross-section
of the structure after construction is illustrated. In FIGS. 6-8,
it is assumed that the basic structure including the eaves part 103
has been already constructed.
[0037] The back release paper sheet 23b (FIG. 4) of a first roofing
shingle YH1 is removed and the shingle YH1 is positioned and
adhered on a roof board 101 in a predetermined orientation along
the eaves part 103, as shown in FIG. 6A. A nail 31 made of
stainless steel is then driven into the roof board 101 through the
aperture 12a of the nailing portion 12 so as to anchor the roofing
shingle YH1 on the board 101. Thereafter, the top release paper
sheet 23a in the zone II having an L-shaped configuration is
removed from the shingle YH1 so that the member 20 is uncovered in
a formation of L-shape to expose the layer 22a.
[0038] Referring to FIG. 6B, a second roofing shingle YH2, from
which the bottom release paper sheet 23b has similarly been
removed, is then adhered to the roof board 101 in a position
adjacent to the shingle YH1, while the second roofing shingle YH2
is displaced in a direction shown by arrow X in FIG. 6B, in a
condition that the fourth seam portion 11d of the shingle YH2 is
engaged with the third seam portion 11c of the first roofing
shingle YH1 and that the shingles YH1, YH2 are longitudinally
aligned with each other. The layer 21 of the second shingle YH2
overlaps the zone II, i.e., the extension area of the layer 21 of
the first shingle YH1, as shown in FIG. 8A.
[0039] The interlocking mechanism is shown in FIG. 8A, which is an
enlarged cross-sectional view of the part C shown in FIG. 6B. The
left edge portion 21d of the second synthetic fiber/synthetic
rubber layer 21 (YH2) closes and sealingly fills a space or gap
formed between the third seam portion 11c of the first sheet metal
11 (YH1) and the fourth seam portion 11d of the second metal sheet
11 (YH2). Therefore, rainwater flowing in a direction of an arrow D
can be surely blocked by the left end 21d of the layer 21, and does
not penetrate therethrough to reach the roof board 101. Thus, a
rainwater leakage of the roof is surely prevented from occurring.
Preferably, a leading edge 27 of the layer 21 of the shingle YH2
outwardly extends across an edge 17 of the seam portion 11c, and
the distance T between the edge 27 and an apex 18 of the seam
portion 11c of the shingle YH1 is equal to or greater than 10
mm.
[0040] In accordance with the steps and the engagement manner as
set forth above, the other roofing shingles YH are successively
placed and anchored on the roof board 101 until the first stage of
roofing shingles YH1, YH2, YH3 . . . are provided in a row along
the eaves part 103 of the roof.
[0041] Referring next to FIG. 7, a roofing shingle YH11 for the
second roofing stage, from which the back release paper sheet 23b
has been removed, is adhered and anchored onto the roof board 101
in a condition that the first seam portions 11a of the roofing
shingle YH11 is aligned and equally engaged with the second seam
portions 11b of the roofing shingles YH1, YH2. In the setting step
of the shingle YH11, the shingle YH11 is upwardly displaced in a
direction of arrow Y in a condition that the first seam portion 11a
of the shingle YH11 is in an interlocking engagement with the
second seam portions 11b of the shingles YH1, YH2. The engagement
manner of the seam portions 11a, 11b are shown in FIG. 8B. The edge
portion 21a of the layer 21 of the shingle YH11 closes and
sealingly fills a space or gap formed between the second seam
portion 11b of the shingle YH1 installed in the first roofing stage
and the seam portion 11a of the shingle YH11 installed in the
second roofing stage. The extension area, i.e., the zone II of the
layer 21 of the shingle YH1 overlaps the layer 21 of the shingle
YH11, as shown in FIG. 8B. The stainless steel nails 31 and nailing
portions 12 of the sheet metals 11, which have been already secured
in the first roofing stage, is completely covered with the layers
21 of the shingle YH11 installed in the second roofing stage.
Preferably, a leading edge 27' of the layer 21 of the shingle YH11
outwardly extends across an edge 17' of the seam portion 11b, and
the distance T' between the edge 27' and an apex 18' of the seam
portion 11b of shingle YH1 is equal to or greater than 10 mm.
[0042] Rainwater flowing in a direction of an arrow E is blocked by
the edge portion 21a of the shingle YH11. The stainless steel nails
31 and nailing portions 12 of the shingle YH1 are completely
covered with the layers 21 of the shingle YH11, and therefore, the
rainwater does not reach the roof board 101. Thus, the rainwater is
surely prevented from penetrating through a series of roofing
shingles YH.
[0043] After the roofing process for the second roofing stage has
been completed, roofing works for the third, fourth and further
roofing stages are successively carried out to complete the whole
roof as shown in FIG. 5, wherein the roofing shingles YH are placed
and anchored in the manner as set forth above.
[0044] II. Second Embodiment
[0045] The first embodiment relates to the roofing shingle adhered
on the roof board. However, the second embodiment relates to a
roofing shingle further comprising means for preventing an
expansion or bulge of waterproofing sheet, which may be caused by
moisture vapor generating from a concrete substrate in a case where
the roofing shingle is mounted on the concrete substrate.
[0046] According to the second embodiment, a roofing shingle YH0
comprises a metallic plate 10 and a waterproofing sheet member 20A,
as shown in FIGS. 9 and 10.
[0047] The waterproofing sheet member 20A comprises a back adhesive
rubber layer 22b as in the first embodiment, a plurality of
nonwoven fabric belts or liner menders 41 integrally attached to
the underside surface of the layer 22b. The belts 41 are spaced
apart from each other, in parallel with each other. The other
nonwoven fabric belts or liner menders 42 are similarly attached to
the underside surface of the layer 22b, the belts 42 extending in a
direction perpendicular to the belts 41 and connecting with the
belts 41 at their ends. A set of the belts 41, 42 acts as a
cushioning member. As the nonwoven fabric, TEXTOGLASS (glass fiber
fabric) is preferably employed, which is available from KANEBO Co.
Ltd.
[0048] When such a roofing shingle YH0 is placed on a concrete
substrate, an expansion or bulge of the material is preventing from
occurring in the roofing shingle YH0, since the moisture vapor from
the concrete substrate is absorbed and dispersed by fluid passages
of the nonwoven fabric belts and exhausted to the atmosphere
therethrough.
[0049] As will be apparent from the foregoing, the present
invention provides an improved roofing shingle which can perform a
substantially perfect waterproofing function for a long time
without maintenance, since the roofing shingle can prevent a
leakage of rainwater and a peeling off from the roof even in a
strong wind and rain upon a typhoon, hurricane or the like.
[0050] Further, the present invention allows the waterproofing and
roofing works to be performed at the same time and therefore, the
cost of construction work can be reduced.
[0051] Furthermore, the present invention may be applied to various
types of roof, such as M-shaped roof, Y-shaped roof, low-pitched
roof, curved roof, arch roof, doomed roof in addition to the normal
gable, shed or pent roof, since a substantially perfect
waterproofing function can be surely achieved.
[0052] In addition, as the waterproofing sheet member is integrally
combined with the roofing shingle, the waterproofing sheet member
follows and cushions a motion of the substrate involved in cracks
or the like. Therefore, the roofing shingle and the waterproofing
sheet member thereof are not broken by the action or motion of the
substrate.
[0053] It is understood that this invention is not to be limited to
the particular embodiments shown and described above, since many
modifications may be made, and it is contemplated by the appended
claims to cover such modifications as fall within the true spirit
and scope of this invention.
[0054] Although the embodiments have been described as to the
roofing shingles of rectangular configuration, the present
invention may similarly be applied to any of various other
configurations such as square or rhombus. Thus, the present
invention may also be applied to a diagonal roofing as well as the
Dutch-lap roof as set forth above.
[0055] Although the aforementioned roofing shingles are made of a
sheet metal (copper), the present invention may similarly be
applied to plates made of various other materials, such as plastic
sheets, flat tiles and slate tiles.
[0056] Moreover, the present invention may be applied to a wide
range of products from a high-quality roofing shingle to an
economical roofing shingle, in dependence on the selection of sheet
metal. As the sheet metal, various kinds of metal, such as
titanium, stainless steel, aluminum and iron, in addition to
copper, may be adopted. Further, a thin sheet metal can be used for
reducing the costs of raw material and manufacture.
[0057] In addition, the shingle in the aforementioned embodiment is
provided with the nailing portion which temporarily hold the
shingle in position. However, the shingle may be provided with a
plurality of nailing portions, or the nailing portion may be
omitted from the shingle. Further, a clip or clips of a
conventional structure may be used for anchoring the shingle on the
roof board.
* * * * *