U.S. patent application number 10/813485 was filed with the patent office on 2005-11-17 for metallic shingle construction.
Invention is credited to Hardin, George.
Application Number | 20050252136 10/813485 |
Document ID | / |
Family ID | 35308061 |
Filed Date | 2005-11-17 |
United States Patent
Application |
20050252136 |
Kind Code |
A1 |
Hardin, George |
November 17, 2005 |
Metallic shingle construction
Abstract
A shingle is formed of a panel of a metallic material. The panel
has a hole formed adjacent one side and a second hole formed
adjacent an opposite side. A plurality of holes are formed adjacent
a back edge of the shingle. Each of the holes resides within an
indentation fanned on the top surface and extending as a protrusion
on the bottom surface. An elastromeric epoxy coating is formed on
the top surface of the panel. Granules are affixed to the bottom
surface of the panel.
Inventors: |
Hardin, George; (Houston,
TX) |
Correspondence
Address: |
Michael B. Jolly
1018 Preston, 4th Floor
Houston
TX
77002
US
|
Family ID: |
35308061 |
Appl. No.: |
10/813485 |
Filed: |
March 30, 2004 |
Current U.S.
Class: |
52/518 |
Current CPC
Class: |
E04D 1/29 20190801; E04D
2001/005 20130101; E04D 1/265 20130101 |
Class at
Publication: |
052/518 |
International
Class: |
E04D 001/00 |
Claims
I claim:
1. A shingle comprising: a panel having a first side edge and a
second side edge and a front edge and a back edge, said panel being
formed of a metallic material, said panel having a first hole
formed adjacent said First side edge and a second hole formed
adjacent said second side edge, said panel having a plurality of
holes formed adjacent said back edge.
2. The shingle of claim 1, said panel having a plurality of slots
formed adjacent said front edge, said plurality of slots extending
transversely to said front edge: and extending partially toward
said back edge.
3. The shingle of claim 1, said panel having atop surface and a
bottom surface, each of said first and second holes being
surrounded by an indentation in said top surface extending
outwardly as a protrusion on said bottom surface.
4. The shingle of claim 3, said protrusion being nestable within
the indentation of another panel positioned below said panel.
5. The shingle of claim 1, said plurality of holes comprising three
holes spaced evenly from each other and positioned on said panel
between said first side edge aJ1d said second side edge.
6. The shingle of claim 3, each of said plurality of holes being
surrounded by another indentation in said top surface which extends
outwardly as a protrusion on said bottom surface.
7. The shingle of claim 1, said panel having an elastromeric epoxy
coating affixed to a surface thereof.
8. The shingle of claim 7, said panel having granules affixed to an
opposite surface thereof.
9. The shingle of claim 8, said panel having a first primer layer
interposed between said granules and said opposite surface of said
panel, said granules being adhesively secured to said first primer
layer, said panel having a second primer layer interposed between
said elastromeric epoxy coating and said panel.
10. A shingle comprising: a panel having a top surface and a bottom
surface, said panel having a plurality of holes formed therein so
as to extend between said top surface and said bottom surface, each
of said plurality of holes being surrounded by an indentation in
said top surface and extending as protrusion on said bottom
surface, said protrusion being nestable within the indentation of
an adjacent panel.
11. The shingle of claim 10, said panel having a first side edge
and second side edge and a front edge and a back edge, a first hole
of said plurality of holes formed adjacent said first side edge
centrally between said front edge and said back edge, a second hole
of said plurality of holes formed adjacent said second side edge
centrally between said front edge and said back edge, a set of
holes of said plurality of holes being formed adjacent said back
edge centrally between said first side edge and said second side
edge.
12. The shingle of claim 11, said panel having a plurality of slots
formed adjacent said front edge, said plurality of slots extending
transversely to said front edge and extending partially toward said
back edge.
14. The shingle of claim 10, said panel having granules affixed to
said top surface thereof, said panel having an elastromeric epoxy
coating affixed to said bottom surface thereof.
15. The shingle of claim 14, said panel having a first primer layer
interposed between said granules and said top surface of said
panel, said granules being adhesively secured to said first primer
layer, said panel having a second primer layer interposed between
said elastromeric epoxy coating and said bottom surface of said
panel.
16. A shingle comprising: a panel formed of a metallic material,
said panel having a top surface and a bottom surface, said panel
having granules affixed to said top surface, said panel having an
elastromeric epoxy coating affixed to said bottom surface.
17. The shingle of claim 16, said panel having a first primer layer
interposed between said granules and said top surface of said
panel, said granules being adhesively secured to said first primer
layer, said panel having a second primer layer interposed between
said elastromeric epoxy coating and said bottom surface of said
panel.
18. The shingle of claim 16, said panel having a first side edge
and second side edge and a front edge and a back edge, said panel
having a first hole formed adjacent said first side edge and a
second hole formed adjacent said second side edge, said panel
having a plurality of holes formed adjacent said back edge.
19. The shingle of claim 18, each of said first hole and said
second hole and said plurality of holes being surrounded by an
indentation in said top surface which extends as a protrusion on
said bottom surface, said protrusion being nestable within the
indentation of an adjacent panel.
20. The shingle of claim 19, further comprising: a fastener,
extending through one of said first hole and said second hole and
said plurality of holes, said fastener having a head residing
within said indentation so as to be at a level flush with said top
surface of said panel.
Description
RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO MICROFICHE APPENDIX
[0003] Not applicable.
FIELD OF THE INVENTION
[0004] The present invention relates to shingles. More
particularly, the present invention relates to shingles that are
formed from a sheet of metallic material. Additionally, the present
invention relates to shingle assemblies whereby the shingles can be
affixed to one another in forming the covering of a roof of a
building.
BACKGROUND OF THE INVENTION
[0005] Wood shakes have been highly regarded for roofing that was
standing that the are subject to deterioration due to moisture,
mildew or other infestation. However, due in part to wood shortage
problems, wood shake roofs have been subject to increasing costs
and dillainishing usage.
[0006] Composite roofing shingles, having alternating layers of
asphalt and 1 :ar-treated felt toped with crushed rock, lack
tensile strengths and can have durability shortcomings. Kiln-fired
clay tile, and less expensive concrete tile versions, provide
overall, strength, but are relatively expensive to install and add
excessive weight to a structure.
[0007] Roof coverings made from sheet material shingles are well
known. The shingles are usually made from sheet metal, notably
copper, terne-coated stainless steel or aluminum, and are used to
provide a long lasting roof.
[0008] In the past, various U.S. patents have issued relating to
metal shingles. For example, U.S. Pat. No. 3,381,426, issued on May
7, 1968 to W. J. Heidrichs, describes a metal roofing structure in
which a pair of roofing panels are secured together by a slotted
covering panel positioned at a juncture of the roofing panels.
[0009] U.S. Pat. No. 3,973,369, issued on Aug. 10, 1976 to R. L.
Smith, describes roofing shingle having apertures formed therein in
upwardly spaced relationship from the lower edges. The apertures
are adapted to receive the lower corners of tabs of the shingles in
the next higher course of shingles. The apertures are designed so
as to permit the passage of rain and other moisture
therethrough.
[0010] U.S. Pat. No. 4,079,3161, issued on Mar. 21, 1978 to L. L.
Vallee, describes a metal roofing shingle having a
triangular-shaped gable and cave starting shingles and square or
rectangular shaped shingles covering the main body of the roof. The
shingles are laid in courses whereby their edges run at an angle
from the gable ends and cave edges upwardly toward the ridge of the
roof. Each of the shingles is secured to the underlying roof
structure by a roofing nail passing through the uppermost corner of
the shingle. The lowermost edges of the shingles are interlocked
over and under the uppermost edges of adjacent shingles and have
their lowermost corners overlapping the uppermost roofing nail
secured in a corner of an adjacent shingle.
[0011] U.S. Pat. No. 4,185,436, issued on Jan. 29, 1980 to L. L.
Vallee, describes a sheet metal starter shingle and a sheet metal
roof covering having these starter shingles. The starter shingle
has an upwardly sloping top edge upon which a plurality of
rectangular sheet metal roofing shingles can be mounted in a
row.
[0012] U.S. Pat. No. 4,527,374, issued on Jul. 9, 1985 to R. L. R.
Corbin, describes a three-tab shingle with staggered butt edge
features. This shingle includes at least one slot dividing the butt
edge into two tabs. The lower edge of the tabs corresponds to a
portion of the butt edge of the shingle and includes specifically
shaped locating edges. These locating edges contribute to the
jagged non-uniform appearance of the shingle. These edges are used
in conjunction with slot cutouts and notched along the leading and
trailing edge of the butt portion to determine proper offset
alignment and butt edge exposure.
[0013] U.S. Pat. No. 5,349,801, issued on Sep. 27,1994 to D. W.
Verbofski, describes a sheet metal shingle for horizontal
application on a roof The shingle has a male portion along its top
edge, a female portion adjacent its lower edge and hook portions
along both vertical edges. A bead of resilient compressible
material is disposed along the male edge of the s][}ingle and a
bead of seal material is disposed in one of the hook portions.
[0014] U.S. Pat. No. 5,442,888, issued on Aug. 22, 1995 to P.
Ilnycky., describes a roofing shingle that is formed from a square
sheet metal blank. One corner of the blank is provided with a pair
of open end, back-to-back U-shaped slots transverse to a diagonal
passing: through the corner. The two sides intersected by the slots
are downwardly turned to form a small margin. The other two sides
are upwardly turned to form a margin of similar width to the
downwardly turned sides. A shingle support is disposed on the under
surface of the shingle. The shingles are laid course by course on a
pitched roof in a diamond configuration. A shingle of an upper
course engages the respective down turned edges of two adjacent
shingles of a lower course.
[0015] U.S. Pat. No. 5,495,654, issued on Mar. 5, 1996 to Goodhart
et al., teaches a method of preparing sheet metal for the
fabrication of roofing shingles. The shingles include a finish
coating of a coloring and thermosetting polymer which facilitates
embossing of exposed portions to simulate the appearance of cedar
shakes.
[0016] U.S. Pat. No. 5,613,337, issued on Mar. 25, 1997 to Plath et
al., teaches a shingle formed with a first side edge folded over
toward the top of surface of the shingle to catch moisture and
direct it downwardly to the top surface of the next lower shingle.
A second side edge of the shingle is not folded. An "S"-shaped
fold, spaced apart from the trailing; edge fold, receives the
unfolded leading edge an adjacent shingle.
[0017] U.S. Pat. No. 5,711,127, issued on Jan. 28, 1998 to B. P.
Sabourin, describes a roof shingle having parallel top and bottom
marginal edges which are turned inwardly of a central area and are
interengagable with similar top and bottom marginal edge portions
of the roof shingles.
[0018] U.S. Pat. No. 5,946,877, issued on Sep. 7, 1999 to Gallinat
et al., describes a composite shingle having target nailing areas.
The shingle has a structure having a top surface with an upper
headlap portion and a lower butt portion. The headlap portion has
one or more targets suitable for indicating a desired fastener
location to a shingle installer.
[0019] U.S. Pat. No. 6,557,315, issued on May 6, 200') to P.
Tremblay, describes a roofing shingle comprised of a flat
rectangular panel made of a metallic sheet material. The top side
displays a series of dimples defining corresponding bosses on the
underside. A series of connecting elements have one end mounted to
a corresponding boss and an opposite end projecting beyond the side
edges for connected to the roof surface. The shingle includes a
locating means on its top and under surfaces for positioning the
shingle with a corresponding shingle so as to define an overlapping
region therebetween.
[0020] U.S. Design Pat. No. 399,981, issued on Oct. 20, 1998,
describes a metal roofing shingle which has a plurality of
indentations formed on a top surface thereof.
[0021] It is an object of the present invention to provide a
metallic shinjgle which facilitates the installation on an adjacent
shingle.
[0022] It is another object of the present invention to provide a
metallic shingle which includes fastener location indications.
[0023] It is another object of the present invention to provide a
metallic shingle which is suitably-coated so as to resist
deterioration from exposure to the elements.
[0024] It is a further object of the present invention to provide a
metallic shingle which is relatively inexpensive, easy to use, and
easy to assemble.
[0025] These and other objects and advantages of the present
invention will become apparent from a reading of the attached
specification and appended claims.
BRIEF SUMMARY OF THE INVENTION
[0026] The present invention is a shingle comprising a panel having
a first side edge, a second side edge, a front edge and a back
edge. The panel is formed of a metallic sheet material. The panel
has a first hole formed adjacent the first side edge and a second
hole formed adjacent to the second side edge. The panel has a
plurality of holes formed adjacent to the back edge.
[0027] In the present invention, a plurality of slots are formed
adjacent to the front edge. This plurality of slots extends
transversely to the front edge and extends partially toward the
back edge.
[0028] The panel has a top surface and a bottom surface. Each of
the first and second holes is surrounded by an indentation in the
top surface which extends downwardly as a protrusion on the bottom
surface. This protrusion is nestable with the indentation
associated with an underlying panel. The plurality of holes are
spaced evenly from each other and positioned on the panel between
the first side edge and the second side edge. Each of the plurality
of holes is also surrounded by another indentation in the top
surface which extends outwardly of a protrusion on the bottom
surface.
[0029] In the present invention, the panel has an elastromeric
epoxy coating affixed to a surface thereof. The panel also has
granules affixed to an opposite surface thereof. The panel has a
first primer layer interposed between the granules and this
opposite surface of the panel. The granules are adhesively secured
to the First primer layer. The panel also has a second primer layer
interposed between the elastromeric epoxy coating and the surface
of the panel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0030] FIG. 1 is a plain view showing the shingle in accordance
with the teachings of the preferred embodiment of the present
invention.
[0031] FIG. 2 shows the assembly of shingles in accordance with the
teachings of the present invention.
[0032] FIG. 3 is a cross-sectional view illustrating the nesting of
the protrusion within the indentations associated with the holes of
the separate panels.
[0033] FIG. 4 is a cross-sectional view of the shingle of FIG.
1.
[0034] FIG. 5 is a plain view showing the manufacturing of the
shingles in accordance with the present invention.
[0035] FIG. 6 is a plain view showing an alternative embodiment of
the shingle of the present invention.
[0036] FIG. 7 is a plain view showing an alternative embodiment of
the shingle of the present invention
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring to FIG. 1, there is shown the shingle 10 in
accordance with the teachings of the present invention. The shingle
10 includes a panel 12 having a first side edge 14, a second side
edge 16, a front edge 18, and a back edge 20. The panel 12 is
formed from a sheet of metallic material. In general, the shingle
10 has a rectangular configuration.
[0038] As can be seen in FIG. 1, a plurality of slots 22 are formed
adjacent to the front edge 18 and extend transversely to the front
edge 18. The slots 22 have a generally narrow configuration and
extend partially toward the back edge 20 of the panel 12. A first
hole 24 is farmed through the panel 12 generally adjacent to the
first side edge 14. A second hole 26 is formed through the panel 12
generally adjacent to the second side edge 16. Sets of holes 28 are
formed adjacent to the back edge 20. Each of the sets of holes 28
comprises a plurality of separate holes 30, 32 and 34 that are
arranged in an aligned configuration and evenly spaced from each
other. Each of the sets 28 are positioned between the first side
edge 14 and the second side edge 16. Separate holes 36 are formed
through the panel 12 in generally axial alignment with the slots
22.
[0039] The unique configuration of the present invention allows the
shingle 10 to be properly applied to the underlying surface,
namely, the roof of a building. Since the shingle 10 is formed of a
metallic material, the shingle 10 of the present invention can be
easily formed by mechanical forming operations, such as punching,
shearing and forming. The various holes, 24, 26, 28 and 36 are
positioned on the surface of the panel 12 in desired position so as
to allow-the panel 12 to be joined to an adjacent panel. In the
nature of standard roofing shingles, the shingle 10 must be
suitable for overlapping relationship with an underlying shingle
and for use in conjunction with adjacent shingles.
[0040] FIG. 2 illustrates the manner in which the shingle 10 can be
joined with the underlying shingles in a desired manner.
[0041] FIG. 2 shows the first course of shingles 10 arranged in
generally side-by-side relationship. In other words, the second
side edge 16 of one shingle 10 will be positioned in side-by-side
relationship to the first side edge 14 of an adjacent shingle 10.
The course in which shingles 10 appear can continue over the
desired dimensions of the underlying surface of the roof. A second
course 40 of shingles, 42 have portion overlying the top surface of
the underlying shingle 10. Importantly, in the concept of the
present invention, the hole 44 will nest into one of the sets of
holes 28 on the underlying shingle 10. Similarly, the hole 46 will
also nest into another one of the sets of holes 28 on the
underlying shingle 10. The hole 24 on underlying shingle 10 can be
secured to the roof surface through the use of a fastener, such as
a screw. Similarly, another fastener can extend through the hole 44
associated with the overlying shingle 42 and also extend through
one of the plurality of holes 30,32 and 34 so as to engage the roof
surface. Another fasltener can extend through the other hole 46 of
each of the overlying shingles 42 and through another one of the
plurality of holes of the set 28 associated with shingle 10.
Through the arrangement of holes associated with the present
invention, it can be seen that the present invention accommodates
different spacings of the shingles 10 and 42. The spacing of
shingles will depend upon the desired offset during the roof
construction. The illustration of the arrangement of shingles 10
and 42 in FIG. 2 is merely illustrative of a single form of the
present invention that is suitable for the roofing of a particular
building.
[0042] FIG. 3 shows a unique configuration of the present invention
and how the overlying shingle 42 is properly joined to the
underlying shingle 10. FIG. 3 in particular, illustrates the manner
in which a fastener 50 will extends through the hole 44 of shingle
42: and also extend through hole 30 of the underlying shingle 10.
It can be seen that each of the shingles 10 and 42 includes an
indentation 52 formed into the top surface 54 of shingle 42. As a
result of the metal forming operation, a protrusion 56 will appear
extending outwardly of the bottom surface 58 of shingle 42. The
protrusion 56 will be received within the corresponding indentation
60 formed in the top surface 62 of the shingle 10. As a result, the
protrusion 56 will "nest" within the: indentation 60 so as to
achieve a proper alignment of the respective holes 30 and 44. The
fastener 50, in the form of a screw, can be easily inserted through
the holes 44 and 30 so that the pointed roof-engaging end 62 can be
either driven into the roofing surface or screwed into the roofing
surface. Head 64 of fastener 50 is illustrated as generally flush
with the top surface 54 of shingle 42. The nesting arrangement of
shingles 10 and 42 allows a quick and accurate placement of one
shingle upon the other. This quick and accurate placement further
assures the alignment of the respective holes 30 and 44 during the
installation and assembly process. As such, a proper guide way for
the fastener 50 is established through the use of the shingles 10
of the present invention.
[0043] FIG. 4 shows a cross-sectional view of the shingle 10 of the
present invention. Importantly, the shingle 10 is particularly
configured for use in the outdoor environment. As such, the metal
sheet material 70 must be suitably protected against the elements.
Initially, a first primer coating 72 is applied to the top surface
74 of pane 170. Granules 76 are attached by glue 78 onto the primer
72 and onto the top surface 74 of metal panel 7O. The granules 76
are in the nature of roofing. These roofing granules cermically
colored minerals that are used as a surfacing material on asphalt
roofing products. These granules 76 are colored with permanent
pigments and ceramically bonded and treated with a coating to
promote adhesion. These granules 76, along with the use of primer
72, serve to assure that the top surface 74 of metal panel 70 is
effectively protected from the elements.
[0044] A coating of a "FLEXGUARD".TM. layer 80 is applied onto a
second primer coating 82 on the bottom surface 84 of metal panel
70. The "FLEXGUARD".TM. layer 80 is a permanent elastromeric epoxy
coating. This single-ply maintenance membrane protects against
ultraviolet radiation, prolonged deepwater ponding, animal fats,
oils, extreme pHs and temperature extremes. As such, both the
bottom surface 84 and the top surface 74 are effectively protected
in the unique coating arrangement associated with the present
invention.
[0045] FIG. 5 is an illustration of the manufacturing process 100
associated with the formation of panels 102, 104 and 106 in
accordance with the teachings of the present invention. Initially,
a large sheet of material 108 is passed through a forming
operation. The forming and scoring operation will form the
plurality of holes 110 and 112 and slots 114. As can be seen, the
holes 110 and 112, along with the slots 114, are formed on each of
the panels 102, 104 and 106 as a continuous unit. Within the
concept of the present invention, it should be noted that the sheet
108 can extend continuously depending upon the number of separate
shingles that are required. Ultimately, a cutting operation will
sever shingle 102 from shingle 104 along cut line 120. Another
cutting op.about.:ation will sever shingle 104 from shingle 106
along cut line 122. Once the separate shingles 102,104 and 106 are
separated from each other, they can be suitably stacked for
shipment and use.
[0046] FIG. 2 shows an alternative em6odiment of the shingle 200 of
the present invention. Shingle 200 is very similar to the
previously described shingle except for the fact that the slots 202
have a greater width than the small slots associated with the
previous embodiment of the present invention. Each of these wide
slots 202 extends inwardly from the front edge 204 of shingle 200.
The alternative embodiment of the shingle 200 also includes the
hole 206 adjacent to side edge 208 and hole 210 adjacent the side
edge 212. Various sets of holes 214, in the form of the previous
embodiment, are positioned adjacent to the back edge 216. The
shingle 200 in this alternative embodiment of the present invention
can be assembled with adjacent shingles in the manner described in
association with FIG. 2 hereinbefore.
[0047] The foregoing disclosure and description of the invention is
illustrative and explanatory thereof. Various changes in the
details of the illustrated construction can be made within the
scope of the appended claims without departing from the true spirit
of the invention. The present invention should only be limited by
the following claims and their legal equivalents.
* * * * *