U.S. patent application number 11/064619 was filed with the patent office on 2006-08-24 for roofing panel.
This patent application is currently assigned to Yankee Barn Homes, Inc.. Invention is credited to Roger Fletcher.
Application Number | 20060185306 11/064619 |
Document ID | / |
Family ID | 36911147 |
Filed Date | 2006-08-24 |
United States Patent
Application |
20060185306 |
Kind Code |
A1 |
Fletcher; Roger |
August 24, 2006 |
Roofing panel
Abstract
A pre-manufactured roofing panel includes a joint having a first
and a second edge that form a locking joint. The first edge
includes a longitudinal protrusion extending outwardly from first
edge. The protrusion has a generally trapezoidal cross-sectional
shape. The second end includes a longitudinal cavity. The cavity
has a generally inverse trapezoidal cross-sectional shaped
substantially corresponding to the size and shape of the
protrusion. The unique shape of the protrusion and cavity greatly
facilitates the alignment of the two edges and reduces the
likelihood of damage to either edge. The panel also includes a
ribbed gasket disposed along an outer edge that seals any voids
created by imperfections in the panels. The gasket is installed at
the factory, and includes a polyethylene foam gasket.
Inventors: |
Fletcher; Roger; (Webster,
NH) |
Correspondence
Address: |
BOURQUE & ASSOCIATES, P.A.
835 HANOVER STREET
SUITE 301
MANCHESTER
NH
03104
US
|
Assignee: |
Yankee Barn Homes, Inc.
Grantham
NH
|
Family ID: |
36911147 |
Appl. No.: |
11/064619 |
Filed: |
February 24, 2005 |
Current U.S.
Class: |
52/591.1 |
Current CPC
Class: |
E04B 7/22 20130101 |
Class at
Publication: |
052/591.1 |
International
Class: |
E04B 2/46 20060101
E04B002/46 |
Claims
1. An edge system comprising: a first edge portion having a first
longitudinal axis, said first edge portion including a single
protrusion extending substantially perpendicular to said first
longitudinal axis, said single protrusion having a generally
trapezoidal cross sectional shape having a base disposed proximate
said first end region and a tip disposed distal to said first edge
portion; and a second edge portion having a second longitudinal
axis and a single groove disposed generally parallel to said second
longitudinal axis, said single groove having an inner surface sized
and shaped to inversely correspond to said generally trapezoidal
cross sectional shape of said single protrusion of said first edge
portion.
2. The edge system as claimed in claim 1 wherein said single
protrusion is disposed substantially within a first middle region
of said first edge region.
3. The edge system as claimed in claim 2 wherein said single groove
is disposed substantially within a second middle region of said
second edge region.
4. The edge system as claimed in claim 1 wherein said single groove
is sized and shaped to frictionally engage said single protrusion
of said first edge portion.
5. The edge system as claimed in claim 1 wherein said single
protrusion includes: a base region, said based region disposed
proximate said first edge portion; a tip region, said tip region
defining an outer most region of said single protrusion; and a
first and a second generally planar surface each having a
longitudinal axis disposed generally parallel to said first
longitudinal axis of said first edge portion, said first and said
second generally planar portion arranged to converge towards said
tip region.
6. The edge system as claimed in claim 5 wherein said tip region is
generally blunt.
7. The edge system as claimed in claim 5 wherein said tip region is
generally planar.
8. The edge system as claimed in claim 5 wherein said tip region
includes a generally triangular cross-sectional shape.
9. A panel comprising: a first member; a first edge portion
disposed along a first side of said first member, said first edge
portion having a first longitudinal axis, said first edge portion
including a single protrusion extending substantially perpendicular
to said first longitudinal axis, said single protrusion including:
a base region, said based region disposed proximate said first edge
portion; a tip region, said tip region defining an outer most
region of said single protrusion; and a first and a second
generally planar surface each having a longitudinal axis disposed
generally parallel to said first longitudinal axis of said first
edge portion, said first and said second generally planar portion
converge towards said tip region; and a second edge portion
disposed along a second side of said first member, said second edge
portion having a second longitudinal axis and a single cavity
disposed generally parallel to said second longitudinal axis, said
single cavity sized and shaped to inversely correspond to said
generally trapezoidal cross sectional shape of said single
protrusion of said first edge portion.
10. The panel as claimed in claim 9 wherein said first member
wherein a single protrusion of a first panel is sized and shaped to
frictionally engage a single cavity of an adjacent panel such that
said first panel and said adjacent panel are substantially locked
together to form a generally planar inner and outer surface.
11. The panel as claimed in claim 10 wherein single cavity includes
a generally trapezoidal cross-sectional shape.
12. The panel as claimed in claim 10 wherein said tip region
includes a generally triangular cross-sectional shape.
13. The panel as claimed in claim 10 wherein said tip region is
generally planar.
14. The panel as claimed in claim 9 wherein an inner surface of
said panel proximate said first and said second edge portions
includes a beveled region disposed along said first and said second
longitudinal axes of said first and said second edge portions.
15. The panel as claimed in claim 14 wherein said first member
includes an outer support surface, a plurality of framing supports
secured to said outer support surface, insulation disposed between
said plurality of framing supports, and a plurality of inner skins
wherein said plurality of inner skins form said inner surface of
said panel.
16. A paneling kit comprising: a plurality of generally rectangular
panels including: an inner and an outer generally parallel and
generally planar surface; a first edge region having a first
longitudinal axis and first transverse axis, said first transverse
axis disposed generally perpendicular to a longitudinal axis of
said inner and said outer surface, said first edge region including
a protrusion disposed along said first longitudinal axis and having
a generally trapezoidal cross-sectional shape extending
substantially perpendicular to said first longitudinal axis; and at
least a second edge region having a second longitudinal axis
disposed substantially parallel to said first longitudinal axis and
second transverse axis disposed generally perpendicular to said
longitudinal axis of said inner and said outer surface, said second
edge region including a cavity disposed substantially along said
second longitudinal axis, said cavity having a generally
trapezoidal cross-sectional shape and sized and shaped to friction
engage said protrusion such that when a protrusion of a first panel
is inserted into an adjacent panel said panels are substantially
locked together and form a generally planar inner and outer
surface.
17. The paneling kit as claimed in claim 16 wherein said tip region
includes a generally triangular cross-sectional shape.
18. The paneling kit as claimed in claim 16 wherein said tip region
is generally blunt.
19. The paneling kit as claimed in claim 16 wherein said tip region
is generally planar.
20. The paneling kit as claimed in claim 16 wherein said inner
surface of said panel proximate said first and said second edge
portions includes a beveled region
21. A pre-manufactured roofing panel comprising: an inner and an
outer support surface; a plurality of framing supports secured to
said inner and said outer support surfaces; insulation disposed
between said inner and said outer support surfaces; a first and a
second support, said first and said second supports disposed about
a longitudinal axis of said roofing panel along a first and a
second outer edge of said inner and outer support surfaces,
respectively; and a ribbed gasket secured at least said first
support while said roofing panel is constructed at the factory.
22. The pre-manufactured roofing panel as claimed in claim 21
wherein ribbed gasket includes a polyethylene foam gasket.
23. The pre-manufactured roofing panel as claimed in claim 22
wherein said inner surface comprises: a first edge portion having a
first longitudinal axis, said first edge portion including a single
protrusion extending substantially perpendicular to said first
longitudinal axis, said single protrusion having a generally
trapezoidal cross sectional shape having a base disposed proximate
said first end region and a tip disposed distal to said first edge
portion; and a second edge portion having a second longitudinal
axis and a single groove disposed generally parallel to said second
longitudinal axis, said single groove having an inner surface sized
and shaped to inversely correspond to said generally trapezoidal
cross sectional shape of said single protrusion of said first edge
portion.
Description
TECHNICAL FIELD
[0001] The present invention relates to roofing panels and more
particularly, relates to pre-manufactured roofing panels.
BACKGROUND INFORMATION
[0002] Pre-manufactured roofing panels have significantly increased
in popularity in recent years for several reasons. Because these
roofing panels are constructed in a manufacturing environment
rather on an ad-hoc basis at the site, the cost of the
pre-manufactured roofing panels is significantly cheaper because
the roofing panels can be constructed in bulk. Additionally,
because the pre-manufactured roofing panels are assembled prior to
arriving at the construction site, the labor costs and time
associated with the construction of the roof is significantly
reduced.
[0003] Yet another reason for the increased popularity of the
pre-manufactured roofing panels is that their overall quality is
better than what is generally constructed at the site. One reason
for this results from the better working environment inside a
manufacturing facility as compared to working outside at a
construction site. Another reason is that the manufacturing process
allows for more precise and accurate cuts and assembly. This
increases the strength and heating efficiency, and further reduces
labor costs.
[0004] While pre-manufactured roofing panels offer many benefits
over conventional, in-site constructed roofs, there are some areas
which can be improved upon. For example, traditional
pre-manufactured roofing panels often suffer from air leaks between
adjacent roofing panels. When the pre-manufactured roofing panels
are constructed in the field, the joints formed by adjacent panels
are often not perfectly straight. While there are a variety of
reasons for this (most often a result of the wood not being
perfectly straight), the voids created between the adjacent roofing
panels allow for air movement. This air movement allows for
condensation to build up between the joints (which can lead to
rotting, mildew, and insects) and also greatly reduces the overall
heat loss.
[0005] One solution is to install a large gasket between the
adjacent panels in the field during the assembly of the roofing
panels. Unfortunately, these large gaskets are difficult to handle
and are easily damaged or broken. Additionally, these large gaskets
are labor intensive to install and difficult to ensure that the
void has been fully filled. The gaskets are prone to movement and
are often skipped or misapplied by the workman.
[0006] Another disadvantage of the known pre-manufactured roofing
panel systems is that it is often very difficult to smoothly join
the inside skins of adjacent panels. The inside skins make up the
finished ceiling surface. As a result, it is imperative that the
transition between adjacent panels be as smooth as possible in
order to ensure that the appearance of the inside skin is
acceptable. If the inside skins of two adjacent panels do not
transition smoothly, the resulting joint is unsightly.
[0007] Traditional tongue-and-groove type joints 10, FIG. 1, are
not practical in this situation. Tongue-and-groove type joints 10
include a tongue 12 disposed along an edge 14 of a first piece 16.
The tongue 12 includes a rectangular cross-sectional shape having
two planar, parallel surfaces 18, 20 disposed at a 90 degree angle
with respect to the edge 14 with a planar end 22 disposed between
the two parallel surfaces 18, 20. An adjacent piece 24 includes the
groove 24 disposed along a second edge 15. The groove 26 includes a
rectangular shape sized and shaped to accept the tongue 12 tightly
and includes two parallel, planar sides 19, 21 and a planar end 23
disposed at a right angle between the two parallel sides 19,
21.
[0008] As discussed above, the roofing panels typically run from
the ridge of the roof down past the header of the wall. As a
result, the overall length of the roofing panel is generally quite
long (often 20 feet or more in length). The overall thickness of
the inner skin is usually quite small (often less than 3/4''), the
actually dimensions of the tongue 12 and groove 24 are
substantially less and are generally quite weak and prone to
breakage. Because of the tight tolerances between the tongue 12 and
groove 24 and the natural imperfections and warping that is common
to any wooden structure, it is often extremely difficult for the
workman to get the tongue 12 and groove 24 to line up properly and
usually requires the workman to pull and push on the panels and
inner skin. This causes a great deal of force and strain on the
tongue 12 and groove 24, often causing the tongue 12 and/or groove
24 to break. Moreover, the natural imperfections and warping makes
lining up the tongue 12 and groove 24 a very tedious and
labor-intensive process.
[0009] Because of the difficulties associated with tongue and
groove type joints, another common method of joining the inner
skins of adjacent panels is to use a shiplap joint. While this is
easier to align and less prone to breakage, shiplap joints are not
a true locking joint and thus allow the inner skins to move
vertically over time. This results in an obvious joint in the
finished ceiling where the adjacent panels are jointed and is
unacceptable.
[0010] Accordingly, what is needed is an improved apparatus and
method of joining the inner skins of adjacent panels. The improved
apparatus and method should preferably create a seemless,
undetectable joint or connection between adjacent inner skins. The
improved apparatus and method also preferably lock the adjacent
inner skins into place, thus preventing the inners skins from
moving over time and creating an obvious joint. The improved
apparatus and method should preferably reduce the amount of labor
required to assemble the panels in the field by facilitating the
alignment of adjacent panels and preferably reduce the likelihood
of inner skin breaking.
[0011] What is also needed is an improved apparatus and method that
reduces the amount of heat loss through the roofing panels. The
improved apparatus and method should also preferably reduce airflow
between adjacent panels, thereby reducing the likelihood of
condensation forming between the adjacent panels. The improved
apparatus and method should preferably reduce the labor required to
assemble the panels.
[0012] It is important to note that the present invention is not
intended to be limited to a system or method which must satisfy one
or more of any stated objects or features of the invention. It is
also important to note that the present invention is not limited to
the preferred, exemplary, or primary embodiment(s) described
herein. Modifications and substitutions by one of ordinary skill in
the art are considered to be within the scope of the present
invention, which is not to be limited except by the following
claims.
SUMMARY
[0013] According to a first embodiment, the present invention
features an edge system. The edge system includes a first and a
second edge portion. The first edge portion includes a first
longitudinal axis and a single protrusion extending substantially
perpendicular to the first longitudinal axis. The single protrusion
preferably has a generally trapezoidal cross sectional shape with a
base disposed proximate the first end region and a tip disposed
distal to the first edge portion. The single protrusion is
preferably disposed substantially within a first middle region of
the first edge region.
[0014] The second edge portion includes a second longitudinal axis
and a single groove disposed generally parallel to the second
longitudinal axis. The single groove includes an inner surface
sized and shaped to inversely correspond to the generally
trapezoidal cross sectional shape of the single protrusion of the
first edge portion. The single groove is preferably disposed
substantially within a second middle region of the second edge
region and is preferably sized and shaped to frictionally engage
the single protrusion of the first edge portion.
[0015] In the preferred embodiment, the single protrusion includes
a base region disposed proximate the first edge portion, a tip
region defining an outer most region of the single protrusion, and
a first and a second generally planar surface each having a
longitudinal axis disposed generally parallel to the first
longitudinal axis of the first edge portion. The first and the
second generally planar portion arranged to converge towards the
tip region. The tip region is generally blunt, generally planar, or
generally triangular.
[0016] According to another embodiment, the present invention
features a panel. The panel includes a first member, a first edge
portion, and a second edge portion. The first edge portion is
disposed along a first side of the first member and includes a
first longitudinal axis and a single protrusion extending
substantially perpendicular to the first longitudinal axis.
[0017] The single protrusion includes a base region disposed
proximate the first edge portion, a tip region defining an outer
most region of the single protrusion, and a first and a second
generally planar surface each having a longitudinal axis disposed
generally parallel to the first longitudinal axis of the first edge
portion. The first and the second generally planar portion converge
towards the tip region.
[0018] The second edge portion is disposed along a second side of
the first member and includes a second longitudinal axis and a
single cavity disposed generally parallel to the second
longitudinal axis. The single cavity is sized and shaped to
inversely correspond to the generally trapezoidal cross sectional
shape of the single protrusion of the first edge portion.
[0019] The single protrusion is preferably sized and shaped to
frictionally engage a single cavity of an adjacent panel such that
the first panel and the adjacent panel are substantially locked
together to form a generally planar inner and outer surface. The
single cavity preferably includes a generally trapezoidal
cross-sectional shape.
[0020] The inner surface of the panel proximate the first and the
second edge portions may include a beveled region disposed along
the first and the second longitudinal axes of the first and the
second edge portions.
[0021] According to a further embodiment, the present invention
features a paneling kit including a plurality of generally
rectangular panels. The panels include an inner and an outer
generally parallel and generally planar surface, a first edge
region, and a second edge region.
[0022] The first edge region includes a first longitudinal axis and
first transverse axis disposed generally perpendicular to a
longitudinal axis of the inner and the outer surface. The first
edge region includes a protrusion disposed along the first
longitudinal axis and having a generally trapezoidal
cross-sectional shape extending substantially perpendicular to the
first longitudinal axis.
[0023] The second edge region includes a second longitudinal axis
disposed substantially parallel to the first longitudinal axis and
second transverse axis disposed generally perpendicular to the
longitudinal axis of the inner and the outer surface. A cavity is
disposed substantially along the second longitudinal axis and has a
generally trapezoidal cross-sectional shape sized and shaped to
friction engage the protrusion such that when a protrusion of a
first panel is inserted into an adjacent panel, the panels are
substantially locked together and form a generally planar inner and
outer surface.
[0024] According to yet a further embodiment, the present invention
features a pre-manufactured roofing panel. The roofing panel
includes an inner and an outer support surface, a plurality of
framing supports secured to the inner and the outer support
surfaces, insulation disposed between the inner and the outer
support surfaces, a first and a second support, and a ribbed
gasket. The first and the second supports are disposed about a
longitudinal axis of the roofing panel along a first and a second
outer edge of the inner and outer support surfaces, respectively.
The ribbed gasket is secured at least the first support while the
roofing panel is constructed at the factory.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] These and other features and advantages of the present
invention will be better understood by reading the following
detailed description, taken together with the drawings wherein:
[0026] FIG. 1 is an end view of a prior art tongue and groove type
connection;
[0027] FIG. 2 is an end view of one embodiment of the improved
method and apparatus for joining adjacent inner skins in the
unlocked position;
[0028] FIG. 3 is an end view of the embodiment shown in FIG. 2 in
the locked position;
[0029] FIG. 4 is an end view of another embodiment of the improved
method and apparatus for joining adjacent inner skins shown in FIG.
2 in the unlocked position;
[0030] FIG. 5 is an end view of further embodiment of the improved
method and apparatus for joining adjacent inner skins shown in FIG.
2 in the unlocked position;
[0031] FIG. 6 is an end view of yet another embodiment of the
improved method and apparatus for joining adjacent inner skins
shown in FIG. 2 in the unlocked position;
[0032] FIG. 7 in a perspective view of one embodiment of the
pre-manufactured roofing panel according to the present
invention;
[0033] FIG. 8 is a plan view of a plurality of roofing panels shown
in FIG. 7 installed to form a roof;
[0034] FIG. 9 is a plan view of the inner surface roofing panel
shown in FIG. 7 according to one embodiment of the present
invention; and
[0035] FIG. 10 is a perspective view of two adjacent roofing panels
shown in FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] According to one embodiment, the present invention features
an improved method and apparatus 50, FIGS. 2-3 (orientation shown
inverted for clarification), for joining two or more adjacent
pre-manufactured roofing panels 52. As will be described in greater
detail hereinbelow, the improved method and joint apparatus 50
features a uniquely shaped connection system which facilitates the
alignment of two or more adjacent pre-manufactured roofing panels
52 (and in particular the inner skins 54) while reducing the
likelihood of breaking the panels 52 and locking the panels 52
together.
[0037] It is important to note that the while the present invention
will be described with respect to pre-manufactured roofing panels
52, this is to satisfy the best mode requirement and is for
illustrative purposes only. Those skilled in the art will readily
recognize that the present invention is suitable for use with a
wide range of products and installations including, but not limited
to, flooring, marine construction, walls, and the like. Any
modifications necessary to the preferred embodiment described
herein for use in these alternate uses are well within the ordinary
knowledge of those skill in the art.
[0038] The improved method and joint apparatus 50 includes a first
edge region 56 including a uniquely shaped protrusion 58 and a
second edge region 60 including a uniquely shaped groove, cavity,
or channel 62. As will be explained in greater detail, the uniquely
shaped protrusion 58 and channel 62 are sized and shaped to matedly
engage each other in close tolerance when aligned adjacent to each
other to create a frictional or wedge-type lock between the
adjacent edge regions 56, 60.
[0039] As discussed above, a traditional tongue and groove
connection 10, FIG. 1, includes a tongue 12 and groove 26 both
including parallel surfaces at right angles to each other 18-23.
The geometry and dimensions of the prior art tongue and groove
connection 10 makes aligning the first and second piece 16, 24 very
difficult, especially when the edges 14, 15 are not perfectly
straight or planar. This difficulty is due, in part, because the
relative thickness of the tongue 12 (i.e., the length of the end
surface 22) is substantially the same as the thickness of the
groove 24 (i.e., the length of the end surface 23). Consequently,
tongue and groove connection 10 is not tolerable of any
imperfections along the edge regions 14, 15. Moreover, the
difficulty in aligning the prior art tongue and groove connection
10 often results in the either the tongue 12 or the groove 14
becoming damaged or broken.
[0040] In contrast, the improved method and joint apparatus 50 of
the present invention includes a uniquely shaped protrusion 58
disposed along a longitudinal axis A of the first edge region 56
and a uniquely shaped cavity 62 disposed along a longitudinal axis
B of the second edge region 60. The uniquely shaped protrusion 58
extends generally outwardly and perpendicular to longitudinal axis
A.
[0041] As best shown in FIG. 2, the uniquely shaped protrusion 58
includes a generally trapezoidal cross-sectional shape. The
generally trapezoidal shaped protrusion 58 includes a base region
64, an end or tip region 66, and a first and a second surface 68,
70 disposed between the base and tip region 64, 66 converging
towards the tip region 66. The base region 64 is disposed proximate
the first edge region 56 whereas the tip region 66 extends
outwardly from the base region 84 and the first edge region 56. The
tip region is preferably the outer most area of the protrusion
58.
[0042] The base region 64 is preferably larger than the tip region
66. According to the preferred embodiment, the base region 64 is
preferably substantially one-piece with the edge region 56.
Alternatively, the base region 64, FIG. 4 (orientation shown
inverted for clarification), includes a generally rectangular shape
extending outwardly from the edge region 56. The protrusion 58
according to this embodiment is still considered generally
trapezoidal in shape.
[0043] The tip region 66, FIG. 2, preferably includes a generally
planar or blunt surface as shown. The tip region 66 is defined as
the outermost region of the protrusion 58. In an alternative
embodiment, the tip region 66, FIG. 5 (orientation shown inverted
for clarification), includes a generally triangular cross-sectional
shape or may include a slightly rounded tip shape as shown in FIG.
6 (orientation shown inverted for clarification). The protrusions
58 according to these embodiments are still considered generally
trapezoidal in shape.
[0044] It is important to note that the first and a second surfaces
68, 70 disposed between the base and tip region 64, 66 converge
towards the tip region 66. As such, the first and second surfaces
68, 70 are not parallel to each other as in the prior art tongue
and groove connection 10 (FIG. 1). It is also important to note
that the tip region 66 according to the present invention does not
have the same thickness as the base region 64, unlike the prior art
tongue and groove 10 (FIG. 1). As will be explained below, the
non-parallel first and second surfaces 68, 70 and the tip region 66
according to the present invention greatly facilitate the alignment
of two or more adjacent inner skins 54.
[0045] In the preferred embodiment, the first and second surfaces
68, 70 are preferably disposed at an angle of a.sub.1 and a.sub.2
of approximately 33 degrees to approximately 110 degrees relative
to the plane C transverse to the longitudinal axis of the base
region 66. The first and second sides 68, 70 are also preferably
generally planar, though may include non-planar sides are as
well.
[0046] The cavity, chamber, or channel 62, FIG. 2, includes a
generally inverse trapezoidal cross-sectional shape and is disposed
along the longitudinal axis B of the second edge region 60. The
cavity 62 includes an opening 80 disposed proximate an outermost
region of the second edge region 60, and end region 82 disposed
within an innermost region the cavity 62, and a first and a second
side surface 84, 86 disposed between the opening 80 and the end
region 82.
[0047] Referring specifically to FIG. 3, the protrusion 58 and the
cavity 62 are sized and shaped to substantially correspond to each
other such that the protrusion 58 and the cavity 62 matedly lock
when the first and second edge portions 56, 60 are aligned
substantially adjacent to each other. Because the protrusion 58 and
the cavity 62 lock together in a wedge-type format, the inner skins
54 cannot move relative to each other.
[0048] While the protrusion 58 and the cavity 62 are shown
corresponding substantially identically, this is not a limitation
of the present invention unless specifically stated otherwise in
the claims. Rather, the protrusion 58 and the cavity 62 must
correspond to each other closely enough such that the protrusion 58
and the cavity 62 do not allow the inner skins 54 to move relative
to each other when aligned. Those skilled in the art will readily
recognize the breadth of this arrangement.
[0049] Referring specifically to FIG. 4, the opening 80 of the
cavity 62 may also include a generally rectangular cross-sectional
region 90 corresponding to the generally rectangular region base
region 64 of the protrusion 58. Alternatively, the end region 82,
FIG. 5, of the cavity 62 may include a generally triangular
cross-sectional region 92 corresponding to the generally triangular
tip region 66 of the protrusion 58. In yet a further embodiment,
the end region 82, FIG. 6, of the cavity 62 may include a slightly
rounded end region rounded cross-sectional shape corresponding to
the slightly rounded tip region 66 of the protrusion 58. All of
these embodiments of the cavity 62 are considered to be generally
trapezoidal.
[0050] The unique shapes of the protrusion 58 and the cavity 62
also greatly facilitates the alignment of two adjacent inner skins
54 because the tip region 66 does not need to be exactly and
perfectly lined up relative to the opening 80. As can be seen from
the FIGS. 2-6, the opening 80 of the cavity 62 is substantially
larger than both the end region 82 of the cavity 62 and the tip
region 66 of the protrusion 58. Additionally, the first and second
sides 68, 70 of the protrusion 66 and the first and second sides
84, 86 of the cavity 62 are tapered. As a result, the user simply
needs to align the tip region 66 proximate to the opening 80. If
the first and second edge regions 56, 60 are not perfectly lined
up, the larger opening 80 allows the tip region 66 to be slightly
offset and the tapered first and second sides 68, 70, 84, 86 helps
to guide the tip region 66 relative to the end region 82 of the
cavity 62.
[0051] Because the arrangement of the protrusion 58 and cavity 62
allows the tip region 66 of the protrusion 58 to be offset relative
to the opening 80 of the cavity 62, the workman do not have to pull
or push on the inner skins 54 to align the edges 56, 60 perfectly.
Consequently, the likelihood of damaging either of the inner skins
54 is substantially reduced.
[0052] The first and second edge regions 56, 60 also preferably
include a beveled region 99 best shown in FIG. 3. The beveled
region 99 gives the present invention a more pleasing
appearance.
[0053] According to another embodiment, the present invention also
features a roofing panel 100, FIG. 7. As discussed above, the
roofing panel 100 is preferably approximately 4 feet wide, though
other dimensions are also possible. The length is determined by the
particular installation. As is well known to those skilled in the
art, a plurality of the roofing panels 100, FIG. 8, are used to
construct a roof 102 by aligning the roofing panels 100 adjacent to
each other. In a typical installation, a first end 104 of the
roofing panels is secured to a header or main beam 106 and a second
end region 108 is secured to a header 110 of a wall 112 or the
like.
[0054] Referring back to FIG. 7, the roofing panel 100 typically
includes a first and a second longitudinal support 114, 116
disposed along a first and second longitudinal side 118, 120,
respectively. A top or outer surface 124 preferably includes a
plywood or similar material suitable for applying the roofing
shingles or the like. A bottom or inner surface 126, FIG. 9, is
preferably a finished inner surface suitable for a finished
ceiling. In the exemplary embodiment, the inner surface preferably
includes the inner skin 54 as described above, though this is not a
limitation of the present invention unless specifically claimed.
The roofing panel 100, FIG. 7, typically includes a plurality of
other supports and cross braces 122 between the first and a second
longitudinal supports 114, 116 as is commonly found.
[0055] The roofing panels 100 are typically constructed primarily
from wood. As is common, the wooden pieces of the roofing panel
100, in particular the first and a second longitudinal supports
114, 116, often are not perfectly straight. As discussed above,
when two adjacent panels 100, FIG. 10 are aligned, imperfections in
either of the first and/or second longitudinal supports 114, 116
can cause voids 120. These voids 120 allow for air movement,
condensation to form, and reduce the overall heat efficiency of the
roofing panels 100.
[0056] In the past, large flexible gaskets have been installed in
the field by the workman in an effort to properly seal the joint
between two adjacent panels. However, these gaskets are hard to
use, are labor intensive, are prone to moving during installation,
prevent the panels from aligning properly, and are often skipped
entirely by the workman.
[0057] The present invention solves this problem with the use of a
novel ribbed gasket 130, FIG. 7, secured along the one or more of
the first and/or second longitudinal supports 114, 116. The ribbed
gasket 130 is preferably installed at the factory while the roofing
panel 100 is being manufactured. As a result, the ribbed gasket 130
will not be skipped by the workman installing the panels 100. The
ribbed gasket 130 includes at least one rib, but preferably
includes a plurality of ribs disposed along the longitudinal axis
of the ribbed gasket 130. In the exemplary embodiment, the ribbed
gaskets 130 include approximately 17 ribs in total.
[0058] In the preferred embodiment, the ribbed gasket 130 is made
from a closed cell foam (for example, but not limited to
polyethylene foam), though those skilled in the art will recognize
that other suitable materials exist. The ribbed gasket 130 is
preferably made from a compressible material. The ribbed gasket 130
is preferably secured to the first and/or second longitudinal
supports 114, 116 using a fastener such as, but not limited to,
staples, nails, or the like, an adhesive, or any other method known
to those skilled in the art.
[0059] In the exemplary embodiment, the ribbed gasket 130 is
approximately 0.25''.times.5.5'' and runs along the entire length
of one or more the first and/or second longitudinal supports 114,
116. It has been found that the extra width of the ribbed gasket
130 effectively fills the entire void 120 between panels 100,
eliminating the air space and reducing the potential for air
movement. An additional expanding foam barrier (foam tape) can be
added on site in the event that the void 120 is too large at any
point for the ribbed gasket.
[0060] Because the ribbed gasket 130 is applied at the factory, the
ribbed gasket 130 minimizes labor on site. Additionally, because
the ribbed gasket 130 is not an expanding foam type gasket, it can
be applied at the factory, thus eliminating the potential that the
gasket could be misapplied or forgotten on site.
[0061] Accordingly, the present invention reduces the amount of
heat loss through the roofing panels. The improved apparatus and
method also reduces airflow between adjacent panels, thereby
reducing the likelihood of condensation forming between the
adjacent panels. The improved apparatus and method further reduces
the labor required to assemble the panels.
[0062] The present invention also includes an improved apparatus
and method of joining the inner skins of adjacent panels. The
improved apparatus and method creates a seemless, undetectable
joint or connection between adjacent inner skins and locks the
adjacent inner skins into place, thus preventing the inners skins
from moving over time and creating an obvious joint. The improved
apparatus and method further reduces the amount of labor required
to assemble the panels in the field by facilitating the alignment
of adjacent panels and reducing the likelihood of inner skin
breaking.
[0063] As mentioned above, the present invention is not intended to
be limited to a system or method which must satisfy one or more of
any stated or implied object or feature of the invention and should
not be limited to the preferred, exemplary, or primary
embodiment(s) described herein. The foregoing description of a
preferred embodiment of the invention has been presented for
purposes of illustration and description. It is not intended to be
exhaustive or to limit the invention to the precise form disclosed.
Obvious modifications or variations are possible in light of the
above teachings. The embodiment was chosen and described to provide
the best illustration of the principles of the invention and its
practical application to thereby enable one of ordinary skill in
the art to utilize the invention in various embodiments and with
various modifications as is suited to the particular use
contemplated. All such modifications and variations are within the
scope of the invention as determined by the claims when interpreted
in accordance with breadth to which they are fairly, legally and
equitably entitled.
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