U.S. patent application number 14/727084 was filed with the patent office on 2015-12-10 for multi-element roofing panel.
This patent application is currently assigned to TAPCO INTERNATIONAL CORPORATION. The applicant listed for this patent is TAPCO INTERNATIONAL CORPORATION. Invention is credited to Clyde G. Allen, Nathan D. Greenway, Matthew M. Jackson, Michael W. Maurer, Matthew Jason Michalski, Kyle P. O'Shea.
Application Number | 20150354224 14/727084 |
Document ID | / |
Family ID | 54769140 |
Filed Date | 2015-12-10 |
United States Patent
Application |
20150354224 |
Kind Code |
A1 |
Maurer; Michael W. ; et
al. |
December 10, 2015 |
MULTI-ELEMENT ROOFING PANEL
Abstract
A multi-element panel system configured for attachment to a
mounting surface includes at least two panels. The panels each have
an upper portion oriented upward and a lower portion oriented
downward, relative to the mounting surface. A plurality of faces
are formed on the panels and a plurality of keyways are formed
between the faces. The keyways are recessed toward the mounting
surface from the faces. The panels have a water trough, which has a
planar intersection with the faces, formed on an exterior side of
the upper portion, and a water channel extending between the upper
and lower portions of one side of the panel. The panels have a side
lap extending between the upper and lower portions on the opposite
side of the panel from the water channel. The side lap of one of
the panels overlaps the water channel of another, horizontally
adjacent, panel.
Inventors: |
Maurer; Michael W.; (Walled
Lake, MI) ; Michalski; Matthew Jason; (Sylvan Lake,
MI) ; Greenway; Nathan D.; (Attica, MI) ;
Allen; Clyde G.; (Columbiaville, MI) ; Jackson;
Matthew M.; (Saline, MI) ; O'Shea; Kyle P.;
(Arvada, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TAPCO INTERNATIONAL CORPORATION |
Wixom |
MI |
US |
|
|
Assignee: |
TAPCO INTERNATIONAL
CORPORATION
Wixom
MI
|
Family ID: |
54769140 |
Appl. No.: |
14/727084 |
Filed: |
June 1, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62008427 |
Jun 5, 2014 |
|
|
|
Current U.S.
Class: |
52/302.1 ;
52/522 |
Current CPC
Class: |
E04D 1/24 20130101; E04F
13/0869 20130101; E04D 1/26 20130101; E04D 1/28 20130101; E04F
13/0873 20130101; E04D 1/12 20130101; E04F 13/0864 20130101; E04D
1/20 20130101; E04D 2001/3455 20130101 |
International
Class: |
E04D 13/04 20060101
E04D013/04; E04D 13/00 20060101 E04D013/00; E04D 1/30 20060101
E04D001/30; E04D 1/34 20060101 E04D001/34; E04B 7/00 20060101
E04B007/00; E04D 1/28 20060101 E04D001/28 |
Claims
1. A multi-element panel system configured for attachment to a
mounting surface with a plurality of fasteners, comprising: a first
panel having: an upper portion configured to be oriented upward
relative to the mounting surface and a lower portion configured to
be oriented downward relative to the mounting surface; a plurality
of faces; a plurality of keyways formed between the faces, wherein
the keyways are recessed toward the mounting surface relative to
the faces; a water trough formed on an exterior side of the upper
portion, wherein the water trough has a planar intersection with
the faces; a water channel extending between the upper portion and
the lower portion of one side of the first panel; and a side lap
extending between the upper portion and the lower portion of the
opposite side of the first panel from the water channel; a second
panel having: an upper portion configured to be oriented upward
relative to the mounting surface and a lower portion configured to
be oriented downward relative to the mounting surface; a plurality
of faces; a plurality of keyways formed between the faces, wherein
the keyways are recessed toward the mounting surface relative to
the faces; a water trough formed on an exterior side of the upper
portion, wherein the water trough has a planar intersection with
the faces; a water channel extending between the upper portion and
the lower portion of one side of the second panel; and a side lap
extending between the upper portion and the lower portion of the
opposite side of the second panel from the water channel; and
wherein the side lap of the second panel overlaps the water channel
of the first panel.
2. The multi-element panel system of claim 1, further comprising: a
horizontal dam formed in the water channel of the first panel; and
a horizontal ledge formed on the side lap of the second panel,
wherein the horizontal dam of the first panel and the horizontal
ledge of the second panel cooperate to define a serpentine path in
the water channel between the upper portion and the lower portion
of the first panel.
3. The multi-element panel system of claim 2, a channel lip formed
on the water channel of the first panel; a lap spacer formed on the
side lap of the second panel; wherein the horizontal dam of the
first panel and the lap spacer of the second panel cooperate to
define a minimum horizontal exposure between the first panel and
the second panel; and wherein the channel lip of the first panel
and the lap spacer of the second panel cooperate to define a
maximum horizontal exposure between the first panel and the second
panel.
4. The multi-element panel system of claim 3, wherein the first
panel is formed as a unitary, one-piece component, and the second
panel is formed as a unitary, one-piece component.
5. The multi-element panel system of claim 4, wherein the first
panel and the second panel further include: a plurality of fastener
strips elevated from the water trough; and a plurality of weeping
channels defined through the fastener strips, such that all
portions of the water trough have a flow path to at least one of
the faces and the keyways.
6. The multi-element panel system of claim 1, a channel lip formed
on the water channel of the first panel; a lap spacer formed on the
side lap of the second panel; wherein the horizontal dam of the
first panel and the lap spacer of the second panel cooperate to
define a minimum horizontal exposure between the first panel and
the second panel; and wherein the channel lip of the first panel
and the lap spacer of the second panel cooperate to define a
maximum horizontal exposure between the first panel and the second
panel.
7. The multi-element panel system of claim 1, wherein the first
panel and the second panel further include: a plurality of fastener
strips elevated from the water trough; and a plurality of weeping
channels defined through the fastener strips, such that all
portions of the water trough have a flow path to at least one of
the faces and the keyways.
8. A multi-element panel system configured for attachment to a
mounting surface with a plurality of fasteners, comprising: a first
panel having: an upper portion configured to be oriented upward
relative to the mounting surface and a lower portion configured to
be oriented downward relative to the mounting surface; a plurality
of faces; a plurality of keyways formed between the faces, wherein
the keyways are recessed toward the mounting surface relative to
the faces; a water channel extending between the upper portion and
the lower portion of one side of the first panel; a horizontal dam
formed in the water channel; and a side lap extending between the
upper portion and the lower portion of the opposite side of the
first panel from the water channel; a second panel having: an upper
portion configured to be oriented upward relative to the mounting
surface and a lower portion configured to be oriented downward
relative to the mounting surface; a plurality of faces; a plurality
of keyways formed between the faces, wherein the keyways are
recessed toward the mounting surface relative to the faces; a water
channel extending between the upper portion and the lower portion
of one side of the second panel; a side lap extending between the
upper portion and the lower portion of the opposite side of the
second panel from the water channel; and a horizontal ledge formed
on the side lap; and wherein the side lap of the second panel
overlaps the water channel of the first panel, and the horizontal
dam of the first panel and the horizontal ledge of the second panel
cooperate to define a serpentine path in the water channel between
the upper portion and the lower portion of the first panel such
that water moving through the water channel is forced through the
serpentine path.
9. The multi-element panel system of claim 8, a channel lip formed
on the water channel of the first panel; a lap spacer formed on the
side lap of the second panel; wherein the horizontal dam of the
first panel and the lap spacer of the second panel cooperate to
define a minimum horizontal exposure between the first panel and
the second panel; and wherein the channel lip of the first panel
and the lap spacer of the second panel cooperate to define a
maximum horizontal exposure between the first panel and the second
panel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/008,427, filed Jun. 5, 2014, which is hereby
incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This disclosure relates to multi-tile or multi-element
roofing or siding systems for attachment to mounting surfaces.
BACKGROUND
[0003] Exterior siding or roofing systems may include a plurality
of tiles, panels, or combinations thereof. Generally, tiles
simulate one or two individual decorative units and panels simulate
a greater number of individual decorative units. For example, tiles
or panels may emulate wooden shakes, wooden shingles, or slate
tiles. However, the decorative units may be formed to simulate
other siding or roofing materials, including stone, ceramics, et
cetera.
SUMMARY
[0004] A multi-element panel system is provided. The panel system
is configured for attachment to a mounting surface with a plurality
of fasteners. Each of at least two panels includes an upper portion
configured to be oriented upward relative to the mounting surface
and a lower portion configured to be oriented downward relative to
the mounting surface.
[0005] The panels have a plurality of faces formed thereon, and a
plurality of keyways formed or defined between the faces. The
keyways are recessed toward the mounting surface relative to the
faces.
[0006] The panels further include a water trough and a water
channel. The water trough is formed on an exterior side of the
upper portion, and has a planar intersection with the faces. The
water channel extends between the upper portion and the lower
portion of one side of the panel.
[0007] The panels also include a side lap extending between the
upper portion and the lower portion of the opposite side of the
panel from the water channel. The side lap of one of the panels
overlaps the water channel of another, horizontally adjacent,
panel.
[0008] The above features and advantages, and other features and
advantages, of the present disclosure are readily apparent from the
following detailed description of some of the best modes and other
embodiments for carrying out the invention, which is defined solely
by the appended claims, when taken in connection with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic isometric view of a roofing system
having a plurality of tiles.
[0010] FIG. 2 is a schematic isometric view of an exterior side of
one of the tiles shown in FIG. 1.
[0011] FIG. 3 is a schematic isometric view of an interior side of
one of the tiles shown in FIG. 1.
[0012] FIG. 4A is a schematic top view of one of the tiles in the
roofing system, illustrating alignment of the interlocking
features.
[0013] FIG. 4B is a schematic top view illustrating relative
alignment of the tiles in the roofing system via interlocking
elements.
[0014] FIG. 5 is a schematic isometric view of an exterior side of
a multi-element panel for attachment to a mounting surface.
[0015] FIG. 6 is a schematic isometric view of an interior side of
the multi-element panel shown in FIG. 5.
[0016] FIG. 7 is a schematic top view illustrating relative
alignment of several multi-element panels assembled to a roofing
system.
[0017] FIG. 8 is a schematic partial cross section illustrating
relative interaction or overlapping between adjacent panels, taken
generally along a line 8-8 from FIG. 7.
DETAILED DESCRIPTION
[0018] Referring to the drawings, like reference numbers correspond
to like or similar components wherever possible throughout the
several figures. There is shown in FIG. 1 a roofing system or
multi-tile system 10 for attachment to a mounting surface 12. The
multi-tile system 10 may be attached to either roofs, vertical
walls, or angled walls, such that the mounting surface 12 may be a
wall or a roof.
[0019] The roofing system or multi-tile system 10 includes at least
a first tile 14, a second tile 16, and a third tile 18. The second
tile 16 and the third tile 18 have similar features to the first
tile 14, such that they may be referred to collectively or
generically as tiles 20.
[0020] An exterior side 22 of the tiles 20, which faces outward and
away from the mounting surface 12, defines a forward direction or
exterior face. An interior side 24 of the tiles 20, which faces
downward toward the mounting surface 12, defines a rearward
direction or interior face.
[0021] While the present subject matter may be described with
respect to specific applications or industries, those skilled in
the art will recognize broader applicability. Those having ordinary
skill in the art will recognize that terms such as "above,"
"below," "upward," "downward," et cetera, are used descriptively of
the figures, and do not represent limitations on the scope of the
invention, as defined by the appended claims, unless stated
otherwise. Any numerical designations, such as "first" or "second"
are illustrative only and are not intended to limit the scope of
the invention in any way.
[0022] Features shown in one figure may be combined with,
substituted for, or modified by, features shown in any of the
figures. Unless stated otherwise, no features, elements, or
limitations are mutually exclusive of any other features, elements,
or limitations. Furthermore, no features, elements, or limitations
are absolutely required for operation. Any specific configurations
shown in the figures are illustrative only and the specific
configurations shown are not limiting of the claims or the
description.
[0023] Referring also to FIG. 2 and to FIG. 3, and with continued
reference to FIG. 1, there are shown two schematic isometric views
of tiles 20. Features of the first tile 14, the second tile 16, and
the third tile 18 will be described with reference to FIG. 1, FIG.
2, and FIG. 3. The described features of the tile 20 shown in FIGS.
2 and 3 may refer to any of the first tile 14, the second tile 16,
or the third tile 18. Note that manufacturing variance may lead to
natural differences between the tiles 20 that are otherwise
intended to be identical.
[0024] FIG. 2 shows the exterior side 22 of one of the tiles 20,
and FIG. 3 shows the interior side 24 of one of the tiles 20. When
assembled to the mounting surface 12, the exterior sides 22 and the
interior sides 24 of the tiles 20 (as viewed in FIGS. 2 and 3,
respectively) cooperate to lock the tiles 20 to the mounting
surface with the assistance of one or more fasteners (not
shown).
[0025] The tiles 20 include a fastener edge, upper portion, or
upper edge 26 defined along one edge, which is shown on the top in
FIGS. 2 and 3. A lap edge, lower portion, or lower edge 28 is
defined opposite the upper edge 26, and is shown on a bottom or
lower edge in FIGS. 2 and 3. The upper edge 26 may also be referred
to as the head of the tile 20 and is lapped or overlapped by the
lower edge 28 of subsequent tiles.
[0026] The exterior side 22 includes a face or fascia of the tiles
20. The face may be textured, painted, or surface-treated to
simulate the look of different roofing materials. In many
configurations of the tiles 20, the face will be configured to
simulate the aesthetic look of slate, such that the multi-tile
system 10 emulates natural slate roofing. However, the exterior
sides 22 of the tiles 20 may also be configured to emulate other
materials, such as, for example and without limitation: wooden
shakes, wooden shingles, or ceramic tiles.
[0027] References to upper and lower directions, regions, or
portions are generally defined relative to gravity and elevation as
the tiles 20 are intended to be assembled to the mounting surface
12. Therefore, the typical flow direction of water or moisture over
the tiles 20 and the structures to which they are mounted (although
wind may cause water to move against gravity) is from the upper
edge 26 toward the lower edge 28--i.e., top down. Similarly,
vertical and horizontal are used descriptively relative to gravity
and elevation. Horizontal is generally parallel to gravity and does
not involve a change in elevation, while vertical is generally
perpendicular to horizontal the horizontal direction and does
involve a change in elevation.
[0028] At least some portion of the upper edge 26 contacts the
mounting surface 12, possibly with an intermediary water barrier
disposed therebetween. The upper edge 26 has a plurality of
fastener holes 30 or fastener points defined therein.
[0029] The fastener holes 30 are configured to mount the tiles 20
to the mounting surface 12 with the fasteners, which may be nails,
screws, staples, et cetera. In some embodiments, the fastener holes
30 may not be fully defined through the upper edge 26 but may
instead be areas designated or identified for piercing by the
fasteners, such that the fasteners at least partially pierce the
material forming the tiles 20. Furthermore, the heads of the
fasteners may stop at the face of the tile 20, as opposed to
plunging into the face of the tile 20 or setting within a recess
formed into the face of the tile 20.
[0030] The tiles 20 may be formed from different polymeric or
composite materials. For example, and without limitation, the tiles
20 may be formed from polymers, reinforced resin, polypropylene,
foamed polypropylene, high density polyethylene, low density
polyethylene, combinations thereof, or other suitable materials. In
many configurations, the tiles 20 may be formed as unitary,
one-piece components, such that each tile 20 is a single component
formed from a single piece of material without subsequent
attachment of pieces formed separately. The tiles 20 may be formed
via injection molding, compression molding, machining, or other
suitable processes.
[0031] As best viewed in FIG. 3, the interior side 24 includes a
system of ribs (not separately numbered), including filleted
diamonds and vertical cut-line ribs. The filleted diamonds may
provide additional structural rigidity and support for impact, such
as from hail. Additionally, the filleted diamonds may prevent or
limit movement of gases or liquefied material during extreme
temperature events. The cut-line ribs may provide structural
rigidity and convenient points for cutting the tiles 20 into
partial tiles during installation of the multi-tile system 10, such
that gaps on the interior side 24 are not viewable from the edges
of partial tiles that are cut along the cut-line ribs.
[0032] A receiving member 32 is formed on the exterior side 22 of
the upper edge 26, and a locking member 34 is formed on the
interior side 24 of the lower edge 28. When the tiles 20 are
assembled to the mounting surface 12, the receiving member 32 of a
lower course (such as those on either the first tile 14 or the
second tile 16 in FIG. 1) is covered or lapped by an upper course
(such as the third tile 18).
[0033] Courses of tiles 20 refer to patterns or sets used during
installation. In the example shown in the figures, each horizontal
row is a separate course. A first course, which would include the
first tile 14 and the second tile 16 in FIG. 1, is installed on the
lowest portion of the mounting surface 12, possibly after
installation of a starter strip or other prep structures, and then
a second course, which would include the third tile 18 I FIG. 1, is
subsequently installed above the first course.
[0034] The receiving member 32 of one tile 20, on the lower course,
interlocks with the locking member 34 of another tile 20, on the
upper course, to limit movement of the lower edge 28 of the upper
tile 20 away from the upper edge 26 of the lower tile 20.
Alternatively stated, the locking member 34 of the lower edge 28 is
held to, or interlocked with, the receiving member 32 of the upper
edge 26.
[0035] As used herein, interlocking between the receiving member 32
and the locking member 34 refers to at least some overlap between
the receiving member 32 and the locking member 34, relative to the
mounting surface 12. The receiving member 32 and the locking member
34 shown include cantilevered or overhanging portions, such that an
opposing force resists separation of the receiving member 32 and
the locking member 34.
[0036] Therefore, even though only the upper edges 26 of the tiles
20 are directly fastened to the mounting surface 12, both the lower
edge 28 and the upper edge 26 are restrained to the mounting
surface 12. Under wind loads that may otherwise pull the lower edge
28 of the tile 20 away from the mounting surface 12, the
interlocking between the receiving member 32 and the locking member
34 helps keep all portions of the tiles 20 restrained to the
mounting surface 12. These uplift forces are counteracted at the
lower edge 28 without any fasteners driven through the lower edge
28.
[0037] Where the lower course of tiles 20, the horizontal row of
FIG. 1 that includes the first tile 14, is the first course
assembled to the mounting surface 12, there may also be a starter
strip or other structure on the front edge of the mounting surface
12. The starter strip may include a set of receiving members 32
that interface with the locking members 34 of the first course,
such that the starter strip emulate the upper portion of a course
tiles 20 and interfaces with the first tile 14.
[0038] In the configuration shown in the figures, the receiving
members 32 and the locking members 34 face inward toward each other
and toward the center of the tiles 20. However, the receiving
members 32 and the locking members 34 could also face outward.
[0039] The receiving members 32 and the locking members 34 are
illustrated in the figures as formed from a single, continuous
piece with the remainder of the tiles 20. However, in other
configurations, either of the receiving members 32 or the locking
members 34 could be formed as separate components and then
subsequently attached to the remainder of the tiles 20. For
example, the receiving members 32 could be formed individually, or
as part of a larger piece, which are then snapped, adhered, or
fastened to toward the upper edge 26.
[0040] Alternatively, the receiving members 32 could be formed
attached to the upper edge 26 through a living hinge, and then
folded to the positions shown. A living hinge may simplify
manufacture of the tiles 20 by removing the need for lifters or
retractable elements in the mold apparatus, while still maintaining
proper draft in the injection-molding process for the tiles 20. The
living hinge configuration may include a strip of material
encompassing of the receiving members 32, which would then be
nailed to the upper portion 26 as the tile 20 is nailed to the
mounting surface 12.
[0041] The receiving member 32 and the locking member 34 provide
continuous vertical adjustment through a vertical range 36, as
opposed to incremental adjustment, such as that provided by
boss-and-cavity or peg-and-hole systems. The continuous vertical
adjustability of the tiles 20 may give the multi-tile system 10 a
more-natural appearance, and provides the ability to adjust to
different roof shapes, particularly those with multiple horizontal
edges at differing vertical heights. The vertical range 36 provides
elevational adjustment between tiles 20.
[0042] In the multi-tile system 10 shown, the receiving member 32
and the locking member 34 also cooperate to define a horizontal
range 38, which provides continuous horizontal adjustment between
the tiles 20. The horizontal range 38 is lesser than the vertical
range 36, but still allows installers to vary the distance between
adjacent tiles 20. Additional horizontal limitations between
adjacent tiles 20 are provided by the interaction between the sides
of the tiles 20, as discussed herein. Vertical and horizontal
adjustability supports maximum and minimum exposure of the tiles
20, particularly vertical exposure, while maintaining proper lap to
promote water flow.
[0043] The tiles 20 further include a gutter or water channel 40
formed on at least one side of the tiles 10 between the upper edge
26 and the lower edge 28. A side lap 42 is formed on the opposite
side from the water channel 40. The side lap 42 is configured to
overlap the water channel 40 of an adjacent tile 20. Interaction
between the side lap 42 and the water channel 40 further limits the
amount of horizontal adjustability between the tiles 20. When
multiple tiles 20 are overlapped, the viewable, or exposed, portion
of the water channel 40 forms a keyway between
horizontally-adjacent tiles 20.
[0044] The tiles 20 include a serpentine path or S-path 44 in the
side water channel 40. The S-path 44 forces water moving upward
through the water channel 40, which may result from wind, to move
around a horizontal dam 46. The S-path 44 reduces the likelihood of
water reaching the uppermost edge of the water channel 40 and
moving over the upper edge 26 onto the mounting surface 12 by
forcing the water to move horizontally. The S-path 44 is a change
in momentum of water moving through the water channel 40.
[0045] The water channel 40 is continuous and does not include any
leaks, cracks, or nail points. Therefore, water within the water
channel 40 cannot leak out of the water channel 40 without going
over a ledge or flowing downward, as intended.
[0046] As viewed in FIG. 3, the side lap 42 also includes a
horizontal ledge 48 that is configured to extend into the water
channel 40 of an adjacent tile 20 to further restrict movement of
water upward. The S-path 44 is shown in FIG. 3 to illustrate the
general flow path when the tiles 20 are assembled or mated
together.
[0047] The tiles 20 include a water trough 50 formed or defined on
the upper edge 26. The water trough 50 is oriented at a trough
angle 52 to the mounting surface 12 or to the exterior side 22 of
the tile 20, such that there is no lip or ledge between the water
trough 50 and the exterior side 22. The trough angle 52 allows
water to flow downward from the water trough 50 onto the face of
the exterior side 22 toward the lower edge 28, as opposed to
trapping water in the water trough 50. Note that on the tiles 20
illustrated, the fastener points 30 are not formed in, or through,
the water trough 50.
[0048] The trough angle 52 is configured to be substantially
horizontal or flat, relative to gravity, when the tile 20 is
assembled to the lowest pitch at which the multi-tile system 10
system is intended to be installed. For example, if the tiles 20
are configured to be installed to a minimum pitch of 3:12, which is
three feet of rise per twelve feet of run, the trough angle 52
would be approximately fourteen-degrees. Note that when assembled
to a steeper roof pitch, the trough angle 52 will also be steeper
relative to gravity and drain more aggressively.
[0049] In some configurations of the tiles 20, the water trough 50
may have a flow channel or hole connecting to the water channel 40.
This connection may allow water to drain from a least a portion of
the water trough 50 into the water channel 40.
[0050] The tiles 20 shown include a trough lip 54 at the upper edge
of the water trough 50. The trough lip 54 is substantially the full
thickness of the tile 20 and may help prevent water, especially
wind-blown water, from going over the back or top of the tile
20.
[0051] The thickness of the upper edge 26 and the lower edge 28 are
substantially equal, such that the tiles 20 shown do not taper.
Alternatively, some configurations of the tiles 20 may taper from
front to back to reduce the amount of material used in the tile.
However, such a taper may limit the depth of the water trough 50
and the height of trough lip 54.
[0052] The distance that the water trough 50 extends from the upper
edge 26 to the face of the tile 20 may define the maximum vertical
exposure of the multi-tile system 10. For example, and without
limitation, the tiles 20 may have a vertical height of twelve
inches and the water trough 50 may have a vertical length of three
inches, such that the maximum vertical exposure of the tiles 20 is
nine inches. The tiles 20 of an upper course generally must cover,
or lap, the water trough 50 of the course just below.
[0053] The trough angle 52 and the height of the trough lip
54--based upon triangle-like geometry--may control the length of
the water trough 50 and, therefore, may also control the amount of
vertical exposure. Using the examples above, the trough lip 54
would be approximately 0.75 inches from the mounting surface 12 for
the fourteen-degree trough angle 52 required for 3:12 roof
pitch.
[0054] Horizontal adjustability and horizontal exposure may be
controlled by the interaction between the water channel 40 and the
side lap 42 of adjacent (side lapping) tiles 20. For absolute
minimum, the side lap 42 may be pushed all the way through the
water channel 40 until the water channel 40 is no longer viewable.
However, such minimum exposure would negate the ability of the
water channel 40 to emulate the natural keyway between, for
example, slate tiles.
[0055] The tiles 20 include a channel lip 56 formed on one side of
the water channel 40. The channel lip 56 limits the maximum
horizontal exposure of the tiles 20 by cooperating with the side
lap 42 to prevent pulling the side lap 42 beyond the water channel
40 and leaving a gap between horizontally-adjacent tiles 20.
[0056] The channel lip 56 also provides a barrier against which
water must move to escape the water channel 40, similar to the
function of the trough lip 54. The channel lip 56 and the trough
lip 54 illustrated in the figures both provide water barrier
features that are substantially perpendicular to the mounting
surface, such that they require water to change momentum in order
move over the edges of the tiles 20.
[0057] In the multi-tile system 10 shown, the tiles 20 include a
channel notch 58 formed on the upper portion of the water channel,
and a lap notch 59 formed on the upper portion of the side lap 42.
The channel notch 58 and the lap notch 59 cooperate to limit the
amount of the side lap 42 that can extend or overlap into the water
channel 40, and ensure that some portion of the water channel 40 is
viewable to simulate the keyway between horizontally-adjacent
tiles. Therefore, in the tiles 20 shown, the channel notch 58 and
the lap notch 59 define the minimum horizontal exposure by limiting
how close adjacent tiles can be properly assembled.
[0058] Referring now to FIG. 4A and to FIG. 4B, and with continued
reference to FIGS. 1-3, there are shown additional views of the
tiles 20 illustrating alignment and interlocking FIG. 4A shows a
top view of one of the tiles 20, and FIG. 4B shows a top view of
three tiles 20 aligned with, and assembled to, each other.
[0059] The locking members 34 are shown in dashed lines in both
FIG. 4A and FIG. 4B. The locking members 34 are spaced apart by a
locking span 60. The receiving members 32 are spaced from the edges
of the tile 20 by a first offset 62 and a second offset 64.
[0060] The locking span 60 is smaller than the first offset 62 and
the second offset 64 combined. Therefore, the locking members 34
are spaced at a smaller distance than the receiving members 32 are
spaced from the edges of the tile 20, and also a smaller distance
than the receiving member 32 of horizontally adjacent tiles 20.
However, if the tiles 20 are assembled with proper side lapping,
these distances change.
[0061] FIG. 4B illustrates proper horizontal and vertical lapping
with the first tile 14 and the second tile 16 on the first (lower)
course, and the third tile 18 on the second (upper) course. Note
that the overlapped portion of the first tile 16 is shown in
phantom. As shown in FIG. 4B, when the tiles 20 are assembled with
the side lap 42 of the second tile 16 overlapping the water channel
40 of the first tile 14--such that the lower course has proper side
lap--the receiving members 32 of the first tile 14 and the second
tile 16 are able to interlock with the locking members 34 of the
third tile 18. However, if the side lap 42 of the second tile 16
did not properly overlap the water channel 40 of the first tile 14,
the locking members 34 of the third tile 18 would not be able to
interlock with the receiving members 32 of the first tile 14 and
the second tile 16.
[0062] The receiving members 32 of the first tile 14 and the second
tile 16, both of which are shown in phantom, are spaced apart by a
first effective offset 62' and a second effective offset 64'. The
first effective offset 62' and the second effective offset 64' are
measured from the centerline of the overlap between the first tile
14 and the second tile 16.
[0063] Therefore, as shown in FIG. 4B, the locking span 60 of the
third tile 18 is greater than the combined offset of the first
effective offset 62' and the second effective offset 64', such that
the locking members 34 of the third tile 18 can interlock with the
receiving members 32 of the first tile 14 and the second tile 16.
If the tiles 20 of lower courses are not properly lapped, the tiles
20 of the subsequent courses will not be able to be interlocked
with the lower courses because the locking span 60 will be less
than the first offset 62 and the second 64 combined.
[0064] In FIG. 4B, the tiles 20 are illustrated with maximum, or
near maximum, vertical exposure. Therefore, the maximum vertical
amount of the first tile 14 and the second tile 16 are viewable
below the third tile 18, and the water trough 50 of the first tile
14 is not viewable below the third tile 18.
[0065] The water channel 40 and the side lap 42 cooperate to define
a viewable keyway between horizontally-adjacent tiles 20, such as
that viewable between the first tile 14 and the second tile 16 in
FIG. 1 and FIG. 4B. The tiles 20 may also include a simulated
keyway 66 formed in the face of the tiles 20, as illustrated in
phantom in FIG. 4B. The simulated keyway 66 may be located variably
across the exterior side 22 of each the tiles 20, and the width of
the simulated keyways 66 may be varied. The simulated keyways 66
may be formed on some, all, or none of the tiles 20.
[0066] The location of the receiving members 32 may be adjusted to
the left or right of the upper edge 26 of the tiles 20. In the
tiles 20 shown, the receiving members 32 are offset relative to the
center of the tile 20, but may alternatively be symmetric about the
tiles 20.
[0067] Using FIG. 1 and FIG. 4B as examples, assembly of the
multi-tile system 10 may occur by aligning the first tile 14 to the
mounting surface 12. The first tile 14 may be aligned with, for
example and without limitation: edges of the mounting surface 12,
with chalk lines applied to the mounting surface 12, with other
alignment markers, or with previously-installed tiles 20. One or
more fasteners may then be driven through the fastener points 30 of
the first tile 14 into the mounting surface 12.
[0068] The second tile 16 may then be assembled to the first tile
14 by placing the side lap 42 over the water channel 40 of the
first tile 14. The second tile 16 is horizontally aligned within
the limits imposed by the water channel 40 and the side lap 42. The
channel notch 58 and the lap notch 59 cooperate to maintain the
minimum horizontal exposure and the channel lip 56 maintains the
maximum exposure. Fasteners may then be inserted to lock the second
tile 16 to the mounting surface 12.
[0069] The third tile 18 may then be aligned to the first tile 14
and the second tile 16. The locking members 34 of the third tile 18
may be interlocked with the receiving members 32 of the first tile
14 and the second tile 16. Note that if the second tile 16 were
incorrectly installed, such that the side lap 42 of the second tile
16 does not overlap the water channel 40 of the first tile 14, the
receiving members 32 of the first tile 14 and the second tile 16
will be spaced too far apart to allow the locking members 34 of the
third tile 18 to interlock therewith.
[0070] The horizontal and vertical alignment of the third tile 16
will be limited by the ability of the locking members 34 and the
receiving members 32 to interlock. The third tile 16 is oriented
such that the first tile 14 and the second tile 16 have nearly
maximum vertical exposure. Fasteners may then be inserted to lock
the upper edge 26 of the third tile 18 to the mounting surface 12.
Interlocking between the locking members 34 of the third tile 18
and the receiving members 32 of the first tile 14 and the second
tile 16 will hold the lower edge 28 of the third tile 18 to the
mounting surface 12.
[0071] Referring to FIG. 5 and to FIG. 6, and with continued
reference to FIGS. 1-4B, there are shown two schematic isometric
views of a multi-element panel 110. An exterior side of the panel
110, which faces outward and away from the mounting surface (not
shown), defines a forward direction or exterior face. An interior
side of the panel 110, which faces downward toward the mounting
surface, defines a rearward direction or interior face. A plurality
of the panels 110 may be assembled to form a roofing or siding
system.
[0072] FIG. 5 shows the exterior side of one of the panels 110, and
FIG. 6 shows the interior side of one of the panels 110. The
exterior side includes a plurality of faces 122 of the panel 110.
The faces 122 may be textured, painted, or surface-treated to
simulate the look of different roofing materials. Further defining
the multiple elements, the panel 110 also includes a plurality of
keyways 124, which separate several of the faces 122. The keyways
124 are recessed from the faces 122 and extend downward from the
faces 122 toward the mounting surface.
[0073] In many configurations of the panel 110, the faces 122 will
be configured to simulate the aesthetic look of a plurality of
natural slate tiles; such that the panel 110, or a number of panels
110 assembled to the mounting surface, emulates natural slate
roofing. Therefore, the keyways 124 simulate the aesthetic look of
the gaps (or keyways) between individual slate tiles in each
horizontal course. However, the exterior sides of the panel 110 may
also be configured to emulate other materials, such as, for example
and without limitation: wooden shakes, wooden shingles, or ceramic
tiles.
[0074] The panel 110 includes a fastener edge, upper portion, or
upper edge 126 defined along one edge, which is shown toward the
top in FIGS. 5 and 6. A lap edge, lower portion, or lower edge 128
is defined opposite the upper edge 126, and is shown on a bottom or
lower edge in FIGS. 5 and 6. The upper edge 126 may also be
referred to as the head of the panel 110 and is lapped or
overlapped by the lower edge 128 of subsequent tiles when
installed.
[0075] References to upper and lower directions, regions, or
portions are generally defined relative to gravity and elevation as
the panels 110 are intended to be assembled to the mounting
surface. The upper edge 126 and the lower edge 128 are also defined
relative to the slope of the mounting surface, such that the upper
edge 126 is higher, relative to gravity, when installed and the
lower edge 128 is lower, relative to gravity, when installed.
Therefore, the typical flow direction of water or moisture over the
panels 110 and the structures to which they are mounted (although
wind may cause water to move against gravity) is from the upper
edge 126 toward the lower edge 128--i.e., top down.
[0076] Similarly, vertical and horizontal are used descriptively
relative to gravity and elevation. Horizontal is generally parallel
to gravity and does not involve a change in elevation, while
vertical is generally perpendicular to the horizontal direction and
does involve a change in elevation.
[0077] As shown in FIGS. 5 and 6, the faces 122 may have varying
lengths, such that the lower edge 128 is at varied distance from
the upper edge 126. The faces 122, therefore, further simulate the
appearance of natural slate tiles or wooden shakes, which may have
varied lengths or be installed with slight variations on the
mounting surface. Note that the panel 110 shown has only two
different lengths of the faces 122, but may have several random
lengths.
[0078] The keyways 124 may be located along the panel 110 based
upon an algorithm designed to result in the appearance of
randomized locations between variable-width, natural state tiles or
wooden shakes. In a roofing system of multiple panels 110, several
different panels 110, having different patterns or locations of the
keyways 124 between the faces 122, may be used to further simulate
the look of natural elements hand-selected and assembled to the
mounting surface. Furthermore, the width of the keyways 124 may be
varied based upon an algorithm to simulate the spacing between
natural state tiles or wooden shakes.
[0079] At least some portion of the upper edge 126 contacts the
mounting surface, possibly with an intermediary water barrier
disposed therebetween. The upper edge 126 has one or more fastener
hems or fastener strips 130 or fastener points defined therein.
[0080] The fastener strips 130 are configured to mount the panel
110 to the mounting surface with a plurality of fasteners (not
shown), which may be nails, screws, staples, et cetera. In some
embodiments, the fastener strips 130 may be areas designated or
identified for piercing by the fasteners, such that the fasteners
at least partially pierce the material forming the panel 110.
Furthermore, the heads of the fasteners may stop at the face of the
panel 110, as opposed to plunging into the face of the panel 110 or
setting within a recess formed into the face of the panel 110. As
shown in FIGS. 5 and 6, the fastener strips 130 may be elevated,
raised, or offset from the exterior side of the panels 110.
[0081] The panel 110 may be formed from different polymeric or
composite materials. For example, and without limitation, the panel
110 may be formed from polymers, reinforced resin, polypropylene,
foamed polypropylene, high density polyethylene, low density
polyethylene, combinations thereof, or other suitable materials. In
many configurations, the panel 110 may be formed as unitary,
one-piece components, such that each panel 110 is a single
component formed from a single piece of material without subsequent
attachment of pieces formed separately. The panel 110 may be formed
via injection molding, compression molding, machining, or other
suitable processes.
[0082] The underside of the faces 122, the keyways 124, and the
fastener strips 130 are viewable in FIG. 6. Although not shown, the
interior side of the panels 110 may include a system of ribs,
similar to those shown in FIG. 3, including filleted diamonds and
vertical cut-line ribs. The cut-line ribs may provide structural
rigidity and convenient points for cutting the panel 110 into
partial tiles during installation of the multi-tile system 110,
such that gaps on the interior side are not viewable from the edges
of partial tiles that are cut along the cut-line ribs. Because the
panel 110 includes multiple elements, there are a large number of
possible cut lines for making partial panels to start or finish a
horizontal course during installation. Therefore, each element may
have multiple cut-line ribs between the keyways 124.
[0083] The panels 110 are configured to be sufficiently rigid to
resist wind uplift forces, particularly at the lower edge 128,
without an interlock between vertically-adjacent panels 110 and
without any fasteners driven through the lower edge 128. Therefore,
only the upper edge 126 includes fasteners driven through the
fastener strips 130. The keyways 124, and particularly the walls
thereof, provide additional structural rigidity by acting as ribs
on the underside of the panels 110, as viewed in FIG. 6.
Furthermore, the panels 110 may include additional ribs.
[0084] The panels 110 further include a gutter or water channel 140
formed on at least one side of the panels 110 between the upper
edge 126 and the lower edge 128. A side lap 142 is formed on the
opposite side of the panel 110 from the water channel 140. The side
lap 142 is configured to overlap the water channel 140 of an
adjacent panel 110. In FIG. 5, the water channel 140 is toward the
right and the side lap 142 is toward the left.
[0085] Interaction between the side lap 142 and the water channel
140 limits the amount of horizontal, and possibly vertical,
adjustability between the panels 110. When multiple panels 110 are
overlapped, the viewable, or exposed, portion of the water channel
140 forms a keyway between horizontally-adjacent panels 110.
[0086] The panels 110 force a serpentine path or S-path in the side
water channel 140. The S-path forces water moving upward through
the water channel 140, which may result from wind, to move around a
horizontal dam 146. The S-path reduces the likelihood of water
reaching the uppermost edge of the water channel 140 and moving
over the upper edge 126 onto the mounting surface by forcing the
water to change momentum and move horizontally before reaching the
upper edge of the water channel 140.
[0087] The water channel 140 is continuous and does not include any
holes, cracks, or nail points. Therefore, water or moisture within
the water channel 140 cannot leak out of the water channel 140
without going over a ledge or flowing downward, as intended.
Instead, water flows downward through the water channel 140 onto
the face 122 of a lower panel 110 or off of the edge of the
mounting surface.
[0088] As viewed in FIG. 6, the side lap 142 includes a horizontal
ledge 148 that is configured to extend into the water channel 140
of an adjacent panel 110 to further restrict movement of water
upward. The horizontal ledge 148 and the horizontal dam 146 of
adjacent panels 110 cooperate to force water to change momentum and
provide a significant barrier against water reaching, and moving
over, the upper edge 126 onto the mounting surface.
[0089] The panels 110 include a water trough 150 formed or defined
on the upper edge 126. The water trough 150 is oriented at a trough
angle 152 to the mounting surface or to the exterior side of the
panel 110, and there is no lip or ledge between the water trough
150 and the exterior side. The water trough 150 is substantially
planar and has a planar intersection abutting to the faces 122,
such that water simply has to flow over the linear edge connecting
the water trough 150 to the faces 122 and the keyways 124, and is
not trapped within the water trough 150.
[0090] The trough angle 152 allows water to flow downward from the
water trough 150 onto the faces 122 of the exterior side toward the
lower edge 128, as opposed to trapping water in the water trough
150. On the panels 110 illustrated, the fastener strips 130 are
raised slightly above the water trough 150, which provides further
protection against moisture moving upward on the panel 110 from
reaching holes around the fasteners.
[0091] The trough angle 152 is configured to be substantially
horizontal or flat, relative to gravity, when the panel 110 is
assembled to the lowest pitch at which the multi-tile system 110
system is intended to be installed. For example, if the panels 110
are configured to be installed to a minimum pitch of 3:12, which is
three feet of rise per twelve feet of run, the trough angle 152
would be approximately fourteen-degrees. Note that when assembled
to a steeper roof pitch, the trough angle 152 will also be steeper
relative to gravity and drain more aggressively.
[0092] A plurality of weeping channels 153 are formed through the
fastener strips 130 to link the water trough 150 and the lower
portions of the panels 110. The weeping channels 153 allow water to
drain from the water trough 150 to the either the faces 122 or the
keyways 124.
[0093] The weeping channels 153 shown are substantially aligned
with the keyways 124. However, the weeping channels 153 may also be
located with consistent spacing along the horizontal length of the
panel 110, such as the average shingle distance.
[0094] In some configurations of the panels 110, such as that shown
in FIG. 5, the water trough 150 has a flow path or connection to
the water channel 140. This connection may allow water to drain
from at least a portion of the water trough 150 into the water
channel 140, further preventing water from collecting in the water
trough 150.
[0095] The panels 110 shown include a trough lip 154 at the upper
edge 126 of the water trough 150. The trough lip 154 is
substantially the full thickness of the panel 110 and may help
prevent water, especially wind-blown water, from going over the
back or top of the panel 110.
[0096] The thickness of the upper edge 126 and the lower edge 128
are substantially equal, such that the panels 110 shown do not
taper. Alternatively, some configurations of the panels 110 may
taper from front to back to reduce the amount of material used in
the panels 110. However, such a taper may limit the depth of the
water trough 150 and the height of trough lip 154.
[0097] The distance that the water trough 150 extends from the
upper edge 126 to the face 122 of the panel 110 may define the
maximum vertical exposure of the multi-tile system 110. The trough
angle 152 and the height of the trough lip 154--based upon
triangle-like geometry--may control the length of the water trough
150 and, therefore, may also control the amount of vertical
exposure.
[0098] Exposure refers to the amount of any panel 110 that is
viewable after installation in the roofing system. Maximum exposure
results in more of each panel 110 being visible and requires
relatively fewer panels 110 to cover the same space. Minimum
exposure results in less of each panel 110 being visible and
requires relatively more panels 110 to cover the same space.
[0099] Horizontal adjustability and horizontal exposure may be
controlled by the interaction between the water channel 140 and the
side lap 142 of horizontally adjacent (side lapping) panels 110.
For absolute minimum, the side lap 142 may be pushed all the way
through the water channel 140 until the water channel 140 is no
longer viewable. However, such minimum exposure would negate the
ability of the water channel 140 to emulate the keyway, which may
be visually similar to one of the keyways 124, between natural
elements.
[0100] The panels 110 include a channel lip 156 formed on one side
of the water channel 140. The channel lip 156 limits the maximum
horizontal exposure of the panels 110 by cooperating with the side
lap 142 to prevent pulling the side lap 142 beyond the water
channel 140 and leaving a gap between horizontally-adjacent panels
110.
[0101] The channel lip 156 also provides a barrier that water must
move over to escape the water channel 140, similar to the function
of the trough lip 154. The channel lip 156 and the trough lip 154
illustrated in the figures both provide water barrier features that
are substantially perpendicular to the mounting surface, such that
they require water to change momentum and move against gravity in
order move over the edges of the panels 110.
[0102] In the multi-element panel roofing system shown, the panels
110 include a lap spacer 160 formed on the upper portion of the
side lap 142. When two panels 110 are assembled together, the lap
spacer 160 cooperates with the horizontal dam 146 of the adjacent
panel 110 to limit the amount of the side lap 142 that can extend
or overlap into the water channel 140, and ensures that some
portion of the water channel 140 is viewable to simulate the keyway
between horizontally-adjacent tiles. The lap spacer 160 also
cooperates with the trough lip 154 to limit the maximum exposure of
the water channel 140.
[0103] If the lap spacer 160 were not formed on the interior side
of the panels 110, the minimum exposure would allow the water
channel 140 to be completely blocked from view and the maximum
exposure would allow the whole water channel 140 to be viewable.
Therefore, in the panels 110 shown, the lap spacer 160 defines both
the minimum and maximum horizontal exposure of properly assembled
panels 110.
[0104] Uplift at the lower edge 128 creates torque about the
connection, at the fastener strips 130, between the panel 110 and
the mounting surface. As shown in FIG. 6, the panels 110 include a
plurality of counter ribs 162 that continue from the underside of
the keyways 124 to the upper edge 126. In the configuration shown,
the counter ribs 162 are aligned below the weeping channels 153.
The counter ribs 162 promote rigidity and counteract torque
generated about the fastener strips 130 by uplift loads at the
lower edge 128.
[0105] A plurality of fastener ribs 164 may provide support against
the loads introduced by fasteners driven through the fastener
strips 130. The fastener ribs 164 may also provide torsional
rigidity by horizontally linking the keyways 124.
[0106] Referring to FIG. 7 and to FIG. 8, and with continued
reference to FIGS. 1-6, there are shown two additional views of a
plurality of panels 110. FIG. 7 shows a top view of three panels
110 illustrating relative alignment for installation, and FIG. 8
shows a cross-sectional view of the side lap between two of the
panels 110, taken generally along the line 8-8.
[0107] During installation of the roofing system, a first panel
110a may be attached to the mounting surface (not numbered). A
second panel 110b may then be aligned to the right of the first
panel 110a and also attached to the mounting surface with a
plurality of fasteners. The first panel 110a and the second panel
110b are part of a first course of panels that are generally
aligned along a horizontal row. A third panel 110c may then be
aligned and assembled in a row above the first panel 110a and the
second panel 110b.
[0108] The third panel 110c covers the water trough 150 of the
panels 110 over which it is installed. In the illustration shown in
FIG. 7, the third panel 110c overlaps only the upper portion 126 of
the first panel 110a. However, depending on the pattern of
installation and whether the first panel 110a or third panel 110c
are beginning a row, the third panel 110c may overlap both the
first panel 110a and the second panel 110b.
[0109] As viewed in FIGS. 7 and 8, the side lap 142 of the second
panel 110b overlaps the water channel 140 of the first panel 110a.
FIG. 8 shows an upward viewpoint of the lap between the first panel
110a and the second panel 110b. Courses of the panels 110 are
horizontally offset relative to the course below and the course
above, as illustrated in FIG. 7.
[0110] During installation, the side lap 142 of the second panel
110b is laid over the water channel 140 of the first panel 110a,
such that portions of the side lap 142 extend into, and direct
water flow to, the water channel 140. The lap spacer 160 of the
second panel 110b is shown with a dashed line in FIG. 7.
[0111] The lap spacer 160 of the second panel 110b may abut the
horizontal dam 146 of the first panel 110a for minimum horizontal
exposure and may abut the trough lip 156 of the first panel 110b
for maximum horizontal exposure. The panels 110 are illustrated in
FIG. 8 at or near maximum horizontal exposure between the first
panel 110a and the second panel 110b, such that nearly the maximum
amount of the water channel 140 is viewable to simulate a
relatively large keyway between elements.
[0112] If the lap spacer 160 were not formed on the interior side
of the panels 110, the minimum horizontal exposure would allow the
water channel 140 to be completely blocked from view and the
maximum exposure would allow the whole water channel 140 to be
viewable. Therefore, in the panels 110 shown, the lap spacer 160
defines both the minimum and maximum horizontal exposure of
properly assembled panels 110.
[0113] The detailed description and the drawings or figures are
supportive and descriptive of the invention, but the scope of the
invention is defined solely by the claims. While some of the best
modes and other embodiments for carrying out the claimed subject
matter have been described in detail, various alternative designs,
configurations, and embodiments exist for practicing the invention
defined in the appended claims.
* * * * *