U.S. patent number 3,667,184 [Application Number 05/013,592] was granted by the patent office on 1972-06-06 for interlocking metal shingle construction.
Invention is credited to Clifford C. Merrill, Carl E. Strombeck.
United States Patent |
3,667,184 |
Merrill , et al. |
June 6, 1972 |
INTERLOCKING METAL SHINGLE CONSTRUCTION
Abstract
A metal shingle construction containing simulated shingles
formed of sheet metal which present the appearance of wooden
Hollywood shakes. The shingles of adjacent courses are in
interlocking engagement as are adjacent shingles in each course so
as to prevent a hard and driven rain from penetrating the joints
between adjacent shingles, as well as to prevent flapping of the
shingles in the wind. Nailing of the shingles to a roof
substructure is only required at one end of each shingle, securance
of the opposite end being provided by interlocking engagement with
the shingles of an adjacent course. The nails, or other fastening
means, are disposed in the shingle construction in completely
sheltered position with respect to the weather without requirement
of mastic or equivalent sealing means. The shingles are arranged
such that prior to attachment of the shingles of each course the
shingles therein may be shifted laterally and angled, or "skewed",
relative to each other to adjust the length of the course to the
dimensions of the roof and thereby prevent the course from
overlapping the edge of the roof. Special forms of shingles are
provided for forming valleys, and another special form is provided
for constructing hip roofs -- both of which are necessary when two
flat roof surfaces intersect to form a valley or a hip. Generally
speaking, the construction of these special shingles is
substantially the same as that outlined above for regular shingles,
but differs in the one respect that one side of the shingle is
formed at an angle to the other side. The shingles designed for use
in valleys are narrow at the lower and thicker end and wider at the
top and thin end, while the shingles designed for hips are wider at
the lower end and narrow at the upper. These special shingles for
both hips and valleys are necessarily constructed, sold and used in
pairs as they must form a special joint where they abut at the hip
or valley. Another difference between these special shingles for
valleys and those for the regular flat roof structure lies in the
fact that there is no flange or gutter where the two valley
shingles of each pair abut each other.
Inventors: |
Merrill; Clifford C. (Ferndale,
CA), Strombeck; Carl E. (Loleta, CA) |
Family
ID: |
21760726 |
Appl.
No.: |
05/013,592 |
Filed: |
February 24, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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804424 |
Mar 5, 1969 |
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Current U.S.
Class: |
52/530;
D25/139 |
Current CPC
Class: |
E04D
13/0445 (20130101); E04D 1/18 (20130101); E04D
1/2942 (20190801); E04D 1/2918 (20190801); E04D
1/2935 (20190801); E04D 1/2916 (20190801); E04D
2013/0454 (20130101) |
Current International
Class: |
E04D
1/12 (20060101); E04D 1/18 (20060101); E04D
13/04 (20060101); E04d 001/00 () |
Field of
Search: |
;52/519-538,542,547 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Murtagh; John E.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of our copending patent
application Ser. No. 804,424, filed Mar. 5, 1969, now abandoned.
Claims
What is claimed is:
1. A metal shingle comprising a body section defining a top wall,
first and second wedge-shaped side walls extending downwardly from
said top wall along opposite sides thereof with the smaller narrow
ends of said side walls being adjacent an upper first end of said
body section and with the larger base ends of said side walls being
adjacent a lower second end of said body section, an end wall
section depending from said top wall adjacent the lower end of said
body section and extending transversely between said side walls to
simulate therewith and with said top wall a wedge-shaped shingle
having a thick lower end and thin upper end, said side walls being
respectively provided with cooperable structure extending
essentially from one end to the other of said body and enabling one
of the side walls of said shingle to be disposed in association
with the opposite side wall of a similar shingle laterally adjacent
thereto in the same course so as to form a joint therebetween
enabling any two such similar laterally adjacent shingles to be
shifted relative to each other to orient the same in accordance
with the requirements of any particular roof, cooperable means
providing elements respectively adjacent the upper end of said body
and adjacent the lower edge of said end wall section for
interlocking said shingle with similar shingles of adjacent upper
and lower courses, respectively, and including adjacent the upper
end of said body a holding flange extending over said top wall to
define therewith a downwardly opening slot and also including
adjacent the lower end of said body a tongue extending upwardly
from the lower edge of said end wall section for reception within
the slot of a similar shingle disposed in a lower course to
interconnect one with the other, said holdingflange element having
opposite lateral edge portions respectively overlying said
cooperable structure along each side of said shingle and being
structurally complementary with respect to each other so that one
lateral edge portion of said shingle will cooperatively interengage
the opposite lateral edge portion of a similar shingle laterally
adjacent thereto in the same course, the elements of said
cooperable means at the upper end of said body for interlocking
said shingle with similar shingles of an upper adjacent course
being meshable with the elements of said cooperable means at the
lower end of such similar shingles in the upper adjacent course to
enable such interlocked shingles of adjacent courses to be shifted
with respect to each other to orient the same in accordance with
the requirements of any particular roof.
2. A metal shingle according to claim 1 in which said cooperable
structure along one of said side walls comprises a generally
U-shaped channel including a third side wall disposed in spaced
apart relation with said first side walland a web extending
therebetween and interconnecting the same adjacent the lower edges
thereof, said body along the underside thereof adjacent said second
side wall being substantially free from obstructions to enable said
second side wall to be inserted into the channel of a similar
laterally adjacent shingle so as to be disposed intermediate the
firstand third side walls thereof, said lateral edge portions
overlying the respectively associated channel and second side
wall.
3. A metal shingle according to claim 1 in which said top wall
defined by said body section is generally rectangular and said
first and second side walls are substantially parallel.
4. A metal shingle according to claim 1 in which the top wall
defined by said body is generally trapezoidal with the thick lower
and thin upper ends thereof being substantially parallel, one of
said first and second side walls being substantially normal to the
lower and upper ends of said shingle and the other such side wall
being angularly disposed with respect thereto.
5. A metal shingle according to claim 1 further including a
metallic starter strip for securing said shingle onto the lower end
of a roof sheathing, said strip including an elongated main section
having a holding flange extending reentrantly upward and inward
from the upper longitudinal end thereof in closely spaced
relationship to said main section to define therewith a downwardly
opening slot for receiving the tongue of said shingle, said strip
having transversely spaced sets of registering holes through said
holding flange thereof and the main section therebeneath rearwardly
of the location in said slot for said tongue, and said strip
further including a sealing lip depending downwardly and inclined
inwardly from the lower end of said main section for butting
engagement with the end of said roof sheathing.
6. A metal shingle according to claim 2 wherein one of the lateral
edge portions of said holding flange extends laterally over the
upper end of said U-shaped channel section and is upwardly and
laterally offset with respect thereto to form with said channel
upper end a socket for receiving therein a locking tab of an
adjacent shingle, and wherein the upper end of said body section
adjacent said second side wall and the lateral edge portion of the
holding flange thereover are upwardly and laterally offset with
said body section corner terminating in a downwardly extending
locking tab engageable within a socket of an adjacent similar
shingle and laterally adjustable therein for substantially the full
width of said socket.
7. A metal shingle according to claim 2 in which said channel is
wide relative to the thickness of said second side wall and tapers
in width from end to end thereof so that said first and third side
walls diverge toward the aforesaid first end of said body section,
the aforesaid shiftability of shingles constituting bodily lateral
displacements of similar adjacent shingles and also angular
displacements thereof so that two such similar laterally adjacent
shingles can be canted with respect to each other from end to end
thereof.
8. A metal shingle according to claim 10 in which the top wall
defined by said body is generally trapezoidal with the thick lower
and thin upper ends thereof being substantially parallel, one of
said first and second side walls being substantially normal to the
lower and upper ends of said shingle and the other such side wall
being angularly disposed with respect thereto.
9. A metal shingle according to claim 8 in which said top wall
defined by said body has a generally trapezoidal configuration with
the thick lower and thin upper ends of said shingle being
substantially parallel, and further comprising an elongated gutter
adapted to underlie the associated side walls forming a joint
between two laterally adjacent trapezoidal shingles at a valley of
a roof structure.
Description
BACKGROUND OF THE INVENTION
This invention relates to a metal roof shingle and, more
particularly, to a metal roof shingle which simulates a wooden
shake shingle and has an improved construction providing it with
versatility and making it easily installable, but yet which assures
a weather-proof roof assembly.
Various metal shingles have been designed to provide a metal
shingle roof construction which in appearance resembles that of a
wooden shingle roof but yet possesses advantages thereover
particularly as to ease of installation, cost, durability, and the
like. However, it has been necessary in the past for metal shingles
to have relatively complicated interlocking structure for securing
adjacent shingles together to assure that the resulting roof is
secure and weatherproof. In some instances, it has been found
necessary or desirable to coat the undersides of the metal shingle
with a mastic or equivalent adhesive sealing means to provide the
roof with the necessary sealed properties. Besides the increased
cost of construction arising from the addition of the sealing means
it is necessary that metal shingles be interlocked on a roof in a
manner which assures that the joints between the shingles are
leakproof.
Most shingle interlocking arrangements provided in the past require
that adjacent shingles be in particular locations with respect to
one another before the shingle joint will have the necessary water
seal. Most metal shingle roofs therefore have a regular pattern of
shingles which distinguishes the same from conventional wood shake
roofs with their more irregular shingle patterns. Moreover, the
interlocking structure between adjacent shingles has generally been
such that the shingles cannot readily be moved relative to one
another in order to adjust the length of a course of shingles to
conform to the dimensions of the roof. Consequently, a course of
shingles frequently overlaps the edge of the roof, and the
outermost shingle of the course must be trimmed flush with the roof
edge. Besides this resulting in an unsightly edge appearance,
problems result in properly sealing the edge to assure a tight,
waterproof seal of the shingles to the roof. Further, the
interlocking structure of former shingles generally prevents
angling, or twisting, of a shingle with respect to those adjacent
to it.
SUMMARY OF THE INVENTION
The instant invention is a metal shingle of improved construction
formed to simulate a wood shake and equipped with structure for
interlocking the shingle with adjacent shingles in a manner which
permits relative adjustability thereof so that the precise location
and orientation of the shingle relative to those adjacent thereto
can be selectively changed both as respects the distance separating
any one shingle from those laterally adjacent thereto in the same
course and as respects the angle at which it lies relative to the
others, all while assuring a weatherproof securence of the shingle
to adjacent shingles and to the roof base.
In its basic aspects, the metal shingle is wedge-shaped and
includes a body section having along opposite longitudinal edges
thereof, first and second downwardly extending tapered or
wedge-shaped side walls which, with a generally rectangular
downwardly extending end wall or base, simulate the wedge-shape of
a conventional wooden shake shingle. The shingle in certain forms
thereof also includes a third wedge-shaped side wall spaced from
and extending along the first side wall to which it is connected by
a web to define at one side of the shingle a U-shaped channel or
gutter section which simulates the spacing ordinarily provided
between wooden shake shingles when fastened onto a roof. The
shingle is provided with cooperable means at both the upper and
lower ends of the body section thereof for interlocking the shingle
with similar shingles of adjacent upper and lower courses,
respectively. Moreover, the second side wall of the shingle is
adapted to overlap the third side wall of a substantially identical
shingle in the same course and engage such adjacent shingle within
its U-shaped channel to interlock the shingles together.
The cooperable means at the upper and lower ends of the body
section of each single for interlocking the same with similar
shingles of both upper and lower courses is meshable with the
corresponding interlocking means of its laterally adjacent shingles
to permit such adjacent shingles to be laterally shiftable with
respect to one another so that the length of a course of shingles
can be readily adjusted to the dimensions of the roof. This
construction also permits the laterally adjacent shingles in the
same course to be angled with respect to one another in order to
adjust the shingles so as to correct variations in the base. The
cooperable means at the upper and lower ends of the body sections
are also designed to permit shingles of the adjacent upper and
lower courses to be secured to the shingle in any lateral position
with respect thereto. In short, the construction of a metal shingle
according to the present invention provides a completely waterproof
joint between each shingle and all adjacent shingles, and yet
permits variations in the spacing of laterally adjacent shingles,
permits the offset of the shingles of one course with respect to
those of an upper or lower course, and permits differences, not
only in the spacing of laterally adjacent shingles, but also in the
angles at which they lie with respect to one another in order to
compensate for the slight variation in the roof base which is
common in building construction. Thus, these shingles provide a
waterproof roof in which the shingles can be adjusted to a
considerable degree with respect to those lying immediately
adjacent thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are illustrated in the accompanying
drawings in which:
FIG. 1 is a perspective view of a plurality of shingles of the
invention illustrating the manner in which they are
interlocked:,
FIG. 2 is a sectional view on an enlarged scale taken on a plane
indicated by the lines 2--2 of FIG. 1 and illustrating the
interlocking arrangement between adjacent shingles in the same
course which permits such adjacent shingles to be laterally shifted
with respect to one another and yet provides a weatherproof
seal;
FIG. 3 is a partial perspective view of interlocked upper end
corners of two adjacent shingles;
FIG. 4 is a sectional view on an enlarged scale taken on a plane
indicated by lines 4--4 of FIG. 1, illustrating the interlocking
structure of the upper end corners of the adjacent shingles and the
manner in which such structure is meshable to permit adjacent
shingles of a course to be shifted laterally with respect to each
other prior to nailing to adjust the length of the shingle course
to the dimensions of a roof;
FIG. 5 is a sectional view taken on a plane indicated by line 5--5
of FIG. 1 and illustrating the cooperating means for interlocking
shingles of adjacent courses together;
FIG. 6 is a partial rear, or bottom, view of a shingle of the
invention interlocked with adjacent shingles and illustrating the
interlocking structure from below;
FIG. 7 is an upper end view of a shingle of the invention secured
to a roof sheathing and interlocked with adjacent shingles;
FIG. 8 is a perspective view of a starter strip for securing the
lowermost course of shingles onto a roof;
FIG. 9 is a partial view of a shingle of a lowermost course of
shingles secured to a roof by the starter strip of FIG. 8;
FIG. 10 is a perspective view of a pair of shingles designed for
the formation of a hip roof;
FIG. 11 is a broken transverse sectional view of the pair of
shingles forming a hip, the section being taken along the line
11--11 of FIG. 10;
FIG. 12 is a broken top plan view of one of the shingles shown in
FIG. 10;
FIG. 13 is a perspective view of a pair of adjacent shingles
forming a valley; and
FIG. 14 is a broken lower end view of the pair of shingles shown in
FIG. 13, the view being taken along the line 14--14 of FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Considering now the invention in detail and referring to the
illustrated form thereof in the drawings, FIG. 1 depicts a roof
shingle arrangement 11 comprising a plurality of interlocking metal
shingles generally referred to by the reference character 12 but
individually characterized by the prime markings ', ", "', and "".
These shingles are arranged in courses with the shingles of
adjacent courses being in interlocking engagement and the adjacent
shingles of each course being in interlocking engagement in a
manner subsequently described. Each shingle is preferably formed of
a single sheet of metal, such as aluminum, in a configuration which
simulates a wooden shake shingle such as that known as a Hollywood
Shake. More particularly, each shingle 12 includes a generally
rectangular body section 13 and various other sections integrally
connected along each one of the four edges thereof and folded with
respect thereto. Preferably, this body section, or top 13 of a
shingle is stamped with irregular corrugations to simulate the
upper surface of a wooden shake. To further simulate a wooden
shake, the first and second wedge-shaped side walls 14, 16,
respectively, are provided at the opposite sides of body section 13
in right angular relation thereto.
The points of the side walls are positioned at the first, or upper,
end 17 of the body section, while the large or base end edges of
the side walls are positioned at opposite, or lower, end 18
thereof. An end wall section 19 depends generally right-angularly
from the end 18 of the body section and extends transversely
between the base ends of side walls 14, 16. It will be noted,
particularly from FIG. 5, that the ends 21 of the end wall 19 are
folded inwardly and tightly around the base ends of the respective
wedge-shaped side walls 14 and 16 similar to the folded seam of a
tin can. Thus, each of the folded over ends 21 is in tight sealing
engagement with its associated side wall end. It has been found
that this arrangement provides a tight water seal between the side
walls and end wall of the shingle so that water cannot get beneath
the shingles through the side wall - end wall joint.
From the above it will be appreciated that the body section 13,
side walls 14 and 16, and end wall 19 present exteriorly the
appearance of a solid wood shake shingle. Each of the shingles 12
further includes means defining a longitudinal channel along its
sides similar to the channel found between wood shingles secured to
a roof. More particularly, one side of the shingle 12 (the left
side in these Figures) consists entirely of the side wall 16, which
terminates at its lower edge in a narrow, flat lip 34 (see
particularly the left side of FIG. 1 and the left side of shingle
12" in FIG. 2). The other side wall 14 defines a part of a U-shaped
channel 22 longitudinally of the other side of the shingle. Such
channel is further defined by a third wedge-shaped side wall 23
which is in spaced parallel relation to side wall 14 and
interconnected therewith by a right angularly extending web 24
which runs lengthwise of the shingle between opposite ends 17, 18
of the shingle body section 13.
Each of the shingles 12 is provided with cooperable means at its
upper and lower ends for interlocking the shingle with similar
shingles of adjacent upper and lower courses. More particularly,
the upper end 17 of the body section 13 of each shingle is provided
with a preferably integral holding flange 26 which extends
substantially the whole width of the body section reentrantly
upwardly and inwardly from the end 17. Such holding flange is
closely spaced to and conforms to the upper surface of the body
section therebeneath to define with such body section a slot 27
(see particularly FIGS. 3 and 5). The lower end of the body section
13 of each shingle is provided with means for engagement within the
slot 27 of a shingle or shingles on an adjacent lower course to
provide the desired interlocking. That is, a tongue 28 extends
inwardly from the lower end edge of the end wall 19 substantially
perpendicular thereto. As best illustrated in FIG. 6, such tongue
28 extends for substantially the full width of the body section
and, as shown in FIG. 5, is receivable within a slot 27 defined by
the shingles of a lower adjacent course.
As mentioned previously, the cooperable means of interlocking
shingles of adjacent courses together is designed to permit the
shingles of the adjacent courses to be interlocked without regard
to the particular location of the shingles to one another. That is,
the shingles of an upper course may be secured over the joint of
two shingles of a lower course such as is illustrated in FIG. 1, as
well as in alignment with one of the lower shingles. The particular
configuration of the holding flange 26 at the upper ends of the
shingles is primarily responsible for this ability. More
particularly, as is best illustrated in FIGS. 3 and 5, flange 26
conforms for its full length fairly closely to the configuration of
the body section therebeneath. In this connection, the uppermost
portion of the body section adjacent its upper end is flat (as
indicated by the reference character 29, FIGS. 5 and 6) for
substantially the full width of the body section and is connected
to the remainder of the body section 13 by an upwardly inclined
portion 30. The holding flange also includes a flat portion
overlying the flat portion of the body section and a section
inclined upwardly with the inclined portion of the body section. At
the free end of the holding flange, it extends upwardly away from
the body section to provide a mouth for the reception of the tongue
of the upwardly adjacent shingle. Thus, neither the holding flange
nor the body section therebeneath has any structure which would
prevent the tongue of an upwardly adjacent shingle from being
inserted within the slot 27 any place along its length, even across
the joint between two shingles.
As is illustrated in FIGS. 5 and 7, the flat upper edge portion of
the body section has another advantage. It provides beneath the
shingle a flat surface 29 for engagement with the flat surface of a
roof sheathing or the like to which the shingle is to be secured.
This mating engagement of the two surfaces assures that when the
shingle is secured to the roof sheathing its upper end will be
rigidly secured thereto for its full width without bending. To
enable securance of the shingles to the roof sheathing, the flat
portion of the upper end of the body section 29 and the holding
flange 26 are provided with transversely spaced sets 31 of
registering holes or apertures for the reception of headed
fasteners, such as the nail 32, to secure the shingle upper ends to
the sheathing. As is best illustrated in FIG. 3, each set of the
holes 31 is provided with an annular raised ridge 33 circumscribing
the same on the upper surface of the holding flange 26. This raised
ridge sealingly engages the head of a fastener 32 passing through
its associated hole set 31 to provide a seal between such fastener
and the hole. The raised ridges 33 are preferably provided by
forming the registering sets 31 of holes by punching the same from
the bottom of the shingle on a punch press which will result in the
area around the hole on the upper side of the shingle having the
ridge.
It should be noted that in installing a plurality of the shingles
of the invention on a roof, the shingles are secured to the roof in
courses with the lowermost course being the first secured to the
roof, the next higher course being the second, and so on. When a
shingle is being secured to a shingle of the next lower course, the
tongue 28 of the former shingle is inserted into the slot 27 at the
upper end of the lower shingle. Most desirably, the tongue 28 of
each shingle is angled downward at an obtuse angle with respect to
its associated end wall 19 and at an angle with respect thereto
greater than the angle of the slot 27 thereto when the shingles are
secured to the roof. The result is that upon the tongue initially
being engaged within the slot 27 of a lower shingle secured to the
roof sheathing, the upper shingle will angle upwardly from its
lower end away from the roof sheathing and its upper end must be
forced down to permit the same to be nailed to the sheathing. Thus,
the shingle is placed in tension at the time it is secured to the
roof. It has been found that such tension at the joints between the
shingles of two adjacent courses provides an enhanced securance of
the shingles together and assures that wind or the like will not be
able to break the connection between such shingles.
As a particularly salient feature of the invention, the
interlocking structure between adjacent shingles in the same course
is designed to permit lateral shifting of the shingles relative to
one another and yet provide the weatherproof seal that is necessary
in the joint between such shingles. As is illustrated in FIG. 2,
adjacent shingles in the same course are interlocked along their
entire length by the wedge-shaped side wall 16 of one shingle being
received within the U-shaped channel 22 of its adjacent shingle
with the side wall 16 encompassing the side wall 23 of its adjacent
shingle. As will be described below, the holding flanges of the
adjacent shingles are meshed in a manner which will permit the
shingles to be laterally adjusted relative to one another between
the illustrated solid line and dotted line positions of the shingle
12' relative to the shingle 12" (FIG. 2). It is especially
important to note that a lip 34 extends laterally outward from the
lower longitudinal edge of the side wall 16 of each shingle for
substantially its full length and that this lip has a width
substantially less than that of web 24. This lip engages the web 24
of the adjacent shingle in a mating relationship as shown. It has
been found that this mating relationship between the shingle and
the web assures that a watertight seal is provided between the
shingles, irrespective of the lateral location of the side wall 16
within the channel 24.
The structure for interlocking the upper end of each shingle with
the lower end of a shingle of an adjacent upper course is made
meshable with the corresponding interlocking structure on the upper
end of the laterally adjacent shingles of the same course so that
the lateral adjustability discussed above is possible. More
particularly, as is best illustrated in FIG. 4, the holding flange
26 of each shingle includes a hooded end portion 36 extending
laterally over the upper end of the channel 22. The corner portion
36 is upwardly and laterally offset with respect to the channel
section to form with the channel upper end a socket 37 adapted to
receive a locking tab 38 of an adjacent shingle.
The locking tab 38 of each shingle is formed by the upper end
corner of the body section opposite to the portion 36 being
upwardly and laterally offset relative to the flat upper end
portion of the shingle and terminating in the downwardly extending
locking tab 38, which is the upper end of the side wall 16 and lip
34. As illustrated, such locking tab is engageable within the
socket 37 in overlapping relationship to the upper end of the
channel side wall 23 of the adjacent shingle. Because of the socket
formed by the upwardly extending holding flange portion 36 and the
channel 22 therebeneath, the locking tab 38 is laterally movable
within such socket between the location shown in solid lines and
that indicated by dotted lines, thereby permitting lateral
adjustment of one shingle relative to another for the full length
of such shingles. This socket construction not only permits lateral
movement of one shingle 12 with respect to the laterally adjacent
one, but it also permits skewing or angling of one shingle 12 with
respect to its laterally adjacent neighbor. It is well-known that
in building construction there are many minor irregularities in a
roof base, and to compensate for such irregularities, it is
desirable to twist, or skew, one shingle 12 slightly with respect
to the one immediately adjacent thereto. The fact that the locking
lip 34 at the bottom edge of the side wall 16 is much narrower than
the web 24 which forms the base of channel 22, and the fact that
the socket 37 also permits lateral adjustment of the top corner of
a shingle, automatically provides the necessary lateral adjustment
of two adjacent shingles, both spatially and angularly.
It should be noted that the meshing structure just described is
located closer to the upper end 17 of the body section that the
depth to which the tongue 28 of an upper adjacent shingle is to
extend within the slot 27. Thus, such meshing structure does not
interfere with the securance of an upper adjacent shingle over a
joint of two shingles in the same course. From FIG. 6 it will be
noted that the side edges of the tongue 28 of each shingle
terminate at locations adjacent the side walls 14 and 16 and such
tongue does not extend beneath the U-shaped channel so that it will
not interfere with the tongues of the laterally adjacent shingles
when they are shifted laterally with respect to the shingle of
which the tongue is a part.
The lateral shiftability of the location of two adjacent shingles
in the same course permits the length of the course to be readily
adjusted to the dimensions of a roof so that overlap of the roof
edge can be prevented. Moreover, it permits the visible width of
the channels between various shingles to be varied or staggered to
provide an irregular shingle arrangement more closely resembling
the shingle arrangement obtained with conventional wood shakes.
As has been explained before, when shingles of the invention are to
be secured onto a roof sheathing, the lowermost course of the
shingles is the first one secured to the sheathing. Means must be
provided for securing the lower ends of the lower course shingles
to such sheathing. FIGS. 8 and 9 illustrate an improved starter
strip, generally referred to by the reference numeral 41, for this
purpose. Starter strip 41 is in the form of an elongated strip of
metal, such as aluminum, which is bent longitudinally thereof to
provide means for sealing the same to the roof sheathing and means
for securing the lower end of the shingles. More particularly,
strip 41 includes a lip 42 which depends downwardly and inwardly
from a longitudinally extending main or flat section 43 adapted for
mating engagement with the upper surface of the roof sheathing. A
holding flange 44 at the upper end of section 43 extends
reentrantly upwardly and inwardly thereof over such section to
define a slot 45 for the tongues 28 of the lowermost course
shingles. As is illustrated, registering sets of holes 46 are
transversely spaced longitudinally along strip 41 and extend
through both holding flange 44 and main section 43 for the passage
of nails or the like to secure such holding strip to a roof
sheathing. When the strip is so secured to a roof sheathing, it is
forced upwardly relative to the edge of the sheathing to cause lip
42 to tightly engage the sheathing edge, and it has been found that
such lip will then provide a good watertight seal between such
sheathing and the starting strip. Thereafter, the tongues 28 of the
lower course shingles are inserted within the slot 45 to thereby
secure the same to the roof edge. It will be appreciated that the
engagement of the tongue within the slot 45 will prevent leakage of
water or the like between the shingle and such strip, thereby
assuring a watertight seal between the shingle and the
sheathing.
Many roof surfaces are formed with an intersection of two planar
surfaces. When an exterior angle is formed by the intersection of
the two roof surfaces, it is known as a "hip" roof; and when an
interior angle is formed by the two intersecting surfaces, it is
known as a "valley." Special shingles are required to accommodate
hips and valleys, as one end of each shingle therefor must be much
wider than the other end thereof. Specifically, a shingle for a hip
roof is wider at the bottom than at the top, and for a valley it is
wider at the top than the bottom. Accordingly, while the shingles
12 heretofore described are substantially rectangular, those
adapted for use on hips and in valleys have somewhat the appearance
of a truncated right triangle, and along their outer sides are
respectively adapted to cooperate with the laterally adjacent
shingles 12 in the same course along their angled sides, the hip
and valley shingles cooperate with one another, and it is believed
apparent that such shingles must be manufactured and sold in pairs,
i.e., a left-hand and right-hand shingle, in order to cooperate
with each other. Further, the outer side of the right-hand shingle
is formed with a channel corresponding to the channel 22 of the
rectangular shingle 12 and the outer side of the left-hand shingle
is formed with a lip corresponding to the lip 34 of the shingles
12.
It is evident that as the slope of the roof surfaces change, the
angle at which the cooperative edges of a pair of hip or a pair of
valley shingles engage must also change. However, we have found
that by using the construction hereinafter described, it is
possible to standardize the shingle pairs so as to afford
sufficient lateral and angular adjustment to accommodate a number
of different slopes. As an example, such shingle pairs can satisfy
the requirements of roofs varying from slopes with a rise in 3
inches per foot of run to a rise of 8 inches per foot of run, or
from a rise of one in four, which is a gently sloping roof, to a
rise of two in three, which is very steep.
A pair of shingles 60, 61 for a hip roof is shown in FIGS. 10 and
11, and such shingles are adapted to cooperate with each other
along their inner adjacent edges and along their respective outer
edges with the shingles 12 shown in FIGS. 1 through 9 which are
intended for generally planar runs or courses. The shingle 61 has a
channel or gutter 62 formed along the right side edge 64 thereof
which is essentially the same as the gutter 22 of the rectangular
shingles 12. Similarly, the left edge 66 of the left-hand shingle
60 is formed with a lip 65 adapted to lie within the channel 22 of
the laterally adjacent shingle 12 and is essentially the same as
the wall and lip 16, 34 thereof. Also, the tops 67 of the shingles
60 and 61, the lower end walls 68 and 69 thereof, the side wall 64
of the channel 62 are substantially the same as described in
connection with the rectangular shingle 12 shown in FIGS. 1 to 9,
inclusive. The upper end 67 of each of the shingles 60, 61 is
provided with an integral holding flange 70 formed in the same
manner as previously described although the flange on the shingle
60 may be slightly longer adjacent its channel or gutter 77 to be
described subsequently. The upper ends 67 are also provided with
nail holes 71 so that the shingles can be securely attached to the
roof structure. It is believed clear to those skilled in the art
that the base or lower end walls 69 are provided with an
interlocking flange or tongue corresponding to the tongue 28
previously described, although such tongue is not shown in FIGS. 10
and 11. It will be appreciated, that the shingles 60, 61 are
generally the same as the shingles 12 described in connection with
FIGS. 1 through 9, including stamped upper surfaces 63 to simulate
the top of a wooden shingle, but their adjacent inner walls 75, 76
are not respectively parallel to their other sides 66, 64. As
previously indicated, the interior walls 75, 76 are respectively
cut at an angle relative to the outer walls 64, 66 such that the
top 67 of each hip shingle is considerably narrower than the
associated lower end walls 68, 69 thereof.
In order to provide for the lateral adjustment and change in
angular relationship between the two hip shingles 60 and 61, the
wall 75 is equipped with a channel or gutter 77 defined by a lip 78
extending laterally from the wall 75 at the bottom thereof and a
wall 79 extending upwardly from the lip in spaced relation with the
wall 75. The walls 75 and 79 diverge rearwardly toward the end 67
so that the gutter 77 is wider at the rear of the shingle 60 than
at the forward end thereof, as shown best in FIG. 12. Also, the
walls 75 and 79 are angularly disposed relative to the plane of the
top wall section 63 and diverge upwardly from the web 78. The wall
76 of the shingle 61 is also angularly disposed relative to the top
wall section 63, and initially inclines outwardly and downwardly
therefrom at its lower edge is equipped with a lip 80 which tapers
from front to rear so as to be substantially wider at the front of
the shingle.
The pair of shingles 90, 91 for forming a valley between two
intersecting roof surfaces are shown in FIGS. 13 and 14. One of the
shingles (91 in this instance) is formed with a gutter 92 on the
same side as the gutters formed on the rectangular shingles 12 (for
purposes of illustration the gutter 22 is shown on the right side
of shingles 12, although it is apparent that the gutter 22 and lip
34 could be reversed). The opposite wall of the other shingle (90
in this instance) is provided with a lip 95 adapted to lie in the
gutter 22 of an adjacent shingle 12 (not shown in these figures).
These shingles, as are all of those described in this application,
are wedge-shaped, being thin at the top 97 and thick at the bottom
98. Necessarily, therefore, these shingles 90, 91 have wedge shaped
side walls 94, 96 which correspond to sides 14, 16 of the
rectangular shingles shown in FIGS. 1 to 9, inclusive.
Plate surface 93 is stamped to simulate the top of the wooden
shingle, or shake, and has a bottom wall 99 corresponding to the
bottom wall 19 of the rectangular shingles. The bottom wall 99 is
provided with a forwardly and downwardly extending tongue 107 which
corresponds to the tongue 28 of the rectangular shingle, which is
shown in FIG. 5. The upper end of the shingle 97 is formed with an
integral holding flange 100, which is similar in construction to
the flange 26 shown in the figures illustrating the rectangular
shingles. This flange and the plate 93 immediately therebelow are
provided with a plurality of nail holes 101 so that the shingles
can be rigidly attached to the roof deck 102. The shingles for
construction of a roof valley are similar to those shown and
described for forming a hip in that the adjacent walls 103 and 104
are angularly disposed, but are provided with lips 105, 106,
respectively, and the base ends 98 are narrower than the upper ends
97 which is the reverse of that for the formation of a hip, as is
shown by comparing FIGS. 10 and 12.
Each of the adjacent walls 103, 104 is formed with a lip, 105 and
106, which will lie in a separate gutter formed by a gutter strip
109 of any suitable material, such as a heavy roofing composition
or a bendable metal strip. The use of the abutting lips 105, 106
permits angular adjustment between the valley shingles 90, 91 as is
necessary to accommodate the angular differences occasioned by
pitch variations in different roofs or different sections of the
same roof. The same pitch variations can be handled as indicated
for the previously described hip shingles 60 and 61. Since the
shingles are formed of bendable metal, the lips 105 and 106 can be
bent to conform to the valley shape. By adjusting the angles
between the shingle walls 103, 104, a wide range of valley angles
can be accommodated by using the standard adjustable shingles
described.
It is believed obvious from the foregoing description that the
shingles 60, 61 used for forming hips and the shingles 90, 91 used
for forming valleys are essentially those of the rectangular form
shown in FIGS. 1 to 9, inclusive. They differ from the regular
shingle in that both are shaped as truncated triangles -- the hip
shingles 60, 61 having their base corresponding to the bottom wall
69 and the truncated top at the upper end 67, while the valley
shingles 90, 91 have their broadest portion (the base of the
triangle) at the top 97 and the truncated narrowest portion at the
lower end 98. It is evident that these shingles must be formed in
pairs comprising left-hand and ring-hand shingles. Thus, for both
hips and valleys, there is a right-hand and a left-hand shingle
necessary to form the paired construction desired.
The spacing between the shingles 90 and 91 along the adjacent edges
thereof may be varied to suit the requirements of any particular
roof installation, and by way of example, the spacing is often of
the order of 4 inches. Since the shingles 90 and 91 are unconnected
to each other, they can be canted or angularly disposed as
necessary so long as the gutter strip 109 continues to underlie the
same. It should be noted that the necessity for relative angular
adjustment between the shingles particularly at a hip and at a
valley is that the base ends of these hip and valley shingles
should define an angle very close to 90.degree. so that the courses
of shingles respectively comprising the same lie along straight
lines on the associated roof sections and align properly with the
other courses and not have some unacceptable angular inclination
which would make the courses run along a skew line. It will be
appreciated that as the pitch of a roof changes, the relative
orientation of the hip-forming shingles 60 and 61 and
valley-forming shingles 90 and 91 must be changed in order to
effect the close approximation to 90.degree. required by the
intersection of the lower base walls 68 and 69 in the case of the
shingles 60 and 61 and by the base walls 99 in the case of the
valley forming shingles 90 and 91.
It will be noted in FIGS. 10 and 13 that the base walls of the hip-
and valley-forming shingles have tabs that bend around the
respectively associated longitudinal side walls so as to
interconnect the same. This is essentially the same as in the case
of the shingles 12 of rectangular configuration in which the tabs
interconnecting the longitudinal side walls and base wall of each
shingle are provided by the base walls and are bent into
continguous relation with the side walls. It is evident that the
tabs can be provided either on the base or side walls, or these
coactive wall elements could be interconnected in some appropriate
alternative to effect the desired mechanical interlock and weather
seal therebetween.
From all of the foregoing, it will be appreciated that all forms of
the shingles provide relative adjustment therebetween, and
ordinarily the lateral bodily displacement indicated in FIG. 2 is
sufficient to enable standardized shingles 12 to be adjusted
sufficiently to accommodate the requirements of flat roofs.
However, any two cooperative shingles can be angularly adjusted or
canted relative to each other, as indicated best in FIG. 10, which
is especially advantageous as concerns the paired hip and paired
valley shingles 60, 61 and 90, 91, respectively, in order to enable
standardized shingle pairs to be adjusted sufficiently to
accommodate the angular variation at a roof hip or valley caused by
changes in the pitch of the roof. The tapering channel 77 which
widens rearwardly and tapering lip 80 which narrows rearwardly
enhance the angular accommodation afforded by the cooperative hip
shingles.
* * * * *