U.S. patent number 3,760,546 [Application Number 05/174,477] was granted by the patent office on 1973-09-25 for modular roof construction.
This patent grant is currently assigned to Holiday Recreation Products, Inc.. Invention is credited to James A. Baccus, Marvin Gurman, Gerald Martin.
United States Patent |
3,760,546 |
Martin , et al. |
September 25, 1973 |
MODULAR ROOF CONSTRUCTION
Abstract
Prefabricated roof modules and associated prefabricated joining
and trim members are described for completing on-the-job roofing
from the joists out in a single carpentry operation. The modules
each comprise a sheet-metal upper layer, a foamed synthetic plastic
interior insulation layer, and a plywood sheathing lower layer. The
sheet-metal upper layer is embossed or pressed-formed to simulate
any desired roof deck construction, and is coated with a protective
layer of vinyl resin of any desired color. The various module
joining and trim members are provided with resilient wedge portions
adapted to be compressed between the abutting edges of adjacent
modules; and coated, power driven nails are used to secure the
joining and trim members, together with their modular roof units,
directly to the roof joists of a building under construction. The
side-to-side length of the roof modules is a multiple of the
conventional spacing between roofing joists or trusses in ordinary
building construction, so that module junctures will overlie
central portions of the trusses for nailing.
Inventors: |
Martin; Gerald (Miami Beach,
FL), Baccus; James A. (North Miami, FL), Gurman;
Marvin (North Miami Beach, FL) |
Assignee: |
Holiday Recreation Products,
Inc. (North Miami, FL)
|
Family
ID: |
22636294 |
Appl.
No.: |
05/174,477 |
Filed: |
August 24, 1971 |
Current U.S.
Class: |
52/555; 52/94;
52/309.9; 52/314; 52/468; 52/515; 52/748.1; 52/793.1 |
Current CPC
Class: |
E04D
1/29 (20190801); E04D 3/352 (20130101); E04D
3/38 (20130101); E04D 1/265 (20130101); E04D
1/365 (20130101) |
Current International
Class: |
E04D
3/00 (20060101); E04D 3/35 (20060101); E04D
1/26 (20060101); E04D 1/00 (20060101); E04D
3/38 (20060101); E04d 001/28 (); E04d 001/36 ();
E04d 003/18 () |
Field of
Search: |
;52/94,309,314,467,468,470,478,465,622,555,316,416,417,459,461,462,464,547,551
;85/1F ;161/116,119,123 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Masterman; John R.
Claims
What we claim as new and desire to secure by Letters Patent is:
1. A roofing module, comprising, in combination, a rectangular,
formed sheet metal outer layer and a comparatively thIck layer of
insulating material attached to the underside of said outer layer,
a layer of rigid roof Sheathing secured against the underside of
said layer of insulating material, said outer layer being
pressed-formed (along) throughout its surface to simulate a
plurality of roof shingles both side-by-side along a course of
shingles and row-upon-row along successive courses of shingles and
having the appearance of a conventional built-up roof construction,
and means for joining a pair of such modules placed edge to edge in
a roof assembly, said joining means comprising a elongated strip of
sheet metal and a wedge strip of foamed plastic material of
T-shaped cross-sectional configuration secured against the
underside of said metal strip and defining a resilient plug portion
extending outwardly of the underside of said metal strip.
2. A roofing module as described in claim 1 wherein the outer
surface of the outer layer is fluidize bed coated with a synthetic
resin.
3. A roofing module as defined in claim 2 wherein said layer of
insulating material is of a foamed synthetic plastic material.
4. A roofing module as defined in claim 3 the length of which is a
multiple of 16 inches.
5. The invention as defined in claim 1 wherein said metal strip is
pressed-formed along its surface to conform with the press forming
of the sheet metal outer layer of said roofing modules.
6. The invention as defined in claim 1 wherein said metal strip is
bent centrally along its length at an obtuse angle for joining an
adjacent pair of such modules along the ridge of a roof under
construction.
7. The invention as defined in claim 1 wherein said joining means
further comprises a plurality of nails driven through marginal edge
portions of said strip and said modules, said strip being disposed
with its resilient plug portion fitted between opposing edge
portions of said roofing modules, the shanks of said nails being
coated with a dry adhesive.
8. The invention as defined in claim 1 and further comprising a
fascia board assembly comprising an elongated wooden board and a
layer of sheet metal covering the outside and the peripheral edges
of said board, and a second joining means for joining the lower
edge of the lowermost one of said modules in a roofing assembly
along the upper edge of said fascia board member at the eaves of a
roofing assembly, said second joining means comprising an elongated
strip of sheet metal and a wedge strip of foamed plastic material
of T-shaped cross-sectional configuration secured against the
underside of said last mentioned metal strip and defining a
resilient plug portion extending outwardly of the underside of said
last mentioned metal strip.
Description
This invention relates to roof construction and is directed
particularly to a modular roof construction comprising a plurality
of roofing modules and module joining and trim members all adapted
to be readily prefabricated at the factory and comprising
sheathing, fireproofing, insulation, outer covering and
weatherproofing to enable roof construction from the rafters or
trusses out in a single operation.
Heretofore it has been common practice in roof construction to
apply the sheathing, insulation, waterproofing and deck or outer
covering in a series of individual layers ordinarily applied by
different workmen having different skills. Thus, carpenters
installed the sheathing, insulation installers the insulation, and
roofers the weatherproofing material and outer decking. This method
of construction is not only costly in the labor involved, but is
also uneconomic in the use of materials because of uncontrollable
wastage at the job site in the various cut-to-fit operations.
It is, accordingly, the principal object of this invention to
provide a modular roof construction wherein the modular roof
components can be factory prefabricated and shipped to the job site
for erection directly upon the trusses or rafters of a building
under construction to complete the roofing in a single
constructional operation involving only carpentry skills, and
thereby not only effecting substantial savings in labor costs, but
also enabling completion of the roof in a substantially shorter
period of time than required in ordinary on-the-job roof
construction methods.
A more particular object of this invention is to provide a modular
roof construction of the character described wherein the roof
modules comprises an outer or deck layer of formed sheet metal the
outside of which is press-shaped or embossed to simulate any
desired conventional roof construction and the underside of which
is provided with either an integral layer of composite roofing
insulation and sheathing or successive layers of insulation and
sheathing.
Another object of the invention is to provide a modular roof member
of the above nature which can readily be press-formed and assembled
in layers of the individual components in mass production by the
use of power press techniques for economy and simplicity of
manufacture.
Still another object of the invention is to provide, in a modular
roof construction, a method and means for joining the roof modules
along their various edges, valleys, ridges and eaves, including the
fascia board, to provide for water and weather-proof integrity of
the completed roof under all climate conditions for long periods of
time.
Other objects, features, and advantages of the invention will be
apparent from the following description when read with reference to
the accompanying drawings. In the drawings, wherein like reference
numerals denote corresponding parts throughout the several
views:
FIG. 1 is an isometric view, as seen from above, of a prefabricated
roof module embodying the invention;
FIG. 2 is a partial, transverse cross-sectional view, taken along
the line 2--2 of FIG. 1 in the direction of the arrow;
FIG. 3 is an isometric view, as seen from above, of a joining strip
for joining the sides of adjacent roof modules, whether in a common
plane or where angles form a roof valley;
FIG. 4 is a front elevational view of the joining strip illustrated
in FIG. 3;
FIG. 5 is a partial side elevational view of the joining strip
illustrated in FIG. 3;
FIG. 6 is an end elevational view of a ridge and corner capping
strip for the roof modules;
FIG. 7 is a partial side elevational view of the ridge and corner
capping strip illustrated in FIG. 6;
FIG. 8 is a front elevational view of the joining strip illustrated
in FIG. 10;
FIG. 9 is a partial side elevational view of the joining strip
illustrated in FIG. 10;
FIG. 10 is an isometric view, as seen from above, of a joining
strip for joining adjacent roof modules along their upper and lower
edges;
FIG. 11 is an isometric view of a fascia board assembly;
FIG. 12 is an end view of the fascia board illustrated in FIG.
11;
FIG. 13 is an isometric view of a side covering member for use with
the roof modules;
FIG. 14 is an end elevational view of the side edge covering member
shown in FIG. 13;
FIG. 15 is a front edge view illustrating the use of the
side-to-side joining strip of FIG. 3 in the assembly of the
prefabricated roof panels in a typical roofing installation;
FIG. 16 is a vertical cross-sectional view illustrating the use of
the joining strip of FIG. 8 in the assembly of the prefabricated
roof panels in a typical roofing installation; and
FIG. 17 is a transverse cross-sectional view illustrating the
assembly of the lower edge of a roof module with a fascia strip
member at the eaves of a typical roofing construction embodying the
invention.
Referring now in detail to the drawings, reference numeral 10
designates, generally, a preferred form of a roofing module
embodying the invention, the same being comprised, generally, of a
formed sheet metal outer layer 11, a foamed synthetic plastic
interior insulating layer 12 and a plywood sheathing bottom layer
13. The roofing module 10, which will preferably be 8 feet long and
4 feet wide, i.e., 4 feet from the lower to the upper edge, has its
sheet metal outer layer 11 stamped to simulate any desired outer
covering such as, for example, tile shingles as illustrated at 14.
As such, the outer layer of sheet metal 11 is formed with
equidistantly-spaced, longitudinally-extending steps or riser
portions 15 simulating the lower ends of courses of simulated tile
14, and a plurality of spaced depressions 16 simulating the spacing
between tiles. Along the lower end of the sheet metal outer layer
11 the longitudinally extending step or riser 15 terminates in a
short, outwardly projecting marginal lip portion 17 for the purpose
hereinafter appearing. As a weatherproof outer coating the sheet
metal outer layer 11 will be fluidize bed coated with a vinyl resin
18 having a minimum thickness of 0.01 inches. Such a protective
coating has not only been found to be impervious to the elements,
but also resistant to fading and substantially color fast.
Fabrication of the roofing module 10 can be simply and economically
effected by the use of a suitable forming and cutting die in a
power or brake press of sufficient size. The individual layers of
sheet metal 11, foamed synthetic plastic 12 and plywood sheathing
13 will be inserted together into the press die, with a suitable
adhesive applied at the interior interfaces, so that the shaping
and sizing of the roof module 10 can be effected in a single
stamping operation.
Means is provided for joining the sides of adjacent roof modules 10
upon roof assembly whether the juncture is to be in a common plane
or along a valley in the finished roof. To this end, side-to-side
and valley joining strips 19 are provided (see FIGS. 3, 4, and 5)
comprising a formed sheet metal outer layer 20 having
course-to-course steps 21, spaced and arranged as in the formed
sheet metal outer layer of the roofing module 10 and further being
formed with a central, longitudinal depression 22 simulating
individual lateral spacing between tiles. The lowermost step 21
terminates in a short, outwardly-projecting lower lip 23. The sheet
metal outer layer 20 of the joining strip 19 will also be provided
with a protective outer coating of a vinyl resin, the same as that
provided on the sheet metal outer ayer of the roofing module 11.
The underside of the sheet metal outer layer 20 has cemented or
otherwise secured to the underside thereof a wedge strip of foamed
plastic 24, substantially T-shaped in transverse cross-section and
having a downwardly-extending, resilient plug portion 25.
Means is also provided to seal and trim the ridges and corners of a
modular roof assembly embodying the invention. To this end, as
illustrated in FIGS. 6 and 7, a ridge and corner capping strip 26
is provided, said strip comprising a formed sheet metal outer layer
27 bent centrally along its length at an obtuse angle to provide
sidewardly and downwardly outwardly projecting, opposed side
portions 28, 28. The underside of the sheet metal outer layer 27
has cemented or otherwise secured thereagainst a wedge strip 29 of
foamed plastic material, substantially T-shaped in transverse
cross-section and integrally formed with a central, downwardly
projecting resilient plug portion 30. The outer surface of the
sheet metal outer layer 27 is also coated with a weather-proofing
vinyl resin.
Means is also provided for joining adjacent roof modules along
their upper and lower edges in the assembly of a roof. To this end,
as illustrated in FIGS. 8, 9, and 10, upper and lower edge joining
strips 31 are provided, said strips being comprised of a formed and
resin-coated sheet metal outer layer 32 having transverse
depressions 33 simulating the side-to-side spacing between
individual tiles. The underside of the sheet metal outer layer 32
has secured thereto, by cementing or the like, a wedge strip 34 of
foamed plastic material, substantially T-shaped in transverse
cross-section and providing a central, downwardly extending plug
portion 35. The use of the above-described joining strips 19, 31
and the capping strip 26 in the on-the-job roofing installation is
hereinbelow described.
The invention also comprises a fascia board assembly 36 (see FIGS.
11 and 12) comprising a fascia board 37 covered at one side and
along the longitudinal edges with a bent sheet metal covering layer
as indicated at 38 and 39, respectively, the outside of which is
also coated with a protective layer of vinyl resin. Sheet metal end
covers or caps 40 are provided for covering the ends of the fascia
board assembly 36, said caps being applied on the job after the
fascia board assembly has been cut to length in any particular
roofing assembly.
The invention also comprises, for use in roofing side edge trim, a
side edge covering member 41 (see FIGS. 13 and 14) comprising a
formed sheet metal outer layer 42, downwardly stepped at one side
as indicated at 43 and terminating in an outwardly extending
longitudinal lip portion 44. The sheet metal outer layer 42 is
formed along the other side with partial wedge-shaped steps 45
simulating overlapping tiles, and is further formed along the lower
end with a downwardly stepped portion 46 terminating in an
outwardly extending lip 47. The underside of the formed sheet metal
outer layer 41 has cemented or otherwise secured against the
underside thereof a wedge strip 48 of foamed plastic material
substantially T-shaped in transverse cross-section and having a
downwardly extending, resilient plug portion 49 arranged in
substantially vertical alignment with the step 43.
In the use of the roofing modules 10 and their associated joining,
capping and trim members in the assembly of a new roof, it is first
to be noted that the size of the modules 10, being 8 feet from side
to side, is such to reach center to center between truss members or
rafters spaced 16 inches on centers, as in common in building
construction, so that overlapping of the modules occurs along such
building roof trusses or roof rafters, whereat they can be nailed
in place as is hereinbelow described. It will further be understood
that wherever necessary to cut a module to fit the roofing job
under construction, this can readily be done with a saber saw.
As illustrated in FIG. 15, joining strips 19, described above with
reference to FIGS. 3, 4, and 5, will be wedged between the opposed
lower-to-upper edges of said modules, whereat they will conform
with the stepped, simulated tile shape of said modules, as
described above, and nailed in place, preferably by the use of two
nails 50, 50 hammered through said joining strip at positions
immediately outwardly of the lower ends of the course-to-course
steps 21. Nails 50, 50, the heads of which are fluidize bed coated
and the shanks of which are coated with a dry adhesive, will be
hammered in by the use of a power tool, whereby they will be
self-sealing with respect to the nail holes thus formed in the
joined modules 10, 10 is passing through and into a roof joist or
truss J. The force-nailing of the nails 50, 50 in place further
serves to tightly compress or squeeze the horizontally extending
portions of the wedge strip 24 against upper marginal surface
portions of the roofing modules 10, 10 in their zone of juncture to
seal against any possibility of water leakage. Although the joining
strip 19 in FIG. 15 is illustrated as joining adjacent side-to-side
roof modules in a common plane, it will be understood that such a
strip could also be used where module edges meet in a valley,
whereat the formed sheet metal outer layer 20 of such a joining
strip can readily be bent along a central longitudinal axis to
conform with the valley angle. The central longitudinal depression
22 in the joining strip 19 will simulate, in the finished roof,
junctures between individual tiles.
FIGS. 8, 9 and 10 illustrate a joining strip for joining and
sealing adjacent upper and lower roof modules 10, 10 in a typical
modular roof construction. As illustrated in FIG. 16, a joining
strip 31, described above with reference to FIGS. 8, 9, and 10,
will be wedged between and along the opposed upper and lower edges
of said modules with the joint-simulating depressions 33 in
alignment with the depressions 16 formed in said roof modules. A
pair of coated nails 51, 51, similar to the nails 50 described
above, will similarly be power-hammered through said joining strip
and through the opposed marginal edge portions of said roof modules
into each of the covered joists J of the roof under construction.
The nails 51, 51, being thus applied in pairs at 16 inch intervals
along the joining strip 31 squeeze the wedge strip 34 in place, as
described above in connection with the use of the side-to-side
valley joining strips 19, to insure weather-tight assembly.
The ridge end corner capping strip 29 illustrated in FIGS. 6 and 7
will be used wherever the side to side edges of modules 10, 10
meet, such as along the ridge of the roof under constuction or
along outside corners. Their use will be as described above in
connection with the nailing in place of the joining strip 31 of
FIGS. 8, 9, and 10, using nails hammered into the roof joists
spaced along 16 inch centers. It will be understood that, here
again, the downwardly projecting side portions 28, 28, upon
installation, can be readily altered in their angular shape to
conform with the particular angle along the meeting edges of the
modules to be joined.
FIG. 17 illustrates how a fascia board 36 (see also FIGS. 11 and
12), applied along the lower ends or eaves of the roof joists J
will be joined to the lower edge of roof modules 10, 10 of a roof
under construction by the use of front-to-back joining strips 31
according to FIGS. 8, 9, and 10. As illustrated in FIG. 17, such
joining strips will be bent along their sides to conform with the
angle of juncture and nailed into the fascia board assembly 36
along the upper edge thereof and into the joists J along 16 inch
centers. Coated power-driven nails 52, 52 together with the
compression of the wedge strip 34 at the junction insures
watertight integrity of the assembled roof for a long period of
time.
The side edges of a roof assembly comprising the roof modules of
the invention can readily be trimmed by the use of side edge
covering members 41 illustrated in FIGS. 13 and 14. Here again, the
wedge strip of foamed plastic material 48 together with the
horizontally-extending portions of said wedge strip upon being
compressed in place by the use of coated power driven nails
extending through outer edge portions of said modules and through
said side edge cover members into the outer joists, provides for
watertight assembly while at the same time providing for a finished
appearance along the side edges of the completed roof.
Preferably, the joining and capping strips 19, 26, 32, and 41 will
be fabricated in 8 foot lengths for ease of storage and
transportation and for convenience in use. A variety of widths of
these strips could be provided, such as 4, 6 and 8 inch widths, to
accommodate the various requirements of individual roof
constructions. It is also to be noted that while I have illustrated
and described herein the roofing modules 10 as being comprised of
three layers, i.e., an outer formed sheet metal layer 11, a foamed
synthetic plastic insulating layer 12, and a plywood sheathing
layer 13, it is contemplated that by making the formed sheet metal
outer layer 11 of increased gauge or thickness to provide the
required structural rigidity, the plywood sheathing bottom layer 13
could be entirely eliminated. In such instances the foamed
synthetic plastic insulating layer would be made substantially
thicker to provide the additional insulation otherwise lost by the
elimination of said plywood sheathing layer.
It is further to be understood that while I have described herein
the interior insulating layer 12 as comprising a foamed synthetic
plastic material, preferably styrofoam or urethane foam, this
material could as well be any material having insulating and fire
retarding properties, while at the same time being light enough in
weight and economical enough in cost to satisfy requirements of
practibility.
While we have illustrated and described herein only one form in
which the invention can conveniently be embodied in practice, this
embodiment is presented by way of example only and not in a
limiting sense. The invention, in brief, comprises all the
embodiments and modifications coming within the scope and spirit of
the following claims.
* * * * *