U.S. patent number 3,852,934 [Application Number 05/323,278] was granted by the patent office on 1974-12-10 for interlocking shingle arrangement.
Invention is credited to William Joseph Kirkhuff.
United States Patent |
3,852,934 |
Kirkhuff |
December 10, 1974 |
INTERLOCKING SHINGLE ARRANGEMENT
Abstract
An interlocking simulated shingle arrangement providing
interlocking interconnections between the simulated shingles in one
course with simulated shingles in adjacent courses and interlocking
sealing interconnection between adjacent shingles in the same
course. The simulated shingles are formed in extended panels
simulating a plurality of shingles. The bottom plate portion of the
simulated shingles are in intimate contact with the supporting
structure, such as the sheeting on a roof or on a wall, throughout
the extended length and width thereof to provide improved thermal
insulation effective structural integrity and reduced environmental
deterioration.
Inventors: |
Kirkhuff; William Joseph
(Torrance, CA) |
Family
ID: |
23258479 |
Appl.
No.: |
05/323,278 |
Filed: |
January 12, 1973 |
Current U.S.
Class: |
52/539; 52/555;
52/560; 52/556 |
Current CPC
Class: |
E04D
1/28 (20130101); E04D 1/2916 (20190801); E04D
1/2918 (20190801); E04D 1/30 (20130101); E04D
1/2956 (20190801); E04D 2001/305 (20130101) |
Current International
Class: |
E04D
1/28 (20060101); E04D 1/30 (20060101); E04d
001/18 (); E04d 001/28 () |
Field of
Search: |
;52/555,535,560,554,542,556,539,530,540,544,541,551 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Braun; Leslie A.
Attorney, Agent or Firm: Finkelstein; Don B.
Claims
I claim:
1. An interlocking simulated shingle arrangement for installation
on roofs, walls and other structures and comprising, in
combination:
a body member having an upper surface, a lower surface transversely
spaced from said upper surface, a forward surface, a rear surface
longitudinally spaced from said forward surface, a pair of side
surfaces laterally spaced from each other, and first walls defining
a channel, and said first walls having a top portion transversely
spaced from said upper surface and extending a first preselected
longitudinal distance from said forward surface towards said rear
surface, and said first walls having a base portion extending from
said lower surface a second preselected transverse distance towards
said upper surface;
a top plate coupled to said upper surface on a rear portion thereof
adjacent said rear surface and extending laterally between said
pair of side surfaces and extending longitudinally substantially
said first preselected longitudinal distance to leave exposed said
upper surface of said body member between said forward surface
thereof and said top plate, and a combined transverse thickness of
said rear portion of said body member at said rear surface thereof
and said top plate substantially equal to said second preselected
transverse distance;
a bottom plate coupled to said lower surface of said body member
and extending laterally between said pair of side surfaces and
having a back edge spaced a third preselected longitudinal distance
from said rear surface of said body member and having a front
portion extending from said base portion of said first walls of
said body member a fourth preselected longitudinal distance
therefrom towards said front surface of said body member and said
front portion underlying and transversely spaced from said top
portion of said first walls;
whereby said top plate and said rear portion of said body member of
a first simulated shingle in a first course of simulated shingles
is positionable in said channel of a second simulated shingle in an
adjacent course of simulated shingles, and said front portion of
said bottom plate of the second simulated shingle underlies the
lower surface of the rear portion of the first shingle, and said
bottom plate of said first and said second simulated shingles are
in substantially continuous contact with the structure upon which
the simulated shingles are installed.
2. The arrangement defined in claim 1 wherein:
said body member is tapered and increases in transverse thickness
from said rear surface towards said forward surface; and
said lower surface and said bottom plate are planar.
3. The arrangement defined in claim 2 wherein:
said body member is foamed polyurethane plastic and said top plate
and said bottom plate are plywood, and each of said top plate and
said bottom plate have a transverse thickness on the order of 1/8
inch;
said top plate has an upper surface substantially coplanar with
said upper surface of said body member; and
a preselected coating means on predetermined surface portions of
said body member for preventing exposure thereof to ultraviolet
light.
4. The arrangement defined in claim 3 wherein said simulated
shingle simulates a shake shingle and further comprising:
second walls in said body member defining a plurality of
longitudinal grooves in said upper surface of said body member
extending longitudinally from said forward surface to said top
plate, and extending transversely a predetermined depth towards
said lower surface, and said plurality of longitudinal grooves in a
predetermined spaced array; and
said upper surface of said body member intermediate said plurality
of longitudinal grooves is undulating and striated.
5. The arrangement defined in claim 2 wherein
said third preselected longitudinal distance is substantially equal
to said fourth preselected longitudinal distance, whereby said rear
surface of the body member of the first simulated shingle in a
first course is positionable adjacent said base portion of said
first walls of said body member of the second simulated shingle in
an adjacent course.
6. The arrangement defined in claim 2 wherein:
said top plate extends a fifth preselected longitudinal distance
from said near surface of said body member towards said front
surface thereof and said fifth preselected longitudinal distance is
less than said first preselected longitudinal distance.
7. The arrangement defined in claim 1 and further comprising:
interlocking sealing means coupled to said pair of side surfaces of
said body member and extending laterally therefrom for providing a
water tight seal between adjacent simulated shingles in the same
course.
8. The arrangement defined in claim 7 wherein said interlocking
sealing means further comprises:
a male sealing member coupled to a first of said pair of side
surfaces of said body member and extending laterally therefrom, and
said male sealing member having at least one longitudinally
extending ridge thereon; and
a female sealing member coupled to the other of said pair of side
surfaces and extending laterally therefrom, and said female sealing
member having walls defining a longitudinally extending, ridge
accepting groove therein for accepting said longitudinally
extending ridge on said male sealing member of an adjacent
simulated shingle in the same course in water tight sealing
relationship.
9. The arrangement defined in claim 8 wherein said interlocking
sealing means further comprises:
a laterally extending ridge on said male sealing member; and
walls defining a laterally extending, ridge accepting groove in
said female sealing member for accepting said laterally extending
ridge on said male sealing member of an adjacent simulated shingle
in the same course in water tight sealing relationship.
10. The arrangement defined in claim 9 wherein:
said male and said female sealing members are unitarily molded with
said body member from a foamed polyurethane;
said laterally extending ridge on said male sealing member is
spaced from said rear surface of said body member; and
a preselected coating means on predetermined surface portions of
said body member for preventing exposure thereof to ultraviolet
light.
11. The arrangement defined in claim 10 wherein:
said top plate and said bottom plate are plywood and each have a
transverse thickness on the order of 1/8 inch;
said lower surface of said body member and said bottom plate are
planar and one of said male and female sealing members has a lower
surface substantially planar with said lower surface of said body
member;
said bottom plate extends co-extensively with and is coupled to
said lower surface of said one of said male and female sealing
members; and
said top plate has an upper surface substantially coplanar with
said upper surface of said body member.
12. The arrangement defined in claim 11 wherein said interlocking
simulated shingles simulates a shake shingle, and further
comprises:
second walls in said body member defining a plurality of
longitudinal grooves in said top surface of said body member
extending longitudinally from said forward surface to said top
plate, and extending transversely a predetermined depth towards
said lower surface from said top surface, and said plurality of
longitudinal grooves in a predetermined spaced array; and
said upper surface of said body members intermediate said plurality
of longitudinal grooves is undulating and striated.
13. The arrangement defined in claim 1 wherein said body member is
symmetrical about a longitudinal plane extending therethrough, and
further comprises:
a first side portion extending from a first of said pair of side
surfaces to said longitudinal plane; and
a second side portion extending from the other of said pair of side
surfaces to said longitudinal plane and intersecting with said
first side portion thereat and at a preselected angle, and said
preselected angle is other than 180.degree..
14. The arrangement defined in claim 13 wherein:
said body member is foamed polyurethane plastic and said top plate
and said bottom plate are plywood, and each of said top plate and
said bottom plate have a transverse thickness in the order of 1/8
inch;
said top plate has an upper surface substantially coplanar with
said upper surface of said body member; and
a preselected coating means on predetermined surface portions of
said body member for preventing exposure thereof to ultraviolet
light.
15. The arrangement defined in claim 14 wherein:
said third preselected longitudinal distance is substantially equal
to said fourth preselected longitudinal distance, whereby said rear
surface of the body member of the first simulated shingle is
positionable adjacent said base portion of said first walls of said
body member of the second simulated shingle.
16. The arrangement defined in claim 15 wherein:
said top plate extends substantially said first preselected
longitudinal distance from said rear surface of said body member
towards said front surface thereof.
17. The arrangement defined in claim 13 wherein:
said top plate extends a fifth preselected longitudinal distance
from said rear surface of said body member towards said front
surface thereof, and said fifth preselected distance is less than
said first preselected longitudinal distance.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the roofing and siding art more
particularly to improved interlocking simulated shingle
construction.
2. Description of the Prior Art
The conventional types of shingles, such as wood, concrete or clay
tiles or asphalt, have generally not proven to be completely
satisfactory in all applications. In general, the comparatively
small size of the individual conventional shingles requires a
comparatively lengthy time for covering an entire roof or wall.
Further, such shingles require periodic maintenance in order to
maintain them in satisfactory condition. These shingles, of course,
have not proven to be effective thermal insulators and normally
some other form of packing or insulation material has been utilized
in the roof, ceiling or wall structure to provide the necessary
thermal insulations.
Therefore, there have heretofore been developed various types of
simulated shingles attempting to solve these problems. For example,
conventional wood shingles were utilized on metallic carriers, such
as those shown in U.S. Pat. Nos. 3,418,777 and 3,232,020. Such
arrangements often require separate elements, such as clips or the
like, for complete installation. Utilization of such metallic
carriers for holding conventional shingles did little to either
decrease the cost of installing a shingle roof or improve the
thermal or structural integrity of the shingles.
Other types of roofing of siding structures have incorporated
various plastic laminates combined with one or more ridged members
for installation as a simulated shingle on roofs or on walls as
sidings. In certain of these prior art simulated shingle
arrangements the nail heads were exposed to the environment thereby
requiring utilization of corrosive resistant steel, or other
similar materials resistant to environmental effects, in order to
avoid rusting or the like. One such arrangement is shown in U.S.
Pat. No. 2,362,236. Such exposed nails or screws detracted from the
true simulated shingle structural appearance of the roof or
wall.
In other simiulated shingles the utilization of metallic elements
not only increased the cost but required cutting tools, generally
not available to the roofer, for sizing the simulated shingle
elements to the particular roof or wall being covered. Thus,
special saws or shears were required to cut through such metallic
elements. Additionally, in utilization of metallic elements the
weight of the load on the roof was thereby increased thus
increasing the required strength of the supporting structure.
Further, the lower edge of most prior art shingles rested on the
top edge of the adjacent course of shingles leaving a void between
the sheeting and the shingles, thus resulting in fractures of the
shingles and increased fire hazard.
One type of simulated shingle heretofore sold by National Pacific
Roofing Products, a Division of Stephan Chemical Company, 8748
Remmet Avenue, Canoga Park, Cal., utilized fiberglass shingle
panels which were heavy, expensive and difficult to trim to size
and then install in the field. Further, while providing a water
tight seal between adjacent shingles in the same course, such a
seal was not interlocked between adjacent courses resulting often
in wind forces loosening an entire panel.
While certain of the prior art simulated shingles have utilized
various forms of interlock between simulated shingles in adjacent
courses, such interlocks have generally not been of the type
allowing a rapid slide fit of one course into the immediately
previously installed course. Further, there has been no provision,
in general, in prior art simulated shingles for a water tight
sealing interlock between adjacent shingles in the same course.
SUMMARY OF THE INVENTION
Accordingly, it is the object of the present invention to provide
an improved simulated shingle arrangement.
It is another object of the present invention to provide an
improved simulated shingle having an interlocking connection
between shingles in adjacent courses as well as between adjacent
shingles in the same course.
It is another object of the present invention to provide an
interlocking shingle arrangement in which no separate structural
elements such as, clips, spacers, or the like are utilized.
It is yet another object of the present invention to provide an
improved simulated shingle that may be rapidly and easily installed
by roofers without utilization of special tools, equipment or
techniques.
It is still another object of the present invention to provide a
simulated shingle that is inexpensive to fabricate, has exceptional
long lasting characteristics without periodic maintenance and is
highly resistant to environmental deterioration.
It is still another object of the present invention to provide a
simulated shingle arrangement in which a minimum number of
structural elements are utilized to provide cover for an entire
roof or wall.
The above and other objects of the present invention are achieved,
in a preferred embodiment of the present invention, by providing a
body member, preferably made of a molded foam plastic such as
polyurethane foam, and the body member has an upper surface, a
lower surface, a forward surface, a rear surface spaced from the
forward surface and a pair of side surfaces. The upper surface of
the body member is textured to simulate any desired type of
surface. For example, it may be textured with undulations and
striations therein to simulate the appearance of shake shingles.
The lateral distance between the side surfaces may be any desired
length to simulate any desired number of adjacent shingles in the
same course. For example, it may be 3, 4, 6, 8, or more feet
between the side surfaces and simulating a corresponding number of
conventional 8 inch wide shake shingles.
Suitable channels, extending longitudinally from the forward
surface towards the rear surface, may be incorporated in the body
member to simulate the division between adjacent shingles in the
same course. The longitudinal width between the forward surface and
rear surface may be, for example, on the order of 15 inches or so
for a simulated shake shingle of one course in longitudinal
depth.
It will be appreciated that in describing a preferred embodiment of
the present invention the description and drawing herein utilize a
simulate shake shingle for illustrative purposes. The present
invention is not limited to only simulated shake shingles but may
equally well be utilized to simulate any type of shingle or other
roofing or wall siding structure.
The body members are also provided with first walls defining a
channel adjacent the forward surface thereof. The first walls have
a top portion spaced from the upper surface of the body member and
extending rearwardly from the forward surface towards the rear
surface and a base portion extending transversely from the lower
surface towards the upper surface. The base portion of the first
wall is spaced a first preselected longitudinal distance from the
forward surface of the body member to define the channel opening
toward the forward surface. The base portion has a second
preselected transverse height.
A top plate which, for example, may be a thin sheet of plywood on
the order of one-eighth of inch thick, is coupled to the upper
surface of the body member on a rear portion thereof and extends
laterally between the side surfaces and extends longitudinally
forwardly from the rear surface toward the front surface and allows
nailing at any desired transverse position. The combined transverse
thickness of the top plate and the rear portion of the body member
at the rear surface of the body member is substantially equal to
the transverse height of the base portion of the first walls in the
body member so that the rear portion of a simulated shingle in one
course fits into and underlies the forward portion of a simulated
shingle in an adjacent course. That is, the top portion of the
first walls defining the channel of one simulated shingle overlays
the top plate of the simulated shingle in the immediately adjacent
course.
A bottom plate, which may also be fabricated from a thin sheet of
plywood, such as one one-eighth of inch plywood, is coupled to the
lower surface of the body member and extends laterally between the
side surfaces. The bottom plate has a back edge that is spaced a
third preselected longitudinal distance from the rear surface of
the body member and has a front portion that extends longitudinally
forwardly from the base portion of the first walls of the body
member towards the forward surface of the body member.
In preferred embodiments of the present invention the top plate and
bottom plate are molded in place during molding of the body member
and thereby are bonded to the body member during the molding of the
body member. It will be appreciated, of course, that any other type
of bonding such as epoxy bonding, or otherwise, may be utilized for
adhering the top and bottom plates to the body member.
The front portion of the bottom plate of one shingle underlies the
lower surface of the rear portion of the shingle in the immediately
adjacent course and thus provides an interlock arrangement between
adjacent courses of simulated shingles. Sufficient overlap between
adjacent courses is provided, in the preferred embodiment of the
present invention, so that spacing between adjacent courses of the
shingles may be made to accommodate any desired size roof. However,
in other preferred embodiments of the present invention such
spacing need not be calculated and the final course of shingles
adjacent to the hip and ridge may be trimmed as desired.
A separate structural element which may be fabricated in lengths
similar to that provided for the course of simulated shingles
defined above is utilized as an eaves starter. The eaves starter
strip is virtually identical to the rear portion of the above
described course of shingles and is provided with the top plate
and, if desired, the rear-most portion of the bottom plate. The
eaves starter strip may also be provided with channels in the
forward face thereof to simulate division between shingles when it
is fabricated in lateral lengths exceeding the length of a single
shingle and be textured to simulate the exposed forward have of a
shingle.
A separate simulated shingle arrangement is utilized for the hip
and ridge shingles and for the rake or wall corner shingles. The
hip and ridge and the rake shingles are similar to the above
described simulated course shingles except that they are
symmetrical about a longitudinal plane and formed in the shape of a
"V" with the plane at the apex thereof. These may be fabricated in
longitudinal lengths simulating, one, two, three or more shingles,
as desired, and are provided with the above described top plate and
bottom plate and the channel to provide interlocking between
adjacent hip and ridge or rake shingles in the same course.
However, there is no necessity, in general, for providing any
interlocking sealing engagement between adjacent courses for the
hip and ridge and the rake shingles. A starter strip which is also
shaped in the form of a "V" and similar to the above described
eaves starter strip is also utilized for the end simulated shingle
in a hip and ridge and rake installation.
Thus, basically, four separate simulated shingle units are utilized
to provide coverage for a roof or wall.
In order to provide a sealing interlock between adjacent simulated
shingle strips in the same course where the length of the roof
exceeds the lateral length of one simulated shingle, panel, sealing
means are provided on each side surface of the simulated shingle.
One side contains a male sealing member having upstanding ridges
thereon and the opposite side is provided with a female sealing
member having walls defining a ridge accepting groove or grooves
therein for sealing interlocking with the male sealing member of an
adjacent simulated shingle.
It will be appreciated that the lateral width of the simulated
shingles may be cut as desired to match the length of the roof and,
in general, may be cut with tools usually available to a
roofer.
The simulated shingle, according to the present invention, is
nailed to the sheeting of the roof, or the siding of the wall, by
driving nails through the top plate in regions thereof overlying
the bottom plate. Thus, the nails are secured to the shingles
through the plates and the nail heads do not bear against the body
member. When the body member is, for example, molded plastic such
as molded foamed polyurethane, such an installation prevents the
nails from pulling loose from the body member or impact destraction
of the body member during nail installation. In the preferred
embodiments of the present invention the bottom plates of the
simulated shingle are planar and lie against, for example, the
sheeting of the roof throughout the extended length and width
thereof. Thus, intimate contact throughout is provided and air gaps
between the simulated shingle and the roof are eliminated. This
prevents the ripping off of the shingles during high winds or the
like. Further, the sealing engagement between adjacent shingles in
the same course and the interlocking engagement between adjacent
courses of shingles provides a waterproof covering for the roof or
wall to prevent moisture and water from impinging directly upon the
structure of the supporting means. The shingles conveniently slide
into one another and are quickly nailed into place, thus minimizing
the cost of installation and allowing easy installation by
conventional roofing techniques.
When the body member is fabricated from a polyurethane foam
suitable exterior coating is applied thereon to prevent
environmental deterioration due to exposure of the polyurethane
foam to the ultraviolet radiation contained in sunlight. All
exposed surfaces may be suitably coated with a protective coating
during the manufacture of the simulated shingles in accordance with
the present invention and where it is necessary to trim the
shingles to fit a particular installation the exposed edges may be
quickly and easily coated on the job site.
BRIEF DESCRIPTION OF THE DRAWING
The above and other embodiments of the present invention may be
more fully understood from the following detailed description taken
together with the accompanying drawings wherein similar reference
characters refer to similar elements throughout and in which:
FIG. 1 is a perspective view of one embodiment of the present
invention;
FIG. 2A is a sectional view on the line 2--2 FIG. 1;
FIG. 2B illustrates another embodiment of a female sealing
member;
FIG. 3 illustrates an eaves starter strip useful in practice of the
present invention;
FIG. 4 illustrates installation of the shingle shown in FIG. 1 and
the eaves starter strip shown in FIG. 3 on a roof;
FIG. 5 illustrates the covering of the roof with shingles in
accordance with the present invention;
FIG. 6 illustrates a hip and ridge or rake shingle in accordance
with the principles of the present invention;
FIG. 7 is a sectional view along with the lines 7--7 of FIG. 6;
and
FIG. 8 illustrates another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing there illustrated in FIG. 1 a
perspective view of one embodiment of the present invention,
generally designated 10. As shown on FIG. 1 the embodiment 10 is a
simulated shingle simulating a shake shingle and has a longitudinal
width in the direction of the arrow 12 approximately equivalent to
the exposed longitudinal width of a single conventional wood shake
shingle as installed. However, as explained below in greater
detail, the longitudinal width may be made to simulate any desired
number of shingles in adjacent courses. Similarly, the lateral
width in the direction of the arrow 13 may also be made to simulate
any desired number of adjacent shingles in the same course.
The body member 14 is provided with an upper surface 16 and a lower
surface 18 that is transversely spaced, in the direction of the
arrow 15, from the upper surface 16. Body member 14 is also
provided with a forward surface 20 and a rear surface 22 that is
longitudinally spaced from the forward surface 20. The body member
14 also has a pair of side surfaces 24 and 26 laterally spaced from
each other. First walls 28 are provided in the body member 14 to
define a channel 30 therein adjacent the forward surface 20 and the
first walls 28 have a top portion 32 transversely spaced from the
upper surface 16 and extending a first preselected longitudinal
distance rearwardly therefrom towards the rear surface 22. The
first walls 28 in the body member 14 are also provided with a base
portion 34 extending from the lower surface 18 a second preselected
transverse distance towards the upper surface 16.
A top plate 36 is coupled to the upper surface 16 of the body
member 14 on a rear portion 38 thereof and extends laterally
between the side surfaces 24 and 26. The top plate 36 also extends
longitudinally from the rear surface 22 towards the front surface
20. The combined transverse thickness of the top plate 36 and the
body member 14 at the rear surface 22 is substantially equal to the
second preselected transverse distance of the base portion 34 of
first walls 28 defining the channel 30.
A bottom plate 40 is coupled to the lower surface 18 of the body
member 14 and extends laterally between the pair of side surfaces
24 and 26 thereof. The bottom plate 40 has a rear edge 42 that has
spaced a third preselected longitudinal distance from the rear
surface 22 of the body member 14 and extends therefrom to a front
edge 44 adjacent the channel 30. A front portion 41 of the bottom
plate 40 extends from the base portion 34 of the first walls 28 of
the body member 14 a fourth preselected distance towards the front
surface 20 of the body member 14 and underlies a section of the top
portion of the first walls 28 in regions adjacent the base portion
34. The bottom plate 40 may extend any desired longitudinal
distance towards the rear surface 22 from the base portion 34.
In a preferred embodiment of the present invention the body member
14 may be fabricated from a foam plastic such as polyurethane, the
top plate 36 and the bottom plate 40 may be fabricated of, for
example, plywood on the order of 1/8 inch in transverse thickness.
The upper surface 36a of the top plate 36 is substantially coplanar
with the upper surface 16 of the body member 14 and the bottom
plate 40 is preferably planar between the rear edge 42 and front
edge 44 thereof.
In the embodiments of the present invention wherein polyurethane is
utilized as the material forming the body member 14, it is
preferable to coat any portion of the polyurethane that may be
exposed to ultraviolet light with a coating to prevent such
exposure. Therefore, in the preferred embodiments of the present
invention, the portions of the body member 14, when the body member
14 is fabricated from foam polyurethane that may normally be
exposed to sunlight after installation, are coated with a coating
such as polyester, adhesive aggregate mixture, polyvinyl chloride,
polyethylene, vinyl weather resistant coating, or the like. These
coatings may be applied after forming of the simulated shingle 10
and also may be quickly applied at the job site during installation
on exposed portions that may be cut in providing coverage on a
given sized roof. The coating need not be applied, of course, to
the top plate 36, bottom plate 40 or to areas that are not exposed
to sunlight.
When the shingle 10 simulates a shake shingle, the upper surface 16
between the forward surface 20 and the top plate 36 is preferably
striated and undulating in order to simulate the appearance of
shake shingles. Further, when the lateral distance between the side
walls 24 and 26 is greater than the conventional lateral width of
wood shake shingles, the upper surface 16 may be provided with
second walls 46 defining a plurality of longitudinal grooves 48
therein to simulate the separation between adjacent shake shingles
in the same course for the shingle 10. For example, the
conventional width of shake shingles is on the order of 11 to 15
inches. Therefore, the lateral spacing between the grooves 48 may
be on the order of 11 to 15 inches in order to simulate the desired
shingle roof appearance after installation. Preferably, the grooves
48 extend transversely towards the lower surface 18 a predetermined
depth in the body member 14 and leave a comparatively thin web
between the top portion 32 of the first walls 28 and the walls 46
defining the grooves 48 since the forward surface 20 of the body
member 14 is exposed to view after installation.
On installation of a plurality of simulated shingles 10 on a roof,
the rear portion 38 of a simulated shingle 10 in a first course
fits into the channel 30 of a simulated shingle 10 in a second
adjacent course and the rear surface 22 of the first simulated
shingle 10 may abut against the base portion 34 of first walls 28
of the simulated shingle 10 in the second adjacent course. The
forward portion 41 of the bottom plate 40 of the simulated shingle
10 in a second source underlies the rear part of the lower surface
18 of the body member 14 of the simulated shingle 10 in the first
course. However, in order to allow flexibility in longitudinal
spacing of adjacent courses of simulated shingles 10, the rear
surface 22 of any simulated shingle 10 may be spaced from the base
portion 34 of the simulated shingle 10 in adjacent course.
Installation of a plurality of simulated shingles 10 on a roof is
described below in greater detail in connection with FIG. 5.
In the preferred embodiment of the present invention, in order to
achieve the planar support of bottom plate 40 upon the supporting
structure the body member 14 is preferably tapered from the forward
surface 20 towards the area surface 22. Upon installation this
provides the simulation of conventional shingles which, in general,
are constant thickness and do not decrease in transverse thickness
between the forward surface and rear surface thereof. Thus, in
conventional shingles the shingles are not in planar contact with
the supporting structure throughout the extent thereof but only
upon the rear edges, the forward edges being supporting on the
shingles of the adjacent course. This allows an air gap between the
supporting structure and the shingles and is often one cause of
shingles being blown away during high winds.
In preferred embodiments of the present invention the simulated
shingle 10 interlocks with an adjacent simulated shingle 10 in the
same course. In order to provide such an interlock, which is also
preferably a water tight sealing interlocking connection,
interlocking sealing means 49 are provided and comprise a male
sealing member 50 coupled to sidewall 24 and a female sealing
member 52 coupled to sidewall 26. The interlocking male sealing
member 50 extends laterally outwardly from the sidewall 24 and is
provided with at least one longitudinally extending ridge 54
thereon. In the embodiment shown in FIGS. 1 and 2, there are
provided two longitudinally extending ridges 54 and also a
laterally extending ridge 56. The upper surface 58 of the male
sealing member 50 is transversely spaced from the upper surface 16
of the body member 14 and, in preferred embodiments of the present
invention, the male sealing member 50 is preferably molded
unitarily with the body member 14. The bottom plate 40 extends
under the lower surface of the male sealing member 50. The
laterally extending ridge 56 is preferably longitudinally spaced
from the rear wall 22 of the body member 14.
As shown more clearly in FIG. 2A, the female sealing member 52,
which is also preferably molded unitarily with the body member 14,
is provided with walls 60 defining a pair of longitudinally
extending ridge accepting grooves 62 for accepting the longitudinal
ridges 54 of an adjacent simulated shingle 10 in the same course
thereof. Similarly, a laterally extending ridge accepting groove 64
is provided in the female sealing member 52 for accepting the
laterally extending ridge 56 of an adjacent male sealing member 50.
The sizes of the ridges 54, 56 and grooves 62, 64 are selected to
provide a substantially water tight sealing therebetween.
FIG. 2B illustrates another embodiment of a female sealing member
52' in which a single groove 60' accepts both ridges 54. This
structure may be preferred where thermal expansion may produce
undesired stresses on the members.
In utilizing the principles of the present invention of the
simulated shingles arrangement for covering a roof, it is
preferable to have a separate eaves starter strip. Such an eaves
starter strip is illustrated in FIG. 3 and is generally designated
70. The eaves starter strip 70 generally simulates the rear portion
38 of the simulated shingle 10 and has a body member 72 which, for
example, may be fabricated from a foam polyurethane and is provided
with a top plate 74 substantially identical to the top plate 36 and
a bottom plate 76 having a rear edge 78 that is spaced from the
rear edge 80 of the body member 72 the above defined third
preselected longitudinal distance. The bottom plate 76 may extend
to the forward face 82 of the eaves starter strip 70 and the
forward face 82 of the eaves starter strip 70 is provided with a
plurality of first walls 84 defining a plurality of grooves 86
therein extending transversely from the bottom surface 88 of the
body member 80 to the top surface 90 thereof and also through the
bottom plate 76. The lateral width of the eaves starter strip 70
may be made in lengths similar to the lateral width of the
simulated shingles 10 described above and thus define a simulation
of any desired number of adjacent shingles in the same course.
Thus, the grooves 86 may be spaced on the order of 11 to 15 inches
apart.
Exposed portions of the body member 82, when the body member 82 is
fabricated of foam polyurethane, may also be coated as described
above in order to prevent exposure thereof to ultraviolet radiation
in the sunlight.
Referring now to FIG. 4 there is shown the installation of a
plurality of shingles 10 in accordance to the present invention as
installed upon a roof structure 92. Roof structure 92 generally
comprises a plurality of interlocking sheeting members 94 upon
which the simulated shake shingles 10 are installed. An eaves
starter strip 70 is installed adjacent the outer edge 96 of the
roof structure 92 and held in place with a conventional roofing
nail 98. As can be seen, the roofing nail 98 is driven through the
top plate 74 and bottom plate 76 of the eaves starter strip 70 and
into the sheeting 94. A first simulated shake shingle 10 in a first
course is then slid into place with the forward portion 41 of the
lower plate 40 underlying the lower surface 88 of the eaves starter
strip 70 and the eaves starter strip 70 fitting into the channel 30
defined by the first walls 28 of the first simulated shake shingle
10. In this embodiment illustrated in FIG. 4 the rear surface 80 of
the body member of the eaves starter strip 70 abuts against the
base portion 34 of the first walls 28 defining the channel 30 in
the first course of simulated shingles 10. Similarly, the forward
edge 44 of the bottom plate 40 abuts against the rear edge 78 of
the bottom plate 76 of the eaves starter strip 70. The roofing nail
98 is thus not exposed to the environment since it is covered by
the first simulated shake shingle course 10. Since the bottom plate
40 is preferably planar it is in substantially continuous contact
with the sheeting 94 throughout the lateral and longitudinal extent
thereof.
Roofing nails 98' are then driven through the top plate 36, and
bottom plate 40 of the simulated shingle 10 in those embodiments
where the bottom plate extends longitudinally thereto, in the first
course and into the sheeting 94 for securing the first course of
simulated shake shingles 10 thereon. It will be appreciated that a
plurality of roofing nails 98 and 98' may be utilized for securing
the simulated shingle in the course of the present invention to
sheeting 94 at any desired location throughout the lateral extent
thereof.
Another course of simulated shake shingles, generally designated
10' is then installed by sliding the simulated shingle 10', which
may be in a second course adjacent to the first course of the
simulated shingles 10, into position so that the rear portion 38 of
the first course of simulated shake shingles 10 is positioned
within the channel 30 defined by the first walls 28 of the
simulated shake shingle 10'.
The lower surface of the rear portion 38 may be tapered slightly to
allow easier installation of the adjacent course of shingles.
As noted above when the body members of the simulated shingles
according to the principles of the present invention are fabricated
from a foam polyurethane it is preferable to apply a coating on
surfaces thereof that after installation may be exposed to sunlight
in order to prevent ultraviolet light from damaging the
polyurethane foam. Accordingly, both FIGS. 2 and 4 show the coating
100 as applied to the upper surfaces 16 of the simulated shingles
10 as well as the forward surfaces 20 thereof. Similarly, for the
eaves starter strip 70 the coating 100 may be applied on the
forward surface 82 thereof. If it is necessary to trim or cut the
simulated shingles 10 or the eaves starter strip 70 during
installation on a roof as shown in FIG. 4 the cut surfaces may be
coated on the job site with an appropriate coating to protect them
from ultraviolet radiation.
FIG. 5 illustrates a section of the roof 92 extending to the hip
and ridge 102. As shown on FIG. 5 each simulated shingle 10
simulates a single course of shingles and adjacent courses are
interlocked in the manner shown in FIG. 4. Thus, adjacent courses
are installed until the hip and ridge 102 is reached. If the
courses have been installed as shown in FIG. 4, then the last
simulated shingle 10a may be trimmed to the appropriate
longitudinal length at the appropriate angle for matching the hip
and ridge. Alternatively, of course, the plurality of courses of
simulated shingles 10 may be installed without complete abutment of
the shingles in the channel of the next succeeding course and the
amount of spacing precalculated so that an integral number of
simulated shingle courses may be utilized up to the hip and ridge
102. Thus, the top plate 36 in each of the simulated shingles 10
may extend longitudinally to the rear surface 22 the first
preselected longitudinal distance which is equivalent to the
longitudinal deepth of the top portion 32 of the first walls 28
defining a channel 30. Alternatively, if it is desired to have a
spacing of the rear surface 22 from the base portion 34 of adjacent
courses simulated shingles then the top plate 36 may extend a
longitudinal distance towards the front surface 20 less than the
first preselected longitudinal distance in order that the top
surface 16 extends up to the next succeeding course of shingles.
Thus, the aesthetic effect of a true simulated shingle roof may be
provided regardless of the method of installation.
As shown in FIG. 5 a separate hip and ridge simulated shingle 104
is provided. The hip and ridge shingle 104 may also be utilized, of
course, as a shingle on the rake of a roof.
The hip and ridge shingle 104 is illustrated in detail in FIGS. 6
and 7 and, as shown, is structurally similar to the simulated shake
shingles 10. The hip and ridge shingle 104 is symmetrical about a
longitudinal plane extending therethrough at the apex 106 thereof
and has a first side portion 108 and a second side portion 110
substantially identical to first side portion 108. The angle b at
which the first side portion 110 intersects the second side portion
108 along the apex 106 is preselected to be other than 180.degree.
and, for example, may be 120.degree. or any other desired angular
value. The shake shingle 104 illustrated in FIGS. 6 and 7 simulates
two adjacent courses of shake shingles and, as is conventional in
roofing, the longitudinal direction of the hip and ridge shake
shingle 104 is at 90.degree. to the longitudinal direction of the
shake shingles 10, as illustrated most clearily in FIG. 5. An eaves
starter strip 112 is utilized in the outer most hip and ridge
shingle 104 in a manner analogous to the utilization of the eaves
starter strip 70 and simulated shingles 10. The eaves starter strip
112 is similarly symmetrical about a plane passing through the apex
thereof and has a lateral width equilvant to the lateral width of
the simulated hip and ridge shingle 104.
The hip and ridge simulated shingle 104 is provided with a body
member 114 which, for example, may be fabricated from foam
polyurethane and the exposed surfaces of which may be coated with
the coating 116, similar to the coating 100 described above. Body
member 114 has a forward surface 118, a rear surface 120 spaced
longitudinally therefrom, an upper surface 122 and a lower surface
124 spaced transversally from the upper surface 122. The body
member 114 is also provided with first walls defining a channel 128
similar to the channel 30 of the simulated shingle 10 described
above. A top plate 132 is coupled to the upper surface 122 at a
rear portion 134 of the body member 114 and extends from the rear
surface 120 longitudinally towards the front surface 118. The top
plate 132 may be similar to the top plate 36 described above. A
bottom plate 136 is coupled to the lower surface 124 and may be
similar to the bottom plate 40 described above.
Each side portion 108 and 110 of the simulated hip and ridge
shingle 104 simulates a single shingle in lateral width and thus
the lateral distances between the side surface 138 and the apex 106
and the side surface 140 and the apex 106 are equilvant to the
lateral width of a single shingle. Thus, grooves simulating the
relationship between adjacent shingles in the same course are not
provided. When the hip and ridge shingle 104 simulates a shake
shingle then the upper surface 122 may be both straited and
undulating as described above.
The simulated hip and ridge shingle 104 simulates two shingles in
adjacent courses. However, it will be appreciated, that the
simulated hip and ridge shingle 104 made be made in any desired
longitudinal length to simulate any desired number of shingles in
adjacent courses. Since the hip and ridge shingle 104 does not
adjoin shingles in the same course, there is no necessity for
providing interlocking sealing means on the side edge 138 and 140
thereof and the side edges 138 and 140 made be coated with the
coating 116 to prevent exposure thereof to ultraviolet radiation.
Successive simulated hip and ridge shingles 104 in adjacent courses
interlock in a matter as described above for the interlocking of
adjacent courses of the shingles 10.
The simulated shingle 10 described above simulated a single course
of shingles. It will be appreciated that the simulated shingles 10
may also be fabricated to simulate not only a plurality of shingles
in the same course but also a plurality of adjacent courses of
shingles extending in the longitudinal direction thereof. FIG. 8
illustrates a sectional view through a simulated shingle, generally
designated 150, which simulates a plurality of courses of shingles.
In general, the simulated shingle 150 is fabricated similarly to
shingle 10 described above. Simulated shingle 150 is provided with
a body member 152 having a forward surface 154, a rear surface 156
longitudinally spaced from the forward surface 154, an upper
surface 158 and a lower surface 160 spaced transversely from the
upper surface 158. The longitudinal spacing between the forward
surface 154 and rear surface 156 is selected, in this embodiment of
a shingle 150, to simulate four adjacent courses of shingles. In
order to provide a more realistic simulation of shingles the walls
162 defining the channels 164 which simulates the separation
between adjacent shingles in the same course, are staggered in the
four portions so they are not longitudinally aligned. Thus, only
the channel 164 in the portion 150' is shown in FIG. 8. The lateral
width of the shingle 150 may simulate any desired number of
adjacent shingles in a single course.
The shingle 150 is also provided with a top plate 166 coupled to
the upper surface 158 in a rear portion 168 of the body member 152
and in general is similar to the top plate 36 described above.
Similarly, a bottom plate 170 is coupled to the lower surface 160
of the body member 152 and in general is similar to the bottom
plate 40 described above. The simulated shingle arangement 150 also
has first walls 172 defining a channel 174 adjacent the forward
surface 154 into which the rear portion 168 of a similar adjacent
shingle may be positioned as described above. It will be
appreciated that simulated shingles 150 may be used in conjunction
with single course simulated shingles, such as simulated shingle 10
described above, in the same roofing installation and with hip and
ridge and rake shingles such as the simulated hip and ridge and
rake shingle 104 shown in FIGS. 6 and 7.
When the body member 152 is fabricated from a foam polyurethane a
coating 176 is applied to the external surfaces thereof that may be
exposed to sunlight. The coating 176 may be similar to the coating
100 described above.
This concludes the description of the preferred embodiments of the
present invention. Those skilled in the art may find many
variations and adaptations thereof and the attached claims are
inteneded to cover all such variations and adaptations falling
within the true scope of spirit thereof.
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