Roofing panel

A pre-manufactured roofing panel includes a joint having a first and a second edge that form a locking joint. The first edge includes a longitudinal protrusion extending outwardly from first edge. The protrusion has a generally trapezoidal cross-sectional shape. The second end includes a longitudinal cavity. The cavity has a generally inverse trapezoidal cross-sectional shaped substantially corresponding to the size and shape of the protrusion. The unique shape of the protrusion and cavity greatly facilitates the alignment of the two edges and reduces the likelihood of damage to either edge. The panel also includes a ribbed gasket disposed along an outer edge that seals any voids created by imperfections in the panels. The gasket is installed at the factory, and includes a polyethylene foam gasket.

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Description
TECHNICAL FIELD

The present invention relates to roofing panels and more particularly, relates to pre-manufactured roofing panels.

BACKGROUND INFORMATION

Pre-manufactured roofing panels have significantly increased in popularity in recent years for several reasons. Because these roofing panels are constructed in a manufacturing environment rather on an ad-hoc basis at the site, the cost of the pre-manufactured roofing panels is significantly cheaper because the roofing panels can be constructed in bulk. Additionally, because the pre-manufactured roofing panels are assembled prior to arriving at the construction site, the labor costs and time associated with the construction of the roof is significantly reduced.

Yet another reason for the increased popularity of the pre-manufactured roofing panels is that their overall quality is better than what is generally constructed at the site. One reason for this results from the better working environment inside a manufacturing facility as compared to working outside at a construction site. Another reason is that the manufacturing process allows for more precise and accurate cuts and assembly. This increases the strength and heating efficiency, and further reduces labor costs.

While pre-manufactured roofing panels offer many benefits over conventional, in-site constructed roofs, there are some areas which can be improved upon. For example, traditional pre-manufactured roofing panels often suffer from air leaks between adjacent roofing panels. When the pre-manufactured roofing panels are constructed in the field, the joints formed by adjacent panels are often not perfectly straight. While there are a variety of reasons for this (most often a result of the wood not being perfectly straight), the voids created between the adjacent roofing panels allow for air movement. This air movement allows for condensation to build up between the joints (which can lead to rotting, mildew, and insects) and also greatly reduces the overall heat loss.

One solution is to install a large gasket between the adjacent panels in the field during the assembly of the roofing panels. Unfortunately, these large gaskets are difficult to handle and are easily damaged or broken. Additionally, these large gaskets are labor intensive to install and difficult to ensure that the void has been fully filled. The gaskets are prone to movement and are often skipped or misapplied by the workman.

Another disadvantage of the known pre-manufactured roofing panel systems is that it is often very difficult to smoothly join the inside skins of adjacent panels. The inside skins make up the finished ceiling surface. As a result, it is imperative that the transition between adjacent panels be as smooth as possible in order to ensure that the appearance of the inside skin is acceptable. If the inside skins of two adjacent panels do not transition smoothly, the resulting joint is unsightly.

Traditional tongue-and-groove type joints 10, FIG. 1, are not practical in this situation. Tongue-and-groove type joints 10 include a tongue 12 disposed along an edge 14 of a first piece 16. The tongue 12 includes a rectangular cross-sectional shape having two planar, parallel surfaces 18, 20 disposed at a 90 degree angle with respect to the edge 14 with a planar end 22 disposed between the two parallel surfaces 18, 20. An adjacent piece 24 includes the groove 24 disposed along a second edge 15. The groove 26 includes a rectangular shape sized and shaped to accept the tongue 12 tightly and includes two parallel, planar sides 19, 21 and a planar end 23 disposed at a right angle between the two parallel sides 19, 21.

As discussed above, the roofing panels typically run from the ridge of the roof down past the header of the wall. As a result, the overall length of the roofing panel is generally quite long (often 20 feet or more in length). The overall thickness of the inner skin is usually quite small (often less than ¾″), the actually dimensions of the tongue 12 and groove 24 are substantially less and are generally quite weak and prone to breakage. Because of the tight tolerances between the tongue 12 and groove 24 and the natural imperfections and warping that is common to any wooden structure, it is often extremely difficult for the workman to get the tongue 12 and groove 24 to line up properly and usually requires the workman to pull and push on the panels and inner skin. This causes a great deal of force and strain on the tongue 12 and groove 24, often causing the tongue 12 and/or groove 24 to break. Moreover, the natural imperfections and warping makes lining up the tongue 12 and groove 24 a very tedious and labor-intensive process.

Because of the difficulties associated with tongue and groove type joints, another common method of joining the inner skins of adjacent panels is to use a shiplap joint. While this is easier to align and less prone to breakage, shiplap joints are not a true locking joint and thus allow the inner skins to move vertically over time. This results in an obvious joint in the finished ceiling where the adjacent panels are jointed and is unacceptable.

Accordingly, what is needed is an improved apparatus and method of joining the inner skins of adjacent panels. The improved apparatus and method should preferably create a seemless, undetectable joint or connection between adjacent inner skins. The improved apparatus and method also preferably lock the adjacent inner skins into place, thus preventing the inners skins from moving over time and creating an obvious joint. The improved apparatus and method should preferably reduce the amount of labor required to assemble the panels in the field by facilitating the alignment of adjacent panels and preferably reduce the likelihood of inner skin breaking.

What is also needed is an improved apparatus and method that reduces the amount of heat loss through the roofing panels. The improved apparatus and method should also preferably reduce airflow between adjacent panels, thereby reducing the likelihood of condensation forming between the adjacent panels. The improved apparatus and method should preferably reduce the labor required to assemble the panels.

It is important to note that the present invention is not intended to be limited to a system or method which must satisfy one or more of any stated objects or features of the invention. It is also important to note that the present invention is not limited to the preferred, exemplary, or primary embodiment(s) described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims.

SUMMARY

According to a first embodiment, the present invention features an edge system. The edge system includes a first and a second edge portion. The first edge portion includes a first longitudinal axis and a single protrusion extending substantially perpendicular to the first longitudinal axis. The single protrusion preferably has a generally trapezoidal cross sectional shape with a base disposed proximate the first end region and a tip disposed distal to the first edge portion. The single protrusion is preferably disposed substantially within a first middle region of the first edge region.

The second edge portion includes a second longitudinal axis and a single groove disposed generally parallel to the second longitudinal axis. The single groove includes an inner surface sized and shaped to inversely correspond to the generally trapezoidal cross sectional shape of the single protrusion of the first edge portion. The single groove is preferably disposed substantially within a second middle region of the second edge region and is preferably sized and shaped to frictionally engage the single protrusion of the first edge portion.

In the preferred embodiment, the single protrusion includes a base region disposed proximate the first edge portion, a tip region defining an outer most region of the single protrusion, and a first and a second generally planar surface each having a longitudinal axis disposed generally parallel to the first longitudinal axis of the first edge portion. The first and the second generally planar portion arranged to converge towards the tip region. The tip region is generally blunt, generally planar, or generally triangular.

According to another embodiment, the present invention features a panel. The panel includes a first member, a first edge portion, and a second edge portion. The first edge portion is disposed along a first side of the first member and includes a first longitudinal axis and a single protrusion extending substantially perpendicular to the first longitudinal axis.

The single protrusion includes a base region disposed proximate the first edge portion, a tip region defining an outer most region of the single protrusion, and a first and a second generally planar surface each having a longitudinal axis disposed generally parallel to the first longitudinal axis of the first edge portion. The first and the second generally planar portion converge towards the tip region.

The second edge portion is disposed along a second side of the first member and includes a second longitudinal axis and a single cavity disposed generally parallel to the second longitudinal axis. The single cavity is sized and shaped to inversely correspond to the generally trapezoidal cross sectional shape of the single protrusion of the first edge portion.

The single protrusion is preferably sized and shaped to frictionally engage a single cavity of an adjacent panel such that the first panel and the adjacent panel are substantially locked together to form a generally planar inner and outer surface. The single cavity preferably includes a generally trapezoidal cross-sectional shape.

The inner surface of the panel proximate the first and the second edge portions may include a beveled region disposed along the first and the second longitudinal axes of the first and the second edge portions.

According to a further embodiment, the present invention features a paneling kit including a plurality of generally rectangular panels. The panels include an inner and an outer generally parallel and generally planar surface, a first edge region, and a second edge region.

The first edge region includes a first longitudinal axis and first transverse axis disposed generally perpendicular to a longitudinal axis of the inner and the outer surface. The first edge region includes a protrusion disposed along the first longitudinal axis and having a generally trapezoidal cross-sectional shape extending substantially perpendicular to the first longitudinal axis.

The second edge region includes a second longitudinal axis disposed substantially parallel to the first longitudinal axis and second transverse axis disposed generally perpendicular to the longitudinal axis of the inner and the outer surface. A cavity is disposed substantially along the second longitudinal axis and has a generally trapezoidal cross-sectional shape sized and shaped to friction engage the protrusion such that when a protrusion of a first panel is inserted into an adjacent panel, the panels are substantially locked together and form a generally planar inner and outer surface.

According to yet a further embodiment, the present invention features a pre-manufactured roofing panel. The roofing panel includes an inner and an outer support surface, a plurality of framing supports secured to the inner and the outer support surfaces, insulation disposed between the inner and the outer support surfaces, a first and a second support, and a ribbed gasket. The first and the second supports are disposed about a longitudinal axis of the roofing panel along a first and a second outer edge of the inner and outer support surfaces, respectively. The ribbed gasket is secured at least the first support while the roofing panel is constructed at the factory.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:

FIG. 1 is an end view of a prior art tongue and groove type connection;

FIG. 2 is an end view of one embodiment of the improved method and apparatus for joining adjacent inner skins in the unlocked position;

FIG. 3 is an end view of the embodiment shown in FIG. 2 in the locked position;

FIG. 4 is an end view of another embodiment of the improved method and apparatus for joining adjacent inner skins shown in FIG. 2 in the unlocked position;

FIG. 5 is an end view of further embodiment of the improved method and apparatus for joining adjacent inner skins shown in FIG. 2 in the unlocked position;

FIG. 6 is an end view of yet another embodiment of the improved method and apparatus for joining adjacent inner skins shown in FIG. 2 in the unlocked position;

FIG. 7 in a perspective view of one embodiment of the pre-manufactured roofing panel according to the present invention;

FIG. 8 is a plan view of a plurality of roofing panels shown in FIG. 7 installed to form a roof;

FIG. 9 is a plan view of the inner surface roofing panel shown in FIG. 7 according to one embodiment of the present invention; and

FIG. 10 is a perspective view of two adjacent roofing panels shown in FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to one embodiment, the present invention features an improved method and apparatus 50, FIGS. 2-3 (orientation shown inverted for clarification), for joining two or more adjacent pre-manufactured roofing panels 52. As will be described in greater detail hereinbelow, the improved method and joint apparatus 50 features a uniquely shaped connection system which facilitates the alignment of two or more adjacent pre-manufactured roofing panels 52 (and in particular the inner skins 54) while reducing the likelihood of breaking the panels 52 and locking the panels 52 together.

It is important to note that the while the present invention will be described with respect to pre-manufactured roofing panels 52, this is to satisfy the best mode requirement and is for illustrative purposes only. Those skilled in the art will readily recognize that the present invention is suitable for use with a wide range of products and installations including, but not limited to, flooring, marine construction, walls, and the like. Any modifications necessary to the preferred embodiment described herein for use in these alternate uses are well within the ordinary knowledge of those skill in the art.

The improved method and joint apparatus 50 includes a first edge region 56 including a uniquely shaped protrusion 58 and a second edge region 60 including a uniquely shaped groove, cavity, or channel 62. As will be explained in greater detail, the uniquely shaped protrusion 58 and channel 62 are sized and shaped to matedly engage each other in close tolerance when aligned adjacent to each other to create a frictional or wedge-type lock between the adjacent edge regions 56, 60.

As discussed above, a traditional tongue and groove connection 10, FIG. 1, includes a tongue 12 and groove 26 both including parallel surfaces at right angles to each other 18-23. The geometry and dimensions of the prior art tongue and groove connection 10 makes aligning the first and second piece 16, 24 very difficult, especially when the edges 14, 15 are not perfectly straight or planar. This difficulty is due, in part, because the relative thickness of the tongue 12 (i.e., the length of the end surface 22) is substantially the same as the thickness of the groove 24 (i.e., the length of the end surface 23). Consequently, tongue and groove connection 10 is not tolerable of any imperfections along the edge regions 14, 15. Moreover, the difficulty in aligning the prior art tongue and groove connection 10 often results in the either the tongue 12 or the groove 14 becoming damaged or broken.

In contrast, the improved method and joint apparatus 50 of the present invention includes a uniquely shaped protrusion 58 disposed along a longitudinal axis A of the first edge region 56 and a uniquely shaped cavity 62 disposed along a longitudinal axis B of the second edge region 60. The uniquely shaped protrusion 58 extends generally outwardly and perpendicular to longitudinal axis A.

As best shown in FIG. 2, the uniquely shaped protrusion 58 includes a generally trapezoidal cross-sectional shape. The generally trapezoidal shaped protrusion 58 includes a base region 64, an end or tip region 66, and a first and a second surface 68, 70 disposed between the base and tip region 64, 66 converging towards the tip region 66. The base region 64 is disposed proximate the first edge region 56 whereas the tip region 66 extends outwardly from the base region 84 and the first edge region 56. The tip region is preferably the outer most area of the protrusion 58.

The base region 64 is preferably larger than the tip region 66. According to the preferred embodiment, the base region 64 is preferably substantially one-piece with the edge region 56. Alternatively, the base region 64, FIG. 4 (orientation shown inverted for clarification), includes a generally rectangular shape extending outwardly from the edge region 56. The protrusion 58 according to this embodiment is still considered generally trapezoidal in shape.

The tip region 66, FIG. 2, preferably includes a generally planar or blunt surface as shown. The tip region 66 is defined as the outermost region of the protrusion 58. In an alternative embodiment, the tip region 66, FIG. 5 (orientation shown inverted for clarification), includes a generally triangular cross-sectional shape or may include a slightly rounded tip shape as shown in FIG. 6 (orientation shown inverted for clarification). The protrusions 58 according to these embodiments are still considered generally trapezoidal in shape.

It is important to note that the first and a second surfaces 68, 70 disposed between the base and tip region 64, 66 converge towards the tip region 66. As such, the first and second surfaces 68, 70 are not parallel to each other as in the prior art tongue and groove connection 10 (FIG. 1). It is also important to note that the tip region 66 according to the present invention does not have the same thickness as the base region 64, unlike the prior art tongue and groove 10 (FIG. 1). As will be explained below, the non-parallel first and second surfaces 68, 70 and the tip region 66 according to the present invention greatly facilitate the alignment of two or more adjacent inner skins 54.

In the preferred embodiment, the first and second surfaces 68, 70 are preferably disposed at an angle of a1 and a2 of approximately 33 degrees to approximately 110 degrees relative to the plane C transverse to the longitudinal axis of the base region 66. The first and second sides 68, 70 are also preferably generally planar, though may include non-planar sides are as well.

The cavity, chamber, or channel 62, FIG. 2, includes a generally inverse trapezoidal cross-sectional shape and is disposed along the longitudinal axis B of the second edge region 60. The cavity 62 includes an opening 80 disposed proximate an outermost region of the second edge region 60, and end region 82 disposed within an innermost region the cavity 62, and a first and a second side surface 84, 86 disposed between the opening 80 and the end region 82.

Referring specifically to FIG. 3, the protrusion 58 and the cavity 62 are sized and shaped to substantially correspond to each other such that the protrusion 58 and the cavity 62 matedly lock when the first and second edge portions 56, 60 are aligned substantially adjacent to each other. Because the protrusion 58 and the cavity 62 lock together in a wedge-type format, the inner skins 54 cannot move relative to each other.

While the protrusion 58 and the cavity 62 are shown corresponding substantially identically, this is not a limitation of the present invention unless specifically stated otherwise in the claims. Rather, the protrusion 58 and the cavity 62 must correspond to each other closely enough such that the protrusion 58 and the cavity 62 do not allow the inner skins 54 to move relative to each other when aligned. Those skilled in the art will readily recognize the breadth of this arrangement.

Referring specifically to FIG. 4, the opening 80 of the cavity 62 may also include a generally rectangular cross-sectional region 90 corresponding to the generally rectangular region base region 64 of the protrusion 58. Alternatively, the end region 82, FIG. 5, of the cavity 62 may include a generally triangular cross-sectional region 92 corresponding to the generally triangular tip region 66 of the protrusion 58. In yet a further embodiment, the end region 82, FIG. 6, of the cavity 62 may include a slightly rounded end region rounded cross-sectional shape corresponding to the slightly rounded tip region 66 of the protrusion 58. All of these embodiments of the cavity 62 are considered to be generally trapezoidal.

The unique shapes of the protrusion 58 and the cavity 62 also greatly facilitates the alignment of two adjacent inner skins 54 because the tip region 66 does not need to be exactly and perfectly lined up relative to the opening 80. As can be seen from the FIGS. 2-6, the opening 80 of the cavity 62 is substantially larger than both the end region 82 of the cavity 62 and the tip region 66 of the protrusion 58. Additionally, the first and second sides 68, 70 of the protrusion 66 and the first and second sides 84, 86 of the cavity 62 are tapered. As a result, the user simply needs to align the tip region 66 proximate to the opening 80. If the first and second edge regions 56, 60 are not perfectly lined up, the larger opening 80 allows the tip region 66 to be slightly offset and the tapered first and second sides 68, 70, 84, 86 helps to guide the tip region 66 relative to the end region 82 of the cavity 62.

Because the arrangement of the protrusion 58 and cavity 62 allows the tip region 66 of the protrusion 58 to be offset relative to the opening 80 of the cavity 62, the workman do not have to pull or push on the inner skins 54 to align the edges 56, 60 perfectly. Consequently, the likelihood of damaging either of the inner skins 54 is substantially reduced.

The first and second edge regions 56, 60 also preferably include a beveled region 99 best shown in FIG. 3. The beveled region 99 gives the present invention a more pleasing appearance.

According to another embodiment, the present invention also features a roofing panel 100, FIG. 7. As discussed above, the roofing panel 100 is preferably approximately 4 feet wide, though other dimensions are also possible. The length is determined by the particular installation. As is well known to those skilled in the art, a plurality of the roofing panels 100, FIG. 8, are used to construct a roof 102 by aligning the roofing panels 100 adjacent to each other. In a typical installation, a first end 104 of the roofing panels is secured to a header or main beam 106 and a second end region 108 is secured to a header 110 of a wall 112 or the like.

Referring back to FIG. 7, the roofing panel 100 typically includes a first and a second longitudinal support 114, 116 disposed along a first and second longitudinal side 118, 120, respectively. A top or outer surface 124 preferably includes a plywood or similar material suitable for applying the roofing shingles or the like. A bottom or inner surface 126, FIG. 9, is preferably a finished inner surface suitable for a finished ceiling. In the exemplary embodiment, the inner surface preferably includes the inner skin 54 as described above, though this is not a limitation of the present invention unless specifically claimed. The roofing panel 100, FIG. 7, typically includes a plurality of other supports and cross braces 122 between the first and a second longitudinal supports 114, 116 as is commonly found.

The roofing panels 100 are typically constructed primarily from wood. As is common, the wooden pieces of the roofing panel 100, in particular the first and a second longitudinal supports 114, 116, often are not perfectly straight. As discussed above, when two adjacent panels 100, FIG. 10 are aligned, imperfections in either of the first and/or second longitudinal supports 114, 116 can cause voids 120. These voids 120 allow for air movement, condensation to form, and reduce the overall heat efficiency of the roofing panels 100.

In the past, large flexible gaskets have been installed in the field by the workman in an effort to properly seal the joint between two adjacent panels. However, these gaskets are hard to use, are labor intensive, are prone to moving during installation, prevent the panels from aligning properly, and are often skipped entirely by the workman.

The present invention solves this problem with the use of a novel ribbed gasket 130, FIG. 7, secured along the one or more of the first and/or second longitudinal supports 114, 116. The ribbed gasket 130 is preferably installed at the factory while the roofing panel 100 is being manufactured. As a result, the ribbed gasket 130 will not be skipped by the workman installing the panels 100. The ribbed gasket 130 includes at least one rib, but preferably includes a plurality of ribs disposed along the longitudinal axis of the ribbed gasket 130. In the exemplary embodiment, the ribbed gaskets 130 include approximately 17 ribs in total.

In the preferred embodiment, the ribbed gasket 130 is made from a closed cell foam (for example, but not limited to polyethylene foam), though those skilled in the art will recognize that other suitable materials exist. The ribbed gasket 130 is preferably made from a compressible material. The ribbed gasket 130 is preferably secured to the first and/or second longitudinal supports 114, 116 using a fastener such as, but not limited to, staples, nails, or the like, an adhesive, or any other method known to those skilled in the art.

In the exemplary embodiment, the ribbed gasket 130 is approximately 0.25″×5.5″ and runs along the entire length of one or more the first and/or second longitudinal supports 114, 116. It has been found that the extra width of the ribbed gasket 130 effectively fills the entire void 120 between panels 100, eliminating the air space and reducing the potential for air movement. An additional expanding foam barrier (foam tape) can be added on site in the event that the void 120 is too large at any point for the ribbed gasket.

Because the ribbed gasket 130 is applied at the factory, the ribbed gasket 130 minimizes labor on site. Additionally, because the ribbed gasket 130 is not an expanding foam type gasket, it can be applied at the factory, thus eliminating the potential that the gasket could be misapplied or forgotten on site.

Accordingly, the present invention reduces the amount of heat loss through the roofing panels. The improved apparatus and method also reduces airflow between adjacent panels, thereby reducing the likelihood of condensation forming between the adjacent panels. The improved apparatus and method further reduces the labor required to assemble the panels.

The present invention also includes an improved apparatus and method of joining the inner skins of adjacent panels. The improved apparatus and method creates a seemless, undetectable joint or connection between adjacent inner skins and locks the adjacent inner skins into place, thus preventing the inners skins from moving over time and creating an obvious joint. The improved apparatus and method further reduces the amount of labor required to assemble the panels in the field by facilitating the alignment of adjacent panels and reducing the likelihood of inner skin breaking.

As mentioned above, the present invention is not intended to be limited to a system or method which must satisfy one or more of any stated or implied object or feature of the invention and should not be limited to the preferred, exemplary, or primary embodiment(s) described herein. The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as is suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the claims when interpreted in accordance with breadth to which they are fairly, legally and equitably entitled.

Claims

1. An edge system comprising:

a first edge portion having a first longitudinal axis, said first edge portion including a single protrusion extending substantially perpendicular to said first longitudinal axis, said single protrusion having a generally trapezoidal cross sectional shape having a base disposed proximate said first end region and a tip disposed distal to said first edge portion; and
a second edge portion having a second longitudinal axis and a single groove disposed generally parallel to said second longitudinal axis, said single groove having an inner surface sized and shaped to inversely correspond to said generally trapezoidal cross sectional shape of said single protrusion of said first edge portion.

2. The edge system as claimed in claim 1 wherein said single protrusion is disposed substantially within a first middle region of said first edge region.

3. The edge system as claimed in claim 2 wherein said single groove is disposed substantially within a second middle region of said second edge region.

4. The edge system as claimed in claim 1 wherein said single groove is sized and shaped to frictionally engage said single protrusion of said first edge portion.

5. The edge system as claimed in claim 1 wherein said single protrusion includes:

a base region, said based region disposed proximate said first edge portion;
a tip region, said tip region defining an outer most region of said single protrusion; and
a first and a second generally planar surface each having a longitudinal axis disposed generally parallel to said first longitudinal axis of said first edge portion, said first and said second generally planar portion arranged to converge towards said tip region.

6. The edge system as claimed in claim 5 wherein said tip region is generally blunt.

7. The edge system as claimed in claim 5 wherein said tip region is generally planar.

8. The edge system as claimed in claim 5 wherein said tip region includes a generally triangular cross-sectional shape.

9. A panel comprising:

a first member;
a first edge portion disposed along a first side of said first member, said first edge portion having a first longitudinal axis, said first edge portion including a single protrusion extending substantially perpendicular to said first longitudinal axis, said single protrusion including: a base region, said based region disposed proximate said first edge portion; a tip region, said tip region defining an outer most region of said single protrusion; and a first and a second generally planar surface each having a longitudinal axis disposed generally parallel to said first longitudinal axis of said first edge portion, said first and said second generally planar portion converge towards said tip region; and
a second edge portion disposed along a second side of said first member, said second edge portion having a second longitudinal axis and a single cavity disposed generally parallel to said second longitudinal axis, said single cavity sized and shaped to inversely correspond to said generally trapezoidal cross sectional shape of said single protrusion of said first edge portion.

10. The panel as claimed in claim 9 wherein said first member wherein a single protrusion of a first panel is sized and shaped to frictionally engage a single cavity of an adjacent panel such that said first panel and said adjacent panel are substantially locked together to form a generally planar inner and outer surface.

11. The panel as claimed in claim 10 wherein single cavity includes a generally trapezoidal cross-sectional shape.

12. The panel as claimed in claim 10 wherein said tip region includes a generally triangular cross-sectional shape.

13. The panel as claimed in claim 10 wherein said tip region is generally planar.

14. The panel as claimed in claim 9 wherein an inner surface of said panel proximate said first and said second edge portions includes a beveled region disposed along said first and said second longitudinal axes of said first and said second edge portions.

15. The panel as claimed in claim 14 wherein said first member includes an outer support surface, a plurality of framing supports secured to said outer support surface, insulation disposed between said plurality of framing supports, and a plurality of inner skins wherein said plurality of inner skins form said inner surface of said panel.

16. A paneling kit comprising:

a plurality of generally rectangular panels including: an inner and an outer generally parallel and generally planar surface; a first edge region having a first longitudinal axis and first transverse axis, said first transverse axis disposed generally perpendicular to a longitudinal axis of said inner and said outer surface, said first edge region including a protrusion disposed along said first longitudinal axis and having a generally trapezoidal cross-sectional shape extending substantially perpendicular to said first longitudinal axis; and at least a second edge region having a second longitudinal axis disposed substantially parallel to said first longitudinal axis and second transverse axis disposed generally perpendicular to said longitudinal axis of said inner and said outer surface, said second edge region including a cavity disposed substantially along said second longitudinal axis, said cavity having a generally trapezoidal cross-sectional shape and sized and shaped to friction engage said protrusion such that when a protrusion of a first panel is inserted into an adjacent panel said panels are substantially locked together and form a generally planar inner and outer surface.

17. The paneling kit as claimed in claim 16 wherein said tip region includes a generally triangular cross-sectional shape.

18. The paneling kit as claimed in claim 16 wherein said tip region is generally blunt.

19. The paneling kit as claimed in claim 16 wherein said tip region is generally planar.

20. The paneling kit as claimed in claim 16 wherein said inner surface of said panel proximate said first and said second edge portions includes a beveled region

21. A pre-manufactured roofing panel comprising:

an inner and an outer support surface;
a plurality of framing supports secured to said inner and said outer support surfaces;
insulation disposed between said inner and said outer support surfaces;
a first and a second support, said first and said second supports disposed about a longitudinal axis of said roofing panel along a first and a second outer edge of said inner and outer support surfaces, respectively; and
a ribbed gasket secured at least said first support while said roofing panel is constructed at the factory.

22. The pre-manufactured roofing panel as claimed in claim 21 wherein ribbed gasket includes a polyethylene foam gasket.

23. The pre-manufactured roofing panel as claimed in claim 22 wherein said inner surface comprises:

a first edge portion having a first longitudinal axis, said first edge portion including a single protrusion extending substantially perpendicular to said first longitudinal axis, said single protrusion having a generally trapezoidal cross sectional shape having a base disposed proximate said first end region and a tip disposed distal to said first edge portion; and
a second edge portion having a second longitudinal axis and a single groove disposed generally parallel to said second longitudinal axis, said single groove having an inner surface sized and shaped to inversely correspond to said generally trapezoidal cross sectional shape of said single protrusion of said first edge portion.
Patent History
Publication number: 20060185306
Type: Application
Filed: Feb 24, 2005
Publication Date: Aug 24, 2006
Applicant: Yankee Barn Homes, Inc. (Grantham, NH)
Inventor: Roger Fletcher (Webster, NH)
Application Number: 11/064,619
Classifications
Current U.S. Class: 52/591.100
International Classification: E04B 2/46 (20060101);