METAL ROOFING SHINGLE, METAL ROOFING SHINGLE SYSTEM, AND METHOD OF INSTALLING
The present invention is directed to a metal roofing shingle system comprising universal flashing installed as either a ridge cap, hip flashing, or valley flashing and including non-visible double-flanged interlock joints that extend beneath the underside surface of the flashing, the interlock joints are adapted to couple with metal shingles; each metal shingle having a planar segment, a first longitudinal edge segment opposite a second longitudinal edge segment that includes a non-visible double-flanged interlock joint that extends beneath the bottom surface of the shingle, and a first transverse edge segment opposite a second transverse edge segment that includes a non-visible double-flanged compression joint that extends beneath the bottom surface of the shingle; and shingle shaping tools.
The present invention is directed to a sheet metal roofing system for installation on a pitched roof beginning at the ridge and ending at the eave, and in particular, it is directed to a sheet metal roofing system that includes a) metal shingles with self-sealing, non-visible interlock joints that provide watertight connections between adjacent shingles without the application of sealant materials, b) universal flashing that includes non-visible interlocking joints adapted to couple with the metal shingles when the universal flashing member is installed as either a ridge cap, hip flashing, or valley flashing, and c) shingle shaping tools that reshape edges of the metal shingles; the combination non-visible interlocking joints, reshaped shingle edges, and an applied paint system providing a sheet metal roofing system having the appearance of slate shingles, terracotta tiles, or like roofing materials.
Water penetration between adjacent metal shingles is a well known problem in the art. Such water problems are most severe in roofs having a moderate pitch, for example between about a 2 in 12 and 4 in 12 roof pitch. The shallower the pitch, the greater the potential for a roof leak. Roof leaks can occur by capillary action, among other reasons, and such water penetration is both difficult to detect and difficult to prevent. There have been various attempts in the past to overcome roof leak problems associated with metal roofing shingles. For example, U.S. Pat. No. 1,519,350 discloses a sheet metal shingle installed from the roof ridge to the eve. The metal shingle includes interlocking joints along the top or weather surface that couple adjacent shingles together. Such exposed joints between shingles are pelted with rain, sleet, and snow and are prone to water penetration. The patent also discloses a ridge cap section that is distinctively different from the valley flashing used with the metal shingles.
U.S. Pat. No. 3,394,515 shows a deformable gasket in a channel along a side edge of a roofing panel. The gasket forms a seal with an interlocking edge of an adjacent panel.
U.S. Pat. No. 5,349,801 discloses metal shingles where it is necessary to apply a sealant material, at the job sight, along the joints that interlock adjacent shingles, and the patent specifically teaches that it is important to form a good bond between the applied sealant and the shingle surface. This creates the possibility of having a poor quality seal and potential roof leakage that the present invention overcomes.
Accordingly, there is a long felt need in the art for a metal roofing shingle system with universal flashing and unexposed interlocking joints that resist water penetration without a need for on site applied caulks, sealants, adhesives, or the like, as well as providing a roofing system that is especially suited for application on a shallow pitched roof.
SUMMARY OF THE INVENTIONAccordingly, it is a first object of the present invention to provide a watertight metal roofing shingle system having metal roofing shingles installed starting at the roof ridge cap and ending at the roof eave edge.
It is another object of the present invention to provide a watertight metal roofing shingle system having no exposed connection joints between adjacent the metal roofing shingles so that the finished metal roofing system has an uninterrupted slate like appearance.
It is still another object of the present invention to provide a metal roofing shingle system that includes universal flashing with interlock joints that couple to the metal roofing shingles.
It is another object of the present invention to provide a metal roofing shingle system whereby, in one embodiment, the universal flashing member is installed as a ridge cap and the interlock joints extend along the underside surface of the ridge cap so that the coupled shingle connection is not visible and is unexposed to weather conditions.
In another embodiment, the universal flashing member is installed as hip flashing along the external angle formed by two different sloping roof sections and the interlock joints extend along the underside surface of the ridge cap so that the coupled shingle connection is not visible and is unexposed to weather conditions.
In still another embodiment, the universal flashing member is installed inverted as valley flashing along the angle where two different roof sections intersect, the inverted interlock joints coupling with intersecting metal roofing shingles to prevent both water and wind damage.
It is another object of the present invention to provide a metal roofing shingle with unexposed, interlocking compression joints that provide a watertight connection between adjacent shingles.
It is still another object of the present invention to provide a metal roofing shingle with unexposed, interlocking compression joints that provide a watertight connection between adjacent shingles without the application of gaskets, or applied beads of caulk, or like materials.
It is another object of the present invention to provide a metal roofing shingle system having unexposed interlocking joints, in combination with modified gable end and eve edge treatments, and in combination with selected paint systems, that furnish a faux slate or a faux terracotta tile roof system.
It is still another object of the present invention to provide a lightweight sheet metal roofing system that suitable for installation over existing asphalt roofing shingles.
In satisfaction of the foregoing objects and advantages, the present invention provides a metal roofing shingle system comprising universal flashing installed as either a ridge cap, hip flashing, or valley flashing and including non-visible double-flanged interlock joints and interlock compression joints that extend along the underside of the flashing, the interlock joints adapted to couple with metal shingles; metal shingles having a planar segment, a first longitudinal edge segment opposite a second longitudinal edge segment that includes a double-flanged interlock joint extending beneath the bottom surface of the planar segment, and a first transverse edge segment opposite a second transverse edge segment, that includes a double-flanged compression joint that extends beneath the bottom surface of the planar segment; and shingle shaping tools to modified metal roofing shingles positioned adjacent the roof gable ends and eve edges.
There have been various attempts in the past to provide metal roofing shingles, for example, shingles manufactured from sheet steel, aluminum, copper or other like metallic materials, to improve service life, insulation characteristics, and appearance in metal roof systems. Such past attempts have had marginal success. State of the art metal shingles are prone to water penetration between adjacent shingles. This is because past mechanical connections between adjacent metal shingles extend along the top or external surface of the shingles where they are exposed to weather conditions. Such exposed joints or connections require the on-sight application of caulks or gaskets along the connection joints to provide watertight integrity. Moreover, the need to apply caulks, adhesives, or like sealants at the job sight is problematic in that, unreliable workers may forget to apply the required sealant, may apply an ineffective amount of sealant material, or apply a poor quality caulk bead. Furthermore, environmental conditions at the job sight, for example rain drizzle or fog that causes shingle dampness, or surface deposits from falling and/or wind blown pollens, or debris from atmospheric conditions, and the like, prevent proper adhesion between the on sight applied sealants and the shingle surfaces. In time, such poor quality mechanical connections result in water leaks that are difficult to locate and repair. Finally, the exposed connection joints associated with metal roofing systems of the past detract from shingle appearance, and the exposed seams fail to provide a slate like appearance along the finished roof.
Referring to the preferred embodiment of the present metal roofing shingle system,
Referring to
In a similar manner, as shown in
Referring to
Referring to the enlarged cross-section in
The first course of metal shingles 32a (
Referring again to
As mentioned above, in the preferred embodiment of the present metal roofing shingle system, the first transverse edge segment 7a that extends outboard of the gable end of the roof, in each course of shingles, is shaped using the tool shown in
The last shingle in each course of shingles, along the opposite gable end, is trimmed, as shown in
Referring once again to
As shown in
In a similar manner, as shown in
Referring now to
Referring to
Shingle-shaping tool 50 is adapted to provide the hooked interlock edge 38a or 38b along the trimmed angled edge segments 37a and 37b (
As such, an invention has been disclosed in terms of preferred embodiments and alternate embodiments thereof, which fulfills each one of the objects of the present invention as set forth above and provides a new metal shingle roof system, an improved metal shingle, and a method of installation. Of course, various changes, modifications, and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims.
Claims
1. A metal roofing shingle system, comprising:
- a) universal flashing including; i) a first leg with a double-flanged interlock joint adapted to couple with metal shingles, said interlock joint having an outward extending nailing hem for attachment to a roof, and ii) a second leg with a double-flanged interlock joint adapted to couple with metal shingles, said interlock joint having an outward extending nailing hem for attachment to a roof, whereby said universal flashing selectively provides a ridge cap or hip flashing when attached to the roof, or valley flashing when attached inverted; and
- b) metal shingles, each metal shingle comprising; i) a planar segment defined by a top surface and a bottom surface, ii) a first transverse edge segment opposite a second transverse edge segment, the second transverse edge segment including a double-flanged compression joint having a first flange that extends beneath said bottom surface, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment, and iii) a first longitudinal edge segment opposite a second longitudinal edge segment, the second longitudinal edge segment including a double-flanged interlock joint that having a first flange that extends beneath said bottom surface, and a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof.
2. The metal roofing shingle system recited in claim 1 whereby, the first longitudinal edge segment of each metal shingle when installed in a first course of shingles is inserted between the flanges of a double-flanged interlock joint of the universal flashing when installed as a ridge cap.
3. The metal roofing shingle system recited in claim 1 whereby, the first longitudinal edge segment of each metal shingle when installed in a second or following course of shingles is inserted between the flanges of a double-flanged interlock joint extending beneath the second longitudinal edge segment in an adjacent course of shingles.
4. The metal roofing shingle system recited in claim 1 whereby, the first transverse edge segment of a metal shingle is inserted into the double-flanged compression joint of an adjacent shingle, causing the compression flange to forcibly engages the bottom surface of said inserted shingle to provide a watertight seal along said compression joint.
5. The metal roofing shingle system recited in claim 4, comprising, insulation material fixed to the bottom surface of said planar segment, the insulation material compressed when said compression flange forcibly engages said bottom surface of said inserted shingle.
6. The metal roofing shingle system recited in claim 1, comprising: a metal roof shingle manufactured from a metal shingle blank, said shingle blank comprising:
- a) a planar segment defined by a top surface and a bottom surface;
- b) a first transverse edge segment opposite a second transverse edge segment having a transverse fold tab; and
- c) a first longitudinal edge segment opposite a second longitudinal edge segment having a longitudinal fold tab; whereby the transverse fold tab on the second transverse edge segment is folded to form a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment; and whereby the longitudinal fold tab on the second longitudinal edge segment is folded to form a double-flanged interlock joint that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint overlapped by said folded second transverse edge segment, and said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface for attachment to a roof; said second transverse edge segment and said second longitudinal edge segment folded to manufacture the metal roof shingle.
7. The metal roofing shingle system recited in claim 6 comprising: insulation material fixed to the bottom surface of the planar segment of said shingle blank.
8. The metal roofing shingle system recited in claim 6, additionally comprising: a shingle shaping tool for shaping said shingle blanks into shingles including an elongated shaping jaw comprising an angle shaped member having a first leg fixed to a second leg, and a circular shaped member fixed to said first leg and extending along the length thereof, said circular shaped member fixed at a position to provide a gap between said circular shaped member and said second leg, said gap sized to releasably fix a shingle edge therein when said shingle is shaped about the circular shaped member surface to form a curvilinear shingle edge.
9. The metal roofing shingle system recited in claim 6, additionally comprising: a shingle shaping tool for shaping said shingle blanks into shingles including an elongated shaping jaw comprising an angle shaped member having a first leg fixed to a second leg, and a rectangular shaped member fixed to said first leg and extending along the length thereof, said rectangular shaped member fixed at a position to provide a gap between said rectangular shaped member and said second leg, said gap sized to loosely hold a shingle edge therein so that said shingle edge rotates within said gap when said shingle is shaped about said rectangular shaped member to form a hooked shingle edge.
10. A metal roof shingle manufactured from a metal shingle blank, said shingle blank comprising:
- a) a planar segment defined by a top surface and a bottom surface;
- b) a first transverse edge segment opposite a second transverse edge segment; and
- c) a first longitudinal edge segment opposite a second longitudinal edge segment; whereby the second transverse edge segment is folded to form a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment; and whereby the second longitudinal edge segment is folded to form a double-flanged interlock joint having a first flange that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint overlapped by said folded second transverse edge segment, and said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof; said second transverse edge segment and said second longitudinal edge segment folded to manufacture the metal roof shingle.
11. The metal roof shingle recited in claim 10 comprising:
- insulation material fixed to the bottom surface of said planar segment.
12. The metal roof shingle recited in claim 10 comprising at least one paint coat applied to the top surface of said planar segment.
13. The metal roof shingle recited in claim 12 whereby, said at least one paint coat is colored.
14. The metal roof shingle recited in claim 12 whereby, said at least one paint coat is colored to simulate slate shingles.
15. The metal roof shingle recited in claim 12 whereby, said at least one paint coat is colored to simulate terracotta shingles.
16. A metal roof shingle comprising:
- a) a planar segment defined by a top surface and a bottom surface;
- b) a first transverse edge segment;
- c) a second transverse opposite said first transverse edge segment, said second transverse edge Segment folded to form a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment;
- d) a first longitudinal edge segment; and
- e) a second longitudinal edge segment opposite said first longitudinal edge segment, the second longitudinal edge segment folded to form a double-flanged interlock joint having a first flange that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint overlapped by said folded second transverse edge segment, and said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof
17. The metal roof shingle recited in claim 16 comprising:
- insulation material fixed to the bottom surface of said planar segment.
18. The metal roof shingle recited in claim 16 comprising:
- a paint system applied to the top surface of said planar segment.
19. The metal roof shingle recited in claim 16 whereby, said paint system is colored.
20. The metal roof shingle recited in claim 16 whereby, said paint system is colored to simulate slate shingles.
21. The metal roof shingle recited in claim 16 whereby, said paint system is colored to simulate terracotta shingles.
22. A method of installing a metal roofing shingle system, comprising:
- a) providing universal flashing including a first leg with an integral double-flanged interlock joint extending along a length thereof, and a second leg fixed to said first leg and including an integral double-flanged interlock joint extending along a length thereof, each said double-flanged interlock joint adapted to couple with metal shingles, each said double-flanged interlock joint including an outward extending nailing hem for attachment to a roof, and b) providing metal roof shingles comprising: i) a planar segment defined by a top surface and a bottom surface, ii) a first transverse edge segment opposite a second transverse edge segment, the second transverse edge segment folded to provide a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment, and iii) a first longitudinal edge segment opposite a second longitudinal edge segment, the second longitudinal edge segment folded to provide a double-flanged interlock joint having a first flange that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof, said folded second longitudinal edge segment being overlapped by said folded transverse edge segment;
- c) attaching said universal flashing as a ridge cap by driving fasteners through said nailing hems extending along the first leg and along the second leg of said universal flashing and into the roof;
- d) installing a first course of metal roof shingles, each shingle having its first longitudinal edge segment inserted between the flanges of one of said interlock joints provided in said universal flashing attached as a ridge cap, each shingle, with the exception of a first shingle in said first course, having its first transverse edge segment inserted between the flanges of the double-flanged compression joint of an adjacent shingle, the compression flange forcibly engaging the bottom surface of said first longitudinal edge segment, each conjoined shingle fixed to the roof by driving fasteners through said nailing hem;
- e) installing a second course through a last course of metal roof shingles, each shingle having the first longitudinal edge segment inserted between the flanges of the double-flanged interlock joint provided along the folded second longitudinal edge segment of an adjacent shingle, and each shingle, with the exception of a first shingle in each second through a last course of shingles, having its first transverse edge segment inserted between the flanges of the double-flanged compression joint of an adjacent shingle, said compression flange forcibly engaging the bottom surface of said conjoined first longitudinal edge segment, each shingle in said second through a last course of shingles fixed to the roof by driving fasteners through said nailing hem.
23. The method of installing the metal roofing shingle system in claim 22, further comprising: positioning the first shingle in each first through last course of shingles at a location that extends the first transverse edge segment outboard of a gable end of the roof; and trimming the second transverse edge segment of the last shingle in each course of shingles so that the trimmed second transverse edge segment of each said last shingle extends outboard of a second gable end at an equal distance to said first transverse edge segment.
24. The method of installing the metal roofing shingle system in claim 23, further comprising: forming a shaped edge that extends beneath the bottom surface of said extended first transverse edge segment, and forming a shaped edge that extends beneath the bottom surface of said extended trimmed second transverse edge segment.
25. The method of installing the metal roofing shingle system in claim 24 whereby, each said shaped edge is curvilinear.
26. The method of installing the metal roofing shingle system in claim 22, further comprising: trimming each second longitudinal edge segment of each shingle installed in the last course of shingles so that each trimmed second longitudinal edge segment extends outboard of an eve edge of the roof.
27. The method of installing the metal roofing shingle system in claim 26, further comprising: forming a shaped edge that extends beneath the bottom surface of each trimmed second longitudinal edge segment extending outboard of the eve edge.
28. The method of installing the metal roofing shingle system in claim 27 whereby, each shaped edge extending outboard of the eve edge is curvilinear.
29. The method of installing the metal roofing shingle system in claim 22, further comprising:
- a) inverting and attaching said universal flashing as valley flashing by driving fasteners through said nailing hems provided along the first leg and along the second leg of said universal flashing and into two different sloped roof sections;
- b) trimming each second longitudinal edge of each metal shingle that intersects the valley flashing, said second longitudinal edge trimmed at an angle that corresponds with said slope between the two different roof sections;
- c) forming a hook along each trimmed edge; and
- d) interlocking said hook edge of each trimmed shingle with one of the integral double-flanged interlock joints exposed along the inverted universal flashing.
30. The method of installing the metal roofing shingle system in claim 22, further comprising:
- a) attaching said universal flashing as hip flashing by driving fasteners through said nailing hems provided along the first leg and along the second leg of said universal flashing and into two different sloped roof sections;
- b) trimming the first longitudinal edge of each first shingle in a course of shingles at an angle that corresponds with said slope between the two different roof sections; and
- c) trimming the second longitudinal edge of each last shingle in a course of shingles at an angle that corresponds with said slope between the two different roof sections.
Type: Application
Filed: Jan 27, 2009
Publication Date: Jul 29, 2010
Inventor: Charles T. Seem (Cherryville, PA)
Application Number: 12/360,369
International Classification: E04D 1/06 (20060101); E04D 13/155 (20060101); E04D 15/02 (20060101); B21K 23/00 (20060101); E04B 1/66 (20060101); E04F 19/00 (20060101); E04B 1/00 (20060101);