ROOFING SYSTEM AND METHOD THEREOF

Abstract

Roofing systems, articles, and methods are discussed herein that can incorporate multiple features, including energy saving features. Ventilation and wind uplift resistance can be provided by features incorporated into roofing units described herein. Other features described herein can provide for easy positioning of roofing units, or allow spacing for thermal expansion. Features of the roofing units can facilitate the removal and replacement of damaged parts.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional U.S. patent application Ser. No. 61/403,715, filed on Sep. 20, 2010, entitled “Ventilated Interlocking Roof System with Wind Uplift Resistance and Being Removable” and mailed Sep. 20, 2010, under Express Mail label number ED 341782132US, signed Sep. 19, 2010, and received Sep. 21, 2010. The entirety of the above-noted application is incorporated herein by reference.

BACKGROUND

Of all components of building structure, none is as problematic as the roof. The problems are daunting: UV degradation, wide temperature deviation, rain, sleet, hale, snow, and ice. These weather conditions cause thermal expansion, leaks and material degradation. Mechanical challenges include wind, snow load, occasional movement of the earth, fire, and the possibility of unknown projectiles. Yet the most significant commercial factor is cost, both in labor and materials.

Roofing systems that purport to solve one problem often are offset by the creation of a different problem, and can lead to increased material costs, or more complex, time consuming and costly installation. In many situations, material may be breakable or not walkable, and may have insufficient wind resistance, poor resistance to ultraviolet (UV) radiation, or degrade relatively rapidly. Additionally, with many roofing systems, replacement of a damaged tile necessitates removal and replacement of the entire row, increasing maintenance costs.

Further, many traditional roofing materials such as clay, slate, asphalt, etc. have limited recyclability and can contribute additional waste to the environment when removed or replaced.

SUMMARY

The following presents a simplified summary of the innovation in order to provide a basic understanding of some aspects of the innovation. This summary is not an extensive overview of the innovation. It is not intended to identify key/critical elements of the innovation or to delineate the scope of the innovation. Its sole purpose is to present some concepts of the innovation in a simplified form as a prelude to the more detailed description that is presented later.

The innovation disclosed and claimed herein, in one aspect thereof, comprises a roofing system. The roofing system can include at least one starter that can include one or more first attachment mechanisms (e.g., tee slots, etc.). Additionally, the system can include at least one roofing unit that can include one or more first attachment mechanisms and one or more second attachment mechanisms (e.g., bosses, etc.). Each of the second attachment mechanisms can be configured to attach with any of the first attachment mechanisms.

In other aspects, the innovation can comprise a method that includes the act of securing one or more starters to a roof. Each starter can include one or more tee slots. The method can also include the act of securing one or more roofing units to a roof. Each roofing unit can include one or more tee slots and one or more bosses. Additionally, the method can include the act of engaging each of the one or more bosses with one of the one or more tee slots.

In accordance with one embodiment discussed herein, the innovation can include a roofing unit (e.g., roofing tile, shingle, etc.) that can be at least one of ventilated or interlocking with other similar units. Optionally, roofing units discussed herein can provide resistance to wind uplift in addition to other features and advantages discussed herein. Moreover, these roofing units can be readily replaceable.

In aspects, the exposed surface of roofing units of the subject innovation can be highly reflective of sunlight and can be easily cleaned by normal rainfall. Features discussed herein can contribute to this, including an optional smooth matte surface. Rain channels can be added across the surface (e.g., diagonal channels, curved channels, etc.), which can provide multiple features, such as cleaning (e.g., the rain channels can act as waterways, moving rain water and foreign particles to the gutters), as well as aesthetic options, such as the ability to customize the appearance of the roofing units. Moreover, although installers need to exercise caution in conditions where dew is on the roof (this is always true with any system), the addition of rain channels (e.g., diagonal, etc.) can give the installer an edge to step on, although some conditions will require caution.

Another advantage of embodiments of the subject innovation is increased resistance to wind uplift (e.g., via a mechanical attachment mechanism, etc.). In aspects, this increased wind resistance can be accomplished via an attachment (e.g., by a boss on the bottom of the overlapping unit which is engaged with (e.g., via a tee slot, etc.) in the adjoining under-lapped unit.

In aspects, systems, methods, and articles discussed herein can employ a method of attachment to the substrate which enables removal of individual units in the event of damage (or other reasons for replacement, as discussed herein, etc.). In one embodiment, tines at the upper area of the unit can be used as the location of fasteners which secure the unit to the substrate. The open ends of the tines can permit easy removal of the unit, while still retaining the wind resistance and other advantages discussed herein.

Aspects of the subject innovation can be used to permit daylight entry into the building structure, for example by manufacturing a section of units from a translucent or transparent material (e.g., a resin, polymer, etc.) to created a day-lighted section. As discussed further herein, ceiling structures under the day-lighted section can be framed to accommodate light entry into the building, which can occur without penetrating the roofing units, thereby providing the advantages of natural lighting (e.g., via a skylight) with other advantages discussed herein (e.g., wind resistance, ease of installation and repair, etc.).

Additionally, embodiments of the subject innovation can be designed to accommodate thermal expansion of a plurality of roofing units. A gap to accommodate thermal expansion can be incorporated into the shape, and the alignment of other portions of the roofing unit (e.g., the bosses and tee slots) can assure the appropriate gap is maintained.

Further, the roofing units discussed herein can provide the option to customize the appearance of a roof or other structure comprising the roofing units. For example, the location of bosses and tee slots can allow for engagement of overlapping units at a range (e.g., ¼, ⅓ or ½, etc.) of the lateral distance of the under-lapped unit. The ability to select the extent of overlap, coupled with the rain channels (or other patterning, treatment, etc. of the surface) can provide a number of different appearances, such as geometric patterns, non-repeating appearances, etc. For example, if diagonal channels are used, a ¼ overlap can cause the rain channels to give a diamond appearance, while a ½ overlap can creates a herringbone appearance.

In aspects of the roofing systems, methods, and articles discussed herein, the roof facing surface or bottom of the system can be ventilating, thereby increasing life of the system and reducing heat gain in the attic. Moreover, this feature can be used in combination with others discussed herein, such that a single roofing unit can provide: ventilation, alignment, self cleaning, solar reflectivity, wind up-lift resistance, ease of replaceability, appearance customizability, daylight accommodation, and energy efficiency, along with other advantages that will be apparent to a person of skill in the art in light of the teachings herein. These roofing units can be interconnected as described herein and overlapped to form an efficient roofing system.

To accomplish the foregoing and related ends, certain illustrative aspects of the innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation can be employed and the subject innovation is intended to include all such aspects and their equivalents. Other advantages and novel features of the innovation will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a portion of an example roof in accordance with aspects of the subject innovation.

FIG. 2 is a portion of a roof constructed according to aspects of the subject innovation, showing a section at a rafter.

FIG. 3 is a perspective of the top side of a roofing unit in accordance with aspects of the subject innovation.

FIG. 4 is a perspective of the bottom or substrate facing side of a roofing unit in accordance with aspects of the subject innovation.

FIG. 5A is a perspective of a section of a first roofing unit prior to engagement with a second roofing unit in accordance with aspects of the subject innovation.

FIG. 5B is a perspective at engagement with another roofing unit in accordance with aspects of the subject innovation.

FIG. 6 is a section of two roofing units engaged in an embodiment of the subject innovation.

FIG. 7 is a plan view of two roofing units of an embodiment of the innovation engaged as seen from the bottom.

FIG. 7A shows a perspective view of a cutaway, which highlights example ventilation channels of aspects of the subject innovation.

FIG. 8A shows a perspective view of an example starter from the top view.

FIG. 8B is a perspective of an example starter from the bottom view.

FIG. 9 is a perspective of an example drip edge accordance to aspects of the innovation.

FIG. 10 is a sectioned perspective of a roof showing a substrate, drip edge, starter and roofing unit according to an embodiment of the subject innovation.

FIG. 11 is a plan view showing an example gap for thermal expansion.

FIG. 12 is a plan view of the top of a roofing unit showing locating features according to aspects of the innovation.

FIG. 12A is a detail of an indicator useable for roofing unit position.

FIG. 12B is a detail of a position indicator useable for nailing.

FIG. 12C is a detail of a pilot useable for alignment of a drill for removal of a roofing unit.

FIG. 13 is a roof portion showing a skylight and the visual effect of ¼ and ½ lateral overlap of roofing units in accordance with aspects of the innovation.

FIG. 14 is a flow chart of a method of removal of a roofing unit.

FIG. 15 is a flow chart of a method of installing a replacement roofing unit.

FIG. 16 illustrates a system that can be used to facilitate roof design in accordance with aspects of the subject innovation.

FIG. 17 illustrates a block diagram of a computer operable to execute the disclosed architecture.

DETAILED DESCRIPTION

The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject innovation. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices may be shown in block diagram form in order to facilitate describing the innovation.

In aspects, the innovation includes systems, methods, and articles that can provide roofing systems with numerous advantages, such as improved wind resistance, ventilation, ease of installation and replacement, enhanced lifespan, and other features and advantages discussed herein.

Turning to the figures, FIG. 1 shows a portion of an example roof in accordance with aspects of the subject innovation, illustrating multiple features of various embodiments of the innovation discussed herein, such as a variety of roofing patterns, the optional inclusion of a skylight or windowed section comprising translucent or transparent roofing units, and other aspects discussed herein. A ridge vent is not shown; any of a number of commercially available ridge vents can be used with the subject innovation, such as Air Vent Inc.'s Shingle Vent II®.

FIG. 2 illustrates an example roof portion sectioned at a rafter or other structural member. The supporting structure 20 can comprise a deck of plywood, OSB (Oriented Strand Board) or other commercially acceptable material. The framing substructure 21 can be a rafter, truss chord or other structural beam. Supporting structure 20 can be covered with a layer of a vapor barrier 22, which can be substantially any vapor barrier known in the art, such as a non-asphaltic vapor barrier, Casella Dorken's barrier, Delta Foxx® or equivalent, or can be made of PET (Polyethelene Terathalate) fabric laminated with a membrane. The perimeter of the structure can have a wood fascia 23. In aspects, a perimeter drip edge 24 can be included, and can be manufactured by substantially any means in the art, such as by die punching and roll forming aluminum roll stock, then anodizing and powder coating the surfaces. The drip edge can be as described further herein. A gutter 25 can be mounted to the fascia 23 and below the drip edge 24. At the bottom edge of the roof and over top of the drip edge 24 can be starters 26, which can be fastened end to end for the length of all bottom edges of the roof. A roofing unit 27 can be attached to the starter 26, such as by the attachment method discussed below in connection with FIGS. 5A, 5B & 6.

While, for purposes of illustration, example roofing units (as well as starters, drip edges, and other aspects of the innovation in the following discussion) is shown simultaneously incorporating multiple innovative features discussed herein, it is to be appreciated that various embodiments could incorporate only some or all of the features discussed herein. Additionally, while specific choices were made (e.g., diagonal channels, patterning for ventilation, dimensions, etc.) in order to illustrate an example for purposes of the following discussion, other options such as those discussed herein and those that would be apparent to a person of ordinary skill in the art in light of the teachings herein are also possible and included within the innovation discussed herein.

FIG. 3 is a perspective of the top view of an example roofing unit 27 (alternatively referred to as unit 27) in accordance with aspects of the innovation. Roofing unit 27 can have one or a series of tabs 30 which, in a partially or completely assembled roof as discussed herein, will be the exposed portions of roofing unit 27, and can include a headlap 31 area of the roofing unit. During assembly, the headlap 31 can be covered by the tabs 30 of an adjoining or mating roofing unit. In an example embodiment such as that shown in FIG. 3, roofing unit 27 can comprise four tabs 30 with slots 32 cut into the roofing unit 27, although in other embodiments, more or less tabs or slots can be included. Rain channels 33 can be included across the face of the tabs 33 on a diagonal (e.g., as shown in FIG. 3), curved path, or in some other manner. As shown in FIG. 3, rain channels 33 can extend in opposing directions from one another, or can be patterned in another manner. In some embodiments, these rain channels 33 can be relatively shallow, and in one embodiment can be about 0.040 inches deep and about 0.375 wide, but a range of other widths and depths can be used (although depending on environmental and other factors, some widths and depths may be preferred to others, such as for avoiding particles from being stuck in the channels). Although referred to as rain channels, rain channels 33 can serve multiple purposes: they can provide for conveyance of rain water and particle removal, they can be used to provide any of a plurality of decorative patterns (based at least in part on the channels 33, any patterning or other decorative aspects of roofing unit 27, etc. Across the top of the headlap 31, a series of tines 34 can be included, and the space between these tines provides a location where fasteners can be applied, as discussed in greater detail in connection with FIG. 12 below. In aspects, a declivity or other guidance mechanism 35 (e.g., an offset portion designed to couple with a corresponding portion of another similar roofing unit, such as a depressed portion to couple with a raised portion, vice versa, etc.) can be included to facilitate alignment and engagement of adjoining or mating roofing units to roofing unit 27. A first attachment mechanism such as an opening or tee slot 36 can be included at the end of the declivity 35 and can be an alignment and securing element such as that discussed below in connection with FIGS. 4, 5A, 5B & 6.

FIG. 4 is a bottom perspective of the example roofing unit, showing the side that can be oriented downward, so as to face the deck 20. On the underside of the headlap 31 area can be included a series of ventilation channels 40 that can run both longitudinally and latitudinally. In the example embodiment depicted in FIG. 4, these ventilation channels can be formed by patterning the portion of a roofing unit on the underside of the headlap with raised portions regularly arranged, in rows and columns oriented roughly parallel to the outer edges of the roofing unit, in other embodiments, different patterns of raised portions can be used (e.g., diagonal or other geometric arrangements, irregular arrangements, etc.) while still retaining the functionality of those depicted. A second attachment mechanism, such as a raised portion like bosses 41 can engage with the first the attachment mechanism, such as tee slots 36, and can secure the tabs 30 from lifting in high wind. Optionally, an additional locating mechanism can be included via an at least partially raised or offset inside edge 42 (which can, for example, be formed by a subset of the raised portions providing ventilation channels 40) that can act as a stop and seat, and can facilitate locating and aligning an adjoining roofing unit (e.g., a roofing unit such as roofing unit 27) by making contact with an outside edge 43 of the adjoining roofing unit (which can also, for example, be formed by a subset of the raised portions providing ventilation channels 40).

FIG. 5A is a section of a perspective view of the engagement of two roofing units in accordance with aspects of the subject innovation, showing one optional mechanism of attachment between roofing units. In some embodiments, there can be a plurality of bosses 41 on a roofing unit, such as shown in the example roofing unit in FIG. 4. FIG. 5A illustrates an example attachment mechanism showing one boss before it engages a tee slot 36. Although for purposes of illustration, this particular attachment mechanism is shown, the portions could be other than as displayed in FIG. 5A, such as other attachment mechanism (tabs and slots, clips, etc.). When a new roofing unit is laid upon a series of already positioned roofing units and the new roofing unit is moved laterally across the positioned units, the boss, etc. can drop into a declivity or other guidance mechanism 35, which can align the boss (or other second attachment mechanism, etc.) so as to naturally slide toward the tee slot (or other first attachment mechanism, etc.). The declivity or other guidance mechanism in the unit can facilitate quick alignment and installation, allowing for quicker installation than that involving aligning conventional shingles. FIG. 5B shows the boss at the end of the declivity just before dropping into the tee slot. It is to be appreciated, of course, that in other embodiments, other attachment mechanism can be used to secure roofing units to one another.

FIG. 6 is a cross-sectional view through two roofing units, wherein the cross-section is through the center of the boss or other attachments mechanism so as to show the engagement of the two roofing units, which could be, for example, such as described above in connection with roofing unit 27. For the purpose of distinguishing the units, the lower unit's parts have an (a) following the part number, while part numbers belonging to the upper unit are followed by a (b). Several features incorporated into various embodiments of the innovation are observable in this view. A taper can be included from the inside edge 43b that can narrow to the outside edge 42b, and can be used to facilitate the nesting of roofing units while maintaining the same overall thickness of engaged roofing units. This optional taper can be seen by comparing the height of the ventilation channels 40a at the outside edge 43a with the height of ventilation channels 40b at the inside edge 42b. The taper can also be seen when comparing the height of the boss 41a to the height of the inside edge 42a of the same roofing unit. The taper of the declivity 35b and the drop to tee slot 36b of the unit can also be seen in this view, although other guidance mechanisms or attachment mechanism (or lack thereof) can also be used in various embodiments. FIG. 6 also shows an example of how the boss 41b of the (b) roofing unit can appear when it is engaged with the tee slot 36a of the (a) roofing unit (although of course, other attachment mechanism could be used alternatively or additionally, and may appear differently, as would be understood in light of the disclosure herein). Rain channels 33a & 33b can also be seen from this view, and as shown are relatively shallow, although, as explained herein, other dimensions may be used than those discussed in connection with rain channels 33.

FIG. 7 shows a plan view of two example roofing units engaged as seen from the bottom. In various embodiments, such as that shown in FIG. 7, when a plurality of roofing units is engaged (e.g., a subset of the roofing units, which can comprise all of the roofing units or can be a proper subset, viz. a subset distinct from the set), the area between the deck 20 and the surface of the roof system can be completely ventilated, as can be seen from the alignment of the ventilation channels 40 on each of the roofing units shown in FIG. 7. The alignment between roofing units via inclusion of the optional inside edge 42 and outside edge 43 can also facilitate contiguous ventilation channels 40 such as is shown in FIG. 7.

FIG. 7A is a blow-up view of the highlighted area in FIG. 7 and is being viewed from the bottom looking up. As can be seen in FIG. 7A, in various embodiment a minority of the roofing unit can come in contact with the roof below the roofing unit; in the pattern of FIG. 7A less than 25% of the roofing unit would come into contact with the roof. Also visible in FIG. 7 is that these ventilation channels 40 can occur around the tee slots 36 (or other first attachment mechanism) and that ventilation is not impacted by the engaging of the bosses 41 (or other second attachment mechanism) of the engaged roofing unit above.

FIG. 8A is a perspective of an example starter 26 from a top view. In various embodiments, a starter such as starter 26 can be used as part of a first course in connection with roofing units such as those discussed herein (e.g., roofing unit 27) as part of a roofing system. The starter 26 can have declivities or guidance mechanism 35 similar to those discussed in connection with roofing unit 27 and can have tee slots or first portions of attachment mechanism 36 (again, similar to those discussed in connection with roofing unit 27), and both the declivities or guidance mechanism 35 and the tee slots (or other first attachment mechanism) 36 can be arranged in the same relative location as those of roofing unit 27, discussed above. Inclusion of similar guidance mechanisms and/or attachment mechanism can facilitate coupling of a roofing unit to the starter 26 in a manner substantially similar to that of coupling roofing units to one another, as discussed above. The starter 26 can be secured to the deck 20 with fasteners 80 placed in the openings between the tines 34. The locating of the starters is discussed in greater detail below in connection with FIG. 10. FIG. 8B is a perspective of the example starter 26 from a bottom view. Ventilation channels 40 can cover the entire surface of the starter, and can be substantially similar to the ventilation channels described above in connection with roofing units. Since starter 26 can be a portion of the first course, it does not need to overlap another roofing member. Starter 26 can include an outer edge (e.g., comprised of patterning for ventilation channels) that facilitates alignment of one or more roofing units to starter 26.

FIG. 9 is a portion of an example drip edge 25 in perspective view. The drip edge 25 can comprise a land 93 where the drip edge can be nailed to the deck 20. A lip 90 can be formed by a portion of the drip edge that bends upward and then downward. In one embodiment, an approximately 90° bend up followed by an approximately 180° bend down can form a lip 90 that can be of varying heights, depending on the embodiment (in one embodiment, lip 90 can be approximately 0.075 inches high). A trough 91 can be formed as a portion of drip edge 25. In aspects, trough 91 can vary in size (in one embodiment, trough 91 can be about 0.500 inches deep and the same in width, although either or both can vary independently of each other). Optionally, at the bottom of the trough, there can be sections of screen 92 (e.g., die cut, etc.) or other similar feature (e.g., mesh, netting, etc.) that can permit air to access the entire ventilation system while filtering other material. Inclusion of a screen 92 or other similar feature can limit or prevent access of insects, small particles, etc. to the roof ventilation. The lip 90 can be used as a locating surface for the placement of starters such as starter 26, and can facilitate aligning starters.

FIG. 10 illustrates a perspective view of an example drip edge, starter and roofing unit installed. Drip edge 24 can be secured to the deck, and the starters 26 can be located against the lip 90 of the drip edge 24. With the starters 26 secure, alignment of the starters can be checked before roofing units 27 are installed. Any misalignment of the starters 26 can be corrected before roofing units are installed, which can thereby prevent further misalignment. The bottom portion of roofing units 27 such as tabs (shown in FIG. 3) can overlap the drip edge 24 and can form a ventilation chamber 100.

FIG. 11 illustrates a plan view of two example roofing units being overlapped by another example unit. The bottom units have a portion in dashed lines. As can be seen in FIG. 11, roofing units can by their shape have a separation gap 110 able to accommodate thermal expansion. In aspects, the gap can accommodate 100° F. above the temperature at installation, although other temperature thresholds can be used, depending on various factors (e.g., choice of materials and their corresponding thermal expansions, actual or expected local environmental conditions, etc.).

FIG. 12 is a perspective view showing several locating features that can be included in a roofing unit in aspects of the innovation, and can assist in installation and removal of roofing units. Features that can be incorporated to assist in installation or removal of roofing units include: lateral alignment lines 120, a fastener alignment line 121 and the pilots 122, each of which is included in this view, although in various embodiments, some or all of these features can be included. As discussed above, fasteners 80 can be located and placed between the tines 34.

FIG. 12A shows lateral alignment lines 120 in accordance with aspects of the innovation, wherein the lateral alignment lines can be used to indicate the final position of a roofing unit above, when the roofing unit above is engaged to the roofing unit beneath. In the example of FIG. 12, lines are located with ¼, ⅓ or ½ lateral overlap, although in various embodiments, other lines may alternatively or additionally be included. The differing overlaps (alone or in connection with other features, such as the inclusion and arrangement of rain channels or any patterning on roofing units) can alter the visual appearance produced by a plurality of roofing units, as discussed below in connection with FIG. 13. Attachment mechanism such as the bosses 41 and the tee slots 36 can be located so as to facilitate these variations in placement (e.g., at the fractional lateral overlap as discussed above).

FIG. 12B shows a fastener alignment line 121 that can serve to locate fasteners 80 in a manner whereby damaged units may be removed. As described herein, fasteners can be placed between the tines 34, and the fastener alignment line 121 can be used to indicate a portion of the tines 34 beyond which a fastener 80 may be placed such that the roofing unit may be more readily removed and/or replaced. Because the tines 34 can define open portions of a roofing unit that are not enclosed on the side opposite the tabs 30, placement of fasteners 80 beyond the fastener alignment line 121 can facilitate removal of a roofing unit by sliding or pulling the roofing unit outward, out from under fasteners 80. This removal can be facilitated by virtue of the fact the open portions defined by the times does not need to be enclosed.

FIG. 12C illustrates a pilot 122 that can be used for locating a drill for replacing a roofing unit incorporating the pilot. The pilot can be located opposite a boss or other second attachment mechanism (e.g., at the same location as it, but above it on an upper face of a roofing unit). The replacement of roofing units and the use of the pilots 122 for drilling is discussed in greater detail in connection with FIG. 14. Some or all of these locating devices—the lateral alignment lines 120, the fastener alignment lines 121, and pilots 122—can be included in the same embodiments, and can be significant time savers in field application and removal of this roof system.

FIG. 13 illustrates a portion of an example roof system with roofing units in place, wherein subsequent rows can be positioned with different offsets (e.g., different amounts of lateral overlap). Depending on whether rain channels are included and what pattern they are, as well as any additional patterning that may be used with the roofing units, any of a number of patterns can result from these factors, combined with the ability to vary the offset of the roofing units. For example, with diagonal rain channels, an offset of ½ can cause a herringbone pattern 131 and an offset of ¼ of the roofing unit width can show a diamond pattern (132). With the same diagonal rain channels, an offset of ⅓ may also be used and can have a non-uniform appearance. Other fractional variations (with or without variations in rain channels or patterning) can be used and can result in other patterns, as would be apparent to a person of skill in the art in light of the teachings herein. Additionally, translucent or transparent roofing units can be used to form a skylight 130. The substructure beneath these translucent or transparent roofing units can be framed to permit light entry into the building.

FIG. 14 is a flow chart of a method that can be used to remove a roofing unit, such as when a roofing unit is damaged, or in other situations (e.g., for later installation of a skylight, roofing units can be removed, substructure can be framed, and translucent or transparent roofing units can be installed in place of the removed roofing units). Accordingly, although the method discusses the removal of a damaged roofing unit, it is to be appreciated that this method can be used for removal of roofing units for substantially any reason, whether or not they are damaged. At step 1410, a square punch with a center point or another similar tool can be used to knock out or break the bosses or other similar portions of an attachment mechanism (e.g., comprising a first and second attachment mechanism as discussed above) of the damaged roofing unit(s), thus freeing the damaged roofing unit from a lower unit (e.g., another roofing unit, a starter, etc.). Optionally, if pilots are included in the roofing unit to be removed, the pilot can facilitate alignment of the square punch, etc. to simplify removal of the damaged roofing unit. At step 1420, the outer edge or tabs of the damaged roofing unit can be lifted. If the damaged roofing unit includes ventilation channels, the roofing unit can be lifted until the inside edge on the underside of the roofing unit is free. Additionally, at 1420, the damaged roofing unit can be pulled out partially until it stops due to the attachment mechanism coupling the damaged roofing unit to an upper unit (e.g., the roofing unit above it, etc.). For example, if the attachment mechanism includes tee slots and bosses, the damaged unit can stop where the bosses of the upper unit are aligned with the openings of the tee slots of the damaged roofing unit. At step 1430, the upper unit can be raised (e.g., by raising the tabs of the upper unit if it is a roofing unit) to detach the attachment mechanism by lifting the upper unit until the attachment mechanism of the upper unit is free of the damaged unit, freeing the damaged roofing unit from the upper unit. At step 1440, the damaged roofing unit can be pulled out. Fasteners attaching the damaged roofing unit to the roof may offer some resistance, and if necessary, mechanical means (e.g., pliers, etc.) can be used to facilitate removal of the damaged roofing unit. For example, the damaged unit can be pulled outward (optionally with the assistance of mechanical means, etc.) until each of the one or more fasteners are free of a tined portion of the first roofing unit.

FIG. 15 illustrates a flow chart of a method that can be used to install a replacement roofing unit. The method of FIG. 15 can be used to install a replacement roofing unit after removal of a roofing unit (e.g., a damaged roofing unit, as part of an installation of a skylight, etc.). If necessary, at step 1510, fasteners (e.g., nails, etc.) attached to the roof (e.g., remaining after removal of a damaged roofing unit, etc.) can be raised away from the roof to permit installation of the replacement roofing unit. A tapered wedge or other similar tool can be used to raise the fasteners. At step 1520, the replacement roofing unit can be slid into place between an upper unit (e.g., the roofing unit formerly above the damaged roofing unit, etc.) and a lower unit (e.g., a starter, the roofing unit formerly below the damaged roofing unit, etc.). At step 1530, the replacement unit can be pushed far enough in so that the bosses (or corresponding portions of the attachment mechanism) from the upper unit can be engaged with the tee slots (or corresponding portions of the attachment mechanism) of the replacement roofing unit. Once all of the attachment mechanism (e.g., bosses and tee slots) are engaged or seated, the replacement unit can be pulled down (e.g., with sheet metal pliers or other similar tools as needed). At step 1540, the fasteners (nails, etc.) can be set again to secure the replacement roofing unit. This can be accomplished by hammering them back down. To avoid damage to the upper unit, a wooden block or other similar article can be used to distribute the force over the surface of the upper unit, for example by placing the block, etc. at the bottom of the tab of the upper unit and hitting the block, etc. with a sharp blow.

FIG. 16 illustrates a system 1600 that can be used to facilitate roof design in accordance with aspects of the subject innovation. In aspects, designs of roofs according to aspects of the subject innovation can be automatically designed by system 1600, which can in embodiments be provided via any of a variety of computing platforms, including as an application run on a mobile device, smart phone, etc. Various information can be provided in system 1600, such as a specification of a roof 1602, for example including dimensions of the roof (length, width, height, slope, etc., as well as requirements related to other features (e.g., chimneys, awnings, etc.)), a requested appearance 1604 (e.g., one or more patterns, colors, etc. requested by, for example, a homeowner, etc.), and one or more optional features 1606 (e.g., a skylight or other special portions of a roof, etc.). This information can be delivered to a roof design component 1608, and be received by receiving component 1610. The information can then be provided to analysis component 1612, which can determine based at least in part on the provided information one or more of arrangements or types of roofing units that could accommodate the provided information. Configuration component 1614 can configure a specification or a presentation based at least in part on the determination of analysis component 1612. Based on the configured specification or presentation, roof design component 1608 can output a roof design specification or presentation 1616 in any of a variety of formats, for example, as a visual display, etc.

Referring now to FIG. 17, there is illustrated a block diagram of a computer operable to execute the disclosed architecture. In order to provide additional context for various aspects of the subject innovation, FIG. 17 and the following discussion are intended to provide a brief, general description of a suitable computing environment 1700 in which the various aspects of the innovation can be implemented. While the innovation has been described above in the general context of computer-executable instructions that may run on one or more computers, those skilled in the art will recognize that the innovation also can be implemented in combination with other program modules and/or as a combination of hardware and software.

Generally, program modules include routines, programs, components, data structures, etc., that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the innovative methods can be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which can be operatively coupled to one or more associated devices.

The illustrated aspects of the innovation may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules can be located in both local and remote memory storage devices.

A computer typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computer and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media can comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the computer.

Communication media typically embodies computer-readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism, and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer-readable media.

With reference again to FIG. 17, the exemplary environment 1700 for implementing various aspects of the innovation includes a computer 1702, the computer 1702 including a processing unit 1704, a system memory 1706 and a system bus 1708. The system bus 1708 couples system components including, but not limited to, the system memory 1706 to the processing unit 1704. The processing unit 1704 can be any of various commercially available processors. Dual microprocessors and other multi-processor architectures may also be employed as the processing unit 1704.

The system bus 1708 can be any of several types of bus structure that may further interconnect to a memory bus (with or without a memory controller), a peripheral bus, and a local bus using any of a variety of commercially available bus architectures. The system memory 1706 includes read-only memory (ROM) 1710 and random access memory (RAM) 1712. A basic input/output system (BIOS) is stored in a non-volatile memory 1710 such as ROM, EPROM, EEPROM, which BIOS contains the basic routines that help to transfer information between elements within the computer 1702, such as during start-up. The RAM 1712 can also include a high-speed RAM such as static RAM for caching data.

The computer 1702 further includes an internal hard disk drive (HDD) 1714 (e.g., EIDE, SATA), which internal hard disk drive 1714 may also be configured for external use in a suitable chassis (not shown), a magnetic floppy disk drive (FDD) 1716, (e.g., to read from or write to a removable diskette 1718) and an optical disk drive 1720, (e.g., reading a CD-ROM disk 1722 or, to read from or write to other high capacity optical media such as the DVD). The hard disk drive 1714, magnetic disk drive 1716 and optical disk drive 1720 can be connected to the system bus 1708 by a hard disk drive interface 1724, a magnetic disk drive interface 1726 and an optical drive interface 1728, respectively. The interface 1724 for external drive implementations includes at least one or both of Universal Serial Bus (USB) and IEEE 1394 interface technologies. Other external drive connection technologies are within contemplation of the subject innovation.

The drives and their associated computer-readable media provide nonvolatile storage of data, data structures, computer-executable instructions, and so forth. For the computer 1702, the drives and media accommodate the storage of any data in a suitable digital format. Although the description of computer-readable media above refers to a HDD, a removable magnetic diskette, and a removable optical media such as a CD or DVD, it should be appreciated by those skilled in the art that other types of media which are readable by a computer, such as zip drives, magnetic cassettes, flash memory cards, cartridges, and the like, may also be used in the exemplary operating environment, and further, that any such media may contain computer-executable instructions for performing the methods of the innovation.

A number of program modules can be stored in the drives and RAM 1712, including an operating system 1730, one or more application programs 1732, other program modules 1734 and program data 1736. All or portions of the operating system, applications, modules, and/or data can also be cached in the RAM 1712. It is appreciated that the innovation can be implemented with various commercially available operating systems or combinations of operating systems.

A user can enter commands and information into the computer 1702 through one or more wired/wireless input devices, e.g., a keyboard 1738 and a pointing device, such as a mouse 1740. Other input devices (not shown) may include a microphone, an IR remote control, a joystick, a game pad, a stylus pen, touch screen, or the like. These and other input devices are often connected to the processing unit 1704 through an input device interface 1742 that is coupled to the system bus 1708, but can be connected by other interfaces, such as a parallel port, an IEEE 1394 serial port, a game port, a USB port, an IR interface, etc.

A monitor 1744 or other type of display device is also connected to the system bus 1708 via an interface, such as a video adapter 1746. In addition to the monitor 1744, a computer typically includes other peripheral output devices (not shown), such as speakers, printers, etc.

The computer 1702 may operate in a networked environment using logical connections via wired and/or wireless communications to one or more remote computers, such as a remote computer(s) 1748. The remote computer(s) 1748 can be a workstation, a server computer, a router, a personal computer, portable computer, microprocessor-based entertainment appliance, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer 1702, although, for purposes of brevity, only a memory/storage device 1750 is illustrated. The logical connections depicted include wired/wireless connectivity to a local area network (LAN) 1752 and/or larger networks, e.g., a wide area network (WAN) 1754. Such LAN and WAN networking environments are commonplace in offices and companies, and facilitate enterprise-wide computer networks, such as intranets, all of which may connect to a global communications network, e.g., the Internet.

When used in a LAN networking environment, the computer 1702 is connected to the local network 1752 through a wired and/or wireless communication network interface or adapter 1756. The adapter 1756 may facilitate wired or wireless communication to the LAN 1752, which may also include a wireless access point disposed thereon for communicating with the wireless adapter 1756.

When used in a WAN networking environment, the computer 1702 can include a modem 1758, or is connected to a communications server on the WAN 1754, or has other means for establishing communications over the WAN 1754, such as by way of the Internet. The modem 1758, which can be internal or external and a wired or wireless device, is connected to the system bus 1708 via the serial port interface 1742. In a networked environment, program modules depicted relative to the computer 1702, or portions thereof, can be stored in the remote memory/storage device 1750. It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers can be used.

The computer 1702 is operable to communicate with any wireless devices or entities operatively disposed in wireless communication, e.g., a printer, scanner, desktop and/or portable computer, portable data assistant, communications satellite, any piece of equipment or location associated with a wirelessly detectable tag (e.g., a kiosk, news stand, restroom), and telephone. This includes at least Wi-Fi and Bluetooth™ wireless technologies. Thus, the communication can be a predefined structure as with a conventional network or simply an ad hoc communication between at least two devices.

Wi-Fi, or Wireless Fidelity, allows connection to the Internet from a couch at home, a bed in a hotel room, or a conference room at work, without wires. Wi-Fi is a wireless technology similar to that used in a cell phone that enables such devices, e.g., computers, to send and receive data indoors and out; anywhere within the range of a base station. Wi-Fi networks use radio technologies called IEEE 802.11(a, b, g, etc.) to provide secure, reliable, fast wireless connectivity. A Wi-Fi network can be used to connect computers to each other, to the Internet, and to wired networks (which use IEEE 802.3 or Ethernet). Wi-Fi networks operate in the unlicensed 2.4 and 5 GHz radio bands, at an 11 Mbps (802.11a) or 54 Mbps (802.11b) data rate, for example, or with products that contain both bands (dual band), so the networks can provide real-world performance similar to the basic 10BaseT wired Ethernet networks used in many offices.

Systems, methods and articles of the subject innovation provide multiple potential advantages in various embodiments. For example, ventilation can be incorporated into the design of the roofing units, obviating the need for multiple layers that are necessary to add ventilation in prior systems. Cost savings can thus accrue from both labor and material. Additionally, a matte surface that is highly reflective of solar radiation can be readily applied to roofing units of the subject innovation, which (alone or when coupled with ventilation) can greatly reduce heat entry into the attic of the structure. Moreover, the surface can be patterned to include rain channels as described herein, such that rain more freely flows without trapping particles as in a granular roof, resulting in a cleaner roof as compared with conventional systems. These features can contribute to a cool roof rating being maintained much longer than with prior systems.

In other aspects, the inclusion of attachment mechanism (e.g., the mechanism of interlocking the bosses with tee slots, etc.) can greatly enhance wind uplift resistance. The attachment mechanism described herein (e.g., the interlocking boss and tee slot mechanism) is very fast to install due to the guiding mechanism (e.g., declivities), which facilitate easy locating and positioning of roofing units.

Moreover, as described herein, in the event of damage to a roofing unit (or other reasons necessitating replacement), it can be removed without requiring removal of any other roofing units. In other aspects, translucent or transparent roofing units can be used to constructs skylights by laying these translucent or transparent units in a pattern and framing the area underneath.

Additionally, systems, methods, and articles of the subject innovation can use recycled materials (e.g., recycled plastics, recycled aluminum, etc.) for construction of roofing units, spacers, and other articles disclosed herein. Materials of construction used to construct these articles may be any acceptable composite that has sufficient UV resistance to degradation. The use of recycled materials for fabrication of articles of the subject innovation can reduce the environmental impact of roofing, providing a green alternative to conventional systems.

CONCLUSION, RAMIFICATION, AND SCOPE

Accordingly the reader will see that, in various embodiments, systems, methods, and articles are provided that have numerous advantages over conventional systems in terms of construction, wind resistance, reduced cost in labor and materials, as well as the ability to minimize the impact on the environment. Multiple advantageous and innovative features disclosed herein can be incorporated into a single roofing unit, or into a single roof comprising one or more of roofing units such as those disclosed herein, starters such as those disclosed herein, or drip edges such as those disclosed herein.

Further, systems, methods, and articles of the subject innovation comprise multiple features or aspects that can have a positive environmental impact in the following ways. For example, material may be at least partially composed of recycled plastics, metals, etc. Ventilation channels can be included in the roofing units, which will have a cooling effect in the attic, thereby reducing air conditioning load and its corresponding environmental impact. Additionally, solar reflectance will be higher than conventional roofs and may be considerably higher, depending on selection of materials and properties (e.g., color, finish, etc.). Also, in some aspects, the non-toxic roof can be utilized to allow the collection of rain water, which can be used for a variety of purposes.

Systems, methods, and articles of the subject innovation, in various aspects, provide numerous advantages and features not present in conventional systems. For example, a mechanical hold down near the front edge (e.g., via an attachment mechanism, such as the boss and tee slot, etc.) can give very high wind uplift resistance. Additionally, attachment mechanism discussed herein, such as the locator bosses and tee slots, can allow for quick installation and accurate alignment. Further, gaps can be incorporated into the alignment of the roofing units discussed herein, and thus can provide for thermal expansion between roofing units. Moreover, in aspects, the method of securing the roofing units can enable the removal of single roofing units in the event of damage, without necessitating the removal of adjacent roofing units. Replacement of a single roofing unit can also be easily accomplished by means of the features and methods discussed herein for securing and fastening roofing units.

Many other ramifications and variations are possible within the teaching of the various embodiments and aspects discussed herein. For example, since different pigments may be used, this system may be manufactured in a variety of colors. Translucent colors may be used for applications involving commercial awnings.

In other words, what has been described above includes examples of the innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject innovation, but one of ordinary skill in the art may recognize that many further combinations and permutations of the innovation are possible. Accordingly, the innovation is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.

Claims

1. A roofing system, comprising:

at least one starter that comprises one or more first attachment mechanisms; and

at least one roofing unit that comprises one or more first attachment mechanisms and one or more second attachment mechanisms, wherein each of the second attachment mechanisms is configured to attach with any of the first attachment mechanisms.

2. The roofing system of claim 1, wherein the first attachment mechanisms are tee slots, the second attachment mechanisms are bosses configured to engage with any of the tee slots.

3. The roofing system of claim 1, wherein each of the at least one roofing units further comprises one or more guidance mechanisms that aligns the one or more first attachment mechanisms with the one or more second attachment mechanisms.

4. The roofing system of claim 1, wherein the at least one starter and the at least one roofing each comprise an underside, wherein the underside comprises patterning defining one or more ventilation channels.

5. The roofing system of claim 4, wherein the underside of each of the at least one roofing units comprises an offset inner edge and an outer edge, wherein each of the inner edges is configured to align with each of the outer edges.

6. The roofing system of claim 1, wherein each of the at least one roofing units comprises rain channels configured to direct water from the at least one roofing unit.

7. The roofing system of claim 1, further comprising a drip edge, wherein the drip edge facilitates alignment of the at least one starter.

8. The roofing system of claim 1, wherein one or more of the at least one starter or the at least one roofing unit comprises recycled material.

9. The roofing system of claim 1, wherein the at least one roofing unit comprises a matte finish.

10. The roofing system of claim 1, wherein the at least one roofing unit comprises a plurality of tines that facilitate at least one of installation or removal of the at least one roofing unit.

11. A method, comprising:

securing one or more starters to a roof, wherein each starter comprises one or more tee slots;

securing one or more roofing units to a roof, wherein each roofing unit comprises one or more tee slots and one or more bosses; and

engaging each of the one or more bosses with one of the one or more tee slots.

12. The method of claim 11, wherein securing the one or more roofing units comprises creating one or more ventilation channels, wherein the one or more ventilation channels are created based at least in part on a pattern on an underside of a subset of the one or more roofing units.

13. The method of claim 11, wherein securing the one or more roofing units comprises applying one or more fasteners through tines of each of the one or more roofing units.

14. The method of claim 11, further comprising aligning the one or more starters with a drip edge.

15. The method of claim 11, wherein securing the one or more roofing units comprises aligning an offset inner edge of each of the one or more roofing units with an outer edge, wherein the outer edge is one or more of an outer edge of another of the one or more roofing units or an outer edge of one of the one or more starters.

16. The method of claim 11, wherein the one or more roofing units comprise at least one translucent or transparent roofing unit, and securing the one or more roofing units comprises creating a skylight based at least in part on arranging the one or more translucent or transparent roofing unit.

17. A method, comprising:

breaking one or more bosses that secure a first roofing unit to a lower unit below the first roofing unit, wherein the first roofing unit is secured to an upper roofing unit above the first roofing unit, and wherein the first roofing unit is secured to a roof by one or more fasteners;

detaching the first roofing unit from the upper unit; and

removing the first roofing unit by pulling the first roofing unit outward.

18. The method of claim 17, wherein detaching the first roofing unit from the upper unit comprises:

pulling the first roofing unit outward; and

lifting the upper unit until one or more upper bosses of the upper unit are free of the first roofing unit.

19. The method of claim 17, wherein removing the first roofing unit comprises sliding the first roofing unit outward until each of the one or more fasteners are free of a tined portion of the first roofing unit.

20. The method of claim 17, further comprising:

sliding a portion of a second roofing unit under the one or more fasteners;

aligning one or more upper bosses of the upper unit with one or more tee slots of the second roofing unit; and

securing the second roofing unit, wherein securing the second roofing unit comprises resetting the one or more fasteners.