F-Shape Rake Edge Metal for Asphalt Shingle Roof Systems

Abstract

A roof system includes a roof deck including a rake edge, an underlayment, a plurality of asphalt shingles, and a one-piece metal apparatus. The one-piece metal apparatus includes a stem, an upper arm, and a lower arm that form an F-shape. The upper arm and lower arm of the one-piece metal apparatus are above the underlayment, and the stem is situated outside and adjacent to the rake edge of the roof deck. The stem, the upper arm, and the lower arm form a three-sided space to accept a thickness of the overlapping rows of the plurality of asphalt shingles. The end of the overlapping rows of the plurality of asphalt shingles are situated within the space formed by the stem, the upper arm, and the lower arm of the one-piece metal apparatus.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Section 111(a) application relating to and claiming the benefit of commonly-owned, co-pending U.S. Provisional Patent Application Ser. No. 63/430,153, filed Dec. 5, 2022, entitled “F-Shaped Rake Edge Metal for Asphalt Shingle Roof Systems,” the contents of which is incorporated herein by reference in its entirety.

FIELD OF INVENTION

The present invention relates to an asphalt shingle roof system and an apparatus for use with an asphalt shingle roof system. More particularly, the present invention relates to an asphalt shingle roof system including an F-shape metal apparatus installed along a rake edge of a roof deck of the asphalt shingle roof system, wherein the F-shape metal apparatus is configured to accept a thickness of overlapping rows of asphalt shingles.

BACKGROUND

Wind damage to asphalt shingle roof systems often occurs at a rake edge of a roof deck of the asphalt shingle roof systems. A need exists for an improved asphalt shingle roof system that overcomes the drawbacks of the existing asphalt shingle roof systems.

SUMMARY

In some embodiments, a roof system comprises a roof deck, wherein the roof deck comprises a rake edge, an underlayment, wherein the underlayment is above the roof deck, a plurality of asphalt shingles, wherein the plurality of asphalt shingles are above the underlayment, and wherein the plurality of asphalt shingles comprise overlapping rows, wherein the overlapping rows of the plurality of asphalt shingles have a thickness, and wherein the overlapping rows of the plurality of asphalt shingles have an end at the rake edge of the roof deck, and a one-piece metal apparatus, wherein the one-piece metal apparatus comprises a stem, an upper arm, and a lower arm, wherein the stem, the upper arm, and the lower arm form an F-shape, wherein the upper arm and lower arm of the one-piece metal apparatus are above the underlayment, wherein the stem of the one-piece metal apparatus is situated outside and adjacent to the rake edge of the roof deck, wherein the stem, the upper arm, and the lower arm are configured to form a three-sided space to accept the thickness of the overlapping rows of the plurality of asphalt shingles, and wherein the end of the overlapping rows of the plurality of asphalt shingles are situated within the space formed by the stem, the upper arm, and the lower arm of the one-piece metal apparatus.

In some embodiments, the one-piece metal apparatus comprises aluminum, aluminum alloy, copper, copper alloy, steel, or steel alloy.

In some embodiments, the one-piece metal apparatus comprises an aluminum alloy extrudate.

In some embodiments, the upper arm has a length, the lower arm has a length, and the length of the lower arm is greater than the length of the upper arm.

In some embodiments, the lower arm has a thickness, and the thickness of the lower arm is configured to allow the lower arm to be mechanically fastened to the roof deck with a standard roofing fastener.

In some embodiments, the roof system comprises a structure supporting the roof deck, and wherein the stem of the one-piece metal apparatus comprises a bottom portion that is angled away from the upper arm and the lower arm and is configured to divert water away from the structure supporting the roof deck.

In some embodiments, the rake edge of the roof deck has a length, and wherein the one-piece metal apparatus has a length that is substantially equal to the length of the rake edge.

In some embodiments, a roof system comprises a roof deck, wherein the roof deck comprises a rake edge, wherein the rake edge of the roof deck has a length, an underlayment, wherein the underlayment is above the roof deck, a plurality of asphalt shingles, wherein the plurality of asphalt shingles are above the underlayment, wherein the plurality of asphalt shingles comprise overlapping rows, wherein the overlapping rows of the plurality of asphalt shingles have a thickness, and wherein the overlapping rows of the plurality of asphalt shingles have an end at the rake edge of the roof deck, and a one-piece metal apparatus, wherein the one-piece metal apparatus comprises a stem, an upper arm, and a lower arm, wherein the stem, the upper arm, and the lower arm form an F-shape, wherein the upper arm has a length, the lower arm has a length, and the length of the lower arm is greater than the length of the upper arm, wherein the lower arm has a thickness, wherein the thickness of the lower arm is configured to allow the lower arm to be mechanically fastened to the roof deck with a standard roofing fastener, wherein the stem, the upper arm, and the lower arm are configured to form a three-sided space to accept the thickness of the overlapping rows of the plurality of asphalt shingles, wherein the stem of the one-piece metal apparatus comprises a bottom portion that is angled away from the upper arm and the lower arm and is configured to divert water away from a structure supporting a roof deck, wherein the one-piece metal apparatus has a length that is substantially equal to the length of the rake edge, wherein the one-piece metal apparatus comprises an aluminum alloy extrudate, wherein the upper arm and the lower arm of the one-piece metal apparatus are above the underlayment, wherein the stem of the one-piece metal apparatus is situated outside and adjacent to the rake edge of the roof deck, wherein the end of the overlapping rows of the plurality of asphalt shingles are situated within the space formed by the stem, the upper arm, and the lower arm of the one-piece metal apparatus, and wherein the lower arm of the one-piece metal apparatus is fastened to the roof deck with a standard roofing fastener.

In some embodiments, an apparatus comprises a one-piece metal apparatus comprising a stem, an upper arm, and a lower arm, wherein the stem, the upper arm, and the lower arm form an F-shape, wherein the stem, the upper arm, and the lower arm form a three-sided space that is configured to accept a thickness of overlapping rows of a plurality of asphalt shingles.

In some embodiments, the one-piece metal apparatus comprises aluminum, aluminum alloy, copper, copper alloy, steel, or steel alloy.

In some embodiments, the one-piece metal apparatus comprises an aluminum alloy extrudate.

In some embodiments, the upper arm has a length, the lower arm has a length, and the length of the lower arm is greater than the length of the upper arm.

In some embodiments, the lower arm has a thickness, and the thickness of the lower arm is configured to allow the lower arm to be mechanically fastened to the roof deck with a standard roofing fastener.

In some embodiments, the stem of the one-piece metal apparatus comprises a bottom portion that is angled away from the upper arm and the lower arm and is configured to divert water away from a structure supporting a roof deck.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a structure with a gable-style asphalt shingle roof system.

FIG. 2 shows a cross-sectional cutaway view of an asphalt shingle roof system.

FIG. 3 shows a cross-sectional view of an asphalt single roof system.

DETAILED DESCRIPTION

The present invention will be further explained with reference to the attached drawings, wherein like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention. Further, some features may be exaggerated to show details of particular components.

In addition, any measurements, specifications and the like shown in the figures are intended to be illustrative, and not restrictive. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the following description taken in conjunction with the figures; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention which are intended to be illustrative, and not restrictive.

Throughout the specification and embodiments, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases “in one embodiment” and “in some embodiments” as used herein do not necessarily refer to the same embodiment(s), though they may. Furthermore, the phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although they may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.

Throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.” Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like, are used for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It is further understood that the terms “front” and “back” are not intended to be limiting and are intended to be interchangeable where appropriate. The terms “comprise” and/or “comprising,” specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term “plurality” means more than one.

As used herein, the phrase “rake edge” refers to an inclined edge of gable-style roof planes. A gable-style roof has two sloping sides that meet at the top.

As used herein, the phrase “F-shape” means substantially shaped like a letter “F” from at least one perspective. An “F-shape” includes a shape comprising a vertical stem, an upper arm, and a lower arm that forms a three-sided space. In some embodiments, the upper arm and lower arm may be of equal length. In some embodiments, the lower arm may be longer than the upper arm, and vice versa.

As used herein, the term “extrudate” means a material that has been extruded through a die.

FIG. 1 is an exploded view of a structure comprising a gable-style asphalt shingle roof system. The roof system comprises a roof deck 100. The roof deck 100 includes rake edges 110.

FIG. 2 shows a cross-sectional cutaway view of an asphalt shingle roof system. FIG. 3 shows a cross-sectional view of an asphalt single roof system.

As shown, the roof system comprises a roof deck 100. The roof deck 100 includes a rake edge 110. In some embodiments, the roof system includes an underlayment 200 above the roof deck 100. In some embodiments, the roof system further comprises a plurality of asphalt shingles 300. The plurality of asphalt shingles 300 include overlapping rows 310 and 320. The overlapping rows 310 and 320 of the plurality of asphalt shingles 300 have a thickness. The overlapping rows 310 and 320 of the plurality of asphalt shingles 300 have an end at the rake edge 110 of the roof deck 100.

The roof system includes a one-piece metal apparatus 400. In some embodiments, the one-piece metal apparatus 400 comprises a stem 410, an upper arm 420, and a lower arm 430. In some embodiments, the upper arm 420 has a length, and the lower arm 430 has a length. In some embodiments, the length of the lower arm 430 is greater than the length of the upper arm 420. The stem 410, the upper arm 420, and the lower arm 430 form an F-shape. In some embodiments, the stem 410 includes a bottom portion 440 that is angled away from the rake edge 110 of the roof deck 100. In some embodiments, the stem 410 of the one-piece metal apparatus 400 comprises a bottom portion 440 that is angled away from the upper arm 420 and the lower arm 420 configured to divert water away from a structure supporting the roof deck 100.

In some embodiments, the upper arm 420 and lower arm 430 of the one-piece metal apparatus 400 are above the underlayment 200. In some embodiments, the stem 410 of the one-piece metal apparatus 400 is situated outside and adjacent to the rake edge 110 of the roof deck 100. The stem 410, the upper arm 420, and the lower arm 420 are configured to form a three-sided space to accept the thickness of the overlapping rows 310 and 320 of the plurality of asphalt shingles 300. In some embodiments, the end of the overlapping rows 310 and 320 of the plurality of asphalt shingles 300 are situated within the space formed by the stem 410, the upper arm 420, and the lower arm 430 of the one-piece metal apparatus 400.

In some embodiments, the lower arm 430 has a thickness, and the thickness of the lower arm 430 is configured to allow the lower arm 430 to be mechanically fastened to the roof deck 100 with a standard roofing fastener. In some embodiments, the one-piece metal apparatus 400 is mechanically fastened to the roof deck 100 with a standard roofing fastener 500. In some embodiments, the standard roofing fastener 500 penetrates the lower arm 430 of the one-piece metal apparatus 400 and the roof deck 100.

In some embodiments, the rake edge 110 of the roof deck 100 is flush with a surface 600 of a structure supporting the roof deck. In some embodiments, the surface 600 includes a fascia board, or an exterior wall of the structure. In some embodiments, the exterior wall comprises sheathing, or siding.

In some embodiments, the rake edge 110 of the roof deck 100 has a length, and the one-piece metal apparatus 400 has a length that is substantially equal to the length of the rake edge 110.

In some embodiments, the roof deck 100 comprises plywood, oriented strand board, or wood.

In some embodiments, the underlayment 200 comprises asphalt-saturated felt, fiberglass-reinforced felt, fire-resistant underlayment, or a synthetic underlayment. In some embodiments, the underlayment 300 includes Shingle-Mate®, Versashield®, Deck-Armor™, Tiger Paw™, or Feltbuster™ underlayments from GAF, or other similar commercially available asphalt shingle underlayments.

In some embodiments, the plurality of asphalt shingles 300 include three-tab shingles, architectural shingles, or designer shingles. In some embodiments, the plurality of asphalt shingles 300 include Timberline® roofing shingles from GAF, or other similar commercially available shingles.

In some embodiments, the one-piece metal apparatus 400 comprises aluminum, aluminum alloy, copper, copper alloy, steel, or steel alloy. In some embodiments, the one-piece metal apparatus 400 comprises an aluminum alloy extrudate.

In some embodiments the standard roofing fastener 500 includes a screw or a nail.

While a number of embodiments of the present invention have been described, it is understood that these embodiments are illustrative only, and not restrictive, and that many modifications may become apparent to those of ordinary skill in the art.

Claims

1. A roof system comprising:

a roof deck, wherein the roof deck comprises a rake edge,

an underlayment, wherein the underlayment is above the roof deck,

a plurality of asphalt shingles, wherein the plurality of asphalt shingles are above the underlayment, wherein the plurality of asphalt shingles comprise overlapping rows, wherein the overlapping rows of the plurality of asphalt shingles have a thickness, and wherein the overlapping rows of the plurality of asphalt shingles have an end at the rake edge of the roof deck, and

a one-piece metal apparatus, wherein the one-piece metal apparatus comprises a stem, an upper arm, and a lower arm, wherein the stem, the upper arm, and the lower arm form an F-shape, wherein the stem, the upper arm, and the lower arm are configured to form a three-sided space to accept the thickness of the overlapping rows of the plurality of asphalt shingles,

wherein the upper arm and the lower arm of the one-piece metal apparatus are above the underlayment,

wherein the stem of the one-piece metal apparatus is situated outside and adjacent to the rake edge of the roof deck, and

wherein the end of the overlapping rows of the plurality of asphalt shingles are situated within the space formed by the stem, the upper arm, and the lower arm of the one-piece metal apparatus.

2. The roof system of claim 1, wherein the one-piece metal apparatus comprises aluminum, aluminum alloy, copper, copper alloy, steel, or steel alloy.

3. The roof system of claim 2, wherein the one-piece metal apparatus comprises an aluminum alloy extrudate.

4. The roof system of claim 1, wherein the upper arm has a length, the lower arm has a length, and the length of the lower arm is greater than the length of the upper arm.

5. The roof system of claim 1, wherein the lower arm has a thickness, and the thickness of the lower arm is configured to allow the lower arm to be mechanically fastened to the roof deck with a standard roofing fastener.

6. The roof system of claim 1, wherein the stem of the one-piece metal apparatus comprises a bottom portion that is angled away from a rake edge of the roof deck.

7. The roof system of claim 1, wherein the rake edge of the roof deck has a length, and wherein the one-piece metal apparatus has a length that is substantially equal to the length of the rake edge.

8. A roof system comprising:

a roof deck, wherein the roof deck comprises a rake edge, wherein the rake edge of the roof deck has a length,

an underlayment, wherein the underlayment is above the roof deck,

a plurality of asphalt shingles, wherein the plurality of asphalt shingles are above the underlayment, wherein the plurality of asphalt shingles comprise overlapping rows, wherein the overlapping rows of the plurality of asphalt shingles have a thickness, and wherein the overlapping rows of the plurality of asphalt shingles have an end at the rake edge of the roof deck, and

a one-piece metal apparatus, wherein the one-piece metal apparatus comprises a stem, an upper arm, and a lower arm, wherein the stem, the upper arm, and the lower arm form an F-shape, wherein the upper arm has a length, the lower arm has a length, and the length of the lower arm is greater than the length of the upper arm, wherein the lower arm has a thickness,  wherein the thickness of the lower arm is configured to allow the lower arm to be mechanically fastened to the roof deck with a standard roofing fastener, wherein the stem, the upper arm, and the lower arm are configured to form a three-sided space to accept the thickness of the overlapping rows of the plurality of asphalt shingles, wherein the stem of the one-piece metal apparatus comprises a bottom portion that is angled away from the upper arm and the lower arm and is configured to divert water away from a structure supporting a roof deck, wherein the one-piece metal apparatus has a length that is substantially equal to the length of the rake edge, wherein the one-piece metal apparatus comprises an aluminum alloy extrudate,

wherein the upper arm and the lower arm of the one-piece metal apparatus are above the underlayment,

wherein the stem of the one-piece metal apparatus is situated outside and adjacent to the rake edge of the roof deck,

wherein the end of the overlapping rows of the plurality of asphalt shingles are situated within the space formed by the stem, the upper arm, and the lower arm of the one-piece metal apparatus, and

wherein the lower arm of the one-piece metal apparatus is fastened to the roof deck with a standard roofing fastener.

9. An apparatus comprising,

a one-piece metal apparatus comprising

a stem,

an upper arm, and

a lower arm, wherein the stem, the upper arm, and the lower arm form an F-shape, wherein the stem, the upper arm, and the lower arm form a three-sided space that is configured to accept a thickness of overlapping rows of a plurality of asphalt shingles.

10. The apparatus of claim 9, wherein the one-piece metal apparatus comprises aluminum, aluminum alloy, copper, copper alloy, steel, or steel alloy.

11. The apparatus of claim 10, wherein the one-piece metal apparatus comprises an aluminum alloy extrudate.

12. The apparatus of claim 9, wherein the upper arm has a length, the lower arm has a length, and the length of the lower arm is greater than the length of the upper arm.

13. The apparatus of claim 9, wherein the lower arm has a thickness, and the thickness of the lower arm is configured to allow the lower arm to be mechanically fastened to the roof deck with a standard roofing fastener.

14. The apparatus claim 9, wherein the stem of the one-piece metal apparatus comprises a bottom portion that is angled away from the upper arm and the lower arm and is configured to divert water away from a structure supporting a roof deck.