U-Channel Roof Connector

Abstract

The present invention offers a u-shaped device for securely connecting ridge cap, hip cap, and sidewall trim to raised seam roof structures. The device comprises a set of flanges that interlock with the roofing trim in a manner that allows for thermal expansion. The u-channel connector features a series of slots along the length of the device to accommodate the geometry of the raised seam, eliminating the need to cut individual connectors between roof seams. The symmetrical configuration of the device enables installation of the trim in either direction, removing concerns about orientation.

Description

BACKGROUND OF THE INVENTION

The invention relates to an improved connector for side wall trim, hip cap trim, and ventilated ridge caps used in standing metal seam roofing. Raised seam roofs are a popular choice due to their clean appearance and lasting durability. These roofs are constructed using a series of metal panels. Panels are joined at interlocking seams that are elevated above the panel surface. These seams create a watertight seal and simultaneously allow for thermal expansion and contraction of the metal panels.

Raised seam roofs are very labor and time intensive to install. Each metal panel must be carefully measured, cut, and mechanically fastened to the roof deck in a manner that allows for thermal flexing. Through this meticulous process, the installer ensures that each seam aligns, overlaps, and interlocks correctly, forming a continuous barrier against the elements. If the roof is not installed properly the thermal movement of the paneling will result in surface rippling known as the "oil can effect" which creates an unsightly appearance and may compromise the roof's ability to shed water.

Trim pieces play a crucial role in both the aesthetics and functionality of a raised seam roof. These elements, such as hip cap and sidewall trim, are installed along the borders of the roof to provide a neat, and visually pleasing appearance to the structure. More importantly, these elements help prevent moisture from entering the building. Without these trim pieces, the edges of the panels would be exposed to water infiltration leading to failure of the roof and underlying structures.

Equally important is the ridge vent, a critical component that enhances the roof's performance by promoting proper ventilation of the building. The ridge vent is installed along the roof's peak to allow warm, moist air to escape while drawing in cooler air from lower openings such as soffits. This natural ventilation process helps regulate the temperature and moisture levels within the building. Proper ventilation reduces the risk of condensation, mold growth, and potential structural damage over time, prolonging the lifespan of the roof, improving air quality, and contributing to the overall energy efficiency of the building. While a ridge vent provides valuable ventilation, it must be properly covered to prevent moisture infiltration and pest infestation. A trim piece called a ridge cap is installed over the vent, serving as a protective barrier while allowing air to flow freely. The ridge cap is positioned over the vent and designed to overlap the roofing panels, creating a weather-resistant seal that helps maintain the roof's durability and performance.

Hip caps, sidewall trim, and ridge caps (collectively referred to as "trim") are elevated on a raised seam roof to enhance water management and to create a secure, weatherproof seal. By positioning the trim above the level of the roof panels, any water that runs off the roof is directed away from critical seams, reducing the risk of water infiltration and subsequent damage. This elevated design increases the barrier, assuring that rainwater is effectively channeled off the roof and away from vulnerable areas.

The trim piece is designed to interface with the roof in a way that allows it to flex with the natural expansion and contraction of the metal panels as temperatures change. The interlocking design allows for a proper overlap between the trim and the panels, maintaining a consistent and durable seal throughout the roof's lifespan. This approach not only protects the roof system but also contributes to its overall longevity and performance.

In the past, trim has been connected to roof panels using Z-bar connectors or Z-flashing that creates the required elevation. A Z-bar is a metal flashing component shaped in the form of the letter "Z." The bottom of the Z shape is fastened to the metal panels while the hip cap, sidewall, or ridge cap trim is hooked over the top of the Z shape. This type of flashing is typically installed as individual pieces between the seams of the metal panels. The installer must manually cut each individual Z-bar, ensuring that it is square with panel seams and in perfect alignment with the other Z-bars before fastening it and moving on to the next segment. This is very time consuming and labor intensive. An error in the alignment of one or more Z-bars could compromise the roof's integrity leading to inadequate connection between the trim and Z bar and superfluous holes if repositioning is required. There is therefore a need in the art for a connector that allows the installer to secure trim to raised seam panels using a series of quickly aligning connectors.

BRIEF SUMMARY OF THE INVENTION

It is an object of this invention to overcome the disadvantages of the prior art by providing a U- channel connector capable of coupling the metal panels of a raised seam roof to hip caps, sidewall trim, and ridge caps (hereinafter collectively referred to as "trim"). The connector is designed to create a secure transition between these roofing components, providing structural support and a weather-tight barrier.

The U-channel connector is ideally formed from one piece of material and has a first side, a second side, and a base connecting the two sides to form a U-shape with a flat base. A projection or flange extends orthogonally from the top of each respective side of the connector, forming a horizontal surface upon which the trim rests. A series of one or more slots are formed or cut within the U-channel such that the connector can be placed over multiple seams on the roof panels. This prevents the installer from having to cut individual connectors to fit between these seams and greatly reduces the labor involved in the trim installation. A U-channel connecter that bridges multiple seams similarly prevents the installer from having to meticulously align each piece between the seams as is required with standard Z-flashing.

The squared off base of the U-channel allows the connector to sit firmly on the metal roof panels. During installation, the builder aligns the connector slots with the raised seams of the roof, advances the connector such that the base of the U-shape is flush with the metal panels and then fixes the connector to the roof using the mechanical fastening means of choice. U-channel connectors are symmetrically designed, allowing the installer to mount a connector in either orientation without concern for a "right- side-up" position. Butyl tape or similar sealant material can be placed between the base of the U-shape and the metal panel to prevent water infiltration at the fastening sites.

Each flange on the U-channel connector is designed to mate with the connection profile or interlocking "lip" formed on standard trim pieces. After one or more U-channel connectors are securely fastened to the roof panels, the flange is inserted into the lip of the ridge cap or trim. This creates a continuous, robust assembly that not only enhances the roofs structural integrity but also prevents water infiltration and maintains the overall aesthetic appeal of the roof system. The nature of the connection allows the ridge cap or trim to remain firmly in place without additional mechanical fasteners even under challenging weather conditions and thermal expansion. The flexible interface allows for natural expansion and contraction of the roof, preventing the "oil can" effect that often occurs when roofing materials are rigidly fixed in place.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1A is a top left side perspective view of an unperforated U-channel connector;

FIG. 1B is a top left side perspective view of a perforated U-channel connector having an optional filter;

FIG. 2A is a bottom right side perspective view of a U-channel connector having weep holes;

FIG. 2B is a bottom right side perspective view of a perforated U-channel connector;

FIG. 3 is an elevational view of the side of an unperforated U-channel connector;

FIG. 4 is a top plan view of a U-channel connector without weep holes;

FIG. 5 is a left side perspective view of an unperforated U-channel connector that has been installed on two seams of a roof with trim positioned above it prior to installation;

FIG. 6 is a left side perspective view of the lip of side trim installed on a U-channel connector flange;

FIG. 7 is a perspective view of a roof having a ridge vent and illustrating a series of U-channel connectors that have been installed on the roof peak;

FIG. 8 is a side view of a roof peak illustrating the lips of a ridge cap installed on two U-channel connector flanges.

DETAILED DESCRIPTION OF THE INVENTION

In this patent application, sidewall trim, ridge caps, and hip caps shall be referred to generally as "trim." The phrase "mechanically fastened" or "mechanically affixed" shall refer to any standard fastening method including but not limited to screws, nuts, bolts, threaded rods, adhesives and the like. The phrase "substantially orthogonal to" an object shall mean within +/- 5 degrees of a 90-degree orientation relative to the object. Use of the word "formation" in relation to formation of the U-channel connector shall broadly refer to any process by which the part is shaped, manufactured, or produced, including but not limited to bending, extruding, molding, casting, forging, stamping, machining, additive manufacturing, or any other method that alters the material's shape, structure, or configuration to achieve the desired form. The use of the word "formation" in relation to the formation of slots in the U-channel connector shall broadly refer to any process by which holes are created, including but not limited to cutting, piercing, punching, drilling, stamping, laser cutting, or any other method that removes, displaces, or reconfigures material to produce an opening.

Referring now to FIGS. 1A, 1B, 2A and 2B, the U-channel connector 5 is comprised of a first side 10, a second side 15 having the same dimensions and shape as the first side 10, and a base 20. The first and second sides 10/15 are connected to the base 20 at their respective bottom ends 25 such that each side 10/15 extends generally vertical and substantially orthogonal to the base 20. This creates the boxy U- shaped cavity 35 depicted in FIGS. 1A, 1B, 2A and 2B. Each of the sides 10/15 must have a height that is greater than or equal to the height of the roofing seam H (depicted in FIG. 5) upon which the connector 5 is being installed in order to ensure that the base 20 rests firmly on the roofing panels 70 when it is secured. The width of the base is not critical; however, it should be wide enough to allow the installer to easily insert fasteners within the U-shaped cavity 35 and narrow enough to be aesthetically pleasing. Inventor contemplates a base that is at least one inch wide.

Referring again to FIGS. 1A, 1B, 2A and 2B, a first flange 40 extends substantially horizontally from the top end 30 of the first side 10 such that the flange 40 is generally parallel to the roofing panels 70 when installed. A second flange 45 of the same dimension and shape as that of the first flange 40, extends substantially horizontally from the top end 30 of the second side 15 such that this flange 45 is also generally parallel to the roofing panels 70 when installed. The width of the flanges is not critical provided that the flange is wide enough to firmly interlock with the lip 75 of the trim when installed. Inventor contemplates flanges that are approximately one inch wide.

U-channel connectors 5 are ideally formed through bending of single piece of material or they may be extruded. It should be recognized that the connector 5 may also be built from independent pieces; however, this would increase manufacturing costs and may compromise the strength of the connector 5. The uniform size and shape of the sides 10/15 and the flanges 40/45 results in a U-channel connector 5 that is symmetric in form about its longitudinal axis A as shown in FIG. 4. This symmetry allows the installer to position the connector 5 on the roof seams 65 in either direction without concern for a specific orientation.

One or more symmetric U- shaped slots or channels 50 are formed along and parallel to the U- shaped cavity 35 as depicted in FIGS. 3-4. Each of the slots 50 are designed to accommodate the size and shape of the seam of the metal roof being installed (the "seam profile"). Metal roofs typically have a 3/8" roofing seam with the width W remaining generally consistent along the height of the seam H as shown in FIGS. 4 and 5. It should be understood that other seams widths may be used. In FIGS. 1-5 and 7, the slots 50 have been depicted as rectangular in shape to accommodate the typical seam profile but it should be understood that the slot geometry can be adjusted for varying seam profiles. In a batten seam roof for instance, the seam may be trapezoidal or rounded in shape and the slots 50 may be manufactured to accommodate this angular variation.

The length L of the U-channel connector 5, as depicted in FIG. 4, is selected to suit common standing seam roof panel widths. Typical panel widths range from 12 to 24 inches in four inch increments (12, 16, 18, 20, and 24) with the most common panel width being 16 inches. Referring now to FIGS. 5 and 7, U-channel connectors 5 are designed to span one or more metal seams 65 and terminate at each end adjacent to a seam to avoid cutting. The distance between the slots 50 in the connector 5 are similarly designed to correspond to standard roofing seam widths. For example, if a standard 16 inch roofing panel system is installed, the length L of the connector 5 would be approximately 47 1/8 inches. This length L would allow the connector 5 to span two seams 65 with each end terminating at a seam as shown in FIG. 5. In this example the slots 50 would be pre-cut or formed to align with the seams 65 on 16 inch centers.

Referring again to FIGS. 5-8 when mounting the U-channel connector 5, the installer aligns the slots 50 over the roof seams 65 and applies sufficient force to advance the connector 5 over the seams 65 until the base 20 is in contact with the roofing panels 70. Butyl tape or similar sealant material is typically placed between the base 20 of the U-shaped cavity 35 and the metal panels 70 to prevent water infiltration at the fastening sites as noted above. Fasteners are placed in the U-shaped cavity 35 to secure the connector to the roof. The process is repeated until all connectors 5 have been aligned and secured to the roofing panels 70.

Referring now to FIGS. 6 and 8, the flange 45 nearest the edge of the trim 60 covering the ridge vent R is inserted into the lip 75, locking that trim 60 in a manner that allows for thermal expansion to prevent metal distortion over time. The U-channel connector 5 is fastened through the U-shaped cavity 35 but also through the frictional connection with the roof seams 65. This forms a significantly stronger connection between the roof and the connector 5 compared to a standard Z-bar connection, while also eliminating the need for additional roof penetrations.

Referring again to FIGS. 5 and 7 one sees that by placing U-channel connectors 5 that span multiple seams 65 (and terminate adjacent to a seam 65) the installer avoids cutting and manually aligning individual connectors between seams 65, thereby avoiding the drawbacks of standard Z-bar installation. This reduces the labor and time required to fasten the trim 60 to the roofing panels 70, decreases material waste, and simplifies the alignment process between the connector 5 and the roof.

Ventilation is critical with respect to ridge cap installation as noted above. For this reason both sides 10/15 of the U-channel connector 35 may be perforated to facilitate airflow when used in a ridge cap installation as depicted in FIGS. 1B and 2B. Optional filters 80 may be inserted into the U-shaped cavity 35, as shown in FIG. 1B, to prevent the accumulation of debris in the perforated U-channel connector. Weep holes 85 may be configured in the base 20, as shown in FIG. 2A, to prevent water accumulation and potential corrosion in applications that require drainage.

While the above description contains many specifics, these should be considered exemplifications of one or more embodiments rather than limitations on the scope of the invention. As previously discussed, many variations are possible and the scope of the invention should not be restricted by the examples illustrated herein.

REFERENCE NUMERALS

5 U-channel Connector

10 First Side

15 Second Side

20 Base

25 Bottom End

30 Top End

35 U-Shaped Cavity

40 First Flange

45 Second Flange

50 Slot/Channel

55 Perforations

60 Trim

65 Roof Seams

70 Roofing Panels

75 Interlocking Lip/Lip

80 Filter

85 Weep Holes

A Longitudinal axis

W Slot/Channel Width

H Seam Height

W Slot/Channel Width

L Length of U-channel Connector

R Ridge Vent

Claims

1. A U-channel connector for mounting standard roofing trim and ridge caps to a raised seam roof structure, the connector comprising: a. a first side and a second side, each of said sides having a top and a bottom end;b. a base extending between and substantially orthogonal to the bottom ends of the first and second sides, thereby forming a U-shaped cavity;c. a first flange extending from and substantially orthogonal to the top end of the first side; d. a second flange extending from and substantially orthogonal to the top end of the second side; wherein one or more slots are formed within and along the U-shaped cavity, the slots having a shape that accommodates the profile of raised seams on a roof structure.

2. The U-channel connector of claim 1, wherein the first and second sides, the base, and the first and second flanges are formed from a single continuous piece of material.

3. The U-channel connector of claim 1, wherein the material is selected from the group consisting of steel, aluminum, and plastic.

4. The U-channel connector of claim 1, wherein a series of perforations penetrate the first side and second sides.

5. The U-channel connector of claim 1, wherein a series of weep holes penetrates the base.

6. The U-channel connector of claim 1, wherein a filter is placed within the U-shaped cavity.