Patent Grant
11384542
The present invention relates to roof shingles for use on, for example, a building roof deck surface, and methods of installing the same.
Molded plastic and/or composite roof shingles for exterior roof surfaces are known in the prior art. These molded panels or shingles may be made from, for example, thermoplastic polymers, including polypropylene, polyethylene, and various mixtures and copolymers thereof.
Many prior art molded or composite shingles are generally rectangular in shape and have substantially flat top and bottom surfaces. Such shingles are often installed by securing a first horizontal row along a bottom of the roof. Such shingles are then typically secured independently to the roof deck, one shingle at a time, using fasteners inserted through an upper portion of the shingle. In such examples, successive courses of shingles may be installed overlaying the previous course by as much as 50% or more so that water or other precipitation will cascade down the roof, from one course to the next, until it is shed from the roof. Such significant overlap is necessary to not only cover the fasteners used to secure the shingles to the roof deck, but also to mitigate against any water that may be blown upwards underneath overlapping rows of shingles and ultimately onto the underlying roof deck.
A disadvantage of such existing designs is, for example, requiring such significant overlap and the wasted surface area covered by adjacent rows, thereby necessitating more shingle material than would be required if such overlap could be minimized. However, shingles utilizing less material suffer from challenges associated with, for example, the leaking concerns from wind-driven water as mentioned above, along with a risk of shingles lifting and blowing off the roof in high-wind scenarios because a significantly overlapping shingle is not present to maintain the shingle in its desired position. For example, rather than secure a lower portion of the shingle to the roof deck or the lower-vertically adjacent row, such prior art shingles often rely on the significant overlap from the upper-vertically adjacent row to prevent undesired lifting of the roof shingle in such high-wind or other similar situations.
Some prior art solutions have sought to overcome certain of the disadvantages discussed above. For example, U.S. Pat. No. 8,590,270 to Martinique proposes so-called “anchor tabs” extending from one side of such shingles that receive an additional fastener at the lower end of the shingle. Such designs have the disadvantages, however, of requiring additional fasteners, which slows installation and puts more holes in the underlying roof deck, thereby increasing the risk of undesirable water infiltration.
To overcome these and other disadvantages, the present application discloses various shingle embodiments and methods for installing the same that provide mechanisms for securing the upper portions of the shingle to the roof deck and securing the lower portions of the shingles to the lower-adjacent row of shingles, rather than the roof deck itself. Such designs advantageously allow for, among other things, draining precipitation that gathers in gutter portions of the shingles onto the weather facing surface of vertically adjacent rows of shingles, thereby maximizing the shingles' ability to withstand high winds and other stresses and minimizing risk of precipitation leaking between courses of shingles to the underlying roof deck.
In some embodiments, a roof shingle tile is provided that may a first side opposite a second side, a top edge opposite a bottom groove, a top gutter, and a side gutter. In some embodiments, the bottom groove may extend along a bottom edge of the tile that includes a bottom edge of the side gutter, and the top edge may include a tongue portion sized to fit within the bottom groove of a vertically adjacent tile. The roof shingle tile may also be configured such that the second side includes an overhang portion sized to overlap the side gutter of a horizontally adjacent tile.
It is also contemplated that the roof shingle tile may include an overhang extending from the bottom edge of the tile, and/or the top gutter may include a sloped lower portion for directing water to the side gutter when installed on a roof. In some embodiments, the top gutter may also include an end stop on the sloped lower portion opposite the side gutter. The side gutter may, in some embodiments, include one or more raised partitions forming water channels. The roof shingle may also include a notched recessed portion on a back surface of the tile for receiving, for example, all or part of the top gutter of a vertically adjacent tile. In some embodiments, the notched recessed portion may be sized such that the bottom surface of the tile and a bottom surface of the vertically adjacent tile form a substantially continuous surface.
The roof shingle tile presented herein may also be configured such that the second side includes a side edge extending substantially to and along the side gutter of the horizontally adjacent tile. In some embodiments, the side gutter may include a slope enabling the side gutter to overhang the bottom groove that extends along the bottom edge of the side gutter.
The present disclosure also teaches a method of installing a plurality of roof shingle tiles on a roof deck. In some embodiments, the method may include providing a plurality of roof shingle tiles such as, for example, those discussed herein and hereinabove. In some embodiments, the method may also include installing a first horizontal row of such tiles along all or part of a substantially lowermost portion of the roof deck, wherein installation may include installing a first tile to the roof deck, and installing a second tile horizontally adjacent the first tile, wherein the overhang of the second side of the second tile overlaps the side gutter of the first tile. The method may also include installing one or more tiles in a second horizontal row vertically adjacent the first row of tiles such that the grooves of the second-row tiles receive the tongues of the first-row tiles.
In some embodiments, the method may include installing each tile by fastening the tile to the roof deck with one or more fasteners (e.g., nails or screws or the like) inserted through an upper portion of the top gutter. The method may also include installing the tiles such that an overhang extending from the bottom edge of the second-row tiles overlaps the top gutter and top edge of the first-row tiles. The method may also include installing the tiles such that a water flow surface of the side gutter of the second-row tiles extends to the upper surface of the first-row tiles.
The method may also include the step of installing a starter strip on the roof deck, wherein the starter strip may include a tongue substantially similar to the tongue of the plurality of roof shingle tiles, and wherein the tongue of the starter strip may be received by the groove of each first-row tile. Such starter strip or installation strip may include a plurality of starter strip pieces installed adjacent one another to form a continuous starter strip. The strip may also include a fastener receiving area, and further wherein the fastener receiving area is overlapped by the first row of tiles during installation.
Specific exemplary embodiments of the inventive subject matter now will be described with reference to the accompanying drawings. This inventive subject matter may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive subject matter to those skilled in the art. In the drawings, like numbers refer to like elements. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. As used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the inventive subject matter. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes,” “comprises,” “including” and/or “comprising,” when used in this specification, 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.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this inventive subject matter belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Some embodiments of the inventive subject matter arise from a realization that improved performance may be obtained from distribution transformers by using them in conjunction with a solid-state power flow controller that may be configured to be coupled in line with the transformer, e.g., between the transformer and the load in a service drop. Millions of distribution transformers are currently used in power distribution systems, and replacement of these devices with solid state or hybrid transformers would generally be prohibitively costly. In addition, replacing existing devices is also potentially wasteful, as existing devices are generally rugged and stand to provide years of additional service with relatively low maintenance. However, conventional distribution transformers typically provide no reactive power control. Such capability may be provided, however, by transformer power flow controller units configured for retrofit of existing distribution transformer installations. Such devices can be relatively low-cost, low voltage devices that are installed on the secondary side of the transformer.
Referring generally to
In some embodiments, side gutter 175 may include a bottom edge 142 that may form all or a part of bottom edge 140. Side gutter 175 may also include one or more raised partitions 177. Such raised partitions 177 may advantageously channel any water flowing into or within gutter 175 (e.g., on a water flow surface 176) into a substantially vertical flow direction and mitigate against any lateral flow of water within side gutter 175. Such mitigation of lateral water flow may be advantageous when, for example, wind or other forces may drive water flowing in side gutter 175 in a lateral direction that may then be somehow forced out of the side gutter 175 and undesirably onto, for example, an underlying roof deck surface.
Roof shingle tile 100 may also include, in some embodiments, a side edge portion 122 along the second side 120 and/or overhang portion 128. In some embodiments, side edge portion 122 may extend from substantially the upper surface 115 of overhang portion 128 downwards or substantially perpendicularly downwards towards the plane of a roof-facing surface 118 (e.g.,
Referring now to
In some embodiments, roof shingle 100 may also include a notch 129 extending along a lower portion of roof-facing surface 118. Notch 129 may, in some embodiments, be sized and shaped to generally receive the top gutter 170 of a lower vertically adjacent shingle 100. In such arrangements, roof-facing surface 118 of a first shingle 100 and roof facing surface 118 of a vertically adjacent shingle 100 may form a substantially continuous and/or substantially flat surface for placement on an underlying roof deck. Notch 129 may also be useful, in some embodiments, for facilitating proper alignment and/or spacing of vertically adjacent tiles during installation.
Referring now to
In some embodiments, side gutter 175 may include a slope 179 to facilitate flow of water or any other matter in side gutter 175 over bottom groove 145 in bottom edge 142 of side gutter 175, and onto upper surface 115 of a vertically adjacent tile. Slope 179 may be, for example, an angle such that water may still flow freely down side gutter 175 by virtue of gravity and the slope provided by the roof deck on which shingle 100 is mounted, yet move the water flow closer to the upper surface 115 relative to roof-facing surface 118 such that water may flow freely onto upper surface 115 of a vertically adjacent shingle.
Referring now to
In preferred embodiments, roof deck 700 may include some amount of pitch such that water or other liquids/objects incident on any roof system or other system installed thereon will tend to drain or otherwise move downwards towards a roof edge 710 of the roof deck 700. For example, roof deck 700 may be pitched between 1 degree and 90 degrees, or in some embodiments, 20 degrees, and water or other matter incident on roof deck 700 or any roof or other system installed thereon will tend to flow substantially downward towards roof edge 710 where such water may be collected (for example, in a roof gutter (not depicted)) and channeled or otherwise transported advantageously away from the building structure. In some embodiments, roof deck 700 may be treated with a primary protective covering (not shown) before installation of any roofing system (e.g., a plurality of roof shingles 100).
In some embodiments, a plurality of roof shingle tiles 100 may be provided and subsequently installed in one or more successive lateral courses. In some embodiments, installation may begin with a first lateral course substantially along roof edge 710, followed by installation of one or more subsequent courses vertically adjacent the first course.
Referring to the exemplary embodiment shown in
With first shingle 100A installed, a second shingle 100B may be installed laterally adjacent shingle 100A. In some embodiments, shingle 100B is installed such that overhang portion 128 of shingle 100B overlaps side gutter 175 of shingle 100A. In some embodiments, upper surface 115 of shingle 100B may contact upper surface 115 of shingle 100A, while in other embodiments, a gap 750 may remain. In some embodiments, top gutter 170 of shingles 100B and 100A may abut one another (see, for example,
Roof shingle 100C may be installed in like manner, with subsequent shingles in the first lowermost row being installed and secured to the roof deck as described herein.
A vertically adjacent second row may also be installed. For example, in some embodiments, shingle 100D may be installed such that shingle 100D overlaps both shingle 100A and 100B. Shingle 100D may also be installed, in some embodiments, so as to overlap all or part of the top gutter 170 of each of shingles 100A and 100B, thereby advantageously covering any laterally abutting edges of top gutters 170 of shingles 100A and 100B.
In addition, shingle 100D may be installed with its bottom groove 145 receiving the tongues 135 of shingles 100A and 100B. The interlocking of tongue 135 and bottom groove 145 may serve to, among other things, secure the lower portion of shingle 100D to one or more of shingles 100A and 100B, and thereby oppose lifting forces acting on shingle 100D such as, for example, high winds.
Such an arrangement may also serve to facilitate water flow down the roof to the roof edge 710. For example, by having the tongue of shingle 100B insert into the bottom groove 145 of the bottom edge 142 of side gutter 175 of shingle 100D, water flowing down side gutter 175 of shingle 100D will exit side gutter 175 directly onto the upper surface 115 of shingle 100B. Similarly, water flowing down upper surface 115 of shingle 100D will flow over overhang 148 of shingle 100D and directly onto upper surface 115 of shingles 100A or 100B. As such, the risk of water flowing on, over, or otherwise incident upon roof shingle 100D reaching roof deck 700 is minimized because any water flowing on or over shingle 100D flows only onto an upper surface 115 or side gutter 175 of a lower adjacent shingle, rather than having the opportunity to become incident on, for example, a contact point between any adjacent shingles where water might infiltrate between the shingles 100 to the roof deck 700. In some embodiments, where water from an upper surface 115 of, for example, shingle 100D may flow into gap 750, the water flows directly into side gutter 175 of, for example, shingle 100A, which then flows off roof edge 710, or would flow onto the upper surface 115 of a lower vertically adjacent shingle in the manner described above.
In like manner, shingle 100E may then be installed laterally adjacent shingle 100D, and vertically adjacent to shingles 100B and 100C, with additional shingles being installed laterally along this second row as desired.
Installation may then continue laterally and vertically as needed, including in some embodiments installation of shingle 100F in a manner that overlaps both shingles 100D and 100E in a manner similar to that described hereinabove. Installation may continue both vertically and/or laterally as needed and/or desired to substantially cover the entirety of roof deck 700.
Advantageously, upon installation of the plurality of roof tile shingles 100 on roof deck 700, water incident any shingle on rows above the lowermost row may exit only to the upper surface 115 of a lower adjacent shingle or into a side gutter 175 of a lower adjacent shingle, where such water may then continue on such path of upper surfaces 115 and/or side gutters 175 all the way to the roof edge 710, minimizing and/or virtually eliminating infiltration of water to the underlying roof deck 700.
In some embodiments, an installation strip or starter strip (not shown) may be provided and installed along roof edge 710. The installation strip may, in some embodiments, include one or more of a top gutter, tongue, and upper surface portion(s) substantially similar to top gutter 170, tongue 135, and upper surface 118 of roof shingle 100. The installation strip may be substantially continuous in some embodiments, such that it is substantially similar to an upper portion of roof shingle 100 that includes top gutter 170, tongue 135 and/or a portion of upper surface 118. The installation strip may, in some embodiments, be installed in a manner substantially similar to shingle 100. For example, in some embodiments, the starter strip may be installed using any appropriate fastener and/or using any appropriate adhesive or other fastening technique known in the art. For example, the tongue of the starter strip may be disposed in the groove 145 of shingles 100A-100C, etc.
In some embodiments, the starter strip may be installed before installation of all or part of a lowermost row of shingles 100, followed by all or part of the lowermost row of roof shingles 100 installed in a manner similar to that described hereinabove. In one embodiment, the installation strip may serve to secure the lower portion of the lowermost row of roof tile shingles 100 to counteract, for example, lifting forces that may be associated with high winds, etc., as described hereinabove.
Referring now to
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
This application claims priority to U.S. Provisional Application No. 62/825,364, filed Mar. 28, 2019, the entirety of which is incorporated herein by reference.
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