Information
-
Patent Grant
-
6619006
-
Patent Number
6,619,006
-
Date Filed
Thursday, March 28, 200222 years ago
-
Date Issued
Tuesday, September 16, 200321 years ago
-
Inventors
-
-
Examiners
- Friedman; Carl D.
- Green; Christy
Agents
- Dennison, Schultz & Dougherty
-
CPC
-
US Classifications
Field of Search
US
- 052 533
- 052 539
- 052 545
- 052 546
- 052 579
- 052 444
- 052 446
- 052 447
- 052 448
- 052 409
- 052 410
- 052 411
- 052 412
- 052 413
- 052 519
- 052 520
- 052 528
- 052 536
- 052 538
- 052 554
- 052 555
- 052 556
- 052 557
- 052 58
- 052 60
- 052 901
-
International Classifications
-
Abstract
The present invention relates to a roofing shingle, which can surely prevent water such as rainwater from leaking through a roof. A roofing shingle has a rectangular plate (11) provided with first through fourth seam portions (11a-11d). The first and second seam portions (11a, 11b) are positioned in a pair along opposite side edges of said plate and folded in opposite directions with respect to a plane of said plate. The third and fourth seam portions (11c, 11d) are positioned in a pair along opposite end edges of said plate and folded in opposite directions with respect to the plane of said plate. The roofing shingle comprises a waterproofing sheet member (20) having a sheet (21) with its configuration greater than that of said plate and adhesive layers (22a, 22b) provided on both sides of the sheet. The sheet member is positioned and adhered on the plate (11) so that a gap or space formed between the seam portion and a corresponding seam portion of an adjacent roofing shingle is closed and filled with an edge portion (21a, 21d) of the sheet.
Description
FIELD OF THE INVENTION
The present invention relates to a roofing shingle, and more particularly, to such a roofing shingle which can surely prevent water such as rainwater from leaking through a roof.
BACKGROUND OF THE INVENTION
FIG. 11
is a perspective view generally illustrating a Dutch-lap roof with use of conventional roofing shingles, the roofing shingles made of a sheet metal being successively laid on a roof board.
As shown in
FIG. 11
, a Dutch-lap type of roof is constructed on a house typically built in a conventional manner, and the Dutch-lap roof has an asphaltic waterproofing material
102
and a thermal insulating material (not shown) laid on a roof board
101
. A plurality of shingles
104
, each being made of a metallic roofing sheet, are installed on the waterproofing material
102
. The metallic roofing shingles
104
are successively arranged on the waterproofing material
102
, starting from a lowermost eaves plate
103
, and the shingles
104
are secured to the roof board
101
at clips
105
by nails
106
, respectively. Reference numerals
107
,
108
denote a sub-structural flashing board and a sub-structural verge board, respectively.
Each of the roofing shingles
104
is formed in a rectangular configuration. The shingle
104
has a first seaming edge portion
104
a
downwardly folded or turned toward its back or underneath side along its longitudinal edge, and a second seaming edge portion
104
b
upwardly folded or turned toward its top or upper side along another longitudinal edge. Further, the roofing shingle
104
has a third seaming edge portion
104
c
upwardly folded or turned toward its top side in its transverse right-hand edge, and a fourth seaming edge portion (not shown) downwardly folded or turned toward its back side along its transverse left-hand edge. These seaming portions allow “flat lock seams” (or pinching lock seams) to be provided on the roof.
The conventional roof with use of such a roofing shingle might be able to effect a satisfactory waterproofing performance, so long as it is observed within a certain term of time after construction.
However, as shown in
FIG. 12
, a clearance or gap may be created between the shingle
104
and the asphaltic waterproofing material
102
during a long-term of use, owing to a deterioration of fixing means for the shingle, or the like. This results in a condition in that a quantity of rainwater may leak into the underside of roofing shingle through a passage of water as shown by arrows A, B. This kind of water leakage tends to be observed especially in a low-pitched part, a crest part or a curved part of a roof, and so forth. Even if the waterproofing work is executed prior to the roofing work, it is difficult to keep its waterproofing performance in a perfect condition. This is because the waterproofing material has to be partially broken by anchor screws or nails used for at least temporarily anchoring the roofing shingles in position of the substrate and the screws or nails in contact with water gradually lose its anchoring force for their rusting or deteriorating tendency.
SUMMARY OF THE INVENTION
An object of the present invention is, therefore, to provide a roofing shingle, which can surely prevent water such as rainwater from penetrating therethrough.
To achieve this object of the invention, the present invention provides a roofing shingle having a plate (
11
) provided with first and second seam portions (
11
a
,
11
b
) positioned in a pair along opposite side edges of said plate and folded in opposite directions with respect to a plane of said plate, and third and fourth seam portions (
11
c
,
11
d
) positioned in a pair along opposite end edges of said plate and folded in opposite directions with respect to the plane of said plate, comprising
a waterproofing sheet member (
20
) having a sheet (
21
) with its configuration greater than that of said plate and adhesive layers (
22
a
,
22
b
) provided on both of top and back sides of the sheet, said sheet member being positioned and adhered on said plate so as to make an extension area of the sheet, and edge portions (
21
a
,
21
d
) of said sheet being inserted into the first and fourth seam portions (
11
a
,
11
d
),
whereby a gap formed between said seam portion and a corresponding seam portion of an adjacent roofing shingle is filled with said edge portion (
21
a
,
21
d
) of said sheet and said extension area of the waterproofing sheet member overlaps with a corresponding waterproofing sheet member of another adjacent roofing shingle to adhere to each other.
According to the present invention, the waterproofing sheet member (
20
) has the sheet (
21
) acting as a waterproofing layer (synthetic fiber/synthetic rubber layer) on a roof board (
101
) and the adhesive layers (adhesive rubber layers) (
22
a
,
22
b
) applied to the top and back sides of the sheet (
21
), as shown in FIG.
4
. The sheet (
21
) is adhered to one side of the plate (sheet metal) (
11
) by the adhesive layer, as shown in FIG.
1
. The edge portion (
21
a
,
21
d
) of the sheet (
21
) is inserted into the seam portion (
11
a
,
11
d
), but the other edge portion of the sheet (
21
) extends over the seam portion (
11
b
,
11
c
) to make an outward extension area, which overlaps with a corresponding sheet of a waterproofing sheet member of another adjacent roofing shingle and which adheres thereon.
When installing the roofing shingles (YH) on the roof board, the flat lock seam portions (
11
c
,
11
d
;
11
a
,
11
b
) of the roofing shingles (YH
1
, YH
2
; YH
1
, YH
11
) are engaged with each other and the extension area of the sheet member adheres to the sheet member of the adjacent shingle, as shown in FIG.
8
. The edge portion (
21
a
,
21
d
) of the sheet seals the upper and lower seam portions (
11
c
,
11
d
;
11
a
,
11
b
) of the shingles (YH
1
, YH
2
; YH
1
, YH
11
) and the nail or screw (
31
) is completely sealed by the overlapping sheet members. Therefore, rainwater does not penetrate into the underside of the shingles.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages will become more readily apparent when considered in relation to the preferred embodiments as set forth in the specification and shown in the drawings in which:
FIG. 1A
,
1
B and
1
C show a longitudinal side elevation, a plan view and a transverse side elevation of a roofing shingle according to a first embodiment of the present invention;
FIG. 2A
,
2
B and
2
C show a longitudinal side elevation, a plan view and a transverse side elevation of a metal plate in the first embodiment:
FIG. 3A
,
3
B and
3
C show a longitudinal side elevation, a plan view and a transverse side elevation of a waterproofing sheet member in the first embodiment;
FIG. 4
shows an enlarged cross-sectional view of the waterproofing sheet member;
FIG. 5
shows a cross-section of the roof constructed with use of the roofing shingle of the first embodiment;
FIG. 6A and 6B
illustrate the process of constructing the roof with use of the roofing shingle of the first embodiment;
FIG. 7
illustrates the roofing process continuing the process shown in
FIG. 6
;
FIG. 8A and 8B
illustrate an function of the roofing shingle of the first embodiment which prevents water from penetrating into the underside of the shingle, wherein
FIG. 8A
shows an enlarged cross-sectional view of a portion indicated by an arrow in FIG.
6
B and
FIG. 8B
shows a cross-section taken along a line VIIIB—VIIIB in
FIG. 7
;
FIG. 9A
,
9
B and
9
C show a longitudinal side elevation, a plan view and a transverse side elevation of a roofing shingle according to a second embodiment of the present invention;
FIG. 10
shows an enlarged cross-section of the waterproofing sheet member according to the second embodiment;
FIG. 11
shows a perspective view, partially broken away, of a roofing shingle of the prior art; and
FIG. 12
shows an enlarged cross-sectional view of the conventional roofing shingle, in which a state of rainwater leakage is illustrated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. First Embodiment
(1) Structure of Roofing Shingle
Referring to
FIG. 1
, a roofing shingle YH, which is a roofing component, segment or module, is generally formed in a rectangular configuration, wherein the shingle YH comprises a metallic (copper) sheet-like member or plate
10
and a waterproofing sheet member
20
, each having a substantially rectangular configuration. The member
20
is provided with an adhesive material applied on the opposite sides thereof and release paper sheets covered on the adhesive material.
Referring to
FIG. 2
, the metallic plate
10
is a panel formed in a generally rectangular profile by a rectangle-shaped sheet metal
11
, which is substantially rigid but elastically deformable. The sheet metal
11
has a first seam portion or flat lock seam portion
11
a
which is downwardly folded or turned toward its back side along its longitudinal edge, and a second seam portion
11
b
which is upwardly folded or turned toward its top or front side along another longitudinal edge. The sheet metal
11
also has a third seam portion
11
c
upwardly folded or turned toward its top side along its transverse edge and a fourth seam portion
11
d
downwardly folded or turned toward its back or underneath side along another transverse edge. These seam portions are formed to have a U-shaped cross-section for “flat lock seam” (or pinching lock seam).
The sheet metal
11
is provided with a nailing portion
12
outwardly extending therefrom at an upper-right corner. The nailing portion
12
has a central aperture
12
a
, which is used for at least temporarily fixing the roofing shingle on a roof board by a nail (not shown). The nailing portion
12
is formed by an extension of the sheet metal
11
and effects the same functions as in the clip
105
of the prior art (see FIG.
11
). Since provision of the clip can be omitted in the present embodiment, a saving in manufacturing cost and a decrease in the number of parts to be installed can be achieved.
As shown in
FIGS. 3 and 4
, the waterproofing sheet member
20
has an elastic waterproofing core layer
21
made from a synthetic fiber and a synthetic rubber. The waterproofing sheet member
20
has a generally rectangular profile greater than that of the sheet metal
11
to make an extension extending across the third and fourth seam portions
11
b
,
11
c
. The waterproofing sheet member
20
is provided with a top adhesive rubber layer
22
a
on the top side surface of member
20
and a top release paper sheet
23
a
over the layer
22
a
. The waterproofing sheet member
20
is further provided with a back adhesive rubber layer
22
b
on the underside of the member
20
and a back release paper sheet
23
b
over the layer
22
b
. A synthetic rubber sheet or rubber/asphalt sheet with adhesive layers, e.g., Gamlon MG base B manufactured by TAJIMA ROOFING Co. Ltd. is preferably employed as the waterproofing sheet member
20
.
Referring now to
FIG. 3
, an exposed area
24
of the waterproofing sheet member
20
is illustrated as a hatched rectangle as indicated by zone-I, in which the top release paper sheet
23
a
is preliminarily removed or peeled from the waterproofing sheet member
20
, so that the top adhesive rubber layer
22
a
is uncovered therein. In the area as indicated by zone II, the layer
22
a
remains covered with the sheet
23
a
. The uncovered area
24
allows the waterproofing sheet member
20
to be preliminarily adhered to the underside of the sheet metal
11
as shown in FIG.
1
. The member
20
and the sheet metal
11
are positioned relatively to each other and integrally combined with each other in such a manner that a notch
25
is formed at the upper-left corner of the shingle YH. The notch
25
is used to temporarily expose the nailing portion
12
of the adjacent sheet metal
11
during the roofing work, as shown in
FIG. 6B
, and is adapted to adjust or regulate the thickness of the roofing. The lower-left corner of the plate
10
as seen in
FIG. 2
has a configuration identical with a configuration of the corresponding corner of the member
20
as seen in
FIG. 3
, and the member
20
and the plate
10
are aligned with each other along their edges as shown in FIG.
1
.
The left and lower edge portions of the sheet member
20
are inserted into the U-shaped seam portions
11
a
,
11
d
to an extent that the edges of the member
20
is in close proximity to the edges of the seam portions
11
a
,
11
d.
(2) Roofing Process
The process of roofing (Dutch-lap roofing) will be described hereinafter with reference to
FIGS. 5-8
. In
FIG. 5
, a cross-section of the structure after construction is illustrated. In
FIGS. 6-8
, it is assumed that the basic structure including the eaves part
103
has been already constructed.
The back release paper sheet
23
b
(
FIG. 4
) of a first roofing shingle YH
1
is removed and the shingle YH
1
is positioned and adhered on a roof board
101
in a predetermined orientation along the eaves part
103
, as shown in
FIG. 6A. A
nail
31
made of stainless steel is then driven into the roof board
101
through the aperture
12
a
of the nailing portion
12
so as to anchor the roofing shingle YH
1
on the board
101
. Thereafter, the top release paper sheet
23
a
in the zone II having an L-shaped configuration is removed from the shingle YH
1
so that the member
20
is uncovered in a formation of L-shape to expose the layer
22
a.
Referring to
FIG. 6B
, a second roofing shingle YH
2
, from which the bottom release paper sheet
23
b
has similarly been removed, is then adhered to the roof board
101
in a position adjacent to the shingle YH
1
, while the second roofing shingle YH
2
is displaced in a direction shown by arrow X in
FIG. 6B
, in a condition that the fourth seam portion
11
d
of the shingle YH
2
is engaged with the third seam portion
11
c
of the first roofing shingle YH
1
and that the shingles YH
1
, YH
2
are longitudinally aligned with each other. The layer
21
of the second shingle YH
2
overlaps the zone II, i.e., the extension area of the layer
21
of the first shingle YH
1
, as shown in FIG.
8
A.
The interlocking mechanism is shown in
FIG. 8A
, which is an enlarged cross-sectional view of the part C shown in FIG.
6
B. The left edge portion
21
d
of the second synthetic fiber/synthetic rubber layer
21
(YH
2
) closes and sealingly fills a space or gap formed between the third seam portion
11
c
of the first sheet metal
11
(YH
1
) and the fourth seam portion
11
d
of the second metal sheet
11
(YH
2
). Therefore, rainwater flowing in a direction of an arrow D can be surely blocked by the left end
21
d
of the layer
21
, and does not penetrate therethrough to reach the roof board
101
. Thus, a rainwater leakage of the roof is surely prevented from occurring. Preferably, a leading edge
27
of the layer
21
of the shingle YH
2
outwardly extends across an edge
17
of the seam portion
11
c
, and the distance T between the edge
27
and an apex
18
of the seam portion
11
c
of the shingle YH
1
is equal to or greater than 10 mm.
In accordance with the steps and the engagement manner as set forth above, the other roofing shingles YH are successively placed and anchored on the roof board
101
until the first stage of roofing shingles YH
1
, YH
2
, YH
3
. . . are provided in a row along the eaves part
103
of the roof.
Referring next to
FIG. 7
, a roofing shingle YH
11
for the second roofing stage, from which the back release paper sheet
23
b
has been removed, is adhered and anchored onto the roof board
101
in a condition that the first seam portions
11
a
of the roofing shingle YH
11
is aligned and equally engaged with the second seam portions
11
b
of the roofing shingles YH
1
, YH
2
. In the setting step of the shingle YH
11
, the shingle YH
11
is upwardly displaced in a direction of arrow Y in a condition that the first seam portion
11
a
of the shingle YH
11
is in an interlocking engagement with the second seam portions
11
b
of the shingles YH
1
, YH
2
. The engagement manner of the seam portions
11
a
,
11
b
are shown in FIG.
8
B. The edge portion
21
a
of the layer
21
of the shingle YH
11
closes and sealingly fills a space or gap formed between the second seam portion
11
b
of the shingle YH
1
installed in the first roofing stage and the seam portion
11
a
of the shingle YH
11
installed in the second roofing stage. The extension area, i.e., the zone II of the layer
21
of the shingle YH
1
overlaps the layer
21
of the shingle YH
11
, as shown in FIG.
8
B. The stainless steel nails
31
and nailing portions
12
of the sheet metals
11
, which have been already secured in the first roofing stage, is completely covered with the layers
21
of the shingle YH
11
installed in the second roofing stage. Preferably, a leading edge
27
′ of the layer
21
of the shingle YH
11
outwardly extends across an edge
17
′ of the seam portion
11
b
, and the distance T′ between the edge
27
′ and an apex
18
′ of the seam portion
11
b
of shingle YH
1
is equal to or greater than 10 mm.
Rainwater flowing in a direction of an arrow E is blocked by the edge portion
21
a
of the shingle YH
11
. The stainless steel nails
31
and nailing portions
12
of the shingle YH
1
are completely covered with the layers
21
of the shingle YH
11
, and therefore, the rainwater does not reach the roof board
101
. Thus, the rainwater is surely prevented from penetrating through a series of roofing shingles YH.
After the roofing process for the second roofing stage has been completed, roofing works for the third, fourth and further roofing stages are successively carried out to complete the whole roof as shown in
FIG. 5
, wherein the roofing shingles YH are placed and anchored in the manner as set forth above.
II. Second Embodiment
The first embodiment relates to the roofing shingle adhered on the roof board. However, the second embodiment relates to a roofing shingle further comprising means for preventing an expansion or bulge of waterproofing sheet, which may be caused by moisture vapor generating from a concrete substrate in a case where the roofing shingle is mounted on the concrete substrate.
According to the second embodiment, a roofing shingle YH
0
comprises a metallic plate
10
and a waterproofing sheet member
20
A, as shown in
FIGS. 9 and 10
.
The waterproofing sheet member
20
A comprises a back adhesive rubber layer
22
b
as in the first embodiment, a plurality of nonwoven fabric belts or liner menders
41
integrally attached to the underside surface of the layer
22
b
. The belts
41
are spaced apart from each other, in parallel with each other. The other nonwoven fabric belts or liner menders
42
are similarly attached to the underside surface of the layer
22
b
, the belts
42
extending in a direction perpendicular to the belts
41
and connecting with the belts
41
at their ends. A set of the belts
41
,
42
acts as a cushioning member. As the nonwoven fabric, TEXTOGLASS (glass fiber fabric) is preferably employed, which is available from KANEBO Co. Ltd.
When such a roofing shingle YH
0
is placed on a concrete substrate, an expansion or bulge of the material is preventing from occurring in the roofing shingle YH
0
, since the moisture vapor from the concrete substrate is absorbed and dispersed by fluid passages of the nonwoven fabric belts and exhausted to the atmosphere therethrough.
As will be apparent from the foregoing, the present invention provides an improved roofing shingle which can perform a substantially perfect waterproofing function for a long time without maintenance, since the roofing shingle can prevent a leakage of rainwater and a peeling off from the roof even in a strong wind and rain upon a typhoon, hurricane or the like.
Further, the present invention allows the waterproofing and roofing works to be performed at the same time and therefore, the cost of construction work can be reduced.
Furthermore, the present invention may be applied to various types of roof, such as M-shaped roof, Y-shaped roof, low-pitched roof, curved roof, arch roof, doomed roof in addition to the normal gable, shed or pent roof, since a substantially perfect waterproofing function can be surely achieved.
In addition, as the waterproofing sheet member is integrally combined with the roofing shingle, the waterproofing sheet member follows and cushions a motion of the substrate involved in cracks or the like. Therefore, the roofing shingle and the waterproofing sheet member thereof are not broken by the action or motion of the substrate.
It is understood that this invention is not to be limited to the particular embodiments shown and described above, since many modifications may be made, and it is contemplated by the appended claims to cover such modifications as fall within the true spirit and scope of this invention.
Although the embodiments have been described as to the roofing shingles of rectangular configuration, the present invention may similarly be applied to any of various other configurations such as square or rhombus. Thus, the present invention may also be applied to a diagonal roofing as well as the Dutch-lap roof as set forth above.
Although the aforementioned roofing shingles are made of a sheet metal (copper), the present invention may similarly be applied to plates made of various other materials, such as plastic sheets, flat tiles and slate tiles.
Moreover, the present invention may be applied to a wide range of products from a high-quality roofing shingle to an economical roofing shingle, in dependence on the selection of sheet metal. As the sheet metal, various kinds of metal, such as titanium, stainless steel, aluminum and iron, in addition to copper, may be adopted. Further, a thin sheet metal can be used for reducing the costs of raw material and manufacture.
In addition, the shingle in the aforementioned embodiment is provided with the nailing portion which temporarily hold the shingle in position. However, the shingle may be provided with a plurality of nailing portions, or the nailing portion may be omitted from the shingle. Further, a clip or clips of a conventional structure may be used for anchoring the shingle on the roof board.
Claims
- 1. A roofing shingle having a plate (11) provided with first and second seam portions (11a, 11b) positioned in a pair along opposite side edges of said plate and folded in opposite directions with respect to a plane of said plate, and third and fourth seam portions (11c, 11d) positioned in a pair along opposite end edges of said plate and folded in opposite directions with respect to the plane of said plate, comprisinga waterproofing sheet member (20) having a sheet (21) with its configuration greater than that of said plate and adhesive layers (22a, 22b) provided on both of top and back sides of the sheet, said sheet member being positioned and adhered on said plate so as to make an extension area of the sheet, and edge portions (21a, 21d) of said sheet being inserted into the first and fourth seam portions (11a, 11d), whereby a gap formed between said seam portion and a corresponding seam portion of an adjacent roofing shingle is filled with said edge portion (21a, 21d) of said sheet and said extension area of the waterproofing sheet member overlaps with a corresponding waterproofing sheet member of another adjacent roofing shingle to adhere to each other.
- 2. A roofing shingle according to claim 1, wherein a configuration of a corner of said sheet adhered on said plate is coincident with a configuration of a corner of said plate and the corner of said sheet is overlaid on the corner of said plate.
- 3. A roofing shingle according to claim 2, wherein said plate (11) is provided with an extending part (12) with an aperture (12a) through which an anchoring member (31) extends.
- 4. A roofing shingle according to claim 1, further comprising a release member applied to cover said adhesive layer in said extension area of said sheet.
- 5. A roofing shingle according to claim 1, further comprising means for cushioning the roofing shingle and venting a backside area of the shingle, which is provided on a backside of said sheet.
- 6. A roofing shingle according to claim 1, wherein said plate is made of a sheet metal.
- 7. A roofing shingle according to claim 3, wherein said sheet is provided with a notch (25) in said extension area so that said extending part (12) of an adjacent roofing shingle is uncovered with said sheet.
- 8. A roofing shingle according to claim 1, wherein said seam portion (11a, 11b, 11c, 11d) is adapted to be brought into interlocking engagement with the corresponding seam portion of an adjacent roofing shingle by relatively displacing one of the roofing shingles, whereby said gap is filled with said edge portion (21a, 21d) of said sheet (21).
- 9. A roofing shingle according to claim 1, wherein said edge portion (21a, 21d) is inserted into said seam portion to an extent that the overlapping distance (T) of a leading edge (27, 27′) of said edge portion (21a, 21d) and an apex (18, 18′) of a seam portion of said adjacent shingle is at least 10 mm.
- 10. A roofing shingle according to claim 1, wherein a leading edge (27, 27′) of said edge portion (21a, 21d) is inserted into said seam portion to an extent that said leading edge is in close proximity to a turning part (17, 17′) of said seam portion (11a, 11d).
US Referenced Citations (53)
