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[0001] This invention relates to roofing systems and, more particularly, to roofing systems that are configured to withstand high winds.
[0002] Standard roofing systems include shingles or panels that are typically attached to a roof sub-structure using simple fasteners, such as nails, or more complex systems, such as the panel/anchor system described in U.S. Pat. No. 4,649,684 to Petree. One object of these systems is to hold the shingles or panels in place relative to the roof sub-structure so that the shingles or panels protect the roof sub-structure from harmful elements such as rain or wind.
[0003] One problem associated with prior art roofing systems is that the panels and shingles of these prior art roofing systems often blow off of the roof sub-structure when the roofing systems are exposed to high winds. While prior art panel/anchor roofing systems are more effective in withstanding high winds than standard shingle-based roofing, the anchors of these systems still often detach from the roof sub-structure during exposure to high winds. This occurs because, when high winds pass over the roofing panels that are attached to the anchors, the panels vibrate and move relative to the roof sub-structure. Because the panels are typically rigidly attached to the anchors, the anchors are urged to move along with the panels. As a result, the panels often work the anchors free from the roof sub-structure. Once this happens, high winds passing over the panels often blow the panels and the anchors away from the roof sub-structure. In such situations, the anchors and panels must be replaced, which can be time consuming and expensive. Accordingly, there is a need in the art for an improved roofing system that can withstand high winds without becoming detached from the roofing sub-structure on which the roofing system is installed.
[0004] The present invention provides a roofing system that can withstand high winds without becoming detached from the roofing sub-structure on which it is installed. As described in greater detail below, the system accomplishes this by providing a roofing system that includes a plurality of mounting brackets that are fixedly attached to the roof sub-structure and a plurality of panels that are configured to attach to the mounting brackets in a manner that allows the panels to slide laterally to the mounting brackets.
[0005] One significant advantage of the present invention is that it is configured so that when the roofing system is exposed to high winds, the panels dissipate much of the energy transferred to the roofing system by the high winds by sliding laterally on the mounting brackets. Because the motion of the panels dissipates the energy imparted on the roofing system by the winds, very little wind-related energy is transferred to the mounting brackets or to the portions of the panels that are attached to the mounting brackets. Thus, even in very high winds, both the mounting brackets and the panels remain properly affixed to the roof sub-structure.
[0006] More particularly speaking, a preferred embodiment of the invention comprises: (1) a mounting bracket comprising a base portion and an elongate panel-attachment portion, the mounting bracket being configured for installation adjacent a roofing substructure; (2) a first panel configured for installation adjacent the elongate panel-attachment portion so that the first panel is substantially free to slide laterally relative to the panel-attachment portion; (3) a second panel configured for installation adjacent the elongate panel-attachment portion so that the second panel is substantially free to slide laterally relative to the panel-attachment portion; and (4) an intermediate member configured for installation adjacent the mounting bracket, the intermediate member being configured to separate at least a portion of the first panel from at least a portion of the second panel when the intermediate member is installed adjacent the mounting bracket. In one embodiment of the invention, the intermediate member is configured to be fixedly attached to the mounting bracket.
[0007] In a preferred embodiment of the invention, the roofing system is configured so that after the roofing system is installed, both the panel-attachment portion of the mounting bracket and the intermediate member are substantially constrained from moving laterally relative to the roofing sub-structure. By the same token, the roofing system is also preferably configured so that after the roofing system is installed, the intermediate member is substantially constrained from moving laterally relative to the mounting brackets' panel-attachment portion.
[0008] The roofing system is further preferably configured so that after the roofing system is installed, the first panel slideably engages at least a portion of the mounting bracket, and also slideably engages at least a portion of the intermediate member. Furthermore, the roofing system is preferably configured so that after the roofing system is installed, the second panel slideably engages at least a portion of the intermediate member.
[0009] A further aspect of a preferred embodiment of the invention is that the intermediate member comprises a first lateral movement restricting portion that is configured for engaging a first lateral side of the mounting bracket to restrict the lateral movement of the intermediate member relative to the mounting bracket in a first direction. Similarly, the intermediate member also preferably comprises a second lateral movement restricting portion that is configured for engaging a second lateral side of the mounting bracket to restrict the lateral movement of the intermediate member relative to the mounting bracket in a second direction that is opposite to the first direction. In a preferred embodiment of the invention, the first and second lateral movement restricting portions are brackets.
[0010] A roofing system according to a further embodiment of the invention comprises: (1) a mounting assembly defining a first mounting portion and a second mounting portion, the first and second mounting portions cooperating to form a sliding chamber, and the second mounting portion defining a sliding surface; (2) a first panel comprising a first roofing portion and a first attachment portion adjacent the first roofing portion, the first attachment portion being configured for sliding engagement within the sliding chamber; and (3) a second panel comprising a second roofing portion and a second attachment portion adjacent the second roofing portion, the second attachment portion being configured for sliding engagement with the sliding surface.
[0011] In a preferred embodiment of the invention, the mounting assembly is configured to allow the first attachment portion to slide substantially freely within the sliding chamber and the mounting assembly is configured to allow the second attachment portion to slide substantially freely on the sliding surface. Furthermore, the mounting assembly, first panel, and second panel are preferably configured so that: (1) when the first attachment portion slides within the sliding chamber, the first panel moves laterally relative to the mounting assembly; and (2) when the second attachment portion slides on the sliding surface, the second panel moves laterally relative to the mounting assembly.
[0012] In the further embodiment of the invention described above, the mounting assembly, the first panel, and the second panel are preferably configured so that both the first panel and the second panel are substantially free to slide laterally relative to the mounting assembly, and so that the first panel is substantially free to slide laterally relative to the mounting assembly independently of the second panel. In this embodiment of the invention, the second mounting portion is configured to separate at least a portion of the first panel from at least a portion of the second panel. The first and second mounting portions are preferably mounted so that they can not move to any substantial extent in a lateral direction relative to the roofing sub-structure.
[0013] A roofing system according to yet another embodiment of the invention comprises: (1) a mounting bracket that includes a base portion, an elongate body portion, and a head portion having a head-portion exterior surface; (2) a first panel that includes a first roofing portion, and a first attachment portion that is adjacent the first roofing portion and that is formed to substantially mate with the mounting bracket's head-portion exterior surface; (3) an intermediate member that includes an intermediate-member interior surface that is formed to substantially mate with an exterior surface of the first panel; (4) a second panel comprising a second roofing portion and a second attachment portion adjacent the second roofing portion, the second attachment portion being formed to substantially mate with an exterior surface of the intermediate-member. In this embodiment of the invention, the intermediate member is configured to separate at least a portion of the first panel from at least a portion of the second panel. In addition, the mounting bracket, the first panel, the intermediate member, and the second panel are configured so that after the roofing system is installed adjacent the roofing sub-structure, the first panel and the second panel are substantially free to slide laterally relative to the mounting bracket.
[0014] In the embodiment of the invention described above, the first and second attachment portions are preferably generally c-shaped. Furthermore, the head portion of the mounting bracket preferably includes a substantially planar first interior portion that is adjacent a first side of the body portion of the mounting bracket and that faces, and is spaced apart from, the mounting bracket's base portion. The first interior portion forms an angle of less than 90 degrees (and preferably less than 80 degrees) with at least a portion of the body portion of the mounting bracket. Furthermore, the head portion preferably includes a substantially planar second interior portion that is adjacent a second side of the body portion of the mounting bracket and that faces, and is spaced apart from, the mounting bracket's base portion. The second interior portion forms an angle of less than 90 degrees (and preferably less than 80 degrees) with at least a portion of the body portion of the mounting bracket.
[0015] A roofing system according to yet another embodiment of the invention comprises: (1) a mounting bracket that comprises a base portion, an elongate body portion, and a head portion, the head portion comprising a head-portion exterior surface; (2) a first panel comprising a first roofing portion and a first attachment portion adjacent the first roofing portion, the first attachment portion being formed to substantially mate with the head-portion exterior surface; (3) an intermediate member that is formed to substantially mate with an exterior surface of the first-panel; and (4) a second panel comprising a second roofing portion and a second attachment portion adjacent the second roofing portion that is formed to substantially mate with an exterior surface of the intermediate-member. In this embodiment of the invention, the intermediate member is configured to separate at least a portion of the first panel from at least a portion of the second panel. Similarly, the mounting bracket, the first panel, the intermediate member, and the second panel are configured so that after the roofing system is installed adjacent a roofing sub-structure, the first panel, the second panel, or both the first panel and the second panel are substantially free to slide laterally relative to the mounting bracket.
[0016] A further embodiment of the invention comprises a method of providing a wind-resistant roof structure adjacent a roofing sub-structure. This method comprises the steps of: (1) mounting, adjacent the roofing sub-structure, a mounting bracket that includes a base portion and an elongate panel-attachment portion; (2) mounting a first panel adjacent the elongate panel-attachment portion so that the first panel can slide laterally relative to the panel-attachment portion; (3) mounting a second panel adjacent the elongate panel-attachment portion so that the second panel can slide laterally relative to the panel-attachment portion; and (4) mounting an intermediate member adjacent the mounting bracket so that the intermediate member separates at least a portion of the first panel from at least a portion of the second panel when the intermediate member is installed adjacent the mounting bracket.
[0017] This method preferably further includes the step of crimping the second panel about a portion of the mounting bracket so that the movement of the second panel relative to the mounting bracket is at least partially restricted, and so that the second panel is substantially free to move in a direction that is substantially lateral to the mounting bracket. Furthermore, this method further comprises the step of crimping a generally c-shaped portion of the first panel, a generally c-shaped portion of the second panel, or c-shaped portions of both the first panel and the second panel about a head portion of the mounting bracket. In a preferred embodiment of the invention, the crimping step is executed so that, after the crimping step, the movement of the first panel relative to the mounting bracket is at least partially restricted, and the first panel is substantially free to move in a direction that is substantially lateral to the mounting bracket.
[0018] A further embodiment of the invention comprises a method of providing a wind-resistant roof structure adjacent a roofing sub-structure that comprises the steps of: (1) providing a mounting bracket comprising a base portion, an elongate body portion, and a head portion that includes a head-portion exterior surface; (2) providing a first panel comprising both a first roofing portion, and a first attachment portion adjacent to the first roofing portion, the first attachment portion being formed to substantially mate with the head-portion exterior surface, and the first attachment portion defining a first-panel exterior surface; (3) providing an intermediate member that defines an intermediate-member exterior surface and an intermediate-member interior surface that is formed to substantially mate with the first-panel exterior surface; (4) providing a second panel comprising both a second roofing portion and a second attachment portion that is adjacent the second roofing portion, the second attachment portion being formed to substantially mate with the intermediate-member exterior surface; (5) mounting the mounting bracket adjacent the roofing sub-structure; and (6) mounting the first panel, second panel, and intermediate panel so that: (a) the first attachment portion substantially mates with the head-portion exterior surface; (b) the intermediate-member interior surface substantially mates with the first-panel exterior surface; and (c) the second attachment portion substantially mates with the intermediate-member exterior surface; and (7) crimping the second panel about a portion of the mounting bracket so that the movement of the first panel relative to the mounting bracket is at least partially restricted, but the first panel is substantially free to move laterally relative to the mounting bracket.
[0019] A preferred embodiment of the method described above further comprises the step of crimping the first panel about a portion of the mounting bracket. Also, the crimping step is preferably executed so that, after the crimping step, the movement of the second panel relative to the mounting bracket is at least partially restricted, but the second panel is substantially free to move laterally relative to the mounting bracket.
[0020] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028] The present invention will now be described more fully below with reference to the accompanying drawings, which show various preferred embodiments of the invention. This invention 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 invention to those skilled in the art. Like numbers refer to like elements throughout.
[0029] Overview of Roofing System
[0030] A roofing system according to a preferred embodiment of the invention is depicted in FIGS.
[0031] In a preferred embodiment of the invention, each panel
[0032] As may be understood from
[0033] More particularly, the first end
[0034] For the purposes of simplicity, the below discussion will focus on the structure and use of a single panel/bracket assembly
[0035] As may be understood from
[0036] Structure of a Panel/Bracket Assembly
[0037] As noted above, a panel/bracket assembly according to a preferred embodiment of the invention comprises: (1) a mounting bracket
[0038] Mounting Bracket
[0039] A mounting bracket
[0040] As shown in
[0041] The body portion
[0042] As may be understood from
[0043] In addition, the head portion
[0044] First End of First Panel
[0045] A first end
[0046] As may be understood from
[0047] The first roofing portion
[0048] As may be understood from
[0049] As shown in
[0050] Generally speaking, the first end
[0051] Intermediate Member
[0052] As may be understood from
[0053] The intermediate member's body portion
[0054] As may be understood from
[0055] As noted above, the intermediate member attachment portion
[0056] In a preferred embodiment of the invention, the intermediate member
[0057] Similarly, the intermediate member
[0058] In a preferred embodiment of the invention, the first and second lateral movement restricting members are substantially perpendicular to the interior face
[0059] Second End of Second Panel
[0060] A second end
[0061] As may be understood from
[0062] The second roofing portion
[0063] In a preferred embodiment of the invention, the third transitional portion
[0064] As may be understood from
[0065] As shown in
[0066] Installation and Use of a Preferred Embodiment of the Invention
[0067] To install a roofing system according to a preferred embodiment of the invention, a user first attaches a plurality of mounting brackets
[0068] After the first row of mounting brackets
[0069] The installation of a single mounting panel/bracket assembly
[0070] Next, the user positions the intermediate member
[0071] The user then positions the second end
[0072] Once the first end of the first panel
[0073] In preferred embodiment of the invention, the intermediate attachment portion
[0074] In a preferred embodiment of the invention, the second attachment portion
[0075] In a preferred embodiment of the invention, after the crimping process described above is complete, a first mounting portion (e.g., the mounting bracket
[0076] In a preferred embodiment of the invention, the mounting assembly is configured to allow the first attachment portion
[0077] As may be understood by the above discussion, the mounting assembly described above is configured to allow the first and second panels
[0078] As a result of this configuration, when the assembly is subjected to high winds, the first and second panels
[0079] Alternative Embodiment of the Invention
[0080] An alternative embodiment of intermediate member is depicted in
[0081] An assembled panel/bracket assembly
[0082] Materials
[0083] In a preferred embodiment of the invention, the roofing system's mounting brackets
[0084] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.