FIELD OF THE INVENTION

The present invention relates to weather coverings and in particular to shingles and related components.

BACKGROUND OF THE INVENTION

Numerous designs for metal shingles have been developed over the years. These shingles typically have edge flanges that are adapted to interconnect with adjacent shingles to attempt to create a substantially weather resistant barrier. Examples of such shingles are provided in U.S. Patents 1,670,041 (Miller), 1,743,206 (Fulenwider et al.) and 1,876,597 (Bennett).

The Miller patent teaches a two-course shingle system where each shingle has an upper course with outwardly tapering side edges and a lower course with inwardly tapering side edges. The top, bottom and side edges of the shingle are overturned and underturned for engaging adjacent shingles. One problem with this shingle system is that shingle is subject to leakage during severe weather conditions when water may be blown upwardly to the upper course of the shingle through openings in the interlocking edges of adjacent shingles. Another problem is that the system requires close tolerances between the engaging shingles. This limits the adjustability of the shingles relative to the course below. This complicates installation when the installer is faced with obstructions such as bathroom vents, hips or valleys.

The Fulenwider patent teaches a single course shingle system where each shingle has opposing side edges that define corresponding shoulders, an underturned bottom edge and an overturned top edge. The overturned top edge is defined by a separate lock fastener that is secured to an upturned flange on the top edge of the shingle. One problem with this shingle design is that the lock fastener does not adequately seal the

joint between adjacent shingles. As a result, this shingle design is subject to leakage during severe weather conditions. Another problem with the shingle system is the structure of the side shoulders. The shoulders are difficult to reproduce on site if it is necessary for an installer to cut a shingle from top to bottom to account for obstructions. As a result, installation is complicated.

The Bennett patent teaches a single course shingle system where each shingle has opposing overturned and underturned side edges and an underturned bottom edge. A separate dam strip is provided for fastening along the top edge of a course of shingles. The dam strip has a foot portion for attaching the strip to the roof, a bulge for receiving the top edge of the shingles and an angular strip that extends generally perpendicular to the roof line. One problem with this system is that the dam strip does not adequately guard against water leakage through nail holes where each shingle is attached to the roof. Also, the strip must include a cutaway portion to receive the joint at adjacent side edges. This cutaway portion is a further area where leakage can occur. Finally, the side edges have complicated contours that are difficult to reproduce on site if an installer needs to cut a shingle. There is a need for a roofing system that overcomes the above problems. Furthermore, the roofing system should be relatively simple to install and inexpensive to manufacture.

SUMMARY OF THE INVENTION

In one aspect the invention provides a shingle system comprising: a fastening strip having a top flange that includes a fastener portion for receiving fasteners; and a plurality of shingles, each said shingle having a body with a top edge, a bottom edge and side edges, each said shingle defining fastening strip connecting means for connecting said shingle to said fastening strip.

In another aspect, the invention provides a fastening strip for shingles, comprising: a top flange including a fastener portion for receiving fasteners; a gasket located on a bottom surface of the fastener portion of the top flange for providing a weather resistant seal along the length of the fastening strip between the fastening strip and at least one shingle.

PRIEF DESC IPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings. The drawings show preferred embodiments of the present invention, in which:

Fig. 1 is a top view of a roof incorporating a plurality of shingles and fastening strips in accordance with the shingle system of the present invention;

Fig. 2 is a top view of a first shingle in accordance with a first embodiment of the present invention;

Fig. 3 is a top view of a second shingle in accordance with the first embodiment of the present invention; Fig. 4 is a sectional view of the first shingle of Fig. 2 taken along lines 4-4;

Fig. 5 is a sectional view of the second shingle of Fig. 3 taken along lines 5-5;

Fig. 6 is a sectional view of the second shingle of Fig. 3 taken along lines 6-6;

Fig. 7 is a sectional view of interconnected side edges of the shingles of Fig. 1 taken along lines 7-7;

Fig. 8 is a sectional view of interconnected side edges of the shingles of Fig. 1 taken along lines 8-8;

Fig. 9 is a perspective partial view of a first embodiment of fastening strip in accordance with the present invention- Fig. 10 is a partial sectional view of adjacent courses of shingles attached to a roof using the fastening strip of Fig. 9; Fig. 11 is a partial perspective view of a second embodiment of fastening strip in accordance with the present invention;

Fig. 12 is a partial sectional view of adjacent courses of shingles attached to a roof using the fastening strip of Fig. 11;

Fig. 13 is a sectional view of a second embodiment of shingle in accordance with the present invention;

Fig. 14 is a top view of a roof cap flat in accordance with the present invention;

Fig. 15 is a perspective view of the roof cap flat of Fig. 14 that has been bent to a desired angle to form a roof cap for fitting to a roof; and Fig. 16 is a partial sectional view of adjacent courses of roof caps attached to a roof as viewed along lines 16-16 of Fig. 15.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A shingle system in accordance with the present invention is shown generally at 10 in Fig. 1. The shingle system 10 comprises a plurality of shingles 12 and a fastening strip 14. The shingles 12 are applied to a surface 16 such as a roof.

The shingles 12 each comprise a body 18 having a top edge

20, a bottom edge 22 and two opposing side edges 24. The bottom edge 22 is bent to define an underturned flange 30. A connector 32 (see Figs. 6, 10 and 12) is located on the flange 30. The body 18 is preferably rectangular with the top and bottom edges 20 and 22 being longer than the side edges 24. It will be appreciated however that the shingles 12 may have other desired shapes that combine with adjacent shingles 12 in a pattern to cover the surface 16.

The shingle body 18 is formed from a sheet of metal, plastic or other durable material that is molded, shaped or bent into a desired form.

A plurality of peaks 26 may be formed in the sheet by a stamping, molding or other appropriate process. The peaks 26 are provided to add rigidity to the body of the shingle 12 and to provide a decorative appearance to the shingled roof. It will be noted that partial peaks 26a are provided adjacent to the side edges 24 of the shingles 12 so that adjacent shingles 12 will combine to form a single peak 26.

It is desirable that a substantial portion of the body 18 remain flat so that it may rest against the roof surface 16 and allow the shingles 12 to be walked upon. Referring to Figs. 6, 10 and 12 it can be seen that the shingle 12 is contoured from top to bottom so that a substantial portion rests against the roof 16 and the bottom portion overlaps a fastening strip 14 or 14' and a lower course shingle 12. This contouring is preferably incorporated as part of the decorative shaping of the shingle. For instance, the bottom portion of the shingle running adjacent to the bottom edge 22 may be stamped to incorporate the contour.

Referring to Figs. 1-8, a first embodiment of the shingle system 10 is shown. In this embodiment, two configurations of shingles are provided in an alternating pattern along each shingle course 13. A first shingle 12a is shown in Figs. 2 and 4 and a second shingle 12b is shown in Figs. 3, 5 and 6.

Referring to Figs. 2 and 4, the first shingle 12a has an overturned flange 28 defined along each side edge 24. The top edge 20 of the first shingle 12a is shorter than the bottom edge 22 so that the side edges 24 taper outwardly from top to bottom. Referring to Figs. 3 and 5, the second shingle 12b has an underturned flange 34 defined along each side edge 24. The top edge 20 of the second shingle 12b is longer than the bottom edge 22 so that the side edges 24 taper inwardly from top to bottom.

As shown in Figs. 7 and 8, the overturned flange 28 and underturned flange 34 of adjacent side edges 24 of shingles 12a and 12b are adapted to slidably interconnect. The flanges 28 and 30 have a relatively

simple L-shaped construction so that an installer can cut a shingle 12 from top to bottom and form a flange with pliers if necessary. The flanges 28 and 34 are arranged in substantially the same plane as the underside of the shingle body 18 so that the body 18 rests against the roof 16. The opposing tapers of the first and second shingles 12a and 12b help to snugly connect the shingles together. It has been found that a taper of 1/4 inch over a height of twelve inches between the top and bottom edges provides a satisfactory snug fit.

Referring to Figs. 9 and 10, a first embodiment of fastening strip 14 is shown. The fastening strip 14 is elongate and preferably has a length that is sufficient to extend along the top edge 20 of several adjacent shingles 12. The fastening strip 14 is preferably constructed from metal or plastic.

The fastening strip 14 includes a top flange 36 and a bottom flange 38 connected by a living hinge 40. The bottom flange 38 of the fastening strip 14 is substantially flat for resting against the surface of a roof 16. The bottom flange 38 may be tacked into place on the roof 16 to conveniently set the position of the fastening strip 14 prior to installing a course 13 of shingles 12. The living hinge 40 conveniently connects the top and bottom flanges 36 and 38 to facilitate lifting the top flange 36 to tack the bottom flange 38 into place on the roof 16. The living hinge 40 also defines a lip 39 for conveniently aligning the fastening strip 14 along the top edge 20 of a shingle 12. Overall, the fastening strip 14 allows each course 13 of shingles 12 to be adjusted relative to a lower course 13. This accounts for slight imperfections that can occur during installation.

The top flange 36 has a hook 42 defined along its free edge for engaging the connector 32 that is located on the underturned flange 30 of an upper course shingle 12. The connector 32 depicted in Fig. 10 is a simple hook that engages to the hook 42 on the fastening strip 14. The top flange 36 further includes a substantially flat fastener portion 44 for receiving a

fastener such as a nail, screw or other appropriate means for attaching a shingle 12 to the roof.

The top edge 20 of a lower course shingle 12 is enveloped between the top flange 36 and bottom flange 38 of the fastening strip 14. A gasket 48 is located on the bottom surface of the fastener portion 44 of the top flange 36 for sealing the connection between the fastener 46, top flange 36 and the lower course shingle 12. The gasket 48 preferably includes a lip 50 at its lower end for improving the seal between the gasket 48 and the lower course shingle 12. The gasket 48 is preferably formed from a sealing material that is weather resistant such as silicone or a rubber composite. The living hinge 40 provides a secondary water resistant guard behind the gasket 48.

Referring to Figs. 11 and 12, a second embodiment of fastening strip is shown as 14'. The fastening strip 14' is similar in construction to the first embodiment of fastening strip 14 except that no bottom flange 38 and living hinge 40 is provided. The fastening strip 14' includes a top flange 36' and gasket 48' with lip 50'. The top flange 36' has a hook 42' defined at one free edge, a flat fastener portion 44' for receiving fasteners 46 and a lip 39' at the other edge for aligning the fastening strip 14' along the top edge 20 of a shingle 12. A different form of connector 32 is shown by way of example in Fig. 10.

When the second embodiment of fastening strip 14' is used, the top edge 20 of the lower course shingle 12 rests against the roof 16. The fastening strip 14' is then positioned along the top edge 20 and fastened with fasteners 46. The fasteners 46 extend through the flat fastening portion 44' of the top flange 36', the gasket 48', the lower course of shingle 12, and the roof 16. The top edge 20 of the lower course shingle 12 preferably defines an upturned lip 21 to add rigidity along the top edge 20 and to provide a secondary water resistant seal along the top edge 20 behind the gasket 48'.

The method of installing the first embodiment of shingle system 10 is shown in Fig. 1 and described below. A fastening strip 14 is fastened along a lower edge of a roof 16 using fasteners 46. The first course 13

of shingles 12a and 12b is then arranged along the roof with the first and second shingles 12a and 12b alternating along the course 13 such that the overturned flange 28 and underturned flange 34 of adjacent side edges 24 slidably interconnect. The underturned flange 30 on the bottom edge 22 of the shingles 12a and 12b is hooked beneath the top flange 36 of the fastening strip 14. Several shingles 12a and 12b may be laid without fasteners 46 so that they can be adjusted to a desired position along the course 13. Once the shingles are positioned as desired, a fastening strip 14 is positioned along the top edge 20 of the shingles 12a and 12b and the shingles 12a and 12b and fastening strip 14 are fastened to the roof 16 with the fasteners 46. The next course 13 of shingles 12a and 12b is then ready to be laid. In the alternative, an installer may first install the fastening strips 14 along successive courses 13 prior to installing the shingles. It will be appreciated that either the first or second embodiment of fastening strip 14 or 14' may be utilized for attaching the above-noted shingle system 10.

It will be appreciated that the shingle system can be installed with simple tools such as snips and pliers. Also, it will be appreciated that the side to side adjustability facilitated by the system and the low profile of the fastening strip 14 or 14' allows the shingle to be installed around vents and the like using a similar cutout method as is used for conventional asphalt or cedar shingles. The system thus provides simplified installation compared to conventional metal shingles.

The fastening strip 14 or 14' acts to provide a water resistant seal along the top edge 20 of a shingle course 13. In effect the course 13 of shingles 12 is substantially sealed without relying upon the adjacent upper course 13 of shingles 12 to be arranged in precise relation to the lower course 13. This allows the installer the freedom to adjust the next shingle course 13 to a desired position to account for obstacles without effecting the water resistant fit of the shingles 12 relative to the lower course 13. Referring to Fig. 13, a side- to-side sectional view (similar to

Figs. 4 and 5) is shown of a second embodiment of shingle 12'. The second

embodiment of shingle 12' is similar to the first embodiment in all respects except that one side edge 24 has an overturned flange 28' and the other side edge 24 has an underturned flange 34'. Also, the side edges 24 have no taper from top to bottom. This second embodiment of shingle 12' does not require a two shingle system such as is used for the first embodiment. Instead, a single shingle 12' is adapted with flanges 28' and 34' on its side edges 24 for interconnecting with an identical single shingle 12'. An advantage of this arrangement is that only one type of shingle 12' needs to be used for covering the roof 16. It will be appreciated that the method for fastening the shingles 12' to the roof using either the first or second embodiment of fastening strips 14 or 14' is similar to the method described earlier with respect to the first embodiment of shingle 12a and 12b.

Referring to Figs. 14-16, a roof cap 70 is depicted for covering the peak of the roof 16. As shown in Fig. 14, the roof cap 70 is provided as a flat sheet 72 having a peak 74 defined along its mid-point. The peak 74 defined along the mid-point of the roof cap 70 defines a fold line 76 for bending the roof cap 70 evenly along its length. The roof cap 70 has a leading edge 78 that defines an underturned flange 80 having a hook 81. The roof cap 70 also has a tailing edge 82 and opposing side edges 84 all of which are flat. Referring to Fig. 15, the roof cap 70 is bent on site to a desired angle approximating the angle of the roof peak. The side edges 84 may taper outwardly from the tailing edge to the leading edge 78 so that bent roof cap 70 has substantially even sides despite the deformity caused by the peak 74.

Referring to Fig. 16, the second embodiment of fastening strip 14' as described above is cut to a length approximating the width between the side edges 84 of the roof cap 70. The fastening strip 14' is similarly bent on site at a mid-point to an angle approximating the roof peak angle. A first course of fastening strip 14' is fastened to one end of the roof 16 with the top flange 36' facing outwardly over the roof end. A roof cap 70 is then positioned with the hook 81 of the underturned flange 80 engaging the hook 42' of the top flange 36' of the fastening strip 14'. A second fastening

strip 14' is then bent and positioned along the tailing edge 82 of the roof cap 70 and fastened to the roof 16 with the fastener 46. The exercise is then repeated along the entire length of the roof peak.

It is to be understood that what has been described are preferred embodiments of the invention. The invention nonetheless is susceptible to certain changes and alternative embodiments fully comprehended by the spirit of the invention as described above, and the scope of the claims set out below.