CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to provisional application Serial No. 61/554,128 entitled SEALING PANEL AND GASKET, AND A METHOD FOR USING A SEALING PANEL AND GASKET WITH A CORRUGATED ROOF, filed on November 1, 2011, which is incorporated herein by reference in its entirety.

TECHNICAL FILED OF THE INVENTION

[0002] The invention is directed to a sealing panel and gasket for use with corrugated roofing sheets.

BACKGROUND OF THE INVENTION

[0003] Corrugated roofing systems are typically are made of zinc or plastic roofing sheets that have continuous corrugated channels formed in them. The corrugated roofing sheets allow water to drain and discharge more rapidly than flat roofing sheets because the corrugations accelerate the flow of water along the sheet and distribute it in an orderly fashion to conduct it efficiently to the drainage pipes, which then conduct the water to the ground.

[0004] In many parts of the world, the predominant type of roofing systems are those which use corrugated roofing sheets, especially in rural areas, middle-class and low- budget homes, rustic homes, warehouses and other structures with simple finishing. Corrugated roofing sheets are also used in some structures ^{^} with high standard finishing, such as garages and storage rooms of homes. In many such cases, the structures are left without any ceiling, which leaves the interior of the structure in direct contact with the inner side of the corrugated roofing sheet. Due to the lack of ceiling in such structures, the air, light, odors, insects, animals, and weather elements filtrate through the open space left between the beams or liners and the tin or plastic corrugated roofing sheets placed on them. [0005] A variety of techniques and systems have been proposed or utilized to seal the openings between the inner surface of the corrugated roofing sheet and the upper surfaces of the side walls of the structure. One such technique has been used by the inventor of the present invention and is the subject of Costa Rican Utility Model Application No. 10042, filed on June 4, 2008. That application discloses a sealing panel for use with corrugated roofing sheets to seal openings between the interior surface of a corrugated roofing sheet and the upper surfaces of the side walls of a structure that employs the roofing system.

[0006] Fig. 1 illustrates a side perspective view of the sealing panel 2 disclosed in Costa Rican Utility Model Application No. 10042. The sealing panel 2 is made of a durable plastic material. The sealing panel 2 is installed in the following manner. The sealing panel 2 has an upper edge 2a that is shaped to match the contour of the interior surface of the corrugated roofing sheet with which the panel 2 will be used. After the corrugated roofing system has been installed on a structure, an interior surface 2b of the panel 2 is held against a side wall of the structure and then pressed upwards until the upper edge 2a of the panel 2 is in abutment with the interior surface of the corrugated roofing sheet. The panel 2 is then secured in this position to the side wall of the structure using a fastening mechanism, such as, for example, nails, staples, rivets, or an adhesive material. In this way, the panel 2 seals any openings that existed at the interface of the interior surfaces of the corrugated roofing sheets and the upper surfaces of the side walls of the structure.

[0007] While the sealing panel 2 generally works well, slight mismatches between the upper edge 2a of the panel 2 and the shape of the corrugated roofing sheet sometimes exist. These mismatches may be caused by manufacturing tolerances of the corrugated roofing sheets and/or of the panels 2, by subsequent changes in the shape of the sheets and/or of the panel, by subsequent shifts in the positions of the sheets and/or of the panels relative to each other, by subsequent shifts in the positions of the side walls, etc. These mismatches can result in small air gaps existing in between the upper edges 2a of the panels 2 and the interior surfaces of the corrugated roofing sheets, which can reduce the effectiveness of the sealing panels 2. [0008] Accordingly, a need exists for a sealing panel and method for use with corrugated roofs the reduces or eliminates the possibility of air gaps existing in between the upper edges 2a of the panels 2 and the interior surfaces of the corrugated roofing sheets.

SUMMARY OF THE INVENTION

[0009] The invention is directed to both a sealing panel and gasket, a system and a method. The system comprises first, a sealing panel having at least a first side surface and an upper edge and second, a deformable gasket. The upper edge substantially matches and fits into the interior surface of a corrugated roofing sheet with which the sealing system is intended to be used. The deformable gasket is disposed on the upper edge of the sealing panel. If the sealing panel is installed on a structure, the gasket is sandwiched between the upper edge of the sealing panel and the interior surface of the corrugated roofing sheet. The gasket ensures a reduction or elimination of air gaps between the upper edge of the sealing panel and the interior surface of the corrugated roofing sheet.

[00010] The method of installing system, the panel having the gasket thereon, comprises the following. After the corrugated roofing system has been installed on a structure, an interior surface of the sealing panel is held against a side wall of the structure and then pressed upwards until the gasket is sandwiched between the upper edge of the panel and the interior surface of the corrugated roofing sheet. When using a deformable gasket, the force exerted on the gasket causes it to deform and create a tight seal between the upper edge of the panel and the interior surface of the corrugated roofing sheet. The panel is then secured in this position to the side wall of the structure using a fastening mechanism, for example, nails, stales, rivets, bolts, or adhesive materials. Installing the system in this manner ensure that a substantial reduction in the number of air pockets and opening that exist at the interface of the interior surfaces of the corrugated roofing sheets and the upper surface of the side walls of the structure. BRIEF DESCRIPTION OF THE DRAWINGS

[00011] Fig. 1 illustrates a side perspective view of a known sealing panel.

[00012] Fig. 2 illustrates a side perspective view of the sealing panel of the invention in accordance with an illustrative embodiment shown without a gasket.

[00013] Fig. 3 illustrates an end view of the sealing panel shown in Fig. 2 having a gasket disposed on an upper edge thereof in accordance with an illustrative embodiment.

[00014] Fig. 4 illustrates a side plan view of the gasket shown in Fig. 2.

DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT

[00015] In accordance with embodiments of the invention, a sealing panel of the type shown in Fig. 1 has a deformable gasket disposed on an upper edge thereof. When the panel and gasket are installed, the gasket deforms as it is pressed against the interior surface of the corrugated roofing sheet. This deformation of the gasket ensures a reduction in air gaps that may otherwise exist between the sealing panel and the interior surface of the corrugated roofing sheet.

[00016] Fig. 2 illustrates a side perspective view of a sealing panel 10 in accordance with an illustrative embodiment for use with corrugated roofing sheets. The sealing panel 10 may be identical to the sealing panel 2 shown in Fig. 1. Fig. 3 illustrates an end view of the sealing panel 10 shown in Fig. 2 having a gasket 20 in accordance with an illustrative embodiment disposed on an upper edge 10a of the sealing panel 10. Fig. 4 illustrates a side plan view of the gasket 20 shown in Fig. 2.

[00017] The sealing panel 10 may be made of any suitable material, including, for example, plastic or metal. With reference to the X-, Y- and Z-Cartesian Coordinate system shown in Fig. 2, the sealing panel 10 is relatively thin in width, i.e., in the X dimension. The sealing panel 10 generally has a width of about 0.8 inches, although it may have smaller or larger widths. Making the panel 10 thin provides the panel 10 with flexibility in the X dimension that allows it to easily conform to the exterior surface of a structure or building on which it will be installed. Typically, the panel 10 is made of a flexible plastic material that repels moisture, such as, for example, a high-density polyethylene. [00018] The sealing panel 10 is generally rigid in the Z dimension so that it retains its shape in the Z dimension before, during and after installation. The sealing panels 10 are manufactured to match the Y and Z dimensions of the interior surfaces of the corrugated roofing sheets with which the panels 10 will be used. In particular, when the sealing panel 10 is manufactured, it is cut such that the upper edge 10a of the panel 10 maps to the interior surface of a corrugated roofing sheet (not shown) in directions along the Y- and Z-axes, which corresponds to the length-wise and height-wise dimensions of the panel 10.

[00019] The gasket 20 may be made of any suitable material, preferably a deformable material, but it is typically made of a plastic material that is moisture repellant. In accordance with the illustrative embodiment shown in Figs. 3 and 4, the gasket 20 comprises a plastic tubing material, such as a dense flexible water resistant plastic foam tube commonly referred to as backing rod. For exemplary purposes, it will be assumed that such a plastic foam tube is used as the gasket 20, although the gasket 20 may have other forms and be made of other materials. The tube 20 has a small opening 20a on an outer surface of the tube formed in it that extends along the length of the tube 20. The opening 20a has a width that is approximately equal to, and typically slightly smaller than, the width of the panel 10. The tube 20 is disposed along the upper edge 10a of the panel such that the upper edge 10a of the panel 10 is gripped by the side walls 20b, 20c and 20d of the opening 20a. An adhesive material, such as epoxy or glue, for example, may be placed on the upper edge 10a of the panel 10 before the tube 20 is disposed thereon to fixedly secure the side walls 20b, 20c and 20d of the opening 20a to the upper edge 10a of the panel 10.

[00020] The panel 10 having the gasket 20 thereon is installed by an installation process as follows. After the corrugated roofing system has been installed on a structure, an interior surface 10b of the panel 10 is held against a side wall of the structure and then pressed upwards until the gasket 20 is sandwiched between the upper edge 10a of the panel 10 and the interior surface of the corrugated roofing sheet. When the gasket 20 is sandwiched in between the upper edge 10a of the panel 10 and the interior surface of the corrugated roofing sheet, the forces exerted on the gasket 20 cause it to deform and create a tight seal between the upper edge 10a of the panel 10 and the interior surface of the corrugated roofing sheet. The panel 10 is then secured in this position to the side wall of the structure using a fastening mechanism, such as, for example, nails, staples, rivets, or an adhesive material. In this way, the panel 10 having the gasket 20 thereon reduces the number of openings or pockets that might have otherwise existed at the interface of the interior surfaces of the corrugated roofing sheets and the upper surfaces of the side walls of the structure.

[00021] In the event that there are slight mismatches between the upper edge 10a of the panel 10 and the shape of the interior surface of the corrugated roofing sheet, which may be due to manufacturing tolerances or shifts that occur after installation, any openings, pockets or air gaps that such mismatches may have caused will be filled in by the deformed gasket 20, thereby improving the effectiveness of the sealing panel 10.