Roofing panel system and method for making same

• US 6,282,858 B1
• Filed: 02/29/2000
• Issued: 09/04/2001
• Est. Priority Date: 03/04/1999
• Status: Expired due to Fees

• Current Assignee: Andrew C. Swick
• Original Assignee: Andrew C. Swick
• Inventors: Swick, Andrew C.
• Primary Examiner(s): Stephan, Beth A.
• Assistant Examiner(s): Glessner, Brian E.
• Application Number:
  US09/516,443
• Time in Patent Office: 553 Days
• Field of Search: 521/98, 523/021, 525/10, 525/19, 525/20, 525/26, 525/33, 525/47, 525/55, 525/914, 525/915
• US Class Current: 52/533
• CPC Class Codes: E04D 1/20 of plastics; of asphalt; of fibrous materials
• CPC Class Codes: E04D 1/22 of specified materials not covered by any one of groups E04D1/14 - E04D1/205, or of combinations of materials, where at least one is not covered by any one of groups E04D1/14 - E04D1/205
• CPC Class Codes: E04D 1/2916 the fastening means taking hold directly on adjacent elements of the same row
• CPC Class Codes: E04D 1/2918 the fastening means taking hold directly on adjacent elements of succeeding rows
• CPC Class Codes: E04D 1/2949 having joints with fluid-handling feature, e.g. a fluid channel for draining
• CPC Class Codes: E04D 1/30 Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles E04D3/40 takes precedence
• CPC Class Codes: E04D 1/36 Devices for sealing the spaces or joints between roof-covering elements sealing joints not restricted to roof-covering elements E04B1/68; channels at the intersection of roof surfaces E04D13/0445
• CPC Class Codes: E04D 2001/305 Ridge or hip tiles

Abstract

An injection molded rigid roof panel system for constructing pitched roof structures of the type affixed directly to roof trusses or rafters and needing no structural or supporting sheathing surface or moisture barrier. Comprised of no less than (23) standard roof panel components of varying shapes, sizes, colors and exposed surfaces replicating conventional roofing surfaces. Panels overlap, underlap and interlock by means of an array of shoulders, locating ribs and clearance channels creating a unitized roof system utilizing integral seals at the seams, subsurface water channels and self sealing, threaded fasteners whose molded-in, counter-bored holes are further sealed by composite plugs. Panels are produced by mixing, extruding and pelletizing a compound of over 60% recycled materials and encapsulating a semi-rigid fiberglass mesh sheet in the panels during the injection molding process producing a roofing product that is fire retardant, impervious to moisture, insects, ultraviolet rays and winds in excess of 130 mph.

Claims

1. A rigid roof panel system that includes a plurality of overlapping, underlapping and interlocking, application specific panels installed on roof structures using trusses or rafters having a minimum roof pitch of 3:

12 wherein each panel is affixed directly to a top edge of said truss or rafter with no conventional plywood or other rigid sheathing and no moisture barrier required and employs a series of horizontally, vertically and diagonally arrayed water channels that perform their function of shedding water beneath the exposed or visible top surface of the overlapping panels while also providing a method of positively positioning each panel with adjacent panels of the same course and adjacent panels of the previous and following courses with said panels employing an integral seal along a horizontal head-lap and a diagonal edge-lap for each overlapping and underlapping seam, and each panel being securely fastened to the trusses or rafters of the roof structure by means of self sealing, threaded fasteners that are tightened to compress the integral seals and are covered by a composite plug whose design features an exposed surface identical in texture and color to the panel in which it has been installed, whereby said panels are injection molded with a thermoplastic compound comprised in part of recycled plastics, tire rubber and printed circuit board resin wherein said thermoplastic resins, additives and rubber unite in a homogenous blend hardening around and binding to the integral printed circuit board resin, and in which a fiberglass mesh sheet is encapsulated in said compound during the injection molding process providing structural rigidity and the ability to withstand the intermittent flame and fire brand tests required to achieve a UL Class A fire rating as well as wind uplift tests as specified by UL125.