Abstract:
An assemblage of sheet metal roof covering pieces is utilized in a novel process to recover and stiffen a deteriorated roof without the necessity for extensive removal of the original roof covering, the deteriorated roof structure further stiffened by spaced stiffening ribs that also serve to fix in interlocked engagement the sheet metal roof covering pieces. Included in the assemblage are interlocking valley pans that are sequentially compressed between the ribs and then fastened with the valley pans then bridged by curved sheet metal caps that are also interlocked. The resulting structure has the pleasing appearance of an Oriental tile roof.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the method and structure for installing sheet metal roofing shingle arrays, and more particularly to the method and structure of mounting stamped sheet metal roof covering pieces conformed to interlock into exterior shapes reproducing the shape of oriental roofing tile and fastened onto reinforcing ribs. 
     2. Description of the Prior Art 
     Over long historic periods a roofing system has been practiced in China in which fired clay or ceramic valley pans are bridged at their adjacent edges by semicircular caps, resulting in a very distinct appearance. This roofing process, with some minor variations, has been adopted in the neighboring areas and is therefore now known by the familiar expression ‘Oriental Roof’. With some frequency this oriental roof styling covers distinctly appearing building structures and it is therefore associated with distinct architectural motifs. The pleasing, well appreciated oriental styling motif obtains its visual underpinnings from the ribbed skeletal structure originally used to support the tile and the convolved shape is particularly useful in creating visual interest and distinctiveness in commonly designed building tracts. When implemented in traditional fired clay or ceramic tile, however, structures that have been appropriately ribbed and reinforced would be needed to accommodate this roofing weight and the ribbed roof exterior therefore suggests some structural efficacy. Recently, however, the construction techniques of frame housing prefer light weight over structural bulk and the interesting ornamental variety of this venerable roofing method has not had appropriate adaptation to our mode of life. 
     One constant process of life is the wear and damage that is universally sustained with time, including the wear and deterioration of the roofing shingles covering our buildings. As result a variety of roof coverings have been devised in the past that can be applied directly onto the most common roof covering, i.e., asphalt shingle, and these replacement roof coverings are now widely used. These, however, do little to improve the structure supporting the roof which very often also suffers some deterioration as the original roof covering fails. Amongst these are various forms of sheet metal shingle, also frequently applied directly on top of the existing asphalt tile, the substantially more rigid and durable aspects of a metal stamping being used to advantage to bridge and cover the deteriorating structure of the asphalt tile and also of its underlayment. Examples of stamped sheet metal roofing tile can be found in the teachings of U.S. Pat. No. 5,613,337 to Plath et al, U.S. Pat. Nos. 4,185,436 and 4,218,857 to Vallee, U.S. Pat. No. 6,298,625 to Sweet, U.S. Pat. No. 5,442,888 to Ilnyckyj and others. While suitable for the purposes intended, each of the foregoing examples describes a generally flat shingle structure which obtains structural stiffness only within the individual stamping itself and therefore lends little support over greater spans. For those instances where longer bridging spans are required, as in roof structures that show some deflection in the joists and beams themselves, little is available in the marketplace. 
     A convenient roof covering technique that includes structural reinforcement is extensively desired and it is one such technique that is described herein utilizing to advantage oriental roofing to accomodate reinforcement of structural beams. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is the general purpose and object of the present invention to provide an assembly of sheet metal roof covering pieces which are useful with stiffening ribs applied in a novel process of recovering a roof. 
     Other objects of the invention are to provide a roof recovering method and structure in which the new roofing tile is installed in conjunction with stiffening ribs. 
     Yet additional objects of the invention are to provide a novel process for recovering roofs in which the roof covering includes reinforcing ribs. 
     Further objects of the invention are to utilize the ornamental aspects of an oriental roof covering to provide stiffening structure in the course of roof repair. 
     Briefly, these and other objects are accomplished within the present invention by providing a stamped sheet metal array of roof covering pieces which are affixed to a roof along with a set of generally parallel wood ribs, selected ones of which being aligned over the roof joists and rafters supporting the roof to provide stiffening thereto. The valleys between these ribs are then covered by stamped pans included in the inventive roofing array and the adjacent edges of the pans are bridged by semicircular caps arched over the subjacent ribs, thus replicating the exterior shape of an oriental roof Additional pieces of the array are then useful as end plugs closing the open cap ends, shaped blocks to cover the voids defined by each pan and other stampings for any necessary ridge covering and ridge connections. This assortment of pieces may be formed from relatively thin sheet metal such as galvanized sheet, aluminium or copper sheeting and may be coated, painted or otherwise colored to reproduce the color scheme of oriental roofing tile. 
     Preferably this combination of sheet metal pieces and the stiffening ribs is laid on top of a surface of roofing felt that is first positioned to cover the old roofing. Thus the ribs provide the further advantage of enhanced attachment of the roofing layers, reducing the incidents of peeling and tearing caused by weather and wind. In addition, the inventive recovering process entails bending of interlocking folds in the course of fastening thereof to the stiffening ribs, this bending process further improving structural integrity. 
     It will be appreciated that the ultimate shape of each cap and valley tile will be determined by the curling and bending thereof in the course of installation. The inventive process, therefore, is particularly suitable for existing structures that have distorted or settled with time effected by reproductions of old roof coverings which themselves varied in the course of their fabrication. Accordingly, the instant process is particularly suitable for the do-it-yourself practitioner. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective illustration, separated by parts, of the inventive roofing combination aligned to recover a previously covered roof; 
     FIG. 2 is a further perspective illustration of the inventive roofing combination in its installed form; 
     FIG. 3 is a sectional view of the inventive roofing combination taken along line  3 — 3  of FIG. 2; 
     FIG. 4 is yet another sectional view of the inventive roofing combination taken along line  4 — 4  of FIG. 2; 
     FIG. 5 is a detail illustration, in perspective and in partial section, of the end structure useful with the inventive roofing combination; 
     FIG. 6 is a further detail illustration, in perspective, of the ridge piece structure useful with the inventive roofing combination; 
     FIG. 7 is a sectional view taken along line  7 — 7  of FIG. 6 of the ridge piece useful with the inventive roofing combination; 
     FIG. 8 is yet a further detail illustration, in perspective, of a ridge fairing useful with the inventive roofing combination; and 
     FIG. 9 is a sequence diagram of the steps comprising the inventive roofing process described herein. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in FIGS. 1-8 the inventive sheet metal roofing array, collectively designated by the numeral  20 , includes a plurality of formed sheet metal valley pans  21 , a further plurality of sheet metal cover caps  31  and also a plurality of stamped ridge caps  41 . Included further in the array are stamped, circular cover cap lids  51  and also semicircular ridge cap lids  61  for finishing off respectively the exposed ends of cover caps  31  and ridge caps  41 . Provided further is an assortment of fairings, flashings and stops including ridge flashing  72 , bird stops  73  and  74  and apex covers  75   a  and  b  and  76   a  and  b . This complement of parts and components is useful with a vertically aligned set of stiffening ribs  111  in the form of conventional  2 ″ by  4 ″ nominal construction lumber that may be laid on top of a layer of roofing felt  112  rolled onto the existing roof covering ERC that, because of its wear, is to be recovered. To obtain the maximum structural benefit selected ones of the stiffening ribs  111  are aligned directly over the subjacent existing roof beams or rafters RJ and fastened thereto by way of long fasteners  113  extending all the way through the the stiffener, the felt layer, the exising roof covering and then into the beam. Depending on the spacing of the roofing framework one or more additional ribs  111  of similar construction lumber may be fastened to the roof between those fastened to the framework and each of the valley pans  21  are therefore dimensioned to accomodate an integer division of typical framework spacing. 
     Those in the art will appreciate that under current practice the roof beam spacing is typically 16 inch or 24 inch center to center. Each of the valley pans  21 , therefore, is sized in width to about a 7 inch planform, allowing for an overlay of its lateral edges  22  and  23  onto the corresponding vertical surfaces  111   a  and  b  of the adjacent ribs  111 , to be fastened thereto by nails or other fasteners  115 . Longitudinally each valley pan  21  is dimensioned to a net dimension once again in integer units (e.g., two feet) defined two transverse edges  24  and  25  each including a corresponding fold  26  and  27  over the opposite pan surfaces for effecting a stepped interlock between the pans as they are fitted in a column up the valley covering the space between adjacent ribs. In each instance the lower edge of the upper pan that is interlocked with the one below it is forced down against the felt layer  112  and as so held the bent upwardly lateral edges  22  and  23  adjacent the interlock are nailed to the side surfaces  111   a  and  b  of the ribs  111 , the overlying alignment resulting from the dimensional excess in the pan width. The fastened edges  22  and  23  on either side of each rib  111  are then covered and bridged by the arched caps  31 , each cap again being defined by lateral edges  32  and  33  extending between transverse edges  34  and  35  formed by opposed folds  36  and  37  that are, once more, interlocked for a stepwise progression over each rib in a manner similar to the pans. 
     It will be appreciated that the foregoing installation process distorts in bending the folded transverse edges that are interlocked with the next valley pan or cap in each instance. Thus the installation sequence assists structural integrity by further crimping the interlock, thereby assuring better resistance to wind damage. Moreover, as each cap and valey pan is fastened to the ribs small adjustments can be effected in the curvature or edge bending to accomodate any settling and other distortion that is usually found in all existing structures. The inventive process, therefore, enhances both the resulting strength of sheet metal roof covering and the stiffness of the whole roof structure while also providing an interesting architectural variant of the finished roof covering. 
     To further enhance both the structural integrity and the visual appearance the lower ends of each of the ribs  111  may be covered by the circular lids  51  fitted subjacent the transverse edges of caps  31 , each lid including a cylindrical skirt  52  formed in the course of its stamping. The sheet metal structure of the skirt is then trimmed and shaped to conform with any roof edge treatment ET and once so shaped may be affixed directly to the rib end by one or more nails  115 . At the top end ridge boards  121  may be affixed on top of the felt  112  on both sides of each roof ridge RR to which the flashing  72  may be affixed and which thereafter may be covered an bridged by ridge caps  41 , again defined by longitudinal edges  42  and  43  extending between transverse edges  44  and  45 . As with caps  31  this interlocked row of ridge caps is curled to a tighter bend in the course of fastening to the ridge boards  121  by nails  115 , thereby crimping the interlocked folds  76  and  77  for better structural engagement. The ends of these ridge cap rows may then be finished off by by one of the several apex covers  75   a ,  75   b , or  76   a  depending on the roof configuration. Bird stops  73  and  74 , each in the form of an L-sectioned sheet metal strip provided with semicircular cut-outs  73   a  or  74   a  in one leg thereof, can then be applied to cover any voids and overhangs formed by the ridge caps, the bird stops being formed to include cutouts  73   a  or  74   a  at various densities to accomodate various ridge alignments. Any open end voids in the cover caps  31  or ridge caps  41  can then be filled by the semicircular caps  61 . 
     It will be appreciated that this inventive process and structure for effecting a sheet metal roof cover is particularly suited for those homeowners that would like to do it themselves. The process permits one to retain the integrity of the old roof covering, thereby permitting a piece-wise construction that creates little disruption in the use of the home being covered. Moreover, the process lends itself to all sorts decorative options and color schemes allowing the home owner the desired freedom of personal taste expression. 
     In each instance the inventive process  200  commences with the original roof covering that may be left in place, or may be removed in those sections that require repair, followed by a covering of a layer of roofing felt in step  201 . The ridges RR are then trimmed with the ridge boards  121  in step  202  and thereafter the vertical stiffeners  111  are fastened to the roof in step  203  with those aligned over the original rafters fastened thereto. This skeletal structure both reinforces the original roof and also provides the attachments and alignment for the installation of the interlocked valley pan  21  in columns between the adjacent stiffeners, in step  204 , which are then bridged by the cover caps  31  in step  205 . In both the steps  204  and  205  substantial manual flexure of the individual pieces while such are fastened both assures a positive structural interlock and also accomodates structural distortions. Once this is done the remaining openiongs and gaps are then trimmed out in step  207 . In this manner a conveniently effected covering technique is devised which replicates the distinct architectural motifs of oriental roofing. 
     Obviously many modifications and variations can be effected without departing from the spirit of the invention instantly disclosed. It is therefore intended that the scope of the invention be determined solely by the claims appended hereto.