Patent Publication Number: US-2023137730-A1

Title: Non-Penetrating Roofing System and Methods of Installation

Description:
BACKGROUND OF THE INVENTION 
     1) Field of the Invention 
     The present disclosure relates to devices and methods for installing a new roof that does not require penetration of the outward facing roof surface, conjoined panels secured with a securement bar provide an easily installed, durable, and non-penetrating surface covering for roofs. 
     2) Description of Related Art 
     Roof installation commonly requires very tedious installation steps, as well as requires puncturing the roof of the building hundreds, if not thousands, of times to secure roof panels or shingles to a structure&#39;s roof. Typically, nails or screws are used to install the roofing along each rib in the panel with screws beginning about seven (7) inches from the bottom of the roof and placing subsequent screws/nails from eighteen (18) to twenty four (24) inches apart along the vertical run. Attempts to prevent leaks, such as placing a washer under the screw or nail head have been attempted to prevent the screw or nail from creating an access for foreign objects, insects and/or water to leak into the structure. However, overtightening or failing to secure the nail or screw can render this attempt useless while also perforating the roof structure. Further, some installations use a line of sealant, such as silicone, between roof panels along the underside of the short edge of the next panel so that the sealant will spread and adhere, creating a seal. 
     Roofing screws are responsible for the majority of leaks on metal roofs. Metal roofing screws seal water out by compressing a rubber washer at the base of the screw head. When the screw is driven into the metal roofing panel the rubber washer forms a “gasket” between the roofing panel and the screw head. It sounds simple enough but several things can go wrong with screw installation such as: under driving screws; over driving screws; driving screws at the wrong angle; and screws that missed the framing member. Even if the screws are installed correctly, leaks may then occur due to failure of the gasket at the screw head. Hot summers followed by hard cold winters are unkind to the washers, which degrade and lose their seal. Moreover, it is can be very difficult visually to distinguish a screw that is leaking from one that is not. 
     What is needed is an improved roofing system that does away with the multitude of punctures created by ordinary roofing systems. Accordingly, it is an object of the present invention to provide a punctureless, non-penetrating roof installation system and methods of installing same. 
     Citation or identification of any document in this application is not an admission that such a document is available as prior art to the present disclosure. 
     SUMMARY OF THE INVENTION 
     The above objectives are accomplished according to the present disclosure by providing in one aspect a non-penetrating roof panel system. The system may include at least one roof panel, at least one retaining bar, the at least one roof panel configured to define at least one first hollow chamber and at least one second hollow chamber, the at least one roof panel configured such that the at least one retaining bar extends through a length of the at least one roof panel via insertion into the at least one first hollow chamber; and wherein the at least one roof panel is configured so that no part of any roof contacting surface of the at least one roof panel penetrates into a surface of a roof upon which the at least one roof panel is affixed. Further, the at least one roof panel may be formed from at least one metal. Still yet, the at least one roof panel may configured to define at least one panel structure. Still again, the at least one panel structure may include at least one mound, at least one ridge, at least one trapezoidal shape, and/or at least one interconnecting region. Further yet, the at least one roof panel may affixed to at least one second roof panel. Moreover, the at least one retaining bar may be malleable. Still again, the at least one first hollow chamber and the at least one second hollow chamber may be configured such that the at least one first hollow chamber of the at least one roof panel will engage and at least partially enclose the at least one second hollow chamber of at least one second roof panel. Further again, the at least one roof panel may extend from at least one panel fascia edge to at least one roof edge of the roof. Still moreover, the at least one retaining bar may be configured to define a fascia engaging end and a roof ridge engaging end and the fascia engaging end and/or the roof engaging end comprise a formed bending point. Further still again, the at least one retaining bar may be held in place with respect to the at least one roof panel without screws, nails or other fixtures penetrating the at least one roof panel to hold the at least one retaining bar in place on the roof. 
     In a further aspect, a method for installing an unpenetrated roof surface is provided. The method may include applying a first panel to a roof surface wherein the first panel defines a first panel first hollow chamber and a first panel second hollow chamber, applying a second panel to the roof surface wherein the second panel defines a second panel first hollow chamber and a second panel second hollow chamber, engaging the second panel to the first panel via complimentary engagement of a first joining edge of the first panel to a second joining edge of the second panel such that the second panel first hollow chamber at least partially encloses the first panel second hollow chamber to form a first panel/second panel hollow cavity, inserting a retaining rod within the first panel/second panel hollow cavity formed by the first panel engaged with the second panel, and fastening the retaining rod to at least a roof fascia or roof ridge of the roof surface. Further, a third panel may be configured to define a third panel first hollow chamber and a third panel second hollow chamber, wherein the second panel is affixed to the third panel via complimentary engagement of a first joining edge of the second panel to a second joining edge of the third panel such that the third panel first hollow chamber at least partially encloses the second panel second hollow chamber to form a second panel/third panel hollow cavity. Further, a second retaining rod may be inserted within the second panel/third panel hollow cavity formed by the second panel engaged with the third panel. Moreover, the method may include joining a series of panels to one another to substantially cover an entirety of the roof surface. Still further, the first panel may be formed from at least one metal. Again, the first panel may define at least one panel structure. Still yet, the at least one panel structure may be configured to include at least one mound, at least one ridge, at least one trapezoidal shape, and/or at least one interconnecting region. Even further, the retaining rod may be malleable. Still yet again, the retaining bar may define a fascia engaging end and a roof ridge engaging end and the fascia engaging end and/or the roof engaging end comprise a formed bending point. Still further yet, the at least one retaining bar may be configured to be held in place without screws, nails or other fixtures penetrating any roof panel or the roof to hold the at least one retaining rod in place on the roof. 
     These and other aspects, objects, features, and advantages of the example embodiments will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of example embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       An understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the disclosure may be utilized, and the accompanying drawings of which: 
         FIG.  1    shows one embodiment of a roof panel of the current disclosure. 
         FIG.  2    shows a front profile of one embodiment of a roof panel of the current disclosure. 
         FIG.  3    shows one embodiment of a retaining bar of the current disclosure. 
         FIG.  4    shows two panels of the current disclosure partially engaged with one another. 
         FIG.  5    shows multiple panels and retaining bars used to place a roof on a structure. 
         FIG.  6    shows one embodiment of a method for creating an unpunctured/nonpenetrated roof surface per the current disclosure. 
     
    
    
     It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of a preferred embodiment and not restrictive of the invention or other alternate embodiments of the invention. In particular, while the invention is described herein with reference to a number of specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention. Various modifications and applications may occur to those who are skilled in the art, without departing from the spirit and the scope of the invention, as described by the appended claims. Likewise, other objects, features, benefits and advantages of the present invention will be apparent from this summary and certain embodiments described below, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above in conjunction with the accompanying examples, data, figures and all reasonable inferences to be drawn therefrom, alone or with consideration of the references incorporated herein. 
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     With reference to the drawings, the invention will now be described in more detail. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are herein described. 
     Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. 
     Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. 
     Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range. 
     Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein inter-changeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween. 
       FIG.  1    shows a non-penetrating roof panel  100  of the current disclosure. Panel  100  may come in a wide variation of shapes, styles and colors. Further, panel  100  may be made from a variety of metals, including but not limited to copper, tin, or aluminum, steel, fiberglass, and/or polymers. Panel  100  may also be comprised of plastics or synthetics to provide lighter weight panels.  FIG.  1    also shows retaining bar  102  that extends through length  104  of panel  100  via panel first hollow chamber  106 . Panel  100  may be shaped along width  108  to form panel structures  110  such as mounds, ridges, trapezoidal shapes, and interconnecting regions  112  that may be flat, curved, etc. Panel  100  also defines panel second hollow chamber  114 . Retaining bar  102  may be made from steel, iron, aluminum, etc. Retaining bar  102  may be made from a steel bar. For instance, steel bars with various thicknesses and widths may be sized to better fit the roof being renovated. 
       FIG.  2    shows an end on front profile view of  FIG.  1   . Roof contacting surfaces  200  will remain unpenetrated during installation as retaining bar  102  runs the length  104  of panel  100 . Thus, no portion of panel  100  will penetrate, extend into, or otherwise pierce the roof surface, such as being screwed into the roof, nailed, or otherwise affixed such that a portion of panel  100  would dig into, abrade, penetrate or otherwise break the plane of the roof surface. This maintains panel upper surface  120  and panel lower surface  122  as unblemished wholes with no screws, nails, or other fixture mechanisms penetrating through either upper surface  120  or lower surface  122  of panel  100 . This creates an unperforated panel surface  124  that extends from panel fascia edge  126  to panel roof ridge edge  128 , which remedies the common leakage issues cause by employing fixtures that penetrate prior art roof panels. In a further embodiment, retaining bar  102  may be formed such that fascia engaging end  408  and roof ridge engaging end  410  may be malleable, such as with a formed bending point  407  as known to those of the art or hinged in order to allow retaining bar  102  to be inserted through panel retaining bar orifice  318 , see  FIG.  3   , and then bent to engage the fascia and roof ridge in order to secure retaining bar  102  to the roof structure, see  FIG.  5   . 
     Panel  100  has a first joining edge  116  and second joining edge  118 . These ends form a complimentary joint  300 , see  FIG.  3    showing two panels partially engaged end to end, whereby first joining edge  116  at least partially overlaps and at least partially covers second joining edge  118 . While first joining edge  116  is shown forming first flange  300 , second flange  302 , third flange  304  and fourth flange  306 , and second joining edge  118  is shown forming fifth flange  308 , sixth flange  310  and seventh flange  312 , the current disclosure is not so limited and more or less flanges are considered within this disclosure such as 8, 9, 10, 11, etc., further, while the flanges are shown with angular bends  314 , the bends may be more rounded or more angled depending on the roof requirements. 
     By placing first joining edge  116  over second joining edge  118 , concurrent panels form panel joint  316 . Panel joint  316  functions by engaging the various flanges to define panel retaining bar orifice  318 . Orifice  318  contains retaining bar  102 , not shown, and provides a weather/insect proof continuous joint that is not penetrated by screws, nails, etc. Here, retaining bar  102  lays atop and at least partially overlaps first flange  300 , which is then pressed into contact with interconnecting region  112 . As  FIG.  3    shows, joining to panels creates retaining bar orifice  318  that defines a hollow cavity  320  that encloses retaining bar  102 . However, due to the “clasping” or male/female engagement of first joining edge  116  and second joining edge  118 , clasping meaning that the panel ends engage and overlap such that the panels at least partially enclose one another and give the appearance of clasping hands or fingers, this enables two adjoining or concurrent panels to be connected along the entirety of their length and affixed to a roof structure without requiring any penetration of panel upper surface  122 , panel lower surface  124 , or any penetration of the roof structure below. Even if water were to enter at Arrow A, which would be closed in use due to the weight of bar  102 , see  FIG.  5   , the flanges create a water tight barrier without requiring sealants, fixtures, etc., to hold the panels in engagement with one another. Many angle variations are possible for the joining edges, such as from 0 to 180 degrees and variations within this range. The current disclosure system may be customized to each roof being renovated/built. 
       FIG.  4    shows retaining bar  102 . Bar  102  has first affixment end  400  and second affixment end  402 . First affixment end  400  may attach to the roof fascia, not shown, while second affixment end  402  affixes to the roof ridge, not shown. Retaining bar  102  may be affixed via attachment orifices  404  via screws, nails, spikes, etc., as known to those of skill in the art. Thus, bar  102  extends along length of panel  104  from the roof fascia to the roof ridge forming a unitary, unpenetrated layer that is held in place via the weight of bar  102  and affixment ends  400  and  402 . Therefore, retaining bar upper body  406  does not require penetration by screws, nails or other fixtures to hold it and panel  100  into place on a roof structure. Many angle variations are possible for the bar ends, such as from 0 to 180 degrees and variations within this range. The current disclosure system may be customized to each roof being renovated/built. 
       FIG.  5    shows first panel  500  joined to second panel  502  at first joint  503 , which in turn is joined to third panel  504  at second joint  505  with restraining bars  102  affixed to the fascia  506  of roof  507  as well as roof ridge  508 . As  FIG.  5    illustrates, the current disclosure provides for a roofing system that securely affixes panels  500 ,  502  and  504  to roof  507  without necessitating use of screws, nails, or other fixtures through any portion of panels  500 ,  502 ,  504 , which in turn form an unpenetrated roof surface  124  with greater resistivity to leakage than currently available roofs. The dimensions of panels  500 ,  502 , and  503  are typically uniform to one another in use but may different sizes depending on the surface being coated. In one embodiment, panels may be cut to a length that spans the “run” of the roof from fascia to roof ridge such that a single panel substantially covers the length of the roof while multiple panels are affixed to one another in order to cover the width of the roof surface. Example panel sizes include, but are not limited to, 24, 36, 48 inches, etc., and the current disclosure should not be considered limited to a particular panel size. Further, different size panels may be simultaneously employed on the same roof, when necessary. 
     The current disclosure also provides methods of installing an unpenetrated roof surface  600 .  FIG.  6    shows one example of an installation method of the current disclosure. At  602 , a first panel is applied to a roof surface. At  604 , a second panel, with a retaining rod “nested” within panel second hollow chamber is placed beside the first panel. At step  606 , the second panel is engaged to the first panel via complimentary engagement of a first joining edge of the first panel to the second joining edge of the second panel. At step  608 , the retaining bar is positioned to engage a portion of at least one flange of the first panel and to overlap at least a portion of an interconnecting region of the second panel, overlap may mean the retaining bar is in direct contact with the interconnecting region or may lay atop a flange over the interconnecting region. At step  610 , the retaining bar is fastened to the roof fascia and roof ridge. At step  612 , a third panel with a nested retaining bar is placed beside the second panel. At step  614 , the third panel is engaged with the first joining edge of the second panel via the second joining edge of the third panel. At step  616 , the second retaining bar is positioned with respect to the third panel and second panel as described at step  608 . At step  616 , the second retaining bar is secured in place to the roof fascia and roof ridge. At step  620 , steps  612 - 618  may be repeated with additional panels and retaining bars until the width of the roof is covered. At step  622 , the last panel may put in place as described previously or it may be sized to end adjacent to the roof or with some portion extending beyond the roof edge. 
     In use, retaining bar  102  may require a metal bending too to shape ends  400  and  402  to place them in position for fastening to the fascia board at the roof edge and at the crown of the roof. Many roofs will vary in shape and will require some adjustment in shaping and bending retaining bar  102 . If a ridge cap is available to cover panel  100 , it may fasten over top of panel(s)  100  and fasten down without driving nails or screws in panel(s)  100 . 
     All patents, patent applications, published applications, and publications, databases, websites and other published materials referred to throughout the entire disclosure herein, unless noted otherwise, are incorporated herein by reference in their entirety. 
     While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.