Abstract:
A novel roofing material simulating natural thatch and methods of applying the roofing material comprises the provision of simulated thatch shingles or rolls of such material. The shingles or rolls are formed of elongate reeds or thatch elements formed of a polymer material and arranged in laterally extending bundles. The thatch elements are folded and secured to a binder and are secured to an appropriate substrate which is secured to the roof. Each shingle or roll extends in overlying relation to produce a shingled arrangement which simulates a natural thatched roof.

Description:
FIELD OF THE INVENTION 
     This invention relates to roofs and roofing materials, and more particularly to thatched roofs. 
     BACKGROUND OF THE INVENTION 
     The style, configuration and color of roofing elements often contribute to the attractiveness of residential houses and buildings of commercial interest. For example, the various thatch roofs of the world, consisting of a multiplicity of natural thatching materials, usually impart a certain aura to the building it has covered. (Just as tile or slate roofs usually impact a regional or ethnic aura.) Although thatch roofs are not uncommon in certain parts of the world, thatched roofs are a relatively rare occurrence in the United States. Natural thatching is uncommon, being often restricted by local building codes, and/or a concern of fire, rot, etc. Additionally, there are few, if any skilled thatchers. 
     SUMMARY OF THE INVENTION 
     It is an object of this invention to provide a novel roofing material and to show an associated method of applying the same and thereby simulate natural thatch. The novel roofing material is comprised of “reeds” or thatch elements simulating natural thatch material but preferably formed of a weather resistant, and in some instances fire resistant, polymers. The thatch elements are bound together with a binder and are arranged in sections or shingles. The simulated thatched roofing may also be arranged in rolls of a predetermined length. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS 
     FIG. 1 is a perspective view of a small building having a roof formed of the simulated thatching material with certain parts thereof broken away to illustrate underlying components; 
     FIG. 2 is a fragmentary exploded perspective view of a portion of a thatch roof and a portion of the underlying roof frame structure illustrating details of construction thereof; 
     FIG. 3 is a cross sectional view taken approximately along line  3 — 3  of FIG.  1  and looking in the direction of the arrows; 
     FIG. 4 is an exploded side view of a thatch shingle and portions of the roof illustrating the manner in which the thatch shingles are attached to the frame, the phantom line configuration illustrating the thatch elements before cutting or as predisposed in offset manner; 
     FIG. 5 is a cross-sectional view of the binder; 
     FIG. 6 is a side elevational view of a thatch shingle, and binder, the phantom line illustrating the cut pattern for shaping the shingle; 
     FIG. 7 is a cross-sectional view illustrating a modification of the binder; 
     FIG. 8 is a cross-sectional view illustrating another modification of the binder; and 
     FIG. 9 is a fragmentary perspective of different embodiment of a shingle. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIG. 1, it will be seen that a building  10  having a roof  11  which incorporates the novel thatch roofing  14  is thereshown. The roof  11  is assumed to be of conventional frame wood, steel or other support memebers  12  to support appropriate roof deck, or substrate  13 , for fastening of the thatch shingle or thatch roll. A water impervious membrane  15  is applied to the roof substrate  13  to serve as either a primary or a secondary, waterproofing. 
     The roofing  14  simulates natural thatching and is comprised of roofing shingles  16  or roofing rolls  160 . The shingles  16  or rolls  160  are formed of a plurality of plastic or polymer “reeds” or “thatch elements  18 ” secured together by an elongate binder  17 . The reeds  18  are disposed in a substantially parallel relation with each other and are arranged in a laterally extending bundle. The reeds  18  are fixed in a binder  17  as individual reeds or as longer reeds folded approximately 180 degrees in the binder  17 . The binder  17  extends transversely of the reeds  18  and is secured to the folded portion of the transversely extending bundle. Each thatch shingle  16  is of a generally rectangular configuration and includes a relatively large number of individual reeds  18  forming a thatch body  16   b with folded portion  16   g and unbound free ends  16   a  all extending in the same direction from the binder  17 . The thatch shingle  16  also has a upper surface  16   c  and a lower surface  16   d . Reeds  18  can be folded around a center element  17   c  of wire or other of a variety of materials and thereby locked in an offset pattern to produce the beveled portion  20 . The binder  17  may be formed of a suitable plastic polymer or metal binder. The binder  17  may be of a variety of shapes and of binding characteristics. The phantom line configuration  16   e  of FIG. 4 illustrates the configuration of the thatch elements  18  of a shingle  16  before these thatch elements  18  are offset or trimmed to produce the beveled or sloping portion  20 , as shown by the phantom line  16   f  of FIG.  6 . 
     The reed or thatch elements  18  are preferably formed of a plastic or polymer of any of various manufacturers, such as, or similar to General Electric Plastics under the trademark GEON. In the embodiment shown in FIGS. 1-6 the reeds  18  are secured to the binder  17  by gluing, heat sealing, sewing. or metal binding and project therefrom. The binder  17  may be of C-shaped configuration as illustrated in FIGS. 1-6 &amp;  9  or may have other shapes. C-shaped binders  15  have a topwall  17   a , open front  17   b . bottom wall  17   d , and a rear wall  19 . The presence of rear wall  19  is not essential. The thatch elements  18  extend through open front  17   b  but are looped about a center element  17   c . If the thatch elements  18  are offset when disposed in the binder  17 , the sloping edge is formed by the free end  16   a . Otherwise the thatch elements  18  may be trimmed. 
     The reeds  18  may be weather resistant, and either UV light resistant and/or fire resistant. Since the reeds or thatch elements  18  simulate thatch, the reeds and thatch elements are somewhat flexible. 
     In the embodiment as shown, the roofing shingles  16  are preferably 36 inches wide and vary in length whether folded bound reeds  18  or singularly bound reeds  18 . The reeds project from the lower longitudinal edge of the binder  17  preferably approximately 8 to 12 inches. 
     Referring to FIGS. 2-4, it will again be noted that the free ends  16   a  extends downwardly and outwardly to define a sloping or beveled portion  20 . In the embodiment shown, the sloping edge portion  20  of the shingles  16  preferably is approximately 5-6 inches in length. The thatched roofing  14  may also be formed in rolls  160 , as shown in FIG. 2, of sufficient length to cover a significant length of the roofing boards from hip to the adjacent valley. The rolls  160 , when unwound are preferably of elongate rectangular configuration and also have the beveled or sloping portion  20  in the manner of the shingles  16 . Various types of fasteners  24  may be used such as nails illustrated in the embodiments of FIGS. 1-5 with fastener apertures  24   a  optionally provided in the binder  17 . Staples  24   b  may also be used as shown in FIG.  6 . 
     The thatch shingles  16  or rolls  160  may be applied by a variety of standard practice applications. They may be installed on battens  21  or the binder  17  itself may be installed directly onto the deck  13  to act as a batten to elevate it off the roof deck  13 . If a batten  21  is used, it may be elongate, rectangular configuration including end surfaces  21   b , top surface  21   c , bottom surface  21   d , front surface  21   e , and rear surface  21   f.    
     Referring now to FIG. 5, the binder  17  is thereshown in crossection. The binder  17  is of generally simple C-shaped configuration having a rear wall  19 , an upper horizontal top wall  17   a  and a lower bottom wall  17   d , which together define a forwardly opening recess  34  which receives the thatched elements or reeds  18  therein. The recess  34  is bounded at its front end by lips  34   a . The reeds or thatch elements  18  may be secured in the recess  34  by glue, heat sealing, sewing, metal binding, or similar means. The binder  19  is secured to the associated batten  21  or roof deck  13  by appropriate fasteners  24  in the manner of the embodiment of FIGS. 1 to  4 . The thatch elements  18  are looped over a center element  17   c  and are offset or trimmed to present the sloping surface  20 . 
     Referring now to FIG. 7, it will be seen that a different embodiment of the binder designated as element  40  is thereshown. The binder  40  is of generally C-shaped configuration having a forwardly opening recess  44  bounded by inwardly projecting lips  44   a . The binder  40  has a depending flange  41  which is integral with an attachment portion  42 . A drain hole  43  is provided in the depending flange  41 . 
     The attachment portion  42  will be secured to the substrate  13  by suitable fasteners  24  . No batten is required with binder  40 . The binder  40  will be provided with a center element  17   c  about which the thatch elements  18  will be looped. 
     A different embodiment of the binder is shown in FIG.  8  and is designated generally by the reference numeral  50 . The binder  50  is also of generally C-shaped configuration with a forwardly opening recess  54  which is bounded by inwardly projecting lips  54   a . The binder  50  is provided with an inclined flange  51  having drain opening  52  therein. An attachment portion  53  is integral with flange  51  and will be attached by suitable fasteners  24  such as nails, staples, or other types of fasteners to the substrate. The binder  50  does not require a batten and will be provided with a center element  17   c  about which the thatch elements  18  will be looped. It will be appreciated that binders having other shapes may be provided. In the embodiments shown, the binders are formed of a metal, but other materials such as polymers may also be used. 
     Referring now to FIG. 9, a further embodiment of a binder designated as element  60  and thatch elements  18  is thereshown. The binder  60  is generally of C-shaped configuration and the thatch elements  18  are fused or welded to binder  60 . The shingle  16  (binder  60  and thatch elements  18 ) will be secured to the substrate  13  or batten  21  by suitable fasteners  24 . Elongate slots  61  may be provided on the binder  60  for accommodating staples. The slots  61  my extend longitudinally, transversely, or in any direction of the binder  60 . An opening  62  for accommodating fasteners  24  may also be provided. Although, different shaped and positioned openings are depicted in the embodiment of FIG. 9, the different openings for accommodating different fasteners  24  are for illustrative purposes only. The shingles  16  will preferably have openings therein of only one shape and disposition. 
     From the foregoing, it will be seen that I have provided a novel roof and method of applying the same which simulates a natural thatch roof. The color of the thatch may be that of the natural thatch material or it may be formed of other colors. It will be appreciated that the simulated thatch roofing not only functions as a protective roofing, but also imparts a highly aesthetic quaint appearance.