Patent ID: 12203271

LIST OF REFERENCE NUMERALS

With regard to reference numerals used, the following numbering is used throughout the drawings.10present invention12metal roof14building16trusses or purlins18sheets/panels19right or first end of panel20screws or fasteners21left or second end of panel22ridge formed by joining edges of panels23ribs formed between ridges24adjacent sheets25top of rib26adjacent sheets27right leg of rib28cap29left leg of rib30hat cap32flat cap34oval cap36top of cap38right leg of cap40left leg of cap42right lower or distal end of right leg of cap44left lower or distal end of left leg of cap45inset (sometimes referred to as offset)46right curved end of leg inset of cap48left curved end of leg inset of cap50lower right leg51lower right foot52lower left leg53free end54raised portion56raised portion57free end58lower right leg60end cap62end wall64top wall66left wall68right wall

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following discussion describes in detail at least one embodiment of the present invention. This discussion should not be construed, however, as limiting the present invention to the particular embodiments described herein since practitioners skilled in the art will recognize numerous other embodiments as well. For a definition of the complete scope of the invention the reader is directed to the appended claims.FIGS.1through9illustrate the present invention wherein a metal roofing system for a building is disclosed and which is generally indicated by reference number10.

Turning toFIG.1, therein is shown a panel18for use with the present invention10being disposed on an upper surface of a building14wherein the panel18having a first raised or upstanding ridge22on the left edge along with a second raised or upstanding ridge22on the right edge wherein the ridges22are formed by overlapping the edge of one panel18with the mating edge of another adjacent panel. Also shown disposed between ridges22, are a plurality of raised or upstanding spaced apart ribs23wherein it is expected that three ribs (although it is possible a number different than three could be used) would normally be disposed between the left and right ridges22. Also shown is a cap28disposed on each ridge22and rib23.

Turning toFIG.1A, therein is shown a cross-sectional view of a single panel18of the present invention10. Shown therein is a left edge21and a right edge19wherein the right edge19includes a raised portion54on the right edge of panel18having a downwardly extending lower right leg50and a lower right foot51which terminates as a free end53and also including a downwardly extending lower left leg52. Also shown on the left edge21is a raised portion56of the left edge of the panel along with a downwardly extending lower right leg58. A plurality of ribs23are spaced apart equally between the right edge19and the left edge21of the panel18. The ribs23each have a top portion25, a right leg27, and a left leg29. It can be seen that the left edge21has an upstanding portion56having a laterally extending horizontal projection to toward the left end which terminates in a free end57. The right edge19has a lower right foot51which forms a laterally extending horizontal projection away from the right end19which provides a rigid vertical strengthening support to prevent crumpling when a screw is later inserted through its top.

Turning toFIGS.2-5, therein is shown the present invention10mounted on a sloped metal roof12which is installed on a building14using metal or wood trusses and purlins16that run longitudinally along the length of the building. The metal roof12comprises a plurality of sheets18of relatively thin sheet metal sections that are attached with screws or fasteners20on the roof. The individual sheets are approximately 32″ to 36″ wide with variable length because they are custom cut to fit according to the particular application. The ridges22, generally indicated by reference numeral22, are formed by the joining overlapping edges of the panels18, and the ridge22runs longitudinally in the sloped direction along the sheets18and is disposed on the overlapping edges of adjacent sheets24,26through which fastener20is inserted. The ridge22is approximately 1 to 1¼ inches high and approximately 1½ inches wide and being tapered outwardly from the base to the top of the ridge so that the ridge22is wider at the top than the bottom. A ridge22would be disposed at the joining edge between each of the adjacent panels24,26of the roof12. The present invention10includes a cap, which is generally indicated by reference numeral28, which is placed over each ridge22and rib23. There are three types of caps including a hat cap30, a flat cap32, and an oval cap34. A typical cap has a top section36, a right leg or side38, a left leg or side40, a lower right end42and a lower left end44having a distally disposed inwardly projecting inset45with arcuate end46on the right and on the left48which is precisely shaped to mate to the lower right end or side50of the ridge22and the lower left end or side52of the ridge22. Inset/offset45is substantially perpendicular to legs38,40of cap28. The length of the offset45is expected to range from about ⅛″ to about ½″ and be effectively long to securely and removably attach the cap28to the ridge22. The convex curved oval or tear-drop shape of the legs46,48conforms to the concave curved shape of the lower sides50,52of the ridge22so that the cap28can be snapped into place; the lower sides50,52form a receptacle for the legs46,48. The ends of the legs46,48securely adhere the cap28to the ridge22so that no leakage occurs between the cap28, screws20, or ridge22because the outer surfaces of the legs46,48are sized and shaped to directly contact and are resiliently biased to mate to the lower sides50,52of the ridge22. The legs38,40are effectively biased toward each other an effective amount to securely and removably attach the cap28to the ridge22so that when a cap28is attached to a ridge22(or rib23) the cap will snap securely into place. Legs52,58form an acute angle relative to the horizontal plane of between 40 and 80 degrees and, more particularly, approximately 60 degrees. In operation, when the cap28is to be installed on a ridge22or rib23, its legs38,40would be initially deflected outwardly and then snapped into place so that the curved ends46,48are disposed into the mating concave shaped receptacles formed at50,52so as to be in a mechanical locking relationship with the ridges and ribs.

Turning toFIG.6, therein is shown a cross-section view of a rib23being an upstanding rib portion of the panel18wherein the rib is located in a non-overlapping or flat portion of the panel18as shown inFIGS.1,1A, and2. Each rib23has a top portion25, a right leg portion27, and a left leg portion29. The ribs23have a cross-sectional shape similar to that of a ridge22and also have mating curved surfaces at the lower ends of the distal portion or distal end of the legs27,29for receiving a cap28similarly to that disclosed relative to ridges22inFIGS.3,4, and5. Rib23is shown mounted onto a part of the framework of a building such as a purlin16.

Turning toFIGS.7-9, therein is shown end caps, generally indicated by reference numeral60, disposed on an open end of a rib23. The end caps60are shaped to conform to the shape of a flat cap32inFIG.7, the hat cap30ofFIG.8, and the oval cap34ofFIG.9. Each end cap60has an end wall62, a top wall64, a left side wall66, and a right side wall68being open on its bottom and opposite end. The end caps60slide into the open ends of the ribs23and ridges22as the walls66,68slide longitudinally along the rib23so that the walls and top of the end cap are disposed between the ridges22or ribs23and the caps28. Each end cap60is slidably, removably disposed and secured on an open end of the ridges22and ribs23so that no ends are left open in order to prevent leakage of water into the ridges22and ribs23.

It is known that metal roofs are lightweight and easy to install. The installation process of metal roofs involves placing the metal sheets18in a side-by-side relationship on the roof so that the sheets/panels overlap as previously described, allowing water to flow from one panel to the next without being able to penetrate the area under the roofing panel. As a first line of defense against water damage, it is important that the metal roof overlap be implemented correctly. The majority of the metal sheets18will go onto the roof whole and intact. As you near the edges of the roof or any points where the roof has gables, you may need to cut the sheets18to custom fit the space. Furthermore, while the sheets18may be made of metal, they may also be made of plastic or plastic-like material such as polyvinyl chloride (PVC) or the like.