Patent ID: 12195966

DETAILED DESCRIPTION

Reference will now be made in more detail to the attached drawing figures. Throughout this patent disclosure, the shingles will be referred to as “metal” shingles for purposes of clarity. It will be understood, however, that the present disclosure is not limited to shingles made of metal but encompasses with equal measure shingles made of any other appropriate material such as, for example, plastic, fiberglass, extruded aluminum, and polymer sheet material to name a few.

Embodiments of the present disclosure also are not limited to roofing structures, and can be used in conjunction with other portions of commercial or residential structures or portions thereof, such as perpendicular or slanted or slope walls or partitions both permanent and temporary and/or other structural portions, such as beams, columns, slabs, etc. or other portion of a commercial or residential structures.

FIG.1shows a general metal roofing shingle of the type described in this disclosure. The shingle21is rectangular, as illustrated inFIG.1, but other configurations also may be utilized. The shingle21has a top edge23, a bottom edge24, a right side edge26, and a left side edge27. An exposure portion22of the shingle is exposed to the elements when the shingle is installed. A headlap portion28of the shingle21is overlapped by the bottom edge portion of a like shingle in a next higher course of installed shingles.

Side lap features, indicated generally as31and32, and sealing features, indicated as38and42inFIGS.2a-2b, extend along the side edges26and27of the single. Various embodiments of the side lap and sealing features will be described in more detail below. In some embodiments, an adhesive material is applied along an area of overlap between the at least one side lap feature of the metal shingle and the corresponding side lap feature of the adjacent metal shingle. For example, a self-seal strip29of adhesive sealant can be applied, extending along the bottom of the shingle21in the portion that will overlap the headlap portion28of a like shingle in a next lower course of shingles. The adhesive sealant also may be applied on the top side of the shingle21along the headlap portion28or in both locations if desired.

In one or more of the embodiments detailed herein, the adhesive sealant may be applied as a bead, a strip, and/or as dots. The standard adhesive strip may range from ⅛ inch to ¾ inch in width and can vary in width depending on the application. A variety of Adhesive sealants can be used depending on application. Duragrip® brand adhesive available from GAF, as well as other adhesives used in a roofing headlap application can be used, as well as other more aggressive adhesives that tack at a colder temperature such as LORD® HM17-1 brand adhesive. The thickness of the adhesive sealant may range from 0.005 inch to 0.2 inch depending on the interlock configuration and position on the shingle. In some embodiments, the thickness of the adhesive sealant may range from 0.005 inch to 0.1 inch depending on the interlock configuration and position on the shingle. In some embodiments, the thickness of the adhesive sealant may range from 0.005 inch to 0.05 inch depending on the interlock configuration and position on the shingle. In some embodiments, the thickness of the adhesive sealant may range from 0.005 inch to 0.01 inch depending on the interlock configuration and position on the shingle. In some embodiments, the thickness of the adhesive sealant may range from 0.05 inch to 0.125 inch depending on the interlock configuration and position on the shingle. In some embodiments, the thickness of the adhesive sealant may range from 0.1 inch to 0.125 inch depending on the interlock configuration and position on the shingle.

In another embodiment, the sealant material may include a pressure sensitive adhesive. In other words, the sealant may include an adhesive that forms a bond when pressure is applied to the adhesive with a surface (e.g., when pressure is applied to one roofing shingle overlapping another roofing shingle). In yet another embodiment, the sealant material may include a bead, strip, or patterned arrangement of a pressure sensitive adhesive with a release material covering strip applied thereto. In such embodiments, prior to connecting two shingles, corresponding release material covering strips may be removed to expose the adhesive.

In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.05 inch to 0.2 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.1 inch to 0.2 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.15 inch to 0.2 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.17 inch to 0.2 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.01 inch to 0.15 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.01 inch to 0.12 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.01 inch to 0.1 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.01 inch to 0.05 inch. In embodiments, the thickness of the metal or other sheet material from which the shingles are made may range from 0.01 inch to 0.03 inch.

The remaining figures illustrate embodiments of side lap and sealing features31-32and38and42according to aspects of the present disclosure. In these figures, dimensions, and particularly thickness dimensions, are substantially exaggerated for clarity and ease of description.

FIGS.2aand2bshow a metal shingle33with one embodiment of side lap features31and32. Side lap feature31comprises a J-bend in the material of the shingle33resulting in an upwardly facing side lap feature with a bight39(which can include a curved or u-shaped section as illustrated, or can include other shaped sections configured to overlap and/or fit together) and a leg41. A bead or strip of adhesive sealant42is applied along the top of the leg41. Similarly, side lap feature32comprises a J-bend resulting in a downwardly facing side lap feature with a bight36and a leg37. A bead or strip of adhesive sealant38is applied along the bottom of the leg37. The bead or strip of headlap adhesive sealant29is visible along the bottom of the shingle33in the region that will overlap a shingle in a next lower course.

FIG.2bshows two like shingles33and34with the side lap features ofFIG.2aas they appear when the shingles are installed in a side-by-side side lapped relationship on a substrate of a roof. The ends of legs41and37are seen to engage one another, which serves to properly align each of the two shingles33and34. Adhesive sealant beads or strips42and38are captured between the legs37,41of the J-bends and adjacent surfaces of the shingles33,34to adhere the shingles33,34together along the side lapped portions. In addition, the shingles can be positioned over and attached directly the substrate of the roof; and in some embodiments, an underlayment such as a thermoplastic polyolefin (TPO) membrane or other underlayment material can be applied between the substrate and the shingles.

Once heated by the sun on a roof, the adhesive sealant becomes partially malleable and cures to form a water tight seal against water incursion or penetration at the side lapped portions of the shingles. In this embodiment, the thickness of installed shingles along their side laps is approximately three times the thickness of the metal roofing shingle plus the relatively small thickness of each bead or strip of adhesive sealant.

FIG.3illustrates a variation of the embodiment ofFIGS.2aand2bwherein the J-bends of the side lap features31/32of shingles46and47are formed to interlock with each other when one shingle is installed side-by-side with a like shingle in a course. Specifically, the J-bend of side lap feature31along the left edges of shingles46and47forms a bight57, an upwardly facing leg58, and a space59between the leg58and the shingle's top surface. The J-bend of side lap feature32along the right edges of shingles46and47forms a bight53, a downwardly facing leg54, and a space56between the leg54and the shingle's bottom surface. The main bodies of the shingles46and47are shown at48and49.

When the two shingles46and47ofFIG.3are joined side-by-side, the leg58of side lap feature31slides into the space56of side lap feature32to interlock the shingles46,47together along their side lap and form a water tight junction. Adhesive sealant may be applied along the junction if desired to adhere and seal the shingles46,47together. In this embodiment, the thickness along the side lap is three times the thickness of the metal of the shingle. In other embodiments, the thickness along the side lap is1,2,3,4,5,6,7,8,9, or10times the thickness of the metal of the shingle. In this embodiment, the headlap adhesive sealant bead or strip29is seen in this example to be tapered across the width of the shingle. Such a configuration provides more adhesive in the regions of the side laps where one shingle is raised slightly above the roof deck relative to the other shingle. Further, such a configuration saves on manufacturing cost.

FIG.4illustrates another embodiment of side lap features31and32. In this embodiment, the right side lap of like adjacent shingles66and67is machined or pressed or otherwise formed with downwardly facing saw tooth features68just inboard of a relatively thin tongue71. The left side lap of shingles66and67are likewise formed with upwardly facing saw tooth features69just inboard of a relatively thin tongue72. The saw tooth features68and69are offset so that when the side lap portions of two side-by-side shingles66and67are brought together as indicated by the arrows, the downwardly facing saw tooth features68intermesh with the upwardly facing saw tooth features69to align two like shingles66and67properly in the horizontal direction.

A bead or strip73of adhesive sealant is disposed along the bottom surface of the tongue71(or along the top surface of tongue72, or both) to adhere the two shingles66and67together along their side lap and to seal against water incursion at the side lap. Further, the saw tooth features68and69reinforce the seal by collecting any water that may seep through the seal and directing the water to the forward edge of the shingle.

FIGS.5aand5billustrate an embodiment of side lap features31and32similar to those ofFIGS.2aand2b. As illustrated inFIG.5a, the right side lap feature of shingle76comprises a J-shaped bend forming a bight78and a downwardly facing leg79. The left side lap feature31of shingle76comprises a J-shaped bend forming a bight80and an upwardly facing leg82. A bead or strip of adhesive sealant81extends along the bottom surface of the shingle76just inside the downwardly facing leg79and a bead or strip of adhesive sealant83extends along the top surface of the shingle76just inside the upwardly facing leg82.

InFIG.5b, two like shingles76and77are brought together in side lapped fashion with the ends of their legs79and82engaging one another to align the two shingles76and77properly with each other. The beads or strips of adhesive sealant81and83adhere the shingles76and77together and form water resistant seals along the side lapped portions of the shingles. One difference from the embodiment ofFIGS.2aand2bis that the legs79and82of the J-shaped bends are significantly longer. In this embodiment, the legs79and82may be between one-half and three-quarters of an inch long, whereas inFIGS.2aand2b, the legs37and41may be shorter such as one-half inches long. In other embodiments, the legs may be between ¼ and 1 inch long. In yet other embodiments, the legs may be between ¼ and ½ inch long. In the embodiments shown inFIGS.2aand2b, the legs may be shorter, such as less than or equal to ½ inch long.

FIG.6is a plan view of a portion of two like side lapped shingles86and87with alignment features comprising buttons91arrayed along the side laps. The buttons91are located within the side lapped regions88of the shingles86and87and a bead or strip of adhesive sealant89may be disposed between the overlapping side edge portions of the shingles86and87to adhere and form a seal.FIG.7is a cross sectional view taken along7-7ofFIG.6showing the buttons91in more detail. Each button comprises a socket92formed in overlapping shingle89and a stud93formed in the overlapped shingle86.

During installation, the sockets92of one shingle are pressed on the studs93of a side lapped shingle to align the two shingles horizontally. The studs93and sockets92may be configured so that they form an interference fit indicated at94to hold the shingles together as the adhesive sealant89cures. The adhesive sealant89, when cured, adheres the shingles together and forms a seal. The thickness in the side lapped region of this embodiment is only twice the thickness of the material of the shingle.

FIG.8illustrates an embodiment wherein the right edge portion of shingle101is formed with a cap103that extends completely along the side lap portion. The cap103has a slight inward draft angle along its interior sides. Like shingle102is formed along its left edge portion with a snap feature104extending completely along the side lap portion. The snap feature104has a slight inward draft angle along its exterior sides. When two side-by-side shingles are side lapped and pressed together along their side lapped edges, the cap103spreads slightly and snaps securely onto the snap feature104. This forms a mechanical interlock indicated at106,107that aligns the singles and holds them together in interlocked relationship. As with other embodiments, adhesive sealant108may be disposed between the side lapped portions to adhere and form a water resistant seal.

FIG.9is a partial plan view of a shingle having side lap features according to another embodiment of the present disclosure. In this embodiment, the edges of a metal shingle are cut with a rotary die or otherwise to form an array of lobes and lobe sockets, sometimes referred to as lollipop features, along the edges. Each cut edge is then bent 180 degrees. InFIG.9, the right edge of shingle111is bent up and over at bend116so that the lobes112and sockets113are disposed on the top side of the shingle111. The left edge of like shingle111are bent at119down and under so that the lobes117and sockets118are disposed on the bottom side of the shingle111.

A strip or bead of adhesive sealant114may be applied along one or both edges before bending so that the adhesive sealant114is exposed in the sockets between lobes of the array after bending. As with other embodiments, headlap sealant strip29is applied along the bottom of the shingle111to form a seal within headlap regions.

FIGS.10aand10billustrate the process of installing two like metal shingles ofFIG.9together in side lapped relationship. Specifically, the left edge portion of shingle111is moved downwardly onto the right edge portion of shingle121as indicated by the arrows. As the edge portions of the shingles111and121engage, the lobes117of shingle111are guided into the sockets113of like shingle121in interlocking fashion. The two side-by-side and side lapped shingles are thus mechanically interlocked and cannot move relative to each other in any in-plane direction. The adhesive sealant114eventually cures to adhere the shingles securely together and form a water barrier.FIG.10bshows the side lapped, interlocked, and sealed shingles111and121after installation.

FIGS.11aand11bshow yet another embodiment of side lap features on two like shingles126and127. In this embodiment, the right side edge of shingle126is machined, pressed, or otherwise formed to define a long downwardly facing groove128bordered by a downwardly extending tongue129. A lip131extends from the tongue129to the right edge of the shingle126. The left side edge of like shingle127is machined, pressed, or otherwise formed to define an upwardly facing tongue132sized to fit into groove128and a recessed adhesive chamber133inboard of the groove132. A bead or strip of adhesive sealant134may be disposed in the adhesive chamber133as shown.

FIG.11bshows opposite edges of like shingles126and127pressed together in side lapped fashion. Tongue132is engaged within groove128to align the shingles126and127properly with each other horizontally. The lip131overlies and covers the adhesive chamber133and the adhesive sealant134is compressed between the floor of the adhesive chamber133and the lip131. As shingles of an installation are heated by the sun, the adhesive sealant cures to adhere side lapped shingles securely together and form a barrier against water intrusion or penetration at side laps. One advantage of this embodiment is that the total thickness along the side laps of adjacent shingles is less than twice the thickness of the metal shingle itself.

FIG.12illustrates an alternate embodiment of like shingles139and141with side lap features that form a miniature “standing seam” configuration between horizontally adjacent shingles. Here, the left side edge of shingle141has a side lap feature31in the form of an upstanding ridge143. The right side edge of like shingle141has a side lap feature32in the form of a ridge cover142with a downwardly facing groove bearing a bead144of adhesive sealant. As shown on the left inFIG.12, when two like shingles139and141are side lapped and pressed together, the upstanding ridge143of one shingle slides into the downwardly facing groove of the ridge cover142of the other shingle. In the process, the adhesive sealant bead144is compressed and fills the space between the upstanding ridge143and the downwardly facing groove of the ridge cover142to bond the two shingles together along their side lap. When cured by the heat of the sun, the adhesive sealant also forms a water tight seal or barrier along the side lap.

An advantage of the embodiment ofFIG.12is that the bottom surfaces of side lapped shingles are co-planer with each other, thus enhancing appearance in the view of some and increasing the efficiency of headlap adhesive sealant.

FIGS.13-14billustrate yet another embodiment of side lap alignment features according to the present disclosure. Referring toFIG.13, a metal shingle161has a body panel162. Upstanding hooks163(3in this case) are formed in the surface of the panel by a gouging process and extend in a line adjacent one side edge of the shingle161. While not visible inFIG.13, hooks164(FIG.14a) also are gouged into the opposite surface of the panel adjacent the other side edge of the shingle. The hooks may range in width from ⅛ inch to ¼ inch.

InFIG.14a, shingle161with gouged hooks163and like shingle166with gouged hooks164are shown by arrows169and171being brought together in side lapped relationship. Hooks161and163are in opposing alignment as the shingles are brought together. Adhesive sealant beads or strips167and168are disposed along the side edges of the shingles outboard of the hooks163and164to adhere the shingles together and form a seal against water incursion or penetration.

InFIG.14b, the two shingles161and166have been brought into contact. To interlock the shingles161and166together and align them in the horizontal direction, the overlapping shingle166is slid relative to the underlying shingle161in the direction indicated by arrow171. This causes the two sets of gouged hooks163and164to engage with each other as shown in dashed lines inFIG.14b. Then, downward pressure exerted on the side lapped regions of the shingle161and166causes the hooks163and164to flatten and interlock securely with each other. At the same time, the adhesive sealant167and168bonds the shingles161and166together along the side lap and forms seals against water incursion or penetration.

One advantage of the embodiment ofFIGS.13-14bis that the total thickness along the side lapped regions of adjacent shingles is only twice the thickness of the metal or other sheet material of the shingles themselves, thus retaining a substantially flat appearance.

FIG.15illustrates another embodiment of the present disclosure. Here, the right edge of a metal shingle181is overlapped onto the left edge of a like shingle182forming a side lapped region185. The rightmost edge183of the left shingle181is visible in this plan view and the leftmost edge184of like shingle182is hidden below the right edge of shingle181. A bead or strip of adhesive sealant186is disposed between the side lapped shingles181and182to adhere the shingles181and182and form a seal along the side lap. Beads or strips of adhesive sealant187and188are disposed on the backs surfaces of shingles181and182and extend generally along the bottom edges of the shingles181and182. These beads or strips of adhesive sealant187and188bond the lower edges of shingles in one course to the headlap portion of shingles in a next lower course. Interlocking and alignment features179and180, described in more detail below, are illustrated in dashed lines inFIG.15.

FIG.16shows the two like shingles181and182separated and illustrates the interlocking and alignment features more clearly. The left edge portions of the shingles are formed with an upper slot191defined between side walls192and193and a forward wall194. The forward wall194is angled downwardly and forwardly for purposes discussed below. A lower slot196is formed adjacent the lower edge of the shingle and is defined between side walls197and198, a rear wall, and a forward wall199. As with the upper slot191, the forward wall199of slot196is angled downwardly and forwardly.

With continued reference toFIG.16, the right edge portions of the shingles are formed on their bottom surfaces with two downwardly and forwardly extending hooks204and203. The hooks204and203in this embodiment are formed in the metal of the shingle by a gouging process wherein the hooks204and203are gouged out of the bottom surface of the shingle leaving gouges201and202. The hooks204and203may, of course, be formed in other appropriate ways or they may be separate elements that are attached to the shingles by an appropriate means such as welding.

During installation, the right edge portion of shingle181is side lapped onto the left edge portion of like shingle182such that it is somewhat upwardly displaced and misaligned with shingle182. Shingle181is then slid or forced forward. As the shingle181moves forwardly, its hooks204and203engage within the slots191and196in the left end portion of shingle182. This both aligns the two shingles with each other horizontally and interlocks the shingles together.

The interlocking and alignment function is illustrated in more detail inFIG.17. Shingle181is shown side lapped onto shingle182and moving in a forward direction210. The hook203formed from the gouge202has dropped into the slot196. As a result of the gouging process, the hook extends downwardly and forwardly from the bottom surface of shingle181. The angle of the forward wall199of the slot196is generally similar to the angle of the gouged out hook203. When the hook203engages the forward wall199, the movement of shingle181is arrested and the two like shingles181and182are properly aligned with each other. Furthermore, due at least in part to the angle of the hook203and the forward wall199, the two shingles are interlocked together along the side lap both at the top and bottom portions of the side lap.

FIGS.18and19Aare two views of an additional embodiment or arrangement of metal roofing shingles and will be described together. As indicated inFIGS.18-19A, a series of metal roofing shingles, here shown as two metal shingles201and202, are arranged side-by-side in an upper course of shingles. These shingles overlap and are sealed at their ends at side lap regions204according to principles of the incorporated provisional applications. A metal shingle203in a next lower course of shingles is seen overlapped by the metal shingles201and202along a headlap region206of the metal shingle203. Headlap alignment features207, described in more detail below, are arrayed along the top edges of the shingles within the headlap region. Beads or strips of sealant208extend around the top edges of each shingle within the headlap region and along one of the side edges of each shingle within the side lap portion.

FIGS.19B through19Eare isometric and side elevation views showing a pair of metal shingles201and202, such as shown inFIGS.18-19A, with peripheral edges201A/202A thereof overlapping, e.g. along the side lap regions204or features thereof, defining a seam or joint205between the metal shingles201and202. A standing seam feature250is further provided, being positioned along the overlapping peripheral edges201A/202A of the metal shingles201and202, covering the seam205. The metal shingles201and202may be arranged side-by-side along a roof deck or substrate, as part of a course of shingles such as indicated inFIGS.18and19A through19D. The side lap regions204or features of the metal shingles201and202overlap and will be configured to adhesively connect to one another. Such an adhesive connection will be adapted to form a substantially waterproof seal along the seam205between the metal shingles so as to provide watershedding features along the seams and prevent intrusion of water through the seam and into contact with the roof deck or substrate below the metal shingles.

For example, as indicated inFIGS.19A-19E, metal shingle202may be positioned so that its side lap region204or feature overlaps a corresponding side lap region204or feature of metal shingle201. An adhesive strip or bead252can be applied along the metal shingle201adjacent the peripheral edge201A thereof to adhesively connect metal shingle202and metal shingle201. In embodiments, the adhesive strip or bead252can include a pressure sensitive sealant material or similar adhesive that can be applied in the field, or can be applied to the metal shingles when formed, such as at a factory, as a bead, strips, dots or in other configurations, and can be covered with a strip of a protective release material. In other embodiments, the metal shingles201and202may be connected to each other via fasteners or other mechanical connection, as described herein, which can be used in addition to or in place of the adhesive strip or bead252.

In another embodiment, the seam205formed between or created by the metal shingles201and202may be covered by a standing seam feature250. The standing seam feature250can be comprised of metal, composite, or other material. For example, in embodiments, the standing seam feature250will be comprised of the same material as the metal shingles201and202. As indicated inFIGS.19B-19F, in some non-limiting embodiments, the standing seam feature250has a body251that can be formed in an elongated square, rectangular262, triangular264, or substantially u-shaped configuration266(as illustrated inFIGS.19F through19H). In embodiments, the body251of the standing seam feature can include a cover portion253, an upper facing surface251aand a lower facing surface251b, and first and second side portions258and260. The standing seam feature250can be formed at a factory or in the field. Other configurations of a standing seam feature, including configurations similar to standing seam features illustrated in various embodiments of the present disclosure, also can be used.

The standing seam feature250further may be formed as one or a single piece component configured to span and cover a length of an entire series of seams205, or may be comprised of sections that can be connected in series such as by an adhesive material, or by fasteners or other mechanical connections. As noted above, the metal shingles201and202can be installed or disposed along a roof deck or substrate, as part of a course of shingles. In such a configuration, the seam205formed by two adjacent metal shingles201and202can be offset in relation to a seam formed above or below by adjacent metal shingles of upper and/or lower courses, as illustrated inFIGS.19C and19D. In such an embodiment, the standing seam feature250may cover portions of metal shingles in addition to seams formed by metal shingles arranged in a plurality of courses along the deck, substrate, rafters, or other supports of the roof on which the metal shingles are installed, providing at least the appearance of a substantially continuous standing seam.

As illustrated inFIGS.19C and19D, the standing seam feature250will connect to an upper surface201B/202B of each of the metal shingles201and202. In embodiments, the standing seam feature250can be attached to the metal shingles201and202via adhesive strips or beads254and256, and/or in other embodiments, can be connected via mechanical fasteners (e.g., screws, nails, rivets, clips, and/or other connectors), or other connections. The adhesive strips or beads254and256and/or mechanical fasteners connect the first and second side portions258and260of the standing seam feature250and the upper surfaces201B/202B of the metal shingles201and202with the standing seam feature250generally arranged over and extending along the seam205defined between the metal shingles201and202.

In embodiments, the standing seam feature250can provide further water intrusion protection along the seam205defined between the metal roofing shingles201and202so as to help shed water and deter the passage of water under the first and second side portions258and260and into the seam between adjacent metal shingles. The standing seam feature250also can provide further protection to substantially reduce and/or improve wind uplift resistance of the metal shingles applied along the roof, such as by covering and protecting the peripheral side edges of the adjacent metal shingles against direct contact with wind.

In some embodiments, the standing seam feature250further may be utilized for aesthetic purposes, whereby, rather than adjacent metal shingles201and202having a visible seam, discontinuities in the appearance of the roof structure in addition to seams, for example, adjacent chimneys or other projections in the roof, also can be covered via the standing seam feature250to provide a desired appearance to the roof. In addition, it further will be understood that the standing seam feature250, while illustrated with overlapping metal shingles201and202inFIGS.19B-19C, also may be utilized in any of the embodiments described herein. The standing seam feature further can be applied in varying configurations and orientations along the roof as part of a desired aesthetic visual appearance of the roof.

In embodiments, the metal shingles and/or standing seam features can be included as part of a kit for installation of the metal roofing shingles and standing seam feature in the field. Other materials and/or components can be included in the kit such as adhesives, mechanical fasteners, clips, and/or other materials and/or components for installation of the metal shingles and/or standing seam. By way of example, in some non-limiting embodiments, the components of such a kit, can include a plurality of metal shingles and/or standing seam features (e.g. sections or lengths of standing seam features that can be attached along seams defined between adjacent metal roofing shingles arranged in a plurality of courses along a roof), which can be shaped and/or sized at the factory (e.g., in a predetermined standard configuration). In other embodiments, the kit can include sheets or lengths of a material from which the metal shingles can be formed, and/or lengths of a standing seam material that similarly can be formed in selected lengths and configurations in the field or at the site of a roof installation.

FIG.20shows a single metal shingle211according to principles of the present disclosure. The metal shingle211has a body213, a top edge215and an opposed bottom edge212, with a main body portion213adefined between the bottom edge212and the headlap alignment features207. The bottom edge is defined by a bend212ain the material of the shingle resulting in an underlying tab220. The underlying tab220has a terminal edge225that may be spaced slightly away from the bottom of the shingle211. The bend212aand underlying tab220with its terminal edge225are better illustrated inFIG.21, which is a cross section along line A-A ofFIG.20.

Line A-A extends through one of the headlap alignment features207. As shown inFIG.21, the headlap alignment features207in this embodiment comprise tabs that are punched out of the material of the metal shingle and bent upwardly to that the tabs stand proud of the top surface of the shingle. These tabs in cooperation with an underlying tab220of a shingle in a next lower course align the two shingles properly along their headlap portions. More specifically, as illustrated inFIG.22, with a shingle203in a lower course previously installed, a shingle202in a next higher course is laid onto shingle203and slid upward as indicated by arrow216.

As the shingle202slides upward, the terminal edge225of its underlying tab220engages and slides beneath the headlap alignment features207, which in this embodiment are raised tabs. When the terminal edge225is fully engaged beneath the tabs, then the overlying shingle202is properly aligned with the underlying shingle203along their headlap regions. The sealant208(FIG.20) then bonds the two shingles together and forms a seal against migration of water through the headlap regions of the shingles. Installation continues with each higher course until a roof is shingled with metal shingles.

FIGS.23athrough23candFIG.24illustrate another embodiment of headlap alignment features according to the present disclosure. In this embodiment, shingles in one course are slid downwardly over the upper edges of shingles in a next lower course for installation. Referring toFIG.23aa metal shingle227in one course has a forward edge formed by a bend228in the material of the shingle. The bend228results in an underlying tab229with a terminal edge234beneath the shingle. Alignment features231are punched out of the underlying tab229and are bent downwardly forming hooks beneath the forward edge of shingle227.

Shingle226in a next lower course has a rear edge portion241. This portion may be formed with upwardly bent tabs242(FIG.24) that align with the hooks when a shingle in one course is slid down onto a shingle of a next lower course. Alternatively, the entire rear edge portion of the shingle in the next lower course may be bent up slightly to form a continuous tab. In any event, the hooks231form alignment features that engage with the rear edge portion241of a next lower shingle to align the shingles along their headlap portions.

FIG.23bis a top view of the overlapped shingles of23ashowing in phantom lines the rear edge241of a lower shingle engaged with a hook231of a next higher shingle, all beneath the surface of the upper shingle.FIG.23cis a view of the same arrangement as seen from the bottom wherein one of the hooks231and the rear edge234of the underlying tab229.

FIG.24is an isometric view from the bottom showing the just described alignment features in more detail. The underlying tab229formed by the bend228is shown as is it rear edge234. Downward hooks231are shown punched from the material of the underlying tab and a bead or strip of sealant259extends just inside the forward edge228of the overlying shingle.FIG.24also shows two alternative embodiments wherein upwardly bent tabs242may be formed along the rear edges of shingles to engage with the hooks231. Alternatively, the entire rear edges of shingles may be bent up slightly to engage the hooks as shown at the lower left portion ofFIG.24.

FIG.25illustrates another embodiment of metal roofing shingles300that can be interlocked or inter-connected across a roofing substrate or deck for forming a roof structure or system in accordance for the principles of the present disclosure. In some embodiments, the metal roofing shingles can be positioned directly over the substrate, while in other embodiments, an underlayment such as a TPO membrane can be applied to the substrate with the metal roofing shingles positioned over the underlayment. The roofing metal roofing shingles300are shown in the embodiment ofFIG.25as metal roofing shingles, though it will be understood that various other materials, including polymer and other materials, as well as combinations of polymer and/or metal materials also can be used. The roofing shingles300further are shown as having a generally rectangular shape inFIG.25, with each roofing shingle300having a body301including a top edge302, a bottom edge303, a right side edge304, and a left side edge306. The body301further will have a lower facing surface307and an exterior surface or exposed surface308, adapted to be exposed to the elements when the roofing shingle installed as part of the roof structure. It will also be understood that other shapes or configurations can be provided.

Side lap portions or features310generally will be formed and extend along one or more side edges of the roofing shingles300. As further illustrated inFIGS.25-26b, the side lap portions310can be formed with and/or will define interlocking features configured to fit over and engage/inter-lock with a corresponding side lap portion310of a laterally or horizontally adjacent/next roofing shingle300′. The interlocking features defined by the side lap portions can be configured in various shapes or configurations, for example, as generally illustrated inFIGS.27aand27b, having a generally arched, domed or rounded configuration, whereby the side lap portion of a first roofing shingle can overlie and can be coupled to a corresponding side lap portion of a second, laterally or horizontally adjacent roofing shingle, as shown inFIG.25.

As further illustrated inFIG.26a, adhesive materials315can be applied along one or both of the side edges304/306, and/or along one or both of the top and bottom edges302/303each roofing shingle. The adhesive sealant materials will be applied to the lower or bottom facing surface307of each roofing shingle, and can include a self-sealing strip of an adhesive sealant (shown in dashed lines316) that can extend along the side and top and/or bottom edges of each roofing shingle. Alternatively, the adhesive materials can include sealants or other, similar materials that can be applied to the roofing shingle in the field by an installer. In addition, in one or more embodiments, as discussed above, the adhesive material may be applied as a bead, strip and/or as dots, or in another pattern, and can be applied in various widths depending on the application of the roofing shingles. During installation of the roofing shingles300, the adhesive material can be exposed or applied along the bottom surface of the roofing shingles, and/or can be applied to the roofing substrate or deck, to attach and seal one or more of the side, top and bottom edges of the roofing shingle to the roofing substrate or deck.

In some embodiments, the roofing shingles300further can include a slot or cut-out320, as illustrated inFIGS.26aand26c. This slot or cut-out320generally can be formed along at least one end of at least one side lap portion310of each roofing shingle300, and will be configured to cause an expansion of the arched or rounded/domed side lap portions310, resulting in a resilient biasing or compression force applied along the lower portions. For example, as shown inFIG.27b, the sides/legs312or lower portions of the side lap portions310can be tapered or biased inwardly to provide a substantially snap-fitting, compressive engagement with the sides of the side lap portion of a previously installed adjacent roofing shingle, such as illustrated inFIG.26b.

As the roofing shingles300are applied to the roofing substrate of deck of a roof structure, as indicated inFIG.25, they will be sealed and attached to the roofing substrate of deck by the applied adhesive material, thereafter, successive roofing shingles300′ will be applied with their side lap portions310fitted over and overlapping corresponding side lap portions of previously installed horizontally or laterally adjacent roofing shingles. The compressive or press-fit engagement between the side lap portions of adjacent roofing shingles help hold the roofing shingles in place in an interlocked arrangement.

Sealant or adhesive materials315′ further can be applied along the side lap portions of the roofing shingles before a next roofing shingle is applied thereover, for example, being applied to top and/or bottom surfaces of the side edges of the overlapped side lap portions310/310′, along a seam314defined between laterally adjacent roofing shingles300/300′ to further assist in waterproofing of the installed roofing shingles300, and formation of water shedding features or pathways along the interconnected roofing shingles.

In addition, fasteners325will be inserted through the roofing shingles and into the roofing substrate or deck to secure longitudinally and laterally adjacent roofing shingles together and to the roof deck or roofing substrate. For example, fasteners can be inserted through the roofing shingles at spaced locations along areas of overlap326between the headlap portions and bottom edges of longitudinally or vertically adjacent roofing shingles300and300′, as illustrated inFIG.25. Fasteners325further can be inserted through the overlapping side lap portions between horizontally or laterally adjacent roofing shingles to further help secure the interconnected roofing shingles to the roofing substrate or deck.

The foregoing description generally illustrates and describes various embodiments of a roofing system, including metal shingles for forming a roof structure according to the principles of the present disclosure. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present disclosure without departing from the spirit and scope of the disclosure as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present disclosure. Accordingly, various features and characteristics of the present disclosure as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present disclosure.