Steep slope roofing panel system and method

Patent metadata

Field	Value
Publication number	US-11970856-B2
Application number	US-202318168924-A
Country	US
Kind code	B2
Filing date	Feb 14, 2023
Priority date	Jan 17, 2020
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

A steep slope roofing panel system includes an underlayment and a plurality of roofing panels installed atop the underlayment. The panels may be installed to provide both protection from the environment and watershedding. Alternatively, the panels and the underlayment may share the watershedding functions of the roof, with one as a primary watershedding component and the other as an auxiliary watershedding component. The roofing system may be custom manufactured off-site based upon predetermined measurements and characteristics of a roof and its protrusions. Alternatively, the roofing system may be custom manufactured at the job site based upon such measurements and characteristics. Each panel may be assigned to a location on the roof and may include imprinted instructions regarding cutting and/or bending the panel to form flashing, drip edges, or other features, as well as the panel's location and installation sequence on the roof.

First claim

The invention claimed is:

1. A roof system, comprising:
a deck having a slope of at least 2:12;
a plurality of metal roofing panels configured to be installed along the deck;
each metal roofing panel comprising:
an upper surface;
a lower surface;
a plurality of peripheral edges, including an upper edge, a lower edge, and side edges;
wherein the upper and lower surfaces of the metal roofing panels along each of the side edges are substantially flat;
at least one sealant or adhesive region positioned on the upper surface and adjacent at least one of the side edges; and

an underlayment positioned between the deck and the metal roofing panels;
wherein the metal roofing panels are installed on the deck with a side edge of a first metal roofing panel overlapping a side edge of an adjacent metal roofing panel in a same course of metal roofing panels, with the lower surface of the first metal roofing panel lying substantially flat against the upper surface of the adjacent metal roofing panel, and with the upper surface of the first metal roofing panel along an entire length of side edge exposed to an external environment; and
wherein the at least one sealant or adhesive region of each of the metal roofing panels is disposed along a region of overlap between the lower surface of the first metal roofing panel and the upper surface of the adjacent metal roofing panel overlapped thereby, such that at least one sealant or adhesive region of the adjacent metal roofing panel is positioned between the lower surface of the first metal roofing panel and the upper surface of the adjacent metal roofing panel so as to attach the lower surface of the metal roofing panel to the upper surface of the adjacent metal roofing panel and restrict migration of water therebetween.

2. The roof system of claim 1 , further comprising instructions applied to the upper surface, the lower surface, or a combination thereof, of at least some of the metal roofing panels; wherein the instructions comprise markings identifying a position at which each metal roofing panel of the plurality of metal roofing panels is to be installed on the deck.

3. The roof system of claim 2 , wherein at least some of the instructions comprise a map, diagram, directions, indicators or combinations thereof, and are configured to instruct an installer as to a metal roofing panel type, a location along the deck, positioning of each metal roofing panel or sets of metal roofing panels along the deck, an installation order of the metal roofing panels, an assigned roof plane for installation of the metal roofing panels, horizontal or vertical offsets of the metal roofing panels, placement of fasteners for securing the metal roofing panels to adjacent metal roofing panels, bending, cutting or manipulating portions of the metal roofing panels for interaction with roof obstructions, or combinations thereof.

4. The roof system of claim 1 , wherein the at least one sealant or adhesive region comprises at least one self-seal strip.

5. The roof system of claim 1 , wherein the at least one sealant or adhesive region comprises at least two sealant or adhesive regions positioned along the upper surface of each metal roofing panel and arranged substantially perpendicular to each other.

6. The roof system of claim 1 , further comprising at least one additional sealant or adhesive region arranged along the lower surface of at least some of the metal roofing panels.

7. The roof system of claim 1 , wherein at least a portion of the plurality of metal roofing panels comprise a quantity of metal roofing panels formed with predetermined standard roofing panel configurations.

8. The roof system of claim 1 , wherein the underlayment comprises a weather resistant material configured to divert water from the deck.

9. A roof assembly kit comprising:
a plurality of metal roofing panels, each comprising an upper surface, a lower surface, a plurality of peripheral edges;
wherein the plurality of peripheral edges includes an upper edge, a lower edge, and side edges;
wherein the upper and lower surfaces of each of the metal roofing panels along the side edges thereof are substantially flat;
at least one sealant or adhesive region positioned on the upper surface or the lower surface and adjacent at least one side edge thereof;
wherein the plurality of metal roofing panels are configured to be installed on a deck of a roof to form the roof in accordance with an assessment of a geometry for the roof; and
instructions for installation of each metal roofing panel of the plurality of metal roofing panels at a predetermined position on the deck of the roof based, at least in part, upon the geometry of the roof, and at least one of a building code requirement, a design requirement, an installation practice, or combinations thereof;
wherein the metal roofing panels are installed on the deck of the roof with a side edge of a first metal roofing panel overlapping a side edge of an adjacent metal roofing panel in a same course of metal roofing panels, with the lower surface of each metal roofing panel lying substantially flat on top of the upper surface of the adjacent metal roofing panel, and with the upper surface of the first metal roofing panel along an entire length of the side edge thereof exposed to an external environment; and
wherein the at least one sealant or adhesive region of at least one of the first metal roofing panel or the adjacent metal roofing panel is disposed along a region of overlap between the lower surface of the first metal roofing panel and the upper surface of the adjacent metal roofing panel so as to attach the upper and lower surfaces of the first metal roofing panel and the adjacent metal roofing panel together and restrict migration of water therebetween.

10. The roof assembly kit of claim 9 , wherein the instructions for installation of each of metal roofing panel are applied along the lower surface of at least one of the plurality of metal roofing panels.

11. The roof assembly kit of claim 9 , wherein the at least one sealant or adhesive region comprises at least one self-seal strip positioned along the upper surface of each metal roofing panel adjacent one of the peripheral edges thereof; the at least one self-seal strip configured to attach the metal roofing panel to a lower surface of an adjacent metal roofing panel.

12. The roof assembly kit of claim 9 , wherein the at least one sealant or adhesive region comprises at least two sealant or adhesive regions positioned along the upper surface, the lower surface, or a combination thereof, of each metal roofing panel and arranged substantially perpendicular.

13. The roof assembly kit of claim 9 , wherein at least a portion of the plurality of metal roofing panels comprise a quantity of roofing panels formed with predetermined standard roofing panel configurations.

14. The roof assembly kit of claim 9 , wherein at least some of the instructions comprise a map, diagram, directions, indicators or combinations thereof, and are configured to instruct an installer as to a metal roofing panel type, a location along the deck, positioning of each metal roofing panel or sets of metal roofing panels along the deck, an installation order of the metal roofing panels, an assigned roof plane for installation of the metal roofing panels, horizontal or vertical offsets of the metal roofing panels, placement of fasteners for securing the metal roofing panels to adjacent metal roofing panels, bending, cutting or manipulating portions of the metal roofing panels for interaction with roof obstructions, or combinations thereof.

15. The roof assembly kit

Assignees

• Bmic Llc

Inventors

• Anderson Eric R
• Zarate Walter R

Classifications

• E04B7/02 Primary

  with plane sloping surfaces, e.g. saddle roofs (E04B7/12 takes precedence) · CPC title

• E04D3/3605 Primary

  of roof covering supported directly by the roof structure (E04D3/3607, E04D3/3608, E04D3/361 - E04D3/369 take precedence) · CPC title

• E04D3/362

  by locking the edge of one slab or sheet within the profiled marginal portion of the adjacent slab or sheet, e.g. using separate connecting elements · CPC title

• E04D3/369

  by welding of the marginal portions of adjacent slabs or sheets {also by soldering, glueing} · CPC title

• E04D15/04

  for roof coverings comprising slabs, sheets or flexible material · CPC title