WO2023115223A1 - Roofing clip, roofing shake and roofing system and method - Google Patents

Roofing clip, roofing shake and roofing system and method Download PDF

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Publication number
WO2023115223A1
WO2023115223A1 PCT/CA2022/051892 CA2022051892W WO2023115223A1 WO 2023115223 A1 WO2023115223 A1 WO 2023115223A1 CA 2022051892 W CA2022051892 W CA 2022051892W WO 2023115223 A1 WO2023115223 A1 WO 2023115223A1
Authority
WO
WIPO (PCT)
Prior art keywords
roofing
clip
tongue
shake
base
Prior art date
Application number
PCT/CA2022/051892
Other languages
French (fr)
Inventor
Gary VAN DER LEEK
Original Assignee
Vanderleek Roofing Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vanderleek Roofing Inc. filed Critical Vanderleek Roofing Inc.
Publication of WO2023115223A1 publication Critical patent/WO2023115223A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/12Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
    • E04D1/23Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface with tapered thickness
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/12Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
    • E04D1/18Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/12Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
    • E04D1/22Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of specified materials not covered by any one of groups E04D1/14 - E04D1/205, or of combinations of materials, where at least one is not covered by any one of groups E04D1/14 - E04D1/205
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/24Roofing elements with cavities, e.g. hollow tiles
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/28Roofing elements comprising two or more layers, e.g. for insulation
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
    • E04D13/15Trimming strips; Edge strips; Fascias; Expansion joints for roofs
    • E04D13/158Trimming strips; Edge strips; Fascias; Expansion joints for roofs covering the overhang at the eave side, e.g. soffits, or the verge of saddle roofs
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3408Fastenings for attaching roof-covering elements to the supporting elements characterised by the fastener type or material
    • E04D2001/3414Metal strips or sheet metal

Definitions

  • Certain aspects of the present disclosure generally relate to a roofing clip for retaining roof shakes, roofing shakes and a related installation system and method.
  • Metal shake roofing systems including retaining clips and shakes can provide a resilient and long-term roof. It is desired to provide a retaining clip, roofing shake and installation system which offers improved durability, strength, resistance to extreme weather conditions and ease of installation over existing apparatus and systems.
  • One aspect of the present disclosure provides a retaining clip and shake for roofing materials and a related installation system.
  • roofing clip adapted for use in installing, on a roof surface, roofing shakes with a slot on one side
  • the roofing clip comprises a substantially planar base, a tongue, extending generally perpendicularly from the base, and a tab extending from the tongue, from the end opposite the base, dimensioned to engage the slot of the roofing shake.
  • the base of the roofing clip further comprises a long axis and a short axis defining two wing sections, and wherein the tongue extends from an edge generally parallel to the long axis of the base.
  • the roofing clip further comprises lateral wings extending generally perpendicular to both the base and the tongue, from the sides of the tongue.
  • the lateral wings of the roofing clip are generally triangular with the base of the lateral wings being substantially parallel to the base of the clip, and define a gap therebetween. In yet another embodiment, the lateral wings are substantially rectangular. In another embodiment, the roofing clip further comprises a first set of secondary wings extending from the lateral wings, the first set of secondary wings being substantially parallel to the base of the clip. In an embodiment, the roofing clip further comprises a second set of secondary wings extending from the lateral wings, the second set of secondary wings being substantially parallel to the base of the clip. In yet another embodiment, the roofing clip further comprises at least one upturned portion generally perpendicular to the base and coplanar to the tongue, extending from the same edge of the base as the tongue.
  • roofing clip adapted for use in installing, on a roof surface, roofing shakes with an interior cavity adjacent one side and a slot on said side, wherein the roofing clip comprises a substantially planar base, a tongue, extending generally perpendicularly from the base, and a vertical projection extending from the tongue, opposite the base, dimensioned to engage the cavity of the roofing shake.
  • the roofing clip further comprises one or more secondary wings extending from the vertical projection in a direction substantially parallel to the base of the clip.
  • the roofing clip further comprises a tab extending from the vertical projection dimensioned to engage the slot of the roofing shake.
  • roofing clip adapted for use as a snow stop and toe hold on a roof surface with roofing shakes with a top surface and four sides, with slits located at the comers of each side, wherein the roofing clip comprises a substantially planar first base portion, a tongue, extending generally perpendicularly from the base from one side, and dimensioned to engage one side of at least one roofing shake by inserting the tongue into a slit adjacent said side.
  • the roofing clip further comprises a vertical stop extending from the first base portion from the side opposite the tongue.
  • the roofing clip further comprises a substantially planar second base portion coplanar with the first base portion, and extending from the side opposite the tongue.
  • a roofing shake that comprises a top surface, four sides extending from and generally perpendicular to the top surface, defining a cavity, and a filler within the cavity extending from the top surface, wherein the filler is configured to extend further from the top surface than each of the four sides.
  • each corner of the roofing shake between adjacent sides further comprise a slit therebetween.
  • the dimensions of the filler are configured to define a gap between one or more of the four sides and the corresponding edges of the filler.
  • one side of the roofing shake further comprises a slot dimensioned to receive a tab from a roofing clip.
  • kits for installation of a roofing system comprising a plurality of clips comprising a base and a tongue extending in a substantially perpendicular manner from one edge of the base, and a plurality of metal shakes with a top surface and four walls defining a cavity, including a filler extending out from the cavity farther than each of the four walls.
  • the kit further comprises a plurality of starter course clips comprising a base and a tongue substantially perpendicular to the base, and wherein the tongue is the same width as the base.
  • the kit further comprises a plurality of edge detail clips comprising a base, a tongue extending substantially perpendicular to the base, and a tab extending substantially perpendicular to the tongue, wherein the height of the tongue at one edge is greater than the height of the tongue at the opposite edge, and wherein the width of the base is greater on the side where the height of the tongue is shorter.
  • the one or more of the plurality of clips of the kit further comprise lateral wings extending from the sides of the tongue generally perpendicular to both the base and the tongue, wherein the lateral wings are generally triangular with the base of the lateral wings being substantially parallel to the base of the clip, and defining a gap therebetween.
  • the one or more of the plurality of clips of the kit further comprise lateral wings extending from the sides of the tongue generally perpendicular to both the base and the tongue, wherein the lateral wings are substantially rectangular, wherein a first set of secondary wings extend from the lateral wings, the first set of secondary wings being substantially parallel to the base of the clip.
  • the kit further comprises a plurality of snow stop and toe hold clips comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, a tongue extending generally perpendicularly from the second base section, and a tab extending generally perpendicularly from the tongue.
  • the kit further comprises a plurality of grab clips comprising a base section, a vertical stop extending generally perpendicularly from one end of the base section, and a substantially flat hook extending generally perpendicular from the opposite end of the base section.
  • Another aspect of the present invention provides a method of installing courses of shakes of a roofing system on a roof surface, wherein the method comprises the step of aligning, in a desired course installation orientation, a roofing clip comprising a base and a tongue, wherein the tongue extends in a generally perpendicular manner from the base, and wherein the base is placed generally coplanar to the roof surface, the step of aligning a roofing shake adjacent to said roofing clip in a desired course installation orientation, by at least aligning a side of said roofing shake with said tongue of said roofing clip, the step of fastening said roofing clip and roofing shake with at least one fastener, said at least one fastener penetrating through at least both said roofing shake and a portion of the base of said roofing clip, wherein the fastener further penetrates at most one preceding course of previously installed roofing shakes.
  • the step of aligning the roofing shake further comprises aligning a butt of the shake with a tongue of a clip in a previously installed course of shakes.
  • the method of installing a roofing system further comprises the step of fastening a butt of the aligned shake to the tongue of the clip in the previously installed course.
  • the step of aligning the roofing shake further comprises aligning a butt of the shake with a tongue of a starter clip aligned with the bottom edge of the roof surface and a previously installed starter course of shakes.
  • the step of aligning a roofing clip further comprises aligning at least one of the back surface of the tongue and an upturned portion extending from the base of the clip from the same edge as the tongue, with an underlayment layer installed on the roof surface.
  • the step of aligning a roofing shake further comprises selecting a shake including an edge detail clip at least partially covering the bottom of the shake, and installing said shake on an overhanging edge of the roof surface.
  • the method further comprises the step of installing a snow stop and toe hold, comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, a tongue extending generally perpendicularly from the second base section, and a tab extending generally perpendicularly from the tongue
  • the step of installing a snow stop and toe hold comprises the step of generally aligning the tongue of the snow stop and toe hold with the surface of a previously installed course of shakes, the step of inserting the tongue and tab into a butt of the aligned shake, the step of rotating the snow stop and toe hold to align the first and second base sections with the surface of the previously installed course of shakes, and the step of fastening the snow stop and toe hold with fasteners to at least one of the previously installed courses of shakes and the aligned shake.
  • the method further comprises the step of installing a snow stop and toe hold, comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, and a tongue extending generally perpendicularly from the second base section, and wherein the installed shake further comprises a slit at each corner
  • the step of installing a snow stop and toe hold comprises the steps of aligning the first and second base sections of the snow stop and toe hold with the surface of a previously installed course of shakes and aligning the tongue of the snow stop and toe hold with a slit of the aligned shake, and the step of translating the snow stop and toe hold to insert the tongue into a slit on a bottom corner of the aligned shake.
  • FIG. 1 A and FIG. 1 B are perspective views of the top and bottom or underside, respectively, of a roofing shake according to one aspect of the present disclosure.
  • FIG. 2 illustrates an exemplary roofing clip according to one aspect of the present disclosure.
  • FIG. 3 is a perspective view of a shake attached to a roof through an underlay and an exemplary roofing clip according to one aspect of the present disclosure.
  • FIG. 4A illustrates a roof installation using an exemplary clip and shake according to one aspect of the present disclosure.
  • FIG. 4B illustrates a cross section of a roof installation using an exemplary shake taken along line 4-4 in FIG. 4A and according to one aspect of the present disclosure.
  • FIG. 5 illustrates another exemplary roofing clip according to one aspect of the present disclosure.
  • FIG. 6 illustrates yet another exemplary roofing clip according to one aspect of the present disclosure.
  • FIG. 7A illustrates another exemplary roofing clip according to another aspect of the present disclosure.
  • FIG. 7B illustrates other embodiments of the exemplary roofing clip of FIG. 7A.
  • FIG. 8 illustrates another exemplary roofing clip according to another aspect of the present disclosure.
  • FIG. 9 illustrates another exemplary roofing clip according to another aspect of the present disclosure.
  • FIG. 10 illustrates an exemplary roofing clip according to one aspect of the present disclosure for use as a combination drip edge, starter edge, and underside cover.
  • FIG. 11 illustrates an exemplary roofing clip according to one aspect of the present disclosure for use with the exemplary roofing clip of FIG. 10.
  • FIG. 12 illustrates an exemplary roofing clip according to one aspect of the present disclosure for use as an edge detail closure piece.
  • FIG. 13A illustrates a roof installation using an exemplary clip and shake according to one aspect of the present disclosure.
  • FIG. 13B illustrates an exemplary clip and shake according to one aspect of the present disclosure.
  • FIG. 14A illustrates an exemplary snow stop and toe hold according to one aspect of the present disclosure.
  • FIG. 14B illustrates an exemplary grab clip according to one aspect of the present disclosure.
  • FIG. 14C illustrates a cross section detail of a roof installation using exemplary snow stop and toe hold, grab clip and roofing shake of the present disclosure.
  • FIG. 14D illustrates a cross section detail of a roof installation using exemplary toe hold, grab clip and roofing shake of the present disclosure.
  • FIG. 15 illustrates an exemplary method of manufacture of an exemplary roofing clip according to one aspect of the present disclosure.
  • a roof surface or roof deck generally comprised of plywood or some other suitable substrate is covered with short non-interlocking shakes that are affixed to the roof surface through an underlayment layer to create a weather-proof and fire-resistant roof.
  • Shakes are generally made from various materials including but not limited to wood such as cedar including red cedar, white cedar, treated wood, treated pine, and rot resistant wood, metal, recycled rubber, recycled plastics, resin-based synthetics, and mixed composites.
  • the shake of the current disclosure is formed from a metal sheet and defines a cavity containing a filler as described below.
  • the filler is generally made from various materials with the desired stability and thermal insulation characteristics, including but not limited to expanded polystyrene foam (EPS) filler, polyisocyanurate (ISO), any other ridged insulation products, or wood.
  • EPS expanded polystyrene foam
  • ISO polyisocyanurate
  • the underlayment is generally laid perpendicular to the direction of the pitch of the roof.
  • the underlayment is used to define the courses or rows of shakes to be installed and is interwoven with each course as the shakes are installed.
  • a course is a row of shakes, shingles or roll roofing running the partial or entire length of a roof surface.
  • the underlayment placing can assist in determining the amount of overlap between the courses, and therefore the exposure and the head lap for the installed shakes as described in more detail below.
  • a roofing clip is preferably inserted under and aligned with the underlayment in the current course.
  • the clip is optionally placed on top of the underlayment, or partially inserted under the underlayment.
  • a shake is positioned and laterally aligned in a first direction with the roofing clip of the current course, and the butt of the shake is aligned in a second direction with a roofing clip from a previously installed course.
  • a fastener or means for affixing the shake to the roof such as a nail, screw, rivet or the like is inserted through both the shake and the roofing clip of the current course, as well as through the underlayment, the shakes from previously installed courses and affixed directly to the roof surface.
  • the shake may also be secured at the butt to the roofing clip from the previously installed course, or is secured using a starter clip as described in detail below.
  • the disclosed roofing system has a number of advantageous features.
  • the roofing clip is preferably placed in the space between two adjacent shakes, or keyway, thereby blocking the keyway with the vertical tab that comprises the clip as described below. Therefore, the keyway is blocked and prevents driving snow and rain from entering the keyway during extreme weather conditions.
  • improved weather resistance is achieved as the roofing clip provides a physical barrier in the keyway between shakes.
  • the roofing shakes are preferably attached at the bottom end to the roofing clips from previous courses, such that the roofing system has greatly increased resistance to extreme weather conditions, such and gale force winds, by providing another anchor point for each shake.
  • increased durability is achieved.
  • the roofing system provides further advantages by allowing the head lap to be reduced because the keyway is blocked and prevents the entrance of moisture. Reducing the head lap increases the shake exposure. Conventional roofing systems require a greater head lap in order to reduce the amount of moisture that can enter the keyway and travel up the shakes. With increased shake exposure, less material is required to cover the roof surface which reduces costs and allows for a faster installation.
  • the roofing system provides further advantages by allowing for a faster installation by providing means to align the shakes along two directions. Shake installation is optionally performed either from left to right or right to left.
  • the roofing clip from the disclosed system will hold and place the shakes when changing pitch positions on the roof.
  • the pitch or slope of the roof is a measure of roof inclination. Roof pitch can be described as a compound value, A/B, indicating the vertical rise or drop A for every measure of B; a 4/12 pitch indicates a vertical rise or drop of 4 inches for every 12 inches, or approximately 18.5 degrees.
  • the clip will hold and place shakes when installing with a 4/12 pitch (approximately 18.5 degrees) and transitioning to an 8/12 pitch (approximately 33.75 degrees), or vice versa, or in a mansard roof going from a 24/12 pitch (approximately 63.43 degrees) to a 4/12 pitch (approximately 18.5 degrees).
  • the roofing shake of the present disclosure provides further advantages by eliminating metal to metal contact between installed shakes because the EPS filler extends farther than all of the sides beyond the shake cavity in the vertical direction and is separated from the vertical sides of the shake. As a result, the opportunity for water to travel through capillary action between the upper and lower shakes is reduced.
  • Further advantages of the shake from the disclosed roofing system include increased air movement inside and underneath installed shakes, between the filler and the shake sides. Increased air movement will prevent moisture from being retained underneath a shake of the roofing system, facilitating diffusion of humidity and droplets after a storm. This overcomes the disadvantages of known interlocking systems, which accumulate condensation inside the roofing shakes.
  • Further advantages of the disclosed roofing system include improved fire resistance, given the multi-layer structure created by the installed metal shakes. Contrary to current industry standard installations, where roofing comprises only one metal layer, the current disclosure teaches multiple layers of shakes. A single metal layer is disadvantageous because the top metal layer is in direct contact with the roof surface, which increases heat transfer. These disadvantages are overcome with the disclosed system. Further, thermal transfer is reduced because of the air gaps which allow hot air to escape, and the filler within the shakes increases thermal insulation between the exposed surface of the shakes and the roof surface on which the roofing system is installed. Fire resistance is achieved in the installed roofing system due to the spaces from the shake cavities between the roof deck and the metal shakes, as at least two cavities prevent heat from burning debris from affecting the roof deck structure. Further, packaging materials are reduced as filler prevents scratches on the finished metal surfaces during packaging and transport.
  • roofing system is non-interlocking, facilitating the removal and repair of individual pieces, such as shakes or clips, if required. This is advantageous as a single shake can be removed and a new shake can be retrofitted on the roofing system, without the need to reinstall multiple shakes and multiple courses of shakes. Further advantages include ease of adding roof features such as skylights and or other roof penetrations without the difficulty of working interlocking roofing panels. Further advantages of a non-interlocking roof are that humidity is able to escape the system, and the individual components can adjust under pressure changes or extreme weather conditions.
  • the disclosed roofing system provides further advantages by a snow stop and toe hold for use with the roofing system as described herein.
  • the shakes in subsequent courses may not lie completely flat.
  • the snow stop as described is advantageous as it is optionally used to deform and conform a shake from a subsequent or upper course so that it lies flat on the upper surface of one or more shakes from a previous or lower course, when fastened to the snow stop, as described herein.
  • the snow stop secures the upper course shake to one of the lower courses, and thereby provides increased weather resistance.
  • Further advantages include that the need for different sized starter course shakes, which are typically shorter than the shakes used for the rest of the roof, is eliminated.
  • snow stop as described herein include that when installed, fasteners only perforate one layer of shakes leaving at least one layer intact beneath the snow stop, and thereby avoiding leaks and degradation of the system components, as is encountered with conventional roofing systems where fasteners perforate through to the roof surface.
  • Another advantage of the snow stop of the present invention is that an installed snow stop can provide up to six fastening points, which can provide additional strength and holding power for the roofing system.
  • roofing system as described herein include the possibility of installing toe holds by laterally sliding them into the bottom or butt of an installed shake located anywhere on a roof surface without the need to dismantle the roofing system and allowing for the removal of a toe hold after use, without damaging or weakening the roofing system components, without compromising the integrity of the roofing system and without requiring repairs, and thereby providing a safer work environment in a maintenance situation.
  • FIG. 1 a roofing shake is described according to one aspect of the present disclosure.
  • FIG. 1 A a top (FIG. 1 A) and underside (FIG. 1 B) perspective views of a roofing shake are shown, where like references numbers refer to like features.
  • the metal shake 10 comprises a flat top surface 11 and four vertical sides 12, 13, 14, 15 defining a cavity 16 between them.
  • a left side 12 a right side 13, an upper side 14 and a lower or butt side 15.
  • the upper side 14 is also referred to as the head, and the lower side 15 is also referred to as the butt.
  • the shake 10 is generally trapezoidal in shape, with the upper side 14 wider than the lower side 15.
  • the length of the shake between the upper side 14 and the lower side 15 is between 16 inches and 24 inches long.
  • the width of the shake W1 is the distance between left side 12 and right side 13, along the upper side 14 of the shake.
  • the height of the shake in FIG. 1 A and FIG. 1 B has been exaggerated in relation to the other dimensions, for illustrative purposes.
  • the height H1 of the upper side 14 along a vertical direction is less than the height H2 of the lower side 15, resulting in the shake 10 being thinner at the head and thicker at the butt.
  • the lower side 15, optionally includes a slot 17 through which a portion of the roofing clip is optionally inserted.
  • the slot 17 is configured to accommodate, for example, the tab or projection 130 of the roofing clip 100 (see below) therethrough.
  • the widths W1 and W2 of the shake are optimally between 4 to 16 inches.
  • the length of the shakes are optimally between 16 to 26 inches.
  • the height H1 is optimally between 0.03125 (1/32) inches to 0.5 (1/2) inches, while the height H2 is optimally between 0.1875 (3/16) and 1 inch.
  • the cavity 16 is filled with a filler 18, for example but not limited to a rectangular EPS filler, separated from each of the vertical sides and extending out of the cavity 16 beyond all sides in the vertical direction, defined by H3, H4.
  • a filler 18 fills the cavity 16 up to the height of the vertical sides.
  • the filler 18 is further configured to allow for a gap between the sides of the filler and each of the corresponding sides 12, 13, 14 and 15.
  • the filler 18 is generally rectangular in shape.
  • the filler 18 is generally wedge-shaped, extending approximately 1/16 of an inch (approximately 1 mm) past the sides 12, 13, 14 and 15 in a vertical direction.
  • H3 is approximately 1 mm greater than H1
  • H4 is approximately 1 mm greater than H2.
  • the gap D1 between the lower side 15 and the corresponding side of the filler 18 is larger than the gap D2 between the upper side 14 and the corresponding side of the filler 18.
  • the gap between the sides of the filler 18 and each of the corresponding sides 12, 13, 14 and 15 is at least approximately 0.5 inches (approximately 12.7 mm).
  • the exposed surface of the filler is grooved or textured.
  • Shake 10 are optionally manufactured from various materials, including but not limited to metal, such as but not limited to copper, zinc, aluminum, stainless steel, and brass.
  • Metal shakes are preferably fabricated from 26 to 16-gauge sheet metal, galvanized metal, pre-painted silicone-modified polyester (SMP) metal and polyvinylidene fluoride (PVDF) coated metal.
  • Shakes are alternately known as shingles, tiles, slates, plates or planks. When installed, the tapered shape of the shakes creates a flared keyway between adjacent shakes that avoids the accumulation of debris within the keyway.
  • shakes are manufactured from a single piece of sheet metal, and the sides 12, 13, 14 and 15 are bent into the desired shape, leaving gaps or slits 19 between the sides 12, 13, 14 and 15.
  • FIG. 2 an exemplary roofing clip 100 according to one aspect of the present disclosure is illustrated.
  • Embodiments of the roofing clip as described herein are preferably fabricated from 26 to 16-gauge metal sheet, including but not limited to sheet metal, including galvanized steel, Galvalume ® steel, stainless steel, copper, zinc, aluminum or any others suitable metal.
  • the roofing clip as described herein can also be fabricated from any other material that provides appropriate properties for flexibility, strength, and weight, such as polycarbonates, acrylonitrile butadiene styrene plastics (ABS), polyvinyl chloride (PVC), thermoplastic polyolefin (TPO), ethylene propylene diene terpolymer (EPDM), carbon fiber composites, or any other suitable thermopolymer or polymer material.
  • ABS acrylonitrile butadiene styrene plastics
  • PVC polyvinyl chloride
  • TPO thermoplastic polyolefin
  • EPDM ethylene propylene diene terpolymer
  • carbon fiber composites or any other suitable thermopolymer or polymer material.
  • the roofing clip 100 comprises a generally flat wing or base 110 and a tongue 120 extending up at a generally right angle from the wing 110.
  • a horizontal plane generally corresponds to the plane of the roof surface 20
  • a vertical plane generally corresponds to a perpendicular plane thereto.
  • the tongue 120 optionally extends in a general vertical direction at substantially 90 degrees with respect to the plane of the wing 110, with a deviation of 01 in the range of 0 to 45 degrees. In FIG. 2, the value of 0i is approximately 10 degrees.
  • the shape of the wing 110 is optionally generally elliptical or rectangular, with a first or major axis A1 that generally corresponds to a first direction and a second or minor axis A2 that generally corresponds to a second direction, defining a left side 112 and a right side 113.
  • the dimensions of each of the left side 112 and right side 113 of wing 110 is sized to permit fasteners 60, 62 to be installed through the top surfaces 11 of shakes 10, 50 to penetrate and affix the shakes and the corresponding left and right sides 112, 113 of the wing 110, holding the clip 100 in place (see FIG. 4A).
  • the tongue 120 optimally has a generally rectangular shape.
  • the width of the tongue 120 is shaped to have the minimum width of the desired resulting keyway or separation between adjacent roofing tiles or shakes 10 from the same course to be installed.
  • the height of the tongue 120 is greater than the thickness of the shake 10 at the location of maximum exposure (see FIG. 4B), the location of maximum exposure is typically about 1 inch.
  • the height of the tongue 120 is sized to be no greater than the thickness of the shake 10 at the location of exposure plus the thickness H2 of the butt of the shake 10, for instance 2 inches or more.
  • the sides of the tongue 120 are substantially vertical and are used to align and space the shakes 10 during roof installation, as described in detail below with reference to FIGS. 3 and 4A.
  • the bottom rear surface of the tongue 120 acts as a stop with the clip 100 inserted under the underlayment 30 and abuts the edge of the underlayment 30.
  • the rear surface of the tongue 120 is oriented to be substantially parallel to the edge of the underlayment 30.
  • the roofing clip 100 is oriented with respect to the underlayment 30 and aligned in a second direction.
  • the roofing clip 100 also includes a tab or projection 130 extending forward from the top of the tongue 120 adapted to be bent at an angle.
  • the width of the tab 130 is optionally the same as the width of the tongue 120, or the width can be different.
  • the shape of the tab 130 is optionally generally rectangular or polygonal (FIG. 5).
  • the tab 130 is made of a material that is sufficiently strong so as to retain its shape, but is adaptable to be bent by a user under their own force, such as sheet metal, including galvanized steel, Galvalume ® steel, stainless steel, copper, zinc, aluminum or any others suitable metal.
  • a roofing system includes a roofing shake 10 installed on a roof surface 20 through an underlayment 30.
  • the roofing shake 10 includes a left side area and a right-side area on the top surface 11 (see FIG. 1 ).
  • the underlayment 30 is placed on the roof surface 20 in rows running generally perpendicular to the direction of the pitch of the roof. These rows of underlayment 30 may define the courses or rows of roofing tiles 10 to be installed.
  • a roofing clip 100 of the present disclosure is shown in relation to the shake 10 and underlayment 30.
  • the roofing clip 100 abuts with the right side of the shake 10 so that the clip 100 is aligned in a first direction, generally running left to right or right to left.
  • the roofing clip 100 is inserted under the underlayment 30 so that the clip 100 is aligned in a second direction, generally running front to back corresponding to the pitch of the roof surface.
  • left to right or right to left generally corresponds to a direction perpendicular to the direction of the pitch of the roof.
  • front to back or back to front generally corresponds to the direction of the pitch of the roof.
  • a fastener 60 such as rivet, screw, nail or other suitable means for affixing the shake is inserted through the top surface 11 of shake 10, a portion of the clip 100, through the underlayment 30 and affixed to the roof deck 10, as described in more detail below.
  • FIG. 4A illustrates a roof installation, where previously installed shakes 40 and previously installed clips 102 are shown.
  • the height of the shake has been exaggerated in relation to the other dimensions, and the clip dimensions relative to the shake dimensions have been exaggerated, for illustrative purposes.
  • a partially fastened shake 10 is also shown.
  • the clip 100 is inserted under the underlayment 30 by sliding the wing 110 underneath the underlayment 30.
  • the clip 100 is positioned such that the left side 122 of the tongue 120 abuts the right side 13 of the shake 10, thereby aligning the clip 100 in the first direction, or along left to right or right to left.
  • the clip 100 is inserted under the underlayment 30 until the back surface of the tongue 120 abuts the front edge 31 of the underlayment 30 substantially parallel to the edge of the underlayment 30, thereby orienting and aligning the clip 100 in the second direction, or generally in the direction of the pitch of the roof surface.
  • a fastener 60 is installed through the top surface 11 of the shake 10 generally adjacent to the right side 13 thereof, underlayment 30, and the left side 112 of wing 110 of clip 100, thereby securing shake 10 in place.
  • the next shake to be installed 50 is then placed in position, aligning the left side 12 of shake 50 until it abuts the right side 123 of the tongue 120 of clip 100.
  • the tab 130 of the previously installed clip 102 is inserted through cavity 16 by lowering the shake 50 and then sliding the tab 130 through slot 17 in the butt of shake 50.
  • Shake 50 is translated up in the direction of the pitch of the roof surface 20, until the interior surface of the butt of shake 50 substantially contacts the front surface of the tongue 120 of clip 102.
  • the tab 130 of clip 102 is then bent downward, securing the butt of shake 50 in place.
  • the butt of the shake 50 is optionally secured by a fastener such as a rivet, screw or other suitable means (not shown) to the tongue 120 of clip 102.
  • a fastener 62 is inserted through the top surface 11 of shake 50 generally adjacent to the left side 12, the underlayment 30, and the right side 113 of wing 110 of clip 100. The shake 50 is now partially fastened, and the process is repeated.
  • FIG. 4B illustrates a cross sectional side view of a roof installation using exemplary shakes in their installed positions taken along line 4-4 in FIG. 4A and according to one aspect of the present disclosure.
  • the height of the shake has been exaggerated in relation to the other dimensions, for illustrative purposes.
  • shakes 10 are installed on roof surface 20.
  • courses are consecutively installed, shakes are placed and affixed on top of previously installed courses in an overlapping manner, starting with an initial or starter course at the lowest part of the roof or surface to be covered.
  • a single course is installed by placing, aligning along a bottom edge and affixing shakes one beside another, and covering the desired roof or surface or portion of roof or surface to be covered.
  • a second course where the bottom edges of the shakes or shingles of the second course is installed by aligning with the bottom edges of the shakes or shingles of the initial or starter course, where the shakes of the second course are laterally displaced from the shakes of the initial or starter course.
  • Subsequent courses are installed by installing shakes displaced from the previously installed course in a direction generally corresponding to the pitch of the roof or surface and generally perpendicular to the previously installed course such that the previous course has an exposed region, and laterally displaced from the shakes of the previous course.
  • the exposed region of each shake, or shake exposure E as illustrated in FIG. 4B is the region of the shake that remains visible and exposed to the environment.
  • the head lap HL is the region where up to three layers of shakes cover the roof or surface.
  • FIG. 5 illustrates another exemplary roofing clip 200 according to one aspect of the present disclosure.
  • the clip 200 includes a generally rectangular wing or base 210, a tongue 220, and a tab 230.
  • the tab 230 of the roofing clip 200 is angled upwards, forming an acute angle A with respect to the horizontal plane.
  • the shape of the tab 230 is generally polygonal, with the distal end to the tongue 220 being narrower than the proximal end, to facilitate insertion into slot 17.
  • the front edge of the wing 210 includes upturned portions 240 which are aligned with the back surface of the tongue 220.
  • the roofing clip 200 further includes lateral wings 250 extending back from the sides of the tongue 220 at the bottom thereof.
  • the lateral wings 250 are preferably shaped in a general triangular shape, with the bottom edge of each lateral wing 250 being substantially parallel to the plane of the wing 210.
  • the distance between the surface of the wing 210 and the bottom edges of the lateral wings 250 are sufficient to readily accommodate the thickness of the underlayment 30.
  • the distal ends of the lateral wings 250 are optionally rounded, to avoid snagging with the underlayment 30 upon inserting the clip 200.
  • the clip 200 is installed using the same installation methods as described above, except where noted. Alignment of the shake 10 with the clip 200 in the first direction is further facilitated by lateral wings 250 upon insertion of clip 200 under the underlayment 30. That is, the side surfaces of wings 250 engage the sides of adjacent shakes 10, 50. Further, upon inserting the clip 200 under the underlayment 30, the upturned portions 240 collaborate with the back of the tongue 220 to act as a stop to orient and align the clip 200 with the underlayment 30 in the first direction. In situations where the shake exposure must be modified and the clip 200 is not inserted so far as to abut the edge of the underlayment 30, the lateral wings 250 provide means to orient the clip 200 and the shakes 10, 50. Upon installation of the next course of shakes, the insertion of the tab 230 into the slot 17 in the butt of the shake is facilitated because of the upturned orientation of tab 230.
  • FIG. 6 illustrates yet another exemplary roofing clip 300 according to one aspect of the present disclosure.
  • the clip 300 includes a generally rectangular wing or base 310 and a substantially vertical tongue 320.
  • the front edge of the wing 310 includes upturned portions 340 which are aligned with the back of the tongue 320.
  • the clip 300 also includes a tab 330 extending backward from the top of the tongue 320 at an oblique angle O with respect to the horizontal plane.
  • the angle O of the tab is between 120 and 125 degrees.
  • the width of the tab 330 is optionally the same as the width of the tongue 320.
  • the tongue 320 extends approximately 1/3 to 2/3 of the thickness of the butt of a shake above an installed shake, generally corresponding to the height at which the slot 17 is located.
  • the roofing clip 300 further includes lateral wings 350 extending forward from the sides of the tongue 320 at the bottom thereof.
  • the lateral wings 350 are preferably shaped in a general triangular shape, with the bottom edge of each lateral wing 350 being substantially parallel to and aligned with the plane of the wing 310.
  • the clip 300 is installed using the same installation methods as described above, except where noted.
  • the orientation and alignment of the shake 10 with the clip 300 in the first direction is further facilitated by lateral wings 350 upon insertion of a clip 300 under the underlayment 30.
  • the clip 300 may be placed over the underlayment 30.
  • the upturned portions 340 collaborate with the back surface of the tongue 320 to act as a stop to orient and align the clip 300 with the underlayment 30 in the first direction.
  • the lateral wings 350 also provide means to orient the clip 300 and the shakes 10, 50.
  • the tab 330 of a previously installed clip 300 is inserted through a slot 17 in the butt of shake.
  • the shake is translated down as opposed to up in the prior embodiment in the direction of the pitch of the roof surface 20, until the exterior surface of the butt of the shake substantially contacts the back surface of the tongue 320 of clip 300 and the distal end of the tab 330 contacts the filler 18 in the shake.
  • the insertion of the tab 330 into the slot 17 in the butt of the shake is facilitated because of the upturned and backward orientation of tab 330.
  • the forward lateral wings 350 on clip 300 are advantageous for retaining the clip 300 in place and in shape when an upward vertical force is applied to the shake, for example due to gale force winds. Further, as the distal end of the tab 330 contacts and engages and makes contact with the underside of the top surface 11 of the shake, the clip 300 is maintained in position.
  • the shape of the wing 310 at the rear end of the clip 300 is optionally modified to facilitate the manufacture of clip 300.
  • the shape of wing 310 is generally rectangular, but includes a void at the rear end of the wing 310 (see FIG. 14).
  • the shape of the void corresponds to the combined shape of a flattened tongue 320, tab 330 and lateral wings 350.
  • FIG. 7A an exemplary roofing clip 400 according to another aspect of the present disclosure is illustrated.
  • the roofing clip 400 comprises a generally flat wing or base 410 and a tongue 420 extending up at a generally right angle from the wing 410 on a horizontal plane.
  • the tongue 420 can extend in a general vertical direction at angles substantially greater or less than 90° with respect to the plane of the wing 410.
  • the shape of the wing 410 is generally polygonal. As illustrated, one side of the polygon is defined by the location from where the tongue 420 extends from the wing 410, which defines the front edge 412 of the wing 410. Additional edges 414 of the polygon sweep back from each side of the front edge 412. As illustrated, two additional edges 416 of the polygon then extend from each of the swept back edges 414, generally perpendicular to the front edge 412. A polygon edge 418 joins edges 416 to complete the polygonal shape of wing 410. While one specific polygonal shape has been illustrated, it will be appreciated by those with skill in the art that other wing shapes can be used and fall within the scope of the present disclosure.
  • the wing 410 can take various concave or convex polygonal shapes.
  • wing shapes such as rectangular shaped wings, trapezoidal shaped wings, triangular shaped wings, and generally polygonal shaped wings are contemplated as acceptable wing shapes for the various embodiments as described herein.
  • the dimensions of the wing 410 on each of the left and right side of the tongue 420 are sufficient to allow for a fastener 60 inserted through a shake 10 to penetrate and affix the corresponding side of the wing 410, holding the clip 400 in place, similar to what is illustrated in FIG. 4A for clip 100.
  • the tongue 420 has a generally flat rectangular shape.
  • the width of the tongue 420 is adapted to correspond to the minimum width of the desired keyway between individual roofing shakes 10 to be installed.
  • the height of the tongue 420 is greater than the thickness of the shake 10 at the location of maximum exposure.
  • the sides of the tongue 420 are vertical and are used to align and space the shakes 10 during roof installation.
  • the bottom rear surface of the tongue 420 acts as a stop upon inserting the clip 400 under the underlayment 30 and abuts the edge of the underlayment 30.
  • the rear surface of the tongue 420 which also corresponds to edge 412, is oriented to be substantially parallel to the edge of the underlayment 30. By this placement, the roofing clip 400 is oriented with respect to the underlayment 30 and aligned in a second direction.
  • the roofing clip 400 also includes a vertical projection 430 extending up from the top of the tongue 420.
  • a tab 440 extends at an approximately right angle from the vertical projection 430.
  • the vertical projection 430 is generally rectangular in shape, and generally as wide as the wing 410. In embodiments, the vertical projection 430 is not as wide as the wing 410, but wider than the tongue 420.
  • the height of vertical projection 430 is less than the depth of the butt side 15 of a shake 10.
  • the tab 440 is optionally as wide as the vertical projection 430. In embodiments, the tab 440 is less wide than the vertical projection 430.
  • the shape of the tab 1440 is generally rectangular or polygonal.
  • the vertical projection 430 is adapted to be inserted into a shake cavity 16, between the butt side 16 and the filler 18.
  • the tab 440 is adapted to be inserted through the slot 17 in a shake 10, and to be bent at an angle during installation. In an alternate embodiment, the tab 440 is angled back and adapted to engage the filler 18 and the underside of the top surface 11 of the shake within cavity 17, as described in the embodiment illustrated in FIG. 6.
  • втори ⁇ ел ⁇ ество 450, 460 extend back from the vertical projection 430 on each side of the tongue 420.
  • the shape of each secondary wing 450, 460 is generally polygonal.
  • secondary wing 450 is depicted as a quadrilateral and as a mirror image of secondary wing 460.
  • each secondary wing 450, 460 can include a fastener indicator (not shown).
  • a fastener indicator (not shown) is one of a visual indicator and/or a physical feature such as a notch or dimple, to readily indicate to a user where to place a fastener.
  • each secondary wing 450, 460 can include a fastener hole (not shown).
  • a fastener hole is a perforation through the surface of the wing that allows a fastener (e.g. nail) to be inserted therethrough.
  • the dimensions of the fastener hole are smaller than the fastener to be used.
  • FIG. 7B illustrates other embodiments of the exemplary roofing clip of FIG.
  • roofing clips 470, 480 and 490 are shown. As illustrated, clips 470 and 480 show generally rectangular wing shapes, while clip 490 shows a generally polygonal wing shape. For example, clips 470 and 480 show solid T-shaped wings connected to the tongue. For example, clip 490 shows a solid T-shaped wing where the base of the “T” is connected to the tongue. Clips 470, 480 and 490 also show generally rectangular-shaped secondary wings. As illustrated, the secondary wings can extend back by different amounts, resulting in smaller or larger secondary wings.
  • the roofing clip 500 comprises a generally flat vertical tongue 520 extending up on a vertical plane.
  • the tongue 520 has a generally rectangular shape.
  • the width of the tongue 520 is adapted to correspond to the minimum width of the desired keyway between individual roofing shakes 10 to be installed.
  • the height of the tongue 520 is greater than the thickness of the shake 10 at the location of maximum exposure.
  • the sides of the tongue 520 are vertical and are used to align and space the shakes 10 during roof installation.
  • An engagement member 510 is shaped to extend down from the tongue 520 and then to extend back upon a generally horizontal plane.
  • the width of the engagement member 510 is generally the same as the width of the tongue 520.
  • Each of the vertical and horizontal portions of the engagement member 510 are generally rectangular in shape.
  • the roofing clip 500 also includes a tab or projection 530 extending vertically from the top of the tongue 520.
  • the width of the tab 530 is optionally the same as the width of the tongue 520, or the width can be different.
  • the shape of the tab 530 is optionally generally rectangular or polygonal. In embodiments, the tab 530 extends horizontally and is adapted to be bent at an angle, after being inserted through the slot 17 in the butt 15 of a shake 10.
  • the roofing clip 500 further includes lateral wings 540, 545 extending back from each one of the sides of the tongue 520.
  • the lateral wings 540, 545 are preferably have a generally rectangular shape, with the bottom edge and the top edge of each lateral wing 540, 545 being substantially horizontal.
  • a lower wing 550, 555 extends horizontally from each of the bottom edges of each lateral wing 540, 545, respectively.
  • the shape of the lower wing 550, 555 is generally polygonal.
  • An upper wing 560, 565 extends horizontally from each of the top edges of each lateral wing 540, 545, respectively.
  • the shape of the lower wing 550, 555 is generally polygonal.
  • the shape of lower wing 550 is the same as upper wing 560
  • the shape of lower wing 555 is the same as upper wing 565.
  • the shape of lower wing 550 is a mirror image of lower wing 555
  • the shape of upper wing 560 is a mirror image of upper wing 565.
  • each of the wings 560, 565 on each of the right and left side of the tongue 520 area adapted to be sufficient to allow for a fastener 60 inserted through a shake 10 to penetrate and affix the corresponding sides of the upper wings 560, 565 and of the lower wings 550, 555, holding the clip 500 in place, similar to what is illustrated in FIG. 4A for clip 100. While one specific polygonal shape has been illustrated in the Figures, it will be appreciated by those with skill in the art that other wing shapes can be used and fall within the scope of the present disclosure.
  • each upper wing 560, 565 can include a fastener indicator (not shown).
  • a fastener indicator (not shown) is one of a visual indicator and/or a physical feature such as a notch or dimple, to readily indicate to a user where to place a fastener.
  • each upper wing 560, 565 can include a fastener hole (not shown).
  • a fastener hole is a perforation through the surface of the wing that allows a fastener (e.g. nail) to be inserted therethrough.
  • the dimensions of the fastener hole are smaller than the fastener to be used.
  • the space defined between the horizontal portion of the engagement member 510 and the lower wings 550, 555 in a vertical direction is at least sufficient to receive therein a layer of underlayment 30.
  • the rear surface of the vertical portion of the engagement member 510 acts as a stop upon insertion of the engagement member of the clip 500 under the underlayment 30 and abuts the edge of the underlayment 30.
  • the rear surface of the vertical portion of the engagement member 510 is oriented to be substantially parallel to the edge of the underlayment 30.
  • the clip 500 is optionally inserted under the underlayment 30 by sliding the wing 510 underneath the underlayment 30.
  • the clip 500 is positioned such that the lateral wing 545 on the tongue 520 abuts the right side 13 of shake 10 in the current course, thereby aligning the clip 500 in the first direction, or along left to right or right to left.
  • the clip 500 is optionally inserted under the underlayment 30 until the back surface of the tongue 520 adjacent the wing 510 abuts the front edge 31 of the underlayment 30 substantially parallel to the edge of the underlayment 30, thereby orienting and aligning the clip 500 in the second direction, or generally in the direction of the pitch of the roof surface.
  • a fastener 60 is installed through upper wing 565 of clip 500, through the top surface 11 of shake 10 generally adjacent to the right side 13 thereof, through lower wing 555, through underlayment 30, and through the top surface of a shake in the preceding course (e.g., top surface 11 of shake 40 in FIG. 4A), thereby securing shake 10 in place.
  • the next shake to be installed 50 is then placed in position, aligning the left side 12 of shake 50 until it abuts the lateral wing 540 on tongue 520 of clip 500.
  • Shake 50 is translated up in the direction of the pitch of the roof surface 20, until the interior surface of the butt of shake 50 is aligned with the front surface of tab 530 of a previously installed clip 500 in previous course of shakes.
  • the tab 530 of the previously installed clip 500 is inserted into cavity 16 of shake 50, such that the rear inner surface of the butt side is aligned with the tongue 520.
  • shake 50 is affixed to tab 530 by using a fastener (not shown) such as, for example, a rivet or screw through the butt side 15 of the shake 50 and the tab 530.
  • tab 530 extends horizontally
  • tab 530 is inserted into the slot 17 in the butt 15 of the shake 50, and bent down to secure the shake 10.
  • a fastener 62 is installed through upper wing 560 of clip 500, through the top surface 11 of shake 50 generally adjacent to the left side 12 thereof, through lower wing 550, through underlayment 30, and through the top surface of a shake in the preceding course. Shake 50 is now partially fastened, and the process is repeated.
  • lateral wings 540, 545 upon insertion of a clip 500 under the underlayment 30. That is, the side surfaces of lateral wings 540, 545 engage the sides of adjacent shakes 10, 50 to facilitate alignment. Further, in situations where the shake exposure must be modified and the clip 500 is not inserted so far as to abut the edge of the underlayment 30, the lateral wings 540, 545 provide means to properly orient the clip 500 and the shakes 10, 50.
  • FIG. 9 an exemplary roofing clip 600 according to another aspect of the present disclosure is illustrated.
  • the clip 600 includes a generally flat rectangular wing or base 610 and a substantially vertical tongue 620.
  • the tongue 620 has a generally rectangular shape.
  • the width of the tongue 620 is adapted to correspond to the minimum width of the desired keyway between individual roofing shakes 10 to be installed.
  • the height of the tongue 620 is be greater than the thickness of the shake 10 at the location of maximum exposure.
  • the roofing clip 600 includes a tab or projection 630 extending forward at an angle from the top of the tongue 620.
  • the width of the tab 630 in one embodiment the same as the width of the tongue 620, or the width can be different.
  • the shape of the tab 630 in one embodiment generally rectangular or polygonal. The tab 630 extends forward and is adapted to be bent at an angle, after being inserted into cavity 16 and through the slot 17 in the butt 15 of a shake 10 during installation as in previous embodiments.
  • the tab 630 extends upwards and a shake 10 is affixed to the tab 630 by using a fastener (not shown) such as, for example, a rivet or screw through the butt side 15 of the shake 10 and the tab 630.
  • a fastener such as, for example, a rivet or screw through the butt side 15 of the shake 10 and the tab 630.
  • the roofing clip 600 includes a tab 630 extending backward from the top of the tongue 620 at an oblique angle with respect to the horizontal plane. Preferably, the angle of the tab is between 120 and 125 degrees.
  • the width of the tab 630 in one embodiment is the same as the width of the tongue 620.
  • the tongue 620 extends approximately 2/3 of the thickness of the butt of a shake above an installed shake.
  • the outer side edges of the wing 610 include flat upturned portions 640 which lie on a plane which is both generally perpendicular to the tongue 620 and generally perpendicular to the wing 610.
  • Each of the upturned portions is generally rectangular in shape.
  • the height of the upturned portions 640 is approximately the same dimension as the sides 12, 13 of a shake, minus approximately 1/8 inch at the point of exposure.
  • the roofing clip 600 further includes lateral wings 650 extending from the sides of the tongue 620 at the bottom thereof.
  • the lateral wings 650 are preferably shaped in a general triangular shape, with the bottom edge of each lateral wing 650 being substantially parallel to the plane of the wing 610.
  • the lateral wings extend backwards, as illustrated in FIG. 9.
  • the lateral wings extend forward from the sides of the tongue 620.
  • the upturned portions 640 are inserted into the cavity 16 behind the rails or sides 12, 13 of a shake 10, at the desired location.
  • the clip 600 is optionally moved forward and backward along the keyway according to the desired shake exposure. Additional fasteners are not required to hold the clip in place.
  • the tab 630 is accommodated as described above.
  • the lateral wings 650 on clip 600 are advantageous for retaining the clip 600 in place and in shape when an upward vertical force is applied to the shake, for example due to gale force winds.
  • the shakes are fabricated from sheet metal, the shakes are adaptable to be bent to accommodate the change in pitch, allowing for a course of shakes to be installed over the change in pitch of the roof surface. Further, as each shake is fastened on all four sides by means of a clip from the present disclosure at the butt and by fasteners on the remaining sides, each shake is securely affixed to the roof surface, resulting in a weather resistant solution.
  • the roofing clip 700 comprises a generally flat wing or base 710 and a tongue 720 extending up at a generally right angle from the wing 710.
  • the shape of the wing 710 is generally rectangular.
  • the width of the wing 710 of clip 700 in one embodiment is as narrow as the width of a single shake 10.
  • the width of the wing 710 of clip 700 is the same as the width of shake 10 between the left side 12 and right side 13, along the upper side 14.
  • the width of the wing 710 of clip 700 is optionally as wide as the roof surface on which the roofing system is being installed.
  • the depth of the wing 710 of clip 700 is greater than the desired overhang at the bottom of the finished roof. In embodiments, the depth of wing 710 is at least twice the desired overhang. In a preferred embodiment the width of wing 710 is between 8 to 10 feet wide.
  • the depth of the wing 710 is approximately 2 to 12 inches.
  • the tongue 720 can have a generally rectangular shape.
  • the width of the tongue 720 corresponds to the width of the wing 710.
  • the height of the tongue 720 is no greater than the thickness of the shake 10 at the butt, minus approximately 1/16 inch (5mm).
  • roofing clip 700 is used as a combination drip edge, starter edge, and underside cover by positioning clip 700 at the bottom edge of the roof, projecting out over the edge by the amount of the desired overhang. Shakes are then positioned onto clip 700, with the tongue 720 inserted into the cavity 16 of the shake 10 immediately behind the lower side 15. In this manner, shakes are aligned with the clip 700, and clip 700 provides an underside cover to the overhanging sections of the shakes at the bottom of the roof. The shakes 10 are then fastened to the roof surface through the top surface of the shake using suitable fasteners such as, but not limited to, ring shank stainless steel nails, where the fasteners also penetrate the wing 710 of clip 700.
  • suitable fasteners such as, but not limited to, ring shank stainless steel nails, where the fasteners also penetrate the wing 710 of clip 700.
  • FIG. 11 an exemplary roofing clip 800 according to one aspect of the present disclosure for use with the exemplary roofing clip of FIG. 10 is illustrated.
  • the roofing clip 800 comprises a generally flat wing 810 and a tongue 820 extending up at a generally right angle from the wing 810.
  • the shape of the wing or base 810 is generally rectangular.
  • the width of the wing 810 of clip 800 is wider than the width of the keyway at a location corresponding to the bottom of the installed shakes. In embodiments, the width of the wing 810 of clip 800 is approximately 2 to 3 times wider than the keyway at a location corresponding to the bottom of the installed shakes.
  • the depth of the wing 810 clip 800 is greater than the desired overhang at the bottom of the finished roof by approximately 1 inch.
  • the tongue 820 can have a generally rectangular shape.
  • the width of the tongue 820 corresponds to the width of the wing 810.
  • the height of the tongue 820 is greater than the thickness of the shake 10 at the butt, as defined by side 15.
  • the height of the tongue 820 is less than twice the thickness of the shake 10 at the butt.
  • clip 800 may also include a rectangular tab 830, adapted to be inserted into a slot 17 of a shake 10.
  • the bottom rear surface of the tongue 820 acts as a stop upon inserting clip 800 under a clip 700 and abuts the butts of the installed shakes on clip 700.
  • the rear surface of the tongue 820 is oriented to be substantially parallel to the edge of the clip 700. By this placement, the roofing clip 800 is oriented with respect to the clip 700 and aligned in the second direction.
  • the roofing clip 900 comprises a generally flat wing or base 910 and a tongue 920 extending up at a generally right angle from the wing 910.
  • the shape of the wing 910 in one embodiment is generally rectangular or trapezoidal, where the depth of the wing at a first side is different to the depth of the wing on the opposite side.
  • the minimum depth of the wing is greater than the desired overhang on the gable.
  • a typical overhang is between 0.5 inches and 1 .5 inches. In embodiments the minimum depth of wing 910 is approximately 2.5 inches.
  • the width of the wing 910 substantially corresponds to the length of a shake, from head to butt. In embodiments, the width of wing 910 is between 16 to 24 inches.
  • the dimensions of the wing 910 is adapted to be sufficient to allow for a fastener inserted through a shake that overhangs a gable to penetrate and affix the wing 910 through to the roof surface, holding the clip 900 in place.
  • the shape of wing 910 corresponds to the shape of surface 11 of shake 10.
  • the tongue 920 has a generally trapezoidal shape.
  • the width of the tongue 920 corresponds to the width of the wing 910.
  • the height of the tongue on a first side is different to the height of the tongue on the opposite side.
  • the height of the tongue 920 is greater on the side of the wing 910 where the depth is smaller, and the height of the tongue 920 is less on the side of the wing 910 where the depth is greater.
  • the tapered height of the tongue generally corresponds to the tapered side profile of a shake 10.
  • the height of the tongue 920 on one side generally corresponds to the height of the upper side 14 of shake 10
  • the height of the tongue 920 on the opposite side generally corresponds to the height of the lower side 15 of shake 10.
  • the roofing clip 900 also includes a tab or projection 930 extending backwards from the top of the tongue 920 substantially perpendicular to the tongue 920.
  • the width of the tab 930 is the same as the width of the tongue 920.
  • the shape of the tab 930 is generally rectangular. In embodiments, the depth of tab 930 is between 0.5 to 1 inch.
  • the rear surface of the tongue 920 acts as a stop upon inserting a clip 900 onto a left or right side of a shake and abuts the corresponding left or right side of the shake.
  • the surface of the tongue 920 is oriented to be substantially parallel to the left side 12 or right side 13 of the shake 10.
  • the roofing clip 900 can also be installed on the exposed edge of shakes that have been cut to size, and used as an end cap.
  • FIG. 13A illustrates a roof installation using the exemplary clips of FIGS. W and 11 and shake according to one aspect of the present disclosure.
  • the height of the shakes has been exaggerated in relation to the other dimensions, and the clip dimensions relative to the shake dimensions have been exaggerated, for illustrative purposes.
  • a clip 700 is placed on the roof surface, overhanging the eve of the roof by a desired amount, typically 1/2 to 1 1/2 inches.
  • a first course of shakes is installed onto clip 700 by sliding the tongue 720 behind side 15 of shake 10, thereby aligning shake 10.
  • clip 800 is inserted under clip 700 by sliding the wing 810 underneath the clip 700.
  • the clip 800 is inserted under clip 700 until the back surface of the tongue 820 abuts the butts of the installed shakes, substantially parallel to the lower sides 15 of the installed shakes, thereby orienting and aligning the clip 800 in the second direction.
  • a shake corresponding to the next course is then positioned over the keyway defined by the shakes in the first course, and the vertical tongue 820 is inserted behind the lower side 15 of the recently positioned shake.
  • a fastener such as e.g., a self-tapping screw, is inserted through the butt of shake and secured to the tongue 820 of clip 800.
  • the recently positioned shake is also affixed to the roof surface as previously described.
  • the next courses of shakes can then be installed as previously described.
  • FIG. 13B illustrates the exemplary clip from FIG. 12 and shake according to one aspect of the present disclosure.
  • the height of the shake has been exaggerated in relation to the other dimensions, and the clip dimensions relative to the shake dimensions have been exaggerated, for illustrative purposes.
  • a clip 900 is aligned with a left side 12 or right side 13 of a shake 10, depending on the configuration of the clip as described above.
  • the clip 900 and shake 10 are aligned with an approximate 30% offset, where the side of the shake 10 abuts the rear surface of the tongue 920 of the clip 900.
  • clip 900 is then slid onto the shake 10, so that the one side of the clip 900 is aligned with the head of the shake 10 and the opposite side of the clip 900 is aligned with the butt of the shake 10.
  • clip 900 provides an edge detail closure piece, where the underside of the portion of the shake 10 that overhangs the gable is covered by clip 900.
  • the shake is positioned and oriented according to the foregoing disclosure, and an additional fastener is inserted through the shake 10 and clip 900, thereby securing the shake in place. It is noted that using clip 900 will provide a square edge for all shakes on the gable edge, whether they are complete shakes or cut shakes on every second row or course.
  • the roofing system in one embodiment further comprises a snow stop and toe hold 1000, as illustrated in FIGS. 14A to 14D.
  • the snow stop and toe hold 1000 comprises a generally flat first base section 1010 and a generally flat second base section 1020.
  • a generally flat stop 1030 extends perpendicularly from between the first base section 1010 and the second base section 1020.
  • the height H5 of the stop 1030 is higher than the height H2 of a shake 10, and is adjusted based on the material of manufacture to retain an adequate strength.
  • An opening 1090 is located on the stop 1030 between the first base section 1010 and the second base section 1020, to allow water run off the roof surface.
  • a flat tongue 1040 extends generally perpendicularly from the second base section 1020 from a side opposite the side that the flat stop 1030 extends from.
  • the height H6 of the tongue 1040 is about the same as the height H2 of the butt 15 of a shake 10, and preferably slightly less.
  • a flat tab or nose 1050 extends in a generally perpendicular manner from the top of the tongue 1040.
  • the depth D3 of the tab 1050 is no larger than the distance D1 of a shake 10.
  • the snow stop 1000 can include one or more supports, such as gussets or goose necks 1060 between one of the first base section 1010 or the second base section 1020, and the stop 1030.
  • each of the first base section 1010, the second base section 1020, or the tab 1050 can include one or more fastener holes 1070.
  • a fastener hole is a perforation through the surface of the first base section 1010 or the second base section 1020 that allows a fastener (e.g., screw or rivet) to be installed therethrough.
  • the dimensions of the fastener hole are configured to match the size of the fastener, for example if a rivet is used, or configured to be smaller than the fastener, for example if a screw is to be used.
  • each of the first base section 1010, the second base section 1020, or the tab 1050 can include one or more fastener holes 1080.
  • the width W5 of the snow stop 1000 is between 3 inches and slightly less than the width W2 of the shake 10.
  • the depth of the first base section 1010 is about 1.5 inches and the depth of the second base section 1020 is about 2 inches.
  • the height H5 of the stop 1030 is about 2.5 inches.
  • the height H6 of the tongue is 0.3125 (5/16) of an inch.
  • the depth D3 of the tab or nose is 0.25 inches.
  • the depth D4 of the first base section is configured to receive a support piece 1300, such as a standard 2x4 piece of lumber lying on its short side as shown in FIG. 14C.
  • the snow stop and toe hold 1000 is optionally manufactured from 24-gauge sheet metal. In embodiments, the snow stop and toe hold 1000 is optionally manufactured from 16-gauge galvanized steel. In embodiments, the snow stop and toe hold 1000 is optionally manufactured from a single piece of metal. In embodiments, the snow stop and toe hold 1000 is optionally painted. In a preferred embodiment, the snow stop and toe hold 1000 is manufactured from extruded aluminum, and coated with a polyvinylidene fluoride (PVDF) paint finish.
  • PVDF polyvinylidene fluoride
  • the snow stop and toe 1000 hold further comprises a coating (not shown) on the underside of the first and second base sections 1010 and 1020.
  • a coating provides a seal between the snow stop 1000 and the shake 10 on which the snow stop 1000 is placed, in addition to acting as a seal at locations, such as at faster holes 1070, where fasteners are installed.
  • this coating is ethylene propylene diene terpolymer (EPDM) or rubber, or applied as silicone coating during installation.
  • the roofing system in one embodiment further comprises a grab clip or safety grab 1100, comprising a stop 1110 of width W6 and height H8 and a substantially flat hook 1120 with height H7, extending from a first side of and substantially parallel to stop 1110, connected by a first base section defining a gap therebetween with a depth D5.
  • the safety grab 1100 can further comprise one or more fastener indicators 1130.
  • a fastener indicator is one of a visual indicator and/or a physical feature such as a notch or dimple, to readily indicate to a user where to place a fastener.
  • H7 is 0.375 inches
  • H8 is 2 inches
  • D5 is 0.125 inches
  • W6 is between 3 inches and slightly less than the width W2 of the shake 10.
  • the snow stop and toe hold and grab clip of the present invention in embodiments is made from various materials, including but not limited to sheet metal, including galvanized steel, Galvalume ® steel, stainless steel, copper, zinc, aluminum or any others suitable metal.
  • the snow stop and toe hold and grab clip can also be made from polycarbonates, acrylonitrile butadiene styrene plastics (ABS), polyvinyl chloride (PVC), thermoplastic polyolefin (TPO), ethylene propylene diene terpolymer (EPDM), carbon fiber composites, or any other suitable thermopolymer or polymer material.
  • ABS acrylonitrile butadiene styrene plastics
  • PVC polyvinyl chloride
  • TPO thermoplastic polyolefin
  • EPDM ethylene propylene diene terpolymer
  • carbon fiber composites or any other suitable thermopolymer or polymer material.
  • the snow stop and toe hold and grab clip in embodiments is manufactured by die cut,
  • a starter course of shakes 10 is installed on a roof surface, and a second course of shakes is then installed on top of the starter course, in a laterally alternating fashion, each course having the heads and butts of the respective shakes aligned with one another (refer to Figs. 4A and 4B).
  • a third course of shakes is installed by driving or inserting fasteners 60, 62 through each shake in the third course. Due to the placement of the shakes, a portion of the shake adjacent to the butt of a shake 10 in the third course may not lie flat against the surfaces of the shakes in the second course, preventing the filler 18 of the shake in the third course from contacting the top surface of the shake in the second course.
  • a snow stop 1000 may be installed to deform the shake in the third course and bring the filler 18 of said shake into engagement with the top surface of the shake in the second course.
  • a snow stop 1000 is placed over said third shake at the desired location with tongue 1040 abutting the lower side 15 of said third shake, and fastener holes 1080 are used to drill fastener holes (not shown) in the butt of said third shake.
  • the snow stop 1000 may be inserted into the butt of the shake 10 in the third course, by rotating the snow stop 1000 so that the tongue 1040 of the snow stop 1000 lies substantially parallel to the surface 11 of the second course of shakes, and inserting the tongue 1040 into the cavity 16 at the butt of the shake 10.
  • the snow stop 1000 is then rotated back so that the first and second base sections 1010 and 1020 lie flat on the surface of the second course of shakes.
  • Fasteners are the installed at one or more locations, such as at faster holes 1070 or fastener holes 1080, fixing the snow stop 1000 to the second and third courses of shakes.
  • the length of the fasteners is selected such that only one shake is perforated. In an embodiment, 0.125-inch rivets are used as fasteners.
  • the stop 1030 of the snow stop 1000 is configured to be set between 6 inches to 2 feet from the edge of the roof, depending on the size of the shakes.
  • a snow stop 1000 is optionally installed on additional shakes on the third and subsequent courses. The distribution and placement of snow stops is determined based on the pitch of the roof and is generally known in the art.
  • a grab clip 1100 is installed in addition to a snow stop and toe hold 1000, at the same location, as illustrated in Fig. 14 D, which is a side view of a roofing system comprising a shake 10, a snow stop and toe hold 1000 and a grab clip 1100 securing a support piece 1300 fastened by fastener F.
  • Fig. 14 D is a side view of a roofing system comprising a shake 10, a snow stop and toe hold 1000 and a grab clip 1100 securing a support piece 1300 fastened by fastener F.
  • grab clip 1100 is aligned with the butt of a shake 10 in a course on the roof surface with an installed snow stop and toe hold 1000, such that the hook 1120 is aligned with the slit 19 between the bottom wall 15 or butt and one of the left side 12 or right side 13 of the shake 10.
  • the grab clip 1100 is then translated laterally, with the hook 1120 entering the cavity 16 behind the bottom side 15 of the shake 10 through slit 19.
  • a support piece 1300 optionally a section of 2 x 4 lumber or a metal support, is placed between the stop 1030 of the snow stop and toe hold, and the stop 1130 of the grab clip 1100, and fixed in place with one or more fasteners F.
  • the one or more fasteners F are optionally removed, allowing for the removal of support piece 1300 allowing for reuse of said support piece, and without damaging the roofing system or compromising the integrity of the same.
  • a snow stop and toe hold 1000 that does not include the optional tab or nose 1050 is installed to provide a snow stop and toe hold, and to improve the safety of the maintenance crew without compromising the integrity of the installed roof system.
  • a snow stop and toe hold 1000 is aligned with the butt of a shake 10 in a course on the roof surface, such that the tongue 1040 is aligned with the gap between the bottom wall 15 or butt and one of the left side 12 or right side 13, while the first and second base sections are flat against the surface of the shakes in the next course down.
  • the snow stop and toe hold 1000 is then translated laterally, with the tongue 1040 entering the cavity 16 behind the bottom side 15 of the shake.
  • the snow stop and toe hold 1000 is translated laterally back in the opposite direction, so that the tongue 1040 enters the cavity 16 behind the bottom side 15 of the adjacent shake 10 in the same course. In this manner, the tongue 1040 of the snow stop and toe hold 1000 engages the back of side 15 of one or more shakes, thereby providing a support for workers performing maintenance on the roof surface.
  • fasteners can optionally be installed to fasten the snow stop and toe hold 1000 in place, for use in the future.
  • the completion of the maintenance activities on the roof surface, the plurality of installed snow stop and toe holds 1000 are removed, without compromising the integrity of the roof system installation, nor weakening the components.
  • the support piece 1300 can comprise a metal support piece for fixedly mounting items onto the roofing system surface, such as solar panels. As described with reference to Fig. 14D, said supports are optionally fastened to snow stop and toe hold 1000 and/or grab clip 1100, to provide a mounting location for such items. Additional fasteners may be added to the roofing system to increase the strength of the system as required.
  • FIG. 15 illustrates an exemplary method of manufacture of an exemplary roofing clip according to one aspect of the present disclosure.
  • a clip of the present disclosure is cut, stamped or generally formed from a sheet metal piece as illustrated for the example clip 300 in Fig. 15.
  • the pattern of a clip is designed in such a way that features such as those corresponding to, for example, the tongue, tab, and lateral wings match features the define the shape of the wing.
  • the tongue, tab and lateral wings of a subsequent clip are formed my means of the same process.
  • the metal is bent or formed to generate the clips as described herein.

Abstract

A roofing clip, roofing shake and roofing system with related installation method. The roofing clip may include a wing, a tongue and a tab. The tongue extends generally perpendicular to the wing, and the tab extends generally perpendicular to the tongue. The roofing clip may also include frontal upturned edge portions on wing and lateral wings for alignment. The roofing shake may include a surface and four side walls defining a cavity. The cavity contains a filler, extending further than each of the side walls in a vertical direction. The filler is separated from each of the side walls by a gap. The roofing system and method includes orienting, aligning and affixing roofing shakes to a roof using the roofing clip. Advantages of the system include increased resistance to extreme weather and durability, ease of installation and reduced costs.

Description

ROOFING CLIP, ROOFING SHAKE AND ROOFING SYSTEM AND METHOD
FIELD
[001] Certain aspects of the present disclosure generally relate to a roofing clip for retaining roof shakes, roofing shakes and a related installation system and method.
BACKGROUND
[002] Metal shake roofing systems, including retaining clips and shakes can provide a resilient and long-term roof. It is desired to provide a retaining clip, roofing shake and installation system which offers improved durability, strength, resistance to extreme weather conditions and ease of installation over existing apparatus and systems.
SUMMARY
[003] Without limiting the scope of the appended claims, various features, aspects and advantages of the present invention are described herein.
[004] Details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages will become apparent from the description, the drawings, and the claims. Note that the relative dimensions of the following figures may not be drawn to scale.
[005] One aspect of the present disclosure provides a retaining clip and shake for roofing materials and a related installation system.
[006] One aspect of the present disclosure provides a roofing clip adapted for use in installing, on a roof surface, roofing shakes with a slot on one side, wherein the roofing clip comprises a substantially planar base, a tongue, extending generally perpendicularly from the base, and a tab extending from the tongue, from the end opposite the base, dimensioned to engage the slot of the roofing shake. In an embodiment, the base of the roofing clip further comprises a long axis and a short axis defining two wing sections, and wherein the tongue extends from an edge generally parallel to the long axis of the base. In a further embodiment, the roofing clip further comprises lateral wings extending generally perpendicular to both the base and the tongue, from the sides of the tongue. In a further embodiment, the lateral wings of the roofing clip are generally triangular with the base of the lateral wings being substantially parallel to the base of the clip, and define a gap therebetween. In yet another embodiment, the lateral wings are substantially rectangular. In another embodiment, the roofing clip further comprises a first set of secondary wings extending from the lateral wings, the first set of secondary wings being substantially parallel to the base of the clip. In an embodiment, the roofing clip further comprises a second set of secondary wings extending from the lateral wings, the second set of secondary wings being substantially parallel to the base of the clip. In yet another embodiment, the roofing clip further comprises at least one upturned portion generally perpendicular to the base and coplanar to the tongue, extending from the same edge of the base as the tongue.
[007] One aspect of the present disclosure provides a roofing clip adapted for use in installing, on a roof surface, roofing shakes with an interior cavity adjacent one side and a slot on said side, wherein the roofing clip comprises a substantially planar base, a tongue, extending generally perpendicularly from the base, and a vertical projection extending from the tongue, opposite the base, dimensioned to engage the cavity of the roofing shake. In an embodiment, the roofing clip further comprises one or more secondary wings extending from the vertical projection in a direction substantially parallel to the base of the clip. In another embodiment, the roofing clip further comprises a tab extending from the vertical projection dimensioned to engage the slot of the roofing shake.
[008] Another aspect of the present disclosure provides a roofing clip adapted for use as a snow stop and toe hold on a roof surface with roofing shakes with a top surface and four sides, with slits located at the comers of each side, wherein the roofing clip comprises a substantially planar first base portion, a tongue, extending generally perpendicularly from the base from one side, and dimensioned to engage one side of at least one roofing shake by inserting the tongue into a slit adjacent said side. In an embodiment the roofing clip further comprises a vertical stop extending from the first base portion from the side opposite the tongue. In an embodiment, the roofing clip further comprises a substantially planar second base portion coplanar with the first base portion, and extending from the side opposite the tongue.
[009] One aspect of the present disclosure provides a roofing shake that comprises a top surface, four sides extending from and generally perpendicular to the top surface, defining a cavity, and a filler within the cavity extending from the top surface, wherein the filler is configured to extend further from the top surface than each of the four sides. In an embodiment, each corner of the roofing shake between adjacent sides further comprise a slit therebetween. In an embodiment, the dimensions of the filler are configured to define a gap between one or more of the four sides and the corresponding edges of the filler. In an additional embodiment, one side of the roofing shake further comprises a slot dimensioned to receive a tab from a roofing clip.
[0010] Yet another aspect of the present invention provides a kit for installation of a roofing system, wherein the kit comprises a plurality of clips comprising a base and a tongue extending in a substantially perpendicular manner from one edge of the base, and a plurality of metal shakes with a top surface and four walls defining a cavity, including a filler extending out from the cavity farther than each of the four walls. In an embodiment the kit further comprises a plurality of starter course clips comprising a base and a tongue substantially perpendicular to the base, and wherein the tongue is the same width as the base. In an embodiment, the kit further comprises a plurality of edge detail clips comprising a base, a tongue extending substantially perpendicular to the base, and a tab extending substantially perpendicular to the tongue, wherein the height of the tongue at one edge is greater than the height of the tongue at the opposite edge, and wherein the width of the base is greater on the side where the height of the tongue is shorter. In a further embodiment, the one or more of the plurality of clips of the kit further comprise lateral wings extending from the sides of the tongue generally perpendicular to both the base and the tongue, wherein the lateral wings are generally triangular with the base of the lateral wings being substantially parallel to the base of the clip, and defining a gap therebetween. In another embodiment, the one or more of the plurality of clips of the kit further comprise lateral wings extending from the sides of the tongue generally perpendicular to both the base and the tongue, wherein the lateral wings are substantially rectangular, wherein a first set of secondary wings extend from the lateral wings, the first set of secondary wings being substantially parallel to the base of the clip. In yet a further embodiment, the kit further comprises a plurality of snow stop and toe hold clips comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, a tongue extending generally perpendicularly from the second base section, and a tab extending generally perpendicularly from the tongue. In another embodiment, the kit further comprises a plurality of grab clips comprising a base section, a vertical stop extending generally perpendicularly from one end of the base section, and a substantially flat hook extending generally perpendicular from the opposite end of the base section.
[0011] Another aspect of the present invention provides a method of installing courses of shakes of a roofing system on a roof surface, wherein the method comprises the step of aligning, in a desired course installation orientation, a roofing clip comprising a base and a tongue, wherein the tongue extends in a generally perpendicular manner from the base, and wherein the base is placed generally coplanar to the roof surface, the step of aligning a roofing shake adjacent to said roofing clip in a desired course installation orientation, by at least aligning a side of said roofing shake with said tongue of said roofing clip, the step of fastening said roofing clip and roofing shake with at least one fastener, said at least one fastener penetrating through at least both said roofing shake and a portion of the base of said roofing clip, wherein the fastener further penetrates at most one preceding course of previously installed roofing shakes. In an embodiment, the step of aligning the roofing shake further comprises aligning a butt of the shake with a tongue of a clip in a previously installed course of shakes. In an embodiment, the method of installing a roofing system further comprises the step of fastening a butt of the aligned shake to the tongue of the clip in the previously installed course. In an embodiment, the step of aligning the roofing shake further comprises aligning a butt of the shake with a tongue of a starter clip aligned with the bottom edge of the roof surface and a previously installed starter course of shakes. In an embodiment, the step of aligning a roofing clip further comprises aligning at least one of the back surface of the tongue and an upturned portion extending from the base of the clip from the same edge as the tongue, with an underlayment layer installed on the roof surface. In an embodiment, the step of aligning a roofing shake further comprises selecting a shake including an edge detail clip at least partially covering the bottom of the shake, and installing said shake on an overhanging edge of the roof surface. In an embodiment, the method further comprises the step of installing a snow stop and toe hold, comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, a tongue extending generally perpendicularly from the second base section, and a tab extending generally perpendicularly from the tongue, wherein the step of installing a snow stop and toe hold comprises the step of generally aligning the tongue of the snow stop and toe hold with the surface of a previously installed course of shakes, the step of inserting the tongue and tab into a butt of the aligned shake, the step of rotating the snow stop and toe hold to align the first and second base sections with the surface of the previously installed course of shakes, and the step of fastening the snow stop and toe hold with fasteners to at least one of the previously installed courses of shakes and the aligned shake. In another embodiment, the method further comprises the step of installing a snow stop and toe hold, comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, and a tongue extending generally perpendicularly from the second base section, and wherein the installed shake further comprises a slit at each corner, wherein the step of installing a snow stop and toe hold comprises the steps of aligning the first and second base sections of the snow stop and toe hold with the surface of a previously installed course of shakes and aligning the tongue of the snow stop and toe hold with a slit of the aligned shake, and the step of translating the snow stop and toe hold to insert the tongue into a slit on a bottom corner of the aligned shake.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 A and FIG. 1 B are perspective views of the top and bottom or underside, respectively, of a roofing shake according to one aspect of the present disclosure.
[0013] FIG. 2 illustrates an exemplary roofing clip according to one aspect of the present disclosure.
[0014] FIG. 3 is a perspective view of a shake attached to a roof through an underlay and an exemplary roofing clip according to one aspect of the present disclosure.
[0015] FIG. 4A illustrates a roof installation using an exemplary clip and shake according to one aspect of the present disclosure.
[0016] FIG. 4B illustrates a cross section of a roof installation using an exemplary shake taken along line 4-4 in FIG. 4A and according to one aspect of the present disclosure.
[0017] FIG. 5 illustrates another exemplary roofing clip according to one aspect of the present disclosure.
[0018] FIG. 6 illustrates yet another exemplary roofing clip according to one aspect of the present disclosure.
[0019] FIG. 7A illustrates another exemplary roofing clip according to another aspect of the present disclosure.
[0020] FIG. 7B illustrates other embodiments of the exemplary roofing clip of FIG. 7A.
[0021] FIG. 8 illustrates another exemplary roofing clip according to another aspect of the present disclosure.
[0022] FIG. 9 illustrates another exemplary roofing clip according to another aspect of the present disclosure. [0023] FIG. 10 illustrates an exemplary roofing clip according to one aspect of the present disclosure for use as a combination drip edge, starter edge, and underside cover.
[0024] FIG. 11 illustrates an exemplary roofing clip according to one aspect of the present disclosure for use with the exemplary roofing clip of FIG. 10.
[0025] FIG. 12 illustrates an exemplary roofing clip according to one aspect of the present disclosure for use as an edge detail closure piece.
[0026] FIG. 13A illustrates a roof installation using an exemplary clip and shake according to one aspect of the present disclosure.
[0027] FIG. 13B illustrates an exemplary clip and shake according to one aspect of the present disclosure.
[0028] FIG. 14A illustrates an exemplary snow stop and toe hold according to one aspect of the present disclosure.
[0029] FIG. 14B illustrates an exemplary grab clip according to one aspect of the present disclosure.
[0030] FIG. 14C illustrates a cross section detail of a roof installation using exemplary snow stop and toe hold, grab clip and roofing shake of the present disclosure.
[0031] FIG. 14D illustrates a cross section detail of a roof installation using exemplary toe hold, grab clip and roofing shake of the present disclosure.
[0032] FIG. 15 illustrates an exemplary method of manufacture of an exemplary roofing clip according to one aspect of the present disclosure.
DETAILED DESCRIPTION
[0033] Various aspects of the novel systems, apparatuses, and methods are described more fully hereinafter with reference to the accompanying drawings. The teachings disclosure can, however, be embodied in many different forms and should not be construed as limited to any specific structure or function presented throughout this disclosure. Rather, these aspects are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Based on the teachings herein one skilled in the art should appreciate that the scope of the disclosure is intended to cover any aspect of the novel systems, apparatuses, and methods disclosed herein, whether implemented independently of or combined with any other aspect of the invention. For example, an apparatus can be implemented, or a method can be practiced using any number of the aspects set forth herein. In addition, the scope of the invention is intended to cover such an apparatus or method which is practiced using other structure, functionality, or structure and functionality in addition to or other than the various aspects of the invention set forth herein. Any aspect disclosed herein can be embodied by one or more elements of a claim.
[0034] Although aspects are described herein, many variations and permutations of these aspects fall within the scope of the disclosure. Although some benefits and advantages of the preferred aspects are mentioned, the scope of the disclosure is not intended to be limited to benefits, uses, or objectives. The detailed description and drawings are merely illustrative of the disclosure rather than limiting.
[0035] In the disclosed roofing system, a roof surface or roof deck generally comprised of plywood or some other suitable substrate is covered with short non-interlocking shakes that are affixed to the roof surface through an underlayment layer to create a weather-proof and fire-resistant roof. Shakes are generally made from various materials including but not limited to wood such as cedar including red cedar, white cedar, treated wood, treated pine, and rot resistant wood, metal, recycled rubber, recycled plastics, resin-based synthetics, and mixed composites. In an embodiment, the shake of the current disclosure is formed from a metal sheet and defines a cavity containing a filler as described below. The filler is generally made from various materials with the desired stability and thermal insulation characteristics, including but not limited to expanded polystyrene foam (EPS) filler, polyisocyanurate (ISO), any other ridged insulation products, or wood.
[0036] The underlayment is generally laid perpendicular to the direction of the pitch of the roof. The underlayment is used to define the courses or rows of shakes to be installed and is interwoven with each course as the shakes are installed. A course is a row of shakes, shingles or roll roofing running the partial or entire length of a roof surface. The underlayment placing can assist in determining the amount of overlap between the courses, and therefore the exposure and the head lap for the installed shakes as described in more detail below.
[0037] During installation, a roofing clip is preferably inserted under and aligned with the underlayment in the current course. In embodiments, the clip is optionally placed on top of the underlayment, or partially inserted under the underlayment. A shake is positioned and laterally aligned in a first direction with the roofing clip of the current course, and the butt of the shake is aligned in a second direction with a roofing clip from a previously installed course. A fastener or means for affixing the shake to the roof such as a nail, screw, rivet or the like is inserted through both the shake and the roofing clip of the current course, as well as through the underlayment, the shakes from previously installed courses and affixed directly to the roof surface. Except for the first course, the shake may also be secured at the butt to the roofing clip from the previously installed course, or is secured using a starter clip as described in detail below.
[0038] The disclosed roofing system has a number of advantageous features. For example, the roofing clip is preferably placed in the space between two adjacent shakes, or keyway, thereby blocking the keyway with the vertical tab that comprises the clip as described below. Therefore, the keyway is blocked and prevents driving snow and rain from entering the keyway during extreme weather conditions. In this manner, improved weather resistance is achieved as the roofing clip provides a physical barrier in the keyway between shakes. Further, the roofing shakes are preferably attached at the bottom end to the roofing clips from previous courses, such that the roofing system has greatly increased resistance to extreme weather conditions, such and gale force winds, by providing another anchor point for each shake. In addition, as a result of the improved weather resistance, increased durability is achieved.
[0039] The roofing system provides further advantages by allowing the head lap to be reduced because the keyway is blocked and prevents the entrance of moisture. Reducing the head lap increases the shake exposure. Conventional roofing systems require a greater head lap in order to reduce the amount of moisture that can enter the keyway and travel up the shakes. With increased shake exposure, less material is required to cover the roof surface which reduces costs and allows for a faster installation.
[0040] The roofing system provides further advantages by allowing for a faster installation by providing means to align the shakes along two directions. Shake installation is optionally performed either from left to right or right to left. In addition, the roofing clip from the disclosed system will hold and place the shakes when changing pitch positions on the roof. The pitch or slope of the roof is a measure of roof inclination. Roof pitch can be described as a compound value, A/B, indicating the vertical rise or drop A for every measure of B; a 4/12 pitch indicates a vertical rise or drop of 4 inches for every 12 inches, or approximately 18.5 degrees. For example, the clip will hold and place shakes when installing with a 4/12 pitch (approximately 18.5 degrees) and transitioning to an 8/12 pitch (approximately 33.75 degrees), or vice versa, or in a mansard roof going from a 24/12 pitch (approximately 63.43 degrees) to a 4/12 pitch (approximately 18.5 degrees).
[0041] In addition, the roofing shake of the present disclosure provides further advantages by eliminating metal to metal contact between installed shakes because the EPS filler extends farther than all of the sides beyond the shake cavity in the vertical direction and is separated from the vertical sides of the shake. As a result, the opportunity for water to travel through capillary action between the upper and lower shakes is reduced. Further advantages of the shake from the disclosed roofing system include increased air movement inside and underneath installed shakes, between the filler and the shake sides. Increased air movement will prevent moisture from being retained underneath a shake of the roofing system, facilitating diffusion of humidity and droplets after a storm. This overcomes the disadvantages of known interlocking systems, which accumulate condensation inside the roofing shakes. Further, as metal to metal contact between shakes is eliminated, thermal transfer through contact between the shakes is eliminated. In this manner, thermal transfer from internal attic spaces onto the roofing is reduced, which in turn reduces the occurrence of ice damming. In consequence, the weather resistance and durability of the roofing system is increased.
[0042] Further advantages of the disclosed roofing system include improved fire resistance, given the multi-layer structure created by the installed metal shakes. Contrary to current industry standard installations, where roofing comprises only one metal layer, the current disclosure teaches multiple layers of shakes. A single metal layer is disadvantageous because the top metal layer is in direct contact with the roof surface, which increases heat transfer. These disadvantages are overcome with the disclosed system. Further, thermal transfer is reduced because of the air gaps which allow hot air to escape, and the filler within the shakes increases thermal insulation between the exposed surface of the shakes and the roof surface on which the roofing system is installed. Fire resistance is achieved in the installed roofing system due to the spaces from the shake cavities between the roof deck and the metal shakes, as at least two cavities prevent heat from burning debris from affecting the roof deck structure. Further, packaging materials are reduced as filler prevents scratches on the finished metal surfaces during packaging and transport.
[0043] Further advantages of the roofing system are that it is non-interlocking, facilitating the removal and repair of individual pieces, such as shakes or clips, if required. This is advantageous as a single shake can be removed and a new shake can be retrofitted on the roofing system, without the need to reinstall multiple shakes and multiple courses of shakes. Further advantages include ease of adding roof features such as skylights and or other roof penetrations without the difficulty of working interlocking roofing panels. Further advantages of a non-interlocking roof are that humidity is able to escape the system, and the individual components can adjust under pressure changes or extreme weather conditions.
[0044] The disclosed roofing system provides further advantages by a snow stop and toe hold for use with the roofing system as described herein. When installing courses of a roofing system, the shakes in subsequent courses may not lie completely flat. The snow stop as described is advantageous as it is optionally used to deform and conform a shake from a subsequent or upper course so that it lies flat on the upper surface of one or more shakes from a previous or lower course, when fastened to the snow stop, as described herein. Once installed, the snow stop secures the upper course shake to one of the lower courses, and thereby provides increased weather resistance. Further advantages include that the need for different sized starter course shakes, which are typically shorter than the shakes used for the rest of the roof, is eliminated. As a result, regular shakes that have been slightly damaged or are esthetically unsuitable for use on a roof surface but otherwise functional are optionally used on a starter course, leading to increased efficiency and less waste. Further advantages of the snow stop as described herein include that when installed, fasteners only perforate one layer of shakes leaving at least one layer intact beneath the snow stop, and thereby avoiding leaks and degradation of the system components, as is encountered with conventional roofing systems where fasteners perforate through to the roof surface. Another advantage of the snow stop of the present invention is that an installed snow stop can provide up to six fastening points, which can provide additional strength and holding power for the roofing system. Advantages of the roofing system as described herein include the possibility of installing toe holds by laterally sliding them into the bottom or butt of an installed shake located anywhere on a roof surface without the need to dismantle the roofing system and allowing for the removal of a toe hold after use, without damaging or weakening the roofing system components, without compromising the integrity of the roofing system and without requiring repairs, and thereby providing a safer work environment in a maintenance situation.
[0045] Turning now to FIG. 1 , a roofing shake is described according to one aspect of the present disclosure. Both a top (FIG. 1 A) and underside (FIG. 1 B) perspective views of a roofing shake are shown, where like references numbers refer to like features. The metal shake 10 comprises a flat top surface 11 and four vertical sides 12, 13, 14, 15 defining a cavity 16 between them. When viewing a shake 10 from above, we define a left side 12, a right side 13, an upper side 14 and a lower or butt side 15. The upper side 14 is also referred to as the head, and the lower side 15 is also referred to as the butt. The shake 10 is generally trapezoidal in shape, with the upper side 14 wider than the lower side 15. In embodiments, the length of the shake between the upper side 14 and the lower side 15 is between 16 inches and 24 inches long. The width of the shake W1 is the distance between left side 12 and right side 13, along the upper side 14 of the shake. The height of the shake in FIG. 1 A and FIG. 1 B has been exaggerated in relation to the other dimensions, for illustrative purposes. The height H1 of the upper side 14 along a vertical direction is less than the height H2 of the lower side 15, resulting in the shake 10 being thinner at the head and thicker at the butt. The lower side 15, optionally includes a slot 17 through which a portion of the roofing clip is optionally inserted. The slot 17 is configured to accommodate, for example, the tab or projection 130 of the roofing clip 100 (see below) therethrough. The widths W1 and W2 of the shake are optimally between 4 to 16 inches. The length of the shakes are optimally between 16 to 26 inches. The height H1 is optimally between 0.03125 (1/32) inches to 0.5 (1/2) inches, while the height H2 is optimally between 0.1875 (3/16) and 1 inch.
[0046] The cavity 16 is filled with a filler 18, for example but not limited to a rectangular EPS filler, separated from each of the vertical sides and extending out of the cavity 16 beyond all sides in the vertical direction, defined by H3, H4. In conventional shakes, the filler fills the cavity 16 up to the height of the vertical sides. The filler 18 is further configured to allow for a gap between the sides of the filler and each of the corresponding sides 12, 13, 14 and 15. In a preferred embodiment, the filler 18 is generally rectangular in shape. In a preferred embodiment, the filler 18 is generally wedge-shaped, extending approximately 1/16 of an inch (approximately 1 mm) past the sides 12, 13, 14 and 15 in a vertical direction. In other words, H3 is approximately 1 mm greater than H1 , and H4 is approximately 1 mm greater than H2. In a preferred embodiment, the gap D1 between the lower side 15 and the corresponding side of the filler 18 is larger than the gap D2 between the upper side 14 and the corresponding side of the filler 18. In a preferred embodiment, the gap between the sides of the filler 18 and each of the corresponding sides 12, 13, 14 and 15 is at least approximately 0.5 inches (approximately 12.7 mm). In embodiments, the exposed surface of the filler is grooved or textured.
[0047] Shake 10 are optionally manufactured from various materials, including but not limited to metal, such as but not limited to copper, zinc, aluminum, stainless steel, and brass. Metal shakes are preferably fabricated from 26 to 16-gauge sheet metal, galvanized metal, pre-painted silicone-modified polyester (SMP) metal and polyvinylidene fluoride (PVDF) coated metal. Shakes are alternately known as shingles, tiles, slates, plates or planks. When installed, the tapered shape of the shakes creates a flared keyway between adjacent shakes that avoids the accumulation of debris within the keyway. In a preferred embodiment, shakes are manufactured from a single piece of sheet metal, and the sides 12, 13, 14 and 15 are bent into the desired shape, leaving gaps or slits 19 between the sides 12, 13, 14 and 15.
[0048] In FIG. 2 an exemplary roofing clip 100 according to one aspect of the present disclosure is illustrated. Embodiments of the roofing clip as described herein are preferably fabricated from 26 to 16-gauge metal sheet, including but not limited to sheet metal, including galvanized steel, Galvalume ® steel, stainless steel, copper, zinc, aluminum or any others suitable metal. The roofing clip as described herein can also be fabricated from any other material that provides appropriate properties for flexibility, strength, and weight, such as polycarbonates, acrylonitrile butadiene styrene plastics (ABS), polyvinyl chloride (PVC), thermoplastic polyolefin (TPO), ethylene propylene diene terpolymer (EPDM), carbon fiber composites, or any other suitable thermopolymer or polymer material.
[0049] The roofing clip 100 comprises a generally flat wing or base 110 and a tongue 120 extending up at a generally right angle from the wing 110. As used herein, a horizontal plane generally corresponds to the plane of the roof surface 20, and a vertical plane generally corresponds to a perpendicular plane thereto. In embodiments, the tongue 120 optionally extends in a general vertical direction at substantially 90 degrees with respect to the plane of the wing 110, with a deviation of 01 in the range of 0 to 45 degrees. In FIG. 2, the value of 0i is approximately 10 degrees.
[0050] The shape of the wing 110 is optionally generally elliptical or rectangular, with a first or major axis A1 that generally corresponds to a first direction and a second or minor axis A2 that generally corresponds to a second direction, defining a left side 112 and a right side 113. The dimensions of each of the left side 112 and right side 113 of wing 110 is sized to permit fasteners 60, 62 to be installed through the top surfaces 11 of shakes 10, 50 to penetrate and affix the shakes and the corresponding left and right sides 112, 113 of the wing 110, holding the clip 100 in place (see FIG. 4A).
[0051] The tongue 120 optimally has a generally rectangular shape. The width of the tongue 120 is shaped to have the minimum width of the desired resulting keyway or separation between adjacent roofing tiles or shakes 10 from the same course to be installed. The height of the tongue 120 is greater than the thickness of the shake 10 at the location of maximum exposure (see FIG. 4B), the location of maximum exposure is typically about 1 inch. The height of the tongue 120 is sized to be no greater than the thickness of the shake 10 at the location of exposure plus the thickness H2 of the butt of the shake 10, for instance 2 inches or more. The sides of the tongue 120 are substantially vertical and are used to align and space the shakes 10 during roof installation, as described in detail below with reference to FIGS. 3 and 4A.
[0052] As described in more detail with respect to FIGS. 3 and 4A below, the bottom rear surface of the tongue 120 acts as a stop with the clip 100 inserted under the underlayment 30 and abuts the edge of the underlayment 30. The rear surface of the tongue 120 is oriented to be substantially parallel to the edge of the underlayment 30. By this placement, the roofing clip 100 is oriented with respect to the underlayment 30 and aligned in a second direction. [0053] The roofing clip 100 also includes a tab or projection 130 extending forward from the top of the tongue 120 adapted to be bent at an angle. The width of the tab 130 is optionally the same as the width of the tongue 120, or the width can be different. The shape of the tab 130 is optionally generally rectangular or polygonal (FIG. 5). The tab 130 is made of a material that is sufficiently strong so as to retain its shape, but is adaptable to be bent by a user under their own force, such as sheet metal, including galvanized steel, Galvalume ® steel, stainless steel, copper, zinc, aluminum or any others suitable metal.
[0054] For example, referring first to FIG. 3, the roofing system and method according to one aspect of the invention will be described in more detail. The height of the shake has been exaggerated in relation to the other dimensions, and the clip dimensions relative to the shake dimensions have been exaggerated, for illustrative purposes. A roofing system includes a roofing shake 10 installed on a roof surface 20 through an underlayment 30. The roofing shake 10 includes a left side area and a right-side area on the top surface 11 (see FIG. 1 ). The underlayment 30 is placed on the roof surface 20 in rows running generally perpendicular to the direction of the pitch of the roof. These rows of underlayment 30 may define the courses or rows of roofing tiles 10 to be installed. The roofing shake 10 of FIG. 2 has been previously aligned with the underlayment 30 and a shake on the opposite side (not shown), and partially affixed to the roof surface 20 over the underlayment layer 30 with a fastener (not shown) inserted through the right-side area of the shake 10 and the wing of clip 100. A roofing clip 100 of the present disclosure is shown in relation to the shake 10 and underlayment 30. The roofing clip 100 abuts with the right side of the shake 10 so that the clip 100 is aligned in a first direction, generally running left to right or right to left. The roofing clip 100 is inserted under the underlayment 30 so that the clip 100 is aligned in a second direction, generally running front to back corresponding to the pitch of the roof surface. As used herein, left to right or right to left generally corresponds to a direction perpendicular to the direction of the pitch of the roof. As used herein, front to back or back to front generally corresponds to the direction of the pitch of the roof. A fastener 60 such as rivet, screw, nail or other suitable means for affixing the shake is inserted through the top surface 11 of shake 10, a portion of the clip 100, through the underlayment 30 and affixed to the roof deck 10, as described in more detail below.
[0055] FIG. 4A illustrates a roof installation, where previously installed shakes 40 and previously installed clips 102 are shown. The height of the shake has been exaggerated in relation to the other dimensions, and the clip dimensions relative to the shake dimensions have been exaggerated, for illustrative purposes. A partially fastened shake 10 is also shown. During installation, the clip 100 is inserted under the underlayment 30 by sliding the wing 110 underneath the underlayment 30. The clip 100 is positioned such that the left side 122 of the tongue 120 abuts the right side 13 of the shake 10, thereby aligning the clip 100 in the first direction, or along left to right or right to left. The clip 100 is inserted under the underlayment 30 until the back surface of the tongue 120 abuts the front edge 31 of the underlayment 30 substantially parallel to the edge of the underlayment 30, thereby orienting and aligning the clip 100 in the second direction, or generally in the direction of the pitch of the roof surface. A fastener 60 is installed through the top surface 11 of the shake 10 generally adjacent to the right side 13 thereof, underlayment 30, and the left side 112 of wing 110 of clip 100, thereby securing shake 10 in place.
[0056] After the clip 100 has been fastened as described above, the next shake to be installed 50 is then placed in position, aligning the left side 12 of shake 50 until it abuts the right side 123 of the tongue 120 of clip 100. The tab 130 of the previously installed clip 102 is inserted through cavity 16 by lowering the shake 50 and then sliding the tab 130 through slot 17 in the butt of shake 50. Shake 50 is translated up in the direction of the pitch of the roof surface 20, until the interior surface of the butt of shake 50 substantially contacts the front surface of the tongue 120 of clip 102. The tab 130 of clip 102 is then bent downward, securing the butt of shake 50 in place. In embodiments, the butt of the shake 50 is optionally secured by a fastener such as a rivet, screw or other suitable means (not shown) to the tongue 120 of clip 102. A fastener 62 is inserted through the top surface 11 of shake 50 generally adjacent to the left side 12, the underlayment 30, and the right side 113 of wing 110 of clip 100. The shake 50 is now partially fastened, and the process is repeated.
[0057] FIG. 4B illustrates a cross sectional side view of a roof installation using exemplary shakes in their installed positions taken along line 4-4 in FIG. 4A and according to one aspect of the present disclosure. The height of the shake has been exaggerated in relation to the other dimensions, for illustrative purposes. During installation, shakes 10 are installed on roof surface 20. As courses are consecutively installed, shakes are placed and affixed on top of previously installed courses in an overlapping manner, starting with an initial or starter course at the lowest part of the roof or surface to be covered. A single course is installed by placing, aligning along a bottom edge and affixing shakes one beside another, and covering the desired roof or surface or portion of roof or surface to be covered. Optionally, a second course where the bottom edges of the shakes or shingles of the second course is installed by aligning with the bottom edges of the shakes or shingles of the initial or starter course, where the shakes of the second course are laterally displaced from the shakes of the initial or starter course. Subsequent courses are installed by installing shakes displaced from the previously installed course in a direction generally corresponding to the pitch of the roof or surface and generally perpendicular to the previously installed course such that the previous course has an exposed region, and laterally displaced from the shakes of the previous course. The exposed region of each shake, or shake exposure E as illustrated in FIG. 4B, is the region of the shake that remains visible and exposed to the environment. The head lap HL is the region where up to three layers of shakes cover the roof or surface.
[0058] As a subsequent course of shakes is installed over the previous course, given that the height of the filler H3, H4 (see FIG. 1 B) is greater than the corresponding height of the sides of the shake H1 , H2 (see FIG. 1A), the filler 18 from a top shake contacts the top metal surface 11 of a bottom shake, thereby avoiding metal to metal contact. In installation, the shakes also tend to deform or bend in a slightly convex manner, as a result of the fasteners used to affix the shakes to the roof surface. As a result, the shake top surface may become convex and the bottom surface of the filler may conform and adapt to the surface on which it is placed upon. However, these features are not represented in detail in FIG. 4B.
[0059] FIG. 5 illustrates another exemplary roofing clip 200 according to one aspect of the present disclosure. The clip 200 includes a generally rectangular wing or base 210, a tongue 220, and a tab 230. The tab 230 of the roofing clip 200 is angled upwards, forming an acute angle A with respect to the horizontal plane. The shape of the tab 230 is generally polygonal, with the distal end to the tongue 220 being narrower than the proximal end, to facilitate insertion into slot 17. The front edge of the wing 210 includes upturned portions 240 which are aligned with the back surface of the tongue 220.
[0060] The roofing clip 200 further includes lateral wings 250 extending back from the sides of the tongue 220 at the bottom thereof. The lateral wings 250 are preferably shaped in a general triangular shape, with the bottom edge of each lateral wing 250 being substantially parallel to the plane of the wing 210. The distance between the surface of the wing 210 and the bottom edges of the lateral wings 250 are sufficient to readily accommodate the thickness of the underlayment 30. The distal ends of the lateral wings 250 are optionally rounded, to avoid snagging with the underlayment 30 upon inserting the clip 200.
[0061] During installation, the clip 200 is installed using the same installation methods as described above, except where noted. Alignment of the shake 10 with the clip 200 in the first direction is further facilitated by lateral wings 250 upon insertion of clip 200 under the underlayment 30. That is, the side surfaces of wings 250 engage the sides of adjacent shakes 10, 50. Further, upon inserting the clip 200 under the underlayment 30, the upturned portions 240 collaborate with the back of the tongue 220 to act as a stop to orient and align the clip 200 with the underlayment 30 in the first direction. In situations where the shake exposure must be modified and the clip 200 is not inserted so far as to abut the edge of the underlayment 30, the lateral wings 250 provide means to orient the clip 200 and the shakes 10, 50. Upon installation of the next course of shakes, the insertion of the tab 230 into the slot 17 in the butt of the shake is facilitated because of the upturned orientation of tab 230.
[0062] FIG. 6 illustrates yet another exemplary roofing clip 300 according to one aspect of the present disclosure. The clip 300 includes a generally rectangular wing or base 310 and a substantially vertical tongue 320. The front edge of the wing 310 includes upturned portions 340 which are aligned with the back of the tongue 320.
[0063] The clip 300 also includes a tab 330 extending backward from the top of the tongue 320 at an oblique angle O with respect to the horizontal plane. Preferably, the angle O of the tab is between 120 and 125 degrees. The width of the tab 330 is optionally the same as the width of the tongue 320. The tongue 320 extends approximately 1/3 to 2/3 of the thickness of the butt of a shake above an installed shake, generally corresponding to the height at which the slot 17 is located.
[0064] The roofing clip 300 further includes lateral wings 350 extending forward from the sides of the tongue 320 at the bottom thereof. The lateral wings 350 are preferably shaped in a general triangular shape, with the bottom edge of each lateral wing 350 being substantially parallel to and aligned with the plane of the wing 310.
[0065] During installation, the clip 300 is installed using the same installation methods as described above, except where noted. The orientation and alignment of the shake 10 with the clip 300 in the first direction is further facilitated by lateral wings 350 upon insertion of a clip 300 under the underlayment 30. Optionally, the clip 300 may be placed over the underlayment 30. With the clip 300 inserted under the underlayment 30, the upturned portions 340 collaborate with the back surface of the tongue 320 to act as a stop to orient and align the clip 300 with the underlayment 30 in the first direction. In situations where the shake exposure must be modified, the lateral wings 350 also provide means to orient the clip 300 and the shakes 10, 50. [0066] During installation of a subsequent course of shakes, the tab 330 of a previously installed clip 300 is inserted through a slot 17 in the butt of shake. The shake is translated down as opposed to up in the prior embodiment in the direction of the pitch of the roof surface 20, until the exterior surface of the butt of the shake substantially contacts the back surface of the tongue 320 of clip 300 and the distal end of the tab 330 contacts the filler 18 in the shake. The insertion of the tab 330 into the slot 17 in the butt of the shake is facilitated because of the upturned and backward orientation of tab 330.
[0067] The forward lateral wings 350 on clip 300 are advantageous for retaining the clip 300 in place and in shape when an upward vertical force is applied to the shake, for example due to gale force winds. Further, as the distal end of the tab 330 contacts and engages and makes contact with the underside of the top surface 11 of the shake, the clip 300 is maintained in position.
[0068] In modalities, the shape of the wing 310 at the rear end of the clip 300 is optionally modified to facilitate the manufacture of clip 300. The shape of wing 310 is generally rectangular, but includes a void at the rear end of the wing 310 (see FIG. 14). The shape of the void corresponds to the combined shape of a flattened tongue 320, tab 330 and lateral wings 350.
[0069] In FIG. 7A an exemplary roofing clip 400 according to another aspect of the present disclosure is illustrated. The roofing clip 400 comprises a generally flat wing or base 410 and a tongue 420 extending up at a generally right angle from the wing 410 on a horizontal plane. In embodiments, the tongue 420 can extend in a general vertical direction at angles substantially greater or less than 90° with respect to the plane of the wing 410.
[0070] The shape of the wing 410 is generally polygonal. As illustrated, one side of the polygon is defined by the location from where the tongue 420 extends from the wing 410, which defines the front edge 412 of the wing 410. Additional edges 414 of the polygon sweep back from each side of the front edge 412. As illustrated, two additional edges 416 of the polygon then extend from each of the swept back edges 414, generally perpendicular to the front edge 412. A polygon edge 418 joins edges 416 to complete the polygonal shape of wing 410. While one specific polygonal shape has been illustrated, it will be appreciated by those with skill in the art that other wing shapes can be used and fall within the scope of the present disclosure. In particular, it should be recognized that the wing 410 can take various concave or convex polygonal shapes. For example, wing shapes such as rectangular shaped wings, trapezoidal shaped wings, triangular shaped wings, and generally polygonal shaped wings are contemplated as acceptable wing shapes for the various embodiments as described herein. The dimensions of the wing 410 on each of the left and right side of the tongue 420 are sufficient to allow for a fastener 60 inserted through a shake 10 to penetrate and affix the corresponding side of the wing 410, holding the clip 400 in place, similar to what is illustrated in FIG. 4A for clip 100.
[0071] The tongue 420 has a generally flat rectangular shape. The width of the tongue 420 is adapted to correspond to the minimum width of the desired keyway between individual roofing shakes 10 to be installed. The height of the tongue 420 is greater than the thickness of the shake 10 at the location of maximum exposure. The sides of the tongue 420 are vertical and are used to align and space the shakes 10 during roof installation.
[0072] The bottom rear surface of the tongue 420 acts as a stop upon inserting the clip 400 under the underlayment 30 and abuts the edge of the underlayment 30. The rear surface of the tongue 420, which also corresponds to edge 412, is oriented to be substantially parallel to the edge of the underlayment 30. By this placement, the roofing clip 400 is oriented with respect to the underlayment 30 and aligned in a second direction.
[0073] The roofing clip 400 also includes a vertical projection 430 extending up from the top of the tongue 420. A tab 440 extends at an approximately right angle from the vertical projection 430. The vertical projection 430 is generally rectangular in shape, and generally as wide as the wing 410. In embodiments, the vertical projection 430 is not as wide as the wing 410, but wider than the tongue 420. The height of vertical projection 430 is less than the depth of the butt side 15 of a shake 10. The tab 440 is optionally as wide as the vertical projection 430. In embodiments, the tab 440 is less wide than the vertical projection 430. The shape of the tab 1440 is generally rectangular or polygonal. The vertical projection 430 is adapted to be inserted into a shake cavity 16, between the butt side 16 and the filler 18. The tab 440 is adapted to be inserted through the slot 17 in a shake 10, and to be bent at an angle during installation. In an alternate embodiment, the tab 440 is angled back and adapted to engage the filler 18 and the underside of the top surface 11 of the shake within cavity 17, as described in the embodiment illustrated in FIG. 6.
[0074] Two generally flat secondary wings 450, 460 extend back from the vertical projection 430 on each side of the tongue 420. The shape of each secondary wing 450, 460 is generally polygonal. In FIG. 7A, secondary wing 450 is depicted as a quadrilateral and as a mirror image of secondary wing 460.
[0075] In embodiments, each secondary wing 450, 460 can include a fastener indicator (not shown). A fastener indicator (not shown) is one of a visual indicator and/or a physical feature such as a notch or dimple, to readily indicate to a user where to place a fastener. In embodiments, each secondary wing 450, 460 can include a fastener hole (not shown). A fastener hole is a perforation through the surface of the wing that allows a fastener (e.g. nail) to be inserted therethrough. Preferably, the dimensions of the fastener hole are smaller than the fastener to be used.
[0076] During installation, the clip 400 is installed as described above for clip 100, except where noted. Upon installing fasteners 60 or 62, these are inserted through each of the corresponding secondary wings 450, 460, in addition to wing 410, thereby affixing the clip both above and below the shake. Upon installation of a subsequent course of shakes is being installed, the vertical projection 430 is inserted into cavity 16 by lowering and sliding the shake, such that the rear inner surface of the butt side is aligned with the vertical projection 430. In embodiments including forward extending tab 440, tab 440 is inserted into the slot 17 in the butt 15 of the shake 10, and bent down to secure the shake 10. [0077] FIG. 7B illustrates other embodiments of the exemplary roofing clip of FIG. 7A. Roofing clips 470, 480 and 490 are shown. As illustrated, clips 470 and 480 show generally rectangular wing shapes, while clip 490 shows a generally polygonal wing shape. For example, clips 470 and 480 show solid T-shaped wings connected to the tongue. For example, clip 490 shows a solid T-shaped wing where the base of the “T” is connected to the tongue. Clips 470, 480 and 490 also show generally rectangular-shaped secondary wings. As illustrated, the secondary wings can extend back by different amounts, resulting in smaller or larger secondary wings.
[0078] Turning now to FIG. 8 an exemplary roofing clip 500 according to another aspect of the present disclosure is illustrated. The roofing clip 500 comprises a generally flat vertical tongue 520 extending up on a vertical plane. The tongue 520 has a generally rectangular shape. The width of the tongue 520 is adapted to correspond to the minimum width of the desired keyway between individual roofing shakes 10 to be installed. The height of the tongue 520 is greater than the thickness of the shake 10 at the location of maximum exposure. The sides of the tongue 520 are vertical and are used to align and space the shakes 10 during roof installation.
[0079] An engagement member 510 is shaped to extend down from the tongue 520 and then to extend back upon a generally horizontal plane. The width of the engagement member 510 is generally the same as the width of the tongue 520. Each of the vertical and horizontal portions of the engagement member 510 are generally rectangular in shape.
[0080] The roofing clip 500 also includes a tab or projection 530 extending vertically from the top of the tongue 520. The width of the tab 530 is optionally the same as the width of the tongue 520, or the width can be different. The shape of the tab 530 is optionally generally rectangular or polygonal. In embodiments, the tab 530 extends horizontally and is adapted to be bent at an angle, after being inserted through the slot 17 in the butt 15 of a shake 10. [0081] The roofing clip 500 further includes lateral wings 540, 545 extending back from each one of the sides of the tongue 520. The lateral wings 540, 545 are preferably have a generally rectangular shape, with the bottom edge and the top edge of each lateral wing 540, 545 being substantially horizontal. A lower wing 550, 555 extends horizontally from each of the bottom edges of each lateral wing 540, 545, respectively. The shape of the lower wing 550, 555 is generally polygonal. An upper wing 560, 565 extends horizontally from each of the top edges of each lateral wing 540, 545, respectively. The shape of the lower wing 550, 555 is generally polygonal. In embodiments, the shape of lower wing 550 is the same as upper wing 560, and the shape of lower wing 555 is the same as upper wing 565. In embodiments, the shape of lower wing 550 is a mirror image of lower wing 555, and the shape of upper wing 560 is a mirror image of upper wing 565.
[0082] The dimensions of each of the wings 560, 565 on each of the right and left side of the tongue 520 area adapted to be sufficient to allow for a fastener 60 inserted through a shake 10 to penetrate and affix the corresponding sides of the upper wings 560, 565 and of the lower wings 550, 555, holding the clip 500 in place, similar to what is illustrated in FIG. 4A for clip 100. While one specific polygonal shape has been illustrated in the Figures, it will be appreciated by those with skill in the art that other wing shapes can be used and fall within the scope of the present disclosure.
[0083] In embodiments, each upper wing 560, 565 can include a fastener indicator (not shown). A fastener indicator (not shown) is one of a visual indicator and/or a physical feature such as a notch or dimple, to readily indicate to a user where to place a fastener. In embodiments, each upper wing 560, 565 can include a fastener hole (not shown). A fastener hole is a perforation through the surface of the wing that allows a fastener (e.g. nail) to be inserted therethrough. Preferably, the dimensions of the fastener hole are smaller than the fastener to be used.
[0084] The space defined between the horizontal portion of the engagement member 510 and the lower wings 550, 555 in a vertical direction is at least sufficient to receive therein a layer of underlayment 30. The rear surface of the vertical portion of the engagement member 510 acts as a stop upon insertion of the engagement member of the clip 500 under the underlayment 30 and abuts the edge of the underlayment 30. The rear surface of the vertical portion of the engagement member 510 is oriented to be substantially parallel to the edge of the underlayment 30. By this placement, the roofing clip 500 is oriented with respect to the underlayment 30 and aligned in a second direction.
[0085] During installation, the clip 500 is optionally inserted under the underlayment 30 by sliding the wing 510 underneath the underlayment 30. The clip 500 is positioned such that the lateral wing 545 on the tongue 520 abuts the right side 13 of shake 10 in the current course, thereby aligning the clip 500 in the first direction, or along left to right or right to left. The clip 500 is optionally inserted under the underlayment 30 until the back surface of the tongue 520 adjacent the wing 510 abuts the front edge 31 of the underlayment 30 substantially parallel to the edge of the underlayment 30, thereby orienting and aligning the clip 500 in the second direction, or generally in the direction of the pitch of the roof surface. A fastener 60 is installed through upper wing 565 of clip 500, through the top surface 11 of shake 10 generally adjacent to the right side 13 thereof, through lower wing 555, through underlayment 30, and through the top surface of a shake in the preceding course (e.g., top surface 11 of shake 40 in FIG. 4A), thereby securing shake 10 in place. Then the next shake to be installed 50 (see FIG. 4A) is then placed in position, aligning the left side 12 of shake 50 until it abuts the lateral wing 540 on tongue 520 of clip 500. Shake 50 is translated up in the direction of the pitch of the roof surface 20, until the interior surface of the butt of shake 50 is aligned with the front surface of tab 530 of a previously installed clip 500 in previous course of shakes. The tab 530 of the previously installed clip 500 is inserted into cavity 16 of shake 50, such that the rear inner surface of the butt side is aligned with the tongue 520. In embodiments where the tab 530 is vertical, shake 50 is affixed to tab 530 by using a fastener (not shown) such as, for example, a rivet or screw through the butt side 15 of the shake 50 and the tab 530. In embodiments where tab 530 extends horizontally, tab 530 is inserted into the slot 17 in the butt 15 of the shake 50, and bent down to secure the shake 10. A fastener 62 is installed through upper wing 560 of clip 500, through the top surface 11 of shake 50 generally adjacent to the left side 12 thereof, through lower wing 550, through underlayment 30, and through the top surface of a shake in the preceding course. Shake 50 is now partially fastened, and the process is repeated.
[0086] Alignment of the shake 10 with the clip 500 in the first direction is further facilitated by lateral wings 540, 545 upon insertion of a clip 500 under the underlayment 30. That is, the side surfaces of lateral wings 540, 545 engage the sides of adjacent shakes 10, 50 to facilitate alignment. Further, in situations where the shake exposure must be modified and the clip 500 is not inserted so far as to abut the edge of the underlayment 30, the lateral wings 540, 545 provide means to properly orient the clip 500 and the shakes 10, 50.
[0087] In FIG. 9 an exemplary roofing clip 600 according to another aspect of the present disclosure is illustrated. The clip 600 includes a generally flat rectangular wing or base 610 and a substantially vertical tongue 620. The tongue 620 has a generally rectangular shape. The width of the tongue 620 is adapted to correspond to the minimum width of the desired keyway between individual roofing shakes 10 to be installed. The height of the tongue 620 is be greater than the thickness of the shake 10 at the location of maximum exposure.
[0088] In embodiments, the roofing clip 600 includes a tab or projection 630 extending forward at an angle from the top of the tongue 620. The width of the tab 630 in one embodiment the same as the width of the tongue 620, or the width can be different. The shape of the tab 630 in one embodiment generally rectangular or polygonal. The tab 630 extends forward and is adapted to be bent at an angle, after being inserted into cavity 16 and through the slot 17 in the butt 15 of a shake 10 during installation as in previous embodiments. In further embodiments, the tab 630 extends upwards and a shake 10 is affixed to the tab 630 by using a fastener (not shown) such as, for example, a rivet or screw through the butt side 15 of the shake 10 and the tab 630. [0089] In embodiments, the roofing clip 600 includes a tab 630 extending backward from the top of the tongue 620 at an oblique angle with respect to the horizontal plane. Preferably, the angle of the tab is between 120 and 125 degrees. The width of the tab 630 in one embodiment is the same as the width of the tongue 620. The tongue 620 extends approximately 2/3 of the thickness of the butt of a shake above an installed shake.
[0090] The outer side edges of the wing 610 include flat upturned portions 640 which lie on a plane which is both generally perpendicular to the tongue 620 and generally perpendicular to the wing 610. Each of the upturned portions is generally rectangular in shape. The height of the upturned portions 640 is approximately the same dimension as the sides 12, 13 of a shake, minus approximately 1/8 inch at the point of exposure.
[0091] The roofing clip 600 further includes lateral wings 650 extending from the sides of the tongue 620 at the bottom thereof. The lateral wings 650 are preferably shaped in a general triangular shape, with the bottom edge of each lateral wing 650 being substantially parallel to the plane of the wing 610. In the embodiment in which the tab 630 extends forward from the tongue 620, the lateral wings extend backwards, as illustrated in FIG. 9. In the embodiment in which the tab 630 extends backwards from the tongue 620, the lateral wings extend forward from the sides of the tongue 620.
[0092] During installation, the upturned portions 640 are inserted into the cavity 16 behind the rails or sides 12, 13 of a shake 10, at the desired location. The clip 600 is optionally moved forward and backward along the keyway according to the desired shake exposure. Additional fasteners are not required to hold the clip in place. Upon installation of a next or subsequent course of shakes, the tab 630 is accommodated as described above. The lateral wings 650 on clip 600 are advantageous for retaining the clip 600 in place and in shape when an upward vertical force is applied to the shake, for example due to gale force winds.
[0093] In addition to the applications described above, the use of the various modalities of the roofing clip, roofing shake and roofing system is advantageous when installed on roof surfaces that have different pitches. Installing shakes on a roof surface with a transition in pitch can be challenging, as the location of the placed underlayment may not correspond to the location of the change in pitch, which may result in irregular courses and variation in roof shake exposure. These disadvantages are overcome with the disclosed invention. Shake exposure for a course is modified by translating a clip up or down within a keyway, while keeping the shakes in the roofing system aligned as previously described. In this manner, the placement of shakes is optimized for the best coverage according to the change in pitch. Further, as the shakes are fabricated from sheet metal, the shakes are adaptable to be bent to accommodate the change in pitch, allowing for a course of shakes to be installed over the change in pitch of the roof surface. Further, as each shake is fastened on all four sides by means of a clip from the present disclosure at the butt and by fasteners on the remaining sides, each shake is securely affixed to the roof surface, resulting in a weather resistant solution.
[0094] Turning now to FIG. 10, an exemplary roofing clip 700 according to one aspect of the present disclosure for use as a combination drip edge, starter edge, and underside cover is illustrated. The roofing clip 700 comprises a generally flat wing or base 710 and a tongue 720 extending up at a generally right angle from the wing 710.
[0095] The shape of the wing 710 is generally rectangular. In embodiments, the width of the wing 710 of clip 700 in one embodiment is as narrow as the width of a single shake 10. In other words, the width of the wing 710 of clip 700 is the same as the width of shake 10 between the left side 12 and right side 13, along the upper side 14. In embodiments, the width of the wing 710 of clip 700 is optionally as wide as the roof surface on which the roofing system is being installed. The depth of the wing 710 of clip 700 is greater than the desired overhang at the bottom of the finished roof. In embodiments, the depth of wing 710 is at least twice the desired overhang. In a preferred embodiment the width of wing 710 is between 8 to 10 feet wide. In a preferred embodiment, the depth of the wing 710 is approximately 2 to 12 inches. [0096] The tongue 720 can have a generally rectangular shape. The width of the tongue 720 corresponds to the width of the wing 710. The height of the tongue 720 is no greater than the thickness of the shake 10 at the butt, minus approximately 1/16 inch (5mm).
[0097] In installation, roofing clip 700 is used as a combination drip edge, starter edge, and underside cover by positioning clip 700 at the bottom edge of the roof, projecting out over the edge by the amount of the desired overhang. Shakes are then positioned onto clip 700, with the tongue 720 inserted into the cavity 16 of the shake 10 immediately behind the lower side 15. In this manner, shakes are aligned with the clip 700, and clip 700 provides an underside cover to the overhanging sections of the shakes at the bottom of the roof. The shakes 10 are then fastened to the roof surface through the top surface of the shake using suitable fasteners such as, but not limited to, ring shank stainless steel nails, where the fasteners also penetrate the wing 710 of clip 700.
[0098] Turning now to FIG. 11 an exemplary roofing clip 800 according to one aspect of the present disclosure for use with the exemplary roofing clip of FIG. 10 is illustrated. The roofing clip 800 comprises a generally flat wing 810 and a tongue 820 extending up at a generally right angle from the wing 810.
[0099] The shape of the wing or base 810 is generally rectangular. The width of the wing 810 of clip 800 is wider than the width of the keyway at a location corresponding to the bottom of the installed shakes. In embodiments, the width of the wing 810 of clip 800 is approximately 2 to 3 times wider than the keyway at a location corresponding to the bottom of the installed shakes. The depth of the wing 810 clip 800 is greater than the desired overhang at the bottom of the finished roof by approximately 1 inch.
[00100] The tongue 820 can have a generally rectangular shape. The width of the tongue 820 corresponds to the width of the wing 810. The height of the tongue 820 is greater than the thickness of the shake 10 at the butt, as defined by side 15. The height of the tongue 820 is less than twice the thickness of the shake 10 at the butt. In embodiments, clip 800 may also include a rectangular tab 830, adapted to be inserted into a slot 17 of a shake 10.
[00101] The bottom rear surface of the tongue 820 acts as a stop upon inserting clip 800 under a clip 700 and abuts the butts of the installed shakes on clip 700. The rear surface of the tongue 820 is oriented to be substantially parallel to the edge of the clip 700. By this placement, the roofing clip 800 is oriented with respect to the clip 700 and aligned in the second direction.
[00102] Turning now to FIG. 12 an exemplary roofing clip 900 according to one aspect of the present disclosure for use as an edge detail closure piece is illustrated. The clip dimensions in the vertical direction have been exaggerated, for illustrative purposes. The roofing clip 900 comprises a generally flat wing or base 910 and a tongue 920 extending up at a generally right angle from the wing 910.
[00103] The shape of the wing 910 in one embodiment is generally rectangular or trapezoidal, where the depth of the wing at a first side is different to the depth of the wing on the opposite side. The minimum depth of the wing is greater than the desired overhang on the gable. A typical overhang is between 0.5 inches and 1 .5 inches. In embodiments the minimum depth of wing 910 is approximately 2.5 inches. The width of the wing 910 substantially corresponds to the length of a shake, from head to butt. In embodiments, the width of wing 910 is between 16 to 24 inches. The dimensions of the wing 910 is adapted to be sufficient to allow for a fastener inserted through a shake that overhangs a gable to penetrate and affix the wing 910 through to the roof surface, holding the clip 900 in place. In embodiments, the shape of wing 910 corresponds to the shape of surface 11 of shake 10.
[00104] The tongue 920 has a generally trapezoidal shape. The width of the tongue 920 corresponds to the width of the wing 910. The height of the tongue on a first side is different to the height of the tongue on the opposite side. In embodiments, the height of the tongue 920 is greater on the side of the wing 910 where the depth is smaller, and the height of the tongue 920 is less on the side of the wing 910 where the depth is greater. The tapered height of the tongue generally corresponds to the tapered side profile of a shake 10. In other words, the height of the tongue 920 on one side generally corresponds to the height of the upper side 14 of shake 10, and the height of the tongue 920 on the opposite side generally corresponds to the height of the lower side 15 of shake 10.
[00105] The roofing clip 900 also includes a tab or projection 930 extending backwards from the top of the tongue 920 substantially perpendicular to the tongue 920. The width of the tab 930 is the same as the width of the tongue 920. The shape of the tab 930 is generally rectangular. In embodiments, the depth of tab 930 is between 0.5 to 1 inch.
[00106] The rear surface of the tongue 920 acts as a stop upon inserting a clip 900 onto a left or right side of a shake and abuts the corresponding left or right side of the shake. The surface of the tongue 920 is oriented to be substantially parallel to the left side 12 or right side 13 of the shake 10. The roofing clip 900 can also be installed on the exposed edge of shakes that have been cut to size, and used as an end cap.
[00107] FIG. 13A illustrates a roof installation using the exemplary clips of FIGS. W and 11 and shake according to one aspect of the present disclosure. The height of the shakes has been exaggerated in relation to the other dimensions, and the clip dimensions relative to the shake dimensions have been exaggerated, for illustrative purposes. During installation, a clip 700 is placed on the roof surface, overhanging the eve of the roof by a desired amount, typically 1/2 to 1 1/2 inches. A first course of shakes is installed onto clip 700 by sliding the tongue 720 behind side 15 of shake 10, thereby aligning shake 10. After the clip 700 from FIG. 10 above has been installed and fastened with a first course of shakes, clip 800 is inserted under clip 700 by sliding the wing 810 underneath the clip 700. The clip 800 is inserted under clip 700 until the back surface of the tongue 820 abuts the butts of the installed shakes, substantially parallel to the lower sides 15 of the installed shakes, thereby orienting and aligning the clip 800 in the second direction. A shake corresponding to the next course is then positioned over the keyway defined by the shakes in the first course, and the vertical tongue 820 is inserted behind the lower side 15 of the recently positioned shake. A fastener, such as e.g., a self-tapping screw, is inserted through the butt of shake and secured to the tongue 820 of clip 800. The recently positioned shake is also affixed to the roof surface as previously described. The next courses of shakes can then be installed as previously described.
[00108] FIG. 13B illustrates the exemplary clip from FIG. 12 and shake according to one aspect of the present disclosure. The height of the shake has been exaggerated in relation to the other dimensions, and the clip dimensions relative to the shake dimensions have been exaggerated, for illustrative purposes. During installation, a clip 900 is aligned with a left side 12 or right side 13 of a shake 10, depending on the configuration of the clip as described above. The clip 900 and shake 10 are aligned with an approximate 30% offset, where the side of the shake 10 abuts the rear surface of the tongue 920 of the clip 900. The clip 900 is then slid onto the shake 10, so that the one side of the clip 900 is aligned with the head of the shake 10 and the opposite side of the clip 900 is aligned with the butt of the shake 10. By this configuration, clip 900 provides an edge detail closure piece, where the underside of the portion of the shake 10 that overhangs the gable is covered by clip 900. The shake is positioned and oriented according to the foregoing disclosure, and an additional fastener is inserted through the shake 10 and clip 900, thereby securing the shake in place. It is noted that using clip 900 will provide a square edge for all shakes on the gable edge, whether they are complete shakes or cut shakes on every second row or course.
[00109] The roofing system in one embodiment further comprises a snow stop and toe hold 1000, as illustrated in FIGS. 14A to 14D. The snow stop and toe hold 1000 comprises a generally flat first base section 1010 and a generally flat second base section 1020. A generally flat stop 1030 extends perpendicularly from between the first base section 1010 and the second base section 1020. The height H5 of the stop 1030 is higher than the height H2 of a shake 10, and is adjusted based on the material of manufacture to retain an adequate strength. An opening 1090 is located on the stop 1030 between the first base section 1010 and the second base section 1020, to allow water run off the roof surface. A flat tongue 1040 extends generally perpendicularly from the second base section 1020 from a side opposite the side that the flat stop 1030 extends from. The height H6 of the tongue 1040 is about the same as the height H2 of the butt 15 of a shake 10, and preferably slightly less. In an optional embodiment, a flat tab or nose 1050 extends in a generally perpendicular manner from the top of the tongue 1040. In embodiments, the depth D3 of the tab 1050 is no larger than the distance D1 of a shake 10. In embodiments, the snow stop 1000 can include one or more supports, such as gussets or goose necks 1060 between one of the first base section 1010 or the second base section 1020, and the stop 1030.
[00110] In embodiments, each of the first base section 1010, the second base section 1020, or the tab 1050 can include one or more fastener holes 1070. A fastener hole is a perforation through the surface of the first base section 1010 or the second base section 1020 that allows a fastener (e.g., screw or rivet) to be installed therethrough. Preferably, the dimensions of the fastener hole are configured to match the size of the fastener, for example if a rivet is used, or configured to be smaller than the fastener, for example if a screw is to be used. In embodiments, each of the first base section 1010, the second base section 1020, or the tab 1050 can include one or more fastener holes 1080.
[00111] In embodiments, the width W5 of the snow stop 1000 is between 3 inches and slightly less than the width W2 of the shake 10. In embodiments, the depth of the first base section 1010 is about 1.5 inches and the depth of the second base section 1020 is about 2 inches. In embodiments, the height H5 of the stop 1030 is about 2.5 inches. In embodiments, the height H6 of the tongue is 0.3125 (5/16) of an inch. In embodiments, the depth D3 of the tab or nose is 0.25 inches. In embodiments, the depth D4 of the first base section is configured to receive a support piece 1300, such as a standard 2x4 piece of lumber lying on its short side as shown in FIG. 14C. In embodiments, the snow stop and toe hold 1000 is optionally manufactured from 24-gauge sheet metal. In embodiments, the snow stop and toe hold 1000 is optionally manufactured from 16-gauge galvanized steel. In embodiments, the snow stop and toe hold 1000 is optionally manufactured from a single piece of metal. In embodiments, the snow stop and toe hold 1000 is optionally painted. In a preferred embodiment, the snow stop and toe hold 1000 is manufactured from extruded aluminum, and coated with a polyvinylidene fluoride (PVDF) paint finish.
[00112] In embodiments, the snow stop and toe 1000 hold further comprises a coating (not shown) on the underside of the first and second base sections 1010 and 1020. Such a coating provides a seal between the snow stop 1000 and the shake 10 on which the snow stop 1000 is placed, in addition to acting as a seal at locations, such as at faster holes 1070, where fasteners are installed. In embodiments, this coating is ethylene propylene diene terpolymer (EPDM) or rubber, or applied as silicone coating during installation.
[00113] With further reference to Fig. 14B, the roofing system in one embodiment further comprises a grab clip or safety grab 1100, comprising a stop 1110 of width W6 and height H8 and a substantially flat hook 1120 with height H7, extending from a first side of and substantially parallel to stop 1110, connected by a first base section defining a gap therebetween with a depth D5. In embodiments, the safety grab 1100 can further comprise one or more fastener indicators 1130. A fastener indicator is one of a visual indicator and/or a physical feature such as a notch or dimple, to readily indicate to a user where to place a fastener. In an embodiment, H7 is 0.375 inches, H8 is 2 inches, D5 is 0.125 inches, and W6 is between 3 inches and slightly less than the width W2 of the shake 10.
[00114] The snow stop and toe hold and grab clip of the present invention in embodiments is made from various materials, including but not limited to sheet metal, including galvanized steel, Galvalume ® steel, stainless steel, copper, zinc, aluminum or any others suitable metal. The snow stop and toe hold and grab clip can also be made from polycarbonates, acrylonitrile butadiene styrene plastics (ABS), polyvinyl chloride (PVC), thermoplastic polyolefin (TPO), ethylene propylene diene terpolymer (EPDM), carbon fiber composites, or any other suitable thermopolymer or polymer material. The snow stop and toe hold and grab clip in embodiments is manufactured by die cut, molding or 3D printing.
[00115] During installation of an embodiment, a starter course of shakes 10 is installed on a roof surface, and a second course of shakes is then installed on top of the starter course, in a laterally alternating fashion, each course having the heads and butts of the respective shakes aligned with one another (refer to Figs. 4A and 4B). A third course of shakes is installed by driving or inserting fasteners 60, 62 through each shake in the third course. Due to the placement of the shakes, a portion of the shake adjacent to the butt of a shake 10 in the third course may not lie flat against the surfaces of the shakes in the second course, preventing the filler 18 of the shake in the third course from contacting the top surface of the shake in the second course. A snow stop 1000 may be installed to deform the shake in the third course and bring the filler 18 of said shake into engagement with the top surface of the shake in the second course. In embodiments, a snow stop 1000 is placed over said third shake at the desired location with tongue 1040 abutting the lower side 15 of said third shake, and fastener holes 1080 are used to drill fastener holes (not shown) in the butt of said third shake. Thereafter, the snow stop 1000 may be inserted into the butt of the shake 10 in the third course, by rotating the snow stop 1000 so that the tongue 1040 of the snow stop 1000 lies substantially parallel to the surface 11 of the second course of shakes, and inserting the tongue 1040 into the cavity 16 at the butt of the shake 10. The snow stop 1000 is then rotated back so that the first and second base sections 1010 and 1020 lie flat on the surface of the second course of shakes. Fasteners are the installed at one or more locations, such as at faster holes 1070 or fastener holes 1080, fixing the snow stop 1000 to the second and third courses of shakes. The length of the fasteners is selected such that only one shake is perforated. In an embodiment, 0.125-inch rivets are used as fasteners. Upon fastening of the snow stop, the shake 10 is deformed, bring the filler 18 of the shake 10 in the third course into contact with the top surface 11 of the shake 10 in the second course. In one embodiment, the stop 1030 of the snow stop 1000 is configured to be set between 6 inches to 2 feet from the edge of the roof, depending on the size of the shakes. In embodiments, a snow stop 1000 is optionally installed on additional shakes on the third and subsequent courses. The distribution and placement of snow stops is determined based on the pitch of the roof and is generally known in the art.
[00116] During the maintenance of an embodiment, a grab clip 1100 is installed in addition to a snow stop and toe hold 1000, at the same location, as illustrated in Fig. 14 D, which is a side view of a roofing system comprising a shake 10, a snow stop and toe hold 1000 and a grab clip 1100 securing a support piece 1300 fastened by fastener F. During maintenance, in order to install grab clip 1100 as described with reference to FIG. 14B, grab clip 1100 is aligned with the butt of a shake 10 in a course on the roof surface with an installed snow stop and toe hold 1000, such that the hook 1120 is aligned with the slit 19 between the bottom wall 15 or butt and one of the left side 12 or right side 13 of the shake 10. The grab clip 1100 is then translated laterally, with the hook 1120 entering the cavity 16 behind the bottom side 15 of the shake 10 through slit 19. A support piece 1300, optionally a section of 2 x 4 lumber or a metal support, is placed between the stop 1030 of the snow stop and toe hold, and the stop 1130 of the grab clip 1100, and fixed in place with one or more fasteners F. This is advantageous, as it fixes the support piece 1300 in place, preventing movement thereof and thereby ensuring a safer work environment. Once maintenance is completed, the one or more fasteners F are optionally removed, allowing for the removal of support piece 1300 allowing for reuse of said support piece, and without damaging the roofing system or compromising the integrity of the same.
[00117] During the installation or maintenance of an embodiment, a snow stop and toe hold 1000 that does not include the optional tab or nose 1050 is installed to provide a snow stop and toe hold, and to improve the safety of the maintenance crew without compromising the integrity of the installed roof system. A snow stop and toe hold 1000 is aligned with the butt of a shake 10 in a course on the roof surface, such that the tongue 1040 is aligned with the gap between the bottom wall 15 or butt and one of the left side 12 or right side 13, while the first and second base sections are flat against the surface of the shakes in the next course down. The snow stop and toe hold 1000 is then translated laterally, with the tongue 1040 entering the cavity 16 behind the bottom side 15 of the shake. In an alternate embodiment, the snow stop and toe hold 1000 is translated laterally back in the opposite direction, so that the tongue 1040 enters the cavity 16 behind the bottom side 15 of the adjacent shake 10 in the same course. In this manner, the tongue 1040 of the snow stop and toe hold 1000 engages the back of side 15 of one or more shakes, thereby providing a support for workers performing maintenance on the roof surface. In one embodiment, fasteners can optionally be installed to fasten the snow stop and toe hold 1000 in place, for use in the future. In one embodiment, the completion of the maintenance activities on the roof surface, the plurality of installed snow stop and toe holds 1000 are removed, without compromising the integrity of the roof system installation, nor weakening the components.
[00118] In a further embodiment, the support piece 1300 can comprise a metal support piece for fixedly mounting items onto the roofing system surface, such as solar panels. As described with reference to Fig. 14D, said supports are optionally fastened to snow stop and toe hold 1000 and/or grab clip 1100, to provide a mounting location for such items. Additional fasteners may be added to the roofing system to increase the strength of the system as required.
[00119] FIG. 15 illustrates an exemplary method of manufacture of an exemplary roofing clip according to one aspect of the present disclosure. During manufacture, a clip of the present disclosure is cut, stamped or generally formed from a sheet metal piece as illustrated for the example clip 300 in Fig. 15. The pattern of a clip is designed in such a way that features such as those corresponding to, for example, the tongue, tab, and lateral wings match features the define the shape of the wing. By forming a void V on the wing of a clip, the tongue, tab and lateral wings of a subsequent clip are formed my means of the same process. After the shape of clip has been separated, e.g. stamped out, the metal is bent or formed to generate the clips as described herein. [00120] It will be appreciated that while only one row of clips is depicted in FIG. 15, many rows of clips may be manufactured from a single sheet of metal or laminar material.
[00121] This is advantageous as it reduces the number of steps required during the manufacturing process, and reduces waste as a void in one clip corresponds to the component shapes of another clip. In addition, an enlarged wing ensures fastening of the clip during installation. It should be appreciated that such modifications to the shape of the wings of the various described modalities, and not only limited to example clip 300, can be carried out without departing from the scope of the present invention.
[00122] While the foregoing is directed to aspects of the present disclosure, other and further aspects of the disclosure can be devised without departing from the basic scope thereof.

Claims

1 . A roofing clip adapted for use in installing, on a roof surface, roofing shakes with a slot on one side, the roofing clip comprising: a substantially planar base; a tongue, extending generally perpendicularly from the base; and a tab extending from the tongue, from the end opposite the base, dimensioned to engage the slot of the roofing shake.
2. The roofing clip of claim 1 , wherein the base further comprises a long axis and a short axis defining two wing sections, and wherein the tongue extends from an edge generally parallel to the long axis of the base.
3. The roofing clip of claim 1 , further comprising lateral wings extending generally perpendicular to both the base and the tongue, from the sides of the tongue.
4. The roofing clip of claim 3, wherein the lateral wings are generally triangular with the base of the lateral wings being substantially parallel to the base of the clip, and defining a gap therebetween.
5. The roofing clip of claim 3, wherein the lateral wings are substantially rectangular.
6. The roofing clip of claim 5, further comprising a first set of secondary wings extending from the lateral wings, the first set of secondary wings being substantially parallel to the base of the clip.
7. The roofing clip of claim 6, further comprising a second set of secondary wings extending from the lateral wings, the second set of secondary wings being substantially parallel to the base of the clip.
8. The roofing clip of claim 1 , further comprising at least one upturned portion generally perpendicular to the base and coplanar to the tongue, extending from the same edge of the base as the tongue.
9. A roofing clip adapted for use in installing, on a roof surface, roofing shakes with an interior cavity adjacent one side and a slot on said side, the roofing clip comprising: a substantially planar base; a tongue, extending generally perpendicularly from the base; and a vertical projection extending from the tongue, opposite the base, dimensioned to engage the cavity of the roofing shake.
10. The roofing clip of claim 9, further comprising one or more secondary wings extending from the vertical projection in a direction substantially parallel to the base of the clip.
11 . The roofing clip of claim 9, further comprising a tab extending from the vertical projection dimensioned to engage the slot of the roofing shake.
12. A roofing clip adapted for use on a roof surface with roofing shakes with a top surface and four sides, with slits located at the comers of each side, the roofing clip comprising: a substantially planar first base portion; a tongue, extending generally perpendicularly from the base from one side, dimensioned to engage one side of at least one roofing shake by inserting the tongue into a slit adjacent said side.
13. The roofing clip of claim 12, further comprising a vertical stop extending from the first base portion from the side opposite the tongue.
14. The roofing clip of claim 12, further comprising a substantially planar second base portion coplanar with the first base portion, and extending from the side opposite the tongue.
15. A roofing shake comprising: a top surface; four sides extending from and generally perpendicular to the top surface, defining a cavity; and a filler within the cavity extending from the top surface, wherein the filler is configured to extend further from the top surface than each of the four sides.
16. The roofing shake of claim 15, wherein each corner between adjacent sides further comprises a slit therebetween.
17. The roofing shake of claim 15, wherein the dimensions of the filler are configured to define a gap between one or more of the four sides and the corresponding edges of the filler.
18. The roofing shake of claim 15, wherein one side further comprises a slot dimensioned to receive a tab from a roofing clip.
19. A kit for installation of a roofing system, the kit comprising: a plurality of clips comprising a base and a tongue extending in a substantially perpendicular manner from one edge of the base; and a plurality of metal shakes with a top surface and four walls defining a cavity, including a filler extending out from the cavity farther than each of the four walls.
20. The kit of claim 19, further comprising a plurality of starter course clips comprising a base and a tongue substantially perpendicular to the base, and wherein the tongue is the same width as the base.
21 . The kit of claim 19, further comprising a plurality of edge detail clips comprising a base, a tongue extending substantially perpendicular to the base, and a tab extending substantially perpendicular to the tongue, wherein the height of the tongue at one edge is greater than the height of the tongue at the opposite edge, and wherein the width of the base is greater on the side where the height of the tongue is shorter.
22. The kit of claim 19, wherein the one or more of the plurality of clips further comprise lateral wings extending from the sides of the tongue generally perpendicular to both the base and the tongue, wherein the lateral wings are generally triangular with the base of the lateral wings being substantially parallel to the base of the clip, and defining a gap therebetween.
23. The kit of claim 19, wherein the one or more of the plurality of clips further comprise lateral wings extending from the sides of the tongue generally perpendicular to both the base and the tongue, wherein the lateral wings are substantially rectangular, wherein a first set of secondary wings extend from the lateral wings, the first set of secondary wings being substantially parallel to the base of the clip.
24. The kit of claim 19, further comprising a plurality of snow stop and toe hold clips comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, a tongue extending generally perpendicularly from the second base section, and a tab extending generally perpendicularly from the tongue.
25. The kit of claim 19, further comprising a plurality of grab clips comprising a base section, a vertical stop extending generally perpendicularly from one end of the base section, and a substantially flat hook extending generally perpendicular from the opposite end of the base section.
26. A method of installing courses of shakes of a roofing system on a roof surface, the method comprising: aligning, in a desired course installation orientation, a roofing clip comprising a base and a tongue, wherein the tongue extends in a generally perpendicular manner from the base, and wherein the base is placed generally coplanar to the roof surface; aligning a roofing shake adjacent to said roofing clip in a desired course installation orientation, by at least aligning a side of said roofing shake with said tongue of said roofing clip; fastening said roofing clip and roofing shake with at least one fastener, said at least one fastener penetrating through at least both said roofing shake and a portion of the base of said roofing clip; wherein the fastener further penetrates at most one preceding course of previously installed roofing shakes.
27. The method of installing a roofing system of claim 26, wherein the step of aligning the roofing shake further comprises aligning a butt of the shake with a tongue of a clip in a previously installed course of shakes.
28. The method of installing a roofing system of claim 27, further comprising the step of fastening the butt of the aligned shake to the tongue of the clip in the previously installed course.
29. The method of installing a roofing system of claim 26, wherein the step of aligning the roofing shake further comprises aligning a butt of the shake with a tongue of a starter clip aligned with the bottom edge of the roof surface and a previously installed starter course of shakes.
30. The method of installing a roofing system of claim 26, wherein the step of aligning a roofing clip further comprises aligning at least one of a back surface of the tongue and an upturned portion extending from the base of the clip from the same edge as the tongue, with an underlayment layer installed on the roof surface.
31 . The method of installing a roofing system of claim 26, wherein the step of aligning a roofing shake further comprises selecting a shake including an edge detail clip at least partially covering the bottom of the shake, and is installed on an overhanging edge of the roof surface.
32. The method of installing a roofing system of claim 26, further comprising the step of installing a snow stop and toe hold, comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, a tongue extending generally perpendicularly from the second base section, and a tab extending generally perpendicularly from the tongue, the step of installing a snow stop and toe hold comprising generally aligning the tongue of the snow stop and toe hold with the surface of a previously installed course of shakes, inserting the tongue and tab into the butt of the aligned shake, rotating the snow stop and toe hold to align the first and second base sections with the surface of the previously installed course of shakes, and fastening the snow stop and toe hold with fasteners to at least one of the previously installed courses of shakes and the aligned shake.
33. The method of installing a roofing system of claim 26, further comprising the step of installing a snow stop and toe hold, comprising a first base section and a second base section, a vertical stop extending generally perpendicularly therebetween, and a tongue extending generally perpendicularly from the second base section, and wherein the installed shake further comprises a slit at each corner, the step of installing a snow stop and toe hold comprising aligning the first and second base sections of the snow stop and toe hold with the surface of a previously installed course of shakes and aligning the tongue of the snow stop and toe hold with a slit of the aligned shake, translating the snow stop and toe hold to insert the tongue into a slit on a bottom corner of the aligned shake.
PCT/CA2022/051892 2021-12-24 2022-12-23 Roofing clip, roofing shake and roofing system and method WO2023115223A1 (en)

Applications Claiming Priority (2)

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US202163293699P 2021-12-24 2021-12-24
US63/293,699 2021-12-24

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3081853A (en) * 1960-08-15 1963-03-19 Tinnerman Products Inc Fastening devices
US4476661A (en) * 1981-12-14 1984-10-16 Hoofe Iii William J Clip locked roofing and siding panels

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3081853A (en) * 1960-08-15 1963-03-19 Tinnerman Products Inc Fastening devices
US4476661A (en) * 1981-12-14 1984-10-16 Hoofe Iii William J Clip locked roofing and siding panels

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