Metal roofing shingle, metal roofing shingle system, and method of installing

Abstract

The present invention is directed to a metal roofing shingle system comprising universal flashing installed as either a ridge cap, hip flashing, or valley flashing and including non-visible double-flanged interlock joints that extend beneath the underside surface of the flashing, the interlock joints are adapted to couple with metal shingles; each metal shingle having a planar segment, a first longitudinal edge segment opposite a second longitudinal edge segment that includes a non-visible double-flanged interlock joint that extends beneath the bottom surface of the shingle, and a first transverse edge segment opposite a second transverse edge segment that includes a non-visible double-flanged compression joint that extends beneath the bottom surface of the shingle; and shingle shaping tools.

1 . A metal roofing shingle system, comprising:
 a) universal flashing including;
 i) a first leg with a double-flanged interlock joint adapted to couple with metal shingles, said interlock joint having an outward extending nailing hem for attachment to a roof, and 
 ii) a second leg with a double-flanged interlock joint adapted to couple with metal shingles, said interlock joint having an outward extending nailing hem for attachment to a roof, 
 whereby said universal flashing selectively provides a ridge cap or hip flashing when attached to the roof, or valley flashing when attached inverted; and 
   b) metal shingles, each metal shingle comprising;
 i) a planar segment defined by a top surface and a bottom surface, 
 ii) a first transverse edge segment opposite a second transverse edge segment, the second transverse edge segment including a double-flanged compression joint having a first flange that extends beneath said bottom surface, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment, and 
 iii) a first longitudinal edge segment opposite a second longitudinal edge segment, the second longitudinal edge segment including a double-flanged interlock joint that having a first flange that extends beneath said bottom surface, and a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof. 
   
   
   
       2 . The metal roofing shingle system recited in  claim 1  whereby, the first longitudinal edge segment of each metal shingle when installed in a first course of shingles is inserted between the flanges of a double-flanged interlock joint of the universal flashing when installed as a ridge cap. 
   
   
       3 . The metal roofing shingle system recited in  claim 1  whereby, the first longitudinal edge segment of each metal shingle when installed in a second or following course of shingles is inserted between the flanges of a double-flanged interlock joint extending beneath the second longitudinal edge segment in an adjacent course of shingles. 
   
   
       4 . The metal roofing shingle system recited in  claim 1  whereby, the first transverse edge segment of a metal shingle is inserted into the double-flanged compression joint of an adjacent shingle, causing the compression flange to forcibly engages the bottom surface of said inserted shingle to provide a watertight seal along said compression joint. 
   
   
       5 . The metal roofing shingle system recited in  claim 4 , comprising, insulation material fixed to the bottom surface of said planar segment, the insulation material compressed when said compression flange forcibly engages said bottom surface of said inserted shingle. 
   
   
       6 . The metal roofing shingle system recited in  claim 1 , comprising: a metal roof shingle manufactured from a metal shingle blank, said shingle blank comprising:
 a) a planar segment defined by a top surface and a bottom surface;   b) a first transverse edge segment opposite a second transverse edge segment having a transverse fold tab; and   c) a first longitudinal edge segment opposite a second longitudinal edge segment having a longitudinal fold tab;
 whereby the transverse fold tab on the second transverse edge segment is folded to form a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment; and 
 whereby the longitudinal fold tab on the second longitudinal edge segment is folded to form a double-flanged interlock joint that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint overlapped by said folded second transverse edge segment, and said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface for attachment to a roof; said second transverse edge segment and said second longitudinal edge segment folded to manufacture the metal roof shingle. 
   
   
   
       7 . The metal roofing shingle system recited in  claim 6  comprising: insulation material fixed to the bottom surface of the planar segment of said shingle blank. 
   
   
       8 . The metal roofing shingle system recited in  claim 6 , additionally comprising: a shingle shaping tool for shaping said shingle blanks into shingles including an elongated shaping jaw comprising an angle shaped member having a first leg fixed to a second leg, and a circular shaped member fixed to said first leg and extending along the length thereof, said circular shaped member fixed at a position to provide a gap between said circular shaped member and said second leg, said gap sized to releasably fix a shingle edge therein when said shingle is shaped about the circular shaped member surface to form a curvilinear shingle edge. 
   
   
       9 . The metal roofing shingle system recited in  claim 6 , additionally comprising: a shingle shaping tool for shaping said shingle blanks into shingles including an elongated shaping jaw comprising an angle shaped member having a first leg fixed to a second leg, and a rectangular shaped member fixed to said first leg and extending along the length thereof, said rectangular shaped member fixed at a position to provide a gap between said rectangular shaped member and said second leg, said gap sized to loosely hold a shingle edge therein so that said shingle edge rotates within said gap when said shingle is shaped about said rectangular shaped member to form a hooked shingle edge. 
   
   
       10 . A metal roof shingle manufactured from a metal shingle blank, said shingle blank comprising:
 a) a planar segment defined by a top surface and a bottom surface;   b) a first transverse edge segment opposite a second transverse edge segment; and   c) a first longitudinal edge segment opposite a second longitudinal edge segment;
 whereby the second transverse edge segment is folded to form a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment; and 
 whereby the second longitudinal edge segment is folded to form a double-flanged interlock joint having a first flange that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint overlapped by said folded second transverse edge segment, and said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof; said second transverse edge segment and said second longitudinal edge segment folded to manufacture the metal roof shingle. 
   
   
   
       11 . The metal roof shingle recited in  claim 10  comprising:
 insulation material fixed to the bottom surface of said planar segment.   
   
   
       12 . The metal roof shingle recited in  claim 10  comprising at least one paint coat applied to the top surface of said planar segment. 
   
   
       13 . The metal roof shingle recited in  claim 12  whereby, said at least one paint coat is colored. 
   
   
       14 . The metal roof shingle recited in  claim 12  whereby, said at least one paint coat is colored to simulate slate shingles. 
   
   
       15 . The metal roof shingle recited in  claim 12  whereby, said at least one paint coat is colored to simulate terracotta shingles. 
   
   
       16 . A metal roof shingle comprising:
 a) a planar segment defined by a top surface and a bottom surface;   b) a first transverse edge segment;   c) a second transverse opposite said first transverse edge segment, said second transverse edge Segment folded to form a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment;   d) a first longitudinal edge segment; and   e) a second longitudinal edge segment opposite said first longitudinal edge segment, the second longitudinal edge segment folded to form a double-flanged interlock joint having a first flange that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint overlapped by said folded second transverse edge segment, and said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof   
   
   
       17 . The metal roof shingle recited in  claim 16  comprising:
 insulation material fixed to the bottom surface of said planar segment.   
   
   
       18 . The metal roof shingle recited in  claim 16  comprising:
 a paint system applied to the top surface of said planar segment.   
   
   
       19 . The metal roof shingle recited in  claim 16  whereby, said paint system is colored. 
   
   
       20 . The metal roof shingle recited in  claim 16  whereby, said paint system is colored to simulate slate shingles. 
   
   
       21 . The metal roof shingle recited in  claim 16  whereby, said paint system is colored to simulate terracotta shingles. 
   
   
       22 . A method of installing a metal roofing shingle system, comprising:
 a) providing universal flashing including a first leg with an integral double-flanged interlock joint extending along a length thereof, and a second leg fixed to said first leg and including an integral double-flanged interlock joint extending along a length thereof, each said double-flanged interlock joint adapted to couple with metal shingles, each said double-flanged interlock joint including an outward extending nailing hem for attachment to a roof, and b) providing metal roof shingles comprising:
 i) a planar segment defined by a top surface and a bottom surface, 
 ii) a first transverse edge segment opposite a second transverse edge segment, the second transverse edge segment folded to provide a double-flanged compression joint that extends beneath the bottom surface of said planar segment, said double-flanged compression joint including a compression flange that extends outward from beneath said bottom surface at an upward angle to said planar segment, and 
 iii) a first longitudinal edge segment opposite a second longitudinal edge segment, the second longitudinal edge segment folded to provide a double-flanged interlock joint having a first flange that extends beneath the bottom surface of said planar segment, said double-flanged interlock joint including a nailing hem that extends outward from beneath said bottom surface in parallel with said first flange for attachment to a roof, said folded second longitudinal edge segment being overlapped by said folded transverse edge segment; 
   c) attaching said universal flashing as a ridge cap by driving fasteners through said nailing hems extending along the first leg and along the second leg of said universal flashing and into the roof;   d) installing a first course of metal roof shingles, each shingle having its first longitudinal edge segment inserted between the flanges of one of said interlock joints provided in said universal flashing attached as a ridge cap, each shingle, with the exception of a first shingle in said first course, having its first transverse edge segment inserted between the flanges of the double-flanged compression joint of an adjacent shingle, the compression flange forcibly engaging the bottom surface of said first longitudinal edge segment, each conjoined shingle fixed to the roof by driving fasteners through said nailing hem;   e) installing a second course through a last course of metal roof shingles, each shingle having the first longitudinal edge segment inserted between the flanges of the double-flanged interlock joint provided along the folded second longitudinal edge segment of an adjacent shingle, and each shingle, with the exception of a first shingle in each second through a last course of shingles, having its first transverse edge segment inserted between the flanges of the double-flanged compression joint of an adjacent shingle, said compression flange forcibly engaging the bottom surface of said conjoined first longitudinal edge segment, each shingle in said second through a last course of shingles fixed to the roof by driving fasteners through said nailing hem.   
   
   
       23 . The method of installing the metal roofing shingle system in  claim 22 , further comprising: positioning the first shingle in each first through last course of shingles at a location that extends the first transverse edge segment outboard of a gable end of the roof; and trimming the second transverse edge segment of the last shingle in each course of shingles so that the trimmed second transverse edge segment of each said last shingle extends outboard of a second gable end at an equal distance to said first transverse edge segment. 
   
   
       24 . The method of installing the metal roofing shingle system in  claim 23 , further comprising: forming a shaped edge that extends beneath the bottom surface of said extended first transverse edge segment, and forming a shaped edge that extends beneath the bottom surface of said extended trimmed second transverse edge segment. 
   
   
       25 . The method of installing the metal roofing shingle system in  claim 24  whereby, each said shaped edge is curvilinear. 
   
   
       26 . The method of installing the metal roofing shingle system in  claim 22 , further comprising: trimming each second longitudinal edge segment of each shingle installed in the last course of shingles so that each trimmed second longitudinal edge segment extends outboard of an eve edge of the roof. 
   
   
       27 . The method of installing the metal roofing shingle system in  claim 26 , further comprising: forming a shaped edge that extends beneath the bottom surface of each trimmed second longitudinal edge segment extending outboard of the eve edge. 
   
   
       28 . The method of installing the metal roofing shingle system in  claim 27  whereby, each shaped edge extending outboard of the eve edge is curvilinear. 
   
   
       29 . The method of installing the metal roofing shingle system in  claim 22 , further comprising:
 a) inverting and attaching said universal flashing as valley flashing by driving fasteners through said nailing hems provided along the first leg and along the second leg of said universal flashing and into two different sloped roof sections;   b) trimming each second longitudinal edge of each metal shingle that intersects the valley flashing, said second longitudinal edge trimmed at an angle that corresponds with said slope between the two different roof sections;   c) forming a hook along each trimmed edge; and   d) interlocking said hook edge of each trimmed shingle with one of the integral double-flanged interlock joints exposed along the inverted universal flashing.   
   
   
       30 . The method of installing the metal roofing shingle system in  claim 22 , further comprising:
 a) attaching said universal flashing as hip flashing by driving fasteners through said nailing hems provided along the first leg and along the second leg of said universal flashing and into two different sloped roof sections;   b) trimming the first longitudinal edge of each first shingle in a course of shingles at an angle that corresponds with said slope between the two different roof sections; and   c) trimming the second longitudinal edge of each last shingle in a course of shingles at an angle that corresponds with said slope between the two different roof sections.