Roof panel system and hanger method for installation

Abstract

The invention is a roof system having panels attached by battens and adjustable hangers. The hangers have a leg, a tail and a hook. The hanger is supported by a batten strip material, typically made of metal with slots. These hangers are permanently secured within the battens and are non removable once the batten is fastened to a roof deck. The hangers themselves are adjustable to different lengths by sliding them within the slot with a predetermined amount of force to accommodate staggered panel edges. This dramatically reduces the labor and costs required to install roofing panels.

Claims

1. A system for roofing or siding comprising: a) a multiplicity of panels; b) a multiplicity of hangers, each comprising at least one hanger hook on a first end and further comprising a second end that has been curved back around to be substantially parallel to the first end forming a curved section between the first and second ends and a parallel section between the curved section and the first and second ends; c) at least one batten containing a multiplicity of hanger slots; wherein said hanger slots are each comprising at least two substantially adjacent openings formed in the batten, leaving a center strip of the batten positioned between the openings; further wherein said openings are capable of receiving said hangers such that the hanger slides through the openings leaving a portion of the parallel section of the hanger behind the center strip of the batten, thereby causing the center strip of the batten to at least partially curve outward, and leaving the curved section of the hanger above said openings and the at least one hanger hook below the said openings; further wherein said hangers translate along the length of the parallel section of the hanger within said hanger slots allowing the hanger hook position to be adjustably extended or shortened in distance relative to the batten in two or more positions without needing to replace said hangers to accommodate a panel of different or varying length; further wherein the at least one batten is fastened to a target surface at a first location using at least one batten fastener to form at least a first batten row; and wherein the lowest edge of the said panels in said first batten row is set in said hanger hooks of said first batten row.

2. The system of claim 1, wherein an edge of said panels comprises at least two substantially parallel but not collinear sections, thereby creating the visual illusion of multiple smaller panels which are physically staggered.

3. The system of claim 2, wherein any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate said panel edge.

4. The system of claim 1, wherein any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate changing a length of the exposed portion of said panels.

5. The system of claim 1, further comprising a locking slot dimple, wherein said locking slot dimple is comprised of a depression formed into the center strip of the batten such that the parallel section of the hanger is at least partially engaged to retain said hangers within said hanger slots.

6. The system of claim 1, further comprising at least one hole in the center strip of the batten capable of receiving at least one of said at least one batten fasteners, wherein the at least one batten fastener will urge the center strip of the batten against the parallel section of the hanger for retaining said hangers within the hanger slots of said batten and giving the hanger mechanical support.

7. The system of claim 1, wherein said panels further comprise a surface texture to simulate the functional properties of multiple natural wood shingles, slates, or tiles or joint lines.

8. The system of claim 1, wherein said hangers are all of one common size.

9. The system of claim 1, wherein said panels further comprise a textured or grooved edge so as to mechanically interface with said hangers.

10. The system of claim 1, wherein said hangers are partially or fully coated with a friction enhancing coating, wherein the friction enhancing coating is selected from the group consisting of rubberized urethane coating or powder coating.

11. The system of claim 1, wherein said hangers are non-removable from said hanger slots and wherein any of said hangers are extended at different distances relative to the batten from said hanger slots to accommodate a staggered panel edge within a row of panels.

12. The system of claim 1, wherein: a) an edge of said panels comprises at least two substantially parallel but not collinear sections, thereby creating the visual illusion of multiple smaller panels which are physically staggered, b) any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate said panel edge, and c) said panels have a surface texture to simulate the functional properties of multiple natural wood shingles, slates, or tiles or joint lines.

13. The system of claim 1, wherein: a) an edge of said panels comprises at least two substantially parallel but not collinear sections, thereby creating the visual illusion of multiple smaller panels which are physically staggered, b) any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate said panel edge, and c) said system further comprising a locking slot dimple, wherein said locking slot dimple is comprised of a depression formed into the center strip of the batten such that the parallel section of the hanger is at least partially engaged to retain said hangers within said hanger slots.

14. The system of claim 1, wherein: a) an edge of said panels comprises at least two substantially parallel but not collinear sections, thereby creating the visual illusion of multiple smaller panels which are physically staggered, b) any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate said panel edge, c) said panels have a surface texture to simulate the functional properties of multiple natural wood shingles, slates, or tiles or joint lines, d) said system further comprising a locking slot dimple, wherein said locking slot dimple is comprised of a depression formed into the center strip of the batten such that the parallel section of the hanger is at least partially engaged to retain said hangers within said hanger slots, and e) said batten further comprises at least one hole in the center strip of the batten capable of receiving at least one of said at least one batten fasteners, wherein the at least one batten fastener will urge the center strip of the batten against the parallel section of the hanger for retaining said hangers within the hanger slots of said batten and giving the hanger mechanical support.

15. The system of claim 1, wherein: a) an edge of said panels comprises at least two substantially parallel but not collinear sections, thereby creating the visual illusion of multiple smaller panels which are physically staggered, b) any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate said panel edge, c) said panels have a surface texture to simulate the functional properties of multiple natural wood shingles, slates, or tiles or joint lines, d) said system further comprising a locking slot dimple, wherein said locking slot dimple is comprised of a depression formed into the center strip of the batten such that the parallel section of the hanger is at least partially engaged to retain said hangers within said hanger slots, and e) said batten further comprises at least one hole in the center strip of the batten capable of receiving at least one of said at least one batten fasteners, wherein the at least one batten fastener will urge the center strip of the batten against the parallel section of the hanger for retaining said hangers within the hanger slots of said batten and giving the hanger mechanical support, and f) said hangers are all of one common size.

16. The system of claim 1, wherein: a) an edge of said panels comprises at least two substantially parallel but not collinear sections, thereby creating the visual illusion of multiple smaller panels which are physically staggered, b) any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate said panel edge, c) said panels have a surface texture to simulate the functional properties of multiple natural wood shingles, slates, or tiles or joint lines, d) said system further comprising a locking slot dimple, wherein said locking slot dimple is comprised of a depression formed into the center strip of the batten such that the parallel section of the hanger is at least partially engaged to retain said hangers within said hanger slots, and e) said batten further comprises at least one hole in the center strip of the batten capable of receiving at least one of said at least one batten fasteners, wherein the at least one batten fastener will urge the center strip of the batten against the parallel section of the hanger for retaining said hangers within the hanger slots of said batten and giving the hanger mechanical support, f) said hangers are all of one common size, g) said panels further comprise a textured and/or grooved edge so as to mechanically interface with said hangers, and h) said hangers are non-removable from said hanger slots.

17. The system of claim 1, wherein said panels are constructed from a material comprising molded clay or porcelain.

18. The system of claim 1, wherein said at least one batten is constructed from a material comprising stainless steel and other metals possessing the characteristics of strength and durability.

19. The system of claim 1, further comprising an underlayment positioned beneath the batten, wherein the underlayment is constructed from a material comprising felt paper, rubberized materials, UV stabilized high density polyethylene and other synthetic materials.

20. The system of claim 1, wherein: a) an edge of said panels comprises at least two substantially parallel but not collinear sections, thereby creating the visual illusion of multiple smaller panels which are physically staggered, b) any of said hangers are extended at different distances relative to the batten within said hanger slots to accommodate said panel edge, c) said panels have a surface texture to simulate the functional properties of multiple natural wood shingles, slates, or tiles or joint lines, d) said system further comprising a locking slot dimple, wherein said locking slot dimple is comprised of a depression formed into the center strip of the batten such that the parallel section of the hanger is at least partially engaged to retain said hangers within said hanger slots, and e) said batten further comprises at least one hole in the center strip of the batten capable of receiving at least one of said at least one batten fasteners, wherein the at least one batten fastener will urge the center strip of the batten against the parallel section of the hanger for retaining said hangers within the hanger slots of said batten and giving the hanger mechanical support, f) said hangers are all of one common size, g) said panels further comprise a textured and/or grooved edge so as to mechanically interface with said hangers, h) said hangers are non-removable from said hanger slots, and i) said system further comprising an underlayment positioned beneath the batten.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top view of the invention showing a batten 2 with a hanger 10 installed.

(2) FIG. 1a is a left side view of the invention shown in FIG. 1 showing the hanger hook 14 and hanger leg 12. The two edge stiffeners 4 of the batten 2 are also shown holding the hanger in place by tension along with the batten hanger slot 8.

(3) FIG. 1b is a lower side view of the invention shown in FIG. 1. This view shows an edge stiffener 4 along with the locking slot dimple 22. The hanger hook 14 and hanger leg 12 are also shown.

(4) FIG. 2 is a top view of the invention showing the hanger normal position 24 (in dotted lines) and the hanger extended position 26. This view illustrates how the hanger can be slid downwards to change positions.

(5) FIG. 2a is a left side view of the hanger normal position 24 (in dotted lines) and the hanger extended position 26. This view illustrates how the hanger can be slid downwards to change positions.

(6) FIG. 2b is a perspective view showing a hanger 10 installed within a batten hanger slot 8. The locking slot dimple 22 can be seen in this figure. This slot dimple helps keep the hanger from sliding too far downwards.

(7) FIG. 3 is a top view of the invention from FIG. 1 fastened to a typical roof deck system. The hole 18 is shown (in dotted lines) after having a roofing fastener 28 placed through it to secure it. The roofing fastener 28 pierces through a layer of underlayment 30 and into the wooden roof deck 32.

(8) FIG. 3a shows a left side view of the scene from FIG. 3. A roofing fastener 28 in shown anchored to the wooden roof deck 32.

(9) FIG. 3b shows a lower side view of the scene from FIG. 3. A roofing fastener 28 is shown anchored to the wooden roof deck 32.

(10) FIG. 4 shows a top view of a strip of the stainless steel batten 2. Multiple hangers are shown in the hanger normal position 24. This configuration is how an installer might first receive the invention from the factory.

(11) FIG. 4a shows a top view of a strip of the stainless steel batten 2. Multiple roofing fasteners 28 are shown piercing through the batten 2. Multiple hangers are shown still in the hanger normal position 24.

(12) FIG. 4b shows a top view of the same scene from FIG. 4a with a staggered roof panel in the process of installation. Hangers that will support the protruding (Long edge) portions of the staggered roof panel are shown in the hanger extended position 26 to accommodate and support the panel going in. Other hangers are shown in the hanger normal position 24 to accommodate and support other (Short edge) areas of the panel.

(13) FIG. 5 is a top view of a staggered roof panel 34. The staggered roof panel long edge 36 along with instances of the staggered roof panel short edge 38.

(14) FIG. 6 shows a perspective view of a portion of a staggered roof panel 34. The roof panel is shown with a grooved or rough edge 40 which mechanically interfaces with a hanger hook 14. This helps prevent sliding and also helps to hide the hanger hook 14.

(15) FIG. 6a shows a top view of a portion of the scene from FIG. 6. The hanger hook 14 can be seen.

(16) FIG. 6b shows the lower side of a portion of the scene from FIG. 6. The hanger hook 14 can be seen.

(17) FIG. 7 shows a top view of the invention being installed on a roof. Multiple examples of the staggered roof panel 34 are shown. The hangers are moved to the appropriate position to accommodate the staggered edges, either the hanger normal position 24 or the hanger extended position 26. The hangers themselves are supported by multiple instances of the batten 2. Waterproof interlayment material 46 is shown installed underneath the staggered roof panels. Waterproof underlayment material 30 is shown installed underneath the battens 2. Everything is affixed to the wooden roof deck 32.

SUMMARY OF PARTS LABELED IN DRAWINGS

(18) 2 Stainless Steel Batten 4 Edge Stiffener 6 Hanger Radius 8 Batten Hanger Slot 10 Hanger 12 Hanger Leg 14 Hanger Hook 16 Hanger Tail 18 Hole 20 Short Leg 22 Locking Slot Dimple 24 Hanger Normal Position 26 Hanger Extended Position 28 Roofing Fastener 30 Underlayment 32 Wooden Roof Deck 34 Staggered Roof Panel 36 Staggered Roof Panel Long Edge 38 Staggered Roof Panel Short Edge 40 Rough Edge 46 Interlayment