WO2021183969A1 - Integrated ventilation and flashing in integrated roof system with engineered wood - Google Patents

Abstract

A multi-layered integrated roofing plank or panel with a base layer comprising engineered or manufactured wood, a water resistant barrier layer covering at least the outer face of the base layer, and at least one of the edges of the base layer. A texturizing material also may be affixed to, or integrated with, the water resistant barrier layer. The edges of the roofing plank or panel may be configured as part of a joint with adjacent planks or panels, including, but not limited to, shiplap joints, tongue-and-groove joints, bead-and-cove joints, butt joints, or combinations or variations thereof.

Description

INTEGRATED VENTILATION AND FLASHING IN INTEGRATED ROOF SYSTEM

WITH ENGINEERED WOOD

This application claims benefit of U.S. Provisional App. No. 62/988,849, filed March 12, 2020, and U.S. Provisional App. No. 63/001,563, filed March 30, 2020, both of which are incorporated herein in their entireties by specific reference for all purposes.

FIELD OF INVENTION

This invention relates to a multi-layered engineered roofing structural panel (which can be wood-based, such as, but not limited to, oriented-strand board (OSB), plywood, or other lignocellulosic -based panel) with integrated ventilation.

BACKGROUND OF THE INVENTION

Current roof assemblies are typically multiple layers of several materials, each performing a single function, that are installed separately on the site in which the building is being constructed. In many roofing systems, there is a deck, an underlayment barrier on top of the deck, covered by a surface layer of shingles (e.g., asphalt, ceramic, metal, and the like). Compatibility between the various layers creates challenges not only for the designer, but also for the installers. In addition, a varied and large amount of materials are required during the installation, as well as during maintenance (e.g., re-roofing).

A central layer in most such assembles in a wood panel product, or an integral composite engineered panel product, including, but not limited to, engineered wood composite products formed of lignocellulosic strands or wafers (sometimes referred to as oriented-strand board, or OSB). Products such as fiberboard and particleboard have been found to be acceptable alternatives in most cases to natural wood paneling, sheathing and decking lumber. Fiberboard and particleboard are produced from wood particles bonded together by an adhesive, the adhesive being selected according to the intended use of and the properties desired for the lumber. Often times, the adhesive is combined with other additives to impart additional properties to the lumber. Additives can include, but are not limited to, fire retardants, insect repellants, moisture resistant substances, fungicides and fungal resistant substances, and color dyes. A significant advantage of fiberboard and particleboard lumber products is that they have many of the properties of plywood, but can be made from lower grade wood species and waste from other wood product production, and can be formed into lumber in lengths and widths independent of size of the harvested timber.

A major reason for increased presence in the marketplace of the above-described product alternatives to natural solid wood lumber is that these materials exhibit properties like those of the equivalent natural solid wood lumber, especially, the properties of retaining strength, durability, stability and finish under exposure to expected environmental and use conditions. A class of alternative products are multilayer oriented wood strand particleboards, particularly those with a layer-to-layer oriented strand pattern, such as OSB. Oriented, multilayer wood strand boards are composed of several layers of thin wood strands, which are wood particles having a length which is several times greater than their width. These strands are formed by slicing larger wood pieces so that the fiber elements in the strands are substantially parallel to the strand length. The strands in each layer are positioned relative to each other with their length in substantial parallel orientation and extending in a direction approaching a line which is parallel to one edge of the layer. The layers are positioned relative to each other with the oriented strands of adjacent layers perpendicular, forming a layer-to-layer cross-oriented strand pattern. Oriented, multilayer wood strand boards of the above-described type, and examples of processes for pressing and production thereof, are described in detail in US. Pat. No. 3,164,511, US. Pat. No. 4,364,984, US. Pat. No. 5,435,976, US. Pat. No. 5,470,631, US. Pat. No. 5,525,394, US. Pat. No. 5,718,786, and US Pat. No. 6,461,743, all of which are incorporated herein in their entireties by specific reference for all purposes.

Roof ventilation is an important part of the building process and service life of a house. A roof without good airflow can result in mold and other wood decay organisms growing under it, due to the increased temperature and moisture content of the environment in the area under the roof, which generates optimal growth conditions for the aforementioned organisms. In contrast, however, a roof with excessive ventilation can cause energy loss by not providing effective temperature regulation (i.e., by letting too much cold and/or hot air escape from the house), thus requiring HVAC and/or AC systems to operate more frequently and increase their energy consumption.

Present methods to ventilate the roof include leaving a gap between the roof sheathing and the edge of the ridge. This gap is then covered with a felt fabric and a ridge cap (some products have the felt integrated with the ridge cap). The ridge cap might have channels to promote air movement. Another method comprises the installers cutting rectangle shaped sections (i.e., exhaust vents) at the ridge of the roof, then covering them with felt and a ridge cap. This latter method relies on the accuracy and experience of the roofer, as the size of the cut off will affect the roof ventilation.

SUMMARY OF INVENTION

In various exemplary embodiments, the present invention comprises a multi-layer panel for use as integrated structural sheathing on a roof. In one embodiment, the multi-layer panel comprises a wood structural core or panel, such as OSB or plywood. The panel may be coated or treated, during or after the manufacturing process, with a product that provides various properties, such as, but not limited to, weather resistance, fungus resistance, insect resistance, and/or fire resistance. The treatment may be integrated with the material forming the wood structural panel, or may be a coating on one or both surfaces. A weather or water resistive barrier (WRB), or the paper base for a WRB, of some kind is applied to the upper or outward facing surface of the panel, effectively serving as an underlayment. The outer surface of the WRB or paper base is then coated with a polymer, adhesive, and/or asphalt. In turn, it is coated with a granular or solid material (such as, but not limited to, ceramic coated granules, clay, rock, glass, slate, rubber or combinations thereof). In one embodiment, the polymer on the paper overlay base serves as the WRB as well as adhesive for the granular material.

In several embodiments, the overlap and underlap of adjacent integrated roofing panels are matched to form an overlapping or shiplap joint, with integrated flashing extending from the overlap end (and over the shiplap joint between the upper and lower adjacent panels when placed on the roofing structure). Flashing is one of the main steps for roofing, where a thin material, such as galvanized steel, is used to protect the sheathing and the outer trusses of the house structure by directing water away from those areas. This step presents a challenge when dealing with an integrated roof panel or plank, as in prior art applications the flashing typically is placed under the water resistance barrier and the asphalt shingles. This invention overcomes that problem by merging the flashing into the integrated roofing panels, thereby reducing installation time.

In several embodiments, the flashing comprises a polymer (which may be rigid, semi rigid, and/or flexible) extending outward on one, two, or more sides of the integrated roofing panel. A piece of flashing may have a constant rigidity or flexibility throughout, or the rigidity or flexibility may be variable. In some embodiments, the flashing may have the same or similar color and/or texture as the upper or outward facing surface of the roofing panel, although in some embodiment a different or contrasting color and/or texture may be used.

The present invention applies the flashing, WRB and/or texturizing aggregate to the panel at the manufacturing facility, prior to shipping or installation at a job site (and thereby avoiding the problems noted above). In one embodiment, a fluid or liquid applied membrane is applied via one or more spray nozzles in a manufactured line process. The spray nozzle or nozzles are in fluid communication with one or more storage tanks, and the liquid may be stored without the use of agitators. As the panel travels down a secondary production line, the WRB coating is sprayed on the top face, and in some embodiments, also the edges, of the panel at a minimum thickness of 5-10 mils. If the coating is not sprayed on the edges, the edges are sealed by other means. The asphalt/adhesive and surface layer may be applied in a similar manner, or as part of the WRB application. In other embodiments, the WRB may be a solid layer (e.g., paper overlay) that is applied during the panel manufacturing process.

In several additional embodiments, end pieces of the present system (i.e., the integrated panels that are installed at or adjacent to the roof of the ridge) comprise vents or other ventilation means installed or integrated with the panel at the factory (i.e., during the manufacturing process). The vents are formed by rectangular sections of longitudinal cuts made along the panel or plank. The cuts may be similar to a vented soffit, but the surface of the cut area is coated with a water- resistant finish. The vents may be located along the upper part of the plank (i.e., proximate the ridge of the roof), which permits coverage by felt fabric and ridge cap.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a sectional view of a roofing panel or plank in accordance with an embodiment of the present invention.

Figure 2 shows a sectional view of an alternative embodiment of a roofing panel or plank in accordance with another embodiment of the present invention.

Figure 3 shows a sectional view of an alternative embodiment of a roofing panel or plank in accordance with another embodiment of the present invention.

Figure 4 shows a sectional view of an alternative embodiment of a roofing panel or plank with overlap and underlap joint sections in accordance with another embodiment of the present invention.

Figure 5 shows an alternative embodiment of the roofing panel or plank of Figure 4.

Figure 6 shows a section view of a “starter” roofing panel or plank.

Figure 7 shows a section view of a “crown” roofing panel or plank

Figure 8 shows a sectional view of an alternative embodiment of a roofing panel or plank with overlap and underlap joint sections with pre-applied double-sided tape or adhesive in accordance with another embodiment of the present invention.

Figure 9 shows a section view and detail of a completed shiplap joint formed with pre applied double-sided tape between vertically adjacent roofing panels or planks.

Figure 10 shows a sectional view of an alternative embodiment of a roofing panel or plank with paper overlay in accordance with another embodiment of the present invention.

Figure 11 shows a top view of a roofing plank or panel with drainage channels.

Figure 12 shows a side section view of a roofing plank or panel with drainage channels.

Figures 13-16 show views of integrated flashing with a roofing panel. Figure 17 shows a perspective view of an integrated roofing panel with factory-installed ventilation.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In various exemplary embodiments, as seen in Figures 1-2, the present invention comprises an improvement to a multi-layer panel or plank 2 for use as integrated structural sheathing on a roof. In the embodiment shown, the multi-layer integrated roofing product comprises a wood structural panel or plank 10. The wood may be natural or manufactured, engineered wood, such as oriented strand board (OSB) or plywood. The panel may be coated or treated, during or after the manufacturing process, with a product that provides various properties, such as, but not limited to, weather resistance, fungus resistance, insect resistance, and/or fire resistance. The treatment may be integrated with the material forming the wood structural panel, or may be a coating on one or both surfaces. An example of an integrated roofing panel is disclosed in U.S. Pat. App. No. 17/068,712, filed Oct. 12, 2020 by Louisiana-Pacific Corp, which is incorporated herein in its entirety by specific reference for all purposes.

In the embodiment shown, a weather or water resistive barrier (WRB) 20 of some kind is applied to the upper or outward facing surface of the panel 10, effectively serving as an underlayment. The WRB may be a form of paper overlay, a form of spray-applied or fluid- applied polymer or material (such as silicone), or other form of WRB. In some embodiments, the WRB may include a granular or solid material 40 as a texturizing aggregate or material (such as, but not limited to, ceramic coated granules, clay, rock, glass, slate, styrene, particles of polymeric plastic, or combinations thereof) as a component or part of the WRB itself (e.g., texturizing aggregate or material may be mixed with a liquid polymer WRB). Alternatively, the granular or solid material 40 may be subsequently applied directly to the WRB after the WRB is applied to the plank/panel. In yet a further embodiment, the outer surface of the WRB may be coated with a polymer, adhesive and/or asphalt 30, which is turn is coated with the granular or solid material 40. In some embodiments, the adhesive and/or asphalt may include the granular or solid material as a component or part (e.g., texturizing aggregate or material may be mixed with the adhesive and/or asphalt). In alternative embodiments, an outer polymeric layer also may act as an aesthetics or appearance layer, in which case addition granular or solid material may or may not be present.

The invention thus effectively combines a structural sheathing panel, WRB layer or polymer, and texturizing aggregates or materials, if present (e.g., surface layer, shingles, metals, or other roof surface materials), as separately applied in the prior art, into one multi-layer panel product, which is less reliant on skilled labor for installation at a job site and reduces installation time by eliminating the separate sequential application of a WRB system and a surface layer in the installation process. As discussed above, in some embodiments, the WRB may be a separate layer, or it may be integrated with the texturizing aggregate/surface layer.

In several embodiments, the texturizing aggregate or top surface layer may be one or more flexible rolls of material, which may be applied by unrolling the material across the panel during manufacture (or, in some embodiments, at the job site). The roll may have a self-adhesive layer on one side. In one embodiment, the surface layer rolls may comprise one or more rolls of one-sided or two-sided construction tape (i.e., with strong, permanent adhesive on one or two sides). One side of the tape adheres to the panel, while the other side contains the surface material. The tape may be applied to the panel at the factory, or otherwise prior to installation at the job site.

Figures 3-4 show an example of a standard integrated roofing panel or plank 100 with a WRB polymer layer as described above 100, with an “uphill” underlap 110 and a “downhill” overlap 120, wherein the overlap and underlap of vertically adjacent integrated roofing panels are matched to form an overlapping or shiplap joint. (Uphill and downhill are described with respect to an angled roof, with uphill being the direction towards the peak or crown of the roof, and downhill being the direction away from the peak or crown of the roof, so that water runs “downhill” and off the roof.) The standard integrated roofing panel or plank is used for the main courses (rows) of roofing planks/panels applied to a roof, with shiplap joints formed between vertically adjacent planks/panels in the courses. The right and left ends of planks/panels may be aligned with the corresponding ends of planks/panels in the vertically adjacent courses, or may be staggered or alternating. Other forms of joints may be used, such as, but not limited to, tongue- and-groove joints, bead-and-cove joints, butt joints, or combinations or variations thereof.

Some or all of the respective faces of the shiplap joint may be covered with the WRB polymer layer 22. Figures 4-8 shows various embodiment of a roofing plank/panel with the WRB polymer protective layer 22 (typically without texturizing granules, as contrasted to the WRB polymer protective layer with texturizing granules or other materials 24 on the outer face) extending around and over the edges, and some or all of parts of the corresponding shiplap joint sections, thereby providing greater protection to the manufactured wood (e.g., OSB) core layer 10. In some embodiments, the WRB polymer protective layer on the edges and/or shiplap joint sections may include texturizing granules or other materials.

An integrated sealant or adhesive material, such as the WRB polymer 22 or other form of sealant or adhesive, is applied to one face (or both faces) of corresponding overlap and/or underlap sections. Where the WRB polymer is used as a sealant, the two surfaces coated with the polymer are placed in contact with each other. Nails or similar fasteners used to affix the planks/panels to the roofing structure may be used in the joint area to keep the surfaces in contact (and apply a level of pressure thereto) to cause the polymer-covered surfaces to self-seal.

In an additional embodiment, as seen in Fig. 9, the sealant comprises industrial double sided tape 28, and extends across the width of the plank/panel (i.e., the full length of the lap section). The tape 28 is pre-applied in the factory or manufacturing facility, with the opposite side remaining covered with a liner. During installation, the installer removes the liner to form the joint between adjacent planks/panels. The double-sided tape also may be used for butt joints (or square end joints) between planks/panels.

“Starter” roofing pieces 110 are shown in Figure 6. These pieces are located along the bottom edge of the roofing, and comprise a square, butt or plain end on the “downhill” or bottom edge, while retaining the underlap 62 on the “uphill” edge to form a shiplap joint with the next adjacent course. In a similar fashion, top or crown pieces 120 are shown in Figure 8. These pieces are located along the top edge of the roofing along the crown of the roof (which may then be covered by a roof ridge cap 150 as known in the prior art). These pieces comprise a square, butt or plain end on the “uphill” or top edge, while retaining the overlap 64 on the “downhill” edge to form a shiplap joint with the next adjacent course.

During installation, a course or row of “starter” roofing pieces 110 is affixed along the bottom edge of the roofing, with the underlap section on the top edge. A course of standard roofing pieces 100 is then applied, with the overlap section on the bottom edge overlaying the underlap section of the lower course to form a shiplap joint that is airtight and watertight. A number of standard roofing piece courses are then added in sequence up the roof to near the top, with the number determined by the size (height) of the roof. A course or row of “crown” roofing pieces 120 is then added as the final topmost course, with the overlap section on the bottom edge overlaying the underlap section of the lower course, as described above.

The right and/or left ends of the plank/panel may be sealed with the WRB or a sealant. As discussed above, one form of sealant may be double-sided tape 28. Alternatively, an “end cap” may be applied to cover the ends.

Figure 10 shows an alternative embodiment of a roofing panel with the protective layer with asphalt granules (i.e., polymer and granules) extending around and over the edges, thereby providing greater protection to the manufactured wood (e.g., OSB) core layer. An integrated sealant or adhesive material is applied to one face (or both faces) of corresponding overlap (and/or underlap) sections. In one embodiment, the sealant comprises industrial double-sided tape, and extends across the width of the panel (i.e., the full length of the lap section). The tape is pre-applied in the factory or manufacturing facility, with the opposite side remaining covered with a liner. During installation, the installer removes the liner to form the joint between adjacent panels. The double-sided tape also may be used for butt joins between panels.

In several embodiments, as seen in Figures 11-12, one or more water evacuation channels or grooves 180 may extend from the shiplap lip proximate the upper edge of each plank/panel at least partway down the outer face. The interior of each channel is coated in a similar manner to the outer face. This allows water that may collect in the horizontal grooves formed by a horizontal shiplap installation to flow down and out of the horizontal grooves onto the outer face (i.e., onto the rooftop). In several embodiments, each channel has a variable depth, with the greatest depth at the shiplap lip (and equal to or approximately equal to the depth (i.e., height) of the lip, with the bottom of the channel then rising to the level of the outer face. The bottom may rise smoothly and gradually, to help promote the flow the water down the channel and out onto the face. The width of the channel should be sufficient to allow water flow down and out, and avoid a capillary effect, but not be so large as to substantially affect the structural integrity of the plank/panel.

The present invention applies the WRB and texturizing aggregate (either integrated or as separate layers) to the plank/panel at a manufacturing facility, prior to shipping or installation at a job site (and thereby avoiding the problems noted above with regard to prior art installations). In one embodiment, a fluid or liquid applied membrane is applied via one or more spray nozzles in a manufactured line process. The spray nozzle or nozzles are in fluid communication with one or more storage tanks, and the membrane liquid may be stored without the use of agitators. Nozzles apply the membrane coating at a constant pressure until reaching the desired wet film thickness. As the plank/panel travels down a secondary production line (typically on a form of conveyor belt), the WRB coating is sprayed on the top face, and in some embodiments, also the edges, of the plank/panel at a minimum thickness of 5-10 mils. If the coating is not sprayed on the edges, the edges are sealed by other means. The asphalt/adhesive and/or surface layers, if separate from each other and from the WRB layer, may be applied in a similar manner. In other embodiments, the WRB may be a solid layer (e.g., paper overlay), as seen in Figure 6, that is applied during the panel manufacturing process.

In some embodiments, the present invention is produced through a curtain coating method. A storage tank containing the membrane liquid is positioned above the secondary production line. The tank has a longitudinal aperture that allows the membrane liquid to flow from the tank onto the plank/panel as it passes beneath the tank. The width of the aperture is adjusted so the amount of liquid flowing onto the plank/panel is the correct amount to achieve the desired wet fdm thickness of the coating. In other embodiments, In some embodiments, the present invention is produced through a roll coating method. Two or more rolls (e.g., a doctor roll and a coating roller) are positioned above the secondary production line. The membrane liquid (e.g., the polymer coating) is located between the rolls, and passes between the rolls and is applied to the surface of the plank/panel traveling on the line by the coating roller. The position of the doctor roll relative to the coating roller is adjusted to let pass the correct amount of liquid pass to achieve the desired wet fdm thickness of the coating.

In several embodiments, the texturizing surface and/or shingle layer may be one or more flexible rolls of material, and applied by unrolling the material across the plank/panel. The roll may have a self-adhesive layer on one side. In one embodiment, the shingle layer rolls may comprise one or more rolls of one-sided or two-sided construction tape (i.e., with strong, permanent adhesive on one or two sides). One side of the tape adheres to the panel, while the other side contains the shingle material. The tape may be applied to the panel at the factory, or otherwise prior to installation at the job site.

Figure 13 shows an example of an integrated roofing panel or plank (with WRB and shingle or granulated layers as described above) 300, with an “uphill” underlap and a “downhill” overlap, wherein the overlap and underlap of adjacent integrated roofing panels are matched to form an overlapping or shiplap joint, with integrated flashing 310 extending from the overlap end (and over the shiplap joint between the upper and lower adjacent panels when placed on the roofing structure). Flashing is one of the main steps for roofing, where a thin material, such as galvanized steel, is used to protect the sheathing and the outer trusses of the house structure by directing water away from those areas. This step presents a challenge when dealing with an integrated roof panel or plank, as in prior art applications the flashing typically is placed under the water resistance barrier and the asphalt shingles. This invention overcomes that problem by merging the flashing 310 into the integrated roofing panels, thereby reducing installation time.

In the embodiments seen in Figures 13-15, the flashing 310, 312 comprises a polymer (which may be rigid, semi-rigid, and/or flexible) extending outward on one, two, or more sides of the integrated roofing panel. A piece of flashing may have a constant rigidity or flexibility throughout, or the rigidity or flexibility may be variable. In some embodiments, the flashing may have the same or similar color and/or texture as the upper or outward facing surface of the roofing panel, although in some embodiment a different or contrasting color and/or texture may be used. Figure 13 shows a cross-section side view of a standard roofing panel, with flashing 310 extending “downhill” from the overlap edge to cover and protect the shiplap joint between adjacent panels. Figure 14 shows a cross-section bottom view, with flashing 312 extending from the right edge of the standard roofing panel to cover the straight joint between adjacent panel edges on their respective right and left sides. Figure 15 shows a top view of the panel of Figures 13 and 14 (with flashing extending from two sides or edges, the bottom and the right).

“Starter” pieces with flashing 314, 316 are shown in Figure 16. These pieces are located along the bottom edge of the roofing, and comprise a square, plain, or angled end on the “downhill” or bottom edge, while retaining the underlap on the “uphill” edge to form a shiplap joint with the next adjacent course. The flashing on the bottom edge can extend straight 314 (as with the overlap on the standard panel as described above) in a plane parallel to the outer face of the panel, or may be in a “folded” 86 or bent configuration so as to attach around a roofing beam or stud, thereby sealing off and protecting the bottom of the roof. The flashing may be folded at one or more points. Similarly, extended or folding flashing can be added to the upper edges of pieces along the crown of the roof. In additional embodiments, the flashing may comprise a flexible polymer that can be molded during installation to the structure that will be flashed.

In a further embodiment, a radiant barrier layer 50 may be applied to the underside of the panel. Radiant barrier sheathing, typically used for roof and attic sheathing, has become a de facto standard in high solar radiation environments. Radiant barriers are installed in homes and structures, usually in attics, primarily to reduce summer heat gain and reduce cooling costs. The barriers consist of a highly reflective material that reflects radiant heat rather than absorbing it. Radiant heat travels in a straight line away from any surface and heats anything solid that absorbs its energy. Most common insulation materials address conductive and convective heat flow, not radiant heat flow. In contrast, a radiant barrier reduces the radiant heat transfer from the underside of the heated roofing materials to other surfaces in the attic, thereby reducing the cooling load of the house.

A layer of aluminum (typically aluminum foil) is commonly used as the reflective material, as it is efficient at not transmitting radiant energy into the attic environment. The aluminum foil used in radiant barriers must be very pure to achieve a low emittance surface. The thickness of the aluminum does not affect performance; the aluminum only needs to cover the surface of the sheathing material. Typically, very thin foils(approximately 0.00025 inches thick) are used. As this foil is too thin (and thus too fragile) to be applied to wood structural panels directly, it may be attached and bonded to another substrate, most often Kraft paper, for support. The combined overlay is then laminated to one side of a wood structural panel face to make the radiant barrier sheathing. As an alternative to foil, a very thin layer of aluminum (or similar metal) can be deposited via vapor deposition manufacturing processes onto a polyethylene sheet (PET) to form a metallized PET sheet. Like foil, the metallized PET sheet can be laminated to Kraft paper, and the combined overlay is laminated to one side of a wood structural panel face to make the radiant barrier sheathing.

In several additional embodiments, end pieces 400 of the present system (i.e., the integrated panels that are installed at or adjacent to the roof of the ridge) comprise vents 410 or other ventilation means installed or integrated with the panel at the factory (i.e., during the manufacturing process). In the embodiment shown, the vents are formed by rectangular sections of longitudinal cuts made along the panel or plank. The cuts may be similar to a vented soffit, but the surface of the cut area is coated with a water-resistant finish. The vents may be located along the upper part of the plank (i.e., proximate the ridge of the roof), which permits coverage by felt fabric and ridge cap.

Installation of the end piece may be done to match the edge of the ridge. The integrated ventilation system saves time and labor, as it allows installers to simply place the end piece by the ridge without leaving gaps (which would need to be measured) or being sawn. The factory- installed vents also create a more controlled and energy efficient roof ventilation system.

The present invention possesses several advantages over the prior art. It provides a superior barrier system that does not allow air movement between the panel face and the applied WRB, and allows a savings in time and labor. Further, coating the panels in a controlled setting (e.g., manufacturing facility), allows the thickness of the coatings to be consistently applied, and allows the coating the opportunity to fully bond with the panel or adjacent layer. More specifically, the coatings can fully cure independent of weather conditions, and be applied without interference from construction-related dirt, debris or humidity. Further, the mineral granules or other texture-providing material may be included to increase the aesthetic appeal of the product, as well as to serve as a cooling agent in some cases, thereby enhancing energy efficiency.

Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art.

Claims

CLAIMS What is claimed is:

1. An integrated roofing product, comprising: a roofing panel or plank, comprising: a base layer comprising engineered wood, the base layer comprising an outer face, a top edge, a bottom edge, a left edge, and a right edge; a water resistant barrier layer covering at least the outer face of the base layer, and at least one of the edges; and one or more flashing pieces extended outward from one or more edges of the roofing panel or plank.

2. The product of claim 1, further comprising texturizing material covering or integrated with the water resistant barrier layer, wherein the texturizing material comprises one or more of: ceramic coated granules, rock, glass, slate, rubber, plastic, or a synthetic polymer.

3. The product of claim 1, wherein the water resistant barrier layer covers the top edge and the bottom edge.

4. The product of claim 1, wherein the upper edge comprises an underlap portion of a shiplap joint, and the bottom edge comprises an overlap portion of a shiplap joint.

5. The product of claim 5, wherein the underlap portion comprises an underlap joint face parallel to the outer face, and the underlap joint face is covered at least in part by the water resistant barrier layer.

6. The product of claim 1, wherein the water resistant barrier layer comprises a polymer.

7. The product of claim 1, wherein the flashing comprises a polymer.

8. The product of claim 1, wherein the flashing is integrated with the base layer or the water resistant barrier layer.

9. The product of claim 4, wherein the flashing extends from the overlap portion and over said shiplap joint.

10. The product of claim 1, wherein the flashing is the same color as an outward facing surface of the roofing panel or plank.

11. The product of claim 1, wherein the flashing extends straight outward in a plane.

12. The product of claim 1, wherein the flashing is bent or folded one or more times.

13. The product of claim 1, wherein the flashing comprises a flexible polymer configured to be molded during installation to a structure to be flashed.

14. The product of claim 1, further comprising one or more vents extending through the roofing panel or plank.

15. The product of claim 14, wherein the one or more vents are located proximate the top edge.

16. The product of claim 1, wherein the flashing is integrated with the roofing panel or plank in a processing line at a manufacturing facility, prior to installation on a structure.

17. The product of claim 14, wherein the one or more vents are integrated with the roofing panel or plank in a processing line at a manufacturing facility, prior to installation on a structure

18. A method of producing the integrated roofing product of claim 1, comprising: providing a base layer with an outer face, a top edge, a bottom edge, a right edge, and a left edge, said base layer comprising engineered wood; applying, in a processing line at a manufacturing facility, a fluid-applied or liquid-applied membrane to the outer face of the base layer, and to at least one edge of the base layer; affixing, in a processing line at a manufacturing facility, one or more pieces of flashing extending outward from one or more edges of the base layer.

19. The method of claim 18, further comprising: installing, in a processing line at a manufacturing facility, one or more vents extending through the base layer and membrane.