U.S. patent application number 10/286938 was filed with the patent office on 2004-06-17 for composite shingle and method of manufacture, method of packaging, and method of installation.
Invention is credited to Heroneme, Gary.
Application Number | 20040111996 10/286938 |
Document ID | / |
Family ID | 32511001 |
Filed Date | 2004-06-17 |
United States Patent
Application |
20040111996 |
Kind Code |
A1 |
Heroneme, Gary |
June 17, 2004 |
Composite shingle and method of manufacture, method of packaging,
and method of installation
Abstract
A composite shingle, comprising a headlap portion, a buttlap
portion, the thickness of the buttlap portion is approximately
between 1/4 inch and 3/4 inch, tab cuts that extend completely
through the buttlap portion to create separate tabs, the tab cuts
disposed along the lower buttlap portion edge such that the width
of the separate tab have random appearance; wherein after
installation of a plurality of the composite shingles, each tab
appears to be a separate shingle. A method of covering a surface
with composite shingles comprising providing a plurality of
composite shingles having a thickness approximating the thickness
of a wood shingle, wherein the plurality of composite shingles each
have a width of between approximately 2 inches and approximately 10
inches; and attaching the plurality of composite shingles to the
surface in a fashion similar to and/or identical to attachment of a
wood shingle to a surface.
Inventors: |
Heroneme, Gary; (Redlands,
CA) |
Correspondence
Address: |
Gary Heroneme
313 E. High Street
Redlands
CA
92374
US
|
Family ID: |
32511001 |
Appl. No.: |
10/286938 |
Filed: |
November 2, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60337305 |
Nov 5, 2001 |
|
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|
Current U.S.
Class: |
52/518 ;
52/311.1 |
Current CPC
Class: |
B32B 7/04 20130101; B44C
3/12 20130101; E04D 1/26 20130101; E04F 13/0864 20130101; B32B
2419/06 20130101; B32B 21/13 20130101; E04F 13/185 20130101; B32B
2307/402 20130101 |
Class at
Publication: |
052/518 ;
052/311.1 |
International
Class: |
E04F 013/00; E04F
015/00 |
Claims
What is claimed:
1. A composite shingle, comprising: (a) a headlap portion, (b) a
buttlap portion, (c) the thickness of the buttlap portion is
approximately between {fraction (1/4)} inch and {fraction (3/4)}
inch, (d) tab cuts that extend completely through the buttlap
portion to create separate tabs, (e) the tab cuts disposed along
the lower buttlap portion edge such that the width of the separate
tab have random appearance; and (f) wherein after installation of a
plurality of the composite shingles, each tab appears to be a
separate shingle.
2. A composite shingle of claim 1, wherein the thickness is
approximately {fraction (3/8)} inch.
3. A composite shingle of claim 1, wherein the thickness is
approximately {fraction (5/8)} inch.
4. A composite shingle of claim 1, wherein the tab cut is
approximately {fraction (1/4)} inch wide.
5. A composite shingle of claim 1, wherein the tabs have a
plurality of colors, such that the tab color appears random within
each tab and/or between neighboring tabs.
6. A composite shingle of claim 1, wherein the tabs have a
plurality of tab lengths, such that each tab length appears
random.
7. A composite shingle of claim 1, wherein the headlap portion has
perforation lines aligned with the tab cuts to allow separation of
the tabs.
8. A composite shingle of claim 1, further comprising nailing
target areas marked on the top surface of the headlap portion.
9. A composite shingle, comprising: (a) a headlap portion, (b) a
buttlap portion, (c) wherein the thickness of the buttlap portion
is approximately {fraction (3/8)} inch, (d) tab cuts that extend
completely through the buttlap portion to create separate tabs; (e)
wherein the tab cuts are approximately {fraction (1/4)} inch wide
and disposed along the lower buttlap portion edge such that the
width of the separate tab have random appearance; (f) wherein the
tabs have a plurality of colors, such that the tab color appears
random within each tab and/or between neighboring tabs, (g) the
tabs have a plurality of tab lengths, such that each tab length
appears random; (h) wherein the headlap portion has perforation
lines aligned with the tab cuts to allow separation of the tabs;
and (i) wherein after installation of a plurality of the composite
shingles, each tab appears to be a separate shingle.
10. A composite shingle of claim 9, wherein nailing target areas
are marked on the top surface of the headlap portion.
11. A composite shingle having a first composite layer, a second
composite layer, and a third composite layer, wherein the first,
second and third composite layers are laminated together such that
the shingle thickness is approximately {fraction (3/8)} of an inch
and the shingle width is between approximately 2 inches and
approximately 10 inches.
12. A method of manufacturing composition shingles comprising: (a)
making a layer of composite shingle that is approximately {fraction
(3/8)} of an inch thick or less; (b) cutting the layer into widths
of between approximately 2 inches and approximately 10 inches; (c)
laminating the composite layers together such that the shingle is
approximately {fraction (3/8)} of an inch thick.
13. Method of claim 12 wherein the composition shingle comprises a
first layer, a second layer and a third layer, wherein each of the
layers has a thickness of approximately {fraction (1/8)} inch, and
wherein the three layers are laminated together.
14. Method of claim 12 wherein the composition shingle comprises a
first layer and a second layer; wherein each layer has a thickness
of approximately {fraction (3/16)} inch, and wherein the two layers
are laminated together.
15. A method of covering a surface with composite shingles
comprising: (a) providing a plurality of composite shingles having
a thickness approximating the thickness of a wood shingle, wherein
the plurality of composite shingles each have a width of between
approximately 2 inches and approximately 10 inches; and (b)
attaching the plurality of composite shingles to the surface in a
fashion similar to and/or identical to attachment of a wood shingle
to a surface.
16. The method of covering a building surface of claim 15, wherein
the plurality of shingles are provided in a plurality of
colors.
17. The method of covering a building surface of claim 15, wherein
the plurality of shingles each have a thickness of approximately
{fraction (3/8)} inch.
18. A method of packaging composition shingles of various widths
comprising: (a) providing a plurality of shingles, each shingle
having a width of approximately 4 inches, approximately 6 inches or
approximately 8 inches; (b) stacking the shingles such that they
form a three dimensional rectangular shape.
19. A method of claim 18, further comprising a second plurality of
shingles, each shingle having a width of approximately 2 inches or
approximately 10 inches.
20. A method of claim 18, wherein a plurality of colors are
provided on the plurality of shingles.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority under 35 U.S.C.
.sctn. 119(e) to U.S. Provisional Application No. 60/337,305, filed
on Nov. 5, 2001, which is expressly incorporated by reference as
though fully set forth herein.
FIELD OF THE INVENTION
[0002] The present invention relates to roofing systems, and in
particular to a composite shingle, a method of manufacture, a
method of packaging, and a method of installation thereof.
BACKGROUND OF THE INVENTION
[0003] Conventional roof coverings for sloped roofs include
composite shingles, cedar shingles, wooden shakes, sheet metal,
slate, clay and concrete tile. Sheet metal, clay and slate are
advantageous because of their high weatherability. One of the
problems with clay tile and slate roofs is that the clay and slate
tiles require significant labor to apply. The composite or wood
shingles are nailable and are simply nailed to a roof deck in
courses, usually from the bottom or eave to the top or ridge of the
roof. Clay, concrete and slate tiles are heavier than composite
shingles, and require more support to hold up the roof. The
installed cost of clay and slate tiles exceeds that of composite
shingles. Clay and slate tiles are inherently fragile, and suffer
much breakage during shipping and installation. These materials are
fragile even after installation on the roof, and can be damaged by
foot traffic on the roof.
[0004] Wooden shingles and shakes are generally flat boards,
usually of cedar or other coniferous trees. A cedar shingle is
generally 3/8" thick and a wooden shake is generally 5/8" thick.
The wooden shingles or shakes are nailed in courses on the roof
deck, with the exposed or tab portions of the shingles of a
subsequent course being laid over the headlap portions of the
previous course of shingles. The shingles are cut so that the wood
grain runs up the slope of the roof for an aesthetically pleasing
appearance. The cutting of the wood, and the subsequent weathering
of the shingles after installation on the roof create grooves and
ridges running in the direction of the wood grain.
[0005] One of the desirable attributes of any roofing material is
to be able to resist fires. This is particularly true in regions
having a hot and dry climate, although fire resistance is desirable
everywhere. A particularly important aspect of fire resistance is
the ability of the roofing material to prevent a fire from burning
through the roofing material to thereby expose the roof deck or
interior of the building to the fire. Metal roofs and clay and tile
roofs have inherent advantages in fire resistance over wood shingle
roofs. Composite shingles are sufficiently fire resistant to obtain
a Class A fire rating when measured by appropriate tests. Wooden
shingles, even when treated with a fire retardant material, are not
generally fire resistant and cannot achieve a Class A fire rating.
From a fire resistance perspective, a disadvantage of wooden
shingles is that they must be applied in a spaced-apart arrangement
to allow room for expansion. Because of the propensity of wooden
shingles to absorb water, they also tend to curl and not remain
flat on the roof. Wood shingles are particularly prone to failing
the fire tests because of the gaps between adjacent shingles
Because of fire safety concerns, in some jurisdictions it is now
illegal to install any roof with less than a Class A rating,
including all currently available wooden shingle roof
materials.
[0006] For historical reasons, composite shingles are also often
referred to as asphalt shingles even if modem composite shingles do
not contain asphalt. Manufacturers of composite shingles have, for
many years, endeavored to produce shingles that resemble natural
materials in appearance. Typical materials that manufacturers have
sought to have composite shingles resemble are natural slate tiles
and cedar shingles. Techniques that manufacturers have employed
have included applying an overlay to the shingle, or making a
multiple-layered or laminated shingle. Such shingles are typically
manufactured in a variety of weights and colors.
[0007] Improvements in shingle manufacturing have been subtle,
often being devoted to the simulation of wood or other natural
appearing shingles, having natural appearing textures. Some
approaches have been toward applying granules of various color
configurations. Other developments have applied shadow bands to
give the appearance of depth at various locations along the
shingles. Still other techniques have involved irregular cuts in
the buttlap portion of the shingles, in an attempt to give a
scalloped or random appearance.
[0008] Attempts have been made to produce more irregular surface
contours, which would give the shingle a bulkier appearance.
Examples of such composite shingles are shown in U.S. Pat. No.
2,099,131 to Miller; U.S. Pat. No. 5,094,058 to Slocum; and
D369,421 to Kiik, et al. The complete disclosures of these patents
are herein incorporated by reference.
[0009] Various composite shingles have been developed in an attempt
to provide an appearance of thickness comparable to wood shingles.
Examples of such composite shingles are shown in U.S. Pat. No.
3,921,358 to Bettoli; U.S. Pat. No. 4,717,614 to Bondoc, et al.;
U.S. Pat. No. 5,232,530 to Malmquist, et al.; and U.S. Pat. Des.
No. 309,027 to Noone, et al. The complete disclosures of these
patents are herein incorporated by reference.
[0010] In U.S. Pat. No. 4,352,837 to Kopenhaver, an overlay is
taught, whereby, a first single layer of shingle is made, comprised
of a mat, asphalt, and granules on an upper surface. The first
single layer thus made receives an overlay in the form of an
additional partial coating of asphalt, which in turn, receives
additional granules thereon, creating localized areas of additional
thickness on the shingle, with such areas of additional thickness
having an ornamentation appearance. The complete disclosure of this
patent is herein incorporated by reference.
[0011] U.S. Pat. No. 5,052,162, to Bush et al, teaches a process of
continually making a composite laminated shingle. The complete
disclosure of this patent is herein incorporated by reference.
[0012] U.S. Pat. No. 5,181,361, to Hannah, et al, teaches a
laminated shingle in which the shingle is comprised of a base layer
and a secondary layer, and with a partial top layer. Each of the
layers is comprised of an asphaltic web with granules applied to
the top of the web. The final shingle has some portions being of
two-layer thickness and other portions being of three-layer
thickness. The complete disclosure of this patent is herein
incorporated by reference.
[0013] U.S. Pat. No. 5,611,186, to Weaver, teaches a laminated
composite shingle with an illusion of depth created by a value
gradation from a light color to a dark color in a portion of the
buttlap section. The complete disclosure of this patent is herein
incorporated by reference.
[0014] U.S. Pat. No. 5,860,263, to Sieling , et al., teaches a
rectangular roofing shingle having dissimilarly shaped,
space-separated, snaggle-toothed sections in the buttlap portion of
the shingle. The complete disclosure of this patent is herein
incorporated by reference.
[0015] U.S. Pat. No. 6,212,843, to Kalkanoglu et al., describes a
shingle and method for making multi-tab composite shingles having a
thicker appearance for the tabs than the actual thickness of the
shingle. The complete disclosure of this patent is herein
incorporated by reference.
[0016] U.S. Pat. No. 6,220,329, to King, et al., describes a method
and apparatus of making a laminated roofing shingle. The complete
disclosure of this patent is herein incorporated by reference.
[0017] U.S. Pat. No. 6,253,512, to Thompson et al., describes a
method of applying tiles to a roof in a random appearing manner so
as to try to create an aesthetically pleasing appearance. The
complete disclosure of this patent is herein incorporated by
reference.
[0018] U.S. Pat. No. 6,289,648, to Freshwater, et al., describes a
laminated composite shingle, the shingle having color striations
across at least some parts of the buttlap portion in an attempt to
improve the aesthetic appearance of the shingle. The complete
disclosure of this patent is herein incorporated by reference.
[0019] Unfortunately, current manufacturing and installation
methods of composite shingle roofing material result in roof with a
less aesthetically pleasing appearance than a wood shingle or slate
tile roof.
[0020] It is an object of the present invention to provide a
composite shingle that will give the appearance of a wood shingles
or a slate tile after installation.
[0021] Another object of the present invention is to provide a
method of installing a plurality composite shingles to give the
appearance of a wood shingle or a slate tile roof.
[0022] Another object of the present invention is to provide a
method of manufacturing shingles that can be readily installed on a
building surface to give the appearance of a wood shingle or slate
tile roof.
[0023] Another object of the present invention is to provide a
method of packaging composite shingles of various widths.
[0024] Other objects and advantages of the present invention will
be readily apparent to those skilled in the art from a reading of
the following summary of the invention, brief description of the
drawing figures, detailed description of the invention and the
appended claims.
SUMMARY OF PREFERRED EMBODIMENTS
[0025] In accordance to the present invention, there has now been
developed a composite shingle and a method of installation that has
the aesthetically pleasing appearance of a wooden shingle or slate
tile roof. The prior art has taught that it is a disadvantage that
wooden shingles or slate tiles must be installed in a spaced-apart
arrangement to allow for expansion. However, this spaced-apart
arrangement is in part what creates an aesthetically pleasing
appearance. Likewise, the propensity of wooden shingles to curl and
not remain flat on the roof creates random shadow lines that are
also part of the aesthetically pleasing appearance. Additionally,
because of the subsequent weathering of the wooden shingles after
installation, variations between shingles in the grooves and ridges
in the wood grain and variations in the color creates part of the
aesthetically pleasing appearance. Even slight differences in color
between neighboring shingles will add to an aesthetically pleasing
appearance. Further still, after installation the width of each
wood shingle or slate tile on the roof usually varies in width from
the neighboring wood shingles or slate tiles. This random width
also adds to the aesthetically pleasing appearance. Also, upon
installation the butt edge portion of a wooden shingle or slate
tile will often vary slightly from neighboring shingles or tiles.
The slight random positioning of the shingles or tiles upon
installation adds to the aesthetically pleasing appearance. Another
random aspect of natural roofing material that adds to the
aesthetically pleasing appearance is a slight variation in
thickness between neighboring shingles or tiles. Past attempts to
make and install composite shingles having the aesthetically
pleasing appearance of wooden shingles or slate tiles have failed
to duplicate one or more of the aesthetical characteristics of a
wood shingle roof or a slate tile roof.
[0026] Currently available shingles attempt to create the illusion
of the dimensions a wood shingles or slate tiles instead of
actually approximating the same dimensions. An advantage of having
composite shingles that are wider than wood shingles is a decrease
in installation cost. However, wider composite shingles have up
until now suffered from a decreased aesthetic appearance and a
decrease in perceived value compared to natural roofing material.
Perhaps because of concerns of having the nails from the underlying
course show through the buttlap portion, currently available
composite shingles almost always have a solid buttlap layer. Tab
shingles are available, but these do not have random widths because
of the problem with nails showing from the underlying course. A
"tab shingle" is defined as a shingle with a cut completely through
all layers of the buttlap portion of the shingle.
[0027] Historically, craftsman attempted to make perfect wood
shingles or slate tiles. However, these craftsmen were limited by
nature. In the past 100 years, the quality of manufacturing
techniques has improved to the point where it is possible to create
an almost perfect shingle. From an aesthetic point of view,
composite roofing material is made too perfectly. Nature is not
perfectly uniform, and as part of nature, people are inherently
uncomfortable in a perfectly uniform setting. A perfectly uniform
roof does not create the same aesthetically pleasing appearance as
a roof with slight random variations.
[0028] The present invention is directed to using composite
shingles in a novel manner to create the aesthetically pleasing
appearance of a wood shingle roof or a slate tile roof. None of the
prior art approaches of manufacturing or installing composite
shingles focused on making the thickness of the shingle, the width
of the shingle, the spacing between shingles, the butt end
alignment of the shingles, and the color of the shingle match a
wood shingle roof or slate tile roof. To more accurately
approximate the appearance of a wood shingle roof, random appearing
dimensions and colors need to be incorporated into the roofing
material and/or installation. For the most aesthetically pleasing
appearance, after installation each tab of a composite shingle
needs to appear to be an independent shingle.
[0029] In one embodiment, a pseudo-wood shingle is created with the
same dimensions as a cedar shingle. Each pseudo-wood shingle is an
independent shingle, and thus the slight randomness in spacing and
alignment inherent in hand installation will add to the
aesthetically pleasing appearance of the roof.
[0030] In another embodiment of the present invention, a random tab
composite shingle is provided with random tab widths, random cut
widths between tabs, random tab colors, and/or random butt edge
alignment. The tabs may also be of slightly random thickness.
[0031] In another embodiment of the present invention, when a
plurality of the random tab composite shingles described herein are
installed to a surface, the composite shingles give the appearance
of independent wood shingles.
[0032] In another embodiment of the present invention, composite
shingles are provided with a thickness and width approximating a
wood shingle. Individual shingles vary in widths less than 18
inches, preferably from between 2 inches and 13 inches, more
preferable between 4 inches and 8 inches. These shingles are called
"pseudo-wood" shingles.
[0033] In another embodiment of the present invention, when a
plurality of the composite shingles described herein are installed
on a roof, the roof will have a Class A fire barrier rating.
[0034] In another aspect of the present invention, composite
shingles are sorted and packaged by color groups and/or dimensional
groups for delivery to construction sites.
[0035] In another embodiment of the present invention, composite
shingles are provided with a width and thickness approximating a
slate tile. Individual shingles vary in widths less than 24 inches,
preferably from between 12 inches and 16 inches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a perspective view of a random tab shingle of the
present invention.
[0037] FIG. 2A is a top plan view of a laminated composite
shingle.
[0038] FIG. 2B is a front plan view of a laminated composite
shingle.
[0039] FIG. 3 is a perspective view of a partial roofing section
after installation in a thatch style of the pseudo-wood tab
shingles by the method of the present invention.
[0040] FIG. 4 is a perspective view of a partial roofing section
after a typical installation of the pseudo-wood tab shingles by the
method of the present invention.
[0041] FIG. 5 is an enlarged perspective view of a partial roofing
section after a typical installation of the pseudo-wood tab
shingles by the method of the present invention.
[0042] FIG. 6 is an enlarged perspective view of a partial roofing
section after a typical installation of the random tab shingles of
the present invention.
[0043] FIG. 7 is an enlarged top plan view of the butt edge
alignment of either pseudo-wood shingles, a random tab shingle, or
pseudo-slate tiles.
[0044] FIG. 8 is an exploded isometric view showing the sectioned
shingle components of the present invention.
[0045] FIG. 9 is a front plan view of the sectioned shingles of the
present invention.
[0046] FIG. 10 is a perspective view of the sectioned shingles of
the present invention and a pseudo-wood shingle of the present
invention.
[0047] FIG. 11 is an illustration showing possible variations in
colors and dimensions of the random tab composite shingles or the
pseudo-wood composite shingles of the present invention after a
typical installation.
[0048] FIG. 12 is a perspective view of a diamond pattern
installation and of a scallops or "fish scales" installation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] First Embodiment--Random Tab Composite Shingle
[0050] In FIGS. 1 and 6, the reference number 10 generally
designates the random tab shingle of the present invention. Shingle
10 has a body portion of a generally flat or planar, polygonal
configuration. Preferably, shingle 10 is of rectangular
configuration. Shingle 10 has a headlap portion 112 and a buttlap
portion 113. Cuts 101 are made through all layers of the butlap
portion 113, creating tabs 105-109. Cuts 101 are preferably random
appearing in width, approximately {fraction (1/4)}" with variations
preferably of plus or minus {fraction (1/16)}". Thus, cuts 101 will
give a spaced-apart appearance of approximately {fraction (1/4)}"
between tab 105 and 106, as well as between tabs 106 and 107, etc.
Cuts 101 are made along the buttlap portion such that they create
random appearing widths 115-119 in tabs 105-109. Tab width 115-119
are less than 18", preferably between 2" and 13", more preferably
between 4" and 8". For illustration purposes only, in FIG. 1 tab
width 105 is 5", tab width 106 is 8", tab width 107 is 4", tab
width 108 is 3", etc. Nail targets 102 are marked on the top
portion of shingle 10 in headlap portion 112. On the topside of
shingle 10 is glue strip 103. The alignment of lower tab edge 104
is optionally random appearing. Lower tab edge 104 is preferably
within 1/8" of the neighboring lower tab edges, more preferably
within {fraction (1/16)}" of neighboring lower tab edges.
Perforations 110 run up from cuts 101 through the headlap portion
112. This allows easy of separation between any of tabs 105-109.
Preferably, the colors of each of tabs 105-109 appear to be random.
The thickness 111 is preferred the same as a cedar shingle, that is
3/8". Thickness 111 can also be that of a wood shake or other
natural roofing material. Further, thickness 111 can vary slightly
between tabs neighboring. Thus, in one embodiment, the random tab
composite shingle may include random appearing tab widths 115-119,
random appearing tab thickness 111, random appearing widths of cuts
101, random appearing colors of tabs 105-109, and random appearing
lower edge alignment 104 of tabs 105-109.
[0051] FIG. 6 shows a partial installation of random tab composite
shingles. First course 601 is installed in the standard manner for
composite shingles. The starter course 602 is completely covered by
the first course 601, except at cuts 101. In the example shown,
shingle 10 is secured to the roof by attaching shingle 10 to the
roof at nail targets 102. The second course 603 covers the headlap
portion of first course 601, third course 604 covers the headlap
portion of second course 603, and fourth course 605 covers the
headlap portion of third course 604.
[0052] After installation, each tab of the random tab composite
shingle will appear to be independent from the neighboring
tabs.
[0053] Second Embodiment--Pseudo-wood Shingle and Installation
Thereof
[0054] In FIGS. 2 and 8, the reference number 20 generally
designates a currently available composite shingle. FIGS. 2A and 2B
show a bi-laminated composite shingle. The Owens Corning.RTM.
thirty year composite shingle is one example of a composite shingle
as shown in FIG. 2. Other shingles can be substituted for the Owens
Corning.RTM. composite shingle and still practice the invention
described herein. Shingle 20 is cut vertically along cut line 208.
Cut line 208 is preferably along the edge of tab lines 209, through
buttlap portion 22, and extends vertically through headlap portion
21. This creates sectioned shingles 202, 204 and 206 of single
thickness, and sectioned shingles 201, 203 and 205 of double
thickness, as shown in FIG. 8. The cutting of the shingles can
easily be done with a razor, shear, knife, or other cutting
means.
[0055] Sectioned shingles 201-206 are sorted according to width and
thickness, as shown in FIG. 9. Single thickness shingles are
matched with double thickness shingles of similar widths. In the
example shown in FIG. 9, sectioned shingle 202 is matched with
sectioned shingle 203, and sectioned shingle 204 is matched with
sectioned shingle 205.
[0056] Sectioned shingles of similar widths are stacked on top of
each other until the desired thickness is achieved. A cedar shingle
is approximately {fraction (3/8)}" thick. The Owens Corning.RTM.
thirty year composite shingles achieves this thickness by stacking
one single layer shingle with one double layer shingle, or three
single layer shingles. This process can be used to "build-up" any
desired thickness. Shake shingles are typically 5/8" thickness, so
if this thickness is desired a total of five layers need to be
stacked on top of each other. Lamination is achieved in part by the
glue strips 207 on the backside of the shingle. Heat from the sun
melts glue strips 207 and causes the shingles to adhere to each
other and act as one shingle. For example, in FIG. 10, sectioned
shingle 202 adheres to shingle 203 and creates pseudo-wood shingle
1001.
[0057] By laminating sectioned shingles in the fashion described,
pseudo-wood shingle 1001 looks and installs in a the same fashion
as a traditional wood shingle. However, the greater ease of cutting
and nailing that comes from composition shingles is also achieved
in the pseudo-wood shingle.
[0058] On a typical roof installation, the roof is prepared in a
manner typical to that for a standard composition roof, preferably
as required by the Uniform Building Code.
[0059] An example of a "thatched roof" style of installation of the
pseudo-wood shingles is shown in FIG. 3. Starter course 301 is
installed, in a manner as required by the installation. This
usually includes roofing paper 302 under the starter course 301.
The pseudo-wood shingles of first course 303 are then installed in
the same fashion as a traditional wood shingle roof. Subsequent
courses 304 are also installed in the traditional fashion.
[0060] An example of a standard wood shingle installation method is
shown in FIGS. 4 and 5. In FIG. 4, the buttlap portion 401 of the
pseudo-wood shingles covers nailing 402 of the previous course.
Roofing paper 302 is completely covered by the pseudo-wood
shingles.
[0061] In FIG. 5, spacing 504 between each pseudo-wood shingle is
the same as spacing between traditional wood shingles on a roof, or
approximately {fraction (1/4)}" to 3/8". Nails 503 are covered by
the buttlap portion of the subsequent courses. For illustration
purposes, the color of pseudo-wood shingle 501 is different than
pseudo-wood shingle 502.
[0062] FIG. 7 illustrates how the lower edge portion of a shingle
can vary. Reference numbers 71-74 designate separate pseudo-wood
shingles or individual tabs of s random tab shingle. For
illustration purposes, in this example lower edge alignment 701
varies slightly with lower edge alignment 702. Lower edge alignment
703 is not exactly perpendicular to the roof edge (not shown).
Lower edge alignment 704 is almost identical to lower edge
alignment 701. An unlimited number of variations are possible while
still maintaining a slight random appearance to the lower edge
alignment.
[0063] A finished roof is shown in FIG. 11. Either random tab
shingles 10 or pseudo-wood shingles 20 may be used to create the
appearance of a wood roof. Reference numbers 1101-1106 designate
separate pseudo-wood shingles or individual tabs of random tab
shingles. Shingles 1101-1106 may appear to be of random width,
spacing, thickness, alignment, and color.
[0064] Third Embodiment--Off-site Manufacture of Shingles
[0065] In another embodiment of the present invention, a single
layer of a composite shingle is manufactured to be approximately
the thickness of a wood shingle. This single layer is then cut to
approximate the dimensions of wood shingles, creating a plurality
of pseudo-wood shingles. The pseudo-wood shingles may then be
sorted by width and/or color. The pseudo-wood shingles may also be
packaged with a plurality of widths and/or colors being provided in
each unit.
[0066] Fourth Embodiment--Fancy Butts and Other Applications
[0067] A fancy butt is an exposed end of a shingle that is cut to
create a decorative effect. Examples are shown in FIG. 12. FIG. 12A
shows a diamond pattern. The buttlap portion of the shingle is cut
as is well known in the art. FIG. 12B shows a scallop or "fish
scale" style.
[0068] Fifth Embodiment--Standard Size Composite Shingle with
Perforations or Grooves
[0069] In another embodiment of the present invention, shingle 20
is made as is known in the art, as shown in FIG. 2. During or after
manufacture, perforations or grooves are made in shingle 20 at cut
lines 208. Sectioned shingles 201-206 are easily separated from
each other, and pseudo-wood shingles are created. Each of sectioned
shingles 201-206 may be a different random appearing color from the
neighboring sectioned shingle.
[0070] Sixth Embodiment--Thick Composite Shingle with Perforations
or Grooves
[0071] In another embodiment of the present invention, a composite
shingle of approximately {fraction (3/8)}" thickness or more is
made, as is known in the art. (Not shown.) During or after
manufacture, perforations or grooves are made in the thick shingle
at random appearing widths. Pseudo-wood shingles are created by
separating the thick shingle at the perforations or grooves. The
buttlap portion of the thick shingle between the perforations or
grooves may be of random appearing colors.
[0072] Seventh Embodiment--Pseudo-slate Tile and Random Tab Slate
Shingle
[0073] The principles described in the first through seventh
embodiments will also apply to slate tiles. Specifically, this
includes random appearance in shingle width, spaced-apart
installation, shingle butt end alignment, shingle thickness, and
shingle color. Composite shingles can be manufactured following an
analogous format for both the pseudo-wood shingle and the random
tab shingle of the first embodiment. Installation methods of the
pseudo-slate shingle
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