U.S. patent application number 11/421039 was filed with the patent office on 2009-04-23 for shingle panel.
This patent application is currently assigned to Shakertown 1992, Inc.. Invention is credited to Brian C. Gabbard, Mark J. Rutledge.
Application Number | 20090100788 11/421039 |
Document ID | / |
Family ID | 32713569 |
Filed Date | 2009-04-23 |
United States Patent
Application |
20090100788 |
Kind Code |
A1 |
Gabbard; Brian C. ; et
al. |
April 23, 2009 |
Shingle panel
Abstract
The shingle panel includes at least one shingle having a first
edge, a second edge, a third edge and a fourth edge and at least
one backing affixed to the shingle with corresponding first,
second, third and fourth edges. The first edge of the backing is
substantially aligned with the first edge of the shingle, the
second edge of the backing is offset the second edge of the
shingle, the third edge of the backing is offset the third edge of
the shingle and the fourth edge of the backing is offset the fourth
edge of the shingle. The shingle panel may be tapered and include
parallel grooves in the shingle and breathing grooves in the
backing. The method for manufacturing the shingle panel includes
pressing multiple backings on either side of a shingle board and
separating the shingle board to produce multiple shingle
panels.
Inventors: |
Gabbard; Brian C.; (Winlock,
WA) ; Rutledge; Mark J.; (Lynden, WA) |
Correspondence
Address: |
BLACK LOWE & GRAHAM, PLLC
701 FIFTH AVENUE, SUITE 4800
SEATTLE
WA
98104
US
|
Assignee: |
Shakertown 1992, Inc.
Winlock
WA
|
Family ID: |
32713569 |
Appl. No.: |
11/421039 |
Filed: |
May 30, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10763067 |
Jan 22, 2004 |
|
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|
11421039 |
|
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60442381 |
Jan 23, 2003 |
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Current U.S.
Class: |
52/745.19 |
Current CPC
Class: |
E04D 1/265 20130101;
E04D 1/205 20130101; E04F 13/10 20130101 |
Class at
Publication: |
52/745.19 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Claims
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. (canceled)
13. (canceled)
14. (canceled)
15. (canceled)
16. (canceled)
17. A method for manufacturing a shingle panel, comprising:
affixing a first backing to a first side of at least one shingle
board having first and second sides, wherein the first side of the
shingle board is substantially opposite the second side of the
shingle board; affixing a second backing to the second side of the
shingle board; separating the shingle board between the affixed
first and second backings to produce at least one shingle panel
comprising at least one shingle associated with the first or second
backing, the shingle having a first edge, a second edge, a third
edge and a fourth edge, wherein the first edge is substantially
opposite the second edge and the third edge is substantially
opposite the fourth edge, the associated first of second backing
having a first edge, a second edge, a third edge and a fourth edge,
wherein the first edge is substantially opposite the second edge
and the third edge is substantially opposite the fourth edge, and
wherein the first edge of the associated first or second backing is
substantially aligned with the first edge of the shingle; producing
an offset in the second edge of the first or second backing
relative to the second edge of the shingle; and producing an offset
in at least one of the third and fourth edges of the first or
second backing.
18. The method of claim 17, wherein the distance between the first
and second edges of at least one of the first and second backings
is less than the distance between the first and second edges of the
shingle.
19. The method of claim 17, wherein the distance between the third
and fourth edges of at least one of the first and second backings
is less than the distance between the third and fourth edges of the
shingle.
20. The method of claim 17, wherein the first and second backings
are affixed to the shingle by glue.
21. The method of claim 20, wherein the first and second backings
are compression pressed to the shingle.
22. The method of claim 21, wherein the first and second backings
compression pressed to the shingle are allowed to cure for a
predetermined period of time.
23. The method of claim 17, wherein: the shingle has a thickness;
and if a tapered shingle panel is desired, separating the shingle
board between the affixed first and second backings at an angle
relative to the first and second backings.
24. The method of claim 17, comprising if a breathing groove is
desired, producing at least one breathing groove substantially
parallel with the third and fourth edges of the backing in at least
one of the first and second backings.
25. The method of claim 24, wherein the at least one breathing
groove extends from the first edge of the backing.
26. The method of claim 17, wherein producing an offset in at least
one of the third and fourth edges of the associated first or second
backing comprises: producing an offset in the third edge of the
first backing relative to the third edge of the shingle; and
producing an offset in the fourth edge of the first backing
relative to the fourth edge of the shingle.
27. (canceled)
28. (canceled)
Description
PRIORITY CLAIM
[0001] This application claims priority from U.S. Provisional
Application Ser. No. 60/442,381, filed Jan. 23, 2003, which is
hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to exterior residential or
commercial siding.
BACKGROUND OF THE INVENTION
[0003] Traditional residential or commercial siding is made of
various materials in a variety of shapes and is installed in
different ways. A classic siding includes wood-based shingles
affixed independently to the side of a building. To improve
installation efficiency, multiple shingles can be joined together
to form pre-made shingle panels, for example 3-course shingle
panels. 3-course shingle panels provide three pre-made rows of
shingle panels, allowing an installer to affix multiple shingles in
much less time. However, 3-course shingle panels result in
significant waste during installation.
SUMMARY OF THE INVENTION
[0004] The present invention is a shingle panel and method for
making the same. The shingle panel includes at least one shingle
having a first edge, a second edge, a third edge and a fourth edge,
wherein the first edge is substantially opposite the second edge
and the third edge is substantially opposite the fourth edge and at
least one backing affixed to the shingle, the backing having a
first edge, a second edge, a third edge and a fourth edge, wherein
the first edge is substantially opposite the second edge and the
third edge is substantially opposite the fourth edge. The first
edge of the backing is substantially aligned with the first edge of
the shingle, the second edge of the backing is offset the second
edge of the shingle, the third edge of the backing is offset the
third edge of the shingle and the fourth edge of the backing is
offset the fourth edge of the shingle.
[0005] In an alternative embodiment, the shingle of the shingle
panel has a thickness and the thickness is tapered from the second
edge to the first edge of the shingle.
[0006] In yet an alternative embodiment, the shingle of the shingle
panel has at least one groove extending substantially between the
first and second edges of the shingle.
[0007] In an alternative embodiment, the backing of the shingle
panel includes at least one breathing groove substantially parallel
with the third and fourth edges of the backing and extending from
the first edge of the backing.
[0008] The preferred method for manufacturing the shingle panel of
the present invention includes affixing a first backing to a first
side of at least one shingle board having first and second sides,
wherein the first side of the shingle board is substantially
opposite the second side of the shingle board. A second backing is
affixed to the second side of the shingle board. The shingle board
affixed between the first and second backings is separated to
produce at least one shingle panel. The resultant shingle panel
includes at least one shingle associated with the first or second
backing, the shingle having a first edge, a second edge, a third
edge and a fourth edge, wherein the first edge is substantially
opposite the second edge and the third edge is substantially
opposite the fourth edge. The associated first of second backing
has a first edge, a second edge, a third edge and a fourth edge,
wherein the first edge is substantially opposite the second edge
and the third edge is substantially opposite the fourth edge. The
first edge of the associated first or second backing is
substantially aligned with the first edge of the shingle. An offset
is produced in the second edge of the associated first or second
backing relative to the second edge of the shingle. Additional
offsets are produced in at least one of the third and fourth edges
of the associated first or second backing.
[0009] In an alternative embodiment, the first and second backings
are compression pressed to the shingle and allowed to cure for a
predetermined period of time.
[0010] In yet an alternative embodiment, the shingle has a
thickness and the shingle board is separated between the affixed
first and second backings at an angle relative to the first and
second backings to produce a taper from the second to the first
edges of the shingle.
[0011] In an alternative embodiment, a breathing groove is produced
substantially parallel with the third and fourth edges of the
backing in at least one of the first and second backings, and the
breathing groove extends from the first edge of the backing.
[0012] The present invention is also directed to a method for
installing a shingle panel system on a building exterior. A first
shingle panel is affixed to the building exterior. The first
shingle panel includes at least one shingle having a first edge, a
second edge, a third edge and a fourth edge, wherein the first edge
is substantially opposite the second edge and the third edge is
substantially opposite the fourth edge, a backing affixed to the
shingle, the backing having a first edge, a second edge, a third
edge and a fourth edge, wherein the first edge is substantially
opposite the second edge and the third edge is substantially
opposite the fourth edge, and wherein the first edge of the backing
is substantially aligned with the first edge of the shingle, the
second edge of the backing is offset the second edge of the
shingle, the third edge of the backing is offset the third edge of
the shingle and the fourth edge of the backing is offset the fourth
edge of the shingle.
[0013] A second shingle panel is then affixed to the building
exterior, the second shingle panel including at least one shingle
having a first edge, a second edge, a third edge and a fourth edge,
wherein the first edge is substantially opposite the second edge
and the third edge is substantially opposite the fourth edge, a
backing affixed to the shingle, the backing having a first edge, a
second edge, a third edge and a fourth edge, wherein the first edge
is substantially opposite the second edge and the third edge is
substantially opposite the fourth edge, and wherein the first edge
of the backing is substantially aligned with the first edge of the
shingle, the second edge of the backing is offset the second edge
of the shingle, the third edge of the backing is offset the third
edge of the shingle and the fourth edge of the backing is offset
the fourth edge of the shingle.
[0014] The first shingle panel is affixed to the building exterior
along the first edge of the shingle of the first shingle panel. The
second shingle panel is affixed to the building exterior along the
first edge of the shingle of the second shingle panel. The second
shingle panel is positioned relative the first shingle panel such
that the first edge of the first and second shingle panels are
substantially aligned, the third edge of a second shingle panel
substantially abuts the fourth edge of the first shingle panel, and
the offset of the third edge of the second shingle panel interlocks
with the offset of the fourth edge of the first shingle panel.
[0015] In an alternative embodiment, a third shingle panel is
affixed to the building exterior, the third shingle panel including
at least one shingle having a first edge, a second edge, a third
edge and a fourth edge, wherein the first edge is substantially
opposite the second edge and the third edge is substantially
opposite the fourth edge, a backing affixed to the shingle, the
backing having a first edge, a second edge, a third edge and a
fourth edge, wherein the first edge is substantially opposite the
second edge and the third edge is substantially opposite the fourth
edge, and wherein the first edge of the backing is substantially
aligned with the first edge of the shingle, the second edge of the
backing is offset the second edge of the shingle, the third edge of
the backing is offset the third edge of the shingle and the fourth
edge of the backing is offset the fourth edge of the shingle. The
third shingle panel is affixed to the building exterior along the
first edge of the shingle of the third shingle panel. The third
shingle panel is positioned relative the first and second shingle
panels such that the second edge of the third shingle panel is
aligned with the first edge of the first and second shingle panels
such that the second edge of the third shingle panel overlaps the
first edge of the first and second shingle panels substantially to
the offset of the backing along the second edge of the third
shingle panel.
[0016] As will be readily appreciated from the foregoing summary,
the invention provides a more efficient and cost-effective shingle
siding system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The preferred and alternative embodiments of the present
invention are described in detail below with reference to the
following drawings.
[0018] FIG. 1 is an illustration showing a front view of the
preferred embodiment of the present invention;
[0019] FIG. 2 is an illustration showing a back view of the
preferred embodiment of the present invention;
[0020] FIG. 3 is an illustration showing a side view of the
preferred embodiment of the present invention;
[0021] FIG. 4 is an illustration showing multiple shingle panels of
the present invention in interlocking fashion;
[0022] FIG. 5 is an illustration showing a front view of the
preferred embodiment of the present invention including keyway
joints;
[0023] FIG. 6 is an illustration showing a back view of the
preferred embodiment of the present invention including keyway
joints;
[0024] FIG. 7 is an illustration showing a perspective side view of
the preferred embodiment of the present invention including keyway
joints;
[0025] FIG. 8 is an illustration showing a front view of the
preferred embodiment of the present invention having an even-butt
line together with a tight contemporary joint;
[0026] FIG. 9 is an illustration showing a front view of the
preferred embodiment of the present invention having a
staggered-butt line together with keyway joints;
[0027] FIG. 10 is an illustration showing a perspective side view
of a shingle board having a keyway joint notch;
[0028] FIG. 11 is an illustration showing a side view of a shingle
panel "sandwich" made in accordance with a preferred embodiment of
the present invention prior to being cut into shingle panels;
and
[0029] FIG. 12 is a flowchart describing a preferred method of
manufacturing a shingle panel in accordance with the present
invention.
DESCRIPTION OF THE PRESENT INVENTION
[0030] As shown with reference to the accompanying drawings and
photographs, the present invention is directed to an improved
shingle panel and method for creating the same that provides
superior benefits over traditional shingle panels. As shown in
FIGS. 1-3, and with further reference to FIGS. 5-7, the preferred
embodiment of the present shingle panel 10 consists of one or more
Western Red cedar shingles 20 held together by a 3-layer plywood
backing 30 that is glued or otherwise affixed to each shingle 20.
The backing 30 preferably extends fully from a first edge 50 of the
shingle 20 the majority of the way to a second edge 60 of the
shingle, thereby providing support for the shingle. The backing 30
preferably terminates short of the second edge 60 of the shingle to
provide an alignment line 70. This alignment line is used during
installation to vertically align shingle panels. The alignment line
also facilitates the overlap of vertically adjacent shingle panels,
which in turn allows blind/concealed nailing of the shingle
panels.
[0031] In the preferred embodiment, the backing 30 is staggered to
provide overlocking end joints 80 and corresponding recessed end
joints 90. This allowed multiple horizontally adjacent shingle
panels to be seamlessly interconnected to provide closely abutting
shingles. This also avoids exposed portions of the paper normally
applied behind the siding.
[0032] In the preferred embodiment, each shingle is cut in a
tapered fashion (see FIG. 3) to provide for a thick butt 40 at the
second end 60 of each shingle 20. This provides an enhanced visual
depth to the installed shingle panel, creating an improved
"shadow-line." Alternatively, each shingle may be cut in a
non-tapered fashion (not shown). As illustrated with reference to
FIGS. 1, 5 and 7, the shingle panel may be formed using shingles
having keyway joints 100. Keyway joints are grooves cut along the
surface of the shingle facing away from the house or other exterior
to which the shingle panel is applied. The keyway joints provide
texturing for the shingle to further enhance the appearance of the
building surface, as well as a way to hide or reduce visibility of
manufacture seam lines between adjoined shingles. The keyway joints
are preferably cut along the vertical line of the shingle, The
keyway joint may be cut to a uniform depth along the shingle.
Alternatively, the keyway joint may be cut unevenly so as to
produce a tapered depth of the joint between edge 50 and edge 60 of
the shingle.
[0033] In an alternative embodiment, the shingle panel may be
formed without a keyway joint, instead having a tight contemporary
joint between shingles (FIG. 8). Likewise, the preferred embodiment
is shown using shingles arranged with an even-butt configuration.
Alternatively, the shingle panel may be formed with shingles of
varying lengths, creating a staggered-butt line configuration (FIG.
9).
[0034] In an alternative embodiment, as shown with reference to
FIGS. 2 and 6, breathing grooves 110 are notched into one or more
locations along the backing 30 of the shingle panel, preferably
along first edge 50 of one or more shingles 20. When the shingle
panels are installed on the exterior of a building, breathing
grooves allow moisture and air to flow vertically behind the
shingle panels down the side of the building. This facilitates
removing moisture from behind the siding, thereby reducing the
possibility of accelerated weathering and deterioration of the
shingle panels, the siding paper typically applied between the
shingle panels and the exterior of the building, and the building
surface.
[0035] Various material alternatives to cedar for the shingles 20
and plywood for the backing 30 may be used. Examples of alternative
shingle material include Eastern White Cedar, Alaskan Yellow Cedar
(Cyprus), Southern Yellow Pine, Fir, Spruce, or any other wood or
other material suitable for exterior siding. The shingles can be
unfinished, primed or finished. Shingles may be finished using any
one of a number of finishes, for example, semi-transparent oil
stain in colors such as Pasadena Green, Beach Grey, Redwood and
Natural Beige. The shingles are preferably finished with an
application useful to reduce or eliminate UV rays. Examples of
alternative backing material include plywood of different layers,
particle board, or any other wood or other material suitable for
supporting shingles in the context of exterior siding.
[0036] As shown with reference to FIGS. 1 and 4, multiple shingle
panels 10 are preferably installed in an interlocking and
overlapping fashion. Specifically, in the horizontal direction, the
recessed end joint 90 of a shingle panel 10 interlocks with the
overlapping end joint 80 of an adjacent shingle panel. In the
vertical direction, shingle panels are preferably nailed, stapled
or otherwise affixed to the building side by placing nails (or
their equivalent) through the shingle and backing near the first
edge 50 of the shingles. The alignment line 70 of a subsequently
installed vertically adjacent shingle panel is positioned to abut
the first edge 50 of the previously installed shingle panel such
that the thick butt 40 at the second end 60 of the shingle overlaps
the first end 50 of the previously installed shingle, thereby
hiding the affixation nail.
[0037] The preferred method of manufacturing shingle panels 10 of
the present invention is described with reference to FIGS. 10 and
11 and the flowchart shown in FIG. 12. A shingle panel 10 is
preferably manufactured by sandwiching a finished shingle board 120
between two plywood backings 140. A shingle board is finished
through a trimming, sanding and cutting process to produce a
shingle board of the desired size and shape. If a keyway joint
configuration is desired, each shingle board is notched along one
edge. In this example, the shingle board 120 includes a keyway
joint notch 130 so that the finished shingle panel 10 will include
a keyway joint 100.
[0038] The preferred method of manufacturing a shingle panel is
more fully described with reference to FIG. 12, At block 200, a
plurality of finished shingle boards are placed adjacent to each
other. At blocks 202 and 204, glue or other bonding material,
preferable PVA (poly vinyl acetate), is placed along the side 150
of the two plywood backing pieces facing the shingle board 120. A
full gluing process is preferably used rather than a beading or
combination beading and staple process. In the preferred
embodiment, at blocks 206 and 208, the configuration is compression
pressed together for twenty minutes and allowed to cure 24 hours at
55 degrees.
[0039] After the combination of shingle boards and two backing
pieces is cured, one of several additional steps may occur, in
varying order depending on manufacturing preference. At decision
block 210, a determination is made whether one or more overlooking
end joints 80 or corresponding recessed end joints 90 are desired.
If overlooking end joints or recessed end joints are desired, the
logic proceeds to block 212, where desired overlooking end joints
80 or corresponding recessed end joints 90 are cut into the shingle
panel 10, preferably using a router. If overlooking end joints or
recessed end joints are not desired, the logic proceeds from
decision block 210 to decision block 214.
[0040] At decision block 214, a determination is made whether
breathing grooves 110 are desired. If breathing grooves are
desired, the logic proceeds to block 216, where breathing grooves
are cut into the backings 140. If breathing grooves are not
desired, the logic proceeds from decision block 214 to decision
block 218.
[0041] At decision block 218, a determination is made whether
tapered shingles are desired. If tapered shingles are desired, the
logic proceeds to block 220, where the combination of shingle
boards and two backing pieces is cut into two separate panels along
the direction of arrow 160 of FIG. 11 at an angle to produce two
separate panels having tapered shingles. This is preferably
accomplished using a band saw. If tapered shingles are not desired,
the logic proceeds from decision block 218 to block 222. At block
222, the combination of shingle boards and two backing pieces is
cut into two separate panels along the direction of arrow 160 of
FIG. 11 along an even line, with no angle, to produce two separate
shingle panels that are not tapered.
[0042] The shingle panels may be sized to predetermined lengths at
various stages during the manufacturing process by cutting the
shingle panels, preferably using a band saw. While the preferred
embodiment of the invention has been illustrated and described, as
noted above, many changes can be made without departing from the
spirit and scope of the invention. Shingle panels of various widths
(having different reveals) and lengths are contemplated. As noted
above, various materials may be used for the components without
departing from the scope of the invention. Also, while the
preferred method of manufacturing the shingle panels has been
described, variations of this method may be employed to produce the
same or similar results. For example, a different bonding agent may
be used, provided it is workable to bond the materials chosen for
the shingles and backing. The precise length of compression
pressing or curing time and temperature may be varied, particularly
if a different bonding agent is used. Different types of saws may
be used to make the noted cuts for the shingle panel, and the steps
of cutting the edges and other notches in the shingle panel may be
performed in different order. For example, the order in which
decision blocks 210, 214 and 218 occur may be varied. Accordingly,
the scope of the invention is not limited by the disclosure of the
preferred embodiment. Instead, the invention should be determined
entirely by reference to the claims that follow.
* * * * *