Pre-Assembled Ventilated Shingle Set

Abstract

An assembly, and method for constructing the assembly, that provides a much faster and more precise shingle installation with required keyway spacing and offsets, and with built-in ventilation that improves the performance of the shingles and protects the wall assembly. Also providing a pleasing distribution of shingle widths with no apparent patterns.

Claims

1. An assembly of shingles comprising: a plurality of side-by-side shingles; one or more connectors between each pair of shingles; the shingles and connectors forming a semi-rigid panel, wherein the shingles are aligned when the panel is installed on a flat surface.

2. The assembly of claim 1, wherein the connectors are substantially contained within the plane of the shingles such that the installed assembly functions as a conventional individual shingle installation.

3. The assembly of claim 1, wherein the connectors allow the shingles to expand and contract, and wherein the shingles and connectors of the semi-rigid panel remain connected to each other throughout handling and installation, and wherein the connectors are substantially contained within the plane of the shingles such that the installed assembly functions as a conventional individual shingle installation.

4. An assembly of shingles comprising: a plurality of side-by-side shingles; one or more connectors between each pair of shingles, the shingles and connectors forming a semi-rigid panel; an alignment gauge on the front face of the panel, wherein the shingles and connectors of the semi-rigid panel remain connected to each other throughout handling and installation, and wherein the shingles are aligned when the panel is installed on a flat surface, and wherein the connectors are substantially contained within the plane of the shingles such that the installed assembly functions as a conventional individual shingle installation, and wherein the shingles within the panel and the alignment gauge being configured in such a manner that a second row of adjacent panels being placed on top of and overlapping a first row of adjacent panels and offset laterally such that a mark or edge of the panels in the second row aligns with a mark or edge of panels in the first row, the keyways of the second row are offset from the keyways in the first row.

5. An assembly of shingles comprising: a plurality of side-by-side shingles; one or more connectors between each pair of shingles, the shingles and connectors forming a semi-rigid panel; an alignment gauge on the front face of the panel, wherein the connectors allow the shingles to expand and contract, and wherein the shingles and connectors of the semi-rigid panel remain connected to each other throughout handling and installation, and wherein the shingles are aligned when the panel is installed on a flat surface, and wherein the connectors are substantially contained within the plane of the shingles such that the installed assembly functions as a conventional individual shingle installation, and wherein the shingles within the panel and the alignment gauge being configured in such a manner that a second row of adjacent panels being placed on top of and overlapping a first row of adjacent panels and offset laterally such that a mark or edge of the panels in the second row aligns with a mark or edge of panels in the first row, the keyways of the second row are offset from the keyways in the first row, and wherein the shingles within the panel and the alignment gauge being configured in such a manner that a third row of adjacent panels being placed on top of and overlapping the second row of adjacent panels and offset laterally such that a mark or edge of the panels in the third row aligns with a mark or edge of panels in the second row, the keyways of the third row are offset from the keyways in the second and first rows.

6. The assembly of claim 4, wherein at least two of the shingles in the assembly have a different width.

7. The assembly of claim 5, wherein at least two of the shingles in the assembly have a different width.

8. The assembly of claim 4, wherein at least two of the shingles in the assembly have a different width, and wherein the keyways of the second panel are offset laterally at least one and one half inches from the keyways of the first panel.

9. The assembly of claim 5, wherein at least two of the shingles in the assembly have a different width, and wherein the keyways of the second panel are offset laterally at least one and one half inches from the keyways of the first panel.

10. A ventilation space for cedar shingle installations comprising: a multitude of ridges or beads or other spacers installed on the back of the shingles; the ridges or beads or other spacers providing a gap between overlapping layers of shingles and between the shingle installation and the substrate, wherein the gap provides a capillary break between shingle layers and between the shingle installation and the substrate, the capillary break preventing the accumulation and entrapment of moisture, and wherein the gap provides an airspace between shingle layers and between the shingle installation and the substrate, the airspace enabling airflow that provides faster and more even drying.

11. The ventilation space of claim 10, wherein the spacers are comprised of ridges or beads that are parallel to the side edges of the shakes or shingles.

12. The ventilation space of claim 10, wherein the spacers are comprised of ridges or beads that are parallel to the side edges of the shakes or shingles, and wherein the ridges or beads are positioned such that they block moisture from moving laterally between shingle layers into underlying keyway joints.

13. The assembly of claim 1, wherein the assembly includes a ventilation space comprising: a multitude of ridges or beads or other spacers installed on the back of the shingles; the ridges or beads or other spacers providing a gap between overlapping layers of shingles and between the shingle installation and the substrate, wherein the gap provides a capillary break between shingle layers and between the shingle installation and the substrate, the capillary break preventing the accumulation and entrapment of moisture, and wherein the gap provides an airspace between shingle layers and between the shingle installation and the substrate, the airspace enabling airflow that provides faster and more even drying.

14. The assembly of claim 1 wherein the assembly includes a ventilation space comprising: a multitude of ridges or beads installed on the back of the shingles; the ridges or beads or providing a gap between overlapping layers of shingles and between the shingle installation and the substrate, wherein the gap provides a capillary break between shingle layers and between the shingle installation and the substrate, the capillary break preventing the accumulation and entrapment of moisture, and wherein the gap provides an airspace between shingle layers and between the shingle installation and the substrate, the airspace enabling airflow that provides faster and more even drying, and wherein the ridges or beads are parallel to the side edges of the shakes or shingles and positioned such that they block moisture from moving laterally between shingle layers into underlying keyway joints.

15. The assembly of claim 4, wherein at least two of the shingles in the assembly have a different width, and wherein the assembly includes a ventilation space comprising: a multitude of ridges or beads installed on the back of the shingles; the ridges or beads or providing a gap between overlapping layers of shingles and between the shingle installation and the substrate, wherein the gap provides a capillary break between shingle layers and between the shingle installation and the substrate, the capillary break preventing the accumulation and entrapment of moisture, and wherein the gap provides an airspace between shingle layers and between the shingle installation and the substrate, the airspace enabling airflow that provides faster and more even drying, and wherein the ridges or beads are parallel to the side edges of the shakes or shingles and positioned such that they block moisture from moving laterally between shingle layers into underlying keyway joints.

16. A connector for connecting side-by-side shingles to each other; the shingles and connectors forming a panel, wherein the structural integrity of the panel is such that the panel will not break or deform when subjected to normal handling, and wherein the shingles are aligned when the panel is installed on a flat surface, and wherein the connectors are substantially contained within the plane of the shingles and allow the shingles to expand and contract normally such that the installed assembly functions as a proper conventional individual shingle installation.

17. A clip for connecting side-by-side shingles to each other, the clip comprising: plates that overlaps the front and back of both shingles; tabs that extend from the outer edge of the plates into slots in the shingles; the plates overlapping each shingle connected to each other in a manner such that a spring tension forces the tabs of the clip into the shingle slots when the clip is installed, wherein the spring tension of the clip is such that the tabs will remain in the shingle slots as the shingles expand and contract normally, and wherein the spring tension of the clip is such that the tabs will remain in the shingle slots when a plurality of connected shingles are bowed in a manner that would be typical during handling and installation, and wherein the installed clips are substantially contained within the plane of the connected shingles such that a plurality of connected shingles functions as a conventional individual shingle installation.

18. The clip of claim 17, wherein the clip provides a consistent keyway space between each pair of connected shingles.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0074] FIG. 1-A is a conceptual diagram illustrating the front-side of a shingle panel, in this configuration, showing seven shingles (1), and two rows of six inter-shingle clips, center clips (2), and upper clips (3). The drawing also shows two horizontal rows of vertically aligned keyway indicators to be used for registering the position of the next course. One row of indicators is close to the top of the shingles and includes a measurement reference number to the right of the indicators (4). The second row of indicators is located near the center of the panel (5). The panel is installed using two nails per shingle (6), following the same fastening conventions as specified by building codes for individual shingles.

[0075] FIGS. 1-B, and 1-C, are drawings of shingle panels that are identical to FIG. 1-A, except for variations in the shingle pattern. All three shingle patterns are interchangeable and use the same indicators in the same position.

[0076] FIG. 2-A shows a typical installed section with keyway joints offset over 3 courses. Panels in the second course are registered with the 12 indicators in the first course. Panels in the third course are registered with the 12 indicators in the second course. All panels in this assembly are of the same pattern shown in FIG. 1-A.

[0077] FIG. 2-B shows a typical installed section with keyway joints offset over 3 courses. Panels in the second course are registered with the 24 indicators in the first course. Panels in the third course are registered with the 24 indicators in the second course. All panels in this assembly are of the same pattern shown in FIG. 1-A.

[0078] FIG. 3-A is the same as FIG. 2-A, except the assembly includes panels of all three shingle panel patterns, randomly distributed.

[0079] FIG. 3-B is the same as FIG. 2-B, except the assembly includes panels of all three shingle panel patterns, randomly distributed.

[0080] FIG. 4 is a flow diagram illustrating the steps involved in installing the shingle panels with keyway offsets over 3 courses.

[0081] FIG. 5 is a perspective view of the back view of a shingle illustrating the ventilation ridges.

[0082] FIG. 6-A is a cross section of the spacer from a previous shingle panel developed and tested by this inventor. The spacer allows shingles to expand and contract so does not need to be removed after installation.

[0083] FIG. 6-B is a cross section of the same spacer shown in FIG. 6A, as installed during assembly, between two side-by-side shingles (1), with the spacer and shingles held in place by a bonding strip (2) that extends across the width of the panel on the back, and with the spacer engaging a shallow slot (3) in each shingle.

[0084] FIG. 6-C is a cross section of the same spacer shown in FIG. 6A that illustrates how the spacer is deformed as the shingles expand and compress the spacer, causing the spacer to disengage from the shingles.

[0085] FIG. 6-D is a cross section of the same shown in FIG. 6A that illustrates how the spacer is deformed as the panel is bowed, causing the spacer to disengage from the shingles.

[0086] FIG. 7-A is a view in perspective of one embodiment of an inter-shingle connector or clip, a component of the present invention. The clip is made from a spring like flexible material, and is designed to snap into place with spring tension when connected to shingles.

[0087] FIG. 7-B is a cross section of the inter-shingle clip of the present invention, showing the uninstalled shape that provides the spring tension when installed. The clip is installed between two shingles with the base (1) against the back of the shingles, the top (2) against the front of the shingles, and the tabs (3) engaged in slots on the front and back of the shingles. The center section of the clip (4) maintains a consistent keyway space between shingles and allows the shingles to expand and contract.

[0088] FIG. 7-C is an illustration of the inter-shingle clip of the present invention from the front.

[0089] FIG. 7-D shows the inter-shingle clip and a cross section of two adjacent shingles (1) showing the slots (2) on the front and back of the shingles that will receive the clip tabs when the clip and the shingles are assembled.

[0090] FIG. 7-E is the same inter-shingle clip shown above, attached to a pair of side-by-side shingles, with the clip tabs engaged in slots on the front and back of each shingle.

[0091] FIG. 7-F is the same inter-shingle clip shown above, attached to a pair of side-by-side shingles, with the clip tabs engaged in slots on the front and back of each shingle. The clip connects the shingles without the use of a bonding strip, and remains connected as the shingles expand and compress the clip.

[0092] FIG. 7-G is the same inter-shingle clip shown above, attached to a pair of side-by-side shingles, with the clip tabs engaged in slots on the front and back of each shingle. The clip connects the shingles without the use of a bonding strip, and remains connected as the panel is bowed.

[0093] FIG. 8 shows the pair of inter-shingle clips used to connect an adjacent pair of shingles in the shingle assembly. The Upper clip (1) connects the shingles closer to the tip of the tapered shingles and is designed for a reduced shingle thickness. The Center clip (2) connects the two adjacent shingles near the center of the shingle height, above the maximum exposure height, and is designed to accommodate the thickness of the shingles at that point.

[0094] FIG. 9 shows the Center clip for an alternative inter-shingle clip design for the present invention, that provides greater panel strength by using angled top and bottom tabs (1) that install in angled shingle slots.

DETAILED DESCRIPTION OF THE INVENTION

[0095] The present invention, as well as features and aspects thereof, is directed towards providing a shingle assembly to aid in the proper installation of shingles and includes a method for installation of the shingles. In general, embodiments of the invention provide panels of shingles and assembly guides that when followed, result in the installation of shingles that meet keyway space requirements and keyway offset requirements, and also provide an aesthetically pleasing distribution of the shingles. Embodiments of the invention also enable a much faster installation, with greater precision than is typically achieved in conventional installation, and include a built-in ventilation system that improves the performance of the shingles.

[0096] Turning now to the figures in which like labels refer to like elements through the several views, various features, aspects and embodiments of the present invention are described.

[0097] FIG. 1-A is a conceptual diagram illustrating the front-side of a shingle panel or shingle-strip, in this embodiment, showing seven shingles (1), a center row of six inter-shingle clips (2), and an upper row of six inter-shingle clips (3). The shingles in this assembly are not connected to each other by any means. Testing has shown that this assembly does not break or fail in any manner when subjected to normal handling associated with manufacturing, packaging, and installation. The panel will flex or bow a limited amount about the keyway axes, each joint providing gradually increasing resistance to excessive bowing, as is necessary to distribute forces encountered in typical handling, but the panel does not break, and the butt line of the shingles installs as a straight line without attention to that alignment by the installer. The clips do not disengage when the shingles expand and contract, or when the panel assembly is normally bowed or flexed. The shingles are not connected to each other by any other means such as backer boards or bonding strips, and thus perform as properly installed conventional shingles.

[0098] FIG. 1-A also shows two horizontal rows of keyway indicators to be used for registering the position of the next course. One row of indicators is close to the top of the shingles and includes a measurement reference number to the right of the indicators (4). The second row of indicators (5) is located near the center of the panel. The upper and lower indicators are aligned. The indicators are in the same position on every panel, and don't need to include numbers, as long as there is a means to differentiate between them such as color coding, geometric shapes, etc. The shingle panel is mounted to the wall or roof using two nails (6) per shingle, following the same fastening conventions as specified by codes for individual shingles.

[0099] FIGS. 1-B, and 1-C, are drawings of shingle panels that are identical to FIG. 1-A, except for variations in the shingle pattern. All three shingle patterns are interchangeable and use the same indicators in the same position. The installer does not need to be aware of shingle pattern variations. These pattern variations enable more efficient shingle inventory management, and further a random installation. Pattern variations are intermittently dispersed when the product is packed in cartons for delivery.

[0100] FIG. 2-A shows a typical installed section with keyway joints offset over 3 courses. The installation system is based on a matrix and may be defined and executed in numerous ways, but the embodiment shown here uses one of the simplest installation methods. Install the first course as a row of adjacent panels. Install the panels with a keyway between panels that is approximately the same width as the keyways between shingles in the panel. Panels are installed using two nails per shingle, just as with conventional individual shingles.

[0101] Start the next course anywhere, typically in the middle and working toward the corners. Align either the left or the right edge of the first panel in the next course with either of the two indicators on the panels in the previous course. Adjust the height of the panel to achieve the desired exposure. The exposure is defined as the height of the exposed shingle in the previous course. In FIG. 2-A, the left edge of the first panel in the second course is aligned with the 12 indicator in the previous course, as are all subsequent panels in this course. The indicator represents the width of the keyway, so the left edge of the panel is aligned with the right edge of the indicator. Continue installing adjacent panels to the left and right, with a keyway space between panels. If the course crosses a door or window opening, register the first panel on the other side of the obstruction to the same indicator, and then continue installing panels from that point. If a course ends with a very narrow shingle segment, replace the last two shingles with a wider shingle from panel cut offs. Individual shingles are easily removed from the panel scraps. All other aspects of the installation such as inside and outside corners, are handled just as with conventional shingles. For the third course in FIG. 2-A, the left edge of the first panel is aligned with the right edge of the 12 indicator in the second course. Following the installation process insures that all joints are offset at least 1 over 3 courses, as required by code for roof installations. All panels in this assembly are of the same pattern shown in FIG. 1-A.

[0102] FIG. 2-B shows a second example of a typical installed section with keyway joints offset over 3 courses. The left edge of the first panel in the second course is aligned with the right edge of the 24 indicators in the first course. The right edge of the first panel in the third course is aligned with the left edge of the 24 indicators in the second course. Following the installation process insures that all joints are offset 1 over 3 courses, as required by code for roof installations. All panels in this assembly are of the same pattern shown in FIG. 1-A.

[0103] FIG. 3-A is the same as FIG. 2-A, except the assembly includes panels of all three patterns, FIG. 1-A, FIG. 1-B, and FIG. 1-C, randomly distributed.

[0104] FIG. 3-B is the same as FIG. 2-B, except the assembly includes panels of all three patterns, FIG. 1-A, FIG. 1-B, and FIG. 1-C, distributed randomly.

[0105] FIG. 4 is a flow diagram illustrating the steps involved in installing the shingle panels for proper keyway offset over any 3 consecutive courses.

[0106] FIG. 5 is a perspective view of the back of a shingle illustrating the ventilation ridges. The ridges can be formed using a variety of techniques and products and the present invention is not limited to any particular method, although the described methods may in and of themselves be considered as novel. In an exemplary embodiment, the ridges are created from beads of hot melt adhesive. The ridges or beads on the back of the shingles should be close to one tenth of an inch in height. A 0.010 height is adequate for providing a rain-screen installation with adequate ventilation to depressurize solar vapor drive, and meets LEED specified rain-screen space requirements. It is also sufficient to provide a capillary break between successive courses that will work to isolate moisture to the top layer of shingles and will prevent trapped moisture between layers that can promote cupping and decay. The frequency of the ridges should be about one ridge every 1 of shingle width to maintain the gap between shingles, and a gap between shingles and the housewrap or sheathing even with slight natural distortions in the shingles. A ridge should be placed about from both side edges of every shingle to function as a baffle that will prevent windblown precipitation from moving sideways between courses to underlying keyway locations.

[0107] FIG. 7-A is a view in perspective of an inter-shingle connector or clip, a component of the present invention. This embodiment of the clip is made from a spring like flexible material, and is designed to snap into place with spring tension when connected to a pair of adjacent shingles. If manufactured from plastic, the clip can be produced as a continuous extrusion cut to required lengths, or it could be injection molded. Prototypes of the clip have been produced using 3D printing processes.

[0108] FIG. 7-B is a cross section of the above inter-shingle clip, showing an uninstalled shape that provides the spring tension when installed. The clip is installed between two shingles with the base (1) against the back of the shingles, the top (2) against the front of the shingles, and the tabs (3) engaged in slots on the front and back of the shingles. The center section of the clip (4) maintains a consistent keyway space between shingles and allows the shingles to expand and contract.

[0109] FIG. 7-C is an illustration of the above inter-shingle clip from the front.

[0110] FIG. 7-D shows the above inter-shingle clip and a cross section of two side-by-side shingles (1) showing the slots (2) on the front and back of the shingles that will receive the clip tabs when the clip and the shingles are assembled.

[0111] FIG. 7-E is the inter-shingle clip shown above, attached to a pair of side-by-side shingles, with the clip tabs engaged in slots on the front and back of each shingle.

[0112] FIG. 7-F is the inter-shingle clip shown above, attached to a pair of side-by-side shingles, with the clip tabs engaged in slots on the front and back of each shingle. The clip connects the shingles without the use of a bonding strip, and remains connected as the shingles expand, compressing the clip.

[0113] FIG. 7-G is the inter-shingle clip shown above, attached to a pair of side-by-side shingles, with the clip tabs engaged in slots on the front and back of each shingle. The clip connects the shingles without the use of a bonding strip, and remains connected as the panel is bowed about the keyway axes.

[0114] FIG. 8 shows the pair of inter-shingle clips used to connect an adjacent pair of shingles in the shingle assembly. The Upper clip (1) connects the shingles closer to the tip of the tapered shingles and is designed for a reduced shingle thickness. The Center clip (2) connects the two adjacent shingles near the center of the shingle height, above the maximum exposure height, and is designed to accommodate the thickness of the shingles at that point.

[0115] FIG. 9 shows the Center clip for an alternative inter-shingle clip design that provides greater panel strength by using angled top and bottom tabs (1) that install in angled shingle slots. Additionally, the angled slots in the shingles for this clip will be less likely to cause the shingles to split when the clips are installed on vertical grain shingles.

[0116] There are numerous alternative connector designs that would achieve the objectives of this invention. Connectors could attach to the shingles by other mechanical means, or could be bonded to the shingles with adhesives, while still providing adequate structural integrity to maintain consistent keyway spacing and shingle alignment during handling and installation without incorporating a bonding layer, which would compromise the shingle assembly performance compared to a conventional individual shingle installation.

[0117] Because the process described here provides an authentic shingle installation, that meets all code requirements and performance standards for conventional shingle installation, this invention can be used for projects where shingles are specified in the architectural plans. All other installation topics not discussed here should be performed in accordance with all of the same guidelines and code requirements established for conventional cedar shingle installation. For instance, sheathing, building wrap, flashing, and details such as doubling the first course, hips, ridges, corners, etc., are all handled the same way as for conventional installation of individual shingles.

[0118] It should be appreciated that the present invention may also be applied in embodiments in which the width of the panel, or the height of the shingles may vary. For instance, typical shingle heights are 14, 16, 18, and 24 inches. For shakes, typical heights are 18 and 24 inches. In one embodiment of the invention, the panel may use various heights in the same panel to create a staggered look. Panels may also be comprised of custom shingle shapes or patterns such as waves, fish scale shapes, diamond patterns, etc. Other embodiments may utilize different types of spacers or clips between the shingles as a structural element, and to ensure that the shingles are parallel to each other.

[0119] In the description and claims of the present application, each of the verbs, comprise, include and have, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements, or parts of the subject or subjects of the verb.

[0120] The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons of the art.

[0121] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described herein above. Rather the scope of the invention is defined by the claims that follow.