Abstract
An assembly, and a machine for constructing the assembly, that provides a much faster and more precise shingle installation with optimized 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, and 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, and wherein manufacturing the assembly can be sufficiently automated to enable efficient and practical production.
2. A machine for assembling the assembly of claim 1.
3. A process for assembling the assembly of claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] FIG. 1-A is a plan view of the shingle assembly of the present invention.
[0075] FIG. 1-B and 1-C are plan views of the shingle assembly of the present invention showing
[0076] shingle pattern variations.
[0077] FIG. 2 is a view of an installation of the shingle assembly of the present invention.
[0078] FIG. 3 is a flow diagram illustrating the steps for installing the shingle assembly of the present
[0079] invention with keyways offset over 3 courses.
[0080] FIG. 4-A is a cross section of the clip or connector of the present invention.
[0081] FIG. 4-B is a perspective view of the clip or connector of the present invention.
[0082] FIG. 5-A shows the components of the clip installation and clinching mechanisms of a machine
[0083] in accordance with an embodiment of the present invention, and the shingles, in the load position.
[0084] FIG. 5-B shows a primary clinching mechanism of the machine of FIG. 5-A with the gun mount bar pressed against the shingles.
[0085] FIG. 5-C shows the primary clinching mechanism of the machine of FIG. 5-A with the gun
[0086] mount bar pressed against the shingles and the clips driven through the shingles.
[0087] FIG. 5-D shows the primary clinching mechanism of the machine of FIG. 5-A moved in one direction to clinch one leg of the clips.
[0088] FIG. 5-E shows the primary clinching mechanism of the machine of FIG. 5-A moved in the opposite direction to clinch the other leg of the clips.
[0089] FIG. 5-F shows the primary clinching mechanism of the machine of FIG. 5-A returning to the centered load position
[0090] FIG. 5-G shows the punches of a secondary clinching mechanism of the machine of FIG. 5-A clinching the clips further into the shingles.
[0091] FIG. 5-H shows the gun mount bar and the punches of the secondary clinching mechanism of the machine of FIG. 5-G returning to the load position.
[0092] FIG. 6-A is a top view of the machine of FIG. 5-A showing shingles as loaded on the infeed side of the clipping mechanism, and the assembled shingle-strip on the outfeed side.
[0093] FIG. 6-B is a side view of the machine of FIG. 5-A showing a set of shingles advanced by the push bar to a clipping position.
[0094] FIG. 6-C is a side view of the machine of the present invention showing a set of shingles in a
[0095] clipping position, with the gun mount bar pressed against the shingles.
[0096] FIG. 6-D is a side view of the machine of the present invention showing a set of shingles in a
[0097] clipping position, the gun mount bar pressed against the shingles, and the clips driven through the shingles.
[0098] FIG. 7 is a flow diagram illustrating the steps for using the machine of the present invention to assemble a set of shingles as a shingle-strip.
[0099] FIG. 8 is a perspective view of the ventilation beads or ridges on the back of the shingles of the present invention.
[0100] FIG. 9 is a detailed side view of a machine for manufacturing a shingle assembly in accordance with an embodiment of the invention.
[0101] FIG. 10 is a detailed top view of the machine of FIG. 9.
[0102] FIG. 11 is a photograph of another embodiment of a machine for manufacturing a shingle assembly.
[0103] FIG. 12 is another photograph of the machine of FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
[0104] The present invention, as well as features and aspects thereof, provides a shingle assembly to aid in the proper installation of shingles, a machine and a method for efficiently manufacturing the shingle assembly, as well as a method for installation of the shingles. In general, embodiments of the invention provide panels of shingles that have alignment guide marks, 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.
[0105] As used herein, the terms shingle-set, shingle-strip, shingle panel, or panel are used interchangeably to describe a shingle assembly. As will be appreciated, embodiments of the invention may be suitable for manufacturing panels or assemblies of shingles or shakes and, as used herein, the term shingle encompasses/includes shakes.
[0106] While embodiments of the invention are described for use with shingles that are produced from Western Red Cedar, Eastern White Cedar, or Alaskan Yellow Cedar, the invention is not so limited, and there are other durable rot resistant woods that can be used effectively. Additionally, embodiments may be used with various synthetic shingles. For simplicity, the terms shingle or cedar shingle will be used as representative of shingles or shakes of any composition. Embodiments of the invention are likewise not limited to any specific shingle size.
[0107] 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.
[0108] FIG. 1-A is a conceptual diagram illustrating the front-side of a shingle-strip or shingle panel or assembly 10 according to an embodiment of the invention. In this embodiment, showing seven shingles that vary in width from about 3- to about 6- forming a shingle-strip that is about 36 in width, and about 17- high. FIG. 1-A includes seven shingles 1, with spaces or keyways 4 between the shingles 1 to allow for expansion, a lower row of six lower shingle clips or fasteners 2, and a row of six upper shingle clips or fasteners 3.
[0109] As will be appreciated, embodiments of the invention are not limited to the specific assembly 10 as depicted in FIGS. 1-A, 1-B, or 1-C. In embodiments, the dimensions, e.g., width or length, of the assembly/panel may vary. Likewise, the dimensions of individual shingles, and the location of the fasteners 2, 3, may vary without departing from the scope of the invention.
[0110] Testing has demonstrated that this shingle assembly 10 does not break or fail in any manner when subjected to normal handling associated with manufacturing, packaging, and installation. The assembly 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 assembly does not break, and the butt line of the shingles installs as a straight line without attention to that alignment by the installer. 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.
[0111] As shown, the shingle assembly 10 also includes two horizontal rows of numbers, or rulers, to be used for registering the position of the next course of shingles. A lower ruler 5 is located just above the lower fasteners 2. An upper ruler 6 is located near the top 14 of the shingle assembly 10. Both the upper ruler 6 and lower ruler 5 include alignment guide marks 7 at an offset distance equal to .sup.rd of the shingle-strip width. The upper and lower alignment guide marks 7 are aligned. The guide marks 7 are in the same position on every shingle-strip, regardless of shingle pattern. The alignment guide marks 7 provide a registration reference for offsetting the next course horizontally. The alignment guide marks 7 could be represented graphically in numerous ways and do not need to include numbers. The shingle assembly 10 is mounted to the wall or roof using two nails per shingle, following the same fastening conventions as specified by codes for individual shingles.
[0112] FIG. 1-B, and FIG. 1-C, are drawings of shingle assemblies 20, 30 that are identical to FIG. 1-A, except for variations in the shingle pattern. Shingle widths in these patterns vary from about 3- to about 8-. All three shingle patterns are interchangeable and use the same alignment guide marks 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.
[0113] FIG. 2 shows a typical installed section 40 of shingle assemblies with keyway joints offset in this embodiment, a minimum of about 1- 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.
[0114] In use, installation begins by installing a first course 42 as a row of adjacent shingle assemblies 10, 20, 10, 30. Install the shingle assemblies allowing a keyway space 44 between shingle assemblies that is approximately the same width as the keyways 4 between shingles 1 in the shingle assemblies. The keyway space 44 in this embodiment is about 3/16. Shingle assemblies are installed using two nails per shingle 1, just as with conventional individual shingles.
[0115] An installer may start the second course 46 anywhere, but typically in the middle and working toward the corners. Align the left edge 48 of the first shingle assembly 10 in the second course 46 with any of the alignment guide marks 7 (FIG. 1-A) in the first course 42. Adjust the height of the shingle assembly 10 to achieve the desired exposure, which is defined as the height of the exposed shingle in the previous course. In FIG. 2, the left edge 48 of the first installed shingle assembly 10 in the second course 46 is aligned with an alignment guide mark of the previous course, as are all subsequent shingle-strips in this course. After installing the first shingle assembly 10 of the course, continue installing adjacent shingle-strips to the left and right, with a keyway space 44 between shingle assemblies.
[0116] If the course crosses a door or window opening, register the first shingle-strip on the other side of the obstruction to any alignment guide mark in the previous course, and then continue installing adjacent shingle-strips from that point. If a course ends with a very narrow shingle segment, replace the last two shingles with a wider shingle from shingle-strip cut offs. Individual shingles are easily removed from the shingle-strip scraps. All other aspects of the installation such as inside and outside corners, are handled just as with conventional shingles. The third and fourth courses 50, 52 in FIG. 2 are installed following the same process as for the second course 46. Following the installation process results in proper joint offsets of at least 1- over 3 courses. Shingle-strips in this assembly include different patterns as shown in FIG. 1-A, FIG. 1-B, and FIG. 1-C.
[0117] FIG. 3 is a flow diagram illustrating the steps involved in installing the shingle panels for proper keyway offset over any 3 consecutive courses.
[0118] Referring now to FIGS. 4-A and 4-B, in an embodiment, the clip/fastener 2, 3 used to secure shingles 1 together into a shingle assembly 10 has a crown width 60 of about 1-, and the leg length 62 is about . As will be appreciated, embodiments may utilize fasteners, e.g., staples, that are larger or smaller depending upon, for example, the thickness of a shingle, and the fasteners may be manufactured from a variety of materials via a variety of processes. In certain embodiments, the fasteners 2, 3 may be manufactured from stainless steel.
[0119] Turning now to FIG. 5-A, a machine, i.e., a manufacturing system 100 according to an embodiment is depicted. This end view is from an input or infeed end of the manufacturing system 100 and shows the butt end/edge 102 of a plurality of shingles 1, repositionable shingle positioning guides 104, a gun mount bar 106 for pneumatic fastener guns, and the position of the fasteners 108 in the fastener guns before the guns are activated, and the guns 112.
[0120] FIG. 5-A also shows the primary clinching mechanism 120 used to fold over the legs of the fastener 2 (e.g., staple) and a secondary clinching mechanism 130 which is utilized to press the folded legs of the fastener 2 into the underside/surface of the shingle so that the fastener ends does not protrude from the underside/surface of the shingle. This process is shown in FIG. 5-F, FIG. 5-G and FIG. 5-H, which are discussed in greater detail below.
[0121] Referring now to FIG. 5-B, FIG. 5-C and FIG. 5-D, in use, the gun mount bar 106 is pressurized against the shingles, and the primary clinching mechanism 120 is in the centered starting position (FIG. 5-B). The fasteners 2 are then driven through the shingle 1 via the fastener guns (FIG. 5-C). The gun mount bar 106 is used to hold the shingles down while the fasteners are driven through them. The bar may be locked in place by various mechanisms to prevent any potentially deleterious effects of gun recoil.
[0122] The primary clinching mechanism 120, which, in an embodiment, is a laterally movable bar that includes first and second protrusions, 122A and 122B, respectively. Each of the fasteners 2, when driven through the shingle 1, sit between a first protrusion 122A and a second protrusion 122B. The primary clinching mechanism 120 may then be moved in a first direction (FIG. 5-D) wherein the first protrusions 122A fold or clinch a leg of each fastener 2. The primary clinching mechanism 120 is then moved laterally in an opposite direction whereby the second protrusions 122B fold or clinch an opposite leg of each fastener 2 to secure the fastener 2 to the shingle 1. As will be appreciated, the protrusion need not be rounded as depicted and may be squared or cuboid in shape.
[0123] In embodiments, the primary clinching mechanism 120 is automated and may be operatively connected to, e.g., controller or control mechanism, that provides a signal to move the mechanism 120 after fasteners have been driven through a shingle assembly. Of course, in other embodiments, the mechanism 120 may be used activated.
[0124] After folding the legs of the fasteners 2, the primary clinching mechanism 120 is returned to its original center starting position in which the fasteners 2 sit between the first and second protrusions 122A and 122B (FIG. 5-F). At this point, a secondary clinching mechanism 130 is employed to push the ends of legs of the fasteners 2 into the back surface of the shingles 1.
[0125] More specifically, and referring to FIG. 5-G and FIG. 5-H, in a specific embodiment, the secondary clinching mechanism 130 has a base portion 132, such as bar or strip of metal or other rigid material, and a series of punches 134 or contact portions formed on or attached to the base portion 132, e.g., one punch 134 for each leg of the fastener 2. The punches 134 may have an angled distal tip as shown, so push the ends of the fastener legs into the underside of the shingle 1. In use, the punches may be selectively raised to contact and clinch the folded legs of the fasteners and then lowered out of contact with the fasteners.
[0126] In the depicted embodiment, the punches 134 extend upward through openings or apertures 124 in the primary clinching mechanism 120. In such embodiments, the primary and secondary clinching mechanisms may reside in a single laterally extending channel in a recessed clinching mechanism channel 150 in a deck portion 160 of the manufacturing system 100. In other embodiments, the primary and secondary clinching mechanisms may be in separate channels, or may be located on separate manufacturing equipment. Much like the primary clinching mechanism, operation of the secondary mechanism may be automated or it may be selectively actuated by a user.
[0127] Embedding the legs of the clips into the shingles provides structural stability that prevents the side-by-side shingles from skewing with respect to each other. This skewing would result in misaligned shingle butts, narrowing of the keyway spaces between shingles, and a narrower overall width of the assembly.
[0128] Referring now to FIG. 5-H, in use, the punches of the secondary clinching mechanism retract downward, and the gun hammers and gun mount bar retract upward, as needed for push bars to freely advance to the next fastening position.
[0129] Turning to FIG. 6-A, in an embodiment, the manufacturing system 100 includes a table or deck portion 160. The deck portion is substantially horizontal and is supported by a plurality of legs (not shown). In certain embodiments, the deck portion 160 may be a composite of two or more materials. That is, the deck may have a rigid base manufactured from, for example, plywood, and a synthetic top surface that contacts the shingles. The synthetic surface may be UHMW or another material that is durable and abrasion resistant, and has a low friction coefficient so that the shingles may readily slide/move thereon. In embodiments, the deck may be separated by the recessed clinching mechanism channel 150 into an infeed deck portion 162 and an outfeed deck portion 164.
[0130] FIG. 6-A is a top view of the assembly machine/manufacturing system 100. As depicted, six individual shingles 1 are loaded on the deck portion 160 between seven repositionable shingle guides. The shingles 1 are moved on the deck portion 160 and into position for joining via fasteners, through the use of conveyer push bars 170 which are operatively attached to a push bar chain drive 173. As shown, there are six fastener guns 112 mounted to the gun mount pressure bar 106. The figure further depicts the recessed clinching mechanism channel 150, the push bar position sensor 172, and the shingle sensor 174 which are used to facilitate automation of the manufacturing process. As will be appreciated, a variety of sensors may be utilized without departing from the scope of the invention.
[0131] In this embodiment of the assembly machine, one of the conveyor push bars 170 advances the shingles 1 to the fastening position while also automatically aligning the butts of the shingles 1. The conveyor push bars 170 are notched on the bottom to allow the push bar to pass over the shingle positioning guides 104 while maintaining contact with the deck portion 160. The conveyor push bar 170 stops at a programmed distance past the push bar sensor 172, in position for installation of the upper fastener 3. The shingle sensor 174 confirms that shingles 1 are loaded before beginning the fastener installation process. Once the upper fasteners 3 are installed, the push bar 170 advances the shingles 1 a programmed distance, stopping in position for installation of the lower clips 2.
[0132] Turning now to FIG. 6-B is a side view of the assembly machine/manufacturing system 100 of the present invention showing a set of individual shingles 1 advanced and aligned by the push bar 170 to a fastening position. Other components of the assembly machine shown in FIG. 6-B include the infeed deck portion 162, the gun mount bar 106, the fastener 2 as loaded in the fastener gun 112, the fastener gun hammer 113, and the primary clinching mechanism 120 in the clinching bar channel 150.
[0133] FIG. 6-C is a side view of the assembly machine of the present invention showing the gun mount bar pressurized downward to contact the shingles 1. FIG. 6-D is a side view of the assembly machine of the present invention showing the gun mount bar pressurized downward, the gun hammer pressurized downward, and the fasteners 2 driven through the shingles 1 into the clinching bar channel 150. The primary clinching mechanism 120 is in the centered position when the fasteners 2 are driven through the shingles 1.
[0134] FIG. 7 is a flow diagram illustrating the steps involved in using the assembly machine of the present invention to assemble a set of individual shingles as a shingle-strip, or panel.
[0135] FIG. 8 is a perspective view of the back of a shingle illustrating the ventilation ridges 180. 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.
[0136] 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.
[0137] 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.
[0138] 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.
[0139] Referring now to FIGS. 9 and 10, in an embodiment, the manufacturing system 200. In The depicted embodiment, the nose of each fastening gun 212 presses into the shingle 1 and is secured in place to prevent recoil during discharge, that is, there is no pressure bar that contacts the shingles 1. As depicted, the deck portion 260 includes a channel 250 that includes the first clinching mechanism 220. The first clinching mechanism 220 sits in a closely fitting channel 250 that is formed in a section of UHMW 222 which sits on the plywood base 224. The channel 250 allows the first clinching mechanism 220 (which has a plurality of protrusions 227 secured to a base bar portion 226) to move laterally back and forth to function as described above. As shown, the deck portion 260 (which includes a plywood base and a UHMW surface) is secured to a support structure 262 having a plurality of legs. Servo motors 264 rotate to move a chain 266 that is operatively attached to and moves push bars 268 that urge shingles 1 into position for fastening. The fastening guns 212 travel in a substantially vertical linear path up and down via a guide structure 270. In the depicted embodiment, dual guide rod air cylinders are utilized to raise and lower the guns 212.
[0140] FIG. 11 is a picture of a manufacturing system 300 according to another embodiment of the invention. In this embodiment, eight shingles (not shown) are assembled into a panel via fasteners from seven fastener guns 312. The shingle position guides 304 are shown on the deck portion 360. In this embodiment, the deck portion 160 further includes a section that includes a features a plurality of longitudinal channels 340 which are sized and shaped to allow shingles to be urged out of the system 300 by the push bars 368 without the staples damaging the UHMW surface of the deck portion 160.
[0141] FIG. 12 depicts the lateral channel 390 that houses the primary clinching mechanism. The protrusions 392 of the mechanism move back and forth in channel 390 to fold over the legs of fasteners (not shown).
[0142] Embodiments of the invention may utilize pneumatic systems that employ compressed air. Such systems may use solenoid valves to control movement and/or operation of various components. The solenoid valves may be electronically interconnected to a controller to automate various portions of the manufacturing process, e.g., advancing and fastening shingles.
[0143] In embodiments, the secondary clinching mechanism may be housed in a separate table/manufacturing station. In certain embodiments, that same station having the secondary clinching mechanism may also include a saw that trims the shingles of a shingle assembly to a single uniform length.
[0144] 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.
[0145] 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.
[0146] 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.
