Shingle design and method of applying

Abstract

Disclosed is a shingle configuration and method of deploying shingles both of which provide improved durability and element resistance. With respect to how the shingles are configured, they are made shorter, thicker, less wide, and have a less dramatic taper than do conventional shingles. Additionally, these shingles are pressure treated with a chemical that provides a barrier making them resistant to wood rot and other elemental maladies. The shingles are then applied to the roof in such a manner that the exposed surface of each individual shingle will be reduced.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/525,973.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of roof shingle designs and methods of applying shingles. More specifically, the present invention relates to an improved configuration for a cedar shake shingle, a chemical treatment of this shingle, and the installation of a plurality of such shingles.

2. Description of the Related Art

Cedar shake shingles have been used for roofing houses for a long time. Shakes are a favorite choice among many homeowners, more for ornamental reasons than for practical ones. Practically speaking, shake shingles have many disadvantages.

One of these disadvantages is in terms of wind resistance. The conventional cedar shake roof will have a difficult time withstanding excessive winds. A typical prior art shingle which would be used on a conventional shake roof is shown in prior art FIGS. 1 and 2. As can be seen in FIG. 1, the prior art shake 10 is relatively thin. It has an upper surface 12, an exposed portion 14, a covered portion 16, a termination and 18, a butt-end 20, an underside 22 and side surfaces 24. The shingle is secured to the conventional roof using 2 fasteners 28, which may be staples or nails. The conventional nails or staples used for such a purpose are typically constructed of electro or hot-dipped galvanized steel.

As will be known to one skilled in the art, shingles are laid in rows, one row over the other, this results in the exposed 14 and covered 16 portions. Portion 16 will be covered by the next row of shingles up the roof, whereas portion 14 is exposed to the elements. The exposed 14 and covered 16 portions are divided by a transition line 26 which is formed by the butt-end 20 of the shingle immediately above it.

The dimensions of the conventional shingle are typically as follows. They typically have a length of 24″, and a butt-end thickness of {fraction (1/2)}″. As maybe seen in FIG. 1, the shingle is tapered towards a termination end 18 which is typically around {fraction (1/8)}″ thick. These dimensions make the ratio of butt-end thickness (about {fraction (1/2)}″), versus termination end thickness (about {fraction (1/8)}″) about 4-1. The distance of the transition line from termination end 18 is typically 10″. Because of the thinness of shingle 10 and its fastener positioning, it is made somewhat vulnerable to excessive winds.

A second disadvantage in a shake roof is in hail resistance. Impact testing of such roofs reveal that even moderate sized hail can create significant damage to the roof's shakes. Similarly, walking on the roof is often avoided because even careful stepping on the roof may resulting damage to the shakes. One of the reasons for this vulnerability of the conventional shake is that its exposure area is very great relative to its overall thickness. It is spread out too thin, in other words.

A third disadvantage present in the prior art shake roof is that its shakes tend, over time, to prematurely curl upwards away from the roof. This makes the overall appearance of the roof somewhat unsightly.

A fourth disadvantage in the conventional shake roof is that it may degrade. This degradation may take the form of dry rot, algae, insect problems, or combinations thereof. These forms of degradation are the result of exposure to the elements, such as rain. The exposed surfaces of the shingles are typically the most affected. This is because they are bare and thus, not barred off from environmental factors.

Because of these four disadvantages, there is a need in the art for a shake, and method of applying that shake, which (i) results in wind and impact resistance, (ii) has better insulation properties, and (iii) forms a barrier between the cedar and the environment to prevent dry rot, algae and insect problems.

SUMMARY OF THE INVENTION

The present invention overcomes these disadvantages in the conventional shake roof by providing a shingle that is thicker with a less dramatic taper, thinner, has a minimized exposure area relative to thickness, and is chemically treated to form a barrier between the cedar and the environment.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present invention is described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a side view of the conventional cedar shake used in the prior art methods.

FIG. 2 is a perspective view of the prior art shake.

FIG. 3 is a side view of the wood shake of the present invention.

FIG. 4 is a perspective view of the wood shake of the present invention.

FIG. 5 is a drawing showing, from a side view, the way in which the shingles of the present invention may be disposed on a roof.

FIG. 6 shows, from a perspective view, how the shingles in the present invention are laid on the roof.

DETAILED DESCRIPTION OF THE INVENTION

The shingle design of the present invention are shown in FIGS. 3 and 4. The manner in which these shingles are laid on a roof are shown in FIGS. 5 and 6.

Referring first to FIG. 3, the shingle of the present invention 30 has an upper surface 32. Upper surface 32 is divided into two portions. The first of these is an exposed portion 34 which will be exposed to the elements. When shingle 30 is nailed on the roof as part of a first row of shingles, a second row of shingles will be laid above it (as shown in FIGS. 5 and 6). The part of upper surface 32 that is not covered by the shingles of the second row creates exposed portion 34. Accordingly, covered portion 36 is the portion of upper surface 32 which is covered by the shingle in the row immediately above it. These two portions 34 and 36 are divided by a transition line 36. Referring to FIG. 6, transition line 36 exists where the butt-end 60 of the shingle in the row above ends, thus exposing portion 34 of shingle 30.

Shingle 30 is configured as follows. From butt-end 40 it may be seen in FIG. 3 that the shingle is tapered until it reaches a termination and 38. The preferred shingle thickness at butt-end 40 is about {fraction (7/8)}″, however, the thickness could fall any where within the {fraction (1/2)}″ to 1″ range—and might even be thicker—and still fall within the parameters of the present invention. The preferred thickness at termination end 38 is approximately {fraction (1/4)}″. These preferred dimensions make the ratio of butt-end thickness ({fraction (7/8)}″), versus termination end thickness, ({fraction (1/4)}″), about 7-2. Comparing this ratio to that of the conventional shingle shown in FIG. 1, which was 4-1, reveals that the shingle of the present invention has a taper that is less extreme, ensuring more longitudinally consistent durability.

Another difference present in shingle 30 from that of shingle 10 is in its overall length. It will be recalled the length of conventional shingle 10 is about 24″. The approximately 18″ shingle of the present invention 30 is significantly shorter.

These differences in taper and thicknesses may be easily observed by comparing the profile of conventional shake's side-surface 24 in FIG. 1 with the side surface 44 of the shake of the present invention shown in FIG. 3. The FIG. 3 profile formed by underside 42, butt-end 40, upper surface 32, and tapered end 38, is much different that that defined by underside 22, butt-end 20, upper surface 12 and tapered end 18 of the conventional shake.

The method of fastening shake 30 to the roof is done using fasteners 48. Fasteners 48 may be electro-galvanized staples or nails. Alternatively, they could be constructed of stainless steel to make them more weather resistant. The fasteners 48 are driven through shake 30 at points approximately one inch up from the transition line 46 and approximately one inch in from the sides 44 of the shake on both sides.

It will now be described the manner in which the shingle is to be chemically treated. The chemical used in applicant's process if known as chromated-copper-arsenate (CCA). CCA is widely used to preserve wooden things. It has most often conventionally been used to preserve wooden articles that are produced from soft woods. Some examples of soft woods might be lodge pole white, jack and red pines. Because pine tends to rot, the CCA is applied in these conventional methods to provide a barrier between the environment and the wood. It has typically been applied to the article on which it is being deposited under pressure. This is so that it penetrates well below the surface of the wood. The chromium component in the CCA bonds with the cellulose in the wood and undergoes a valence change from the hexavalent to the trivalent state. Once this change in states has occurred, the CCA, over a relatively short period of time, under pressure, will not leach out of the wood over the course of time.

The methods of the present invention involve using this CCA method which has already been well-established in the art in terms of being used on pines, to treat cedar for use on shake roofs. Though a different recipient (cedar) is used for the CCA, the process for administering the CCA is the same. It is administered to the shakes, and allowed to impregnate the wood (under pressure) over time. These methods of administering the CCA will be known to those skilled in the art. The only significant difference from that which is conventional is that the CCA is being used to treat shakes instead of the types of wood, and types of products described as conventional above.

Once the cedar shingles for use in the present invention methods have been appropriately CCA treated, they will be ready for installation on a roof.

FIG. 5 shows how the shingles are installed from a side view. In the figure, it may be seen that in upper shingle 50, is disposed on top of shingle 30. Also seeing in this figure is that the butt-end 60 of shingle 50 is what defines the transition line between exposed surface 34 and covered surface 36 on shingle 30. In FIG. 4, it may also be seen that transition line 46 along with the edges of the shingle define an exposed surface (34) which is much smaller than the exposed surface 14 of the conventional shake.

This different in exposure area is significant when coupled with the concept that shake 30 is significantly thicker and less tapered than is conventional. This aspect of the present invention provides numerous advantages. For one, the shingle will be held more tightly to the roof. This is because the shingle in the row immediately above it 50 is thicker, and thus more steady, and has more weight. This helps secure shingle 30 (referring to FIG. 5) better because the bottom of shingle 50 is pressing down harder. This greatly improves the wind resistance and other durability aspects of the shingle 30. The wind resistance will also be improved by the aerodynamics of shingle 30. When conventional shingles become slightly loosed, as will occur over time, they are more easily blown off because of their thinness. There is also more potential lift area that makes the shingle vulnerable to wind that might enter under and lift up on the shingle.

Another advantage created by minimizing the exposure area 34 of the shingle versus the shingles thickness is that there is less surface per shingle that is exposed to the elements. This will minimize environmental degradation.

Also advantageous in shingle 30 over conventional shingle 10, which is thinner, wider, and longer, is that the shingle of the present invention is more durable to hail and to workers stepping on it. Like a pencil is more easily broken than a baseball bat, so is prior art shingle 10 more easily broken than present invention shingle 30. Because of the more uniform thickness of shingle 30 along its length. These factors in combination with the more gradual taper of shingle 30, make it much more durable than the conventional shingle.

A further advantage in the shingle of the present invention is due to the application of CCA. The application of this CCA in combination with the durability improvements caused by the present invention shingles configurations make it even more durable and weather resistant. This is because of the barrier the chemical creates. The combination of all these factors in combination provide a shingled roof which is capable of withstanding winds exceeding 130 mph. Additionally, it may be walked on without the fear of causing significant damage to the shingles. Users will also be added the benefit of improved insulation. The shingles will keep the home cooler in the summer and warmer in the winter. A roof constructed of the methods of the present invention will also be able to withstand extreme temperatures and freeze-thaw conditions found in various climates. Insect, dry rot and algae problems will also be greatly reduced.

Although the invention has been described with reference to the preferred embodiment illustrated in the attached drawing figures, it is noted that substitutions may be made and equivalents employed herein without departing from the scope of the invention as recited in the claims.

Claims

1. A shingle for use on a roof, the shingle comprising:

an upper surface;

an under side;

a side surface;

a butt end

a thickness at said butt end;

a termination end;

said termination end having a thickness;

a ratio of said butt end thickness versus said termination end thickness, said ratio being adapted to improve durability;

a length;

a width;

an exposed portion; and

a covered portion wherein said covered portion is larger than said exposed portion.

2. The shingle in accordance with claim 1 wherein said ratio minimizes environmental degradation.

3. The shingle according to claim 1 wherein including a protective barrier.

4. The shingle according to claim 3 wherein said protective barrier provides chemical protection.

5. The shingle according to claim 4 wherein said protective barrier is chromated-copper-arsenate.

6. The shingle according to claim 1 wherein said ratio is about 7/2.

7. A method of deploying a method of putting shingles on a roof, said method comprising:

providing a plurality of shake shingles each of said shingles having a butt end thickness and a termination end thickness;

configuring said shingles such that a ratio of but end thickness to termination end thickness maximizes durability;

putting down a first row of shingles, each of said shingles in said first row having upper surfaces; and

superimposing a second row of shingles above said first row covering portions of the upper surfaces of said shingles in said first row and leaving an exposed proportion of each of the shingles of the first row which is smaller than said covered portions.

8. The method of claim 7, comprising applying a protective chemical barrier.

9. The method of claim 7 wherein said ratio is about 7/2.

10. A method of deploying shingles on a roof comprising:

reducing a length and a width of the shingles used;

increasing the overall shingle thickness;

applying a protective chemical to at least one exposed surface of the shingles; and

installing the shingles on said roof.