IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0192203
(2011-07-27)
|
등록번호 |
US-8567601
(2013-10-29)
|
발명자
/ 주소 |
- Turek, Travis
- Guenther, Adam
|
출원인 / 주소 |
- TAMKO Building Products, Inc.
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
3 인용 특허 :
32 |
초록
▼
A starter block and a shingle are utilized to form courses that may be positioned in overlapping fashion on a roof to form a roofing covering system. The particular design of the starter block and shingle result in a roofing product that provides increased durability over previous designs. The start
A starter block and a shingle are utilized to form courses that may be positioned in overlapping fashion on a roof to form a roofing covering system. The particular design of the starter block and shingle result in a roofing product that provides increased durability over previous designs. The starter block may be formed with top and bottom surfaces, opposite side surfaces with tapering heights, and a front surface having a greater height than a back surface of the starter block. When the starter block is coupled to a roof deck, a semi-rigid shingle having a generally planar bottom surface may be placed upon the starter block so that a portion of the shingle extends off of the starter block over the back surface thereof and onto the roof deck to facilitate contact between the shingle and the roof deck at a location more proximal to the starter block back surface than if the same back surface had the same height as the front surface. Additionally, the semi-rigid shingle may have an exposed portion and a headlap portion, with the exposed portion extending from a forward shingle edge to the headlap portion and the headlap portion extending from a back shingle edge to the exposed portion. The exposed portion has a central region with a generally uniform thickness moving in the longitudinal direction. Unlike the exposed portion, the headlap portion has a taper in average thickness moving in the longitudinal direction. The taper extends for at least a substantial part of the headlap portion.
대표청구항
▼
1. A method for manufacturing a composite semi-rigid shingle comprising: manufacturing a composite semi-rigid shingle; andforming an arcuate bowed profile in said shingle by stacking a plurality of said shingles in a stacking arrangement, said stacking arrangement comprises at least a first layer an
1. A method for manufacturing a composite semi-rigid shingle comprising: manufacturing a composite semi-rigid shingle; andforming an arcuate bowed profile in said shingle by stacking a plurality of said shingles in a stacking arrangement, said stacking arrangement comprises at least a first layer and a second layer of shingle bundles, each shingle bundle comprising a plurality of shingles stacked on top of each other in the same direction wherein the top surface faces up and each layer comprising a plurality of shingle bundles configured in at least a first row and a second row and each row comprising a plurality of shingle bundles wherein the back edges of the shingles in the shingle bundles of the first row are adjacent to and face the back edges of the shingles in the bundles of the second row, and wherein the second layer of shingle bundles is similarly arranged and aligned orthogonally or perpendicularly to the first layer. 2. The method of claim 1 wherein the forming an arcuate bowed profile in said shingle further comprises stacking more than two layers of shingle bundles wherein each layer is aligned orthogonally or perpendicularly to the preceding layer. 3. The method of claim 1 wherein said stacking arrangement further comprises stacking bundles of shingles on a pallet, each bundle having a group of shingles stacked atop and in alignment with one another and coupled together in the bundle, and each shingle having a forward edge, a back edge, an exposed portion and a headlap portion, the exposed portion extending from the forward edge to the headlap portion, and the headlap portion extending from the exposed portion to the back edge with a longitudinal taper in thickness for at least a substantial part of the headlap portion; assembling each bundle of shingles by placing a plurality of shingles atop one another so that the exposed portions and the headlap portions of each shingle are in alignment with the other shingles of the respective bundle, and then coupling the shingles of the bundle together;stacking the first layer of shingle bundles on the pallet laterally adjacent one another, the first layer including at least the first row and the second row of shingle bundles, each of the first and second rows having the shingle bundles within the respective row in alignment with one another so that the headlap portions of the plurality of shingles of each bundle are facing the same direction and towards the headlap portions of the plurality of shingles of each bundle of the other one of the first and second rows;stacking the second layer of shingle bundles on the pallet laterally adjacent one another and on top of the first layer of shingle bundles, the second layer including at least one row of shingle bundles positioned above the headlap portions of the shingle bundles of the first layer and aligned perpendicularly therewith;wherein the at least one row of shingle bundles of the second layer compresses the headlap portions of the shingle bundles of the first layer to form the first layer shingle bundles with an arcuate bow extending in the longitudinal direction. 4. The method of claim 3 further comprising stacking a third layer of shingle bundles on the pallet laterally adjacent one another and on top of the second layer of shingle bundles, the third layer including at least one row of shingle bundles positioned above the headlap portions of the shingle bundles of the second layer and aligned perpendicularly therewith. 5. The method of claim 1 wherein the shingle is a composite shingle having a forward edge and a back edge and being subdivided into an exposed portion and a headlap portion, the exposed portion extending from the forward edge to the headlap portion and having a central region with a substantially uniform thickness in the longitudinal direction, and the headlap portion extending from the exposed portion to the back edge with a taper in average thickness across the headlap portion moving longitudinally towards the back edge, the taper extending for at least a substantial part of the headlap portion. 6. The method of claim 5 wherein the thickness of the exposed portion of the shingle across an entire width of the shingle and the thickness of the headlap portion are substantially equal in a region where the exposed portion transitions to the tapered headlap portion and wherein the headlap portion includes opposed side surfaces, the side surfaces angling laterally inwardly towards one another near the back edge of the shingle to narrow the shingle width moving towards the back edge. 7. The method of claim 5 wherein the average thickness of the shingle at a transition between the exposed portion and the headlap portion is at least about two times greater than the average thickness of the shingle at the back edge. 8. The method of claim 5 wherein the headlap portion includes opposed side surfaces with at least one nib extending from each of the opposed side surfaces, the at least one nib on one of the side surfaces being longitudinally offset from the corresponding at least one nib on the other side surface such that alignment of the shingles laterally adjacent to another shingle on the roof deck results in at least one nib of one shingle mating with at least one nib of the adjacent shingle. 9. The method of claim 1 wherein the composite material of the composite shingle is a combination of at least a polymer component and a filler component. 10. The method of claim 9 wherein the filler component includes limestone. 11. The method of claim 1 wherein a top surface of the shingle is configured to resemble slate. 12. The method of claim 1 wherein a bottom surface of the shingle is generally planar. 13. A method for manufacturing a composite semi-rigid shingle comprising: manufacturing a composite semi-rigid shingle, said shingle having a forward edge and a back edge and being subdivided into an exposed portion and a headlap portion, the exposed portion extending from the forward edge to the headlap portion and having a central region with a substantially uniform thickness in the longitudinal direction, and the headlap portion extending from the exposed portion to the back edge with a taper in average thickness across the headlap portion moving longitudinally towards the back edge, the taper extending for at least a substantial part of the headlap portion; andforming an arcuate bowed profile in said shingle by stacking a plurality of said shingles in a stacking arrangement, said stacking arrangement comprising stacking bundles of said shingles on a pallet, each bundle having a group of shingles stacked atop and in alignment with one another and coupled together in the bundle, and each shingle having a forward edge, a back edge, an exposed portion and a headlap portion, the exposed portion extending from the forward edge to the headlap portion, and the headlap portion extending from the exposed portion to the back edge with a longitudinal taper in thickness for at least a substantial part of the headlap portion,the forming the arcuate bowed profile further comprising assembling each bundle of shingles by placing a plurality of shingles atop one another so that the exposed portions and the headlap portions of each shingle are in alignment with the other shingles of the respective bundle, and then coupling the shingles of the bundle together;stacking a first layer of shingle bundles on the pallet laterally adjacent one another, the first layer including at least a first row and a second row of shingle bundles, each of the first and second rows having the shingle bundles within the respective row in alignment with one another so that the headlap portions of the plurality of shingles of each bundle are facing the same direction and towards the headlap portions of the plurality of shingles of each bundle of the other one of the first and second rows;stacking a second layer of shingle bundles on the pallet laterally adjacent one another and on top of the first layer of shingle bundles, the second layer including at least one row of shingle bundles positioned above the headlap portions of the shingle bundles of the first layer and aligned perpendicularly therewith;wherein the at least one row of shingle bundles of the second layer compresses the headlap portions of the shingle bundles of the first layer to form the first layer shingle bundles with an arcuate bow extending in the longitudinal direction. 14. A method for manufacturing a composite semi-rigid shingle comprising: manufacturing a composite semi-rigid shingle, said shingle having an exposed portion and a headlap portion; andforming an arcuate bowed profile in said shingle by stacking a plurality of said shingles in a stacking arrangement, said stacking arrangement comprises at least a first layer and a second layer of shingle bundles, each shingle bundle comprising a plurality of shingles stacked on top of each other in the same direction wherein the top surface faces up;wherein said first layer comprises a plurality of shingle bundles configured in at least a first row and a second row, the first layer is configured such that the headlap portion of the first row of shingle bundles abuts the headlap portion of the second row of shingle bundles; andwherein the second layer comprises one row of shingle bundles wherein said row of said second layer is on top of a portion of the headlap portion the shingle bundles of the first row of said first layer and a portion of the headlap portion of said shingle bundles of said second row of said first layer.
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