Shingle panel

This application claims priority from U.S. Provisional Application Ser. No. 60/442,381, filed Jan. 23, 2003, which is hereby incorporated by reference.

This invention relates generally to exterior residential or commercial siding.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

As will be readily appreciated from the foregoing summary, the invention provides a more efficient and cost-effective shingle siding system.