Shake Panel and Method for Forming a Shake Surface

Abstract

A shake panel is disclosed having a flexible underlayment layer having a leading edge, an opposite a trailing edge, an upper edge, and an opposite lower edge. A plurality of shakes are provided, each shake having an upper portion affixed to the underlayment layer and a lower portion extending toward the underlayment layer lower edge, each shake extending side-by-side along an adjacent shake to define a keyway space therebetween. In a method for forming a shake surface, a first shake panel is secured to the surface with the leading edge adjacent a leading edge of the surface and the lower edge adjacent a lower edge of the surface. A second shake panel is secured to the surface with the second layer leading edge overlaying the first shake panel trailing edge adjacent a trailing edge of the shakes of the first shake panel.

Having thus described the aforementioned invention, what is claimed is: 
     
         1 . A shake panel comprising:
 a flexible underlayment layer having a leading edge, an opposite a trailing edge, an upper edge, and an opposite lower edge; and   a plurality of shakes, each said shake having an upper portion affixed to said underlayment layer and a lower portion extending toward said underlayment layer lower edge, each said shake extending side-by-side along an adjacent shake to define a keyway space therebetween.   
     
     
         2 . The shake panel of  claim 1 , each said shake lower portion overlying said underlayment layer lower edge, and each said shake having a lower end extending beyond said underlayment layer lower edge. 
     
     
         3 . The shake panel of  claim 2 , each said shake lower end terminating at a distance from said underlayment lower edge equal to that of an adjacent shake of said shake panel. 
     
     
         4 . The shake panel of  claim 3 , each of said shakes being of an equal length to one another. 
     
     
         5 . The shake panel of  claim 1 , said plurality of shakes extending in side-by-side relationship from said underlayment layer leading edge along said underlayment layer lower edge. 
     
     
         6 . The shake panel of  claim 5 , said underlayment layer trailing edge extending beyond said plurality of shakes to define a first overlapping portion configured to underlie an underlayment layer leading edge of an adjacent shake panel. 
     
     
         7 . The shake panel of  claim 6 , said underlayment layer upper edge extending beyond said plurality of shakes to define a second overlapping portion configured to underlie an underlayment layer lower edge of an overlapping shake panel. 
     
     
         8 . The shake panel of  claim 1 , wherein said plurality of shakes comprise shakes having a first width, shakes having a second width, and shakes having a third width. 
     
     
         9 . The shake panel of  claim 8 , said shakes being arranged along said underlayment layer lower edge in a predetermined pattern. 
     
     
         10 . The shake panel of  claim 9 , said predetermined pattern corresponding to the pattern “B-B-A-C-B-A-B-C,” where “A” represents a shake having said first width, “B” represents a shake having said second width, and “C” represents a shake having said third width. 
     
     
         11 . The shake panel of  claim 10 , wherein said first width is approximately 3.5 inches, said second width is approximately 4.5 inches, and said third width is approximately 5.5 inches. 
     
     
         12 . A method for forming a shake surface, said method comprising the operations of:
 a. providing a plurality of underlayment layers, each layer having a leading edge, an opposite trailing edge, an upper edge, and an opposite lower edge, each layer further having a plurality of shakes secured thereto, each shake having an upper portion affixed to its corresponding layer and a lower portion extending toward the lower edge of its corresponding layer, wherein each shake of each layer extends side-by-side along an adjacent shake to define a keyway space therebetween;   b. securing a first of the layers to the surface with the first layer leading edge adjacent a leading edge of the surface and the first layer lower edge adjacent a lower edge of the surface; and   c. securing a second of the layers to the surface with the second layer leading edge overlaying the first layer trailing edge adjacent a trailing edge of the shakes of the first layer;   whereby the shakes of at least the first and second layers cooperate to form a first course of shakes extending along the lower edges of the first and second layers.   
     
     
         13 . The method of  claim 12  further comprising the operation of securing a third of the layers to the surface with the third layer lower edge overlaying the first layer upper edge, whereby the shakes of at least the third layer cooperate to form a second course of shakes extending along the lower edge of the third layer. 
     
     
         14 . The method of  claim 13  further comprising the operation of securing a first starter shake to the surface with a leading edge of the first starter shake adjacent a leading edge of the surface, wherein the third layer is secured to the surface with a leading edge of the third layer adjacent a trailing edge of the first starter shake, whereby the first starter shake cooperates with the shakes of at least the third layer to form a second course of shakes extending along the lower edge of the third layer. 
     
     
         15 . The method of  claim 14 , wherein the first starter shake is selected to have a width along the lower edges of the layers sufficient to horizontally offset the shakes of the second course from the shakes of the first course such that interfaces between the shakes of the second course do not directly overlie interfaces between the shakes of the first course. 
     
     
         16 . The method of  claim 15  further comprising the operation of securing a second starter shake to the surface with a leading edge of the second starter shake adjacent a leading edge of the surface. 
     
     
         17 . The method of  claim 16  further comprising the operation of securing a fourth of the layers to the surface with the fourth layer lower edge overlaying the third layer upper edge, whereby the second starter shake cooperates with the shakes of at least the fourth layer to form a third course of shakes extending along the lower edge of the fourth layer. 
     
     
         18 . The method of  claim 17 , wherein the second starter shake has a width along the lower edges of the layers different from the width of the first starter shake. 
     
     
         19 . The method of  claim 18 , wherein the second starter shake is selected to have a width along the lower edges of the layers sufficient to horizontally offset the shakes of the third course from the shakes of the second course such that interfaces between the shakes of the third course do not directly overlie interfaces between the shakes of the second course. 
     
     
         20 . The method of  claim 19  further including the operation of securing an upper portion of each of the shakes to its corresponding layer with a lower portion of each shake overlying and extending beyond the lower edge of its corresponding layer, with each shake extending side-by-side along an adjacent shake to define a keyway space therebetween.