Abstract:
Is hereby provided an apparatus for batch cutting shingles, the apparatus comprising a table including a carriage module for receiving a plurality of shingle sheets thereon; and a power pack module supported by the table and operatively connected to a cutting module including at least two cutting blades mounted on a support arm, the two cutting blades being disposed at an angle thereof and adapted to simultaneously cut the plurality of shingle sheets to produce a plurality of shingle caps. A method of billing shingles cuttings with an apparatus for batch cutting shingle sheets and a method of cutting bundles of sheaves is also provided.

Description:
CROSS-REFERENCE 
       [0001]    The present United States patent application relates to and claims priority from U.S. provisional patent application No. 61/267,168, filed Dec. 7, 2009, entitled CAP&#39;S CUTTER, which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The technical field relates to shingles cutting apparatuses. More precisely, the present technical field relates to a shingle caps cutter apparatus. 
       BACKGROUND 
       [0003]    Asphalt shingles are commonly installed on roofs to prevent water infiltration in buildings. They also have an aesthetic purpose if only for their color. New constructions nowadays tend to have a plurality of gable and attic windows. Every ridge requires to be capped with shingle caps to prevent water infiltration thereof and to improve the uniformity of the roof finishing. 
         [0004]    A significant number of shingle caps can be required on a single roof. It is not rare to find 5, 10 and even more complete bundles of asphalt shingles cut to cap all the roof ridges. This makes a lot of shingle caps obtained with a lot of work in addition to the risks of getting injured in the process of cutting each shingle in caps. 
         [0005]    Therefore, a need has been felt for a shingle cutting apparatus that can cut sheaves in caps. It is also desirable to provide a shingle cutting apparatus that can batch process the cutting of shingles and a method of monitoring cuttings thereof. Another need, inter alia, has been felt over the existing art for computerized shingle cutting apparatus adapted to monitor and calculate the number of cuts made with the apparatus. 
       SUMMARY 
       [0006]    It is one aspect of the present invention to alleviate one or more of the drawbacks of the background art by addressing one or more of the existing needs in the art. 
         [0007]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles to convert each shingle in a plurality of asphalt shingle caps; the apparatus being adapted to simultaneously make a plurality of cuts and provided with a sliding table to effortlessly move a bundle of shingles at the time in a desired cutting position; a plurality of diamond coated circular blade are arranged in a layout configured to adequately cut one or more shingle caps at the same time; one or more motors are operatively connected to the blades and adapted to be powered at the request of a user; spring loaded arms are effortlessly moved by the user to locate and move the blades as desired by the user; the circular blades are adapted to move deep in the plurality of asphalt shingles so that a tangential portion of the blade is reaching the complete depth of each cut. 
         [0008]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles. 
         [0009]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles into an asphalt shingles caps. 
         [0010]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles including a plurality of blades or cutting members to simultaneously perform a plurality of cuts. 
         [0011]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles including a plurality of spring-loaded blade-supporting arms. 
         [0012]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles including a plurality of angularly adjustable spring-loaded blade-supporting arms. 
         [0013]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles including pre-set cutting positions. 
         [0014]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles including at least one blade-supporting arm provided with pivotal and translation motion capability. 
         [0015]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles accompanied with a mechanism capable of 1) sensing when a user is next to the apparatus; 2) sensing the activation of the motor; 3) sensing the angular movement of the blade-supporting arm; 4) sensing the translational movements of the blade-supporting arm; and 5) calculating the amount of time the apparatus is used. 
         [0016]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles that is connectable to a network for transmitting data from the apparatus to a computer. 
         [0017]    At least one embodiment of the present invention provides an apparatus for batch cutting asphalt shingles equipped with a camera for recording the use of the apparatus. 
         [0018]    At least one embodiment of the present invention provides a network-ready apparatus for batch cutting asphalt shingles. 
         [0019]    At least one embodiment of the present invention provides a method of billing for the use of an apparatus for batch cutting asphalt shingles considering, inter alia, the number of cuts made with the apparatus. 
         [0020]    At least one embodiment of the present invention provides an apparatus for batch cutting shingles, the apparatus comprising a table including a carriage module for receiving a plurality of shingle sheets thereon; and a power pack module supported by the table and operatively connected to a cutting module including at least two cutting blades mounted on a support arm, the two cutting blades being disposed at an angle thereof and adapted to simultaneously cut the plurality of shingle sheets to produce a plurality of shingle caps. 
         [0021]    At least one embodiment of the present invention provides a method of billing shingles cuttings with an apparatus for batch cutting shingle sheets, the method comprising sensing a cut of shingle sheets with blades of the apparatus for batch cutting shingle sheets and sending a signal thereof; and providing a price based, at least in part, on the number of sensed cut performed with the shingle cutting apparatus. 
         [0022]    At least one embodiment of the present invention provides a method of cutting bundles of sheaves comprising providing a bundle of shingles; placing the bundle of shingles on a carriage; rotating a plurality of circular blades disposed at an angle thereof; and cutting the bundle of shingles with the plurality of circular blades to make a pile of shingles caps. 
         [0023]    Other objects, aspects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
         [0024]    Additional and/or alternative advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, disclose preferred embodiments of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0025]      FIG. 1  shows an isometric illustration of a shingles cutting apparatus in accordance with an embodiment of the present invention; 
           [0026]      FIG. 2  shows a top plan view of a shingles cutting apparatus in accordance with an embodiment of the present invention; 
           [0027]      FIG. 3  shows an isometric illustration of a portion of the shingles cutting apparatus in accordance with an embodiment of the present invention; 
           [0028]      FIG. 4  shows an exploded isometric illustration of a portion of the shingles cutting apparatus in accordance with an embodiment of the present invention; 
           [0029]      FIG. 5  shows an exploded isometric illustration of a portion of the shingles cutting apparatus in accordance with an embodiment of the present invention; 
           [0030]      FIG. 6  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention; 
           [0031]      FIG. 7  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention; 
           [0032]      FIG. 8  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention; 
           [0033]      FIG. 9  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention. 
           [0034]      FIG. 10  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention. 
           [0035]      FIG. 11  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention. 
           [0036]      FIG. 12  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention. 
           [0037]      FIG. 13  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention. 
           [0038]      FIG. 14  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention. 
           [0039]      FIG. 15  depicts an isometric illustration of the shingles cutting apparatus in a specific cutting position in accordance with an embodiment of the present invention. 
           [0040]      FIG. 16  depicts a top plan view of a sheet of shingle in accordance with an embodiment of the present invention. 
           [0041]      FIG. 17  depicts a top plan view of three caps cut from a sheet of shingle in accordance with an embodiment of the present invention. 
           [0042]      FIG. 18  is a right side elevational view of the shingles cutting apparatus in accordance with an embodiment of the present invention. 
           [0043]      FIG. 19  is a magnified view of a portion of the shingles cutting apparatus of  FIG. 18 . 
           [0044]      FIG. 20  is a magnified view of a portion of the shingles cutting apparatus of  FIG. 18 ; 
           [0045]      FIG. 21  is an isometric view of the shingles cutting apparatus in accordance with an embodiment of the present invention. 
           [0046]      FIG. 22  is a magnified view of a portion of the shingles cutting apparatus of  FIG. 21 . 
           [0047]      FIG. 23  is a block diagram of a communication system associated with the  FIG. 18  is a right side elevational view of the depicts a top plan view of the shingles cutting apparatus in accordance with an embodiment of the present invention. 
           [0048]      FIG. 24  is an illustration of a network connecting a plurality of shingles cutting apparatuses in accordance with an embodiment of the present invention; and 
           [0049]      FIG. 25  is an illustrative flow chart of a method of billing the use of shingles cutting apparatuses in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0050]    The present invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It may be evident, however, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the present invention. 
         [0051]    In respect with an embodiment of the invention,  FIG. 1  and  FIG. 2  illustrate a shingles cutting apparatus  10 . The shingles cutting apparatus  10  includes a table  14  adapted to support a power pack module  18  and a cutting module  22 . The table  14  can be made of welded metallic members  26  and sheet metal  30  as shown in  FIG. 1 . The table could also be made of formed sheet metal (not shown), casted parts (not shown), injected and fiber charged plastic (not shown) or from any suitable material suitable for this type of shingles cutting apparatus  10 . 
         [0052]    The power pack module  18  illustrated in  FIG. 1  and  FIGS. 6-13  is an internal combustion engine  34  similar to utility four-stroke engines sold by companies like Honda®. The power pack module  18  is removably and adjustably secured to the table  14  with a series of slots  36  and fasteners (not shown). An electric motor, shown in  FIG. 2  and  FIG. 5 , or a pneumatic motor (not shown) could alternatively be used and remains within the scope of the present application. The power pack module  18  can be directly operatively connected to the cutting module  22  and have a 1:1 transmission ratio. The internal combustion engine  34  of the present embodiment is associated with a secondary transmission  38  adapted to change the transmission ratio thereof. In the present situation the secondary transmission  38  includes two pulleys  42  used in conjunction with an interconnecting endless belt  46 . A power pack drive  50  is provided and adapted to operatively connect with a counterpart cutting module drive  54 . A vibration damper (not shown) and/or a quick drive connection (not shown) could alternatively be used to operatively connect the power pack module  18  with the cutting module  22 . 
         [0053]    A motor  34  is used in the present embodiment to rotate the cutting module drive  54 . In an alternate embodiment, a plurality of motors (not shown) could be used on the shingles cutting apparatus  10 . The plurality of motors  34  could be operatively connected in series to power the cutting module  22 . In contrast, each motor of the plurality of motors  34  can be operatively connected to its respective cutting blade  70 . 
         [0054]    The cutting module  22  of the present embodiment includes a plurality of diamond coated circular blades  70  adapted for cutting shingles. The cutting module  22  is secured to the table  14  via a plurality of bearing units  58  provided with slots and holes  62  sized and designed to receive fasteners (not shown) therein to fasten the cutting module  22  to the table  14 . The presently embodied cutting module  22  includes two circular blades  70 . Two bearing units  58  are used to pivotally secure an arm  66  to which is operatively secured a circular blade  70 . The arm  66  pivots about an axle  74  defining an arm pivot axis  78  and is spring-loaded with spring  82  (not visible on  FIG. 1 ) and biased in the upper position. The arm  66  mechanically supports the circular blade  70  and includes a drive mechanism  84  therein transmitting the power from the cutting module drive  54  to the circular blade axle  86 . The arm  66  is also accompanied with a safety guard  88  protecting a user against the moving transmission parts thereunder. The drive mechanism  84  contained in the arm  66  might be composed of two pulleys and an interconnecting endless belt as it can be seen in  FIG. 5 . A series of interconnected gears or a drive shaft with relevant associated sets of gears (not shown) could alternatively be used. 
         [0055]    The arm  66  is provided with an elongated handlebar  90  secured thereto on a first end and to which is connected a handle  94  on a second end. The handlebar  90  is a lever multiplying the strength of a user pushing down the circular blade  70  toward the shingle material to cut. The spring-loaded arm  66  raises back the handlebar  90  in its upper position when the user reduces the down force applied thereon. A switch  92  is located on, or about, to the handle  94  to selectively power the cutting module  22 . A safety guard  98  covers the circular blade  70  to prevent direct accidental contact of a user with the circular blade  70 . The safety guard  98  does not cover a lower portion of the circular blade  70  to allow contact of the circular blade  70  with the material to cut. The table  14  is also provided with slots  102  therein to allow the circular blade  70  to get sufficiently low to perform the entire cut. 
         [0056]    As best seen in  FIG. 2 , the second circular blade  70  (illustrated on the left side of  FIG. 2 ) is supported with a similar arrangement of parts: a second handlebar  90 , handle  94  and safety guard  98  are provided therewith. It can be appreciated that the two circular blades  70  are disposed at an angle α thereof. The angle α is representative of the desired shape of a side cut of shingle caps, as it will be discussed below with more details. The angle between both circular blades  70  is adjustable to allow cutting caps with different side angles. Preferably, both sides of the caps are symmetrically cut. Slots and pivots could be provided in the table  14  to provide some adjustments (not illustrated in the Figures). A single motor  34  is used in the present embodiment and the power is drawn between the two circular blades  70  with a universal joint  106  installed therebetween. 
         [0057]    The table  14  is further provided with a carriage module  110 . The carriage module  110  is adapted to receive thereon one or a plurality of asphalt shingles and move laterally in respect with the cutting module  22 . The carriage module  110  can be built in the table  14  of the shingles cutting apparatus  10 . Conversely, as it is depicted in the present embodiment, the lower portion of the carriage module  110  is fastened to the table  14  and can be removed to ease transport. Rails  114  are installed on the table  14  to receive thereon the carriage  118  equipped with cooperating rails  120  provided underneath. One rail  114  of the carriage module  110  includes a plurality of locating holes  122  used to locate the transversal position of the carriage  118 . A spring-loaded plunger  126 , visible in  FIG. 2 , is used to laterally secure the carriage  118  to the table  14  thus preventing undesirable movements therebetween. Three distinct carriage positions are provided to locate the carriage at the positions required to cut three sets of shingle caps from one shingle sheet, as it will be discussed in further details below. 
         [0058]    The carriage  118  includes a plurality of “V” shaped indentations  130  allowing the circular blades  70  to be lowered without cutting the carriage  118 . The shape of the indentations  130  could change depending on the positions of the circular blades  70  without departing from the scope of the present invention. Carriages  118  having different indentation shapes  130  can also be provided in a kit of parts or as a separate addition to an existing shingles cutting apparatus  10 . 
         [0059]    Moreover, the carriage  118  is provided with a lateral stopper  134  and a plurality of rear stoppers  138  to properly locate the sheet of shingles to be cut with the shingles cutting apparatus  10 . All the stoppers  134 ,  138  are adjustably secured to the carriage  118  with slots  142  and fasteners. 
         [0060]    As best seen in  FIG. 2 ,  FIG. 3  and  FIG. 4 , the carriage module  110  is further equipped with a clamping mechanism  150  for securing the shingles to the carriage  118 . The clamping mechanism  150  is provided with a plurality of connector members  154  pivotally affixed to the rear stoppers  138  with pivots  158  defined thereof. Each connector member  154  is associated with a spring loaded pressure plate  162  secured to linkage members  166 . The pressure plates  162  are adapted to contact the shingles disposed on the carriage  118  and use the strength of the springs  170  to apply pressure thereon. The force generated by the springs  170  helps lock the locking mechanism  174  when the hook  178  engages the hook-receiving portion  182 . The clamping mechanism  150  further includes a front stopper  186  adapted to further secure the shingles on the carriage  118  and defines some openings  190  therein to see the side and the thickness of shingles secured on the carriage  118 . An exploded view of the shingles cutting apparatus  10  is illustrated in  FIG. 5  for a better overview of the structure. 
         [0061]    Turning now to the series of  FIG. 6  through  FIG. 15  illustrating various operating positions of the carriage  118  in respect with the pair of circular blades  70 .  FIG. 6  illustrates the carriage  118  in its rightmost position without any sheets of shingles  200  thereon whereas  FIG. 7  depicts the same carriage  118  position as  FIG. 6  with a plurality of sheets of shingles  200  thereon.  FIG. 8  shows a cut of the shingles  200  to produce a first pile of caps  200 . 1 .  FIG. 9  illustrates when the arms  66  are raised back in their upper position. The carriage  118  is pushed one position left in  FIG. 10 . The circular blades  70  are cutting the shingles in  FIG. 11  to produce a second pile of caps  200 . 2 .  FIG. 12  illustrates when the arms  66  are raised back in their upper position. The carriage  118  is pushed one position left in  FIG. 13 . The circular blades  70  are cutting the shingles in  FIG. 14  to produce a third pile of caps  200 . 3 .  FIG. 15  depicts the arms  66  in their upper position. 
         [0062]    A typical sheet of shingle  200  is illustrated in  FIG. 16 . The sheet of shingle  200  of the present embodiment includes three separations  204  that half separate the sheet of shingle  200  into three substantially identical shingle portions  208  having a substantially identical width  212 . Each shingle portion  208  is going to be transformed into a cap  200 . 1 ,  200 . 2  and  200 . 3  as it can be appreciated from  FIG. 17 . The angle β (that is in fact two times the angle α between the circular blades  70  and the distance  216  should be adjusted such that the circular blades  70  are reaching the proximal end  220  of two juxtaposed separations  204  in a sheet of shingle  200  to maximize the surface of the sheet of shingle  200 . The distance  216  indicating the position where the planes of the circular blades  70  intersect. The distance  216  would be equal to: 
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         [0063]      FIG. 17  illustrates three caps  200 . 1 ,  200 . 2  and  200 . 3  cut from a sheet of shingle  200  in accordance with an embodiment of the present invention. 
         [0064]    Referring now to  FIG. 18  illustrating a shingles cutting apparatus  10  with a sensor  230  protected by a cover  226  as seen in  FIG. 19  and  FIG. 20 . The sensor  230  is used to send a signal when the arm  90  is in its upper position or not. The signal from sensor  230  is primarily used to increase a counter indicating the number of times the arm  90  has been moved from its upper position. The movement of the arm  90  is one possible way to calculate the number of cut made by the shingles cutting apparatus  10 . 
         [0065]    An alternate embodiment is illustrated in  FIG. 21  and  FIG. 22 . A mechanical counting device  234  is actuated, via actuating member  238 , each time the arm  90  is moved. The number of cut made with the shingles cutting apparatus  10  can be inferred from the number of time the arm  90  has been moved. 
         [0066]    Turning now to  FIG. 23  illustrating a schematic system connecting the shingles cutting apparatus  10  with a network-ready computer system  250  to monitor the use of the shingles cutting apparatus  10 . Firstly there are some possible sensors that can be collectively of individually used in cooperation with the computer system  250 . A microphone  254 , a camera  258 , a motion sensor  262 , a motor RPM sensor  266 , a motor actuation sensor  92  and/or an arm position sensor  230  are operatively connected to a computer system  250  via (or directly) an I/O module  270 . An Ethernet or IP communication interface  274  is connected to the computer system  250  to send data to a counterpart computer system  278  via Internet  282 , or another type of network, and a counterpart I/O module  286 . 
         [0067]    The electronic signal communication provided by the system illustrated in  FIG. 23  is adapted to create a network  290  of interconnected shingles cutting apparatus  10  with optionally appended I/O modules  270 ,  274  as it can be appreciated in  FIG. 24 . The network of shingles cutting apparatuses  10  are also networked with a counterpart computer/server  294  adapted to make cost of use analysis with a billing engine  298  associated therewith. The cost of use analysis is based, at least in part, on the data collected from the various sensors identified in  FIG. 23 . 
         [0068]    A method of billing the use of the shingles cutting apparatus  10  is illustrated in the block diagram of  FIG. 25 . The camera  258  or another motion detection  304  sensor  262  is used to wake up the system  250  that a user is nearby  300  the shingles cutting apparatus  10 . The camera  258  is used to collect images and the microphone is used to collect sound of the use of the shingles cutting apparatus  10 . The computer  250  starts recording  308  while the user uses the saw  312 . The motor RPM  316  and the position  320  of the arm  90  is sensed and the data thereof is sent  324  through the network  290  and received  328  by a counterpart computer  294 . The data is analyzed  332  by the counterpart computer  294  and a billing engine  298  to define a cost associated with the use of the shingles cutting apparatus  10  and provides billing/invoicing  336  thereof. 
         [0069]    The description and the drawings that are presented above are meant to be illustrative of the present invention. They are not meant to be limiting of the scope of the present invention. Modifications to the embodiments described may be made without departing from the present invention, the scope of which is defined by the following claims: