ENCLOSURE FOR WARMING BUILDING MATERIALS

Description

BACKGROUND OF THE INVENTION

Many home builders and roofers utilize materials that are temperature-sensitive. For instance, asphalt shingles may not properly adhere to one another when they are installed at a temperature below about forty degrees Fahrenheit. Consequently, roofers may not be able to work year round in some geographic locations. Some roofers, however, continue to work despite the impact of the temperature on their materials. This can cause shingles to crack and warp, which can lead to a leaky and/or not aesthetically attractive roof.

BRIEF SUMMARY OF THE INVENTION

Techniques for warming building materials are provided. In various implementations, a cover is positioned over building materials and secured in place. The cover at least partially defines an interior space in which the building materials are located. The cover is then connected to a mechanical heating device. The mechanical heating device is activated to provide heat to an interior space. At least some of the building materials are removed from the interior space and used in a building project. In some implementations, the building materials are a pallet of shingles.

Also described herein is a device that can be used in various implementations. The device includes a cover that is configured to at least partially define an interior space to accept materials and provide a barrier to an exterior environment and a mechanical heating device that is coupled to the cover. The mechanical heating device is configured to provide heat to the interior space and to the materials. In various implementations, the mechanical heating device is a blower. The device does not include a frame in various implementations.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items. Entities represented in the figures may be indicative of one or more entities and thus reference may be made interchangeably to single or plural forms of the entities in the discussion.

FIG. 1 is a perspective view of an example enclosure being lowered to enclose a stack of building material that is supported by a pallet, according to one embodiment;

FIG. 2 is a side view of the example enclosure of FIG. 1 in a compressed state for storage, according to one embodiment;

FIG. 3 is a perspective view of the example enclosure of FIG. 1 with a cinching device, according to one embodiment;

FIG. 4 is a bottom perspective view of the example enclosure that includes a bottom strap, according to one embodiment; and

FIG. 5 is a perspective view of the example enclosure of FIG. 1 with an attached heating device, according to one embodiment;

FIG. 6 is a flow diagram of a method for warming building materials using an enclosure, according to one embodiment;

FIG. 7 is a top perspective view of a second example enclosure have a top lid and weighted, rigid seal, according to one embodiment;

FIG. 8 is a side view of the second example enclosure of FIG. 7, according to one embodiment;

FIG. 9 is a perspective detail view of a lower corner of the second example enclosure of FIG. 7, according to one embodiment;

FIG. 10 is a perspective detail view of the lower corner of the second example enclosure of FIG. 9 with an inserted board, according to one embodiment; and

FIG. 11 is a perspective view of third example enclosure with a side opening, according to one embodiment.

DETAILED DESCRIPTION

Temperatures below approximately forty degrees Fahrenheit can render roof installation difficult. For example, shingles and other materials can become brittle and break when a nail gun is used for installation. Additionally, cold shingles may warp or buckle and may not lay flat on the roof. Because the shingles are butted together during installation, shingles that are warped may never lie flat or adhere to the shingles underneath. This may create a pocket such that wind can get under the single and cause blow-offs. Nonetheless, many roofers may attempt to install a new roof, or repair an existing roof, because of customer needs or the roofer's need to continue earning income through colder seasons.

Techniques described herein enable the warming of shingles and other building materials. A cover may be placed over a pallet of building materials and is attached to a heat blower. These techniques may be employed such that the shingles are brought to a temperature between approximately forty degrees and eighty degrees Fahrenheit. For example, a pallet of shingles can be covered with the cover and the heat blower can be activated for approximately twenty-four to forty-eight hours before the roofing job begins. Because the heat blower circulates warm air and warms the shingles up to an appropriate temperature, shingles can be installed without cracking or warping. Thus, a roofer can install a new roof year round, regardless of the temperature. Further discussion of examples of covers and techniques employing such covers may be found in relation to the following sections.

In the following discussion, an example environment is first described that may employ the techniques described herein. Example procedures are then described which may be performed in the example environment as well as other environments. Consequently, performance of the example procedures is not limited to the example environment and the example environment is not limited to performance of the example procedures.

FIG. 1 illustrates a warming enclosure 100 for building material that is operable to employ the techniques described herein. The warming enclosure 100 is sized to encompass a pallet 101 that supports a stack of building materials 102. In one embodiment, the warming enclosure 100 is a portable apparatus having a cover 104 formed of a weather resistant material that defines an interior space 105 that communicates with a bottom opening 106. The cover 104 is placed placement over the stack of building material 108 and lowered so that the bottom opening 106 receives the stack of building material 108. A heater 110 warms the interior space inside of the cover 104.

In one embodiment, the heater 110 is an electrical heating element. In one embodiment the heating element runs on alternating current (“AC”). In another embodiment, the heating element runs on direct current (“DC”). In another embodiment, the heater 110 is a fuel-based heating element. In one embodiment the heating element runs on a hydrocarbon fuel selected from the group consisting of methane, ethane, propane, butane and mixtures thereof.

The stack of materials 102 can be, for example, a pallet load that includes shingles, tar paper, flashing, boxes of nails, drip edge, siding, and other building materials that may or may not conventionally be stored on pallets 101. In some implementations, cover 104 can be used to cover materials that are stored in a manner other than on a pallet. For example, boxes of nails or boxes of shingles can be covered with cover 104. Thus, although the description of various implementations herein refers to a pallet 101 or a stack of materials, use of the cover 104 to cover materials not stored on a pallet 101 are contemplated.

A seal structure 114 of the bottom opening 106 substantially encloses the interior space to one of the stack of building material and a supporting surface for the stack of building material. In one embodiment, the seal structure 114 of the bottom opening 106 substantially pneumatically encloses the interior space to one of the stack of building material and a supporting surface for the stack of building material. The latter can be a ground or floor beside the stack of building material 108 or the pallet 101.

Although cover 104 is shown as having a shape substantially similar to a cube, in some implementations, the cover 104 can have other shapes. For example, cover 104 can have a long, rectangular shape, such as the shape of one or more boxes of siding or other packages of building materials. In addition, because cover 104 is flexible, the cover 104 can take various shapes depending on the materials it is covering.

Cover 104 is configured to substantially cover the stack of materials 102, including the perimeter of the stack of materials 102 and the height of the stack of materials 102, to at least partially define an interior space and provide a barrier to the exterior environment. Cover 104 can be a single-layer of material such as canvas, polyester, vinyl, or another durable non-insulated material. In various implementations, durable materials enable the cover 104 to withstand materials being moved in and out of the cover, transportation, and overall use without developing a hole, tear, or rip. In some implementations, the cover 104 is made of a material that is additionally water-resistant, air tight, and ultra violet (UV)-protected.

Conventional covers consist of multiple layers of insulating material designed to prevent heat from being lost to the external environment. However, these covers can be heavy and bulky. Consequently, roofers may find them to be difficult to transport from job to job and store when not in use. Accordingly, roofers may find conventional covers to be burdensome. By reducing the amount of material used in making the cover, the weight of the cover 104 can be reduced and the cover 104 may be more manageable. For example, consider a compressed state 200 of the cover 104 in FIG. 2.

In FIG. 2, cover 104 is illustrated to show that it is flexible and does not have a rigid frame. Accordingly, the cover 104 can be scrunched up, folded, or otherwise condensed for easy transportation. In some implementations, the cover 104 can be wrapped up and put into a pouch or similar bag for storage and transportation. Additionally or alternately, the cover 104 may be folded in such a way as to form its own storage pouch.

FIG. 3 illustrates a second example warming enclosure 300 having a cover 304 that is cinched by a circumferentially attached strap 306 proximate to a bottom opening 306. In warming enclosure 300, cover 304 is shown in place over a stack of materials. Thus, the cover 304 has taken the shape of the stack of materials. Cover 304 includes at least one flap 312. Flap 312 can enable a roofer to access the materials on the pallet without removing the cover. In various implementations, the flap 312 can be secured via a zipper 307, although other means of securing the flap 312 to the rest of the cover 304 are contemplated. For example, hook and loop fasteners (e.g., Velcro® brand hook and loop fasteners), magnets, or other means of securing the flap 302 can be used. The flap 312 can be located on the top of the cover 304, as shown in FIG. 3, or on any side of the cover 304.

In addition to the flap 302, the cover 304 includes the strap 306 that forms a ring around the cover 304. The strap 306 can be threaded through one or more tabs 308 that secure the strap 306 to the cover 304 while enabling the strap 306 to remain at least partially slideably moveable. The strap 306 can be cinched or tightened around the cover 304 to secure the cover 304 around the stack of materials. The strap 306 can include a clasp, buckle, or other fastener to keep the strap 306 in place once it has been tightened.

In FIG. 4, a warming enclosure 400 includes a cover 404 of a rectoid shape that includes a first strap 406 to cinch to the stack of materials and a second strap 409 that is configured to slide beneath or through the pallet and further secure the cover 404 to the pallet that supports the stack of materials. The second strap 409 can be attached to one side of the cover 404 at one end, and may be buckled or otherwise attached to at an opposing side of the cover 404 at the other end of the second strap 409. The warming enclosure 400 includes an intake manifold 411 with a cinch strap 413 to be attached to an air warming blower. A top portion of the cover 404 opens as a lid 412.

FIG. 5 illustrates another example warming enclosure 500 having a cover 504 connected to a blower 510. The blower 510 may be any type of commercially available hot air blower. In various implementations, other types of mechanical heating devices may be used to increase the temperature of the interior space. Blower 510 is connected to the interior of the cover 504 via a blower inlet 404. In various implementations, the blower 402 is attached to blower inlet 411 via a transfer tube or other duct.

When connected to the interior of the cover 504, blower 510 is configured to provide heat to the interior space surrounded by the cover 504 and to the materials that are placed therein. Furthermore, when the blower 402 is attached and the cover 404 is secured in place, the blower 510 is configured to retain within the interior space heat generated by the blower 510. By retaining the generated heat within the interior space, the blower is able to warm the air in the interior space of the cover 404 to a desired temperature. In various implementations, the desired temperature is between approximately forty degrees and eighty degrees Fahrenheit.

Another embodiment of the present invention comprises process controls for controlling the temperature of the warmer. In this embodiment, the invention further comprises a temperature sensor positioned to sense the temperature of the interior chamber of the warmer and to transmit a temperature signal. In one embodiment, the temperature sensor is selected from the group consisting of a thermistor, a thermocouple, and a solid state thermal sensor. In another embodiment, the invention further comprises a controller operatively connected to receive the temperature signal from the sensor and transmit a control signal responsive to the temperature signal. In one embodiment, the controller is a microcontroller. In another embodiment, the controller is an analog controller. In other embodiments, temperature may be regulated by controlling fuel flow into the heater. Additionally, temperature may be controlled by mixing small amounts of unheated air with the heated air exiting the warming device. One embodiment of the invention comprises igniting a hydrocarbon fuel source using catalytic combustion in a portable heat exchanger. In another embodiments, the igniting is performed using a glow plug or a spark igniter.

The invention also provides a controller for operating the heater device. Optionally, the heater device can comprise two or more independent heater portions adapted to heat respectively two or more distinct zones of the warming enclosure 100 and the controller is able to operate the heater portions simultaneously or sequentially, and/or at different heating intensities/wavelengths/temperatures. The heating element can be any known form of heating element. In certain embodiments, the heating elements comprise infrared electrical elements. These infrared elements may be in the form of, for example, quartz tubes or ceramic tiles. Alternatively, they may comprise diffused gas combusting devices, powered for example by propane or natural gas. Examples of these include gas catalytic heaters. In one embodiment, the warming enclosure 100 includes a fuel intake port configured to couple to a fuel source, e.g., butane, propane, white case, kerosene, alcohol, gas, electricity and so on. The heat outlet may take any of a variety of forms, such as burner. In one embodiment, the warming enclosure 100 may further comprise a frame member adapted to be disposed around the building materials. As will be appreciated, the warming enclosure 100 may have any number of heat zones for any desired application. In addition, the controller may be actuated manually or under the control of an automatic primary controller, optionally with pre-set temperature and timing for a selection of a variety of building materials and/or applications.

In some implementations, a thermostat can be used to regulate the temperature within the cover 404 to prevent overheating or to maintain the temperature at a temperature of about the desired temperature. Embodiments may be implemented where the temperature is determined by selecting a thermostat with a fixed temperature rating. Other embodiments may be implemented where the temperature setting of the thermostat can be adjusted to a predetermined temperature at manufacturing time. In some embodiments, the thermostat may be user accessible to allow a user to adjust the thermostat settings. Although a thermostat is referenced, other temperature controls may be implemented. In some embodiments, the temperature controller includes a digital display that allows a user to visually interact with the temperature controller. The digital display may be configured to display temperatures in □C., □F., or K according to a user selection.

Techniques employing a cover, such as described in FIGS. 1-5, may be illustrated according to the following example. Assume that a roofer is scheduled to install a roof for a client. Though the weather is generally mild in this area at this time of year, the temperature has dropped substantially and snow is in the forecast. Thus, assume that for the past week, the high temperature during the day has only been in the mid-thirties. Conventionally, the roofer may choose to reschedule the installation to avoid shattering or cracking the shingles and/or a warped final product. However, assume that the roofer has a warming cover, such as cover 104. The roofer may use the cover 104 to warm the materials in accordance with the techniques described herein to enable proper installation of the roof despite the low temperatures.

FIG. 6 illustrates an example method 600 for warming building materials according to the techniques provided herein that may be used by the roofer. Building materials can include, for example, shingles, siding, tar paper, flashing, boxes of nails, drip edge, and other building materials. The materials can be stored on a pallet, although they need not be. Thus, although the description provided herein refers to a “pallet” and a “stack of materials,” it is contemplated that the cover is configured to substantially receive, surround, and/or enclose materials whether on a pallet or not.

First, the cover is positioned over a stack of materials and secured in place (block 602). Returning to our example, the roofer may place the cover over a pallet of shingles. The cover may be secured in place using the strap, and the roofer may pull the strap tight around the pallet of shingles. As described above, a second strap may be additionally be run between the pallet and the ground and attached to the cover to further secure the cover to the stack of materials. In some implementations, this may be performed on the site the materials will be used, although it may be performed at other locations. For example, the roofer may cover the stack of materials at the location where he will be installing the roof, or he may cover the stack of materials at a warehouse and transport the stack of materials and the cover to the job site at a later date.

Next, a blower is connected to the cover (block 604). For example, blower can be connected to the cover 104 via the blower inlet. Once connected, the blower is activated (block 606). The roofer can plug in the blower or otherwise connect the blower to a power source and turn it on. In implementations in which the blower or cover has an associated thermostat or other temperature control device, the roofer may adjust and/or confirm the settings. In various implementations, the blower is activated between about 48 hours and about 24 hours before the materials are planned to be used. Once activated, the blower is configured to warm the air within the cover to a temperature of between about forty degrees and eighty degrees Fahrenheit.

When the roofer is ready to use the materials that are covered by the cover 104, the roofer may open the flap to access the shingles (block 608), and the roofer removes the materials as needed may remove the amount of shingles needed (block 610) and uses the materials. For example, the roofer can remove two or three boxes of shingles at a time, while leaving the remaining shingles in the warming cover. The flap may then be closed and the cover can maintain the warm air around the remaining materials while the roofer installs the shingles he removed from the cover. The roofer can return to the cover and remove additional shingles as needed during the installation. Thus, even the last of the materials that the roofer accesses can be utilized in a warmed state, regardless of the exterior temperature.

The techniques described herein enable builders, roofers, and others who utilize temperature-sensitive materials to perform their jobs regardless of the temperature outside. Additionally, the materials can be warmed using blown air, enabling the warm air around the materials to warm them rather than providing direct heat to the materials themselves, which can contaminate or scorch the materials. The flexible, frameless cover can be condensed into a small package for transportation and storage, enabling the builder to use the cover without sacrificing space. In various implementations, because the cover is constructed of a single layer of durable, airtight, water-resistant material, it is easy to manufacture and can withstand the weather and wear and tear that may occur at a building site.

FIGS. 7-8 illustrate an additional example warming enclosure 700 having a cover 704 that further includes a closable extension 723 for receiving a propane tank 724 to fuel heating. A transparent window 725 on one or more sides of the cover 704 can receive marketing or product identification information. The cover 704 includes an intake duct 711 for attaching to a blower 710 (FIG. 8). A top lid 712 is provided for withdrawing building materials for use. In one embodiment, a rigid, weighted seal 714 maintains a shape that closely conforms to a pallet and holds down the cover 704.

FIG. 9 illustrates a further addition of completing assembly of the warming enclosure 700 by inserting a board 726, such as 2×4 board of appropriate length into a seal sleeve 728. FIG. 10 illustrates covering the end of the board 726 with a third strap 730 that affixes to a Velcro® receiver 732.

FIG. 10 illustrates a warming enclosure 1100 having a cover 1104 with a side flap 1112 for accessing the stack of building material 102.

FIG. 11 illustrates a further addition of completing assembly of the warming enclosure 1100 by having one or more means of keeping the enclosure covering the stack of building material 102. In one embodiment, the warming enclosure 1100 is maintained in substantial contact with the ground or other supporting surface with a weighted material that is removeably attached or substantially fixed to the warming enclosure 1100. In one embodiment, the warming enclosure 1100 is maintained in substantial contact with the ground or other supporting surface with a weighted compartment 1150 or 1154, wherein the weighted compartment 1150 or 1154 may be affixed with one or more attachment such as Velcro®, zippers, ties, flaps, buttons, snaps, straps, fasteners.

In another embodiment, the warming enclosure 1100 is attached to the ground or other surface with a stake using a lower flap 1152 for staking down the enclosure In one embodiment, a weighted compartment 1150 or 1154 is pre-filled with a material. In another embodiment, weighted compartment 1150 or 1154 is fillable on-site with a ballast material. Ballast material used for weighting can be any suitable material such as water, sand, wood, rocks, or metal weights.

All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated as incorporated by reference. It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “colorant agent” includes two or more such agents.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein.

As will be appreciated by one having ordinary skill in the art, the methods and compositions of the invention substantially reduce or eliminate the disadvantages and drawbacks associated with prior art methods and compositions.

It should be noted that, when employed in the present disclosure, the terms “comprises,” “comprising,” and other derivatives from the root term “comprise” are intended to be open-ended terms that specify the presence of any stated features, elements, integers, steps, or components, and are not intended to preclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

While it is apparent that the illustrative embodiments of the invention herein disclosed fulfill the objectives stated above, it will be appreciated that numerous modifications and other embodiments may be devised by one of ordinary skill in the art. Accordingly, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which.