U.S. patent application number 10/412049 was filed with the patent office on 2003-10-09 for roofing shingle having an insulating material and associated method for making the same.
Invention is credited to Parsons, Colbey Lynn.
Application Number | 20030188503 10/412049 |
Document ID | / |
Family ID | 28678089 |
Filed Date | 2003-10-09 |
United States Patent
Application |
20030188503 |
Kind Code |
A1 |
Parsons, Colbey Lynn |
October 9, 2003 |
Roofing shingle having an insulating material and associated method
for making the same
Abstract
A roofing shingle includes a substrate layer which is adapted to
be secured to a roof of a building. The roofing shingle also
includes an insulator layer co-extruded or otherwise secured to the
substrate layer. The insulator layer includes a resin film having
borosilicate implanted therein. A method of fabricating a roofing
shingle is also disclosed.
Inventors: |
Parsons, Colbey Lynn;
(Greenfield, IN) |
Correspondence
Address: |
BARNES & THORNBURG
11 SOUTH MERIDIAN
INDIANAPOLIS
IN
46204
|
Family ID: |
28678089 |
Appl. No.: |
10/412049 |
Filed: |
April 11, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10412049 |
Apr 11, 2003 |
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09624706 |
Jul 24, 2000 |
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6546688 |
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09624706 |
Jul 24, 2000 |
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09296507 |
Apr 22, 1999 |
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6125609 |
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Current U.S.
Class: |
52/518 ;
52/309.8; 52/408 |
Current CPC
Class: |
E04D 5/10 20130101; E04D
1/265 20130101; E04D 1/28 20130101 |
Class at
Publication: |
52/518 ;
52/309.8; 52/408 |
International
Class: |
E04D 001/00 |
Claims
What is claimed is:
1. A roofing shingle, comprising: a substrate layer which is
adapted to be secured to a roof of a building; and an insulator
layer secured to said substrate layer, said insulator layer
comprising borosilicate.
2. The roofing shingle of claim 1, wherein said insulator layer
includes a resin film with said borosilicate being implanted into
said resin film.
3. The roofing shingle of claim 2, wherein said borosilicate is
injection molded into said resin film.
4. The roofing shingle of claim 2, wherein said resin film includes
an olefin film.
5. The roofing shingle of claim 2, wherein said resin film includes
a polymer film.
6. The roofing shingle of claim 1, wherein said substrate layer
includes a re-vulcanized rubber material.
7. The roofing shingle of claim 1, wherein said substrate layer is
co-extruded with said insulator layer so as to be secured
thereto.
8. A method of fabricating a roofing shingle, comprising the steps
of: fabricating a substrate layer, said substrate layer being
adapted to fabricating a substrate layer, be secured to a roof of a
building; fabricating an insulator layer which includes
borosilicate; and securing said substrate layer and said insulator
layer to one another
9. The method of claim 8, wherein: said insulator layer includes a
resin film, and said insulator layer fabricating step includes the
step of implanting 15 said borosilcate into said resin film.
10. The method of claim 9, wherein said implanting step includes
the step of injection molding said borosilicate into said resin
film.
11. The method of claim 8, wherein: said insulatorlayer includes an
olefin film, and said insulator layer fabricating step includes the
step of implanting said borosilcate into said olefin film.
12. The method of claim 8, wherein: said insulator layer includes a
polymeric film, and said insulator layer fabricating step includes
the step of implanting said borosilcate into said polymeric
film.
13. The method of claim 8, wherein said substrate layer fabricating
step includes the step of fabricating said substrate layer from a
re-vulcanized rubber material.
14. The method of claim 8, wherein said securing step includes the
step of co-extruding said substrate layer and said insulator
layer.
15. A method of fabricating a roofing shingle, comprising the steps
of: fabricating a substrate layer, said substrate layer being
adapted to be secured to a roof of a building; implanting an
insulating material into a resin film; and securing said resin film
to said substrate layer.
16. The method of claim 15, wherein said securing step is performed
subsequent to said implanting step.
17. The method of claim 15, wherein: said insulating material
includes borosilicate, and said implanting step includes the step
of implanting said borosilicate into said resin film.
18. The method of claim 15, wherein said implanting step includes
the step of injection molding said insulating material into said
resin film.
19. The method of claim 15, wherein: said resin film includes an
olefin film, and said implanting step includes the step of
implanting said insulating material into said olefin film.
20. The method of claim 15, wherein: said resin film includes a
polymeric film, and said implanting step includes the step of
implanting said insulating material into said polymeric film.
21. The method of claim IS, wherein said substrate layer
fabricating step includes the step of fabricating said substrate
layer from a re-vulcanized rubber material.
22. The method of claim 15, wherein said securing step includes the
step of co-extruding said substrate layer and said resin film.
23. A roofing shingle, comprising: a substrate adapted to be
secured to a roof of a building; and a resin film secured to said
substrate, said resin film having an insulating material implanted
therein.
24. The roofing shingle of claim 23, wherein said insulating 10
material includes borosilicate which is implanted into said resin
film.
25. The roofing shingle of claim 23, wherein said insulating
material is injection molded into said resin film.
26. The roofing shingle of claim 23, wherein: said resin film
includes an olefin film, and said insulating material is implanted
into said olefin film
27. The roofing shingle of claim 23, wherein: said resin film
includes an polymeric film, and said insulating material is
implanted into said polymeric film.
28. The roofing shingle of claim 23, wherein said substrate is
constructed from a re-vulcanized rubber material.
29. The roofing shingle of claim 23, wherein said substrate layer
and said resin film are co-extruded.
30. A method of fabricating a roofing shingle, comprising the steps
of: implanting an insulating material into a film so as to form an
10 implanted film; co-extruding said implanted film with a
substrate material so as to form a co-extruded composite material;
and altering a shape of said co-extruded composite material so as
to form said roofing shingle.
31. The method of claim 30, wherein said altering step includes the
step of die cutting said co-extruded composite material so as to
form said roofing shingle.
32. The method of claim 30, wherein: said substrate material
includes a thermoplastic vulcanate material, and said co-extruding
step includes the step of co-extruding said 5 implanted film with
said thermoplastic vulcanate so as to form said co-extruded
composite material.
33. The method of claim 30, wherein: said insulating material
includes borosilicate, and said implanting step includes the step
of implanting said borosilicate into said film.
34. A roof assembly for a building, comprising: a wooden deck; and
a roofing shingle secured to said wooden deck, said roofing shingle
being prepared by a process including the steps of (i) implanting
an insulating material into a film so as to form an implanted film,
(ii) co-extruding said implanted film with a substrate material so
as to form a coextruded composite material, and (iii) altering a
shape of said co-extruded composite material so as to form said
roofing shingle.
35. The roofing shingle of claim 34, wherein said altering step
includes the step of die cutting said co-extruded composite
material so as to form said roofing shingle.
36. The roofing shingle of claim 34, wherein: said substrate
material includes a thermoplastic vulcanate material, and said
co-extruding step includes the step of co-extruding said implanted
film with said thermoplastic vulcanate so as to form said
co-extruded composite material.
37. The roofing shingle of claim 34, wherein: said insulating
material includes borosilicate, and said implanting step includes
the step of implanting said borosilicate into said film.
Description
[0001] This application is a continuation-in-part application of
copending U.S. patent application Ser. No. 09/296,507, filed on
Apr. 22, 1999, entitled "Roofing Shingle Assembly" by Colbey L.
Parsons.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates generally to roofing shingle,
and more particularly to roofing shingle having an insulating
material and associated method for making the same.
BACKGROUND OF THE INVENTION
[0003] Roofing shingles are widely utilized on the roof of a
residential or is commercial building to protect the roof from the
elements such as water, snow, wind, and ultraviolet rays from the
sun. Heretofore designed roofing shingles typically include a tar
and/or asphalt substrate with a number of granules secured thereto.
The granules are often made from ground up, recycled road material
(e.g. asphalt) and are provided to both protect the substrate and
also increases the rigidity of the shingle by reducing the
`elasticity` of the substrate.
[0004] One drawback associated with heretofore designed roofing
shingles is that the shingles themselves provide little to no
insulation to the building. In fact, heretofore designed roofing
shingles often absorb heat in hot climates and transfer such heat
through the roof and into the attic and/or upper floors of the
building. Such a heat transfer into the building increases costs
associated with cooling the building.
[0005] Moreover, another drawback associated with heretofore
designed roofing shingles is the material content thereof Although,
as described above, certain roofing shingle designs have utilized
granules that are 15 formed from recycled road surfaces, recycled
materials have not commonly been utilized in the other components
of the roofing shingle such as the substrate.
[0006] What is needed therefore is roofing shingle that overcomes
one or more of the above-mentioned drawbacks. What is particularly
needed is a roofing shingle that has a relatively high insulating
value. What is also particularly needed is a roofing shingle that
may be easily constructed and utilizes numerous recycled
components.
SUMMARY OF THE INVENTION
[0007] In accordance with one embodiment of the present invention,
there is provided a roofing shingle. The roofing shingle includes a
substrate layer which is adapted to be secured to a roof of a
building. The roofing 5 shingle also includes an insulator layer
secured to the substrate layer. The insulator layer includes
borosilicate.
[0008] In accordance with another embodiment of the present
invention, there is provided a method of fabricating a roofing
shingle. The method includes the step of fabricating a substrate
layer. The substrate layer is adapted to be secured to a roof of a
building. The method also includes the step of fabricating an
insulator layer which includes borosilicate. The method yet further
includes the step of securing the substrate layer and the insulator
layer to one another.
[0009] In accordance with a further embodiment of the present
invention, 15 there is provided a method of fabricating a roofing
shingle. The method includes the step of fabricating a substrate
layer. The substrate layer is adapted to be secured to a roof of a
building. The method also includes the step of implanting an
insulating material into a resin film. Yet further, the method
includes the step of securing the resin film to the substrate
layer.
[0010] In accordance with yet another embodiment of the present
invention, there is provided a roofing shingle. The roofing shingle
includes a substrate adapted to be secured to a roof of a building.
The roofing shingle also includes a resin film secured to the
substrate. The resin film has an insulating material implanted
therein.
[0011] In accordance with a further embodiment of the present
invention, there is provided a method of fabricating a roofing
shingle. The method includes the step of implanting an insulating
material into a film so as to form an implanted film. The method
also includes the step of co-extruding the implanted film with a
substrate material so as to form a co-extruded composite material.
Yet further, the method includes the step of altering the shape of
the co-extruded composite material so as to form the roofing
shingle.
[0012] In accordance with another embodiment of the present
invention, there is provided a roof assembly for a building. The
roof assembly includes a wooden deck. The roof assembly also
includes a roofing shingle secured to the wooden deck. The roofing
shingle is prepared by a process including the steps of (i)
implanting an insulating material into a film so as to form an
implanted film, (ii) co-extruding the implanted film with a
substrate material so as to form a co-extruded composite material,
and (iii) altering a shape of the co-extruded composite material so
as to form the roofing shingle.
[0013] It is therefore an object of the present invention to
provide a new and useful roofing shingle.
[0014] It is moreover an object of the present invention to provide
an improved roofing shingle.
[0015] It is also an object of the present invention to provide a
new and useful roofing assembly for a building.
[0016] It is further an object of the present invention to provide
an improved roofing assembly for a building.
[0017] It is yet further object of the present invention to provide
a new and useful method of making a roofing shingle.
[0018] It is also an object of the present invention to provide an
improved method of making a roofing shingle.
[0019] It is also an object of the present invention to provide
roofing shingle which has a relatively high insulating value.
[0020] It is yet further an object of the present invention to
provide a roofing shingle that is constructed of numerous recycled
components.
[0021] The above and other objects, features, and advantages of the
present invention will become apparent from the following
description and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a roofing shingle which
incorporates the features of the present invention therein;
[0023] FIG. 2 is a cross sectional view taken along the line 2-2 of
FIG. 1, as viewed in the direction of the arrows, note that FIG. 2
also shows a weatherproofing liner and the roof to which the
roofing shingle is secured;
[0024] FIGS. 3 and 4 are perspective views of alternative
configurations of the roofing shingle of FIG. 1; and
[0025] FIG. 5 is a flowchart which shows a fabrication process for
fabricating the roofing shingle of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0026] While the invention is susceptible to various modifications
and alternative forms, specific embodiments thereof have been shown
by way of example in the drawings and will herein be described in
detail. It should be understood, however, that there is no intent
to limit the invention to the particular forms disclosed, but on
the contrary, the intention is to cover all modifications,
equivalents, and alternatives falling within the spirit and scope
of the invention as defined by the appended claims.
[0027] Referring now to FIGS. 1 and 2, there is shown a roofing
shingle 10. The roofing shingle 10 is adapted to be secured to a
roof assembly 12 of a residential or commercial building (not
shown). In particular, the roofing shingle 10 is typically nailed
or otherwise secured to a wooden deck 14 of the roof assembly 12.
As shown in FIG. 2, the wooden deck 14 is typically supported by a
number of wooden beams 16 associated with the roof assembly 12. A
weatherproofing liner 18 is interposed between the roofing shingle
10 and the wooden deck 14 of the roof assembly 12 in order to help
prevent the intrusion of moisture into the wooden deck 14.
[0028] The roofing shingle 10 includes a substrate layer 20 and an
insulator layer 22. The substrate layer 20 may be constructed of
any type of material which is suitable for use in a roofing
shingle. Examples of such suitable materials include asphalt and
tar based material. However, as shall be discussed below in greater
detail, the substrate layer 20 is preferably constructed from a
re-vulcanized rubber. One re-vulcanized rubber which is
particularly useful for construction of the substrate layer 20 is a
thermoplastic vulcanate (TPV). Thermoplastic vulcanate is a crumb
rubber-based material that has been chemically processed into a
thermoplastic. One specific example of a thermoplastic vulcanate is
commercially available from Landstar, Incorporated of Dayton,
Ohio.
[0029] The insulator layer 22 on the other hand includes an
insulating 15 material 24 which is implanted into a thin film 26.
The insulating material 24 may be any type of insulating material
which, when implanted into the thin film 26, reduces heat
absorption into the roof assembly 12. For example, the insulating
material 24 of the present invention may be embodied as a
cyclosilicate. Certain cyclosilicates are characterized by
relatively high insulating properties that derive from their
relatively high thermal emissivity properties. In particular,
certain cyclosilicates are particularly good insulators in the
sense that they emit thermal energy back into the surrounding air,
as opposed to absorbing such thermal energy and transferring it
through the roofing shingle 10 and into the building. One
cyclosilicate that has been found to be particularly useful as the
insulating material 24 of the present invention is
borosilicate.
[0030] Alternatively, certain igneous materials have also been
found to S demonstrate a relatively high thermal emissivity
property thereby functioning as a relatively favorable insulating
material 24. One such igneous material that has been found to be
particularly useful as the insulating material 24 of the present
invention is purlite.
[0031] As alluded to above, there is no intent to limit the present
invention 10 to the use of borosilicate or purlite as the
insulating material 24. Conversely, although the use of
borosilicate and purlite provides numerous advantages to the
present invention, certain of such advantages may be achieved by
use of other insulating materials are also contemplated for use
herein as the insulating material 24.
[0032] The thin film 26 may be embodied as any type of film such as
a resin, polymer, or olefin film which has the desired properties
of a given roofing shingle design. In particular, the insulating
material 24 (e.g. borosilicate) is preferably implanted into the
thin film 26 via injection molding so as to form an implanted
material composite which is later co-extruded or otherwise secured
to the substrate layer 20. Hence, the thin film 26 is preferably
constructed of a natural or synthetic material which is capable of
being processed in the aforedescribed manner. One thin film 26
which has been found to be particularly useful as the thin film 26
of the present invention is ethyl vinyl acetate which is
commercially available from PPG Industries of Pittsburgh, Pa.
[0033] In a specific exemplary embodiment, the insulator layer 22
is provided as a composite of borosilicate and an olefin film. In
particular, borosilicate granules are implanted into a thin film of
ethyl vinyl acetate. One preferable manner to implant the
borosilicate granules into the thin film of ethyl vinyl acetate is
by injection molding. As shall be discussed below in greater
detail, the resultant implanted insulator layer 22 is then secured
to the substrate layer 20 so as to form the roofing shingle 10.
[0034] In certain configurations, it may be desirable to include a
number of silica or mica granules in the roofing shingle 10. As
with a conventional roofing shingle, the addition of silica or mica
granules may be utilized to provide additional protection to the
substrate layer 20. In such a case, the silica or mica granules may
be injection molded (along with the insulating granules 24) into
the thin film 26.
[0035] The substrate layer 20 and the insulator layer 22 may be
secured to one another in any one of numerous manners. One
particularly useful manner for securing the layers 20, 22 to one
another is to co-extrude the two layers 20, 22 together. Hence, in
the specific exemplary embodiments described above, a substrate
stock of thermoplastic vulcanate is co-extruded with insulator
layer material constructed of a thin film of ethyl vinyl acetate
having borosilicate granules implanted therein.
[0036] Hence, when used herein, the term "layer" is not intended to
mean that the material associated therewith is strictly discrete
from the material associated with other "layers". For example, the
co-extrusion process causes materials from the insulator layer 22
to be co-mingled with materials from the substrate layer 20.
[0037] The resultant co-extruded composite material including the
substrate and insulator layers 22, 24 may be formed into any shape
or configuration by the co-extrusion process. However, the
co-extrusion process preferably forms the resultant composite
material into a relatively flat stock of material which may be die
cut or otherwise formed so as to assume the general configuration
of the roofing shingle 10 shown in FIG. 1.
[0038] However, it should be appreciated that the co-extrusion
process may alternatively be configured to produce roofing shingles
of various designs and shapes. For example, the co-extrusion
process may be configured to produce a stock that when die-cut (or
otherwise singulated) produces a Spanish shingle 30 (see FIG. 3) or
a shake shingle 32 (see FIG. 4).
OPERATION OF THE PRESENT INVENTION
[0039] In operation, the roofing shingle 10 of the present
invention may be fabricated by a fabrication process 50 described
in reference to the flowchart shown in FIG. 5. The fabrication
process 50 begins with step 52 in which the material for the
substrate layer 20 is fabricated. In particular, as described
above, the substrate layer 20 is preferably constructed from a
re-vulcanized rubber such as a thermoplastic vulcanate (TPV).
Hence, in step 52, crumb rubber-based material is chemically
processed into the desired thermoplastic. The resultant
intermediate product of thermoplastic vulcanate is preferably
provided as a continuously rolled stock.
[0040] The fabrication process 50 also includes step 54 in which
the insulator layer 22 is fabricated. In particular, as described
above, the insulator layer 22 is preferably provided as a composite
of borosilicate and an olefin film. More specifically, borosilicate
granules are implanted into a thin film of ethyl vinyl acetate via
injection molding. The resultant implanted insulator layer 22 is
preferably provided on a continuously rolled stock.
[0041] Moreover, as discussed above, in certain configurations, it
may be desirable to include a number of silica or mica granules in
the roofing shingle 10. As with a conventional roofing shingle, the
addition of silica or mica granules may be utilized to provide
additional protection to the substrate layer 20. In such a case,
the silica or mica granules may be injection molded (along with the
insulating granules 24) into the thin film 26 in step 54.
[0042] The fabrication process 50 then advances to step 56 in which
the material of the substrate layer 20 and the material of the
insulating layer are secured to one another in any one of numerous
manners. Preferably, the material associated with the layers 20, 22
is secured to one another via co-extrusion. Hence, in the specific
exemplary embodiment described herein, the rolled stock of
thermoplastic vulcanate and the rolled stock of the composite
insulator layer material (i.e. the thin film of ethyl vinyl acetate
having borosilicate granules implanted therein) are both advanced
into an extrusion machine (not shown) so as to be co-extruded with
one another.
[0043] The resultant co-extruded composite material including the
10 substrate layer 20 and insulator layers 22 may be formed into
any shape or configuration by the extrusion machine. However, the
extrusion machine preferably forms the co-extruded composite
material into a relatively flat stock of material which may be
die-cut or otherwise formed so as to assume the general
configuration of the roofing shingle 10 shown in FIG. 1. However,
the extrusion machine may also be configured to produce a stock
that when die-cut (or otherwise singulated) produces the Spanish
shingle 30 (see FIG. 3) or the shake shingle 32 (see FIG. 4).
[0044] Thereafter, the resultant co-extruded composite material is
advanced through a forming machine which alters the shape of the
composite material so as to form the shingle 10 (or shingles 30,
32, as desired). In particular, the co-extruded composite material
may be advanced through a die-cutting machine which singulates or
otherwise cuts the composite material into the desired shingle
shape and configuration. Thereafter, the individual roofing
shingles may be bundled for storage and/or shipping.
[0045] Hence, as described herein, the roofing shingle 10 (along
with the associated manufacturing process) provides numerous
advantages over heretofore designed roofing shingles. For example,
the roofing shingle 10 provides significant insulating advantages
to a roofing assembly constructed therewith relative to heretofore
designed, non-insulated shingles. In particular, the roofing
shingle 10 of the present invention emits the thermal energy that
is directed thereon from the sun back into the surrounding air
thereby preventing such thermal energy from being directed into the
building. Moreover, the fabrication process described herein may be
utilized to quickly and easily produce insulated shingles from
recycled components thereby reducing the costs associated with
manufacture of the roofing shingles.
[0046] While the invention has been illustrated and described in
detail in the drawings and foregoing description, such an
illustration and description is to be considered as exemplary and
not restrictive in character, it being understood that only the
preferred embodiments have been shown and described and that all
changes and modifications that come within the spirit of the
invention are desired to be protected.
[0047] There are a plurality of advantages of the present invention
arising from the various features of the roofing shingle described
herein. It will be noted that alternative embodiments of the
roofing shingle of the present invention may not include all of the
features described yet still benefit from at least some of the
advantages of such features. Those of ordinary skill in the art may
readily devise their own implementations of a roofing shingle that
incorporate one or more of the features of the present invention
and fall within the spirit and scope of the present invention as
defined by the appended claims.
[0048] For example, the concepts of the present invention may be
utilized in the construction of other types of building materials.
For example, the concepts of the present invention may be utilized
in the construction of insulated floorings such as sidewalk payers
or insulated wallboards.
* * * * *