U.S. patent application number 10/289441 was filed with the patent office on 2004-05-06 for laminated shingle with wider nailing zone.
Invention is credited to Donaldson, John K., Kalkanoglu, Husnu M., Stahl, Kermit E..
Application Number | 20040083674 10/289441 |
Document ID | / |
Family ID | 32176066 |
Filed Date | 2004-05-06 |
United States Patent
Application |
20040083674 |
Kind Code |
A1 |
Kalkanoglu, Husnu M. ; et
al. |
May 6, 2004 |
Laminated shingle with wider nailing zone
Abstract
A multiple-layer laminated shingle and a method of making the
shingle are provided, in which at least one adhesive of high
temperature resistance is applied for securing the shingle layers
together, to reduce reliance on a roofer having to fasten (via
nails, staples or the like) through a narrow headlap zone of a
posterior shingle layer in order to secure the posterior shingle
layer to a roof, such that a vertically wide portion of the headlap
area of the anterior shingle layer is presented to the roofer as a
nailing zone.
Inventors: |
Kalkanoglu, Husnu M.;
(Swarthmore, PA) ; Stahl, Kermit E.; (North Wales,
PA) ; Donaldson, John K.; (Newtown Sq., PA) |
Correspondence
Address: |
PAUL AND PAUL
2900 TWO THOUSAND MARKET STREET
PHILADELPHIA
PA
19103
US
|
Family ID: |
32176066 |
Appl. No.: |
10/289441 |
Filed: |
November 6, 2002 |
Current U.S.
Class: |
52/555 |
Current CPC
Class: |
E04D 1/26 20130101; B32B
37/1284 20130101; Y10T 428/24752 20150115; B32B 38/10 20130101 |
Class at
Publication: |
052/555 |
International
Class: |
E04D 001/00 |
Claims
What is claimed is:
1. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; (e) a
first adhesive having heat resistance to a first temperature level
and disposed between said shingle layers, securing said layers
together; and (f) a second adhesive having high heat resistance to
a second temperature level, higher than said first temperature
level, and disposed between said shingle layers, securing said
layers together.
2. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; and (e) a
non-bituminous adhesive having heat resistance to a predetermined
temperature level and disposed between said shingle layers,
securing said layers together.
3. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; and (e)
an epoxy adhesive having heat resistance to a predetermined
temperature level and disposed between said shingle layers,
securing said layers together.
4. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; and (e) a
two-part thermal set adhesive having heat resistance to a
predetermined temperature level and disposed between said shingle
layers, securing said layers together.
5. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; and (e) a
one-part thermal set or moisture cured adhesive having heat
resistance to a predetermined temperature level and disposed
between said shingle layers, securing said layers together.
6. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; and (e) a
high softening point adhesive having a softening point at least as
high as 197.degree. F. and having heat resistance to a
predetermined temperature level and disposed between said shingle
layers, securing said layers together.
7. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; and (e)
an adhesive having at approximately at least 150.degree. F. an
initial shear modulus greater than 10,000 Newtons/m.sup.2, and
having a shear modulus greater than 1,000 Newtons/m.sup.2 after
1000 seconds of stress exposure induced by constant loading and
having heat resistance to a predetermined temperature level and
disposed between said shingle layers, securing said layers
together.
8. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces with at least one cutout extending
into the width of the anterior shingle layer an amount terminating
in an upper cutout edge; (b) a posterior shingle layer of a second
width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer and
comprising a double layer area, leaving an upper area of the rear
surface of the anterior shingle layer not having the posterior
shingle layer disposed thereagainst; (e) an adhesive having heat
resistance to a predetermined temperature level and disposed
between said shingle layers, securing said layers together; (f) a
visibly marked fastening zone on the front surface of the anterior
shingle layer, with said fastening zone being defined by upper and
lower demarcation limits; (g) the upper demarcation limit being
opposite the upper area of the rear surface of the anterior shingle
layer; (h) the lower demarcation limit being opposite the lower
area of the rear surface of the anterior shingle layer, and above
the upper cutout edge of the anterior shingle layer; and (i)
whereby the fastening zone on the anterior shingle layer is, in
part, through only the anterior shingle layer.
9. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces with at least one cut out extending
into the width of the anterior shingle layer an amount terminating
in an upper cut out edge; (b) a posterior shingle layer of a second
width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer and
comprising a double layer area leaving a single thickness upper
area of the rear surface of the anterior shingle layer not having
the posterior shingle layer disposed thereagainst; (e) an adhesive
having heat resistance to a predetermined temperature level and
disposed between said shingle layers, securing said layers
together; (f) optional first and second fastening zones on the
front surface of the anterior shingle layer and defined by at least
three demarcation limits; (g) the first optional fastening zone
being defined by demarcation limits opposite the double layer area
and above the upper cut out edge of the anterior shingle layer; (h)
the second optional fastening zone being defined by a demarcation
limit opposite the single thickness upper area of the rear surface
of the anterior shingle layer and by one of the demarcation limits
of clause (g) above, and (i) whereby a shingle installer has the
option of fastening the shingle through either or both of the first
and second fastening zones.
10. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; (e) an
adhesive having heat resistance to a predetermined temperature
level and disposed between said shingle layers, securing said
layers together; (f) three demarcation limits on the front surface
of the anterior shingle layer, located thereon to comprise means
for defining; (i) a first fastening zone for fastening the shingle
to a roof by fasteners applied through both anterior and posterior
layers; and (ii) a second fastening zone for fastening the shingle
to a roof by fasteners applied through only the anterior shingle
layer, with said second nailing zone having a majority of its area
present only over the front surface of the anterior shingle
layer.
11. The shingle of any one of claims 1-10, wherein at least some
said adhesive is heat resistant to at least 140.degree. F.
12. The shingle of any one of claims 1-10, wherein at least some
said adhesive is heat resistant to at least 170.degree. F.
13. The shingle of any one of claims 1-10, wherein at least some
said adhesive has a softening point at least as high as 197.degree.
F.
14. The shingle of any one of claims 1-10, wherein at least some
said adhesive has a softening point at least as high as 240.degree.
F.
15. The shingle of any one of claims 1-10, wherein at least some
said adhesive is selected from the group of ethylene vinyl acetate,
polyamide, and polyurethane.
16. A multi-layer laminated shingle comprising: (a) an anterior
shingle layer of a first width between upper and lower edges and
having front and rear surfaces; (b) a posterior shingle layer of a
second width, less than the first width, and having front and rear
surfaces; (c) with the anterior shingle layer having upper and
lower areas on the rear surface thereof; (d) with the front surface
of the posterior shingle layer being disposed against the lower
area of the rear surface of the anterior shingle layer, leaving an
upper area of the rear surface of the anterior shingle layer not
having the posterior shingle layer disposed thereagainst; (e) a
high heat resistant adhesive having heat resistance to a
temperature level and disposed between said shingle layers,
securing said layers together; and (f) said adhesive having no
temperature-responsive softening point.
17. The shingle of any one of claims 8-10, wherein at least some of
said demarcation limits comprise marked lines.
18. The shingle of any one of claims 8-10, wherein at least some of
said demarcation limits comprise adhesive lines.
19. The shingle of any one of claims 8-10, wherein at least some of
at least said demarcation limits define at least one band.
20. The shingle of any one of claims 8-10, wherein the demarcation
limits comprise three marked lines, two of which define a
double-layer fastening zone, and two of which define a single-layer
fastening zone, the single-layer fastening zone having a width that
is greater than that of the double layer fastening zone, comprising
means presenting fastening zone options of different sizes.
Description
BACKGROUND OF THE INVENTION
[0001] Laminated shingles are known in the art to be made from
asphaltic roofing material overlaid upon one another, and secured
together by means of an adhesive to provide a shingle having a
thicker section. The anterior layer of the shingle has alternating
tabs and cut out portions in the form of slots of various dimension
in the lower end of the shingle, and an upper end of the shingle
that is not divided into tabs. The posterior shingle layer, often
called a backing sheet is applied, generally to the rear surface of
the lower end of the anterior shingle layer, covering the rear
surfaces of the tabs, such that the two shingle layers are not
coextensive in area.
[0002] In applying the shingles to a roof, by means of fasteners
such as nails, staples or the like in accordance with the teachings
of the prior art, there is a longitudinal strip of double thickness
through which the nails, staples or the like fasteners must be
applied, in which they will pass through both shingle layers, such
strip being above the area of the slots, but below the upper edge
of the posterior shingle layer.
[0003] In order to most efficiently package a plurality of shingles
in a given bundle, the posterior shingle layer is generally less
than one half the width of the shingle, such that the shingles may
be alternated in packaging without a stack of packaged shingles
forming a "hump". Typically, a backer strip or posterior shingle
layer for a shingle of 12 inches in width, is usually 57/8 to
5{fraction (15/16)} inches wide in order to avoid the creation of
an unduly high zone or "hump" in the middle of the shingle bundle,
which is not desirable. Such 12 inch wide shingles then typically
have an exposure width of 5 inches, leaving the common bond area
between the laminated shingle layers to be a longitudinal strip of
less than 1 inch in width.
[0004] Professional roofers find this width too narrow, as it
interferes with efficient fastening of shingles to a roof, slowing
down the speed of shingle application.
[0005] One approach to the problem is set forth in U.S. Pat. No.
6,145,265, granted Nov. 14, 2000, the complete disclosure of which
is herein incorporated by reference. That approach has been to
enlarge the width of the posterior shingle layer, to provide a
larger (higher) common bond strip, of greater width than 1 inch, so
that the nails, staples or like fasteners have a wider strip for
passing through two layers.
[0006] Where laminated shingles have a common bond area that is too
narrow, such as 1 inch or less, there can be a tendency for roofers
to fail to apply the nail or staple fasteners into the common bond
area, but to apply their fasteners above the common bond area, such
that the fasteners pass through only the anterior shingle layer,
and do not intercept the upper portion of the posterior shingle
layer.
[0007] On roofs having a gentle slope or pitch, such misapplication
of shingle fasteners may not be so susceptible to later problems.
However, in roofs of steep pitch or slope, especially in warmer
weather, such as summer weather, and in more southerly locations
where roofs are subjected to more sun and greater heat in the
summer, the temperature of a roof, particularly a dark roof, can
reach 170.degree. F. In more northerly locations in the summer, the
temperature of a lighter colored roof, such as a white or light
gray roof, in summer conditions may not reach a temperature higher
than 140.degree. F.
[0008] Most particularly, in more southern geographic areas, during
the summer, and wherein roofs are of darker color, the temperature
of the roof may approach the softening temperature of the normally
bitumen-based adhesive, such as asphalt, which adheres two
laminated layers of the laminated shingle together. With such
softening of the bitumen-based adhesive, there leaves the
possibility, especially for roofs of steeper pitch or slope, that
the posterior shingle layer of any given shingle, if the fasteners
have not penetrated such posterior layer when the shingle was
applied to the roof, the posterior shingle layer, under its own
weight, may overcome the adhesive quality and deformation
resistance of the softening bitumen, and slide out beneath the
anterior shingle layer, at least compromising the quality of the
roof.
SUMMARY OF INVENTION
[0009] The present invention is directed toward solving the above
problems by providing a laminated shingle in which a stronger
adhesive is applied, having a higher heat resistant temperature
than the adhesive that normally fastens the shingle layers
together, such that under hot conditions and on steep roofs, the
stronger adhesive will be sufficient to keep the two shingle layers
adhered together even if the heat resistant temperature, or
softening point temperature of a prior art shingle laminating
adhesive is reached, such that if fasteners that are used to fasten
the shingle to a roof are applied through the anterior shingle
layer only and not the posterior shingle layer, the posterior
shingle layer will nevertheless remain in place, adhered behind the
anterior shingle layer.
[0010] A wide fastening zone is provided on the shingle, not
limited to inserting fasteners through the double layers of
shingle, but wherein the fastening zone is sufficiently wide to
embrace at least a portion of the anterior shingle layer only,
having no posterior shingle layer therebehind. In another facet of
the invention, optional single shingle layer and double shingle
layer areas are presented corresponding to wider and narrower
fastening zones, respectively, leaving the installer the option of
nailing through two layers of shingle, or only a single layer of
shingle, when nailing or otherwise fastening a shingle to a roof.
The fastening zones may be defined by demarcation limits, such as
marked lines, lines of adhesive, or combinations of both.
[0011] Accordingly, it is a primary object of this invention to
provide a novel multi-layer laminated shingle, in which at least
one high softening point adhesive is used to secure the shingle
layers together.
[0012] It is another object of this invention to accomplish the
above object, in which if more than one adhesive is used, one of
the adhesives has a heat resistance to a temperature level that is
higher than that of the other adhesive.
[0013] It is a further object of this invention to accomplish the
above objects, wherein temperature levels normally reached during
various seasonal parts of the year, and even for darker shingles,
are not sufficiently high to soften an adhesive that is used to
adhere the shingle layers together.
[0014] It is yet another object of this invention to provide a
laminated shingle having a wide nailing zone, without having a wide
double-layer nailing zone, by using a high temperature softening
point adhesive or an adhesive that does not soften at high
temperatures or an adhesive having a high shear modulus, to secure
the layers of the laminated shingle together, such that it is no
longer necessary to nail the shingle through both layers of the
laminate in order to retain the posterior layer on a roof.
[0015] Other objects of the invention comprise providing optional
fastening zones for fastening a shingle to a roof through either
one two-layer fastening zone, or through a single-layer fastening
zone, or combinations of both.
[0016] Other objects and advantages of the present invention will
be readily apparent upon a reading of the following brief
descriptions of the drawing figures, the detailed descriptions of
the preferred embodiments, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0017] FIG. 1 is a top perspective view of a prior art shingle of
the type discussed herein.
[0018] FIG. 2 is a side elevational view of a schematic of
multi-layer shingle manufacture, looking in the transverse
direction, wherein shingle material is conveyed left-to-right, in a
longitudinal direction, and in which adhesive application between
the shingle layers is illustrated.
[0019] FIG. 3 is a top plan view of the rear surface of an anterior
shingle layer, wherein two adhesive applications are shown being
applied to the shingle layer.
[0020] FIG. 4 is a top plan view of a shingle made in accordance
with this invention, wherein the second adhesive is shown in a
series of longitudinal dotted applications, with the common bond
area between the two shingle layers being shown in dotted lines as
well.
[0021] FIG. 5 is a top perspective view of another embodiment of
the shingle of this invention.
[0022] FIG. 6 is an illustration similar to that of FIG. 5, but of
yet another alternative embodiment in accordance with this
invention.
[0023] FIG. 7 is an illustration similar to that of FIGS. 5 and 6,
but wherein the upper surface of the anterior shingle layer is
provided with three demarcation limits, defining a fastening zone
for fastening through two shingle layers, and a fastening zone for
fastening through, at least in principal part, a single layer
fastening zone, such that the installer has options.
[0024] FIG. 8 is an illustration similar to that of FIG. 7, but
wherein the demarcation limits for the fastening zones of FIG. 7
are comprised of spaced-apart lines of either markings or
adhesive.
DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS
[0025] Referring now to the drawings in detail, reference is first
made to FIG. 1, wherein a prior art shingle is generally designated
by the numeral 10, as having an anterior shingle layer 11 and a
posterior shingle layer 12. The anterior shingle layer 11 has a
plurality of tabs 13, separated by substantial cut-outs 14, spaced
apart by the tabs 13, and formed as sizable slotted openings
between the tabs 13. The shingle of FIG. 1 is often referred to as
a multiple-ply dragon-tooth design.
[0026] The anterior shingle layer 11 has a front surface 15 and a
rear surface 16. The posterior shingle layer 12 has a front surface
17 and a rear surface 18. The posterior shingle layer 12 has an
upper edge 20. The cut-outs 14 in the anterior shingle layer 11
have an upper edge 21. Widthwise, the longitudinal area between the
upper edge 21 of t h e cut-outs 14 and the upper edge 20 of the
posterior shingle layer defines the common bond area 22, which runs
from the right-most edge 23 of the shingle of FIG. 1, to the
left-most edge 24. This common bond area, in which the two shingle
layers 11 and 12 are co-extensive, defines the nailing or stapling
zone that is desired by many installers for applying shingles to a
roof.
[0027] Referring to FIG. 2, a description of the manufacture of
shingles in accordance with this invention will be understood. In
FIG. 2, continuous layers of shingle material for making the
posterior shingle layers in accordance with this invention and the
anterior shingle layers in accordance with this invention are shown
at 30 and 31, respectively, being conveyed along rollers 32 and 33,
respectively in their longitudinal paths of travel, as indicated by
the arrows 34 and 35 respectively. For the layer of posterior
shingle material 30, a cutting roller 36 and associated back-up
roller 37 are shown, and for the anterior shingle layer 31, cutting
and back-up rollers respectively numbered 40 and 41 are shown, with
the roller 40 having a plurality of cutting blades 42, for cutting
the cut-outs similar to those 14 shown in FIG. 1. The layer 31 of
shingle material then passes over a pair of adhesive applicators 43
and 44, and the layers 30 and 31 of shingle material are brought
together after passing around suitable turning rollers 45, 46, 47,
48 and 50, to be laminated together by adhesives delivered from the
applicators 43 and 44, to then pass between cutting and back-up
rollers 51, 52, whereby cutting type blade means 53 severs the
laminated shingle material into discrete laminated shingles 54 at
the left end of FIG. 2.
[0028] It will be understood that various techniques for making
laminated shingles may be employed, such as those set forth in U.S.
Pat. No. 6,092,345, issued Jul. 25, 2000.
[0029] Referring now to FIG. 3, it will be seen that, in one
embodiment of the invention, horizontal adhesive strips S1, S2 and
S3 of asphalt, bitumen or other adhesives are applied from rollers
R1, R2, R3, respectively, of adhesive applicator 44, as the sheet
of shingle material 31 moves leftward in the direction arrow 35 in
FIGS. 2 and 3. It will also be seen that the adhesive applicator 43
is shown as applying a plurality of spots 55 of adhesive onto a
rear surface of an anterior layer of the shingle material 31, in
zones of tabs T between spaced-apart cut-outs 56, below the upper
edge 57 of the cut-outs at a vertical location where strips of
adhesive S1, S2, S3 are not applied. The adhesive applicator 43,
like the applicator 44, may be of any type for applying an
adhesive, from a single brush, roller, or the like, or may be of a
type for applying adhesive from a two components adhesive
application gun, as shown. In the applicator 43, two discrete
adhesive applicator lines 58, 60 are shown, for delivering adhesive
to two sides 61, 62 of an adhesive applicator gun, wherein the two
component adhesive will undergo a chemical reaction when the two
components which are normally separated combine within the gun,
with the chemical reaction thereby occurring forming a chemical
bond that secures the shingle layers 30, 31 together.
Alternatively, one or both adhesive lines 58, 60 may deliver a
conventional hot melt adhesive, such as ethylene vinyl acetate, a
polyamide, a glue, or a bitumen-based adhesive, such as an asphalt,
or the like. The adhesive applicator 44 will generally apply an
adhesive of bitumen, asphalt or of any other type suitable to
secure the two layers of shingle material 30, 31, together.
[0030] With reference to FIG. 4, it will be seen that a shingle 70
in accordance with this invention is shown as having anterior and
posterior layers 71, 72, with a common bond or headlap area 73
shown therebetween, between the upper edge 74 of the posterior
shingle layer 72 and the upper edge 57 of the cut-outs 56 in the
anterior shingle layer 71. Also shown in phantom are the adhesive
dots or spots 75, (like those 55 of FIG. 3), which secure the two
shingle layers together, and which have a heat resistance at a
temperature level that is higher than the heat resistance of the
adhesive of the strips S1, S2, S3 applied to tabs 59 and headlap
zone 73, such as via applicator 44. It will be apparent that the
application of adhesive, instead of being drops or spots 75, may be
a continuous strip, between the right-most end 76 of the shingle 70
of FIG. 4 and the left-most end 77, as may be desired. Possibly
also, the adhesive applied via applicator 44 will be co-extensive
with those portions of the rear surface of the anterior shingle
layer 71 that form the tabs 59, or in horizontal strips as shown or
as spots (not shown). The adhesive that is applied as spots 75 will
preferably be that which has the higher level of heat resistance,
to at least 140.degree. F., and more preferably to at least
170.degree. F. along the common bond area 73, between the
right-most end 76 of the shingle 70 of FIG. 4 and the left-most end
77, as may be desired. Preferably, the adhesive applied via
applicator 44 will be co-extensive with those portions of the rear
surface of the anterior shingle layer 71 that form the tabs 59. The
adhesive that is applied to the common bond area 73 will preferably
be that which has the higher level of heat resistance, to at least
140.degree. F., and more preferably to at least 170.degree. F. Such
adhesive will have a softening point that is at least as high as
197.degree. F., and more preferably, at least as high as
240.degree. F., and perhaps as high as 275-300.degree. F.
Alternatively, the adhesives that form strips S1, S2, S3 and spots
75 may be applied to the anterior surface of the posterior shingle
layer to secure the layers 71 and 72 together, or to contacting
surfaces of both layers 71, 72.
[0031] The adhesive that is applied as spots 75, or in some other
form, and which is a high temperature softening point adhesive, and
preferably a high heat resistance adhesive may comprise a
non-bituminous adhesive having heat resistance to a predetermined
temperature level, which may be an epoxy adhesive and/or may be a
two-part thermal set adhesive or a one-part thermal or moisture set
adhesive and will also preferably have a high shear modulus for
securely holding the two to layers of shingle together. Such sheer
modulus (SM) is defined as the ratio of shear stress to shear
strain. Thus, if shear stress is defined as shearing Force divided
by the Area and if shear strain is defined as the change in
dimension (x) relative to the original dimension (y), then shear
modulus is defined as: 1 SM = F / A x / y
[0032] In the metric system, the modulus is expressed in Newtons
per square meter (Newtons/m.sup.2).
[0033] A preferred shear modulus in accordance with the present
invention is one that is greater than 10,000 Newtons/m.sup.2 and
having a shear modulus after 1000 seconds of stress exposure at
constant loading at approximately at least 150.degree. F., greater
than 1000 Newtons/m.sup.2.
[0034] Referring now to FIG. 5, it will be seen that a shingle 90
is provided, comprised of two shingle layers 91 and 92, that are
adhered together in a manner similar to the shingle layers of FIG.
4, such that the same will not be repeated here.
[0035] However, in FIG. 5, it will be seen that a pair of rows of
sealant 94, 95 are shown on the anterior surface of the anterior
shingle layer. These rows of sealant may preferably be provided
with strips of release paper thereon, when the shingles 90 are
packaged together, to be removed prior to installation on a roof,
or in the alternative, those portions of a shingle that are
packaged adjacent the shingle 90 when the same are packaged
together, may have release paper on those portions of that shingle
that would be packaged against the sealant rows 94, 95, in the
packaged condition, to prevent adjacent shingles in a given package
from sticking together. In any event, a shingle as shown in FIG. 5,
prior to its installation on a roof, will not have release paper
disposed over sealant 94, 95, at that time that the shingle is
applied to a roof.
[0036] It will be seen that the sealant row 94 is provided
generally in that headlap portion 96, below the upper edge 93 of
the posterior shingle layer, and above the upper edge 97 of the
cut-out in the anterior shingle layer, to define for the shingle
installer, on the top surface of the shingle as it is being
installed on a roof, a lower end to a nailing zone, the upper end
of which nailing zone 98 is defined by the row of sealant 95,
placed as shown.
[0037] In the embodiment of FIG. 5, the rows of sealant 94, 95, are
spaced apart a distance "c", which may be, for example, on the
order of two inches, whereas the distance above the upper edge 93
of the posterior shingle layer, that the row of sealant strips 95
is disposed may be a distance "b" that is on the order of 17/8 to 2
inches, and with the headlap distance "a" being an overlap on the
order of 3/8 inches or 1/2 inches, or even 1 inch. The wide nailing
zone 98 that is displayed to a roofing installer, thereby suggests
to the roofer, staples or the like, which secure the shingles to a
roof, should be essentially through the single layer 91 of shingle
material of the shingle 90, essentially above the upper edge 93 of
the posterior shingle layer, because of the close proximity of the
sealant layer 94 thereto, and below the line defined by the strips
of sealant 95.
[0038] It should be apparent from the above that, in accordance
with this invention, the overlapping headlap zone "a" can be
reduced, resulting in a saving in material, and packaging of
shingles without creating a "humping" when shingles are packaged
due to excessive height of the posterior shingle layer, while
allowing for rapid installation of the shingles in the field.
[0039] However, instead of the row of sealant 95 of FIG. 5, there
is provided a scribe or score line 105, which, in lieu a row of
sealant at that location, can provide for the roofing installer, an
upper indication of the nailing zone 98.
[0040] It will be apparent from the foregoing that if fasteners
happen to be applied through only the anterior shingle layer 71,
and through only that portion of the anterior shingle layer 80 that
is above the upper edge 74 of the posterior shingle layer 72, then
with the stronger adhesive 75 applied in the common bond area e.g.
like that shown in FIG. 4, the posterior shingle layer will remain
in place even under high temperature conditions and on roofs of
steeper slope or pitch.
[0041] With reference now to FIG. 6, it will be shown that there is
a shigle that, for the most part, is constructed like the shingle
of FIG. 5, with the shingle 100 being comprised of anterior and
posterior layers 101, 102 the posterior layer of which has an upper
edge 103, and with a row of sealant 104 being disposed on the
anterior shingle layer 101 similar to the row of sealant 94 of FIG.
5.
[0042] Referring now to FIG. 7, an alternative multi-layer
laminated shingle 120 is shown, having anterior and posterior
layers, 121, 122, respectively, with cut-outs 123 in the anterior
shingle layer, spacing apart tabs 124 of the anterior shingle
layer, and having a width for the anterior shingle layer "m" of 12
inches, with the posterior shingle layer having a width "q" of
approximately 6 inches, leaving a common bond headlap area above
the upper edge 125 of the cut-out areas 123, designated as "n", of
approximately 7/8 inch to 1 inch.
[0043] Demarcation limits or lines 126, 127 and 128 are shown,
which are markings to guide a shingle installer, as to where the
nails, staples or other forms of fastener should be placed, to
fasten the shingle 120 to a roof or the like. The line 126, 127 and
128 may be discrete lines, as shown, or may be demarcation limits
in the form of upper and lower ends of bands, of different color,
shading, etc, as desired. The demarcation limits 126, 127 and 128
may also be scribed lines, or any other form of marking to enable a
shingle installer to see the zones that such demarcation limits
present for fastening the shingle to a roof.
[0044] For example, the width of the zone between lines 126 and
127, of "o" may perhaps be {fraction (5/16)} inches, for guiding
the installer as to where a fastener may be applied to assure that
it will go through both posterior and anterior shingle layers, if
the perceived security of nailing through two layers is
desired.
[0045] The distance between demarcation limits 126 and 128, as
shown by "p", may, however, be on the order of 13/4 inches, more or
less, to define a wider fastening zone, for instances where the
installer is comfortable fastening the shingle through either a
shingle thickness in the anterior shingle layer only, or a double
thickness portion through both the anterior and posterior shingle
layers.
[0046] Alternatively, if the installer is comfortable nailing only
through a single layer of the laminated shingle; namely the
anterior shingle layer, the fastener can be applied between
demarcation limits 127 and 128, in a zone of approximately 13/8
inch in width. The layers 121 and 122 of shingle 120 are adhered
together by any of the higher temperature or high shear modulus
adhesives discussed above, that will securely hold them together
under the above-mentioned conditions of temperature, slope,
etc.
[0047] With reference now to FIG. 8, it will be seen that a shingle
130, comprised of anterior and posterior shingle layers 131, 132 is
also provided, and is constructed essentially similarly to that of
the shingle of FIG. 7, except that the demarcation limits or lines
136, 137 and 138 of the shingle of FIG. 8 are illustrated as being
broken or spaced-apart lines. Such lines may be scribe lines,
colored lines, portions of a bands or the like, or may be comprised
of lines of adhesive. The dimensions m', n', o', p', and q' may be
similar to the dimensions m n o p q of FIG. 7, just as the adhesive
that adheres layers 131 and 132 together may be as described above
for the shingle of FIG. 7.
[0048] Accordingly, it will be apparent from the foregoing that the
objects of the present invention are satisfied, and that various
modifications may be made in the details of construction, as well
as in the use and operation of shingles in accordance with the
present invention, all within the spirit and scope of the invention
as defined in the appended claims.
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