U.S. patent application number 10/390756 was filed with the patent office on 2004-09-23 for multi-layer shingle with shiplap joint.
Invention is credited to Koschitzky, Henry.
Application Number | 20040182032 10/390756 |
Document ID | / |
Family ID | 32824845 |
Filed Date | 2004-09-23 |
United States Patent
Application |
20040182032 |
Kind Code |
A1 |
Koschitzky, Henry |
September 23, 2004 |
Multi-layer shingle with shiplap joint
Abstract
A multi-layer laminate shingle has a base layer and at least a
second layer above the base layer. At one end of the shingle the
base layer projects beyond the second layer while at the other end
the second layer projects beyond the base layer. When the shingles
are laid in a course along the roof, the projecting end of the
second layer overlaps the projecting end of the base layer of the
next shingle, forming a shiplap joint over all or substantially all
of the width of the shingle, protecting the joint against rain
penetration. This shiplap feature allows the headlap to exposure
ratio of the shingle to be reduced to less than 1 and even to 0.5
or less, thus reducing the cost of shingles per unit of roof
coverage area. If desired, a narrow strip can be adhered to the top
of the headlap portion of the shingle or beneath the butt portion
of the shingle to emulate the appearance of a costly triple
laminate shingle.
Inventors: |
Koschitzky, Henry;
(Downsview, CA) |
Correspondence
Address: |
BERESKIN AND PARR
SCOTIA PLAZA
40 KING STREET WEST-SUITE 4000 BOX 401
TORONTO
ON
M5H 3Y2
CA
|
Family ID: |
32824845 |
Appl. No.: |
10/390756 |
Filed: |
March 19, 2003 |
Current U.S.
Class: |
52/518 ;
52/555 |
Current CPC
Class: |
E04D 1/2963 20190801;
E04D 1/28 20130101; E04D 2001/005 20130101; E04D 1/26 20130101;
E04D 1/2916 20190801 |
Class at
Publication: |
052/518 ;
052/555 |
International
Class: |
E04D 001/00 |
Claims
1. A roofing shingle comprising: a) a base layer having first and
second longitudinally spaced-apart end edges defining between them
a length for said base layer, said base layer also having laterally
spaced-apart top and bottom edges defining a width for said base
layer, said base layer having an upper surface, b) a second layer
laminated to said upper surface of said base layer, c) said second
layer having a first end portion inset from said first end edge of
said base layer over at least a substantial portion of the width of
said base layer, said first end portion being inset from said first
end edge from a position adjacent said top edge of said base layer
to a position at or near said bottom edge of said base layer, so
that said first end edge of said base layer extends in a
longitudinal direction beyond said first end portion of said second
layer over said substantial portion of the width of the base layer
to form a projecting end of said base layer, d) said second layer
having a second end portion extending longitudinally beyond said
second end edge of said base layer over at least a substantial
portion of the width of said base layer, said second end portion so
extending from a position adjacent said top edge of said base layer
to a position at or near said bottom edge of said base layer to
form a projecting end of said second layer, e) so that when two or
more of said shingles are assembled end to end to form a horizontal
course of shingles, said projecting end of said second layer of one
shingle will extend over the projecting end of said base layer of
an adjacent shingle to form a shiplap joint, whereby to protect the
joint between adjacent shingles from penetration by rain.
2. A roofing shingle according to claim 1 and having a headlap area
adapted to be covered by the next higher course of shingles, and an
exposed area adapted to be visible on a roof, and wherein the ratio
of said headlap area to said exposed area is less than or equal to
1.
3. A roofing shingle according to claim 2 wherein said ratio is
less than 1.
4. A roofing shingle according to claim 3 wherein said ratio is
less than 0.5.
5. A roofing shingle according to claim 3 wherein the length of
said projecting end of said base layer and the length of said
projecting end of said second layer are substantially the same.
6. A roofing shingle according to claim 5 wherein said length of
said projecting portions is between 2 inches and 6 inches.
7. A roofing shingle according to claim 1 wherein said second layer
comprises a plurality of separate portions.
8. A roofing shingle according to claim 1 wherein said second layer
comprises a single sheet having cutouts therein to form tabs.
9. A roofing shingle according to claim 1 and including a third
sheet laminated on top of a portion of said second layer.
10. A roofing shingle according to claim 1 and including a third
sheet laminated beneath said base layer.
11. A plurality of roofing shingles each in accordance with claim
1, said roofing shingles being assembled end-to-end to form a
horizontal course of shingles with vertical joints between them, at
least a substantial portion of said vertical joint between each
adjacent pair of shingles being covered by a said projecting end of
said second layer of one of said shingles.
Description
FIELD OF THE INVENTION
[0001] This invention relates to the designs of multi-layer
shingles. In particular, it relates to multi-layer shingles having
shiplap joints.
BACKGROUND OF THE INVENTION
[0002] Asphalt roofing shingles have been in general use on roofs
for nearly 100 years. They provide excellent water shedding
characteristics to protect roofs from water leaks. The shingles are
installed on a roof and overlap each other in a way that water
cannot-leak through the joints of the shingles to the base board of
the roof. Typically, each course of shingles is horizontally
offset, about 4" to 10", relative to the preceding course of
shingles so that the joints of the shingles in a course do not line
up with the joints of the shingles in the preceding or succeeding
course. In addition, except for the starter course, each course of
shingles overlaps the preceding course of shingles by more than 50%
of the shingle width. This is to ensure that all portions of the
joints in the same course either are placed on top of the shingles
in the preceding course or are covered by shingles in the
succeeding course. This means that over 50% of the total shingle
surface area is covered by other shingles, which is a costly use of
material.
[0003] A shingle surface can be divided into two areas, called the
"headlap portion" and the "exposure portion". After the shingles
are installed on the roof, the headlap portion is the area of the
shingle covered by the shingles of the succeeding (i.e. next
higher) course of shingles, while the exposure portion is the area
of the shingle exposed to the environment. More overlapping area
means less roof coverage area for the shingle. Hence, the higher
the ratio of the headlap portion to the exposure portion, the
higher the shingle cost per unit of roof coverage area is, because
a larger overall shingle area is required to provide an amount of
exposure which is equal to the roof coverage area. In order to
maintain the water shedding integrity of the shingle system, the
headlap to exposure ratio cannot (in the prior art) be reduced to
less than one.
BRIEF SUMMARY OF THE INVENTION
[0004] While single layer shingles are very common, due to their
low price, double layer and triple layer laminate shingles are
becoming more widely used, because of their attractive ornamental
appearance. The applicant has realized that when such multiple
layer laminate shingles are used, their multiple layer construction
can be used to provide a shingle design which can substantially
reduce the headlap to exposure ratio of the shingle, while
maintaining the water shedding integrity of a roofing system formed
from such shingles.
[0005] In one aspect the invention provides a roofing shingle
comprising: (a) a base layer having first and second longitudinally
spaced-apart end edges defining between them a length for said base
layer, said base layer also having laterally spaced-apart top and
bottom edges defining a width for said base layer, said base layer
having an upper surface, (b) a second layer laminated to said upper
surface of said base layer, (c) said second layer having a first
end portion inset from said first end edge of said base layer over
at least a substantial portion of the width of said base layer,
said first end portion being inset from said first end edge from a
position adjacent said top edge of said base layer to a position at
or near said bottom edge of said base layer, so that said first end
edge of said base layer extends in a longitudinal direction beyond
said first end portion of said second layer over said substantial
portion of the width of the base layer to form a projecting end of
said base layer, (d) said second layer having a second end portion
extending longitudinally beyond said second end edge of said base
layer over at least a substantial portion of the width of said base
layer, said second end portion so extending from a position
adjacent said top edge of said base layer to a position at or near
said bottom edge of said base layer to form a projecting end of
said second layer, (e) so that when two or more of said shingles
are assembled end to end to form a horizontal course of shingles,
said projecting end of said second layer of one shingle will extend
over the projecting end of said base layer of an adjacent shingle
to form a shiplap joint, whereby to protect the joint between
adjacent shingles from penetration by rain.
[0006] Further objects and advantages of the invention will appear
from the following description, taken together with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the drawings:
[0008] FIG. 1a is a top view of a double laminate shingle according
to the invention;
[0009] FIG. 1b is an isometric view of the double laminate shingle
of FIG. 1;
[0010] FIG. 2 is a top view showing several courses of prior art
shingles on a roof, laid so as to illustrate the joint coverage
problem;
[0011] FIG. 3a is a top view of a modified double laminate shingle
according to the invention;
[0012] FIG. 3b is an isometric view of the double laminate shingle
of FIG. 3a;
[0013] FIG. 4a is a top view of a triple laminate shingle according
to the invention;
[0014] FIG. 4b is an isometric view of the triple laminate shingle
of FIG. 4a;
[0015] FIG. 5a is a top view of another triple laminate shingle
according to the invention;
[0016] FIG. 5b is an isometric view of the triple laminate shingle
of FIG. 4a.
[0017] FIG. 6a is a top view of still another triple laminate
shingle according to the invention;
[0018] FIG. 6b is an isometric view of the shingle of FIG. 6a;
and
[0019] FIG. 6c is a top view of a strip used in the FIG. 6a
shingle.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0020] In conventional multi-layer asphalt roofing shingles, the
typical size of each shingle is about 393/8" (long).times.131/4"
(wide). Usually, such shingles are installed across the roof in
horizontal courses, without overlapping any other shingles in the
same horizontal course. However they overlap the shingles in the
preceding course, as courses or rows are applied vertically up the
roof. In addition, each course of shingles is installed with an
offset horizontally to the preceding course, so that joints between
the shingles in the same course do not line up with the joints
between the shingles in the preceding course or succeeding course.
In the aforementioned shingle, the typical exposure of the shingle
is about 55/8" out of the 131/4" width of the shingle. In the other
words, 75/8" (from the total shingle width of 131/4") is the
headlap portion, which is covered by the shingles in the succeeding
course after installation. (More generally, the exposure portion is
usually the width of the shingle less 2", divided by 2, which
yields the 55/8" exposure portion in the above example.)
[0021] In the example given, the headlap-to-exposure ratio of the
shingle is 75/8" divided by 55/8" and is equal to 1.36. To avoid
rain water leaking through the joints between two consecutive
shingles in the same horizontal course, it is clearly important not
to reduce the headlap-to-exposure ratio close to one or less than
one. All portions of the vertical joint between horizontally
adjacent shingles in the same course must either be placed on top
of the shingles in the preceding course or be covered by the
shingles in the succeeding course.
[0022] The inventor has realized that when multiple layer laminate
shingles are used, they can be designed to provide a shiplap
feature which can eliminate the restriction that the
headlap-to-exposure ratio must be greater than 1. Once the
restriction is removed, the headlap-to-exposure ratio can be
reduced significantly. A smaller shingle width will then be
required to provide the same amount of roof coverage area, or
alternatively the same overall shingle width can provide a larger
amount of roof coverage area.
[0023] A shiplap joint is the overlapping portion of two
consecutive shingles in the same course after installation.
Reference is first made to FIGS. 1a, 1b which show a double
laminate shingle 10. Shingle 10 includes a base layer 12 having
longitudinally spaced-apart end edges 14, 16 which define between
them the length of the shingle base layer, and laterally
spaced-apart top and bottom edges 18, 20 which define between them
the width of the base layer. (When the shingle 10 is laid, the top
edge 18 will be at the top of the headlap portion and the bottom
edge 20 will be at the bottom of the exposure portion.)
[0024] Shingle 10 also includes a second layer 24, formed in the
FIGS. 1a, 1b embodiment by four individual tabs 26, 28, 30, and 32.
The number, spacing and size of these tabs is largely optional,
except as will be explained. (For example, the tabs 26, 28, 30 and
32 can be of substantially equal size.) The tabs 26-32, which can
have various colors of granules applied to them, are laminated to
the base layer 12 in conventional fashion, with slots 34 between
the tabs 26-32 to provide an ornamental appearance.
[0025] In accordance with the invention, one end tab 26 has an end
edge 36 extending longitudinally beyond the end edge 14 of the base
layer 12 by a first longitudinal offset indicated at 38. Typically
the first longitudinal offset 38 is about 2" to 6".
[0026] Similarly, the end edge 40 of the fourth tab 32 is inset
from the end edge 16 of the base layer by a second longitudinal
offset 42 which is preferably of the same longitudinal extent as
offset 38 (although offset 42 can be slightly smaller or larger if
desired).
[0027] It will be realized that the end edges 36, 40 will usually
not be straight, since they are cut to a shape such that the end
edge 36 of one shingle, and the end edge 40 of its adjacent
shingle, form one of the slots 34 when the shingles are installed
on a roof.
[0028] Thus, the shingle 10 has at one end a projecting tab portion
44 and at the other end a projecting base layer portion 46. When
the shingles 10 are installed in a horizontal course across the
roof, the projecting tab portion 44 will cover the projecting base
layer portion 46 for adjacent shingles, thus forming a set of
shiplap joints which cover any gaps between horizontally adjacent
shingles in the same course. Therefore, no rain water can leak
through the joints, even if the joints are neither placed on top of
shingles in the preceding (lower) course nor covered by the
shingles in the succeeding (next higher) course. Therefore, the
headlap-to-exposure ratio no longer needs to be greater than 1.
However, preferably the headlap width 48 of the double laminate
shingle 10 is larger than 2", to provide sufficient overlapping
area between successive courses of shingles to avoid rain water
being driven up between the courses by high winds and leaking
through in the headlap area. The exposure portion of the shingle
may be between 6" and 18". The headlap-to-exposure ratio can be
reduced from more than 1 to 1.0 or less, or (preferably) 0.5 or
less.
[0029] In the FIGS. 1a, 1b embodiment, it will be seen that the tab
26 which has the projecting portion 44 extends fully from the top
edge 18 to the bottom edge 20 of the base layer 12. With this
arrangement, the vertical joint between horizontally adjacent
shingles is fully covered (from top to bottom) by the projecting
tab portion 44. However it is not essential that the projecting tab
portion 44 extend over the full width of the shingle, although it
is desirable that it do so, or at least that it extend over most of
the shingle width. It is particularly desirable that the tab 26
extend to a position adjacent (at or near) the top edge 18 of the
base layer 12. The bottom edge of the tab 26 can be displaced
slightly upwardly from the bottom edge 20 of the base layer 12
(e.g. for decorative purposes), but it should preferably be close
to (e.g. within an inch or two of the bottom edge 20 of the base
layer 12.
[0030] The reasons for this will best be understood from FIG. 2,
which shows portions of three courses of prior art shingles 50 laid
on a roof (without any shiplap joints). For purposes of
illustration, the prior art shingles 50 may each be assumed to be
three units wide (i.e. high) and have vertical joints 52 between
horizontally adjacent shingles. In this arrangement, and looking at
joint 52-1, it will be seen that the top 1/3 of this joint
(indicated at 52-1a and located in the headlap portion 54) will be
covered by the succeeding course, and in addition the bottom third
of the joint (indicated at 52-1c) will be protected by the
preceding course which is beneath it. However the middle third of
the joint (indicated at 52-1b) is exposed and will be penetrated by
rain. It is this middle portion 52-1b of the joint which needs to
be protected by the shiplap joint. In theory the shiplap joint can
extend only a short distance above and below the middle third 52-1b
of the joint 52-1 and will provide protection against rain
penetration. However in practice this would not normally be
sufficient to prevent wind driven rain penetration. Therefore it is
preferred that the tab 26 having the projecting portion 44 extend
from a position at or close to the top edge 18, to a position at or
close to, or at least not spaced too much above, the bottom edge 20
of the base layer 12.
[0031] Reference is next made to FIGS. 3a, 3b which show a double
laminate shingle very similar to that of FIGS. 1a, 1b, and in which
primed reference numerals indicate corresponding parts. The only
difference between the FIGS. 3a, 3b embodiment and that of FIGS.
1a, 1b is that in the FIGS. 3a, 3b embodiment, the second layer 24'
is formed from a single sheet instead of from a plurality of
individual tabs. The second layer 24' contains cutouts or slots 34'
extending from its bottom edge over part of its width to form
decorative tabs, which can have various colors of granules applied
thereto.
[0032] Reference is next made to FIGS. 4a, 4b, which show an
embodiment which is the same as that of FIGS. 3a, 3b except that a
longitudinally extending narrow strip 60 (which forms a third
layer) has been adhered on top of the headlap portion of the double
laminate shingle, adjacent the top edge 18'. The length of the
narrow strip 60 can be equal to or less than the overall length of
the second layer 24'. The strip 60 does not affect the shiplap
joint previously described, but when the shingles of FIGS. 4a, 4b
are installed on a roof, the butts of the shingles in each
succeeding course will line up with the bottom longitudinal edges
of the narrow strips 60. Therefore these shingles after
installation will to some extent have the appearance of more costly
triple laminate shingles.
[0033] FIGS. 5a, 5b show another design which is the same as that
of FIGS. 4a, 4b except that strip 60 has been omitted and a narrow
strip 62 has now been adhered beneath the base layer 12', flush
with the butt or bottom edge 20' of the base layer 12'. Again the
length of the narrow strip 62 can be equal to or less than the
length of the base layer 12' and will provide the appearance of a
more costly triple laminate shingle.
[0034] Finally, reference is made to FIGS. 6a, 6b and 6c, which
show an embodiment similar to that of FIGS. 5a, 5b except that the
narrow strip or third layer 64 (similar to strip 62) is now
irregular in shape, having wider portions 66, which project below
the bottom edge 20' of the base layer 12' in selected locations as
shown for projections 68. The projections 68 can be of desired
width, e.g. 1/4 to {fraction (1/2)} inch, or they can be of
different widths, or they can be slanted, i.e. starting at zero
projection and ending at 1/4 or {fraction (1/2)} inch. The
projections 68 will normally have colored granules applied thereto
(as will the remainder of the exposed portions of the shingles),
but use of granules in the remainder of strip 64 is optional.
Preferably the locations for projections 68 are chosen to be
aligned with tabs of the second layer, e.g. the second and fourth
tabs 28', 32', as shown in FIGS. 6a, 6b. This again provides a more
decorative appearance for the shingle, at relatively low cost.
[0035] While preferred embodiments of the invention have been
described, it will be understood that modifications may be made
within the scope of the invention, and such scope is intended to be
limited only by the attached claims.
* * * * *