U.S. patent application number 10/955864 was filed with the patent office on 2005-04-07 for high profile composition shingles for roofs.
Invention is credited to Williams, Scott.
Application Number | 20050072092 10/955864 |
Document ID | / |
Family ID | 34396404 |
Filed Date | 2005-04-07 |
United States Patent
Application |
20050072092 |
Kind Code |
A1 |
Williams, Scott |
April 7, 2005 |
High profile composition shingles for roofs
Abstract
A high profile shingle for roofs includes a weather layer of
composition material and a plurality of members of composition
material arranged under said weather layer which are of varying
lengths and arranged to cause the butt end of the shingle to be
substantially thicker than the weather layer. In one embodiment,
the members under the weather layer are a series of spaced, tapered
strips arranged with their thick ends toward one end of the shingle
and having an additional end strip abutted against the thick ends.
Another embodiment uses a series of underlayers of the same width
as the weather layer but of lengths varying from approximately
one-half down to about one-eighth the length of the weather layer.
A third embodiment uses a base layer of substantially greater width
than the weather layer, a series of layers of progressively shorter
lengths below the weather layer with the ends of the layers in
registry at the butt end of the shingle with cut-out sections. A
fourth embodiment comprises a weather layer and a plurality of
underlayers of different lengths and the same width as the weather
layer. The underlayers have one end aligned, their surfaces all
bonded to its adjacent layer and fastened by staples with the
outermost longest underlayment layer bonded to the underside of the
weather layer. One edge of the weather layer and the common edges
of the underlayment layers constituting the butt of the
shingle.
Inventors: |
Williams, Scott; (La Canada,
CA) |
Correspondence
Address: |
John E. Wagner, Esq.
LAW OFFICES OF JOHN E. WAGNER
3541 Ocean View Boulevard
Glendale
CA
91208
US
|
Family ID: |
34396404 |
Appl. No.: |
10/955864 |
Filed: |
September 29, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60507994 |
Oct 1, 2003 |
|
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Current U.S.
Class: |
52/518 |
Current CPC
Class: |
E04D 1/22 20130101; E04D
2001/005 20130101; E04D 1/28 20130101 |
Class at
Publication: |
052/518 |
International
Class: |
E04D 001/00 |
Claims
I claim:
1. A high profile composition shingle for roofs comprising a
weather layer of a composition material having a granulated
surface: a plurality of members of composition material positioned
under said weather layer, said members being of varying lengths and
arranged such that the butt end of said shingle is substantially
thicker than said weather layer; said layers below the weather
layer being stapled together at the butt end region of said
shingle.
2. A high profile composition shingle as claimed in claim 1 wherein
said weather layer includes cut-outs extending from its outside
edges over a substantial portion of its width.
3. A high profile composition shingle as claimed in claim 1 wherein
said members of composition material below said weather layer are
tapered from the butt end of different lengths.
4. A high profile composition shingle as claimed in claim 3 wherein
a plurality of said layers of composition material have internal
cut-out areas to provide internal recesses below said weather
layers.
5. A high profile composition shingle as claimed in claim 3 wherein
said shingle includes a base layer and said base layer is of
substantially greater width than others of said layers.
6. A high profile composition shingle as claimed in claim 3 wherein
said weather layer and said layers are tapered in length and are of
substantially uniform width.
7. A high profile composition shingle for roofs comprising: a
weather layer of composition material having a granulated surface;
a plurality of tapered ribs of composition material spaced across
the butt end of said weather layer, each said ribs having a thick
end and all of the thick ends positioned near the butt end of said
weather layer; and a butt end rib located adjacent the thick end of
said spaced ribs below said weather layer.
8. A high profile composition shingle as claimed in claim 8 wherein
selected ribs of said spaced ribs are longer than other said
ribs.
9. A high profile composition shingle as claimed in claim 8 wherein
the widths of the spaces between said ribs are greater than the
widths of the ribs.
10. A high profile composition shingle as claimed in claim 8
wherein the thickness of said butt end rib is substantially greater
than the thickness of said weather layer.
11. A high profile composition shingle as claimed in claim 8
wherein said tapered ribs abut against said butt end rib and the
thickness of said tapered ribs adjacent said butt end rib is
substantially the same as the thickness of said butt end rib.
12. A high profile composition shingle for roofs comprising: a
generally rectangular weather layer; a plurality of underlayers
secured to said weather layer, said underlayers together being
progressively tapered in length with one end of each of said
underlayers being stacked in registry to form the butt end of said
shingle said plurality of underlayers being stapled together near
said butt end.
13. A high profile composition shingle for roofs comprising: an
elongated weather layer of granule-covered roofing composition; a
plurality of different length underlayment layers bonded to each
other at one end of each to form a tapered underlayment bonded to
said weather layer, the longest of said underlayment layers being
in the order of one half the length of said weather layer, one end
of said underlayment layers being bonded to one end of said weather
layer to form with said weather layer the butt end of said
shingle.
14. A shingle in accordance with claim 13 wherein said underlayment
layers are all mechanically fastened together at one end.
15. A shingle in accordance with claim 16 wherein the mechanical
fastening is provided by at least one staple.
16. A shingle in accordance with claim 14 wherein said underment
layers and said weather layers are of the same width at least in
the weather region when installed.
17. A high profile composition shingle for roofs comprising: a
generally rectangular weather layer; a first underlayer under said
weather layer of substantially the same width as and approximately
one-half the length of said weather layer; a second underlayer
under said first underlayer of substantially the same width as and
substantially shorter than said first underlayer; a third
underlayer under said second underlayer of substantially the same
width as and substantially shorter than said second underlayer; a
fourth underlayer under said third underlayer of substantially the
same width as and substantially shorter than the third underlayer;
and a fifth underlayer under said fourth underlayer of
substantially the same width as and substantially shorter than said
fourth underlayer; said first through fifth underlayers all being
of composition roofing material and all said underlayers being
stacked together with one end aligned with one end of said weather
layer to form a thickened butt end of said high profile composition
shingle, said first through fifth underlayers being stapled
together at said butt end.
Description
REFERENCE TO RELATED APPLICATION
[0001] This Non-Provisional Patent Application claims benefit of
U.S. Provisional Patent Application Ser. No. 60/507,994 filed Oct.
1, 2003, and hereby claims the benefit of the embodiments therein
and of the filing date thereof.
BACKGROUND OF THE INVENTION
[0002] The need for improved roofing materials as substitutes for
actual slate or wooden shake shingles has been recognized for many
years. The classic slate roofs commonly used abroad, and in some of
the most expensive homes in the United States of America, are
characterized by their expense and, most importantly, in the
extreme weight of slate shingles which typically run to over 1000
pounds per square.
[0003] Wood shake shingles are quite attractive due to their
irregularity and their depth presenting a high profile; however,
they are significantly more expensive than composition shingles and
do not meet the fire safety codes. Attempts have been made to
fireproof them with varying degrees of success, but they still do
not meet the fire codes that are easily met by granular covered
asphaltic composition roofs. Some attempts to make simulated slate
or wood shingle shakes have used cementitious materials. These
materials, while not as heavy as slate, still have weight in the
order of 600 pounds per square, and usually lack the irregularity
and high profile of natural slate or wood shake.
[0004] Other attempts have involved the use of molded plastic
materials to present the irregular surface of shake roofs or the
shape and appearance of natural slate. These materials can be
molded to provide the additional thickness found in shake shingles;
however, they fail to meet the same fire safety standards as
composition roofs.
[0005] U.S. Pat. No. 6,510,664 discloses a method of creating
multi-layered composition shingles from a single sheet of asphalt
material. This is accomplished by forming tabs on the sheet, which
are folded over to provide three-layer sections.
[0006] U.S. Pat. No. 6,351,913 also shows an arrangement for
forming multi-layered shingle of asphalt composition, particularly
for ridge covers on roofs. Again, a single sheet of asphalt
composition material is folded to form a triple thick shingle.
[0007] U.S. Pat. No. 6,058,670 shows a shingle containing a single
sheet having an upper individual headlap portion and a lower butt
portion divided into uniformly spaced tabs, with each tab having
two opposing terminal corners defining the bottom boundary of the
butt portion and an undivided top strip having indentations along
its bottom edge conforming in outline to the boundary and corners
of the tabs, this strip being laminated over the surface of the
sheet headlap and positioned at the tab upper boundaries where the
tabs depend from the headlap and situated so that the indentations
of the strip are located above the tabs at approximately the mid
point of their widths. In some versions, the strip is of a color
contrasting with the color of the tabs.
[0008] U.S. Pat. No. 4,226,069 shows a flat strip of roofing
material with a thin, flexible underlying plastic base sheet having
a self-sealing asphalt mastic coating layer and a mineral granule
front surface layer. The strip has on each of its opposite faces a
longitudinally extending groove adjacent to and spaced from
opposite ones of its longitudinally extending edges. The strip
material is foldable along the grooves around the edge of an
adjacent folded strip edge. In this manner, the butt edges have
three layers of roofing material which are nailed to the underlying
sheeting, plus one layer folded over the tops of the nails.
[0009] Other attempts to make multi-layered added thickness
composition roofs have results in delamination due to wind alone or
in combination with deterioration of adhesive due to solar heating
or alternate freezing and thawing of moisture. Delamination
destroys the illusion of thickness and is difficult, if not
impossible, to repair.
BRIEF DESCRIPTION OF THE INVENTION
[0010] It occurred to the applicant that it might be possible to
design wood shake and slate-appearing shingles completely from
composition materials that would meet the fire-resistance standards
of composition roofs, while at the same time presenting the
external appearance of either a slate or wooden shake roof. In
particular, it appeared possible to provide composition shingles
with the irregular surface and the gaps characteristic of the shake
shingles and the high profile and somewhat scalloped surface
commonly found in slate shingles made from natural material.
[0011] It is possible to make such shingles solely from composition
materials with multiple layers, adding greatly to the depth of the
body and of the shingles, and providing a tapered appearance on the
sides of the shingles, while maintaining a weight that is within
the range of composition roofs and not exceeding the weight of
other simulated slate or shake shingles. This roof meets all the
fire code standards or exceeds the standards of a conventional
composition roof.
[0012] One embodiment of this particular invention involves several
composition layers, either the size of a single or multiple
shingles, carrying a granular face and incidentally having
identified nail positions for the installer. Three such nailing
positions per single shingle may be adequate to meet building code
standards and to insure integrity of the roof. Overlaying part of
the concealed portion of the base layer are a series of graduated
layers of composition roof material having cut-out portions which
provide a cavity within the shingle. The cavity or cavities extend
longitudinally with internal ribs supporting the weather layer
between the ribs. The butt end of the shingle includes a number of
exposed edges of the graduated layers, which can present a height
and thickness in the order of one-half to three-quarters of an inch
if desired. Any side of the shingle that is exposed will be
graduated in the thickness below the base weather layer to give the
appearance of a true graduated thickness shingle. The entire
shingle, however, including the weather cover with or without any
cavity, is of approved composition material.
[0013] In another and preferred embodiment, the shingle is formed
of a weather layer backed by a series of graduated length, full
width single layers. Each are adhered to adjacent layers by
suitable roofing adhesive. The butt end has the greatest number of
layers, e.g., six, including the weather layer. The underlayers may
be granule covered or not. Granules can add depth and provide good
bonding. Most important is by fastening means, for example, two
large roofing staples which penetrate all underlayers and are
crimped at their ends, partially embedded in the outer layers. This
avoids any visible bumps on the weather layer.
[0014] The multiple layers provide an overall tapered appearance
throughout the exposed length of the shingle as viewed from the
side and a thick butt, e.g., six times the thickness of regular
composition shingles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] This invention may be more clearly understood with the
following detailed description and by reference to the drawings in
which:
[0016] FIG. 1 is a perspective view of a roof with a conventional
prior art cementitious shingle roof simulating wood shakes;
[0017] FIG. 2 is a perspective view showing a prior art roof having
cementitious shingles simulating slate shingles;
[0018] FIG. 3 is a perspective view of a roof section having
composition shingles according to the invention;
[0019] FIG. 4 is a perspective view on an enlarged scale showing a
part of the roof section of FIG. 3;
[0020] FIG. 5 is a perspective view showing a bottom perspective
view of the shingle of the invention as shown in FIGS. 3 and 4;
[0021] FIG. 6 is a perspective view showing a side view of the
shingle of FIG. 5;
[0022] FIG. 7 is a perspective view showing the lower or butt end
view of shingles according to one embodiment of the invention;
[0023] FIG. 8 is a top perspective view of the shingle of the
invention;
[0024] FIG. 9 is a longitudinal sectional view of the shingle of
FIG. 8 taken along lines 9-9 of FIG. 8;
[0025] FIG. 10 is a transverse sectional view of the shingle of
FIG. 8 taken along line 10-10 of FIG. 8;
[0026] FIG. 11 is a top plan view of the shingle of FIG. 8 with the
weather layer removed to show the internal construction of the
shingle of FIG. 8;
[0027] FIG. 12 is an exploded perspective view of the shingle of
FIGS. 8-12.
[0028] FIG. 13 is a perspective view of the shingle of FIG. 8 after
installation showing the natural undulations which develop in the
shingle after placement;
[0029] FIG. 14 is a top plan view of another embodiment in this
invention;
[0030] FIG. 15 is an enlarged side elevational view of the shingle
of FIG. 14;
[0031] FIG. 16 is a butt-end elevational view of the shingle of
FIG. 14;
[0032] FIG. 17 is a top plan view of the shingle of FIGS. 14-17
with the weather cover removed;
[0033] FIG. 18 is a perspective view of a shingle according to a
third embodiment of this invention;
[0034] FIG. 19 is a side view, with weather layer exploded away, of
the shingle of FIG. 18; and
[0035] FIG. 20 is an end view of the shingle of FIGS. 18 and 19,
also with the weather layer exploded away.
DETAILED DESCRIPTION
[0036] FIGS. 1 and 2 of this application are perspective views of
two types of existing roofing materials which are man-made and are
designed to simulate, in the case of FIG. 1, wood shake shingles
marked by their irregularity and gaps that produce deep, regular
shadows, as are illustrated in FIG. 1. The shingles of FIG. 1 are
of cementitious material, which is significantly heavier than
normal wood shakes but do provide effective roofing with no danger
of flammability, as is a real problem for wood shakes.
[0037] In FIG. 2, simulated slate shingles made of cementitious
material are shown having a depth noted by the shadows, even in the
face of direct sunlight. This roof is greater in cost than normal
composition roofs and comparable to some slate roofs.
[0038] Both the roofs in FIGS. 1 and 2 tend to be heavier than most
composition roofs but do provide a reasonable replica of the
appearance of wood shakes or slate roofs.
[0039] FIG. 3 shows a sample roof of this invention made totally
with standard composition roofing material but having a
significantly greater depth at the lower or butt end of each
shingle. As illustrated in FIG. 4, which shows a portion of the
roof of FIG. 3 on an enlarged scale, the lower or butt edges of the
shingles appear to have a depth in the order of {fraction (1/2)}
inch, thereby giving the desired look of depth and irregularity
desired.
[0040] FIG. 5 shows a single shingle of one embodiment of the
invention inverted in the form to be applied. The shingle 10 has a
full weather layer 12 and includes a thick butt portion 25 that is
bonded to the underside of the layer 12. The butt portion 25
extending along the full width of the shingle is in the order of
1/2-inch in thickness, 1/2-inch in depth, and is bonded securely to
the butt end of the shingle 10.
[0041] Ranging away from the butt end, approximately two-thirds of
the length of the shingle, are three wedge-shaped parts 26, 28, and
30 tapering from 1/2-inch of depth at the butt end to nearly zero
thickness. The center wedge 28 is shown extending somewhat longer
than the two-edge wedges 26 and 30, which adds to the textured
effect of the roof when installed. Each of these wedges is
thermally bonded to the weather layer as is the butt member 25. The
regions between the wedges 54, 56 will rest above the level of the
rough underlay, which is usually plywood covered with suitable felt
roll material. Trapped inside the shingle are small air pockets
between the wedges adding some insulating value to the roof in
addition to that afforded by the roofing material itself. Also,
these pockets may be filled with insulting foam to further enhance
the insulating properties of the shingle 10.
[0042] Because of the fact that portions of the weather surfaces
are unsupported between the wedges, the roof in time will develop
small recesses which serve to give an added degree of irregularity
to the roof to give it a more natural wood shake or slate irregular
appearance.
[0043] FIG. 6 is a perspective view of a shingle 10 according to
the invention, including an edge view of the top or weather layer
12, the shingle 10 being installed on a roof. The butt end 25 is
visible as well as one side wedge 30.
[0044] FIG. 7 is a perspective view showing an alternate form of
the shingle of the invention and is included because it shows the
thickness of the butt-end portion 24. Thicknesses of the
underlayers 24A making up butt end portion 24 on top of a base
layer 24B and below a shaped weather layer 24W have been
exaggerated for clarity.
[0045] FIG. 8 is a perspective drawing of a shingle 20 according to
the invention. This view shows the weather or top layer 22, the
butt portion 25, and a side wedge 26.
[0046] FIG. 9 is a sectional view taken along line 9-9 of FIG. 8.
Shown are the weather layer 22, the butt portion 25, and wedge 28,
which is a center wedge somewhat longer than side wedge 26.
[0047] FIG. 10 is a sectional view taken along line 10-10 of FIG. 8
and shows weather layer 22, center wedge 28, and side wedge 26. A
second side wedge 30 is essentially identical to side wedge 26.
[0048] FIG. 11 is a plan view of shingle 20 with the weather layer
removed and showing butt portion 25, side wedges 26 and 30, and the
longer center wedge 28. Wedges 26, 28, and 30 and butt portion 25
define spaces 54 and 56.
[0049] While FIGS. 8-11 show a somewhat narrow shingle 20, which
might be, e.g., 5 inches wide, the shingle of the invention would
typically also be made in widths of 7 inches or 12 inches wide.
Each such shingle would have one longer wedge 28 and other wedges
26, 30 spaced approximately every 2-{fraction (1/2)} inches.
[0050] FIG. 12 is an exploded perspective view of the shingle of
FIGS. 8-11 showing the weather layer 22, wedges 26, 28, and 30 and
butt portion 25.
[0051] FIG. 13 is a perspective view of a small section of shingles
of the invention after installation showing the natural undulations
which develop in the shingle after placement. The shingles 20 are
shown with weather layers 22, butt portions 25, and side wedges 26.
Shallow, hollow areas 32 appear over time in the weather layers 22
over spaces 54 and 56 where the weather layers are not supported by
wedge members 26, 28, or 30.
[0052] One way to manufacture the above-described shingles is to
utilize commercially available walking pads, which are of asphalt
composition material of varying thickness. Available such pads are
one-half inch thick and are 4 feet.times.3 feet in area. These pads
have a granulated surface similar to that of typical composition
shingles. By setting a shearing machine to cut wedges of the
desired dimensions, these wedges can be cut quite rapidly. They are
then turned 90.degree. to orient the taper with the surface of the
weather layers, which are, or may be, conventional composition
shingles. By heating the wedges and the weather layer to
300.degree. F. for 15-20 seconds, the wedges will be secured to the
weather layer and the shingle is complete. Typically, the weather
layer consists of a 21-inch asphalt composition shingle and the
outside wedges are about 12 inches long with alternate inside
wedges being 18 inches long to give the desired effect.
[0053] FIG. 14 is a top plan view of an alternate embodiment of the
shingle of the invention. This shingle 33 includes a base layer 35
of greater width than the remainder of the shingle, a top layer 34
having cut-outs 36 and 38, and a second layer 40. There are several
other underlayment layers below layer 40, discussed below. All
layers are of the conventional asphaltic composition used in
typical prior art composition roofs. Such composition shingles are
formed of an organic resinous material, such as asphalt, containing
greater than 60 percent filler of finely ground inorganic
particulate material, such as clay particles, slate particles,
shale particles, and glass fibers.
[0054] FIG. 15 is a side view of the shingle of FIG. 13. A number
of layers have been included to build up the thickness of the butt
end. Layers 42, 44, and 46 are below the outer or weather layer 40
and are shorter than layer 40. A layer 48 is approximately the
length of second layer 40. An additional layer 50 is almost the
length of the shingle and a layer 52 is the length of the
shingle.
[0055] FIG. 16 is a butt end elevational view of the shingle of
FIGS. 14 and 15. Again, it will be appreciated that the thicknesses
of the various layers have been exaggerated for clarity.
[0056] All layers between layer 40 and base layer 32 are cut out to
provide the recesses, as described above.
[0057] FIG. 17 is a plan view of shingle 33 with top layer 34 and
second layer 40 removed to show the cut out areas of layers 42, 44,
46, 48, and 50.
[0058] Subsequent to filing the Provisional Patent Application
referred to above, applicant devised a further embodiment shown in
FIGS. 18, 19, and 20, and an improvement over the embodiment of
FIGS. 14-16.
[0059] FIG. 18 is a perspective view, and FIG. 19 is a side view of
this further embodiment with the weather layer exploded away. FIGS.
18 and 19 show a high-profile composition shingle 60 having a
weather layer 62 and a series of composition layers 64, 66, 68, 70,
and 72 of graduated lengths below the weather layer. Nailing
locations may be marked on the shingle and nails 78, 80, and 82 are
shown in phantom which would be placed in such locations. Layer 64
is the longest of the lower layers, being approximately one-half
the length of the weather layer 62 and is positioned immediately
below the weather layer 62.
[0060] Additional layers 66, 68, 70, and 72 are progressively
shorter in length as shown in FIGS. 18 and 19. All of layers 64,
66, 68, 70, and 72 are of a usual composition material described
above and are stapled together at the butt end of the shingle by
means of staples 74 and 76. Staples 74 and 76 do not penetrate the
weather layer 62.
[0061] In this embodiment, the entire weather or exposed portion of
each shingle is solid roofing material and without voids or
cutouts. The top or weather layer 62 is preferably 90#
granule-covered composition material, such as 90# fiberglass cap
sheet. The completed shingle, as shown in FIG. 18, constitutes a
480# per square shingle (600# max).
[0062] The staples 74 and 76 are preferably #16 gauge construction
staples, which are driven and crimped over at the butt region of
the shingle 60 through layers 64, 66, 68, 70, and 72, with
sufficient force to crimp but not embed the ends into the upper
stapled layer 64 to secure the underlayers together. The ends are
invisible through the weather layer 62. Staples 74 and 76 added to
the adhesive layer which bonds all layers together makes
delaminating or shingle butt curling or lifting of little concern.
Staples may also be used in the embodiments described above.
[0063] The adhesive used is preferably elastomeric roofing cement
of the Henry Company of a dark or the same color as the body
material of the layers 62-72 and thereby aids in presenting an
appearance of a solid single piece of tapered thickness.
[0064] The above-described embodiments of the present invention are
merely descriptive of its principles and are not to be considered
limiting. The scope of the present invention instead shall be
determined from the scope of the following claims including their
equivalents.
* * * * *