U.S. patent application number 11/021573 was filed with the patent office on 2005-09-22 for impact resistant shingle.
Invention is credited to Jacobs, Gregory F., Kalkanoglu, Husnu M., Snyder, Richard Allan.
Application Number | 20050204675 11/021573 |
Document ID | / |
Family ID | 46205430 |
Filed Date | 2005-09-22 |
United States Patent
Application |
20050204675 |
Kind Code |
A1 |
Snyder, Richard Allan ; et
al. |
September 22, 2005 |
Impact resistant shingle
Abstract
An impact resistant shingle is provided, wherein the base mat is
impregnated with an asphaltic material, with an asphaltic material
on the upper surface of the shingle, and wherein another asphaltic
material is disposed on the rear surface of the shingle, which
other asphaltic material is softer with greater elongation than the
asphaltic material used elsewhere in the shingle, such that crack
resistance is afforded because energy from impact on the shingle is
dissipated.
Inventors: |
Snyder, Richard Allan;
(Eagleville, PA) ; Kalkanoglu, Husnu M.;
(Swarthmore, PA) ; Jacobs, Gregory F.; (Oreland,
PA) |
Correspondence
Address: |
John F. McNulty
Paul & Paul
2900 Two Thousand Market Street
Philadelphia
PA
19103
US
|
Family ID: |
46205430 |
Appl. No.: |
11/021573 |
Filed: |
December 23, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11021573 |
Dec 23, 2004 |
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10871911 |
Jun 18, 2004 |
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10871911 |
Jun 18, 2004 |
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10288747 |
Nov 6, 2002 |
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6758019 |
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Current U.S.
Class: |
52/555 ; 52/518;
52/553; 52/557; 52/559; 52/560 |
Current CPC
Class: |
E04D 2001/005 20130101;
E04D 1/26 20130101; B32B 2419/06 20130101; B32B 11/12 20130101;
B32B 11/04 20130101; B32B 2395/00 20130101; B32B 11/02 20130101;
B32B 2260/042 20130101; B32B 2260/021 20130101; Y10T 428/24372
20150115 |
Class at
Publication: |
052/555 ;
052/518; 052/553; 052/557; 052/559; 052/560 |
International
Class: |
E04D 001/00 |
Claims
What is claimed is:
1. An impact resistant shingle having upper and lower surfaces,
comprising; (a) a base mat having upper and lower surfaces and
impregnated with a first asphaltic material; (b) the first
asphaltic material having an elasticity as determined by a first
softness and a first elongation at break; (c) a second asphaltic
material being on the upper surface of the base mat; (d) a layer of
mineral granules being disposed on and adhered to the second
asphaltic material on the upper surface of the base mat, and
comprising at least a portion of the upper surface of the shingle;
(e) a third asphaltic material being disposed beneath the lower
surface of the base mat; (f) the third asphaltic material being of
a second softness that is a softer material than the softness of
the first asphaltic material, and of a second elongation at break
that is greater than the elongation at break of the first asphaltic
material, whereby; (g) energy from impacts on the upper surface of
the shingle is at least partially dissipated at the lower surface
of the shingle by the softness and elongation of the third
asphaltic material, such that crack formation on the lower surface
of the shingle due to impacts on the upper surface of the shingle,
is avoided.
2. The shingle of claim 1, wherein the first and second asphaltic
materials are of the same formulation.
3. The shingle of claim 1, wherein the first and second asphaltic
materials are of different formulations.
4. The shingle of claim 1, wherein the third asphaltic material is
disposed against the lower surface of the base mat.
5. The shingle of claim 1, wherein first asphaltic material is
disposed against the lower surface of the base mat, and the third
asphaltic material is disposed below and adhered to the first
asphaltic material.
6. The shingle of any one of claims 4 and 5, wherein the third
asphaltic material is a liquid-applied coating during the
manufacture of the shingle.
7. The shingle of any one of claims 4 and 5, wherein the third
asphaltic material comprises a sheet of asphaltic material, applied
to the shingle in sheet form.
8. The shingle of any one of claims 1, 4 and 5, wherein the shingle
comprises a first thickness layer between upper and lower surfaces
thereof, wherein a wind-resistant layer of a second thickness of
substantially thinner dimension than that of said first thickness
layer, is provided on the lower surface of the first thickness
layer, over at least a portion of the lower surface of the first
thickness layer, adhered thereto.
9. The shingle of claim 8, wherein the second thickness layer is
adhered to the first thickness layer by an asphaltic material.
10. The shingle of claim 8, wherein the second thickness layer is
adhered to the first thickness layer by the third asphaltic
material.
11. The shingle of claim 8, wherein a granular material is disposed
between said first thickness layer and the second thickness
layer.
12. The shingle of claim 11, wherein the second thickness layer is
adhered to the first thickness layer by an asphaltic material.
13. The shingle of claim 11, wherein the second thickness layer is
adhered to the first thickness layer by the third asphaltic
material.
14. The shingle of any one of claims 1, 4 and 5, wherein the third
asphaltic material comprises a polymer-modified asphaltic
material.
15. The shingle of claim 8, wherein the second thickness layer
comprises a material selected from the group consisting of any one
of: (a) thin fabric; (b) plastic film; (c) paper; (d) parchment;
and (e) foil; (f) metal screen; (g) plastic netting; (h) glass
fibers pressed into the second asphaltic material; (i) plastic
fibers pressed into the second asphaltic material; or (l) spin
blown fibers pressed into the second asphaltic material; (k)
scrim.
16. The shingle of any one of claims 2 and 3, wherein the shingle
comprises a first thickness layer between upper and lower surfaces
thereof; wherein a wind-resistant layer of a second thickness of
substantially thinner dimension than that of said first thickness
layer, is provided on the lower surface of the first thickness
layer, over at least a portion of the lower surface of the first
thickness layer, adhered thereto, with the shingle having a butt
portion adapted to being substantially covered by another shingle
when applied to a roof and a tab portion adapted to being exposed
to weather when applied to a roof, wherein the second thickness
layer comprises crossing strands of reinforcing material disposed
behind the tab portion of the shingle and substantially completely
covering the surface behind said tab portion of the shingle.
17. A shingle according to claim 1, wherein the third asphaltic
material has an elongation at break of at least two percent.
18. A shingle according to claim 17, wherein the third asphaltic
material has an elongation at break of at least two percent
measured at about 30.degree. F. after ageing the shingle for at
least ten weeks at 158.degree. F.
19. A shingle according to claim 17, wherein the third asphaltic
material has a penetration of less than about 150 decimillimeters
at 77.degree. F.
20. A shingle according to claim 1, wherein the third asphaltic
material is non-adhesive at ambient temperature.
21. A shingle according to claim 1, wherein the third asphaltic
material includes a softening composition comprising elastomer and
plasticizer.
22. An impact resistant roofing element having upper and lower
surfaces, comprising; (a) a base mat having upper and lower
surfaces and impregnated with a first asphaltic material; (b) the
first asphaltic material having an elasticity as determined by a
first softness and a first elongation at break; (c) a second
asphaltic material being on the upper surface of the base mat; (d)
a layer of mineral granules being disposed on and adhered to the
second asphaltic material on the upper surface of the base mat, and
comprising at least a portion of the upper surface of the roofing
element; (e) a third asphaltic material being disposed beneath the
lower surface of the base mat; (f) the third asphaltic material
being of a second softness that is a softer material than the
softness of the first asphaltic material, and of a second
elongation at break that is greater than the elongation at break of
the first asphaltic material, whereby; (g) energy from impacts on
the upper surface of the roofing element is at least partially
dissipated at the lower surface of the roofing element by the
softness and elongation of the third asphaltic material, such that
crack formation on the lower surface of the roofing element due to
impacts on the upper surface of the roofing element, is
avoided.
23. A shingle according to claim 1, wherein the third asphaltic
material has self-adhesive properties, the self adhesive properties
allowing the product to be adhered to a roofing substrate.
24. A shingle according to claim 21, wherein a lower surface of the
third asphaltic material is protected by a release agent surfaced
layer, the release agent surfaced layer being removable from the
lower surface of the third asphaltic material to expose the
self-adhesive third asphaltic material at the lower surface of the
shingle.
25. A method of making an impact resistant roof covering system,
comprising the steps of: (a) providing a shingle comprising a first
asphaltic material having an elasticity as determined by a first
softness and a first elongation at break; (b) providing a layer of
a second asphaltic material of a second softness that is softer
than the softness of the first asphaltic material, and of a second
elongation at break that is greater than the elongation at break of
the first asphaltic material; (c) applying the layer of the second
asphaltic material to a roof substrate; and, (d) applying the
shingle to the roof substrate.
26. The method according to claim 23, wherein the layer of the
second asphaltic material is applied to the roof substrate prior to
applying the shingle.
27. The method according to claim 23, wherein the layer of the
second asphaltic material is applied to a lower surface of the
shingle prior to applying the shingle to the roof substrate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. application Ser. No.
10/871,911, filed Jun. 18, 2004, which in turn is a continuation of
Ser. No. 10/288,747, filed Nov. 6, 2002, the complete disclosures
both of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] It is known in the shingle art that today's shingles are
generally made of a base mat of fibrous construction, most usually
of fiberglass construction, that is impregnated with an asphaltic
material. The asphaltic material, generally bitumen, of some
formulation is disposed on the upper surface of the base mat, and
serves to adhere a layer of mineral granules into the asphaltic
material on the upper surface of the base mat. Generally such
occurs over the entirety of the upper surface of the shingle, but,
such mineral granules can, if desired, be applied only to a visible
portion of the upper surface of the shingle, to be visible in the
installed condition, and to be subject to elements of weather in
the installed condition.
[0003] Generally, the rear or lower surface of the shingle also has
a layer of asphaltic material, and usually has a fine layer of
mineral granules, such as sand, talc, mica, or other mineral
granules disposed on the lower surface of the shingle.
[0004] It has been found that when shingles that have been
installed on a roof are subjected to various kinds of impacts, such
as falling tree branches, workman walking on the shingles, or hail
stones striking the shingles, especially during cold weather
conditions, cracks can develop in the lower surface of the shingle
as a result of such impacts.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to an impact resistant
shingle, in which an asphaltic material impregnates the base mat of
the shingle and the upper surface of the shingle, but wherein an
additional layer of a modified asphaltic material, having greater
ability to resist cracking than that of the principal asphaltic
material and being softer than the principal asphaltic material, is
provided, such that the softer asphaltic material is on the rear
surface of the shingle that faces the roof on which the shingle is
to be applied. When impacts from hail stones, tree branches,
walking, or any other impacts are applied against an upper surface
of a shingle that is installed on the roof, the softer asphaltic
material on the rear surface of the shingle provides a means for
dissipating at least some of the impact, whereby crack formation on
the lower surface of the shingle is avoided. The modified asphaltic
material should have the ability to dissipate mechanical energy. A
polymer modified asphalt can have such ability, such that it can
resist cracking because it yields or flexes when sharply struck,
rather than fracturing.
[0006] Accordingly, it is a primary object of this invention to
provide a shingle having a softer, impact-resistant layer of
modified asphaltic material on its lower surface, that has a
greater ability to resist cracking and a greater ability to
dissipate energy under conditions in which the upper surface of the
shingle is subjected to impact, than the other asphaltic material
that is used in the manufacture of the shingle.
[0007] It is another object of this invention to accomplish the
above object, wherein a layer of reinforcing material is applied to
the rear surface of the shingle.
[0008] Other objects and advantages of the present invention will
be readily apparent to those skilled in the art from the reading of
the following brief descriptions of the drawing figures, the
detailed descriptions of the preferred embodiments, and the
appended claims.
[0009] Thus, the present invention is directed toward providing a
modified asphaltic material on the lower surface of the shingle,
below the base mat, and preferably just above or below the layer of
sand, talc, mica or other fine mineral application to the shingle
or an application of a fabric, paper, film, scrim or the like, such
that the asphaltic material applied to the lower surface of the
shingle, being softer, has an ability to resist cracking and an
ability to dissipate energy to a greater extent than the asphaltic
material that generally comprises most or all of the asphaltic
material used in the rest of the shingle.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0010] FIG. 1 is a front view of a shingle, showing multiple tabs
separated by spaced apart slots, with mineral granules disposed on
the upper surface of the shingle.
[0011] FIG. 2 is a horizontal sectional view, taken through the
shingle of FIG. 1, generally along the line of II-II of FIG. 1.
[0012] FIG. 2A is an illustration similar to that of FIG. 2, but
wherein a release liner is shown on the rear surface, instead of
fine granules.
[0013] FIG. 3 is a horizontal sectional view, similar to that of
FIG. 2, but taken through a shingle having a layer of modified
asphaltic material spaced from the base mat by a layer of harder
asphaltic material, but otherwise being similar to the illustration
of FIG. 2.
[0014] FIG. 3A is an illustration similar to that of FIG. 3, but
wherein a release liner is shown on the rear surface, instead of
fine granules.
[0015] FIG. 4 is a rear plan view of the shingle of each of FIGS.
1, 2 and 3, taken along the lines IV-IV of FIGS. 2, 2A, 3 and 3A
(in the case of FIGS. 2A and 3A, after removal of the release
liner), wherein a wind and/or crack-resistant layer of reinforcing
material is applied to the lower, or rear surface of the shingle,
and adhered thereto.
[0016] FIG. 5 is a representation of a fragmentary rear view of a
shingle of prior art type, in which the asphaltic material on the
rear surface of the shingle displays a crack formation of a type
resultant from impact on the opposite, or upper, front surface of
the shingle.
[0017] FIG. 5A is a representation of a fragmentary illustration of
the rear or lower surface of a shingle similar to that of FIG. 5,
but wherein the shingle of FIG. 5A has a modified asphaltic
material on its rear surface, such that, after impact, no crack
formation is illustrated.
[0018] FIG. 6 is a photographic representation of a rear view of a
shingle of prior art type, in which the asphaltic material on the
rear surface of the shingle displays a crack formation of a type
resultant from impact on the opposite, or upper, front surface of
the shingle.
[0019] FIG. 6A is a photographic representation of the rear or
lower surface of a shingle, similar to that of FIG. 6, but wherein
the shingle of FIG. 6A has a modified asphaltic material on its
rear surface, and a reinforcement layer, for example a scrim layer,
such that, after impact, no crack formation is illustrated.
[0020] FIG. 7 is a vertical sectional view, taken through an
alternative embodiment of a shingle of this invention, wherein a
two-layer laminated shingle is illustrated, with each layer of
shingle material being constructed like the illustration of FIG.
2.
[0021] FIG. 8 is a schematic illustration of the manner in which
the layer of modified asphaltic material is applied to an
otherwise-formed shingle, during the manufacturing process, by
moving the shingle across an asphalt-applying roller.
[0022] FIG. 9 is schematic illustration of another method of
applying a layer of modified asphaltic material to an otherwise
formed shingle, wherein the softer layer is applied as an
already-formed layer of material.
DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS
[0023] Referring now to the drawings in detail, reference is first
made to FIG. 1, wherein a shingle is shown, generally designated by
the numeral 10. The shingle 10 is comprised of an upper headlap
portion 11 and lower tab portions 12, with the tab portions being
four in number. The various tab portions 12 are spaced apart by
slotted openings 13.
[0024] The upper headlap portion 11 is that which is disposed above
the upper ends of the slotted openings 14. Left and right edges 15
and 16, respectively, of the shingle 10 have partial cut-outs 15a
and 16a, respectively, such that when shingles 10 are aligned
left-to-right, portions of slotted openings 15a and 16a will come
together forming full slotted openings.
[0025] With reference to the shingle of FIGS. 2 and 2A, the shingle
10 has respective upper and lower surfaces 7, 8 and is comprised of
a base mat 17 of preferably fiberglass mat construction, although
the same can be comprised of organic mat, or fibered polymeric mat
construction (or a construction comprised of combinations thereof),
if desired. The mat 17 is impregnated with a first asphaltic
material 18, typically having a softening point between about
100.degree. F. and 160.degree. F. when used with an organic mat and
between about 190.degree. F. and 240.degree. F. when used with a
fiberglass mat. The asphaltic material 18 preferably has a hardness
as measured by penetration at 77.degree. F. greater than about 30
dmm when used with an organic mat and a hardness greater than about
18 dmm when used with a glass mat. Disposed above the impregnated
mat 17, 18 is a layer of asphaltic material 20 which, may or may
not be of the same asphaltic material construction as the asphaltic
material 18. If desired, the asphaltic materials 18, 20, may be
comprised of a single layer.
[0026] Irrespective of whether the asphaltic materials 18 and 20
are comprised of a single layer, or of multiple layers, there will
normally be disposed on the upper surface of the shingle, a layer
of mineral granules 21, which can, if desired, serve to deflect
heat, infrared radiation, and ultraviolet rays, and which can
provide a desired color or pigmentation to the shingle 10.
[0027] Below the asphaltic impregnated mat 17, 18, there is
provided an additional layer of asphaltic material that is a
modified asphaltic material, designated by the numeral 22. The
asphaltic material layer 22 is asphaltic material that is modified
relative to the asphaltic materials 18, 20, to be softer, having
greater ability than the asphaltic material 18, 20 to dissipate
energy and resist cracking at the temperatures normally encountered
on a roof, regardless of the ambient weather conditions, and
regardless of the climate in which the roof is disposed. The
softness of the softer or modified asphaltic material 22 can also
be referred to as having a lower elastic modulus than that of the
asphaltic materials 18, 20.
[0028] The layer 22 of modified asphaltic material can be provided
directly to the asphalt impregnated mat 18, or to another
intermediate coating of asphaltic material that has been applied to
the impregnated mat 18, via lick-on, roll-on, fused powder-coating
or spray-on techniques, or otherwise, as may be desired. More than
one impact resistant layer or a number of dissipative layers 22 may
be used.
[0029] Preferably, the layer 22 of modified asphaltic material
underlies the entire lower area of the shingle 10, or at least
underlies the entire exposed portion of the shingle.
[0030] The modified asphaltic material of layer 22 should not be so
soft as to create problems of sticking to an adjacent shingle when
shingles are stacked together under warm conditions; however, such
a concern, should it arise, could be alleviated by a layer 23 of
fine granules, such as sand, talc, mica or the like, or
alternatively, a release paper, or liner 23a, other parting agent
or layer of fabric, paper, plastic film or the like optionally
applied beneath the layer 22, for assuring separation between
adjacent stacked shingles. The layer 23 or 23a could be permanently
or temporarily adhered thereto. The layer 22 of modified asphaltic
material can optionally have self-adhesive properties for allowing
the product to be adhered to a roofing substrate. In such an
embodiment, the layer 22 will preferably be provided with a release
paper or tape 23a, or other parting agent, to allow stacking of the
shingles prior to adhering them to a roofing substrate, after
removal of the release agent to expose the self-adhesive layer
22.
[0031] The modified asphaltic material of layer 22 will preferably
have a finite yield point and viscosity that is sufficiently high
that the material 22 does not flow when in a packaged state, nor
when shingles 10 are installed on a steep-sloped roof in hot, sunny
weather when they can be subjected to internal or surface
temperatures in the range of 140.degree. F. to 180.degree. F.
[0032] In the present invention, the modified asphaltic material 22
preferably has greater elongation or extensibility than the
material 18. The improved elongation is preferably exhibited even
at low temperatures, such as, for example, 30.degree. F. The
improved elongation can be a result of the presence of additives
which also enhance the ductility at low temperatures and contribute
greater resistance to changes in properties as a function of time
or temperature than the asphaltic material 18. Preferably, the
elongation of the modified asphaltic material 22 is at least two
percent, even after extensive exterior exposure, such as that
simulated by accelerated ageing carried out by storing shingles
made with the modified asphaltic material at 158.degree. F. for at
least 10 weeks.
[0033] Preferably, however, the modified asphaltic material is not
so soft that its penetration at 77.degree. F. is greater than about
150 dmm, as measured according to ASTM D-5. Further, it is
preferred that the lower surface of the modified asphaltic material
be non-adhesive at ambient temperatures, reducing the likelihood
that the improved shingles will become stuck together during
shipment and prior to installation, or that the modified asphaltic
material will become dislodged by handling during installation or
subsequently thereto. Optionally, when a roofing product having
self-adhesive properties in the modified asphalt material is
desired, a removable or peelable release liner in film or sheet
form may be applied to the lower surface of the shingle, so as to
prevent sticking together of the shingles during shipment or prior
to installation, and subsequently removed when applying the roofing
product to a roof substrate.
[0034] It is preferred that enhanced temperature elongation be
achieved by including in the modified asphaltic material a
composition comprising one or more additives selected from
elastomers, plasticizers, and resins, and blends thereof.
Preferably, the elastomer is selected from natural rubber and
thermoplastic elastomers, including styrene-isoprene-styrene block
copolymer, styrene-butadiene-styrene block copolymer, and
styrene-ethylene-butadiene-styrene block copolymer. The formulation
can also include one or more antioxidants, and additional
components such as oils.
[0035] The modified asphaltic material has greater elongation at
low temperatures, such as about 32.degree. F., than the asphaltic
material 18 and retains an elongation at 32.degree. F. of at least
two percent even after years of exterior exposure, such that the
shingle 10 shows no cracking under impact.
[0036] The modified asphaltic material 22 may also have a lower
modulus, especially at low temperatures, than the asphaltic
material 18. That is, the modified asphaltic material is more
extensible, as measured for example by the absence of cracking
under stress or impact conditions in which the material 18 would
crack. In particular, the modified asphaltic material 22 preferably
has an elongation at break at low temperature, such as at
30.degree. F., of at least two percent, even after accelerated
ageing simulating years of exterior exposure, such as at least ten
weeks of storage at 158.degree. F. The modified asphaltic material
will also be initially softer or have a lower initial modulus than
the material 18, as measured for example by a higher penetration,
particularly at higher temperatures. However, in non-self-adhesive
applications, the modified asphaltic material 22 is preferably not
so soft so as to be tacky or adhesive under ambient conditions, and
preferably is not so soft as to "scuff" or suffer mechanical damage
from handling during installation.
[0037] Under actual exterior exposure or simulated exterior
exposure by accelerated ageing, it is often found that the modulus
of asphaltic materials tends to increase such that the material
becomes harder. The increase in modulus is often accompanied by a
decrease in extensibility or elongation. As "toughness"
conventionally refers to the area under a stress-strain curve, a
material which requires increasing stress to attain a fixed strain
as it ages can be said to be "tougher". In the present invention,
the modified asphaltic material 22 can become tougher as it ages,
provided it retains the extensibility to provide an elongation at
break of at least two percent.
[0038] Preferably, the enhanced extensibility is obtained by mixing
an additive, a preblended admixture, or several additives with the
same type of asphaltic material used for the asphaltic coating 18,
and using this as the modified asphaltic material 22. For example,
the material 18 can be a standard coating-grade asphalt (softening
point 200.degree. F.-240.degree. F.), and the modified asphaltic
material 22 can be prepared by mixing a jelly-like premixed asphalt
modifier, such as those blends comprising from about 30 percent to
70 percent by weight of a thermoplastic block copolymer, the
remainder comprising plasticizers, oils, antioxidants and the like
to promote polymer/asphalt compatibility and low temperature
flexibility. Examples of such asphalt modifying compositions
include but are not limited to those sold by the Chemseco Division
of Sika Corporation (Kansas City, Mo.) under the Sikamod.TM.
trademark. The modifying compositions are preferably blended with
the steep or coating grade asphalt at a temperature between about
300.degree. F. and 400.degree. F., with agitation sufficient to
produce a homogeneous mixture. The choice of asphalt could also
include an oxidized straight run type of asphalt that could be
modified with a thermoplastic polymer.
[0039] Examples of polymeric materials which can be used include
that which are known to improve the physical, low temperature, and
durability performance characteristics of asphalt, such as atactic
polypropylene (APP), isotactic polypropylene (IPP),
styrene-butadiene rubber (SBS), chloroprene rubber (CR), natural
and reclaimed rubbers, butadiene rubber (BR),
acrylonitrile-butadiene rubber (NBR), isoprene rubber (IR),
styrene-polyisoprene (SI), butyl rubber, ethylene propylene rubber
(EPR), ethylene propylene diene monomer rubber (EPDM),
polyisobutylene (PIB), chlorinated polyethylene (CPE), styrene
ethylene-butylene-styrene (SEBS), and vinylacetate/polyethylene
(EVA). Preferably a thermoplastic elastomer, such as a block
copolymer of polystyrene, polybutadiene, and polystyrene blocks is
employed.
[0040] Plasticizers may be selected from the group consisting of
petroleum-derived oils, phthalate esters (or their derivatives) and
mellitates. Various petroleum resins, polyolefins, rosin (or its
derivatives,) tall oil, terpene and coumarone-indene resins can
also be employed.
[0041] With reference now to FIG. 3, it will be seen that a base
mat 37 is provided, impregnated with a first asphaltic material 38,
having a layer of asphaltic material 40 thereon, which, like the
embodiment of FIG. 2, may or may not be the same asphaltic material
as that 38, and with a layer of granules 41 applied thereto,
similar to that of the embodiment of FIG. 2. Another layer 42 of
asphaltic material is applied beneath the impregnated mat 37, 38,
which layer 42 may or may not be comprised of the same asphaltic
material that comprises that 38 and 40. In the embodiment of FIG.
3, the lower layer of asphaltic material 44 is the layer of
modified asphaltic material formulated as described above for layer
22, and having the same characteristics thereof, and which has a
greater ability to resist cracking and a greater ability to
dissipate energy that that of layers 38, 40. A layer 43 of fine
granules, such as sand, talc, mica or the like, or alternatively, a
release paper, other parting agent or layer of fabric, paper,
plastic film or the like, is applied beneath the layer 44.
[0042] Thus, in the embodiment of FIG. 3, the shingle 110 has
respective upper and lower surfaces 27 and 28, similar to the
respective upper and lower surfaces 7 and 8 for the shingle of the
embodiment of FIG. 2.
[0043] With reference to FIGS. 2A and 3A, it will be seen that the
structures are the same as with FIGS. 2 and 3, respectively, except
that the rear surfaces 8 and 28 are provided with a removable
release liner 23a, 43a, respectively, in lieu of a fine layer of
granules, and that the layers 22, 44, are self-adhesive, such that
after the release liners 23a, 43a are removed, the shingles 10,
110, can be adhered to a substrate.
[0044] Referring now to FIG. 4, it will be seen that the rear
surface of the shingle of either of FIGS. 2 and 3 appears the same,
such that the illustration of FIG. 4 will be addressed only with
respect to its relationship to the illustration of FIG. 3, it being
understood that for purposes of the illustration of FIG. 4, the
same description can be applied to a shingle as illustrated in FIG.
2.
[0045] The shingle 110, on its lower surface, is provided with a
wind and/or crack-resistant reinforcement layer 50. The layer 50
may comprise a scrim, or thin fabric, or it may be comprised of a
plastic film, paper, parchment or foil. In the case of a scrim, the
scrim could be knitted, woven, non-woven, laminated scrim or the
like. In the embodiment shown in FIG. 4, the reinforcement layer 50
is shown as comprising a woven construction, involving woven
strands disposed at right angles to each other, with a preferred
density of, for example, nine strands in the vertical direction and
nine strands in the horizontal direction per square inch of
reinforcement, covering the lower half of the rear surface of the
shingle behind the tabs, although the layer 50 could, cover less of
the rear surface of the shingle or the entire rear surface of the
shingle, if desired. The layer 50 could be a woven or non-woven
polyester, which would tend to make it a thinner layer. The layer
50 is preferably not applied deeply into the asphaltic material on
the lower surface of the shingle 1 10, but rather is preferably
slightly embedded into or placed on to the surface 28.
[0046] The reinforcement layer 50 of scrim or other material will
ordinarily not be coated on its lower surface with a bitumen or
other asphaltic material, nor will it have granules applied
thereto, such that any filaments of the reinforcing material 50,
especially those extending vertically as shown in FIG. 4, can
resist bending and resist failure in the form of the likelihood of
forming horizontal cracks across the upper end of the tab portion
of the shingle when the shingle is bent upwardly within its elastic
limit under forces applied by winds. However, if desired a thin
layer of adhesive could be applied beneath the scrim or other
reinforcement layer, with small particles of granular material, for
example sand or the like, applied thereto. Additionally, the
reinforcement material 50 may also serve to dissipate energy from
impacts on the opposite, or upper surface, thus resisting crack
formation on the rear surface. The vertical and horizontal strands
of the reinforcement layer 50 can be of different materials, as may
be desired, or may be disposed at other angles other than 90
degrees, such as diagonal, with or without vertical or horizontal
strands. Optionally, the strands of the reinforcement layer could
have random orientation, as, for example, from a non-woven web.
Also, optionally, portions of the strands could be knitted.
[0047] The reinforcement material 50 may be comprised of various
compositions other than fiberglass, such as polyester, and/or
nylon, and the reinforcement 50 may either be slightly embedded in
the asphaltic layer 44 on the rear of the shingle 110, or may be
adhered to the rear of the shingle by an additional post-applied
thin layer of asphaltic or non-asphaltic adhesive.
[0048] The asphaltic material that comprises the layers 22 and 44
may be constructed in accordance with the second asphaltic binder
disclosed in U.S. Pat. No. 5,347,785, or as is the second asphaltic
binder or modified asphalt as disclosed in U.S. Pat. No. 5,488,807,
the complete disclosures of each of which are herein incorporated
by reference, so long as they are in accordance with the
above-mentioned characteristics.
[0049] Alternatively, the asphaltic material 22, 44, may be
constructed of any other formulation that meets energy dissipation
and crack resistant conditions desired when the front surface of
the shingle is subjected to impact, so long as it is in accordance
with the above-mentioned characteristics.
[0050] It will also be seen, with reference to FIG. 4, that a
plurality of adhesive zones 49 can appear on the rear surface 28 of
the shingle, toward the lower end of the tab zone of the shingle,
beneath the layer of reinforcement material 50, such that the
sealant that comprises the sealant patches 49 may bond to a
next-subjacent shingle on a roof, by passing through openings in
the mesh or web of the reinforcement material 50. The patches of
sealant 49 are therefore an option for the embodiment of FIG. 4.
Such patches 49, may, if desired, be arranged in a band, as shown,
and may also, optionally be as set forth in U.S. Pat. No.
5,239,802, the complete disclosure of which is herein incorporated
by reference.
[0051] With reference now to FIG. 5, it will be seen that a
fragmentary illustration of a multi-tab shingle 210 is illustrated
as comprising a shingle portion of the prior art type. The
illustration of FIG. 5 demonstrates the result that can occur when
impact against the upper surface of the shingle 210 occurs, such as
being struck by a rock, tree limb, hail stone or the like, and
wherein the rear or lower surface 211 of the shingle is subjected
to cracking, in the form of what often occurs as partially circular
cracks 212 along with partially radial cracks 213, which can result
in shingle failure.
[0052] With reference to FIG. 5A, a fragmentary illustration of a
shingle 310 in accordance with the present invention, wherein a
modified asphaltic material 312 like that 22 of FIG. 2, having
improved energy dissipation and crack resistance, is shown on the
lower or rear surface of the shingle, and wherein the shingle of
FIG. 5A has likewise been subjected to impact on its opposite
surface, but wherein no crack formation is visible on the lower or
rear surface 312 of the shingle of FIG. 5A.
[0053] With reference now to FIG. 6, the photographic illustration
of a crack, similar to that of FIG. 5, is shown, where an impact
has caused the crack 315 on the rear surface of the shingle.
[0054] In FIG. 6A, a photographic illustration appears, wherein a
reinforcement layer, such as a scrim, is shown in the form of a
rectangular grid on the rear surface, overlying the surface of
modified asphalt layer, and wherein a circular zone 320 appears in
the shingle, showing evidence of energy absorption after impact,
but wherein no crack appears. The residual pattern after the impact
shows movement, but not fracture within the modified asphalt layer
of the shingle.
[0055] With reference to FIG. 7, there is illustrated a vertical
sectional view, taken through a two layer laminated shingle,
generally designated by the numeral 410. The shingle 410 is
comprised of a full height shingle layer 411, constructed in
section like the shingle of FIG. 2, which is adhered to a
fractional layer, in this case, a substantially half-height shingle
layer 412, with the layer 412 being substantially disposed against
the posterior layer 413 of the shingle layer 411, below the headlap
zone 414 thereof, to be disposed behind the tab zone 415 of the
shingle layer 411. The half-height shingle layer 412 is likewise
constructed like the shingle of FIG. 2, and the two shingle layers
411 and 412 are adhered together where their surfaces mate, by a
suitable adhesive, at 416, disposed in layer form. One or more
portions of the half-height shingle layer 412 may optionally extend
below the lower edge 417 of the tab zone 415 of the shingle layer
411. Optionally, the shingle layer 412 could be a full back layer
as shown in phantom in FIG. 7, such that the entire shingle layer
412 is impact resistant.
[0056] Referring now to FIG. 8, it will be seen that a shingle
layer 510, having granules 511 on its upper surface, already
impregnated with an asphaltic material, is delivered along a
horizontal path, in the direction of the arrow 512, over suitable
conveyor rollers 513 or the like, to pass over an applicator such
as that 514 of the roller-in-tank type 515, wherein the modified
asphaltic material 516, like that of 22 in FIG. 2, disposed in the
tank 515 is applied to the under surface 517 of the shingle
material 510, as it passes over the roller 514, rotating in the
direction of the arrow 518. In this manner, a thin layer of molten
asphaltic material of the modified type can be applied, generally
at a factory installation, in liquid applicator form.
Alternatively, an applicator capable of a spray coating or other
coating application method (not shown) could be used to apply the
modified asphaltic material 516 to the under surface 517 of the
shingle material 510. Following the application of the modified
asphaltic material 516, the bottom side of the applied modified
asphaltic layer like that of 22 of FIG. 2 could be covered by sand,
talc, mica or other fine mineral material, or by a layer fabric,
polymeric film, scrim, paper or the like as 23 of FIG. 2.
[0057] With reference to FIG. 9, it will be seen that a layer of
shingle 610 having granules 611 on an upper surface thereof, is
already fully formed, except that a layer of modified asphaltic
material 612, like that 22 of FIG. 2, may be post-manufacture
adhered, applied as an already-formed layer, by moving the same in
the direction of the arrows 613, and applying heat, or adhesive
means, to adhere the layer 612 of modified asphaltic material, to
the lower surface 614 of the shingle 610. Thus, in the embodiment
of FIG. 9, the layer 612 of modified asphaltic material may be
provided either at the site of manufacture, or at the site of
installation, as may be desired.
[0058] In either of the embodiments of FIGS. 8 and 9, the layer of
material 516 or 612 could alternatively be an impact energy
dissipation layer having a lower elastic modulus (i.e. being
softer) and having the desired elongation capability such as being
comprised of a thin layer of membrane, self-adhesive or
non-self-adhesive (in the latter case secured thereto by another
adhesive), including but not limited to a polymer-modified
asphaltic material layer or an elastomeric membrane like
ethylene-propylene-diene monomer (EPDM). In the embodiment of FIG.
9, the energy dissipation layer could be applied to the lower
surface of the shingle or to a roofing membrane. Alternatively, the
energy dissipation layer could be applied to a roof substrate and
the lower surface of a shingle could subsequently be applied
thereto.
[0059] In accordance with this invention, it will also be seen that
there is provided a method of making an impact resistant roof
covering system. In accordance with such a method, a shingle is
provided having a first asphaltic material that has an elasticity
as determined by a first level of softness and a first level of
elongation at break. A layer of a second asphaltic material that
has a second softness that is softer than the softness of the first
asphaltic material, and which has a second elongation at break that
is greater than the elongation at break of the first asphaltic
material. The second asphaltic material is applied to a roof
substrate, and thereafter the shingle is applied to the roof
substrate. Alternatively, the second asphaltic material can be
applied to the lower surface of the shingle prior to applying the
shingle to the roof substrate.
[0060] It will be apparent from the foregoing that various
modifications may be made in the details of construction, as well
as in the use and operation of the present invention, all within
the spirit and scope of the invention, as claimed.
* * * * *