U.S. patent application number 11/050535 was filed with the patent office on 2006-08-17 for laminated shingle with spacer bands for level stacking.
Invention is credited to Bert W. Elliott, Gerald G. JR. Greaves, Carla A. Miller.
Application Number | 20060179767 11/050535 |
Document ID | / |
Family ID | 36814210 |
Filed Date | 2006-08-17 |
United States Patent
Application |
20060179767 |
Kind Code |
A1 |
Miller; Carla A. ; et
al. |
August 17, 2006 |
Laminated shingle with spacer bands for level stacking
Abstract
A roofing shingle includes a shingle overlay sheet, a shingle
underlay sheet, and at least one shingle spacer. The underlay sheet
and the spacer sheet are secured to the overlay sheet in a manner
to prevent humping when the shingles are formed into bundles.
Inventors: |
Miller; Carla A.; (Newark,
OH) ; Elliott; Bert W.; (Toledo, OH) ;
Greaves; Gerald G. JR.; (Granville, OH) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
36814210 |
Appl. No.: |
11/050535 |
Filed: |
February 3, 2005 |
Current U.S.
Class: |
52/555 |
Current CPC
Class: |
E04D 1/26 20130101; B32B
5/022 20130101; B32B 3/30 20130101; B32B 2307/402 20130101; E04D
2001/005 20130101; B32B 5/24 20130101; B32B 5/30 20130101; B32B
2419/06 20130101; B32B 2260/021 20130101; B32B 3/08 20130101; B32B
5/16 20130101; B32B 2307/71 20130101; B32B 2307/306 20130101; B32B
2260/042 20130101 |
Class at
Publication: |
052/555 |
International
Class: |
E04D 1/00 20060101
E04D001/00 |
Claims
1. A roofing shingle comprising: a shingle overlay sheet having an
upper edge, a lower edge, a top surface, and a rear surface; a
shingle underlay sheet having an upper edge, a lower edge, a top
surface, and a rear surface; and at least one shingle spacer sheet
having an upper edge, a lower edge, a top surface, and a rear
surface; wherein the shingle underlay sheet is secured to the rear
surface of the shingle overlay sheet and wherein the at least one
shingle spacer sheet is provided secured to the rear surface of the
shingle overlay sheet.
2. The roofing shingle according to claim 1, wherein the top
surface of the spacer sheet and the top surface of the underlay
sheet are substantially coplanar.
3. The roofing shingle according to claim 1, wherein the rear
surface of the spacer sheet and the rear surface of the underlay
sheet are substantially coplanar.
4. The roofing shingle according to claim 1, wherein the spacer
sheet is formed integral to the overlay sheet and folded below the
rear surface of the overlay sheet.
5. The roofing shingle according to claim 1, wherein the spacer
sheet has a first thickness, and the underlay sheet has a second
thickness such that the first thickness of the spacer sheet is
greater than the second thickness of the underlay sheet.
6. The roofing shingle according to claim 5, wherein the spacer
sheet of a first shingle is secured to the first shingle at a
position such that, when the first shingle is installed on a roof,
the spacer sheet can be used to align the first shingle upon the
roof.
7. The roofing shingle according to claim 6, wherein the lower edge
of the spacer sheet of a first shingle is configured to abut an
upper edge of an overlay sheet of a second shingle similar to the
first shingle to align the second shingle to the first shingle.
8. The roofing shingle according to claim 1, wherein the upper edge
of the shingle overlay sheet and the upper edge of the shingle
spacer sheet are aligned.
9. The roofing shingle according to claim 1, wherein the shingle
underlay sheet and the shingle spacer sheet are secured to the rear
surface of the shingle overlay sheet such that the lower edge of
the shingle spacer sheet and the upper edge of the shingle underlay
sheet define a gap therebetween.
10. The roofing shingle according to claim 1, wherein the overlay
sheet has a height extending from the lower edge of the overlay
sheet to the upper edge of the overlay sheet, the spacer has a
height extending from the lower edge of the spacer to the upper
edge of the spacer, the underlay sheet has a height extending from
the lower edge of the underlay sheet to the upper edge of the
underlay sheet, and wherein the height of the overlay sheet is
substantially equal to the cumulative heights of the spacer and the
underlay sheet.
11. The roofing shingle according to claim 1, wherein the overlay
sheet has a height extending from the lower edge of the overlay
sheet to the upper edge of the overlay sheet, the underlay sheet
comprises at least one tab defining a tab height extending from the
lower edge of the underlay sheet to a top end of the tab, and
wherein the height of the tab portion is at least half the height
of the overlay sheet.
12. The roofing shingle according to claim 1, wherein the shingle
underlay sheet is formed from a first material and the spacer sheet
is formed from a second material.
13. The roofing shingle according to claim 1, wherein the shingle
spacer sheet is selected from a group consisting of tape,
cardboard, paper, foam, foamed asphalt, asphalt, cotton shoddy,
natural fibers, asphalt coated mat and polymer coated mat
materials.
14. The roofing shingle according to claim 13, wherein the shingle
spacer sheet comprises a foam material.
15. The roofing shingle according to claim 14, wherein the shingle
spacer sheet comprises a foamed asphalt material.
16. The roofing shingle according to claim 13, wherein the shingle
spacer sheet comprises a mat coated with an asphalt or polymer
material and wherein the spacer sheet provides improved impact
resistance.
17. The roofing shingle according to claim 1, wherein the shingle
spacer sheet comprises a connector strip, the spacer sheet being
secured to the rear surface of the shingle overlay sheet at the
upper edge of the spacer sheet and secured to the rear surface of
the underlay at the lower edge of the spacer sheet.
18. A bundle of roofing shingles for at least partially covering a
surface, the bundle comprising a plurality of shingles including at
least a first shingle and at least a second shingle, wherein each
shingle comprises: a shingle overlay sheet having an upper edge and
a lower edge, a top surface, and a rear surface, the overlay sheet
having a height defined by the distance between the upper edge and
the lower edge; a shingle underlay sheet having an upper edge, a
lower edge, a top surface, and a rear surface; and at least one
shingle spacer sheet having an upper edge, a lower edge, a top
surface, and a rear surface; the shingle underlay sheet being
secured to the rear surface of the shingle overlay sheet, and the
at least one shingle spacer sheet being secured to the rear surface
of the shingle overlay sheet, wherein at least one of the plurality
of roofing shingles is stacked upon another of the plurality of
roofing shingles in the bundle.
19. The bundle of roofing shingles according to claim 18, wherein
the upper edges of the overlay sheet and spacer sheet of the at
least first shingle are aligned with the upper edges of the overlay
sheet and spacer sheet of the at least second shingle.
20. The bundle of roofing shingles according to claim 18, wherein
each shingle has the shingle underlay sheet and the shingle spacer
sheet secured to the rear surface of the shingle overlay sheet such
that the lower edge of the shingle spacer sheet and the upper edge
of the shingle underlay sheet define a gap therebetween.
21. The bundle of roofing shingles according to claim 18, wherein
each shingle has the shingle underlay sheet defining a tab portion
that is at least half the height of the overlay sheet.
22. The bundle of roofing shingles according to claim 18, wherein
each shingle has the shingle underlay sheet having a height defined
by a distance between the upper edge and the lower edge thereof,
wherein the underlay sheet height is greater than half the height
of the overlay sheet.
23. The bundle of roofing shingles according to claim 18, wherein
each shingle has the shingle underlay sheet formed from a first
material and the spacer sheet formed from a second material.
24. The bundle of roofing shingles according to claim 18, wherein
the shingle spacer sheet comprises a foam material.
25. A method of reducing humping of a bundle of roofing shingles
when one or more roofing shingles are stacked with others of the
roofing shingles, the roofing shingles being suitable for at least
partially covering a roof deck surface, the bundle comprising a
plurality of shingles including at least a first shingle and at
least a second shingle, wherein the shingles comprise: a shingle
overlay sheet having an upper edge, a lower edge, a top surface,
and a rear surface; a shingle underlay sheet having an upper edge,
a lower edge, a top surface, and a rear surface; and at least one
shingle spacer sheet having an upper edge, a lower edge, a top
surface, and a rear surface; whereby the method comprises:
providing the shingle overlay sheet and the shingle underlay sheet;
aligning the shingle underlay sheet with the shingle overlay sheet;
and aligning the at least one spacer sheet with the shingle overlay
sheet, thereby forming the roofing shingle; wherein the at least
one shingle spacer sheet is secured to the rear surface of the
shingle overlay sheet.
26. The method according to claim 25, wherein the step of aligning
the spacer sheet with the overlay sheet further includes aligning
the upper edge of the shingle overlay sheet and the upper edge of
the spacer sheet.
27. The method according to claim 25, wherein the shingle underlay
sheet and the spacer sheet are secured to the rear surface of the
shingle overlay sheet such that lower edge of the spacer sheet and
the upper edge of the shingle underlay sheet define a gap
therebetween.
28. The method according to claim 25, wherein the method further
includes stacking a first one of the roofing shingles upon a second
shingle, such that the rear surface of the shingle underlay sheet
and the rear surface of the spacer sheet of the first roofing
shingle face the top surface of the shingle overlay sheet of the
second roofing shingle, and wherein the first and second roofing
shingles are further stacked such that the lower edges of the
overlay sheet and the underlay sheet of the first roofing shingle
are aligned with the lower edges of the overlay sheet and underlay
sheet of the second roofing shingle.
29. The method according to claim 25, wherein the method further
includes stacking a first one of the roofing shingles upon a second
shingle, such that the rear surface of the shingle underlay sheet
and the rear surface of the spacer sheet of the first roofing
shingle face the top surface of the shingle overlay sheet of the
second roofing shingle, and wherein the first and second roofing
shingles are further stacked such that the lower edges of the
overlay sheet and underlay sheet of the first roofing shingle are
aligned with the upper edges of the overlay sheet and the spacer
sheet of the second roofing shingle.
30. The method according to claim 25, wherein the method further
includes stacking the at least first roofing shingle upon the at
least second roofing shingle such that the top surface of the
shingle overlay sheet of the first roofing shingle faces the top
surface of the shingle overlay sheet of the second roofing shingle,
and wherein the first and second roofing shingles are further
stacked such that the lower edges of the overlay sheet and underlay
sheets of the first roofing shingle are aligned with the lower
edges of the overlay sheet and underlay sheet of the second roofing
shingle.
31. The method according to claim 25, wherein the method further
includes stacking the at least first roofing shingle upon the at
least second roofing shingle such that the top surface of the
shingle overlay sheet of the first roofing shingle faces the top
surface of the shingle overlay sheet of the second roofing shingle,
and wherein the first and second roofing shingle are further
stacked such that the lower edges of the overlay sheet and underlay
sheet of the first roofing shingle are aligned with the upper edges
of the overlay sheet and spacer sheet of the second roofing
shingle.
32. The method according to claim 25, wherein the method further
includes stacking the at least first roofing shingle upon the at
least second roofing shingle such that the rear surfaces of the
underlay sheet and the spacer sheet of the first roofing shingle
face the rear surfaces of the underlay sheet and spacer sheet of
the second roofing shingle, and wherein the first and second
roofing shingles are further stacked such that the lower edges of
the overlay sheet and the underlay sheet of the first roofing
shingle are aligned with the lower edges of the overlay sheet and
the underlay sheet of the second roofing shingle.
33. The method according to claim 25, wherein the method further
includes stacking the at least first roofing shingle upon the at
least second roofing shingle such that the rear surfaces of the
underlay sheet and the spacer sheet of the first roofing shingle
face the rear surfaces of the underlay sheet and spacer sheet of
the second roofing shingle, and wherein the first and second
roofing shingle are further stacked such that the lower edges of
the overlay sheet and the underlay sheet of the first roofing
shingle are aligned with the upper edges of the overlay sheet and
the spacer sheet of the second roofing shingle.
34. The method according to claim 25, wherein the shingle underlay
sheet defines a tab portion that is at least half the height of the
overlay sheet.
35. The method according to claim 25, wherein the shingle underlay
sheet is formed from a first material and the spacer sheet is
formed from a second material.
36. The method according to claim 25, wherein the shingle spacer
sheet comprises a foam material.
37. At least three roofing shingles comprising: a first, second and
third shingle overlay sheet, each overlay sheet having an upper
edge, a lower edge, a top surface, a rear surface and an overlay
height defined by the distance between the upper edge and lower
edge thereof; a first, second and third shingle underlay sheet,
each underlay sheet having an upper edge, a lower edge, a top
surface, a rear surface and an underlay height defined by the
distance between the upper edge and lower edge thereof, each
underlay height being greater than half the overlay height; each
shingle underlay sheet being secured to the respective rear surface
of a respective one of the shingle overlay sheets adjacent the
lower edge of the overlay sheet; thereafter placing the roofing
shingles in a bundle and forming a vertical gap between at least
two of said shingles; and providing at least one spacer sheet for
bridging the gap between said at least two shingles.
38. The roofing shingles of claim 37, wherein the at least one
shingle spacer sheet is provided secured to the rear surface of one
of the shingle overlay sheets.
39. The roofing shingles of claim 38, wherein each of said shingles
comprises a shingle spacer sheet secured to the rear surface of one
of the shingle overlay sheets.
40. The roofing shingles of claim 37, wherein the at least one
shingle spacer sheet is provided secured to the rear surface of one
of the shingle underlay sheets.
41. The roofing shingles according to claim 39, wherein the rear
surface of the spacer sheets and the rear surface of the underlay
sheets are substantially coplanar.
42. The roofing shingles according to claim 38, wherein the spacer
sheet has a first thickness, and the underlay sheet has a second
thickness such that the first thickness of the spacer sheet is
greater than the second thickness of the underlay sheet.
43. The roofing shingles according to claim 42, wherein the spacer
sheet of a first shingle is secured to the first shingle at a
position such that, when the first shingle is installed on a roof,
the spacer sheet can be used to align the first shingle upon the
roof.
44. The roofing shingles according to claim 37, wherein the spacer
sheet is removed and discarded when the shingles are installed on a
roof.
45. The roofing shingles according to claim 37, wherein the shingle
spacer sheet is selected from a group consisting of tape,
cardboard, paper, foam, asphalt, foamed asphalt, cotton shoddy,
natural fibers, and asphalt coated mat and polymer coated mat
materials.
46. The roofing shingles according to claim 45, wherein the spacer
sheet is removed and discarded when the shingles are installed on a
roof.
47. The roofing shingle according to claim 37, wherein the shingle
spacer sheet comprises an adhesive material.
Description
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0001] This invention relates to roofing shingles, and more
particularly to an improved laminated shingle which lies flat when
the laminated shingle is stacked with other similar laminated
shingles. The improved shingle also provides a suitably wide zone
for nailing the shingles to a roof.
BACKGROUND OF THE INVENTION
[0002] It is well known in the roofing industry that irregularity
or variation in shingle design provides a roof that is
aesthetically pleasing and in popular demand. Mass produced asphalt
roofing shingles of the ordinary three-tab variety, when placed on
the roof, result in a roof that sometimes appears flat,
dimensionless and uninteresting. Shingle manufacturers have
attempted to provide a better appearance to such roofs by using
variations in the thickness and in the tab cutout design of
shingles. The goal is to produce a random looking sequence or
pattern of shingles on the roof, similar to the appearance given by
a roof shingled with wood shingles having varying widths, lengths
and thicknesses.
[0003] Innovations to improve the random-like character of shingles
include the use of laminated shingles. A common type of laminated
shingle consists of an overlay having tabs and cutouts in the
exposed portion of the shingle, and an underlay adhered to the rear
of the overlay below the tabs and cutouts. The laminated shingle
includes laminated or double-layered portions where the overlay and
underlay overlap, and nonlaminated or single-layered, portions
where the underlay portions and overlay portions do not overlap.
The laminated portions include tab areas and a longitudinal central
area of the shingle between the inner ends of the cutouts and the
top end of the underlay. The nonlaminated portions include the
areas of the cutouts, and the area of the shingle that does not
include the underlay.
[0004] After manufacture, the laminated shingles are packaged in a
stack or bundle of the shingles. The laminated shingles are often
stacked by turning every other shingle 180.degree. relative to the
adjacent shingles. This stacking method attempts to minimize uneven
build-up in the bundle caused by the differences in thickness
between the area of the shingle that includes the underlay and the
area that does not include the underlay. However, unevenness, or
"humping" problems occur along the central area of the bundle
because the longitudinal central areas of the shingles are
double-layered whereas the cutout areas of the shingles on the
sides of the central areas are single-layered, similar to that as
described in detail in commonly assigned U.S. Pat. No. 6,471,812,
which is incorporated herein by reference.
[0005] The difference in the thickness of the finished shingle
causes a hump or ridge along the central area of the bundle that
becomes progressively higher as the number of shingles in the
bundle is increased. When multiple shingle bundles are stacked on a
pallet, the humps amplify themselves and can cause such problems as
instability of the stacked bundles, high contact pressures on the
bundles at the intersections of the overlapping bundles, and
unsightly pallet build-up. The high contact pressures caused by the
weight of the stacked bundles on lower stacked bundles can cause
shingle deformation and sticking between individual shingles.
[0006] Therefore, it would be desirable to provide an improved
shingle which lies flat when stacked with other similar shingles,
thereby reducing humping when the shingle is stacked with others of
the shingle.
[0007] Further, in certain types of shingles it is especially
desired that the shingles define a sufficiently wide area, often
known in the industry as the "nail zone", where the nail penetrates
both layers of a laminated shingle as described in detail in U.S.
Pat. No. 6,145,265 to Malarkey, which is incorporated herein by
reference. A wide nail zone makes installation of roofs using such
elaborately laminated shingles more efficient and secure. It is
especially desired that the shingles define a nail zone that allows
the installers to have some latitude in the nail placement. Because
the nails installed in each course of shingles on a roof are
covered by the succeeding course of shingles installed on the roof,
the nail zone must exist above the cutouts in the overlay sheet,
but must reside below the top of the underlay to capture both
layers.
[0008] As noted above, it is preferred that the nail zone includes
both the overlay and underlay layers, so the installed nails
penetrate both layers. Because of the humping issue described
above, typically the underlay is less than half the height of the
overlay so within a bundle of shingles, adjacent shingles are
stacked so as to nest the single layer in the headlap area against
the double layer of an adjacent flipped shingle, resulting in a
relatively consistent thickness along the width of the stacked
shingles. However, due to the relatively short distance between the
top of the cutout between the tabs of the overlay and the top of
the underlay in the prior art shingle, the nail zone is typically
narrow, as described in detail in Malarkey '265.
[0009] Malarkey '265 attempts to address the narrow nail zone issue
by providing a wider underlay with asphalt removed from a portion
of the underlay, to minimize the thickness in the overlap area of
stacked shingles within a bundle. Unfortunately, Malarkey still
creates extra thickness in the center of the shingle. Because each
shingle has this extra thickness, when stacked in a bundle of
shingles, this cumulative excess thickness continues to create a
humping issue for the bundle, similar to that described above.
Additionally, Malarkey requires the asphalt to be removed from the
underlay in this area, which creates manufacturing issues.
[0010] As such, there is also a need for d shingles where the
underlay portions have a width that is at least about 50%, or
greater, in width as the width of the overlay portion and which is
simple to manufacture. This greater width of the underlay portion,
however, exacerbates the problems of humping in stacks of
shingles.
SUMMARY OF THE INVENTION
[0011] The present invention relates to a d roofing shingle for at
least partially covering a roof deck surface. The shingle includes
at least one shingle overlay sheet having an upper edge, a lower
edge, a top surface, and a rear surface; at least one shingle
underlay sheet having an upper edge, a lower edge a lower edge, a
top surface, and a rear surface; and at least one shingle spacer
sheet having an upper edge, a lower edge a lower edge, a top
surface, and a rear surface. The shingle underlay sheet is aligned,
and in certain embodiments, laminated to the rear surface of the
shingle overlay sheet. The at least one shingle spacer sheet is
secured to, and in certain embodiments, laminated to the rear
surface of the shingle overlay sheet such that the top surface of
the shingle overlay sheet is held in a spaced apart and parallel
relationship to the roof deck surface. The upper edge of the
shingle overlay sheet and the upper edge of the shingle spacer
sheet can be aligned in various configurations. Also, in certain
embodiments, the shingle underlay sheet and the shingle spacer
sheet are laminated to the rear surface of the shingle overlay
sheet such that the lower edge of the shingle spacer sheet and the
upper edge of the shingle underlay sheet define a gap
therebetween.
[0012] In another aspect, the present invention relates to a bundle
of roofing shingles for at least partially covering a roof deck
surface. The bundle comprising a plurality of shingles includes at
least a first shingle and at least a second shingle where at least
one of the pluralities of roofing shingles is stacked upon another
of the plurality of roofing shingles.
[0013] In certain embodiments, the upper edges of the overlay sheet
and spacer sheet of the at least first shingle are aligned with the
upper edges of the overlay sheet and spacer sheet of the at least
second shingle. Also, in certain embodiments, each shingle has the
shingle underlay sheet and the shingle spacer sheet laminated to
the rear surface of the shingle overlay sheet such that the lower
edge of the shingle spacer sheet and the upper edge of the shingle
underlay sheet define a gap therebetween.
[0014] In another aspect, the present invention relates to a method
of reducing humping of a bundle of roofing shingles when one or
more roofing shingles are stacked with others of the roofing
shingles. The roofing shingles are useful for at least partially
covering a roof deck surface, the bundle comprising a plurality of
shingles including at least a first shingle and at least a second
shingle. The shingle includes at least one shingle overlay sheet
having an upper edge, a lower edge, a top surface, and a rear
surface. The shingle underlay sheet has an upper edge, a lower
edge, a top surface, and a rear surface. At least one shingle
spacer sheet has an upper edge, a lower edge a lower edge, a top
surface, and a rear surface. The shingle underlay sheet is secured
to, and in certain embodiments, laminated to the rear surface of
the shingle overlay sheet. The at least one shingle spacer sheet is
laminated to the rear surface of the shingle overlay sheet such
that the top surface of the shingle overlay sheet is held in a
spaced apart and parallel relationship to the roof deck surface.
The method includes providing the shingle overlay and the shingle
underlay; aligning the shingle underlay with the shingle overlay,
and aligning the at one spacer sheet with the shingle overlay. In
certain embodiments the method includes a step of aligning the
spacer sheet with the overlay sheet by aligning the upper edge of
the shingle overlay sheet and the upper edge of the spacer
sheet.
[0015] Other advantages of this invention will become apparent to
those skilled in the art from the following detailed description of
the invention, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic elevational view of a shingle
manufacturing operation capable of making shingles having a spacer
sheet of material therein.
[0017] FIG. 2 is a schematic elevational view of another shingle
manufacturing operation capable of making shingles having a spacer
sheet of material therein.
[0018] FIG. 3 is a plan view of a shingle, partially in phantom and
partially broken away, having a spacer sheet of material
therein.
[0019] FIG. 4 is a plan view of an overlay sheet of the shingle
shown in FIG. 3.
[0020] FIG. 5 is a plan view of an underlay sheet of the shingle
shown in FIG. 3.
[0021] FIG. 6A is a perspective view, partially in phantom, of a
shingle, having a spacer sheet of material therein.
[0022] FIG. 6B is a schematic cross-sectional view of a prior art
shingle.
[0023] FIG. 6C is a schematic cross-sectional view of the shingle
of FIG. 6A.
[0024] FIG. 7 is a schematic side elevational view of another
embodiment of a shingle having a spacer sheet of material
therein.
[0025] FIG. 8 is a schematic cross-sectional view of one method for
stacking shingles.
[0026] FIG. 9 is a schematic cross-sectional view of another method
for stacking shingles.
[0027] FIG. 10 is a schematic cross-sectional view of another
method for stacking shingles.
[0028] FIG. 11 is a schematic cross-sectional view of another
method for stacking shingles.
[0029] FIG. 12 is a schematic cross-sectional view of another
method for stacking shingles.
[0030] FIG. 13 is a schematic cross-sectional view of another
method for stacking shingles.
[0031] FIG. 14 is a schematic cross-sectional view of an alternate
shingle according to the present invention.
[0032] FIG. 15 is a schematic cross-sectional view of two shingles
from FIG. 14 in an installed position.
[0033] FIG. 16 is a schematic cross-sectional view of two shingles
from FIG. 14 in a stacked position.
[0034] FIG. 17 is a schematic cross-sectional view of an
alternative embodiment according to the present invention.
[0035] FIG. 18 is a schematic cross-sectional view of an
alternative embodiment according to the present invention.
[0036] FIG. 19 is a schematic cross-sectional view of an
alternative embodiment according to the present invention.
[0037] FIG. 20 is a schematic cross-sectional view of an
alternative embodiment according to the present invention.
[0038] FIG. 21 is a schematic cross-sectional view of an
alternative embodiment according to the present invention.
[0039] FIG. 22 is a schematic cross-sectional view of an
alternative embodiment according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Composite shingles, such as asphalt shingles, are a commonly
used roofing product. Asphalt shingle production generally includes
feeding a base material from a roll fed downstream and coating it
first with a composite material, then a layer of granules. The base
material is typically made from a fiberglass mat provided in a
continuous shingle membrane or sheet. It should be understood that
the base material can be any suitable support material.
[0041] The composite material, such as an asphalt material, is
added to the continuous shingle membrane for strength and improved
weathering characteristics. The composite material can be any
suitable material, preferably low in cost, durable, and resistant
to fire. The layer of granules is typically applied with one or
more granule applicators, such as pneumatic blenders, to the
asphalt material covering the continuous shingle membrane. The
pneumatic blender is a type of granule applicator known in the art.
The granules shield the asphalt material from direct sunlight,
offer resistance to fire, and provide texture to the shingle. The
granules can be colored in a way known in the art, preferably
before being applied to the asphalt coated continuous shingle
membrane. The granules are preferably applied to the continuous
shingle membrane in color patterns to provide the shingles with an
aesthetically pleasing appearance.
[0042] The description and drawings disclose an improved laminated
shingle and a method for making the improved shingle. Referring now
to the drawings, FIG. 1 shows an apparatus 10 for manufacturing a
roofing shingle having a spacer sheet of material. The illustrated
manufacturing process involves passing a continuous sheet of
shingle mat 12 in a machine direction (indicated by the arrows)
through a series of manufacturing operations. The shingle mat 12
may move at any acceptable speed. In certain embodiments, the
shingle mat 12 preferably moves at a speed of at least about 200
feet/minute (61 meters/minute), and typically at a speed within the
range of about 450 feet/minute (137 meters/minute) to about 800
feet/minute (244 meters/minute).
[0043] In a first step of the manufacturing process, the shingle
mat 12 is payed out from a roll 14. The shingle mat 12 can be any
type known for use in reinforcing asphalt-based roofing materials,
such as a nonwoven web of glass fibers. The shingle mat 12 is then
fed through a coater 16 where an asphalt coating is applied to the
shingle mat 12. The asphalt coating can be applied in any suitable
manner. In the illustrated embodiment, the shingle mat 12 is
submerged in a supply of hot, melted asphalt coating to completely
cover the sheet with the tacky coating. However, in other
embodiments, the asphalt coating could be sprayed on, rolled on, or
applied to the shingle mat 12 by other means. Typically, the
asphalt material is highly filled with a ground stone filler
material, amounting to at least about 60 percent by weight of the
asphalt/filler combination.
[0044] The resulting asphalt-coated sheet 18 is then passed beneath
one or more granule dispensers 20 for the application of granules
to the upper surface of the asphalt-coated sheet 18. FIG. 1 shows
two granule dispensers 24 and 26, although any suitable number of
granule dispensers may be employed. The granule dispensers 24 and
26 can be of any type suitable for depositing granules onto the
asphalt-coated sheet 18. One suitable granule dispenser is a
granule blender of the type disclosed in U.S. Pat. No. 5,599,581 to
Burton et al., which is hereby incorporated by reference, in its
entirety. For example, the granule blender 24 can be used to
deposit accent color granules on the asphalt-coated sheet 18, and
the granule blender 26 can be used to apply background granules,
thereby defining a granule covered sheet 40. A preferred technique
for assuring a generally sharp demarcation between zones of
different colors is disclosed in U.S. Pat. No. 5,405,647 to Grubka
et al., which is hereby incorporated by reference in its
entirety.
[0045] After being treated with the granules, the asphalt-coated
sheet 18 can then engage a slate drum 44 to temporarily invert the
granule-covered sheet 40, thereby assisting in gravity removal of
the excess granules.
[0046] In one exemplary embodiment illustrated, the continuous
granule-covered sheet 40 is fed through pull rolls 78 that regulate
the speed of the granule-covered sheet 40 as the granule-covered
sheet 40 moves downstream. In a preferred embodiment, at least one
of the pull rolls 78 is driven by a motor (not shown). The
granule-covered sheet 40 is preferably then fed through a rotary
pattern cutter 52. The rotary pattern cutter 52 preferably includes
a bladed cutting cylinder 54, and a backup roll 56.
[0047] The pattern cutter 52 also cuts, or divides, the
granule-covered sheet 40 into a continuous underlay sheet 66 and a
continuous overlay sheet 68. The underlay sheet 66 is directed to
be aligned beneath a lower portion of the overlay sheet 68. As
shown in FIG. 1, the underlay sheet 66 is routed on a longer path
than the path of the overlay sheet 68. In this exemplary
embodiment, a further set of rolls 76 feeds a continuous sheet of
spacer material 64 beneath a portion on the overlay sheet 66 to
form a continuous laminated sheet 70, as will be further explained
in detail below.
[0048] Further downstream, the continuous laminated sheet 70 is
passed into contact with a rotary length cutter 72 that cuts the
laminated sheet 70 into individual laminated roofing shingles 74.
It will be understood that alternate embodiments of the apparatus
10 and the method of manufacturing roofing shingles according to
the invention are contemplated.
[0049] In another exemplary embodiment, as shown in FIG. 2, the
pattern cutter 52 cuts, or divides the granule-covered sheet 40
into a continuous underlay sheet 66, a continuous overlay sheet 68,
and a continuous strip of spacer sheet 64.
[0050] A layer of adhesive (not shown) may be applied to a rear
surface of the overlay sheet 68 by an adhesive applicator roll 148.
The layer of adhesive causes the underlay sheet 66 and the spacer
sheet 64 to adhere to the overlay sheet 68 to form the continuous
laminated sheet 70. In a preferred embodiment, the overlay sheet
68, the underlay sheet 66 and the spacer sheet 64 are joined at a
pair of joining rolls 140.
[0051] The position of the shingle overlay sheet 68 is synchronized
with respect to the position of the shingle underlay sheet 66 and
with respect to the shingle spacer sheet 64. Preferably, the
synchronization includes comparing a sensed occurrence (e.g. the
beginning) of any two suitable portions of a shingle. The
synchronizing of the position of the continuous overlay sheet 68
with respect to the continuous underlay sheet 66 may be done
approximately randomly. The synchronizing of the position of the
continuous overlay sheet 68 with respect to the continuous underlay
sheet 66 may also be done according to a pattern. Synchronization
can also be accomplished by sensing discrepancies in the desired
relative positions of the sheets 66 and 68, and increasing or
decreasing the underlay pathway distance, either in response to the
sensed error signals or in response to other signals. It is to be
understood that various devices can be used to synchronize and to
re-establish registration once a change in synchronization is
required, and that such devices are within the contemplated scope
of the present invention. For example, commonly owned U.S. Pat.
Nos. 6,521,076 B1, 6,692,608 B2 and 6,748,713 B2 are fully
incorporated herein by reference in their entireties. An error in
synchronization includes instances where the pattern is not
positioned as desired. Various other rollers, not shown, can be
used to change the length of the underlay pathway and/or spacer
material pathway. In the event at least one or more of the
underlay, the overlay and/or spacer material are mated using an
offline process, the re-establishment of synchronization could
include speeding up or slowing down one of more of the overlay
sheet 68, the underlay sheet 66, and/or the spacer sheet 64. In a
preferred embodiment, combining rolls 160 are provided downstream
from the joining roll 140. The combining rolls 160 can be operated
to press the continuous shingle overlay sheet 68 together with the
continuous shingle underlay sheet 66 and the spacer sheet 64 to
form the continuous laminated sheet 70. The continuous laminated
sheet 70 is then cut into shingles 74 by a length cutter 72.
[0052] As shown in FIG. 3, a shingle 200 has a longitudinal axis
A-A, and includes a spacer sheet 202, shown in the cutaway portion.
The shingle also has an overlay sheet 204 and an underlay sheet
208.
[0053] It is within the contemplated scope of the present invention
that the spacer sheet 202 can be applied to the shingle overlay 204
at any suitable time in the process for manufacturing the shingles.
For example, the spacer sheet 202 can be applied to the shingle
overlay sheet 204 concurrently with application of the shingle
underlay sheet 208 to the shingle overlay sheet 204, before
application of backdust, or off-line after the laminated sheet 70
has been cut into the individual roofing shingles 74.
[0054] It is to be understood, that in certain embodiments, the
spacer sheet 202 is formed from the coated web material that is
used to form the overlay sheet 204 and the underlay sheet 208. In
certain other embodiments, the spacer sheet 202 can be made of any
suitable material, preferably low in cost, flexible, durable, and
resistant to fire, such as any material known for use in
asphalt-based roofing shingles. For example, scrap roofing
material, asphalt-based film, foamed asphalt (similar to that
described in U.S. Pat. No. 4,817,358, which is incorporated herein
by reference in its entirety), and polymeric foam such as
polyurethane foam, can be used to form the spacer sheet 202.
Additional materials which could be used for the spacer 202 include
tape, cardboard, paper, rubber, shoddy, jute, wood, and any other
natural or man-made material which fills the void between shingles,
and which does not impart undesirable properties to the shingle.
One skilled in the art appreciates that further processing, such as
additives or coatings, may be required to overcome shortcomings of
these materials (for example fire resistance or durability), but
these will not be described here in detail. Accordingly, one
skilled in the art will understand that any suitable material can
be used to form the spacer sheet 202. If the spacer sheet 202 has
granules, it can be attached either granule side up or granule side
down.
[0055] As shown in FIGS. 3 and 6A, the spacer sheet 202 has a top
surface 240 and a rear surface 242. The spacer sheet 202 also
defines an upper edge 244 and a lower edge 246.
[0056] The overlay sheet 204 has a top surface 250 and a rear
surface 252. The overlay sheet 204 also defines an upper edge 254
and a lower edge 256.
[0057] The underlay sheet 208 has a top surface 260 and a rear
surface 262. The underlay sheet 208 also defines an upper edge 264
and a lower edge 266.
[0058] At least a certain portion of the top surface 260 of the
underlay sheet 208 is fixed to the rear surface 252 of the overlay
sheet 204 in a known manner. In certain embodiments, the lower edge
266 of the underlay sheet 208 is coterminous with the lower edge
256 of the overlay sheet 204. Likewise, the top surface 240 of the
spacer sheet 202 is preferably fixed to the rear surface 252 of the
overlay sheet 204. In certain embodiments, the upper edge 244 of
the spacer sheet 202 is generally aligned and coterminous with the
upper edge 254 of the overlay sheet 204.
[0059] In the embodiment shown in FIG. 3, the overlay sheet 204
also includes a headlap portion 212 and a tab portion 216. The
headlap portion 212 terminates at the upper edge 254 while the tab
portion terminates at the lower edge 256. The tab portion 216, for
the illustrated overlay sheet 204, includes five tabs 220, although
any suitable number of tabs 220 may be employed. The headlap
portion 212 and the tabs 220 may include one or more granule
patterns. As shown in FIG. 4, the tabs 220 can optionally have
different widths along the longitudinal axis A-A, such as the
illustrated widths W1, W2, and W3. The widths W1, W2, and W3 are
first widths. Likewise, the tabs 220 may be of differing heights,
such as the illustrated heights H1, H2, and H3. The tab portion 216
also defines one or more cutouts 224. The cutouts 224 include
widths along the longitudinal axis A-A. These widths may be the
same widths as the widths of the tabs 220, or may have different
widths.
[0060] As shown in FIG. 5, the underlay sheet 208 likewise includes
a headlap portion 228 and a tab portion 232. In the embodiment
shown, the height of the underlay sheet 208 is greater than half
the height of the overlay sheet 204. As defined herein, the height
of the overlay sheet 204 is generally the distance extending from
the upper edge 254 to the lower edge 256. It is also within the
contemplated scope of the present invention that other shingle
configurations can be practiced with the present invention,
including, for example, a configuration where the underlay sheet
208 has a height that is substantially the same height as the
overlay sheet 204 less the height of the spacer sheet 202. In yet
other embodiments, the underlay sheet 208 has a height that is
approximately half the height of the overlay sheet 204. As will be
appreciated by one skilled in the art, the present invention
enables the manufacture of shingles having a higher coverage ratio;
i.e. the headlap portion may be smaller than the tab portion, as
shown in FIG. 3; however, this is not essential to the practice of
the invention, as a shingle may comprise a variety of laminated
configurations, such as that illustrated in FIG. 6A.
[0061] As shown in FIG. 6B, a prior art shingle includes an overlay
550 with a cutout 524 extending from the bottom edge 556 of the
overlay to an upper edge 531 of the cutout. The underlay 508
extends from the bottom edge 556 of the overlay to the top edge 564
of the underlay, the top edge extending no further than the median
axis M'-M' of the shingle to accommodate bundling of the shingles
in a back to back manner, as described above. While FIG. 6B
illustrates the underlay extending to the median axis, such is not
the industry practice, since manufacturing variation would cause
the underlay to extend beyond this point; and as such FIG. 6B
illustrates an unrealistic condition, as it is too extreme.
Accordingly, the maximum nail zone of the prior art shingle,
indicated as "N'", extends from the upper edge 531 of the cutout
524 to the upper edge 564 of the underlay, while the actual nail
zone is somewhat less in practice, as the installer must nail
between the upper edge 531 of the cutout and the upper edge 564 of
the underlay to ensure that two layers are secured, and to ensure
the nail heads are covered by the next course of shingles.
[0062] As shown in FIG. 6C, a shingle according to the present
invention may enjoy a much wider maximum nail zone N (as well as
actual nail zone), since the upper edge 264 of the underlay 208 may
extend beyond the median axis M-M of the shingle. In fact, the
instant invention may enable higher coverage ratios for the
shingles, since the installer may be able to leave a larger portion
of the shingle exposed, and/or the cutouts may extend further
toward the upper edge of the shingle, e.g. as shown in FIG. 3.
[0063] As shown in FIG. 3, the underlay sheet 208 preferably
includes at least one shadow patch 236. The underlay sheet 208 also
preferably includes a headliner shadow 238, which is part of the
shadow patch 236. A portion of the shadow patch 236 is uncovered,
and therefore visible through the overlay cutouts 224 after the
underlay and overlay are laminated together. In certain
embodiments, the shadow patch 236 is darker or denser in pattern
than the pattern of the tabs 220 which the shadow patch 236
borders. A portion of the shadow patch 236 is covered with the tab
220 to leave a remainder portion 235 of the shadow patch 236
uncovered by the tab 220. As shown, the remainder portion 235 has a
vertical portion 237. The vertical portion 237 of the remainder
portion 235 is positioned approximately perpendicular to the
longitudinal axis A-A. Also, the height H1 of certain tabs, shown
here as tab 234, is less than the height of the underlay 208, and
preferably less than half the height of the overlay 250. The
remainder portion 235 has a horizontal or longitudinal portion 239.
The longitudinal portion 239 of the remainder portion 235 is
positioned approximately parallel to the longitudinal axis A-A. It
is to be understood that synchronization of the overlay sheet 204
and the underlay sheet 208 does not require that each shingle look
the same since the appearance of the shingles may vary. For
example, the position of the shadow patch 236 and the position of
the tab 234 can be synchronized in any suitable manner. Also, the
synchronizing of the position of the shadow patch 236 and the tab
234 may be done approximately randomly. The synchronizing of the
position of the shadow patch 236 and tab 234 may also be done
according to a pattern. It is to be understood, however, that the
present invention can be practiced with shingles having other
arrangements, and that such arrangements are within the
contemplated scope of the present invention.
[0064] In certain embodiments, it is desired that the spacer sheet
202 have approximately the same thickness as the underlay sheet 208
such that the stacking of multiple shingles will not cause any
humping or bending of the bundle of shingles. As defined herein,
"thickness" is generally the distance between the top surface and
the rear surface. By these examples, it is understood that the
spacer sheet 202 can have any appropriate cross-sectional shape,
such as, for example, square or rectangular, or alternatively could
comprise any appropriate shape, such as a series of longitudinal
beads, so long as the spacer sheet 202 provides the necessary
functions as described herein. In certain embodiments, the spacer
sheet 202 preferably comprises a single continuous piece of
material extending the full width across the shingle overlay sheet
204. It is also within the contemplated scope of the present
invention, however, that the spacer sheet 202 can be comprised of a
series of short sections spaced along the rear surface 252 of the
overlay sheet 204 (the sections being short in either the
longitudinal or lateral dimensions).
[0065] When the shingle members 200 are stacked into bundles, the
spacer sheet 202 maintains the overlay sheet 204 in a generally
planar, or horizontal, position with respect to a flat supporting
surface on which the shingle may be placed. The shingle underlay
sheet and the spacer sheet are laminated to the rear surface of the
shingle overlay sheet such that the top surface of the shingle
overlay sheet is held in a spaced apart and parallel relationship
to a supporting surface on which the laminated roofing shingle is
laid.
[0066] The result is a bundle of shingles that have little or no
undesirable bending or flexing of the shingles when placed in a
stack. Further, the stack, or bundle, of shingles shows no humping
or flexing. That is, the top of the shingle bundle has a much more
planar top surface than would be the case for shingles not
employing the spacer sheet 202 of the invention. Preferably, the
top of the bundle is substantially straight and even.
[0067] In certain embodiments, as shown in FIG. 7, the shingle
overlay sheet 204 defines a first thickness x, and preferably, has
a generally uniform thickness. The shingle underlay sheet 208
defines a second thickness y and, preferably, has a generally
uniform thickness. The spacer sheet 202 defines a third thickness
z, and, preferably, the spacer sheet 202 has a generally uniform
thickness. The third thickness z of the spacer sheet 202 is
preferably substantially equal to the second thickness y of the
underlay sheet 204 such that the overlay sheet 204 is maintained in
a substantially planar position when the shingle is itself planar,
or in a horizontal position. That is, the upper edge 254 and the
lower edge 256 of the overlay sheet 204 are in a spaced apart and
parallel relationship with respect to one another. When the
laminated roofing shingle 200 is disposed on a substantially planar
supporting surface, such as a building roof deck, the shingle
underlay sheet 208 and the spacer sheet 202 maintain the shingle
overlay sheet 204 in a spaced apart and parallel relationship to
the supporting surface. As shown in FIG. 7, the spacer sheet 202
may fill the entire area from the top of the underlay sheet 208 to
the top of the overlay sheet 204.
[0068] In certain embodiments, the underlay sheet 208 and the
spacer sheet 202 are aligned with, and in certain embodiments,
laminated to the rear surface 252 of the overlay sheet 204 such
that the lower edge 246 of the spacer sheet 202 and the upper edge
264 of the underlay sheet 208 define a gap 270 therebetween, as
shown in FIGS. 6A and 6C. It will be understood however, that the
gap 270 is not required. For example, the underlay sheet 208 and
the spacer sheet 202 can be secured to the rear surface 252 of the
overlay sheet 204 such that the lower edge 246 of the spacer sheet
202 and the upper edge 264 of the underlay sheet 208 are secured to
one another, as illustrated in FIG. 7. One skilled in the art
appreciates that the gap 270 should be optimized such that the
shingles are not damaged during shipment and so the bundle stacks
in an appropriate manner. It should be noted that while the figures
illustrate a two-layer shingle, these principles apply similarly to
other configurations not shown, such as tri-layer shingles.
[0069] Referring now to FIGS. 8-13, in another aspect, the present
invention relates to stacks, or bundles, of shingles, and in yet
another aspect, to methods for stacking at least one of the roofing
shingles upon another of the roofing shingles where the stacked
roofing shingles define a bundle of the roofing shingles.
[0070] FIG. 8 shows first shingle 200 and a second shingle 200'.
For ease of illustration the second shingle 200' will be numbered
with the same corresponding numbers, marked as prime numbers, as
the first shingle 200. Thus, second shingle 200' is stacked secured
to the first shingle 200 such that the rear surface 262' of the
underlay sheet 208' and the rear surface 242' of the spacer sheet
202' face the top surface 250 of the first shingle 200. The first
and second roofing shingles 200 and 200' are further stacked such
that the lower edges 256 and 266 of the first roofing shingle 200
are aligned with the lower edges 256' and 266' of the second
roofing shingle 200'.
[0071] For the purpose of defining the relationship of the shingles
shown in the figures, the relative position of the shingles of FIG.
8 will be considered "parallel"; FIG. 9 will be considered
"rotated"; FIG. 10 will be considered "mirrored face to face"; FIG.
11 will be considered "rotated face to face"; FIG. 12 will be
considered "mirrored back to back"; and FIGS. 13 and 16 will be
considered "rotated back to back". While it is generally preferred
that every other shingle is packaged as shown in these figures, it
is foreseeable that a bundle could have any or all combinations of
these arrangements to facilitate manufacturing (flipping of
shingles) and/or packaging considerations (bundle density,
stability, handling) and/or installation preference.
[0072] FIG. 9 shows an alternative method for stacking shingles
where the first and second roofing shingles 200 and 200' are
stacked such that the lower edges 256 and 266 of the first roofing
shingle 200 are aligned with the upper edges 244' and 254' of the
second shingle 200'. The second shingle 200' is stacked adjacent
the first shingle 200 such that the rear surface 262' of the
underlay sheet 208' and the rear surface 242' of the spacer sheet
202' face the top surface 250 of the first shingle 200.
[0073] FIG. 10 shows another alternative method for stacking
shingles where the first shingle 200 is stacked upon the second
shingle 200' such that the top surface 250 of the overlay sheet 208
faces the top surface 250' of the second shingle 200'. The upper
edges 244 and 254 of the first shingle 200 are aligned with the
upper edges 244' and 254' of the second shingle 200'. The lower
edges 256 and 266 of the first shingle 200 are aligned with the
lower edges 256' and 266' of the second shingle 200'.
[0074] FIG. 11 shows yet another method for stacking shingles where
the first shingle 200 is stacked upon the second shingle 200' such
that the top surface 250 of the overlay sheet 208 faces the top
surface 250' of the second shingle 200'. The upper edges 244 and
254 of the first shingle 200 are aligned with the lower edges 256'
and 266' of the second shingle 200'. The lower edges 256 and 266 of
the first shingle 200 are aligned with the upper edges 244' and
254' of the second shingle 200'.
[0075] FIG. 12 shows still another method for stacking shingles
where the first shingle 200 is stacked upon the second shingle
200', and where the rear surface 242 of the spacer sheet 202 and
the rear surface 262 of the underlay sheet 204 face the rear
surface 242' and the rear surface 262' of the underlay sheet 204'.
The upper edges 244 and 254 of the first shingle 200 are aligned
with the upper edges 244' and 254' of the second shingle 200'. The
lower edges 256 and 266 of the first shingle 200 are aligned with
the lower edges 256' and 266 of the second shingle 200'. It will be
appreciated that the spacer sheets 244 and 244' fill a vertical gap
between the shingles.
[0076] FIG. 13 shows still another method for stacking shingles
where the first shingle 200 is stacked upon the second shingle 200'
where the rear surface 242 of the spacer sheet 202 and the rear
surface 262 of the underlay sheet 204 face the rear surface 242'
and the rear surface 262' of the underlay sheet 204'. The upper
edges 244 and 254 of the first shingle 200 are aligned with the
lower edges 256' and 266' of the second shingle 200'. The lower
edges 256 and 266 of the first shingle 200 are aligned with the
upper edges 244' and 254' of the second shingle 200'. It will be
appreciated that the spacer sheets 244 and 244' fill a vertical gap
between the shingles, and likewise if there were a third shingle
shown in FIG. 11 above or below the shingles illustrated, at least
one of the spacer sheets would fill a gap between two of the
shingles.
[0077] FIGS. 14-16 show another embodiment of stackable shingles
that incorporates certain concepts of commonly assigned U.S. Pat.
No. 6,367,221, which is incorporated herein by reference in its
entirety. In this embodiment, the shingle 200 includes an overlay
sheet 204, underlay sheet 208, and spacer sheet 202 as described
above. Preferably, the underlay sheet 208 extends under the tab
portion of the overlay sheet 204, and the spacer sheet 202 is
provided under the headlap portion of the overlay sheet 204 as
described above. In this embodiment, the underlay sheet 208
preferably extends over one half the height of the overlay sheet
204. Furthermore, spacer sheet 202 defines a first thickness depth
"X", and, preferably, the spacer sheet 202 has a generally uniform
thickness.
[0078] As shown in FIG. 14, the thickness "X" of the spacer sheet
202 is preferably greater than a second thickness "Y" of the
underlay sheet 204. Accordingly, the spacer sheet 202 serves as an
alignment mechanism as shown in FIG. 15, wherein a course of first
shingles 200 is secured to a roof deck (not shown), and a
subsequent course of shingles 200' is installed above the first
shingles 200'. As shown, the lower edge 246' of the spacer sheet
202' of the second shingle 200' abuts against the upper edge 254 of
the first shingle 200. As such, the second shingle is aligned with
the first shingle. As shown in FIG. 16, the shingles of this
embodiment are preferably packaged, or stacked, in a manner similar
to that described in FIG. 13, such that two stacked shingles will
have a substantially constant thickness. The stack shown in FIG. 16
has a void area 300 between the shingles in instances where the
spacer sheet 244 is less than half the height of the shingle 200.
Furthermore, the spacer sheet 244 is preferably coextensive with
the top edge 254 of the shingle, but may not be so if additional
features are desired, such as an interlock between the bottom of
the spacer sheet and the top of the shingle in a manner similar to
that shown in FIG. 9B of the '221 patent. As noted above, the
spacer sheet 244 may be a continuous sheet, or may include cutouts
and/or may comprise any other form, such as discrete pieces or a
series of beads.
[0079] FIGS. 17-20 show other embodiments of stackable shingles. In
the embodiment shown in FIG. 17, the spacer strip comprises a
connector strip 302 secured to the rear surface 262 of the underlay
208. The connector strip 302 extends along at least a portion of
the rear surface 252 of the overlay 204 above the upper edge 264 of
the underlay and preferably beyond the median axis M-M of the
shingle. Preferably, the connector strip 302 is adhered to the rear
surface 252 of the overlay 204 as well. When the shingle is nailed
to a roof, the nail will penetrate at least two layers, including
the overlay 204 and/or the underlay 208, and the connector strip
302. Accordingly, the maximum nail zone indicated as "N" extends
from above the upper edge 231 of the cutout to the upper edge of
the connector strip 302, which is above the upper edge 264 of the
underlay 208. In this embodiment, it is not necessary to have an
underlay 208 which is more than half the height of the overlay to
attain a wider nail zone. In one embodiment, the rear surface of
the connector strip 302 is provided with a non-stick coating so it
can serve as a release tape, thereby assuring that any adhesive
provided on a shingle does not stick to an adjacent shingle in a
bundle.
[0080] The connector strip 302 may be any material having adequate
properties to ensure adhesion to the underlay 208 (with or without
additional adhesive), while maintaining sufficient strength at high
temperature to not permit the underlay to slip if it were to become
delaminated from the overlay 250. Furthermore, the connector strip
302 must be nailable (including not brittle at cold temperatures)
and preferably flexible, with proper tensile, tear and elongation
properties. It must serve its purpose for the life of the shingle,
and do so within the environment to which it will be exposed on the
roof. One such material is a polyolefin scrim available from
American Profol of Cedar Rapids Iowa.
[0081] In a further alternate embodiment shown in FIG. 18, the
connector strip 302 is secured to the shingle as described in the
preceding paragraph with reference to FIG. 17, but the connector
trip 302 extends along the entire height of the underlay 208 and
terminates at the bottom edge 256 of the shingle. In a preferred
embodiment, the connector strip 302 comprises a material having the
properties described in commonly assigned U.S. Pat. No. 6,709,994,
which is incorporated herein by reference in its entirety. As such,
the connector strip 302 serves both functions of providing an
extended nail zone, as well as improved impact performance as
described in the '994 patent. Additionally, the shingle may include
a protective coating on the top surface as described in the '994
patent. The connector strip 302 may be applied in a manner similar
to that described in the '994 patent, or the connector strip 302
may be adhered to the shingle after lamination is complete.
[0082] FIG. 19 illustrates a further alternative embodiment to that
shown in FIGS. 17 and 18, wherein the connector strip 302 extends
along the entire height of the shingle, from the bottom edge 256 to
the top edge 254.
[0083] FIG. 20 illustrates a further alternative embodiment, where,
in a configuration similar to the embodiments of FIGS. 17-19, a
connector strip 302 is provided to extend the nail zone. In this
embodiment, the underlay 208 is manufactured in a manner similar to
that described in U.S. Pat. No. 6,044,608, which is incorporated
herein by reference, in that the underlay 208 includes at least one
tab 249 under the headlap area, as shown in FIGS. 5 and 6 of the
'608 patent. Additionally, the present invention includes a
connector strip 302 provided between the tabs of the underlay in
the headlap area, so as to provide a wider nail zone along the
entire length of the shingles. Although not illustrated here, the
connector strip 302 of FIGS. 17-20 may be used along with a second
strip similar to the strip 202 shown in FIG. 6, if the underlay is
desired to be longer, or if the strip of FIGS. 17-20 creates a
thickness issue.
[0084] FIGS. 21 and 22 illustrate another embodiment of stackable
shingles. This embodiment is similar to those described above for
FIGS. 7-13, except that the shingle includes a spacer strip 402
being integrally formed in the overlay 204, or attached to the top
of the overlay 250 in a hinged manner. In a preferred embodiment,
as illustrated in FIGS. 21-22, the overlay 204 includes a score
line 251 near the upper edge of the shingle. The score line 251
extends along the width of the shingle and permits the spacer strip
402 to be bent from the overlay 204 and tucked below the overlay as
shown in FIG. 22. The spacer strip 402 may be adhered in this
position. Alternatively, the spacer strip 402 may be bent back to
the position shown in FIG. 22 at the jobsite and installed on the
roof in this position as part of the headlap area, thereby
permitting the shingle to have all the dimensions of a typical
shingle, except it may also permit the underlay 208 to extend
beyond half the height of the overlay and/or the bundle may be
narrower from the upper edge 254 to the bottom, when the lower edge
254 is in the folded position shown in FIG. 22. The score line 251
may be positioned anywhere between the upper edge 254 and half the
distance between the upper edge 254 and the upper edge 264 of the
underlay 208.
[0085] One skilled in the art will further appreciate that while
the spacer strip is described as being secured to the shingles in
the above embodiments, the present invention further envisions
embodiments where such a strip is merely packaged between shingles,
and may comprise any inexpensive material; e.g., scrap shingles,
cardboard, foam, etc., packaged in the void created between
adjacent shingles. In one embodiment (not illustrated), such
materials are disposed at the jobsite, and therefore do not have
any significant property requirements other than thickness. In a
preferred one of these embodiments, the spacer is twice the
thickness of the underlay, and therefore one spacer fills the void
between two shingles packaged e.g. as shown in FIG. 12, in place of
the above-described spacers 208 and 208'.
[0086] In yet further embodiments (not shown), a spacer sheet is
provided below the underlay, and adjacent pairs of shingles are
stacked in a back-to-back and rotated relationship (similar to that
shown in FIG. 13), so that the bottom surface of a spacer of a
first shingle abuts the bottom surface of the facer sheet of an
adjacent shingle to enable a flat bundle of shingles as described
above. In these embodiments, the spacer sheet is provided in the
form of e.g. a strip similar to that described with regard to FIGS.
7, 9 and 21, or in the form of one or more beads. Such beads may
comprise a sealant to adhere the bottom of the shingle after it is
secured upon the roof; in which case a release tape may be useful
on the bottom of the overlay in registration with the bead of an
abutting shingle. In the embodiments of this paragraph, the spacer
sheet is thus relocated to the rear surface of the underlay
adjacent the lower edge thereof, and abutting shingles (within a
bundle) look similar to that depicted in FIG. 13, except that the
spacer sheet is attached to the underlay 266, instead of the
overlay 254 as described above. Thus in these embodiments, the
spacer sheet may provide additional thickness (as a trilaminate),
or serve as an adhesive on the roof. Alternatively, such a spacer
sheet may be removable and discarded at the jobsite.
[0087] One skilled in the art appreciates that while this
description and the figures describe the invention with respect to
a two-layer laminated shingle, the invention may be applied to a
laminated shingle having additional layers, such as a trilaminate
shingle. Of course in these instances, the thickness of the spacer
sheet is adjusted accordingly, by either providing additional
thickness or additional layers of spacer sheets.
[0088] The principle and mode of operation of this invention have
been described in its preferred embodiments. However, it should be
noted that this invention may be practiced otherwise than as
specifically illustrated and described without departing from its
scope.
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