U.S. patent application number 11/215086 was filed with the patent office on 2007-03-01 for shingle layer or shingle having thick appearance.
Invention is credited to Husnu M. Kalkanoglu.
Application Number | 20070044410 11/215086 |
Document ID | / |
Family ID | 37802114 |
Filed Date | 2007-03-01 |
United States Patent
Application |
20070044410 |
Kind Code |
A1 |
Kalkanoglu; Husnu M. |
March 1, 2007 |
Shingle layer or shingle having thick appearance
Abstract
A shingle layer of shingle is provided having an increased
thickness adhesive coating on at least a portion of its rear
surface, with granules embedded therein, with the granules being of
a size range that is larger than the fine particles normally
applied to the rear surface of a shingle layer.
Inventors: |
Kalkanoglu; Husnu M.;
(Swarthmore, PA) |
Correspondence
Address: |
PAUL AND PAUL
2000 MARKET STREET
SUITE 2900
PHILADELPHIA
PA
19103
US
|
Family ID: |
37802114 |
Appl. No.: |
11/215086 |
Filed: |
August 30, 2005 |
Current U.S.
Class: |
52/526 ;
52/518 |
Current CPC
Class: |
Y10T 428/24372 20150115;
E04D 1/26 20130101; E04D 2001/005 20130101 |
Class at
Publication: |
052/526 ;
052/518 |
International
Class: |
E04D 1/00 20060101
E04D001/00 |
Claims
1. A shingle layer having a front surface and a rear surface and
comprising a bitumen-coated web; (a) with the front surface having
a tab portion normally exposed when in use on a roof; (b) with the
front surface having a butt portion normally unexposed when in use
on a roof; (c) with the rear surface having a first zone behind
said tab portion and a second zone behind said butt portion; (d) a
front layer of granules of a size range from about 0.3 to about 3
mm on at least the tab portion of the front surface; (e) an
adhesive coating of a thickness within the range of about 0.1 to
about 2 mm on at least a portion of the first zone of the rear
surface; (f) a rear layer of granules of a size range from about
0.3 to about 3 mm embedded in said adhesive coating; (g) the
thickness of the shingle layer between the tab portion of the front
surface and the first zone of the rear surface being substantially
uniform; (h) whereby the rear layer of granules provides an
appearance of thickness to the shingle layer.
2. The shingle of claim 1, wherein said adhesive coating comprises
bitumen from the bitumen-coated web and wherein the rear layer of
granules is adhered directly to the bitumen-coated web.
3. The shingle layer of claim 1, wherein the rear layer of granules
comprises an overlay that is adhered to the adhesive coating, that,
in turn, is disposed against a layer of fine particles of a size
range from about 0.05 to about 0.6 mm, with the layer of fine
particles being adhered to the bitumen-coated web.
4. The shingle layer of claim 1, wherein the rear layer of granules
comprises an overlay that is adhered to the adhesive coating, that,
in turn, is disposed against a layer of particles of a size range
from about 0.3 to about 3 mm, with the layer of particles being
adhered to the bitumen-coated web.
5. The shingle layer of claim 1, wherein the adhesive coating and
the rear layer of granules comprise a first overlay on the rear
surface, and the shingle layer further comprises a second overlay
adhered to at least a portion of said first overlay, said second
overlay comprising a second rear layer of granules and a second
adhesive coating.
6. The shingle layer of claim 1, wherein the front layer of
granules covers substantially the entire front surface of the
shingle layer.
7. The shingle layer of claim 1, wherein the rear layer of granules
covers substantially the entire rear surface of the shingle
layer.
8. The shingle layer of claim 1, wherein the rear layer of granules
is in a predetermined pattern on the rear surface.
9. The shingle layer of claim 1, wherein the shingle layer
comprises a shingle.
10. The shingle layer of claim 1, wherein the shingle layer
comprises the top shingle layer of a laminated multiple-layer
shingle.
11. The shingle layer of claim 1, wherein the butt portion of the
shingle layer has a top edge and the tab portion of the shingle
layer has a bottom edge; with the shingle layer having end edges at
opposite ends, connecting said top and bottom edges; with the rear
layer of granules being adhered to the adhesive coating, at least
along said bottom edge.
12. The shingle layer of claim 1, wherein said adhesive coating
comprises bitumen from the bitumen-coated web and wherein the rear
layer of granules is adhered directly to the bitumen-coated web,
wherein the shingle layer comprises a shingle.
13. The shingle layer of claim 1, wherein the rear layer of
granules comprises an overlay that is adhered to the adhesive
coating disposed against a layer of fine particles of a size range
from about 0.05 to about 0.6 mm, with the layer of fine particles
being adhered to the bitumen-coated web and wherein the shingle
layer comprises a shingle.
14. The shingle layer of claim 1 wherein the rear layer of granules
comprises an overlay that is adhered to the adhesive coating
disposed against a layer of particles of a size range from about
0.3 to about 3 mm, with the layer of particles being adhered to the
bitumen-coated web and wherein the shingle layer comprises a
shingle.
15. A method of making a shingle layer, the method comprising the
steps of; (a) providing a web; (b) coating the web with bitumen to
yield a bitumen coated web having a front surface and a rear
surface; (c) denoting a tab portion and a butt portion of the web;
(d) adhering a front layer of granules to the front surface of the
web to yield a granule coated front surface; (e) adhering an
adhesive coating to at least a first zone of the rear surface of
the tab portion; and, (f) adhering a rear layer of granules to the
first zone of the rear surface of the tab portion such that the
thickness of the shingle layer between the granule coated front
surface and the granule coated rear surface of the tab portion is
substantially uniform.
16. A method of enhancing the apparent thickness of a shingle
layer, the method comprising the steps of; (a) providing a shingle
layer having a front surface and a rear surface, the shingle layer
having an upper edge, a lower edge, a tab portion and a butt
portion and a first zone of the rear surface of the tab portion;
and, (b) adhering a rear layer of granules to the first zone of the
rear surface of the tab portion by means of an adhesive coating
such that the thickness of the shingle layer between the granule
coated front surface and the granule coated rear surface of the tab
portion is substantially uniform.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to providing a shingle or shingle
layer of increased thickness, whether the shingle layer comprises a
single layer shingle, or a single layer of a multiple-layer
shingle.
[0002] Shingles are generally made by providing a bitumen-coated
web, with the web being either of organic or inorganic (generally
fiberglass) material. The bitumen is generally asphalt. The front
or top surface of the shingle or shingle layer is provided with
granules, generally of a certain predetermined size, which granules
are embedded in the asphalt or other bitumen that coats the web.
The construction and arrangement of such granules can take on
various forms, for various purposes, such as color, light
reflection, fungus-resistance, ultra-violet or infrared
reflectiveness, or of any other forms, for facilitating the
longevity of the shingle, or simply for aesthetic purposes. Where
aesthetics are important, the granules can be various combinations
of colored granules, or various arrangements of color, all of which
are known in the art.
[0003] The bottom or rear surface of the shingle is generally
provided with a very thin layer of adhesive, such as asphalt or
other bitumen coating. Fine particles are applied to this very thin
layer of adhesive coating on the bottom, or rear surface of the
shingle. Such fine particles can include sand, limestone, talc,
mica, etc. embedded in the fine adhesive coating.
[0004] Attempts have been made to produce shingles having ordinary
roofing granules embedded in this thin layer of adhesive coating on
the rear surface of the shingle. However, if granules of an
approximate size such as those that are used on the front or top
surface of the shingle or shingle layer are used, to be embedded in
the very thin layer of adhesive coating that is applied to the rear
of the shingles, the adhesion provided by the thin layer of coating
is not sufficient to ensure that the granules will remain embedded
in the thin layer of adhesive coating, such that such granules on
the rear surface of the shingle can become loose, creating safety
issues on the roofing by acting like small roller bearings under
the feet of the contractor or other installer, potentially causing
slipping, sliding and accidents.
THE PRESENT INVENTION
[0005] In accordance with the present invention, a shingle layer is
constructed in the usual manner, except that on a portion of the
rear surface of the shingle, an adhesive coating is applied that is
of greater thickness than is ordinary applied to the rear surface
of the shingle and granules of a larger size than the normal size
of sand, limestone, talc, mica, etc. is then applied to the thick
coating of adhesive, to at least a portion behind the tab portion
of the shingle, and most preferably at least along the lower edge
thereof, such that the shingle or shingle layer actually becomes
thicker at that location and provides the three-dimensional
appearance of a generally thicker shingle.
[0006] Accordingly, it is an object of this invention to provide a
novel shingle layer of increased thickness, at least at the lower
edge of the tab portion of the shingle, by providing on the rear
surface of the shingle layer, granules of a larger size than
particles that are normally applied to the rear surface of a
shingle layer, the granules being embedded in an adhesive coating
that has been applied to the rear surface of the shingle layer,
which adhesive coating is sufficiently thick to retain the granules
adhered to the shingle layer on the rear surface of the shingle
layer.
[0007] It is another object of this invention to accomplish the
above object, wherein the shingle layer comprises a shingle.
[0008] It is another object of this invention to apply the adhesive
coating to the rear of the shingle layer, against a layer of fine
particles of a size range that are normally applied to the rear
surface of the shingle, with the layer of fine particles being
adhered to a bitumen-coated web of the shingle layer.
[0009] It is a further object of this invention to provide a
laminated multiple-layer shingle in accordance with the objects set
forth above.
[0010] Other objects and advantages of the present invention will
be readily apparent to those skilled in the art from a reading of
the following brief descriptions of the drawing figures, the
detailed descriptions of the preferred embodiments and the appended
claims.
BRIEF DESCRIPTIONS OF THE DRAWING FIGURES
[0011] FIG. 1 is a vertical sectional view, taken along line I-I of
FIG. 4, through the shingle of FIG. 4, wherein the extra coating of
adhesive is shown, having granules embedded therein, applied to the
rear surface of a shingle layer, against the layer of fine
particles on the rear surface of the shingle, that, in turn, are
embedded in the bitumen-coated web.
[0012] FIG. 2 is a vertical sectional view, like that of FIG. 1,
but wherein the layer of granules are applied directly to the
bitumen-coated web on the rear surface of the shingle.
[0013] FIG. 3 is a vertical sectional view, taken through a
laminated composite shingle, the upper laminate of which is
constructed like the embodiment of FIG. 1, but with the rear
laminate being applied to the rear surface of the upper laminate
also being constructed like the embodiment of FIG. 1, but wherein
the rear laminate is adhered to an adhesive coating applied to the
fine particles on the rear surface of the upper laminate.
[0014] FIG. 4 is the rear surface of a shingle layer in accordance
with this invention, wherein the larger granules on the rear
surface of the shingle are shown applied along the lower edge of
the tab portion of the shingle.
[0015] FIG. 5 is an illustration similar to that of FIG. 4, but
wherein the larger granules are applied to the rear surface of the
shingle in an alternative pattern.
[0016] FIG. 6 is an illustration like that of FIG. 5, but wherein
the larger granules are applied in yet another alternative
pattern.
DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS
[0017] Referring now to FIG. 1 in detail, it will be seen that the
shingle layer generally designated by the numeral 10 comprises a
bitumen-coated web 11, with the bitumen illustrated by the numeral
12.
[0018] Conventional granules 13 appear on the front surface 14 of
the shingle layer.
[0019] The rear surface 15 of the shingle layer 10 has small
particles 16 embedded in the bitumen 12, in the conventional
manner. Such small particles comprise sand, limestone, talc, mica,
or like other small particles, or the like.
[0020] The granules 13 on the front surface of the shingle layer
are generally of a size range from about 0.3 to about 3 mm, and
preferably from about 0.4 to about 2.5 mm.
[0021] The small particles 16 on the rear surface 15 of the shingle
layer are generally of a size range from about 0.05 to about 0.6
mm, and preferably from about 0.1 to about 0.5 mm.
[0022] A layer of adhesive coating 17 is provided against the rear
surface onto the fine particles 16, as shown in FIG. 1, with such
adhesive coating generally preferably being an asphalt or bitumen,
and of a thickness within the range of about 0.1 to about 2 mm,
preferably from about 0.2 to about 1.5 mm. Granules 18 are applied
to the adhesive coating 17 on the rear surface of the shingle
layer, with the granules 18 being of a size range from about 0.3 to
about 3 mm, preferably from about 0.4 to about 2.5 mm, more
preferably from about 0.5 to about 2 mm, and being embedded in the
adhesive coating 17. Generally, the adhesive coating 17 is at least
about one fourth of the average particle size of the granules 18 in
thickness, and more preferably at least about one third the average
particle size of the granules 18 in thickness. Although not
required, the thickness of coating 17 is preferably less than the
size of the largest granules 18 applied to the adhesive coating
17.
[0023] It will be seen that the shingle layer of FIG. 1 thus
provides, as shown in FIG. 4, an area on the rear surface 20 of the
shingle layer, along the lower edge 21 of the first zone 19 covered
by the granules 18, an enhanced thickness portion of the shingle,
as a portion of the tab portion 23 of the shingle layer, above the
tab lower edge 21.
[0024] The tab portion 23 of the shingle layer of FIG. 4, as shown,
comprises a plurality of tabs 24, 25, 26, separated by spaced-apart
slots, 27 and 28. The portion of the shingle layer rear surface 20
above the tabs 24, 25 and 26, that extends from the upper ends 30
and 31 of the slots 27, 28, to the upper edge 32 of the shingle
layer, comprises the butt portion 33 of the shingle layer. End
edges 34 and 35 connect the upper edge 32 of the butt portion and
the lower edge 21 of the tab portion.
[0025] It will be seen that the thickness T of the entire shingle
layer 10 of FIG. 1, for at least that portion which includes the
added granules 18 and adhesive coating 17 underlying the lower
surface 15 of the shingle layer 10, is substantially uniform.
[0026] With reference now to FIG. 2, an alternative embodiment for
the shingle layer of FIG. 1 is illustrated, having a similar
construction to the embodiment illustrated in FIG. 1, except that
the granules 18' are not applied to a separate adhesive coating on
the rear surface of the shingle layer, but, rather, are applied
directly to the bitumen 12' of the bitumen coated web 11'. In all
other respects, the construction of FIG. 2 is the same as that of
FIG. 1. However, it will be noted that the thickness T' of that
portion of the shingle layer of FIG. 2 in which the granules 18'
are applied to the rear surface, is of a different thickness than
the thickness T of the shingle layer of FIG. 1, albeit also of a
substantially uniform thickness T'.
[0027] In some embodiments, a further layer of granules (not shown)
may optionally be adhered to at least some portions of the first
layer of granules 18' by means of a further adhesive layer. Such a
second overlay can provide an additional aesthetic effect of
enhanced apparent thickness, such regions employing a second
overlay being of a substantially uniform thickness.
[0028] With reference now to the embodiment of FIG. 3, it will be
seen that a shingle layer 10'' is constructed like that of the
shingle layer 10 of FIG. 1, except that, rather than having
granules 18 applied to the rear surface as shown in FIG. 1 against
and embedded in an adhesive 17, another complete layer of shingle
material 40 is applied to the adhesive layer 17''. The complete
layer 40 of shingle material is constructed of a bitumen coated web
41 having granules 42 on an upper surface thereof as shown in FIG.
3, adhered to the adhesive 17'', with a layer of fine particles 43
of the sand, talc, mica, limestone or other type applied to its
undersurface, with a layer of adhesive 44 therebeneath, holding a
layer of granules 45 thereto. The layer of granules 45 will
comprise granules of a size range of about 0.3 to about 3 mm, as
may the layer of granules 42.
[0029] In the embodiment of FIG. 3, it will be noted that the
posterior shingle layer 40 is thus adhered to the anterior shingle
layer 10'', with the layer 40 having its lower edge 47 extending
beyond, or below, the lower edge 48 of the anterior shingle layer
10'', an amount "D", to yield a "petticoat" effect, providing
increased visual thickness for the overall shingle. Such a
"petticoat" effect is optional and may be variably controlled in
the assembly during construction of a laminated shingle having a
plurality of shingle layers. In some instances, it may be desirable
for the amount of extension "D" to take on negative values, whereby
the lower edge 47 of the layer 40 is recessed beneath the lower
edge 48 of the anterior shingle layer 10''. Suitable amounts of
extension "D" can range from 0 to about 5 cm in absolute value,
depending on the visual effect desired.
[0030] It will also be understood that the posterior shingle layer
40 may, if desired, cover only a portion of the anterior shingle
layer 10'', as shown in solid lines in FIG. 3, or may cover the
entirety of the rear surface of the anterior shingle layer 10'', as
shown in phantom at 50, in FIG. 3.
[0031] With reference to FIG. 5, it will be seen that a shingle
layer 60 is provided, with additional granules of the type 18
applied thereto, on adhesive coatings (unnumbered), in the form of
a plurality of generally horizontal stripes 61-64.
[0032] With reference to FIG. 6, it will be seen that a shingle
layer 65 is provided, with granules similar to those 18 of FIG. 4
applied to the rear surface thereof, embedded in an adhesive
coating (unnumbered), in the form of a generally rectangular grid
pattern 66.
[0033] It will be apparent from the foregoing that various other
patterns for application of the larger granules may be applied to
various portions of the rear surface of the shingle layer, as may
be desired.
[0034] It will be understood that, in accordance with this
invention, the shingle layer has been defined as including a tab
portion and a butt portion. The tab portion of the shingle may
comprise a plurality of tabs separated by spaced-apart slots, as
shown in the embodiments of FIGS. 4-6, or the tab portion may
comprise a single tab, having no slots separating the tab portion
into smaller individual tabs, all within the scope of the invention
as claimed. It will also be understood that alternatively, the tab
portion could optionally have cutout regions in one or more layers
of the shingle construction, exhibiting a dragon's tooth effect, in
a multilayer shingle, such cutout regions, when employed, being
present in at least a top layer and optionally through one or more
lower layers of the construction.
[0035] In accordance with this invention, the layer of granules
that is applied as an overlay to the rear surface of the shingle
layer can be less expensive granules, in that, because they would
not normally be directly exposed to the elements, including
sunlight, they need not be specially colored, nor have other
treatments, such as anti-fungal properties, ultraviolet resistance
properties, etc. This provides an economic benefit in the
manufacture of a shingle or shingle layer, while achieving an
increased thickness for that portion of a shingle/shingle layer
that is visible to an observer.
[0036] 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 invention as set forth in the
appended claims.
* * * * *