U.S. patent application number 11/594841 was filed with the patent office on 2008-06-12 for shingle with improved fastener pull-through resistance.
Invention is credited to Henry Koschitzky.
Application Number | 20080134612 11/594841 |
Document ID | / |
Family ID | 39367194 |
Filed Date | 2008-06-12 |
United States Patent
Application |
20080134612 |
Kind Code |
A1 |
Koschitzky; Henry |
June 12, 2008 |
Shingle with improved fastener pull-through resistance
Abstract
A laminated shingle resistant to fastener-head pull-through. The
shingle includes an upper layer having a tab portion and a headlap
portion, and a shim extending below the tab portion and part of the
headlap portion. The part of the shim behind the tab portion forms,
with the headlap portion, a dual thickness nailing zone. Since
roofers sometimes drive fasteners such as roofing nails through the
shingle behind the nailing zone, resulting in only a single layer
available to resist fastener-head pull-through, a reinforcing tape
which can have reinforcing strands is adhered to the bottom of the
headlap portion immediately behind the rear edge of the shim. This
effectively increases the size of the nailing zone without
incurring the bulk, weight and cost of increasing the size of the
shim.
Inventors: |
Koschitzky; Henry;
(Downsview, CA) |
Correspondence
Address: |
BERESKIN AND PARR
40 KING STREET WEST, BOX 401
TORONTO
ON
M5H 3Y2
omitted
|
Family ID: |
39367194 |
Appl. No.: |
11/594841 |
Filed: |
November 9, 2006 |
Current U.S.
Class: |
52/553 ;
52/518 |
Current CPC
Class: |
E04D 1/26 20130101; E04D
2001/005 20130101 |
Class at
Publication: |
52/553 ;
52/518 |
International
Class: |
E04D 1/28 20060101
E04D001/28; E04D 1/12 20060101 E04D001/12 |
Claims
1. A laminated shingle resistant to fastener-head pull-through,
comprising: a) an upper layer having a tab portion having a front
edge, and a headlap portion having a rear edge, b) the headlap
portion being adapted to be covered by another shingle and the tab
portion being adapted to be exposed to the elements, c) the tab
portion comprising a plurality of tabs separated by spaces, the
spaces having rear ends, d) a lower layer located below said upper
layer and extending from approximately said front edge of said
upper layer to a position rearwardly of the rear edges of said
spaces but forwardly of the rear edge of said upper layer, said
lower layer defining with said upper layer a fastening zone of dual
thickness for receiving fasteners having heads to hold said shingle
on a roof, said fastening zone coinciding with part of said headlap
portion, e) and a reinforcing tape extending longitudinally of said
shingle over at least a portion of said headlap portion rearwardly
of said fastening zone, said tape being resistant to the head of a
fastener being pulled therethrough, so that if a fastener is driven
into said headlap portion rearwardly of said fastening zone, then
if a wind pulls said shingle upwardly, said tape will resist the
tendency of said shingle to pull past the head of said
fastener.
2. A shingle according to claim 1 wherein said upper layer has a
lower surface, and said tape is self-adhesive and is adhered to the
lower surface of said upper layer.
3. A shingle according to claim 2 wherein said tape has a front
edge which is located immediately rearwardly of the rear edge of
said lower layer.
4. A shingle according to claim 1 wherein said upper layer has an
upper surface, and wherein said tape is positioned on or near said
upper surface.
5. A shingle according to claim 4 wherein said tape extends
forwardly to said rear ends of said spaces.
6. A shingle resistant to fastener head pull-through, comprising:
(a) a layer having a tab portion having a front edge, and a headlap
portion having a rear edge, (b) the headlap portion being adapted
to be covered by another shingle and the tab portion being adapted
to be exposed to the elements, c) the tab portion comprising a
plurality of tabs separated by spaces, the spaces having rear ends,
(d) said layer having a fastening zone extending from approximately
the rear ends of said spaces rearwardly, said fastening zone having
a rear edge spaced forwardly of the rear edge of said headlap
portion, said fastening zone being adapted to receive fasteners
having heads to hold said shingle on a roof, (e) and a reinforcing
tape extending longitudinally of said shingle over at least a
portion of said headlap portion in said fastening zone, said
reinforcing tape extending rearwardly of the rear edge of said
fastening zone and not extending forwardly of the rear ends of said
spaces, said tape being resistant to the head of a fastener passing
therethrough.
7. A shingle according to claim 6 wherein said reinforcing tape is
located on a lower surface of said shingle.
8. A shingle according to claim 6 wherein said reinforcing tape is
inset into an upper surface of said shingle.
9. A shingle resistant to fastener-head pull-through, comprising:
(a) a layer having a front portion and a headlap portion behind
said front portion, said front portion having a front edge, said
headlap portion having a rear edge, and there being a dividing line
between said front portion and said headlap portion, (b) the
headlap portion being adapted to be covered by another shingle, and
the front portion being adapted to be exposed to the elements, (c)
said layer having a fastening zone extending from said dividing
line rearwardly, said fastening zone having a rear edge spaced
forwardly of the rear edge of said headlap portion, said fastening
zone being adapted to receive fasteners having heads to hold said
shingle on a roof, (d) and a reinforcing tape extending
longitudinally of said shingle over at least a portion of said
headlap portion in said fastening zone, said reinforcing tape
extending rearwardly of the rear edge of said fastening zone and
not extending forwardly of said dividing line, said tape being
resistant to the head of a fastener passing there through.
10. A shingle according to claim 9 wherein said reinforcing tape is
located on a lower surface of said shingle.
11. A shingle according to claim 9 wherein said reinforcing tape is
set into an upper surface of said shingle.
Description
FIELD OF THE INVENTION
[0001] This invention relates to shingles which have improved
resistance to pull-through of the heads of nails or other fasteners
securing the shingles to a roof or to other surfaces.
BACKGROUND OF THE INVENTION
[0002] When shingles installed on a roof are subjected to high
winds, the winds tend to bend the front or tab part of the shingles
upwardly and may tear the shingles off the roof. This has been a
long-standing problem, and various attempts have been made to
prevent this undesirable event from occurring.
[0003] For example, in Venrick U.S. Pat. No. 2,161,440, issued Jun.
6, 1939, reinforcing strips are placed on the underside (or even on
the upper surface) of shingles, to (among other things) increase
the resistance of the shingles to being bent upwardly by the
wind.
[0004] In Kalkanoglu et al. U.S. Pat. No. 6,758,019, a reinforcing
layer is attached to the rear surface of the shingle below the nail
fastening zone, again to increase the resistance of the shingle
against having its lower edge bent upwardly by the wind.
[0005] Approaches such as those described in the above patents can
be costly, and may add undesired bulk to the shingle, and do not
adequately deal with another problem, namely, that when shingles
are pulled upwardly by the wind (whether or not they are bent), the
heads of the roofing nails or other fasteners securing the shingles
to a roof tend to pull through the shingle material, causing
failure of the shingle.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention, in one
of its aspects, to provide a shingle with improved resistance
against fastener pull-through.
[0007] In one aspect the invention provides a laminated shingle
with improved resistance to fastener-head pull-through,
comprising:
[0008] a) an upper layer having a tab portion having a front edge,
and a headlap portion having a rear edge,
[0009] b) the headlap portion being adapted to be covered by
another shingle and the tab portion being adapted to be exposed to
the elements,
[0010] c) the tab portion comprising a plurality of tabs separated
by spaces, the spaces having rear ends,
[0011] d) a lower layer located below said upper layer and
extending from approximately said front edge of said upper layer to
a position rearwardly of the rear edges of said spaces but
forwardly of the rear edge of said upper layer, said lower layer
defining with said upper layer a fastening zone of dual thickness
for receiving fasteners having heads to hold said shingle on a
roof, said fastening zone coinciding with part of said headlap
portion,
[0012] e) and a reinforcing tape extending longitudinally of said
shingle over at least a portion of said headlap portion rearwardly
of said fastening zone, said tape being resistant to the head of a
fastener being pulled therethrough, so that if a fastener is driven
into said headlap portion rearwardly of said fastening zone, then
if a wind pulls said shingle upwardly, said tape will resist the
tendency of said shingle to pull past the head of said
fastener.
[0013] Further objects and advantages of the invention will appear
from the following description, taken together with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In the drawings:
[0015] FIG. 1 is a perspective view of a shingle according to the
invention;
[0016] FIG. 2 is an end cross-sectional view of the shingle of FIG.
1;
[0017] FIG. 3 is a plan view of a tape used in the FIGS. 1 and 2
shingle;
[0018] FIG. 4 is an end view of a modified shingle according to the
invention;
[0019] FIG. 5 is a perspective view of a further modified shingle
according to the invention;
[0020] FIG. 6 is an end view of another modified shingle according
to the invention;
[0021] FIG. 7 is a perspective view of another modified shingle
according to the invention; and
[0022] FIG. 8 is an end view of the shingle of FIG. 7.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] Reference is first made to FIGS. 1 and 2, which show a
shingle 10 having an upper layer 11. The upper layer 11 includes a
set of tabs 12 which will be exposed to the elements when the
shingle is properly installed on a roof, and a headlap portion 14
which is intended to be covered by another shingle when the shingle
10 is installed on a roof. The tabs 12 are covered by protective
granules, as is well known, to protect them against the sun.
[0024] The shingle 10 has the appearance of a typical laminated
shingle, with the tabs 12 being separated by spaces 16. To provide
a laminated appearance, as well as necessary protection against the
elements, the shingle 10 includes a lower layer or shim 20, which
extends from the front edge 22 of the shingle rearwardly to a shim
rear edge 24 spaced rearwardly of the rear ends 26 of the spaces
16. However, the rear edge 24 of the shim 20 is located well
forwardly of the rear edge 30 of the headlap portion 14 of the
upper layer 11.
[0025] The upper layer 11 and shim 20 together define a nailing
zone 34, which extends from the rear ends 26 of the spaces 16 to
the rear edge 24 of the shim 20. If desired, e.g. for esthetic
reasons, the front edge 35 of the nailing zone 34 can be spaced
slightly rearwardly of the rear ends of the spaces 16.
[0026] The nailing zone 34 is a zone of dual thickness. Roofers who
install the shingles are instructed to drive their roofing
fasteners, here shown as roofing nails 38, through the nailing zone
34, where the fasteners' shanks will extend through two layers of
the shingle, namely, the upper layer 11 and the shim 20. If the
nails are installed correctly, then if and when a wind bends or
pulls the front edge 22 of the shingle upwardly, overcoming other
shingle features like an adhesive dot or layer added to the
underside of upper layer 11 or to the upper surface of shim 20 to
resist lifting during wind actions, then the two layer thickness of
the nailing zone 34 will provide increased resistance against the
shingle material being pulled through or over the heads 36 of the
roofing nails 38 used to attach the shingles to the roof. (The
nailing zone 34 and nails 38 in use are normally covered by the
shim and tabs of another adjacent shingle on the roof.) Thus, the
nailing zone 34 coincides with part of the headlap portion 14.
[0027] Unfortunately, roofers are sometimes careless and tend to
drive roofing nails or other fasteners through or into the headlap
portion 14 rearwardly of the nailing zone 34. This can happen even
if lines are marked in the shingle to define the nailing zone.
Nails improperly installed in this way extend only through a single
layer of the shingle, namely, the part of the headlap 14 behind
shim 20, so if a wind or other environmental force (e.g. freeze and
thaw cycles) pulls the shingle upwardly, there is only a single
layer which will resist the pull-through of the nail-heads 36 to
cause removal of the shingle from the roof. (This may be termed
"nail-head pull-through", meaning that the nail-heads are in effect
being pulled through the shingle as the shingle is lifted by the
wind. It will be realized that in this process, the nail-heads are
generally stationary or fixed and the shingles move.) Thus, failure
of the shingle is more likely to occur if the nails are not
accurately placed.
[0028] Therefore, the invention in a preferred embodiment provides
a layer of thin, strongly adhesive tape 42 extending along the
lower surface of the upper layer 11. The front edge 43 of tape 42
is located immediately rearwardly of the rear edge 24 of the shim
and hence immediately rearwardly of the normally defined nailing
zone 34. The tape 42 may typically be a conventional strong
packaging tape of the kind used by stores and movers to seal boxes.
The tape 42 is preferably strongly self-adhesive so that it adheres
firmly to the lower surface of the upper layer 11 with strong
resistance to being pulled off. The tape 42 may be fiber
reinforced, with reinforcing strands running in multiple directions
(e.g. cross-wise and lengthwise of the tape) as shown at 44, 46 in
FIG. 3. With the reinforcing strands 44, 46, which are preferably
closely spaced, the tape 42 will be resistant to tearing.
Therefore, when the shingle experiences a lifting force from the
wind, the tape 42 will strongly resist being pulled past the
nail-heads 36. However, when the nails 38 are applied to install
the shingle, if the tip of a nail encounters a strand, then because
the nail tip is tapered, the strand will simply move to one side
allowing the nail to penetrate the tape 42. The strands 44, 46 may
be of any conventional strong material used in packaging tape.
[0029] Because the tape 42 is located rearwardly of the nailing
zone 34, the nailing zone is effectively made wider without the
need for extending the shim 20 rearwardly. Therefore, increased
resistance against nail-head pull-through, and against shingle
loosening and tearing, is provided, while avoiding the increased
weight and greater bulk of a larger shim which could otherwise need
to be used to achieve these objectives. The ability to use a
smaller shim facilitates shipping, storage and handling of the
shingles (they can be thinner over part of their width, and lighter
then would otherwise be necessary), and also reduces cost since a
larger shim would normally be more expensive then applying the tape
42.
[0030] Although the reinforcement against nail-head pull-through
has been shown as a tape 42 applied to the undersurface of the
upper layer 11, if desired the tape 42 can be embedded in the upper
layer 11 during manufacturing of the upper layer, e.g. before the
mat which forms the upper layer 11 is impregnated with asphalt.
Alternatively, the tape 42 may be of an open weave construction so
that it can sink into the hot asphalt which is applied to the top
and bottom of the shingles during manufacturing and so that the
tape 42 will be embedded in the upper layer 11 (either near the top
or the bottom thereof). In that case, the tape 42 need not be
self-adhesive.
[0031] Although it has been assumed that the shingles 10 are
fastened to the roof with nails, other types of fasteners can be
used, e.g. screws, or staples, brads or a combination of screws,
nails, brads and staples.
[0032] The tape 42 can be any woven or non-woven, or rolled or
extruded, material, so long as it is a strip of strong material. If
desired, when the tape 42 is placed on or near the top of upper
layer 11, then the tape 42 can extend forwardly across all or part
of the nailing zone 34, as shown at 42' in FIG. 4, where primed
reference numerals indicate parts corresponding to those of FIGS. 1
to 3. An advantage of this is that tape 42' provides increased
resistance against shingle tearing and nail-head pull-through even
when the nails are correctly installed in nailing zone 34' since
there are now two shingle layers plus a third layer (the tape
layer) to resist nail-head pull-through. Of course the wider tape
42' adds cost over the tape 42, but if the tape 42' is on the upper
surface of upper layer 11, then the granules normally used on
shingle surfaces (for ultra-violet protection) will not or may not
stick to tape 42'. Therefore fewer granules are needed for the
shingle 10', thus reducing the cost of the shingle.
[0033] If desired, the tape 42 can be attached to the underside of
layer 11 and tape 42' on the topside of layer 11 simultaneously.
This provides two extra layers to resist shingle tearing and nail
or fastener-head pull-through.
[0034] This invention applies equally to shingles made of oxidized
asphalt or modified asphalt, or shingles made from a combination of
both. Since shingles made with modified asphalt are soft, this
invention adds extra protection for such products.
[0035] While the invention has been described as applying to
laminated shingles, it will be realized that it also applies to
specialty shingles, such as hip and ridge shingles, which can be
exposed to similar wind forces and actions. Since hip and ridge
shingles are sometimes made with modified forms of asphalt, this
invention adds extra protection for such products.
[0036] In another aspect, the invention provides improved
resistance against fastener head pull-through for a single layer
shingle, as shown in FIG. 5, where double primed reference numerals
indicate parts corresponding to those of FIGS. 1 to 4. FIG. 5 shows
a single layer shingle 10'', corresponding to the upper layer 11
and 11' of FIGS. 1 to 4. As before, the shingle 10'' has a set of
tabs 12'' at its front and a rear headlap portion 14'' which will
be covered by another shingle. Since there is no shim, a nailing
zone 34'' is somewhat arbitrarily marked on the upper surface of
the shingle 10''. The front edge 50 of the nailing zone 34'' is
located at the rear ends 26'' of the tab spaces 16''. The rear edge
52 of the nailing zone 34'' is spaced rearwardly from the front
edge 50. Preferably the nailing zone 34'' does not extend too far
rearwardly on the shingle, to reduce the leverage which upwardly
directed wind generated forces may have on the fasteners applied to
the nailing zone 34''.
[0037] In the same manner as described previously, a reinforcing
tape 42'' may be adhered or otherwise fastened to the bottom
surface of the shingle 10''. The front edge 54 of the reinforcing
tape 42'' should not extend forwardly of the read ends 26'' of the
spaces 16'', since the spaces 16'' should not be blocked. The rear
edge 56 of the reinforcing tape 42'' extends rearwardly of the rear
edge 52 of the nailing zone 34''.
[0038] Thus, when a roofer drives fasteners such as roofing nails
into the nailing zone 34'', then if the roofer is careless and
positions some fasteners slightly rearwardly of the rear edge 52 of
the nailing zone, these fasteners will penetrate reinforcing tape
42'', which will offer resistance to fastener head pull-through.
Therefore, the tape 42'' offers the dual advantage of insuring that
there are two layers in the area of the nailing zone to resist
fastener head pull-through, and that in an area behind the nailing
zone 34'', there are still two layers to resist fastener head
pull-through. Therefore the nailing zone 34 has been effectively
widened in a light, cost-effective manner, and without interfering
with the tabs 12''.
[0039] While the reinforcing tape 42'' has been shown in FIG. 5 as
located on the bottom surface of the shingle 10'', it may instead
be located on the top surface of the shingle, as shown in FIG. 6
where triple primed reference numerals indicate parts corresponding
to those of the previous figures. Preferably the tape 42''' is
inset into the upper surface of shingle 10''' so as not to create a
"bump" in the upper surface of the shingle. As before, the tape
42''' does not extend forwardly of the rear ends 26''' of the tab
spaces, but does extend rearwardly of the rear edge 52''' of the
nailing zone 34'''. As before, this increases the width of the
nailing zone in a front to rear direction and adds an extra layer
(which is thin and strong) to resist fastener head
pull-through.
[0040] In some specialty single layer shingles, there may be no
tabs, in which case the shingle will simply be a single layer sheet
without cutouts, as shown at 10'''' in FIGS. 7 and 8 (where
quadruple primed marks indicate parts corresponding to those of
FIGS. 1 to 6). The shingle 10'''' comprises a single sheet 11''''
having a front portion 60 covered by protective granules 62, and a
headlap portion 14'''' which is normally covered by another shingle
when the shingle 10'''' is installed on a roof. The headlap portion
14'''' includes at its front a nailing zone 34'''', as before.
[0041] As in the FIGS. 5 and 6 embodiment, a reinforcing tape
42'''' is adhered or otherwise fastened to the bottom surface of
the shingle 10''''. The front edge 54'''' of the reinforcing tape
42'''' should not extend forwardly of the nailing zone, since the
portion of the shingle forwardly of the nailing zone 34'''' is
exposed to the elements and therefore should not have nails or
other fasteners driven through it. However, the rear edge 56'''' of
the reinforcing tape 42'''' extends rearwardly of the rear edge
52'''' of the nailing zone 34''''.
[0042] Therefore, as in the FIGS. 5 and 6 embodiments, if the
roofer is careless and positions some fasteners slightly rearwardly
of the rear edge 52'''' of the nailing zone, these fasteners will
penetrate the reinforcing tape which will offer resistance to
fastener-head pull-through. Therefore, the tape 42'''' again offers
the dual advantage of ensuring that there are two layers in the
area of the nailing zone to resist fastener-head pull-through, and
that in an area behind the nailing zone 34'''', there are still two
layers to resist fastener-head pull-through.
[0043] If desired, the tape 42'''' may be located on the top
surface of the shingle, in the same manner as shown in FIG. 6.
[0044] While preferred embodiments of the invention have been
described, modifications may be made if desired.
* * * * *