U.S. patent application number 13/155600 was filed with the patent office on 2011-09-29 for roofing shingle including sheet as headlap.
Invention is credited to James S. Belt, Bert W. Elliott.
Application Number | 20110232220 13/155600 |
Document ID | / |
Family ID | 38370418 |
Filed Date | 2011-09-29 |
United States Patent
Application |
20110232220 |
Kind Code |
A1 |
Belt; James S. ; et
al. |
September 29, 2011 |
ROOFING SHINGLE INCLUDING SHEET AS HEADLAP
Abstract
A roofing shingle including a buttlap portion and a headlap
portion is provided. The roofing shingle includes a coated mat
having a roofing mat coated with an organic-based coating material.
The coated mat has a width that extends entirely through the
buttlap portion and does not extend more than 20% into the headlap
portion of the roofing shingle. A water impermeable sheet is
adjacent to the coated mat. The sheet has a width that extends from
a head edge through at least 80% of the headlap portion and does
not extend to a butt edge of the roofing shingle. A nail zone
region is formed at an overlap of the coated mat and the water
impermeable sheet. The nail zone region is marked by a dissimilar
material.
Inventors: |
Belt; James S.; (Utica,
OH) ; Elliott; Bert W.; (Toledo, OH) |
Family ID: |
38370418 |
Appl. No.: |
13/155600 |
Filed: |
June 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11396498 |
Apr 3, 2006 |
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13155600 |
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11198522 |
Aug 5, 2005 |
7836654 |
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11396498 |
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Current U.S.
Class: |
52/521 |
Current CPC
Class: |
E04D 1/28 20130101; Y10T
428/24355 20150115; E04D 2001/005 20130101; E04D 1/26 20130101;
Y10T 428/24372 20150115 |
Class at
Publication: |
52/521 |
International
Class: |
E04D 1/26 20060101
E04D001/26 |
Claims
1. A roofing shingle including a buttlap portion and a headlap
portion, the roofing shingle comprising: a coated mat comprising a
roofing mat coated with an organic-based coating material, the
coated mat having a width that extends entirely through the buttlap
portion and does not extend more than 20% into the headlap portion
of the roofing shingle; and a water impermeable sheet adjacent to
the coated mat, the sheet having a width that extends from a head
edge through at least 80% of the headlap portion and does not
extend to a butt edge of the roofing shingle; wherein a nail zone
region is formed at an overlap of the coated mat and the water
impermeable sheet, and wherein the nail zone region is marked by a
dissimilar material.
2. The roofing shingle of claim 1, wherein the dissimilar material
is sand.
3. The roofing shingle of claim 1 wherein the coated mat has a
width that does not extend more than 10% into the headlap portion,
and the sheet has a width that extends through at least 90% of the
headlap portion of the roofing shingle.
4. The roofing shingle of claim 1 wherein the sheet is a
nonlaminated sheet made from plastic or metal.
5. The roofing shingle of claim 1, wherein the roofing shingle is a
first roofing shingle, and the first roofing shingle has a weight
reduction of at least about 25% compared to a second roofing
shingle identical to the first roofing shingle except that the
second roofing shingle does not include the water impermeable sheet
and the coated mat extends to the head edge of the roofing
shingle.
6. The roofing shingle of claim 5 wherein the first roofing shingle
has a weight reduction of at least about 40% compared to the second
roofing shingle.
7. The roofing shingle of claim 1 wherein the sheet does not have
an ionic charge.
8. The roofing shingle of claim 1, wherein the roofing shingle has
a limited width characterized by at least one of the following: (a)
the entire roofing shingle has a width of not more than about 17
inches (about 43 cm), (b) the buttlap portion of the roofing
shingle has a width of not more than about 7 inches (about 18 cm),
and (c) the sheet has a width of not more than about 8 inches
(about 20 cm).
9. A roofing shingle including a buttlap portion and a headlap
portion, the roofing shingle comprising: a coated mat comprising a
roofing mat coated with an organic-based coating material, the
coated mat having a width that extends entirely through the buttlap
portion and does not extend more than 20% into the headlap portion
of the roofing shingle; and a water impermeable sheet adjacent to
the coated mat, the sheet having a width that extends from a head
edge through at least 80% of the headlap portion and does not
extend to a butt edge of the roofing shingle; wherein a nail zone
region is formed at an overlap of the coated mat and the water
impermeable sheet, wherein the nail zone region is marked by a
dissimilar material, and wherein the nail zone region marked by the
dissimilar material is configured to form an area of reduced
thickness of the roofing shingle.
10. The roofing shingle of claim 9, wherein the dissimilar material
is sand.
11. The roofing shingle of claim 9 wherein the coated mat has a
width that does not extend more than 10% into the headlap portion,
and the sheet has a width that extends through at least 90% of the
headlap portion of the roofing shingle.
12. The roofing shingle of claim 9 wherein the sheet is a
nonlaminated sheet made from plastic or metal.
13. The roofing shingle of claim 9, wherein the roofing shingle is
a first roofing shingle, and the first roofing shingle has a weight
reduction of at least about 25% compared to a second roofing
shingle identical to the first roofing shingle except that the
second roofing shingle does not include the water impermeable sheet
and the coated mat extends to the head edge of the roofing
shingle.
14. The roofing shingle of claim 13 wherein the first roofing
shingle has a weight reduction of at least about 40% compared to
the second roofing shingle.
15. The roofing shingle of claim 9 wherein the sheet does not have
an ionic charge.
16. The roofing shingle of claim 9, wherein the roofing shingle has
a limited width characterized by at least one of the following: (a)
the entire roofing shingle has a width of not more than about 17
inches (about 43 cm), (b) the buttlap portion of the roofing
shingle has a width of not more than about 7 inches (about 18 cm),
and (c) the sheet has a width of not more than about 8 inches
(about 20 cm).
Description
RELATED APPLICATIONS
[0001] This application is a continuation of pending U.S. patent
application Ser. No. 11/396,498, filed Apr. 3, 2006, entitled
"Roofing Shingle Including Sheet as Headlap", which is a
continuation-in-part of U.S. patent application Ser. No. 11/198,522
filed Aug. 5, 2005, entitled "Shingle with Reinforced Nail Zone and
Method of Manufacturing", both of which are incorporated by
reference herein in its entirety.
TECHNICAL FIELD
[0002] This invention relates in general to the field of roof
coverings, and in particular the invention is useful in the
manufacture of asphalt-based roofing shingles.
BACKGROUND
[0003] Typical asphalt-based roofing shingles include a roofing mat
coated with asphalt and covered with a layer of roofing granules.
The shingles include a buttlap portion that is exposed when the
shingles are installed on a roof and a headlap portion that is
covered by the upper adjacent course of shingles when the shingles
are installed on a roof. Laminated roofing shingles also include an
overlay made from a second asphalt-coated mat on the buttlap
portion of the shingles.
[0004] U.S. Pat. No. 6,990,779 B2 to Kiik et al. (Elk Premium
Building Products) discloses a roofing system having alternating
courses of roofing shingles and interply material. The roofing
shingles are constructed to have a wider buttlap portion and a
narrower headlap portion. The interply material can be comprised of
a substrate having an ionic charge coated on both sides with a
coating having essentially the same ionic charge, and a water
impermeable plastic film or metal foil on one or both sides of the
coated substrate. A roofing shingle is commercially available from
Elk in which a sheet of interply material is attached to the
headlap portion of the shingle.
[0005] The following patents disclose metal or plastic sheets
attached to the buttlap portions of roofing shingles: U.S. Pat. No.
1,655,222; U.S. Pat. No. 1,799,500; U.S. Pat. No. 2,847,948; U.S.
Pat. No. 3,377,762; and U.S. Pat. No. 3,468,092.
SUMMARY OF THE INVENTION
[0006] The above objects as well as other objects not specifically
enumerated are achieved by a roofing shingle including a buttlap
portion and a headlap portion. The roofing shingle includes a
coated mat having a roofing mat coated with an organic-based
coating material. The coated mat has a width that extends entirely
through the buttlap portion and does not extend more than 20% into
the headlap portion of the roofing shingle. A water impermeable
sheet is adjacent to the coated mat. The sheet has a width that
extends from a head edge through at least 80% of the headlap
portion and does not extend to a butt edge of the roofing shingle.
A nail zone region is formed at an overlap of the coated mat and
the water impermeable sheet. The nail zone region is marked by a
dissimilar material.
[0007] According to this invention there is also provided a roofing
shingle including a buttlap portion and a headlap portion. The
roofing shingle includes a coated mat having a roofing mat coated
with an organic-based coating material. The coated mat has a width
that extends entirely through the buttlap portion and does not
extend more than 20% into the headlap portion of the roofing
shingle. A water impermeable sheet is adjacent to the coated mat.
The sheet has a width that extends from a head edge through at
least 80% of the headlap portion and does not extend to a butt edge
of the roofing shingle. A nail zone region is formed at an overlap
of the coated mat and the water impermeable sheet. The nail zone
region is marked by a dissimilar material. The nail zone region
marked by the dissimilar material is configured to form an area of
reduced thickness of the roofing shingle.
[0008] Various objects and advantages of this invention will become
apparent to those skilled in the art from the following detailed
description of the various embodiments, when read in light of the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a top view of a roofing shingle according to one
embodiment of the invention.
[0010] FIG. 2 is a cross-sectional view taken along line 2-2 of
FIG. 1.
[0011] FIG. 3 is a cross-sectional view taken along line 3-3 of
FIG. 1.
[0012] FIG. 4 is a cross-sectional view of a roofing shingle
according to an alternate embodiment of the invention.
[0013] FIG. 5 is a different cross-sectional view of the alternate
embodiment roofing shingle of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The roofing shingles of the invention can be laminated or
non-laminated (e.g., three-tab) shingles. As known in the roofing
industry, non-laminated shingles may be made with or without tabs,
and three-tab roofing shingles usually include three tabs in the
buttlap portion of the shingle and relatively narrow cutouts
between the tabs. Laminated roofing shingles usually include an
overlay that extends the entire width of the shingle and includes
relatively wide cutouts in the buttlap portion of the shingle, and
an underlay positioned below the overlay that extends the width of
the buttlap portion under the cutouts and a short distance into the
headlap portion of the shingle. Numerous alternate laminate
constructions are available, such as full length laminates,
trilaminates, and other constructions known to one skilled in the
art.
[0015] The buttlap is the portion of the roofing shingle that is
exposed when the shingle is installed on a roof, and the headlap is
the portion of the roofing shingle that is not exposed when the
shingle is installed on a roof because it is covered by the
adjacent upper row of shingles. On a laminated roofing shingle or a
three-tab roofing shingle, the buttlap portion usually extends
about to the inner edge of the cutouts. If the cutouts have
different widths, the buttlap portion usually extends about to the
inner edge of the cutout(s) with the largest width. The lower edge
of the roofing shingle is often referred to as the butt edge while
the upper edge of the shingle may be referred to as the head
edge.
[0016] As discussed below, a preferred roofing shingle of the
invention includes a coated roofing mat and a water impermeable
sheet. The term "roofing shingle", as used herein, includes the
sheet attached to the coated roofing mat, and it also includes an
assembly of the sheet and the coated roofing mat where the sheet is
adjacent to the mat but not attached to it. For example, the sheet
may be attached to the roof separately from the coated roofing mat
and/or it may be attached to the coated roofing mat when it is
installed on the roof. Alternatively, the sheet may be unattached
on the roof but held in place by the adjacent upper and lower
coated roofing mats or by other means. In an alternative
embodiment, the sheet comprises the reinforcement for the wide nail
zone, as described in copending application Ser. No.
11/198,522.
[0017] The coated roofing mat includes a roofing mat typically
coated with an organic-based coating material. The roofing mat can
be any type suitable for reinforcing the roofing shingle, such as a
web, scrim or felt of synthetic or natural fibrous materials,
including nonwoven or woven mats. The fibrous materials may
include, for example, mineral fibers, polymer fibers, carbon
fibers, cellulose fibers, rag fibers, or mixtures of these fibers.
Suitable mineral fibers may include fibers of a heat-softenable
mineral material, such as glass, ceramic, rock, slag, or basalt. In
one embodiment, the roofing mat is a nonwoven web of glass
fibers.
[0018] The organic-based coating material can be any type suitable
for use on a roofing shingle. Typically, the coating material is a
bituminous material and/or a polymeric material (e.g., a polymer, a
recycled polymer stream or ground tire rubber). Any type of
suitable bituminous material can be used, such as asphalt, tar,
pitch, or a mixture thereof. By "organic-based" is meant that the
organic material forms the continuous phase of the coating
material. The coating material usually includes at least about 20%
organic material by weight, and often at least about 40%. The
coating material can also include various additives and/or
modifiers, such as inorganic fillers or mineral stabilizers. In a
typical asphalt roofing shingle, the coating material includes
asphalt and a filler of finely ground inorganic particulate matter,
such as ground limestone, dolomite or silica, in an amount of from
about 40% to about 80% by weight of the coating material.
[0019] The water impermeable sheet can be any type suitable for use
on a roofing shingle. By "water impermeable" is meant that the
sheet forms a barrier that substantially prevents penetration by
water through the sheet during normal use of the roofing shingles
on a roof. Optionally, the water impermeability of the sheet can be
tested by any suitable method, for example, by placing 0.5 liter of
water at room temperature over a section of the sheet having an
area of 400 cm.sup.2, and observing no substantial penetration of
the sheet by the water after 24 hours. The sheet can have any
thickness suitable for providing the water barrier, although
relatively thin sheets are usually preferred for cost and weight
reduction. The term "sheet" includes films, membranes, tapes,
foils, and the like, usually in substantially continuous form.
Alternatively, the "sheet" may be formed on site by extruding a
polymer sheet, or by applying a liquid to the surface of the coated
mat 38 by rolling, spraying, or other known processes.
[0020] In some embodiments, the sheet is made from a polymer or a
metal. Any suitable polymer or mixture of different polymers can be
used to make the sheet. For example, the polymer can be a
polyolefin such as polypropylene, polyethylene, polybutene, or
polyisoprene. Some other examples of polymers that may be suitable
include polypropylene, polyethylene, polyester terephthalate,
polyester, polyethylene terephthalate, polyvinyl chloride, EPDM
(terpolymer elastomer made from ethylene-propylene diene monomer),
and other polymers and polymer blends known to one skilled in the
art. The polymer may be high or low density. A polymer sheet may
also include additives to improve the flame retardancy of the
sheet, as known to one skilled in the art. Furthermore, the sheet
materials can be chemically treated or surface charged to improve
properties.
[0021] Any suitable metal or combination of metals can be used to
make the sheet. Recycled metals can also be used. Some examples of
metals that may be suitable include aluminum and copper.
[0022] Preferably, the sheet is a nonlaminated sheet made from
polymer or metal. It is also preferred that the sheet does not have
an ionic charge.
[0023] The sheet may also be made from a roofing mat as described
above, provided the mat is made sufficiently water impermeable by
coating or other means.
[0024] In the embodiments of the invention where the sheet is
attached to the coated mat, these materials can be attached
together by any suitable means. For example, they can be attached
by the use of any suitable type of adhesive. Some examples of
adhesives that may be suitable include polymeric hot-melt adhesives
and modified asphalt hot-melt adhesives. Alternatively, the sheet
and the coated mat can be attached together by mechanical means
such as by sewing, stitching, stapling, or by the use of any other
suitable fasteners, or may be adhered to the coating material in
molten form.
[0025] The roofing shingles of the invention may provide advantages
compared to conventional shingles. In one embodiment of the
invention, roofing shingles are made in which the headlap portion
of a conventional shingle is mostly replaced with the water
impermeable sheet. The replacement of most of the headlap portion
may provide weight and cost advantages. A reduction in the weight
of the shingle could provide freight and installation benefits.
Replacing most of the headlap portion of the shingle could increase
the capacity of existing shingle manufacturing lines and reduce the
amount of raw material brought into a plant.
[0026] Referring now to the drawings, FIGS. 1-3 illustrate an
embodiment of the invention in which most of the headlap portion of
a conventional roofing shingle is replaced with the water
impermeable sheet. The roofing shingle 10 includes a buttlap
portion 12 with a butt edge 14 and a headlap portion 16 with a head
edge 18. The roofing shingle includes a coated mat 20 comprising a
roofing mat coated with an organic-based coating material. The
coated mat 20 has a width that extends entirely through the buttlap
portion 12 and preferably does not extend more than 20% into the
headlap portion 16 of the shingle. In some embodiments, the coated
mat 20 does not extend more than 15%, 10% or 5% of the distance
into the headlap portion 16. The roofing shingle 10 also includes a
water impermeable sheet 22 adjacent to the coated mat. The term
"adjacent", as used herein, includes overlapping or end-to-end.
Either the coated mat 20 or the sheet 22 can be on top when they
overlap. In the illustrated embodiment, the coated mat 20 and the
sheet 22 overlap a short distance into the headlap portion 16 of
the roofing shingle and they are attached together by an adhesive
24. The sheet 22 has a width that extends from the head edge 18
through at least 80% of the headlap portion 16 and does not extend
to the butt edge 14 of the roofing shingle. In some embodiments,
the sheet 22 extends through at least 85%, 90% or 95% of the
headlap portion 16. The illustrated roofing shingle is a laminated
shingle in which the coated mat 20 is the underlay, and the shingle
further includes an overlay in the form of a second coated mat 26
cut in a dragon-tooth pattern. In a laminated shingle, the end of
the sheet 22 could alternatively be attached between the overlay
and the underlay, although it is usually positioned either above
the overlay or below the underlay. Although the figures relate to a
laminated roofing shingle, the invention also includes
non-laminated roofing shingles as discussed above.
[0027] The second coated mat 26 is adhered to the first coated mat
20 using a laminate adhesive as is well known to one skilled in the
art. The shingle further includes a sealant, preferably a polymer
modified asphalt (PMA) such as described in commonly assigned U.S.
Pat. No. 4,824,880 to Algrim et al, which is incorporated herein by
reference in its entirety (the '880 patent). A preferred laminate
adhesive includes a polymer-modified asphalt, typically including
one or more styrene block polymer materials, such as those taught
in the sealant of the '880 patent. In a preferred embodiment, the
adhesive comprises less than ten percent by weight of polymer
material, up to sixty percent or more of a mineral filler, such as
limestone or dolomite, and the balance being primarily asphalt, and
may include additional other modifiers and such, including for
example extender oils, acid treatments and other known modifiers in
the asphalt industry. The filler percentage may be more or less,
depending on adhesive properties needed, but typically at least
about forty percent filler is desirable. For improved economy and
adhesion, more preferably, the polymer is less than six percent,
and even more preferably about four percent or less. As an
adhesive, it is preferable the asphalt has a penetration greater
than 8 dmm at 77 F and a softening point greater than 130 F, and
more preferably greater than 10 dmm pen. and 150 F SP.
[0028] The roofing shingles of the invention can also be
characterized in terms of their limited width. The roofing shingles
disclosed in U.S. Pat. No. 6,990,779 B2 (Elk) use conventional
width shingles but increase the width of the buttlap portion of the
shingles. Then an interply material is attached to the head edge of
the shingle. For purpose of comparison with the roofing shingles of
the invention, if the "shingle" disclosed in U.S. Pat. No.
6,990,779 is considered to be the combination of the roofing
shingle and the interply material, the shingle has a greatly
increased width compared to conventional shingles. In contrast, the
roofing shingles of the invention can replace most of the headlap
portion of the shingles with the water impermeable sheet, and
therefore the total width of the shingles is not greatly increased
compared to conventional shingles, and in some embodiments the
total width is the same as conventional shingles.
[0029] Thus, a preferred roofing shingle according to the invention
may have a limited width characterized by at least one of the
following: (a) the entire roofing shingle (including the coated mat
and the water impermeable sheet) has a width of not more than about
17 inches (about 43 cm), and preferably not more than about 15
inches (about 38 cm), (b) the buttlap portion of the roofing
shingle has a width of not more than about 7 inches (about 18 cm),
and preferably not more than 6 inches (about 15 cm), and (c) the
sheet has a width of not more than 8 inches (about 20 cm), and
preferably not more than 7 inches (about 18 cm). In some
embodiments, the limited width of the roofing shingle is
characterized by at least two of (a), (b) and (c), and in some
embodiments by all three of (a), (b) and (c). Alternatively, other
size shingles, such as larger format shingles, for example the
Berkshire.RTM. shingle sold by Owens Corning, can be made using the
present invention, using proportionally sized buttlap and sheet
materials.
[0030] Replacing most of the headlap portion of the roofing
shingles with the water impermeable sheet can allow shingles to be
made in which the overall weight of the shingles is decreased
compared to conventional shingles, in contrast to the roofing
shingles disclosed in U.S. Pat. No. 6,990,779 B2 which will be
increased in weight. For example, the roofing shingle may have a
weight reduction of at least about 25% compared to another roofing
shingle that is identical except that it does not include the water
impermeable sheet and the coated mat extends the full width of the
roofing shingle, and sometimes a weight reduction of at least about
40%.
[0031] While not illustrated in the Figures, the lower portion of
the sheet may be printed with lines or other markings to indicate a
preferred nail zone for attaching the shingle to the roof. Such a
nail zone is described in the '522 application. However, where the
sheet covers substantially the entire headlap area, a preferred
embodiment provides a nail zone between the bottom of the exposed
portion of the film and a line provided on the film parallel to the
bottom of the film (or other markings). Accordingly, the sheet
provides the function of the reinforcement described and claimed in
the '522 application. Alternatively, the film may be located above
the nail zone region, and a separate reinforcement applied to the
nail zone as described in the '522 application.
[0032] In yet another embodiment as shown in FIG. 2, a nail zone
may be formed at a portion of the roofing shingle where the coated
mat 20, second coated mat 26 and sheet 22 overlap. As shown in FIG.
2, the buttlap portion 12 of the roofing shingle 10 can be coated
with roofing granules. However, in this embodiment, the nail zone
region of the buttlap portion 12 may be marked by a dissimilar
material to indicate the nail zone region. The term "dissimilar
material", as used herein, is defined to mean a material having
different characteristics from the roofing granules covering the
buttlap portion 12 of the roofing shingle 10. Examples of
dissimilar materials include granules having a different color or
surface treatment, or another material, such as for example sand or
a lightweight material, or materials having a finer grade than the
roofing granules. Use of the dissimilar materials to mark the nail
zone region can result in a reduced thickness of the roofing
shingle 10 in the nail zone region, and can reduce the weight of
the shingle and improve the bundle flatness.
[0033] FIGS. 4-5 illustrate another embodiment of the invention in
which the buttlap portion of the roofing shingle is coated with
roofing granules, but the use of the water impermeable sheet allows
the shingles to be made without roofing granules on at least most
of the headlap portion of the shingles. The roofing shingle 30
includes a buttlap portion 32 with a butt edge 34 and a headlap
portion 36. The roofing shingle includes a coated mat 38 comprising
a roofing mat coated with an organic-based coating material. The
coated mat 38 has a width that extends entirely through the buttlap
32 and headlap 36 portions of the roofing shingle. A layer of
roofing granules 40 is adhered to the coating material in the
buttlap portion 32. However, the roofing granules are substantially
excluded in a non-granule area having a width that extends through
at least most (at least more than 50%, preferably at least more
than 80%) of the headlap portion 36. The roofing shingle also
includes the water impermeable sheet 42 adjacent to the coated mat
38. The sheet 42 has a width that extends entirely through at least
the non-granule area and does not extend to the butt edge 34 of the
roofing shingle. Although the sheet 42 is attached above the coated
mat 38 in the embodiment shown, alternatively it could be attached
below the coated mat. The illustrated roofing shingle is a
laminated shingle in which the coated mat 38 is the underlay, and
the shingle further includes an overlay in the form of a second
coated mat 44. Optionally, a UV resistant material could be added
to the coating in the headlap portion and/or a layer of backdust
material could be applied instead of roofing granules in the
non-granule area.
[0034] In an alternative embodiment, a shingle may comprise a strip
shingle, and the second coated mat 44 would not be present. In such
an embodiment, the buttlap portion of the sheet 38 would be covered
by granules (similar to that shown in the cutout areas shown in
FIG. 5 below the overlay 44). When a strip shingle comprises a
tabbed shingle, the sheet 42 must have a color and appearance which
is acceptable through the tab cutouts, and should include a UV
inhibitor.
[0035] In a further embodiment, the invention relates to a roofing
shingle including a buttlap portion with a butt edge and a headlap
portion. The roofing shingle includes a coated mat comprising a
roofing mat coated with an organic-based coating material. The
coated mat has a width that extends entirely through the buttlap
and headlap portions of the roofing shingle. The roofing shingle
also includes a layer of roofing granules adhered to the coating
material in the buttlap portion. However, the roofing granules are
substantially excluded in a non-granule area having a width that
extends through at least most of the headlap portion. The roofing
shingle further includes a water impermeable sheet adjacent to the
coated mat. The sheet has a width that extends through at least the
non-granule area and does not extend to the butt edge of the
roofing shingle.
[0036] It is known to include an adhesive material known as a
sealant on roofing shingles to seal the shingles together when they
are installed on a roof. For example, a typical laminated roofing
shingle includes a line of sealant on the back surface of the
shingle near the butt edge. When the next upper row of shingles is
installed on the roof, the upper shingles cover the headlap
portions of the lower shingles, and the sealant causes the back
surfaces of the upper shingles to adhere to the top surfaces of the
lower shingles. Sealing the shingles together on the roof helps to
prevent wind uplift of the shingles. The sealant can be any
suitable adhesive material, such as an adhesive made from asphalt,
a polymer, or a combination of asphalt and polymer. The sealant can
be applied in a discontinuous or continuous manner, and in any
suitable configuration, and alternatively may be applied to the
upper surface of the shingle to seal to the bottom of the adjacent
course of shingles.
[0037] Advantageously, the roofing shingles of the present
invention, and the reinforced nail zone shingles disclosed in U.S.
Ser. No. 11/198,522, can improve the wind resistance of the
shingles by improving the adhesion between the shingles when they
are sealed together on the roof. As described above, the shingles
of the present invention include a water impermeable sheet, such as
a polymer or metallic sheet, in the headlap portion of the shingle.
Similarly, the reinforced nail zone shingles include a
reinforcement member, typically made from a polymer, adhered to the
headlap portion of the shingle. The sheet or the reinforcement
member can be positioned on the shingle so that when the next upper
row of shingles is installed on the roof, the sealant on the back
of an upper shingle comes into contact with the sheet or
reinforcement member on the lower shingle. The sealant may adhere
better to a polymer or metallic material than to an asphalt-based
coating material with roofing granules on a typical roofing
shingle, and preferably the sealant comprises a polymer modified
asphalt sealant such as those taught in the '880 patent, or a
variation thereof. A preferred film for comprises a polymer having
good adhesion to a polymer modified asphalt, such as a surface
charged PET material. Additionally, the film may be mechanically
locked to the coated mat by physical overlap of granules (i.e. the
granules are preferably dropped onto the sheet after the film is
applied, and the granules are adhered to the molten organic-based
coating material, and a number of the granules will extend over the
film and mechanically lock the film, as the granule will be adhered
to the sheet by the organic-based coating material after
solidification) . One skilled in the art will further improve
adhesion of the film by applying pressure to the film at
application to imbed the film into the coating, as well as the
further mechanical interlock of the granules after the granules are
pressed into the sheet.
[0038] Thus, another embodiment of the invention relates to a
roofing shingle including a buttlap portion and a headlap portion.
The roofing shingle includes a coated mat comprising a roofing mat
coated with an organic-based coating material. A sealant is applied
on a back surface of the coated mat in the buttlap portion of the
roofing shingle. A reinforcement member or a water impermeable
sheet is attached to the coated mat and forms a top surface of the
roofing shingle that is located at least partly in the headlap
portion. The sealant and the reinforcement member or the water
impermeable sheet are positioned such that when a second identical
shingle is laid over the headlap portion of the shingle, the
sealant on the back surface of the second shingle comes into
contact with the reinforcement member or the water impermeable
sheet, thereby creating a strong bond between the shingles.
Preferably, the sealant forms a bond with the reinforcement member
or the water impermeable sheet that it at least twice as strong at
21.degree. C. as the bond between the sealant and an asphalt-based
coating material containing 40% asphalt and 60% ground limestone,
and more preferably at least three times as strong. To enhance the
bonding, in a preferred embodiment of the invention the sealant is
a polymer modified asphalt and/or the reinforcement member or the
water impermeable sheet is a polymer film. A specific example of a
preferred polymer film is a polyester terephthalate film.
[0039] In addition to the improved wind resistance caused by the
improved bonding between the shingles, the invention may also
provide other advantages. For example, the sealant may be able to
seal faster than a sealant on a conventional roofing shingle,
because a sealant to film bond is quicker than a sealant to
asphalt/granule bond. Preferably, the sealant is able to seal at
least 50% faster. The sealant may also be able to develop a
stronger bond at lower temperatures than a sealant on a
conventional roofing shingle.
[0040] In accordance with the provisions of the patent statutes,
the principle and mode of operation of this invention have been
explained and illustrated in its preferred embodiments. However, it
must be understood that this invention may be practiced otherwise
than as specifically explained and illustrated without departing
from its spirit or scope.
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