U.S. patent application number 13/193900 was filed with the patent office on 2011-11-24 for method of manufacturing a shingle.
This patent application is currently assigned to OWENS CORNING INTELLECTUAL CAPITAL, LLC. Invention is credited to David P. Aschenbeck, James S. Belt, Bert W. Elliott, Barry M. Lewis, Stephanie A. Rinne, Michael S. Ugorek, Donn Vermilion.
Application Number | 20110283646 13/193900 |
Document ID | / |
Family ID | 44971269 |
Filed Date | 2011-11-24 |
United States Patent
Application |
20110283646 |
Kind Code |
A1 |
Vermilion; Donn ; et
al. |
November 24, 2011 |
METHOD OF MANUFACTURING A SHINGLE
Abstract
A roofing shingle includes a headlap portion and a tab portion.
A layer of a first granular material is adhered to a back side of
the headlap portion and defines a first surface. A bead of tab
sealant extends longitudinally on a back side of the tab portion. A
longitudinally extending groove is formed in the first surface of
the back side of the headlap portion.
Inventors: |
Vermilion; Donn; (Newark,
OH) ; Rinne; Stephanie A.; (Granville, OH) ;
Ugorek; Michael S.; (New Albany, OH) ; Belt; James
S.; (Utica, OH) ; Elliott; Bert W.; (Ottawa
Hills, OH) ; Aschenbeck; David P.; (Newark, OH)
; Lewis; Barry M.; (Newark, OH) |
Assignee: |
OWENS CORNING INTELLECTUAL CAPITAL,
LLC
Toledo
OH
|
Family ID: |
44971269 |
Appl. No.: |
13/193900 |
Filed: |
July 29, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13155600 |
Jun 8, 2011 |
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13193900 |
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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: |
52/539 |
Current CPC
Class: |
E04D 2001/005 20130101;
E04D 1/26 20130101 |
Class at
Publication: |
52/539 |
International
Class: |
E04D 1/00 20060101
E04D001/00 |
Claims
1. A roofing shingle comprising: a headlap portion and a tab
portion, a layer of a first granular material adhered to a back
side of the headlap portion and defining a first surface; a bead of
tab sealant extending longitudinally on a back side of the tab
portion; and a longitudinally extending groove formed in the first
surface of the back side of the headlap portion.
2. The roofing shingle according to claim 1, wherein the
longitudinally extending groove is defined by a second granular
material having a granule size relatively smaller than the first
granular material.
3. The roofing shingle according to claim 2, wherein the second
granular material is formed from sand.
4. The roofing shingle according to claim 2, wherein the second
granular material is formed from materials having a finer grade
than the first granular material.
5. The roofing shingle according to claim 1, wherein the
longitudinally extending bead of tab sealant and the longitudinally
extending groove are configured such that when a plurality of the
roofing shingles are stacked in a bundle such that every other of
the roofing shingles is inverted and turned 180 degrees relative to
an adjacent one of the roofing shingles, the bead of tab sealant
aligns with and nests within the longitudinally extending groove of
an adjacent one of the roofing shingles.
6. The roofing shingle according to claim 5, wherein leading and
trailing edges of the roofing shingles define edge zones of the
bundle, wherein the nesting of the bead of tab sealant within the
longitudinally extending groove of the stacked shingles results in
the edge zones of the bundle having a height substantially
identical to a height of a remainder of the bundle outside of edge
zones.
7. The roofing shingle according to claim 1, further including a
strip of material disposed within the longitudinally extending
groove.
8. The roofing shingle according to claim 7, wherein the strip of
material is formed from compressible material.
9. The roofing shingle according to claim 8, wherein the
longitudinally extending bead of tab sealant and the strip of
material are configured such that when a plurality of the roofing
shingles are stacked in a bundle such that every other of the
roofing shingles is inverted and turned 180 degrees relative to an
adjacent one of the roofing shingles, the bead of tab sealant
aligns with and engages the strip of material of an adjacent one of
the roofing shingles.
10. The roofing shingle according to claim 9, wherein when the
plurality of the roofing shingles are stacked in the bundle, an
outwardly facing surface of the strip of material is compressed by
the bead of tab sealant of an adjacent one of the roofing shingles
and defines a groove within the strip of material, and wherein the
bead of tab sealant nests within the groove formed within the strip
of material of an adjacent one of the roofing shingles.
11. The roofing shingle according to claim 10, wherein leading and
trailing edges of the roofing shingles define edge zones of the
bundle, and wherein the nesting of the bead of tab sealant within
the groove formed within the strip of material of an adjacent one
of the roofing shingles results in the edge zones of the bundle
having a height substantially identical to a height of a remainder
of the bundle outside of edge zones.
12. The roofing shingle according to claim 1, wherein the groove
has a width within the range of from about 0.0625 inches to about
0.25 inches larger than a width of the bead of tab sealant.
13. A roofing shingle comprising: a headlap portion and a tab
portion, a layer of a first granular material adhered to a back
side of the headlap portion and defining a first surface; a bead of
tab sealant extending longitudinally on a back side of the tab
portion; and a longitudinally extending groove formed in the first
surface of the back side of the headlap portion, wherein the
longitudinally extending groove is defined by a second granular
material having a granule size relatively smaller than the first
granular material, wherein the longitudinally extending bead of tab
sealant and the longitudinally extending groove are configured such
that when a plurality of the roofing shingles are stacked in a
bundle such that every other of the roofing shingles is inverted
and turned 180 degrees relative to an adjacent one of the roofing
shingles, the bead of tab sealant aligns with and nests within the
longitudinally extending groove of an adjacent one of the roofing
shingles, wherein leading and trailing edges of the roofing
shingles define edge zones of the bundle, and wherein the nesting
of the bead of tab sealant within the longitudinally extending
groove of the stacked shingles results in the edge zones of the
bundle having a height substantially identical to a height of a
remainder of the bundle outside of edge zones.
14. A roofing shingle comprising: an overlay sheet including a
headlap portion and a tab portion, a layer of a first granular
material adhered to a back side of the headlap portion and defining
a first surface; an underlay sheet secured to the overlay sheet
such that a region of the underlay sheet overlaps a region of the
headlap portion of the overlay sheet, thereby defining a two-layer
portion and a single-layer portion of the roofing shingle; a bead
of tab sealant extending longitudinally on a back side of the
underlay sheet; and a longitudinally extending groove formed in the
first surface of the back side of the headlap portion.
15. The roofing shingle according to claim 14, wherein the
longitudinally extending groove is defined by a second granular
material having a granule size relatively smaller than the first
granular material.
16. The roofing shingle according to claim 15, wherein the second
granular material is formed from sand.
17. The roofing shingle according to claim 15, wherein the second
granular material is formed from materials having a finer grade
than the first granular material.
18. The roofing shingle according to claim 14, wherein the
longitudinally extending bead of tab sealant and the longitudinally
extending groove are configured such that when a plurality of the
roofing shingles are stacked in a bundle such that every other of
the roofing shingles is inverted and turned 180 degrees relative to
an adjacent one of the roofing shingles, the bead of tab sealant
aligns with and nests within the longitudinally extending groove of
an adjacent one of the roofing shingles.
19. The roofing shingle according to claim 18, wherein leading and
trailing edges of the roofing shingles define edge zones of the
bundle, wherein the nesting of the bead of tab sealant within the
longitudinally extending groove of the stacked shingles results in
the edge zones of the bundle having a height substantially
identical to a height of a remainder of the bundle outside of edge
zones.
20. The roofing shingle according to claim 14, further including a
strip of material disposed within the longitudinally extending
groove.
21. The roofing shingle according to claim 20, wherein the strip of
material is formed from compressible material.
22. The roofing shingle according to claim 21, wherein the
longitudinally extending bead of tab sealant and the strip of
material are configured such that when a plurality of the roofing
shingles are stacked in a bundle such that every other of the
roofing shingles is inverted and turned 180 degrees relative to an
adjacent one of the roofing shingles, the bead of tab sealant
aligns with and engages the strip of material of an adjacent one of
the roofing shingles.
23. The roofing shingle according to claim 22, wherein when the
plurality of the roofing shingles are stacked in the bundle, an
outwardly facing surface of the strip of material is compressed by
the bead of tab sealant of an adjacent one of the roofing shingles
and defines a groove within the strip of material, and wherein the
bead of tab sealant nests within the groove formed within the strip
of material of an adjacent one of the roofing shingles.
24. The roofing shingle according to claim 23, wherein leading and
trailing edges of the roofing shingles define edge zones of the
bundle, and wherein the nesting of the bead of tab sealant within
the groove formed within the strip of material of an adjacent one
of the roofing shingles results in the edge zones of the bundle
having a height substantially identical to a height of a remainder
of the bundle outside of edge zones.
25. The roofing shingle according to claim 14, wherein the groove
has a width within the range of from about 0.0625 inches to about
0.25 inches larger than a width of the bead of tab sealant.
Description
RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part of pending U.S.
patent application Ser. No. 13/155,600, filed Jun. 8, 2011,
entitled "Roofing Shingle Including Sheet as Headlap," which 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. Pat. No.
7,836,654 filed Aug. 5, 2005, entitled "Shingle with Reinforced
Nail Zone and Method of Manufacturing", all of which are
incorporated by reference herein in their entirety.
BACKGROUND
[0002] 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.
[0003] Asphalt-based roofing materials, such as roofing shingles,
roll roofing, and commercial roofing, are installed on the roofs of
buildings to provide protection from the elements, and to give the
roof an aesthetically pleasing appearance. Typically, the roofing
material is constructed of a substrate such as a glass fiber mat or
an organic felt, an asphalt coating on the substrate, and a surface
layer of granules embedded in the asphalt coating.
[0004] A common method for the manufacture of asphalt shingles is
the production of a continuous sheet of asphalt material followed
by a shingle cutting operation which cuts the material into
individual shingles. In the production of asphalt sheet material,
either a glass fiber mat or an organic felt mat is passed through a
coater containing hot liquid asphalt filled with limestone to form
a tacky, asphalt coated sheet. Subsequently, the hot asphalt coated
sheet is passed beneath one or more granule applicators which
discharge protective and decorative surface granules onto portions
of the asphalt sheet material.
[0005] 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," in order to make installation of roofs
using shingles, such as laminated shingles, more efficient and
secure. One or more lines or other indicia painted or otherwise
marked longitudinally on the surface of the shingle may define such
a nail zone. It is especially desired that the shingles define a
nail zone to guide installers in the placement of nails.
[0006] Additionally, shingles may experience lift in high wind
situations. This lift may be exacerbated if the shingle tabs are
not sealed or adhered to the shingle below. Therefore, there is
also a need for shingles that have a sufficiently high nail
pull-through value so that the installed shingles have improved
performance in high wind situations.
[0007] After manufacture, laminated shingles may be packaged in a
stack or bundle. The laminated shingles are often stacked by
turning every other shingle 180 degrees relative to the adjacent
shingles. This stacking method minimizes uneven build in the bundle
caused by the difference in thickness between the area of the
shingle that includes the underlay and the area that does not
include the underlay. However, stacking the shingles in this manner
may result in an undesirable thickness along the central area of
the bundle because the longitudinal central areas of the shingles
are double-layered and the cutout areas of the shingles on the
sides of the central areas are single-layered. The difference in
thickness causes an unsightly 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 may cause
unsightly pallet build, instability of the stacked bundles, and
high contact pressures at the intersections of the overlapping
bundles. The high contact pressures may cause shingle deformation
and sticking between individual shingles.
[0008] This undesirable thickness or humping in a bundle of
shingles is not limited to laminated shingles. Both laminated
shingles and single-layered, such as "three-tab" shingles, often
include a sealant bead at an edge of the shingle to seal or adhere
the tabs of one course of shingles to an adjacent overlapping
course of shingles when the shingles are installed on a roof. The
added thickness of the sealant beads may also cause undesirable
thickness or humping along the edges of the bundle of shingles.
SUMMARY OF THE INVENTION
[0009] The present application describes various embodiments of a
roofing shingle. One embodiment of the roofing shingle includes a
headlap portion and a tab portion. A layer of a first granular
material is adhered to a back side of the headlap portion and
defines a first surface. A bead of tab sealant extends
longitudinally on a back side of the tab portion. A longitudinally
extending groove is formed in the first surface of the back side of
the headlap portion.
[0010] In another embodiment, the roofing shingle includes a
headlap portion and a tab portion. A layer of a first granular
material is adhered to a back side of the headlap portion and
defines a first surface. A bead of tab sealant extends
longitudinally on a back side of the tab portion. A longitudinally
extending groove is formed in the first surface of the back side of
the headlap portion, wherein the longitudinally extending groove is
defined by a second granular material having a granule size
relatively smaller than the first granular material. The
longitudinally extending bead of tab sealant and the longitudinally
extending groove are configured such that when a plurality of the
roofing shingles are stacked in a bundle such that every other of
the roofing shingles is inverted and turned 180 degrees relative to
an adjacent one of the roofing shingles, the bead of tab sealant
aligns with and nests within the longitudinally extending groove of
an adjacent one of the roofing shingles. Leading and trailing edges
of the roofing shingles define edge zones of the bundle. The
nesting of the bead of tab sealant within the longitudinally
extending groove of the stacked shingles results in the edge zones
of the bundle having a height substantially identical to a height
of a remainder of the bundle outside of edge zones.
[0011] In a further embodiment, the roofing shingle includes an
overlay sheet having a headlap portion and a tab portion. A layer
of a first granular material adhered to a back side of the headlap
portion and defining a first surface. An underlay sheet is secured
to the overlay sheet such that a region of the underlay sheet
overlaps a region of the headlap portion of the overlay sheet,
thereby defining a two-layer portion and a single-layer portion of
the roofing shingle. A bead of tab sealant extends longitudinally
on a back side of the underlay sheet. A longitudinally extending
groove is formed in the first surface of the back side of the
headlap portion.
[0012] Other advantages of the roofing shingle will become apparent
to those skilled in the art from the following detailed
description, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a plan view of a roofing shingle according to a
first embodiment of the invention.
[0014] FIG. 2 is a cross-sectional view taken along the line 2-2 of
FIG. 1.
[0015] FIG. 3 is a cross-sectional view taken along the line 3-3 of
FIG. 1.
[0016] FIG. 4 is a cross-sectional view of a roofing shingle
according to a second embodiment of the invention.
[0017] FIG. 5 is an alternate cross-sectional view of the roofing
shingle illustrated in FIG. 4.
[0018] FIG. 6 is a perspective view of a third embodiment of a
laminated shingle having reinforcement material in accordance with
the invention.
[0019] FIG. 7 is a plan view of the front of the laminated shingle
illustrated in FIG. 6.
[0020] FIG. 8 is a plan view of the back of the laminated shingle
illustrated in FIGS. 6 and 7.
[0021] FIG. 9 is a perspective view of a portion of a fourth
embodiment of a laminated shingle having reinforcement material in
accordance with the invention.
[0022] FIG. 10 is a plan view of the back of a fifth embodiment of
a laminated shingle in accordance with the invention.
[0023] FIG. 11 is a schematic sectional view of a pair of the
laminated roofing shingles illustrated in FIG. 10, shown stacked
together in a bundle and in exaggerated thickness.
[0024] FIG. 12 is an exploded schematic sectional view of a pair of
a sixth embodiment of laminated roofing shingles according to the
invention, shown stacked together in a bundle and in exaggerated
thickness.
DETAILED DESCRIPTION
[0025] The present invention will now be described with occasional
reference to the illustrated embodiments of the invention. This
invention may, however, be embodied in different forms and should
not be construed as limited to the embodiments set forth herein,
nor in any order of preference. Rather, these embodiments are
provided so that this disclosure will be more thorough, and will
convey the scope of the invention to those skilled in the art.
[0026] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0027] Unless otherwise indicated, all numbers expressing
quantities of ingredients, properties such as molecular weight,
reaction conditions, and so forth as used in the specification and
claims are to be understood as being modified in all instances by
the term "about." Accordingly, unless otherwise indicated, the
numerical properties set forth in the specification and claims are
approximations that may vary depending on the desired properties
sought to be obtained in embodiments of the present invention.
Notwithstanding that the numerical ranges and parameters setting
forth the broad scope of the invention are approximations, the
numerical values set forth in the specific examples are reported as
precisely as possible. Any numerical values, however, inherently
contain certain errors necessarily resulting from error found in
their respective measurements.
[0028] As used in the description of the invention and the appended
claims, the term "asphalt coating" is defined as any type of
bituminous material suitable for use on a roofing material, such as
asphalts, tars, pitches, or mixtures thereof. The asphalt may be
either manufactured asphalt produced by refining petroleum or
naturally occurring asphalt. The asphalt coating may include
various additives and/or modifiers, such as inorganic fillers,
mineral stabilizers, non-polymers, and organic materials such as
polymers, recycled streams, or ground tire rubber. Preferably, the
asphalt coating is a filled-asphalt that contains asphalt and an
inorganic filler or mineral stabilizer.
[0029] As used in the description of the invention and the appended
claims, the term "longitudinal" or "longitudinally" is defined as
substantially parallel with the machine direction.
[0030] As used in the description of the invention and the appended
claims, the terms "shingle blow off" or "blow off" are defined as
the occurrence of installed shingles being forced off a roof deck
when the installed shingles are subjected to high winds. Also, the
term "shingle blow through" or "blow through" are defined as the
situation that occurs when a nail has been driven too deeply into
the shingle and the nail head penetrates through at least the
shingle overlay.
[0031] As used in the description of the invention and the appended
claims, the term "wet" or "wet out" is defined as the ability of
sealant or adhesive to flow and/or reflow over a surface to
maximize bond strength based on a larger contact area.
[0032] Composite shingles, such as asphalt shingles, are a commonly
used roofing product. Asphalt shingle production generally includes
feeding a base material from an upstream roll and coating it first
with a roofing asphalt 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 may be any suitable support material.
[0033] Composite shingles may have a headlap region and a prime
region. The headlap region may be ultimately covered by adjacent
shingles when installed upon a roof. The prime region will be
ultimately visible when the shingles are installed upon a roof.
[0034] The granules deposited on the composite material shield the
roofing asphalt material from direct sunlight, offer resistance to
fire, and provide texture and color to the shingle. The granules
generally involve at least two different types of granules. Headlap
granules are applied to the headlap region. Headlap granules are
relatively low in cost and primarily serve the functional purposes
of covering the underlying asphalt material for a consistent
shingle construction, balancing sheet weight, and preventing
overlapping shingles from sticking to one another. Colored granules
or other prime granules are relatively expensive and are applied to
the shingle at the prime regions. Prime granules are disposed upon
the asphalt strip for both the functional purpose of protecting the
underlying asphalt strip and for providing an aesthetically
pleasing appearance of the roof.
[0035] The performance of an installed shingle, such as in high
wind conditions, may be enhanced by reinforcing the nail zone of
the shingle. By reinforcing the nail zone, the occurrence of nail
blow through during shingle installation may be reduced. Reducing
the occurrence of nail blow through advantageously reduces the
possibility of a roof leak if water travels under the shingle tab.
A reinforced nail zone also improves the efficiency of the shingle
installer by reducing the likelihood of nail blow through when the
shingle is weakened due to high temperatures, such as when the
temperature is above about 120 degrees F., or when nail gun air
pressure is too high. The reinforced nail zone may also provide a
defined and relatively wide area in which the installer may nail.
Advantageously, the reinforced nail zone will increase the force
required to pull a nail through the shingle, thereby reducing the
likelihood of shingle blow off.
[0036] The nail zone may also be used as the bonding substrate area
or bonding surface for tab sealant bonded to the underside of the
tabs of the overlay sheet. The nail zone may provide an improved
bonding surface for tab sealant.
[0037] It is known that most debonding energy, such as is generated
between the tab sealant and the bonding surface is due to
viscoelastic loss in the tab sealant as it is stretched during
debonding. Further, the polymer modified asphalt sealants typically
used as tab sealants on shingles may lose their viscoelastic
characteristics when the temperature drops to 40 degrees F. or
below.
[0038] Advantageously, the use of woven or non-woven fabric to
reinforce the nail zone and to define the bonding surface for tab
sealant has been shown to improve or retain debonding loads of
polymer modified asphalt sealants relative to shingles without a
reinforced nail zone at relatively low temperatures, such as
temperatures below about 40 degrees F. This relatively strong
debonding load between woven or non-woven fabric and modified
asphalt sealants, including polymer and non-polymer modified
asphalt tab sealants, occurs because the woven or non-woven fabric
mechanically bonds to the sealant. For example, mechanical
attachment occurs as the polymer modified asphalt sealant flows
around individual filaments and fiber bundles within the woven or
non-woven fabric during bonding. The energy required to debond the
polymer modified asphalt sealant from the woven or non-woven fabric
is increased or comparable to the energy required to debond the
polymer modified asphalt sealant from a shingle without a
reinforced nail zone. Because the tab sealant is reinforced with
the filaments and fiber bundles within the woven or non-woven
fabric at the interface between the polymer modified asphalt
sealant and the woven or non-woven fabric, the interior of the
sealant becomes the weakest portion of the bond.
[0039] An additional advantage of using woven or non-woven fabric
to reinforce the nail zone is that the fabric may be installed
during shingle production. During shingle production, the woven or
non-woven fabric may be pushed into the hot, filled-asphalt
coating, such that some of the filled-asphalt bleeds up and around
the individual fibers and fiber bundles of the fabric. This creates
a positive mechanical bond between the fabric and the shingle
substrate. Further, the filled-asphalt that bleeds up and into the
fabric aids in forming a bond between the tab sealant and the
shingle because the filled-asphalt diffuses into the tab sealant.
When installed on a roof, this creates a robust continuous path for
the transfer of debonding loads from the tab above to the nail in
the shingle below.
[0040] The roofing shingles of the invention may 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.
[0041] 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.
[0042] 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 commonly assigned U.S. Pat. No.
7,836,654.
[0043] The coated roofing mat includes a roofing mat typically
coated with an organic-based coating material. The roofing mat may
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.
[0044] The organic-based coating material may 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 may 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 may 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.
[0045] The water impermeable sheet may 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 may 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 cm2, and observing no substantial penetration of the
sheet by the water after 24 hours. The sheet may 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.
[0046] In some embodiments, the sheet is made from a polymer or a
metal. Any suitable polymer or mixture of different polymers may be
used to make the sheet. For example, the polymer may 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 may be chemically treated or surface charged to improve
properties.
[0047] Any suitable metal or combination of metals may be used to
make the sheet. Recycled metals may also be used. Some examples of
metals that may be suitable include aluminum and copper.
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. 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.
[0048] In the embodiments of the invention where the sheet is
attached to the coated mat, these materials may be attached
together by any suitable means. For example, they may 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 may 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.
[0049] 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.
[0050] Referring now to the drawings, FIGS. 1-3 illustrate a first
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 may 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.
[0051] 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. 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 hardness greater than 8
dmm at 77 degrees F. and a softening point greater than 130 degrees
F., and more preferably a penetration hardness greater than 10 dmm
at 150 degrees F.
[0052] The roofing shingles of the invention may also be
characterized in terms of their limited width. The roofing shingles
disclosed in U.S. Pat. No. 6,990,779 B2 (to Elk Premium Building
Products, Inc.) 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 may
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.
[0053] 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, may be made using the
present invention, using proportionally sized buttlap and sheet
materials.
[0054] Replacing most of the headlap portion of the roofing
shingles with the water impermeable sheet may 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%.
[0055] 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 U.S. Pat. No. 7,836,654. 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
U.S. Pat. No. 7,836,654. Alternatively, the film may be located
above the nail zone region, and a separate reinforcement applied to
the nail zone as described in U.S. Pat. No. 7,836,654, and shown in
FIG. 6.
[0056] 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 may 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 may result in a reduced thickness of the roofing
shingle 10 in the nail zone region, and may reduce the weight of
the shingle and improve the bundle flatness.
[0057] FIGS. 4-5 illustrate a second 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.
[0058] 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.
[0059] 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.
[0060] 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, as clearly shown at 50 in FIGS. 2-5.
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 may be any suitable adhesive material, such
as an adhesive made from asphalt, a polymer, or a combination of
asphalt and polymer. The sealant may 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.
[0061] Advantageously, the roofing shingles of the present
invention, and the reinforced nail zone shingles disclosed in U.S.
Pat. No. 7,836,654, may 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 may 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 commonly assigned U.S. Pat.
No. 4,824,880, or a variation thereof.
[0062] 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.
[0063] 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.
[0064] Preferably, the sealant forms a bond with the reinforcement
member or the water impermeable sheet that is 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.
[0065] 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.
[0066] Referring now to FIGS. 6, 7, and 8, a third embodiment of a
laminated roofing shingle is shown generally at 74. In the
illustrated embodiment, the shingle 74 has a length L and includes
the overlay sheet 68 attached to the underlay sheet 66 and has a
first end or leading edge 74A and a second end or trailing edge
74B. In the illustrated embodiment, the laminated roofing shingle
74 has a length L of about 39.375 inches. Alternatively, the length
L may be within the range of from about 39.125 inches to about
39.625 inches. The shingle 74 may also be manufactured having any
other desired length. The shingle 74 also includes a longitudinal
axis A. The overlay sheet 68 may include a headlap portion 76 and a
tab portion 78. The headlap portion 76 may include a lower zone 76A
and an upper zone 76B. The tab portion 78 defines a plurality of
tabs 80 and cutouts 82 between adjacent tabs 80.
[0067] In the illustrated embodiment, the tab portion 78 includes
four tabs 80, although any suitable number of tabs 80 may be
provided. The headlap portion 76 and the tabs 80 may include one or
more granule patterns thereon. Each cutout 82 has a first height
H1. In the illustrated embodiment, the cutout 82 has a first height
H1 of about 5.625 inches. Alternatively, the first height H1 may be
within the range of from about 5.5 inches to about 5.75 inches. In
the illustrated embodiment, the cutouts 82 are shown as having the
same height H1. It will be understood however, that each cutout 82
may be of different heights. A line B is collinear with an upper
edge 82A of the cutouts 82 and defines an upper limit of an exposed
region 84 of the underlay sheet 66. In the illustrated embodiment,
the height of the exposed region 84 is equal to the first height
H1, although the height of the exposed region 84 may be any desired
height. In a shingle wherein the cutouts 82 have different heights,
the line B may be collinear with an upper edge 82A of the cutout 82
having the largest height. In the illustrated embodiment, the
overlay sheet 68 has a second height H2.
[0068] The reinforcement material 19 has a width W of about 1.0
inch. Alternatively, the width W may be within the range of from
about 0.75 inch to about 1.5 inches. Additionally, the width W may
be within the range of from about 0.5 inch to about 2.0 inches. The
reinforcement material 19 may be disposed longitudinally on the
headlap portion 76. In the illustrated embodiment, the
reinforcement material 19 extends longitudinally from the first end
74A to the second end 74B of the shingle 74 within the lower zone
76A of the headlap portion 76. A lower edge 19A of the
reinforcement material 19 may be spaced apart from the line B by a
distance D1. In the illustrated embodiment, the distance D1 is
about 0.25 inch. Alternatively, the distance D1 may be within the
range of from about 0.125 inch to about 0.375 inch. The distance D1
may, however, be of any other desired length. For example, if
desired, the reinforcement material 19 may substantially cover the
entire headlap portion 76 of the overlay sheet 68. It will be
understood that the reinforcement material 19 need not extend from
the first end 74A to the second end 74B of the shingle 74, and may
be disposed in one or more sections or portions on the shingle
74.
[0069] The reinforcement material 19 defines a reinforced nail zone
98 and may include text such as "NAIL HERE .cndot.", as shown in
FIG. 6. It will be understood, however, that any other text or
other indicia may be included on the reinforcement material 19. It
will also be understood that the reinforcement material 19 may be
provided without such text or indicia. These indicia on the
reinforcement material 19 ensure that the reinforced nail zone 98
may be easily and quickly identified by the shingle installer.
[0070] In the embodiment illustrated in FIGS. 6 and 8, the underlay
sheet 66 includes a leading edge 66A and a trailing edge 66B and
has a third height H3. In the illustrated embodiment, the height H3
of the underlay sheet 66 is about 6.625 inches. Alternatively, the
height H3 may be within the range of from about 6.5 inches to about
6.75 inches. The underlay sheet 66 may also be manufactured having
any other desired height.
[0071] In the illustrated embodiment, the third height H3 of the
underlay sheet 66 is equal to about one-half the second height H2
of the overlay sheet 68. The overlay sheet 68 and the underlay
sheet 66 thereby overlap to define a two-layer portion of the
laminated shingle 74 and a single-layer portion of the laminated
shingle 74. More specifically, a region of the underlay sheet 66
overlaps a region of the headlap portion 76 of the overlay sheet
68, thereby defining a two-layer portion and a single-layer portion
of the laminated shingle 74 within the headlap portion 76. At least
a portion of the reinforcement material 19 is adhered to the
single-layer portion of the laminated shingle 74. Alternately, the
third height H3 of the underlay sheet 66 may be greater than
one-half of the second height H2 of the overlay sheet 68. This
relationship between the underlay sheet 66 and the overlay sheet 68
allows the reinforcement material 19 to be positioned such that a
reinforced nail zone is provided at the two-layer portion of the
laminated shingle 74.
[0072] Referring now to FIG. 8, a bottom or back side of the
laminated shingle 74 is shown. The back side of the laminated
shingle 74 may be covered in a backdust material. The backdust
material is useful to prevent the back side of the laminated
shingle 74 from undesirably adhering or sticking to another
laminated shingle 74 when a plurality of the laminated shingles 74
are stacked together in a bundle. The backdust material may be made
from any desired material, such as crushed rock in the form of
talc, carbonate, or rock dust, and sand, such as silica sand.
[0073] A discontinuous bead of tab sealant 96 may extend
longitudinally and may be adhered to a lower surface of the back
side of the laminated shingle 74 adjacent and parallel to a leading
edge 74A of the laminated shingle 74. The tab sealant 96 may be
spaced a distance D2 from the leading edge 74A of the laminated
shingle 74. In the illustrated embodiment, the tab sealant 96 is
spaced about 0.5 inches from the leading edge 74A of the laminated
shingle 74. Alternatively, the tab sealant 96 may be spaced within
the range of from about 0.375 inch to about 0.625 inch from the
leading edge 74A of the laminated shingle 74. In the illustrated
embodiment, the tab sealant 96 includes segments 96S having a
length 96L of about 3.0 inches. Alternatively, the tab sealant
segments 96S may have a length 96L within the range of from about
2.25 inches to about 4.25 inches. The tab sealant segments 96S may
be spaced apart a distance 96D. In the illustrated embodiment, the
tab sealant segments 96S are spaced about 1.0 inch apart.
Alternatively, the tab sealant segments 96S may be spaced within
the range of from about 0.25 inch to about 1.5 inches apart.
[0074] The tab sealant segments 96S may have a width 96W. In the
illustrated embodiment, the tab sealant segments 96S have a width
96W of about 0.5 inch. Alternatively, the tab sealant segments 96S
may have a width 96W within the range of from about 0.375 inches to
about 0.675 inches. The tab sealant segments 96S may also be
applied having any other desired width. In the illustrated
embodiment, the tab sealant segments 96S have a thickness of about
0.035 inch. Alternatively, the tab sealant segments 96S may have a
thickness within the range of from about 0.028 inches to about
0.050 inches. The tab sealant segments 96S may also be applied
having any other desired thickness. It will be understood that the
bead of tab sealant 96 may be applied as a continuous bead of
sealant.
[0075] If desired, a continuous strip of release tape 94 may extend
longitudinally and may be adhered to an upper surface of the back
side of the laminated shingle 74 adjacent and parallel to a
trailing edge 74B of the laminated shingle 74. The release tape 94
is positioned such that it will be opposite the tab sealant 96 when
the laminated shingles 74 are stacked, such as when packaged for
shipment. The release tape 94 may be spaced a distance D1 from the
trailing edge 74B of the laminated shingle 74. In the illustrated
embodiment, the release tape 94 is spaced about 0.125 inches from
the trailing edge 74B of the laminated shingle 74. Alternatively,
the release tape 94 may be placed at any desired location on the
back side of the laminated shingle 74, such that the release tape
94 contacts and covers the sealant 96 when a plurality of the
laminated shingles 74 are stacked in a bundle, such as for
shipping.
[0076] In the illustrated embodiment, wherein the reinforcement
material 19 has a width W of about 1.0 inch, the reinforcement
material 19 is positioned such that about 75 percent (0.75 inch) of
the reinforced nail zone is positioned over the two-layer portion
of the laminated shingle 74, and about 25 percent (0.25 inch) of
the reinforced nail zone is positioned over the single-layer
portion of the laminated shingle 74. Alternatively, a portion of
the reinforced nail zone within the range of from about 62.5
percent (0.625 inch) to about 87.5 percent (0.875) of the nail zone
is positioned over the two-layer portion of the laminated shingle
74, and a portion of the reinforced nail zone within the range of
from about 12.5 percent (0.125 inch) to about 37.5 percent (0.375
inch) of the nail zone is positioned over the single-layer portion
of the laminated shingle 74.
[0077] Additionally, a portion of the reinforced nail zone within
the range of from about 50 percent (0.50 inch) to about 100 percent
(1.0 inch) of the nail zone is positioned over the two-layer
portion of the laminated shingle 74, and a portion of the
reinforced nail zone within the range of from about 0.0 percent
(0.0 inch) to about 50 percent (0.50 inch) of the nail zone is
positioned over the single-layer portion of the laminated shingle
74. For example, a second embodiment of the laminated shingle 174
is shown in FIG. 9, and includes the underlay sheet 166 and the
overlay sheet 168. The reinforcement material 19 is attached to the
overlay sheet 168 as described above and is positioned such that
about 100 percent of the reinforced nail zone 198 is positioned
over the two-layer portion of the laminated shingle 174, and about
0 percent of the reinforced nail zone 198 is positioned over the
single-layer portion of the laminated shingle 174.
[0078] Referring to FIG. 10, the back side of a fifth embodiment of
the laminated shingle is shown at 274. The laminated shingle 274
includes an overlay sheet 268 and an underlay sheet 266. If
desired, a depression or groove 194 may be formed in the back side
of the laminated shingle 274 in lieu of the continuous strip of
release tape 94 described above.
[0079] FIG. 11 is a schematic sectional view of a representative
pair of the third embodiment of the laminated shingles 274
manufactured according to the present invention. As shown in FIG.
11, the laminated roofing shingles 274 are stacked such that every
other of the shingles 274 is inverted and turned 180 degrees
relative to an adjacent one of the shingles 274 to define a bundle
200. It will be understood however, that the shingles 274 may be
stacked such that every other of such shingles 274 are either
inverted or turned 180 degrees, or both.
[0080] As best shown in FIG. 11, the groove 194 is positioned such
that it will be opposite the tab sealant 96 when the laminated
shingles 274 are stacked in the bundle 200, such as when packaged
for shipment. As disclosed above regarding the release tape 94, the
groove 194 may be spaced a distance D1 from the trailing edge 274B
of the laminated shingle 274. In the illustrated embodiment, the
groove 194 is spaced about 0.125 inches from the trailing edge 274B
of the laminated shingle 274. Alternatively, the groove 194 may be
placed at any desired location on the back side of the laminated
shingle 274, such that the sealant 96 nests within the groove 194
when a plurality of the laminated shingles 274 are stacked in the
bundle 200. As used in the description of the invention and the
appended claims, the term "nest" or "nests" is used to describe
embodiments wherein the sealant 96 fits completely within the
groove 194, and embodiments wherein less than 100 percent of the
sealant 96 fits within the groove, such as embodiments wherein the
sealant 96 fits substantially within the groove 194, or fits
partially within the groove 194.
[0081] The groove 194 may have a width 194W that need only be
slightly wider than the width 96W (described in detail above) of
the tab sealant 96. In the illustrated embodiment, the groove 194
has a width 194W of about 0.625 inches. Alternatively, the groove
194 may have a width 194W within the range of from about 0.0625
inches to about 0.125 inches larger than the width 96W of the tab
sealant 96. Additionally, the groove 194 may have a width 194W
within the range of from about 0.125 inches to about 0.25 inches
larger than the width 96W of the tab sealant 96.
[0082] In the illustrated embodiment, the groove 194 has a depth
194D of about 0.030 inches. Alternatively, the groove 194 may have
a depth 194D within the range of from about 0.020 inches to about
0.040 inches. Additionally, the groove 194 may have a depth 194D
within the range of from about 0.010 inches to about 0.050
inches.
[0083] As described above, the back side of the overlay sheet 268
of the laminated shingle 274 is typically coated with a layer of
first granular or backdust material, as described above. In a first
embodiment of the laminated shingle 274 as shown in FIG. 11, the
portion 268G of the overlay sheet 268 that will define the groove
194 may be coated with a second granular material. In the
illustrated embodiment, the second granular material is a material
having granules relatively smaller than the granules of the
backdust material that covers a remainder of the back side of the
overlay sheet 268. The second granular material may be any desired
material, such as relatively finer crushed rock, talc, carbonate,
or rock dust, relatively finer sand, and other materials having a
finer grade than the backdust material.
[0084] By coating the portion 268G of the overlay sheet 268 with
one of the second material, the groove 194 will be formed between
areas of the back side of the overlay sheet 268 covered by backdust
granules. As shown in FIG. 11, the tab sealant 96 will nest in the
groove 194, thereby improving bundle flatness by reducing the
thickness of the bundle 200 of roofing shingles 274 along edge
zones 200E of the bundle 200 of shingles. Additionally, the groove
194 may reduce the weight of the shingle 274 relative to the weight
of otherwise identical shingles formed without the groove 194.
[0085] FIG. 12 is a schematic sectional view of a representative
pair of a sixth embodiment of laminated shingles 374 manufactured
according to the present invention. As shown in FIG. 12, the
laminated roofing shingles 374 are stacked such that every other of
the shingles 374 is inverted and turned 180 degrees relative to an
adjacent one of the shingles 374 to define a bundle 202. It will be
understood however, that the shingles 374 may be stacked such that
every other of such shingles 374 are either inverted or turned 180
degrees, or both.
[0086] In a second embodiment of the laminated shingle 374 as shown
in FIG. 12, a longitudinally extending strip of material 204 may be
applied to the back side of the laminated shingle 374 in lieu of
the continuous strip of release tape 94 described above, and in
lieu of the groove 194.
[0087] Referring again to FIG. 12, the strip of material 204 may be
formed from materials having a thickness which causes a second
broad face 204B of the material 204 to extend outwardly of a broad
face 374B of the back side of the laminated shingle 374. These
materials may compress when the laminated shingles 374 are stacked
in the bundle 202, such that the tab sealant 96 will form a groove
206 in the material 204, thereby nesting within the groove 206 and
improving bundle flatness by reducing the thickness of the bundle
202 of roofing shingles 374 along the edge zones 202E of the bundle
202 of shingles. Additionally, the use of material 204 may reduce
the weight of the shingle 374, relative to the weight of otherwise
identical shingles formed without the material 204.
[0088] Alternatively, as shown at 208 in FIG. 12, the second broad
face 208B of the material 208 may be substantially parallel to the
broad face 374B of the laminated shingle 374. Examples of suitable
compressible materials include foamed rubbers such as EPDM Styrene
Butadiene Rubber (SBR) foam, polyurethane, and texturized
fabrics.
[0089] Although the invention has been disclosed in the context of
a laminated shingle 74, it will be understood that the
reinforcement material 19 may be attached to any other type of
shingle, such as a single layer shingle.
[0090] The present invention should not be considered limited to
the specific examples described herein, but rather should be
understood to cover all aspects of the invention. Various
modifications, equivalent processes, as well as numerous structures
and devices to which the present invention may be applicable will
be readily apparent to those of skill in the art. Those skilled in
the art will understand that various changes may be made without
departing from the scope of the invention, which is not to be
considered limited to what is described in the specification.
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