U.S. patent application number 13/193883 was filed with the patent office on 2013-01-31 for method of sealing overlapping installed shingles.
This patent application is currently assigned to OWENS CORNING INTELLECTUAL CAPITAL, LLC. The applicant listed for this patent is D. Greg Hendershot, Stephanie A. Rinne, Michael S. Ugorek, Donn Vermilion. Invention is credited to D. Greg Hendershot, Stephanie A. Rinne, Michael S. Ugorek, Donn Vermilion.
Application Number | 20130025225 13/193883 |
Document ID | / |
Family ID | 47596065 |
Filed Date | 2013-01-31 |
United States Patent
Application |
20130025225 |
Kind Code |
A1 |
Vermilion; Donn ; et
al. |
January 31, 2013 |
METHOD OF SEALING OVERLAPPING INSTALLED SHINGLES
Abstract
A roofing shingle includes a headlap portion and a tab portion.
A bead of tab sealant extends longitudinally on a back side of the
tab portion. Reinforcement material is secured to the headlap
portion and includes outwardly extending attachment members
configured to penetrate and mechanically bond with the tab sealant
of an overlapping roofing shingle when installed on a roof.
Inventors: |
Vermilion; Donn; (Newark,
OH) ; Rinne; Stephanie A.; (Granville, OH) ;
Ugorek; Michael S.; (New Albany, OH) ; Hendershot; D.
Greg; (Columbus, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Vermilion; Donn
Rinne; Stephanie A.
Ugorek; Michael S.
Hendershot; D. Greg |
Newark
Granville
New Albany
Columbus |
OH
OH
OH
OH |
US
US
US
US |
|
|
Assignee: |
OWENS CORNING INTELLECTUAL CAPITAL,
LLC
Toledo
OH
|
Family ID: |
47596065 |
Appl. No.: |
13/193883 |
Filed: |
July 29, 2011 |
Current U.S.
Class: |
52/518 ;
52/741.4 |
Current CPC
Class: |
E04D 1/26 20130101 |
Class at
Publication: |
52/518 ;
52/741.4 |
International
Class: |
E04D 1/36 20060101
E04D001/36; E04B 1/66 20060101 E04B001/66 |
Claims
1. A roofing shingle comprising: a headlap portion and a tab
portion; a bead of tab sealant extending longitudinally on a back
side of the tab portion; and reinforcement material secured to the
headlap portion, wherein the reinforcement material includes
outwardly extending attachment members configured to penetrate and
mechanically bond with the tab sealant of an overlapping roofing
shingle when installed on a roof.
2. The roofing shingle according to claim 1, wherein the bead of
tab sealant is a discontinuous bead of tab sealant adhered to a
lower surface of a back side of the tab portion adjacent and
parallel to a leading edge of the roofing shingle.
3. The roofing shingle according to claim 1, wherein the
reinforcement material is formed from woven material.
4. The roofing shingle according to claim 3, wherein the attachment
members are outwardly extending fibers of yarns used to form the
woven reinforcement material.
5. The roofing shingle according to claim 3, wherein yarns used to
form the woven reinforcement material are crimped yarns.
6. The roofing shingle according to claim 3, wherein yarns used to
form the woven reinforcement material are texturized yarns.
7. The roofing shingle according to claim 6, wherein the outwardly
extending attachment members include one of the broken ends of
individual fibers and loops of fiber.
8. The roofing shingle according to claim 3, wherein the
reinforcement material has a first broad face engaging the headlap
portion and a second broad face opposite the first broad face, and
wherein yarns used to form the woven reinforcement material are
formed from non-continuous fibers twisted together, such that ends
of the non-continuous fibers extend outwardly of the second broad
face of the reinforcement material.
9. The roofing shingle according to claim 3, wherein the attachment
members are outwardly extending hooks.
10. The roofing shingle according to claim 3, wherein the
attachment members are outwardly extending loops.
11. The roofing shingle according to claim 3, wherein the
reinforcement material has a first broad face engaging the headlap
portion and a second broad face opposite the first broad face, and
wherein the attachment members comprise a plurality of individual
fibers inserted through the reinforcement material such that ends
of the individual fibers extend outwardly of the second broad face
of the reinforcement material.
12. The roofing shingle according to claim 11, wherein ends of the
individual fibers further extend outwardly of the first broad face
of the reinforcement material.
13. The roofing shingle according to claim 3, wherein an outwardly
facing surface of the headlap portion defines a broad face of the
roofing shingle, wherein the reinforcement material has a first
broad face engaging the headlap portion and a second broad face
opposite the first broad face, the attachment members extending
outwardly of the second broad face of the reinforcement material,
wherein the attachment members further extend outwardly of the
broad face of the roofing shingle, and wherein when a plurality of
the roofing shingles are stacked in a bundle, the outwardly
extending attachment members are compressed by an adjacent one of
the roofing shingles to be at or below the broad face of the
roofing shingle.
14. The roofing shingle according to claim 13, wherein when the
roofing shingles are removed from the bundle, the outwardly
extending attachment members again extend outwardly of the broad
face of the roofing shingle, the outwardly extending attachment
members thereby configured to engage and bond with the tab sealant
of an overlapping roofing shingle when installed on a roof.
15. The roofing shingle according to claim 1, wherein the
reinforcement material has a first broad face engaging the headlap
portion and a second broad face opposite the first broad face, and
wherein the second broad face of the reinforcement material
includes a coating of a material which lowers the viscosity of the
tab sealant of an overlapping roofing shingle when installed on a
roof.
16. The roofing shingle according to claim 15, wherein the coating
is one of a sealant, oil, and a low melting temperature wax.
17. The roofing shingle according to claim 1, wherein the
reinforcement material is formed from plastic film.
18. A roofing shingle comprising: an overlay sheet including a
headlap portion and a tab portion; 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 reinforcement material
secured to the headlap portion, wherein the reinforcement material
is formed from woven material, and wherein the reinforcement
material includes outwardly extending attachment members configured
to penetrate and mechanically bond with the tab sealant of an
overlapping roofing shingle when installed on a roof.
19. The roofing shingle according to claim 18, wherein the
attachment members are outwardly extending fibers of yarns used to
form the woven reinforcement material.
20. The roofing shingle according to claim 18, wherein the
reinforcement material has a first broad face engaging the headlap
portion and a second broad face opposite the first broad face, and
wherein yarns used to form the woven reinforcement material are
formed from non-continuous fibers twisted together, such that ends
of the non-continuous fibers extend outwardly of the second broad
face of the reinforcement material.
21. The roofing shingle according to claim 18, wherein the
reinforcement material has a first broad face engaging the headlap
portion and a second broad face opposite the first broad face, and
wherein the attachment members comprise a plurality of individual
fibers inserted through the reinforcement material such that ends
of the individual fibers extend outwardly of the second broad face
of the reinforcement material.
22. The roofing shingle according to claim 18, wherein the
reinforcement material has a first broad face engaging the headlap
portion and a second broad face opposite the first broad face, and
wherein the second broad face of the reinforcement material
includes a coating of a material which lowers the viscosity of the
tab sealant of an overlapping roofing shingle when installed on a
roof.
23. A method of manufacturing a roofing shingle comprising:
applying an asphalt coating to a substrate to define an asphalt
coated sheet, the asphalt coated sheet including a headlap portion
and a tab portion; applying a bead of tab sealant longitudinally on
a back side of the tab portion; modifying reinforcement material
such that the reinforcement material includes outwardly extending
attachment members configured to penetrate and mechanically bond
with the tab sealant of an overlapping roofing shingle when
installed on a roof; and applying and securing the reinforcement
material to the headlap portion of the asphalt coated sheet.
24. A roofing shingle comprising: a headlap portion and a tab
portion; a bead of tab sealant extending longitudinally on a back
side of the tab portion; and reinforcement material secured to the
headlap portion, wherein the reinforcement material is formed from
compressible material.
25. The roofing shingle according to claim 24, wherein an outwardly
facing surface of the headlap portion defines a broad face of the
roofing shingle, wherein the reinforcement material has a first
broad face engaging the headlap portion and a second broad face
opposite the first broad face, wherein a portion of the
reinforcement material extends outwardly of the broad face of the
roofing shingle, and wherein when a plurality of the roofing
shingles are stacked in a bundle, the outwardly extending portion
of the reinforcement material is compressed by an adjacent one of
the roofing shingles to be at or below the broad face of the
roofing shingle.
26. The roofing shingle according to claim 25, wherein the roofing
shingles are removed from the bundle, the portions of the
reinforcement material expand to again extend outwardly of the
broad face of the roofing shingle, the reinforcement material
thereby configured to engage and bond with the tab sealant of an
overlapping roofing shingle when installed on a roof.
Description
BACKGROUND
[0001] 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.
[0002] 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.
[0003] 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 that guides installers in the placement of nails.
[0004] 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.
SUMMARY OF THE INVENTION
[0005] The present application describes various embodiments of a
roofing shingle and a method of manufacturing a roofing shingle.
One embodiment of the roofing shingle includes a headlap portion
and a tab portion. A bead of tab sealant extends longitudinally on
a back side of the tab portion. Reinforcement material is secured
to the headlap portion and includes outwardly extending attachment
members configured to penetrate and mechanically bond with the tab
sealant of an overlapping roofing shingle when installed on a
roof.
[0006] In another embodiment, the roofing shingle includes an
overlay sheet having a headlap portion and a tab portion. 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.
Reinforcement material is secured to the headlap portion and is
formed from woven material. The reinforcement material includes
outwardly extending attachment members configured to penetrate and
mechanically bond with the tab sealant of an overlapping roofing
shingle when installed on a roof.
[0007] In a further embodiment, a method of manufacturing a roofing
shingle includes applying an asphalt coating to a substrate to
define an asphalt coated sheet, the asphalt coated sheet having a
headlap portion and a tab portion. A bead of tab sealant is applied
longitudinally on a back side of the tab portion. Reinforcement
material is modified to include outwardly extending attachment
members configured to penetrate and mechanically bond with the tab
sealant of an overlapping roofing shingle when installed on a roof.
The reinforcement material is applied and secured to the headlap
portion of the asphalt coated sheet.
[0008] In an additional embodiment, the roofing shingle includes a
headlap portion and a tab portion. A bead of tab sealant extends
longitudinally on a back side of the tab portion. Reinforcement
material secured to the headlap portion and is formed from
compressible material.
[0009] Other advantages of the roofing shingle and the method of
manufacturing a 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
[0010] FIG. 1 is a schematic elevational view of an apparatus for
manufacturing shingles according to the invention.
[0011] FIG. 2 is a perspective view of a first embodiment of a
laminated shingle having reinforcement material in accordance with
the invention.
[0012] FIG. 3 is a plan view of the front of the laminated shingle
illustrated in FIG. 2.
[0013] FIG. 4 is a plan view of the back of the laminated shingle
illustrated in FIGS. 2 and 3.
[0014] FIG. 5 is a perspective view of a portion of a second
embodiment of a laminated shingle having reinforcement material in
accordance with the invention.
[0015] FIG. 6 is an enlarged schematic elevational view of a
portion of the laminated shingle illustrated in FIGS. 2, 3, and
4.
[0016] FIG. 7 is an enlarged exploded elevational view of two of
the laminated shingles illustrated in FIGS. 2, 3, and 4 as
installed on a roof.
[0017] FIG. 8 is a perspective view of a portion of a second
embodiment of the reinforcement material illustrated in FIGS. 2, 3,
and 5.
[0018] FIG. 9 is a perspective view of a portion of a third
embodiment of the reinforcement material illustrated in FIGS. 2, 3,
and 5.
[0019] FIG. 10 is a perspective view of a portion of a fourth
embodiment of the reinforcement material illustrated in FIGS. 2, 3,
and 5.
[0020] FIG. 11 is an enlarged schematic elevational view of a
portion of a fifth embodiment of the reinforcement material
illustrated in FIGS. 2, 3, and 5.
[0021] FIG. 12 is an enlarged schematic view of a crimped yarn of
the reinforcement material illustrated in FIG. 8.
[0022] FIG. 13 is a schematic sectional view of a pair of known
laminated roofing shingles stacked together and shown in
exaggerated thickness to illustrate humping of the stacked
shingles.
[0023] FIG. 14 is a schematic sectional view of a pair of laminated
roofing shingles according to the invention stacked together in a
bundle and shown in exaggerated thickness.
[0024] FIG. 15 is an enlarged elevational view of a third
embodiment of a laminated shingle having reinforcement material in
accordance with the invention.
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] As used in the description of the invention and the appended
claims, the term "waywind" is defined as fibers, or strips of
material or fabric that are collected, applied to, or wound on a
spool or bobbin in a pattern that changes the angle of the material
relative to the longitudinal axis of the spool.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] 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 roof
or shingle 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] Referring now to the drawings, there is shown in FIG. 1 an
apparatus 10 for manufacturing an asphalt-based roofing material
according to the invention. The illustrated manufacturing process
involves passing a continuous sheet of substrate or shingle mat 11
in a machine direction 12 through a series of manufacturing
operations. The mat 11 usually moves at a speed of at least about
200 feet/minute (61 meters/minute), and typically at a speed within
the range of between about 450 feet/minute (137 meters/minute) and
about 800 feet/minute (244 meters/minute). The sheet, however, may
move at any desired speed.
[0042] In a first step of the manufacturing process, the continuous
sheet of shingle mat 11 is payed out from a roll 13. The shingle
mat 11 may be any type known for use in reinforcing asphalt-based
roofing materials, such as a nonwoven web of glass fibers.
Alternatively, the substrate may be a scrim or felt of fibrous
materials such as mineral fibers, cellulose fibers, rag fibers,
mixtures of mineral and synthetic fibers, or the like.
[0043] The sheet of shingle mat 11 is passed from the roll 13
through an accumulator 14. The accumulator 14 allows time for
splicing one roll 13 of substrate to another, during which time the
shingle mat 11 within the accumulator 14 is fed to the
manufacturing process so that the splicing does not interrupt
manufacturing.
[0044] Next, the shingle mat 11 is passed through a coater 16 where
a coating of asphalt 17 is applied to the shingle mat 11 to form a
first asphalt-coated sheet 18. The asphalt coating 17 may be
applied in any suitable manner. In the illustrated embodiment, the
shingle mat 11 contacts a supply of hot, melted asphalt 17 to
completely cover the shingle mat 11 with a tacky coating of asphalt
17. However, in other embodiments, the asphalt coating 17 could be
sprayed on, rolled on, or applied to the shingle mat 11 by other
means. Typically, the asphalt coating is highly filled with a
ground mineral filler material, amounting to at least about 60
percent by weight of the asphalt/filler combination. In one
embodiment, the asphalt coating 17 is in a range from about
350.degree. F. to about 400.degree. F. In another embodiment, the
asphalt coating 17 may be more than 400.degree. F. or less than
350.degree. F. The shingle mat 11 exits the coater 16 as a first
asphalt-coated sheet 18. The asphalt coating 17 on the first
asphalt-coated sheet 18 remains hot.
[0045] A continuous strip of a reinforcement material 19, as will
be described in detail herein, may then be payed out from a roll
20. The reinforcement material 19 adheres to the first
asphalt-coated sheet 18 to define a second asphalt-coated sheet 22.
In a first embodiment, the reinforcement material 19 is attached to
the sheet 18 by the adhesive mixture of the asphalt in the first
asphalt-coated sheet 18. The reinforcement material 19, however,
may be attached to the sheet 18 by any suitable means, such as
other adhesives. As described in detail below, the material 19 may
be formed from any material for reinforcing and strengthening the
nail zone of a shingle, such as, for example, paper, film, scrim
material, and woven or non-woven glass fibers.
[0046] The resulting second asphalt coated sheet 22 may then be
passed beneath a series of granule dispensers 24 for the
application of granules to the upper surface of the second
asphalt-coated sheet 22. The granule dispensers may be of any type
suitable for depositing granules onto the asphalt-coated sheet. A
granule dispenser that may be used is a granule valve of the type
disclosed in U.S. Pat. No. 6,610,147 to Aschenbeck. The initial
granule blender 26 may deposit partial blend drops of background
granules of a first color blend on the tab portion of the second
asphalt coated sheet 22 in a pattern that sets or establishes the
trailing edge of subsequent blend drops of a second color blend (of
an accent color) and a third color blend (of a different accent
color). For purposes of this patent application, the first color
blend and the background granules are synonymous. The use of
initially applied partial blend drops to define the trailing edge
of subsequent blend drops is useful where accurate or sharp leading
edges are possible, but accurate trailing edges at high shingle
manufacturing speeds are difficult.
[0047] As is well known in the art, blend drops applied to the
asphalt-coated sheet are often made up of granules of several
different colors. For example, one particular blend drop that is
supposed to simulate a weathered wood appearance might actually
consist of some brown granules, some dark gray granules, and some
light gray granules. When these granules are mixed together and
applied to the sheet in a generally uniformly mixed manner, the
overall appearance of weathered wood is achieved. For this reason,
the blend drops are referred to as having a color blend, which
gives an overall color appearance. This overall appearance may be
different from any of the actual colors of the granules in the
color blend. In addition, blend drops of darker and lighter shades
of the same color, such as, for example, dark gray and light gray,
are referred to as different color blends rather than merely
different shades of one color.
[0048] As shown in FIG. 1, the series of dispensers 24 includes
four color-blend blenders 26, 28, 30, and 32. Any desired number of
blenders, however, may be used. The final blender may be the
background blender 34. Each of the blenders may be supplied with
granules from sources of granules, not shown. After the blend drops
are deposited on the second asphalt-coated sheet 22, the remaining,
uncovered areas are still tacky with warm, uncovered asphalt, and
the background granules from the background blender 34 will adhere
to the areas that are not already covered with blend drop granules.
After all the granules are deposited on the second asphalt-coated
sheet 22 by the series of dispensers 24, the sheet 22 becomes a
granule-covered sheet 40.
[0049] In the illustrated embodiment, the reinforcement material 19
includes an upper surface to which granules substantially will not
adhere. Granules may therefore be deposited onto substantially the
entire second asphalt-coated sheet 22, including the material 19,
but wherein the reinforcement material 19 includes an upper surface
to which granules substantially will not adhere.
[0050] The granule-covered sheet 40 may then be turned around a
slate drum 44 to press the granules into the asphalt coating and to
temporarily invert the sheet so that the excess granules will fall
off and will be recovered and reused. Typically, the granules
applied by the background blender 34 are made up by collecting the
backfall granules falling from the slate drum 44.
[0051] The granule-covered sheet 40 may subsequently be fed through
a rotary pattern cutter 52, which includes a bladed cutting
cylinder 54 and a backup roll 56, as shown in FIG. 1. If desired,
the pattern cutter 52 may cut a series of cutouts in the tab
portion of the granule-covered sheet 40, and cut a series of
notches in the underlay portion of the granule-covered sheet
40.
[0052] The pattern cutter 52 may also cut the granule-covered sheet
40 into a continuous underlay sheet 66 and a continuous overlay
sheet 68. The underlay sheet 66 may be directed to be aligned
beneath the overlay sheet 68, and the two sheets may be laminated
together to form a continuous laminated sheet 70. As shown in FIG.
1, the continuous underlay sheet 66 may be routed on a longer path
than the path of the continuous overlay sheet 68. Further
downstream, the continuous laminated sheet 70 may be passed into
contact with a rotary length cutter 72 that cuts the laminated
sheet into individual laminated shingles 74.
[0053] In order to facilitate synchronization of the cutting and
laminating steps, various sensors and controls may be employed. For
example, sensors, such as photo eyes 86 and 88 may be used to
synchronize the continuous underlay sheet 66 with the continuous
overlay sheet 68. Sensors 90 may also be used to synchronize the
notches and cutouts of the continuous laminated sheet with the end
cutter or length cutter 72.
[0054] In a second embodiment, the reinforcement material may be
attached to a lower surface (the downwardly facing surface when
viewing FIG. 1) of the mat 11, the first asphalt coated sheet 18,
the second asphalt coated sheet 22, or the granule-covered sheet
40, as shown at 19A and 19B in FIG. 1. The reinforcement material
19A and 19B may be attached to the mat 11, the first asphalt coated
sheet 18, the second asphalt coated sheet 22, or the
granule-covered sheet 40 by any suitable means, such as hot, melted
asphalt, other adhesives, or suitable fasteners. In such an
embodiment, the reinforcement material 19A and 19B may be attached
to the lower surface of the nail zone of either of the overlay
sheet 68 or the underlay sheet 66, thereby reinforcing and
strengthening the nail zone as described herein.
[0055] Referring now to FIGS. 2, 3, and 4, a first 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 74C and a second end or trailing edge
74D. 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.
[0056] 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.
[0057] 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.
[0058] The reinforcement material 19 defines a reinforced nail zone
98 and may include text such as "NAIL HERE ", as shown in FIG. 2.
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 can 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.
[0059] In the embodiment illustrated in FIGS. 2 and 4, 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.
[0060] 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.
[0061] Referring now to FIG. 4, a back side of the laminated
shingle 74 is shown. 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 74D 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 74D of the laminated shingle 74. In the
illustrated embodiment, the release tape 94 is spaced about 0.125
inches from the trailing edge 74D 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.
[0062] 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 74C of the laminated shingle 74. The tab sealant 96 may be
spaced a distance D2 from the leading edge 74C of the laminated
shingle 74. In the illustrated embodiment, the tab sealant 96 is
spaced about 0.5 inches from the leading edge 74C 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 74C 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.
[0063] 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.
[0064] 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, within the
range of from about 62.5 percent (0.625 inch) to about 87.5 percent
(0.875) of the reinforced nail zone is positioned over the
two-layer portion of the laminated shingle 74, and within the range
of from about 12.5 percent (0.125 inch) to about 37.5 percent
(0.375 inch) of the reinforced nail zone is positioned over the
single-layer portion of the laminated shingle 74.
[0065] Additionally, within the range of from about 50 percent
(0.50 inch) to about 100 percent (1.0 inch) of the reinforced nail
zone is positioned over the two-layer portion of the laminated
shingle 74, and within the range of from about 0.0 percent (0.0
inch) to about 50 percent (0.50 inch) of the reinforced 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. 5, 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.
[0066] An enlarged schematic view of a portion of the laminated
shingle 74 is shown in FIG. 6. As shown, the reinforcement material
19 of the reinforced nail zone 98 is shown with a nail 90 installed
through the reinforcement material 19 where it is adhered to the
single-layer portion of the laminated shingle 74. The nail 90
extends only through the reinforcement material 19 and the overlay
sheet 68, but a portion of the nail head 92 (left most portion of
the nail head 92 when viewing FIG. 6) extends over the two-layer
portion of the laminated shingle 74. Advantageously, the position
of the reinforcement material 19 relative to the two-layer portion
of the laminated shingle 74 significantly reduces the occurrence of
shingle blow through and significantly increases nail pull through
resistance during installation and wind uplift events such as
occurs during high winds. Even if an installer drives a nail 90
through the upper most portion of the reinforcement material 19
(right most portion of reinforcement material 19 when viewing FIG.
6), as shown in FIG. 6, at least a portion of the nail head 92 will
extend over and engage the two-layer portion of the laminated
shingle 74, and thus be substantially prevented from blowing
through the laminated shingle 74.
[0067] The embodiment of the reinforcement material 19 illustrated
in FIGS. 2 and 3 is a woven material or web woven from polyester
fabric yarns of about 150 denier. Alternatively, the reinforcement
material 19 may be a material woven from fabric yarns within the
range of from about 125 denier to about 175 denier. Additionally,
the reinforcement material 19 may be a material woven from fabric
yarns within the range of from about 100 denier to about 200
denier.
[0068] The embodiment of the woven reinforcement material 19
illustrated in FIGS. 2 and 3 is a 150 denier material having a
density of about 80 yarns per inch in the warp or machine direction
and about 45 yarns per inch in the cross-machine direction.
Alternatively, the reinforcement material 19 may be a woven
material having a density within the range of from about 65 yarns
per inch to about 90 yarns per inch in the warp direction and
within the range of from about 35 yarns per inch to about 55 yarns
per inch in the cross-machine direction. It has been shown that 150
denier woven polyester material having a density within the range
of from about 90 yarns per inch to about 100 yarns per inch in the
warp direction and 60 yarns per inch or greater in the
cross-machine direction do not satisfactorily adhere to the
adhesive mixture of the asphalt in the first asphalt coated sheet
18.
[0069] The embodiment of the woven reinforcement material 19
illustrated in FIGS. 2 and 3 may have a weight of about 2.8
ounces/yard.sup.2. Alternatively, the reinforcement material 19 may
be a woven material having a weight within the range of from about
2.0 ounces/yard.sup.2to about 3.5 ounces/yard.sup.2. Additionally,
the reinforcement material 19 may be a woven material having a
weight within the range of from about 1.5 ounces/yard.sup.2to about
4.5 ounces/yard.sup.2.
[0070] The embodiment of the woven reinforcement material 19
illustrated in FIGS. 2 and 3 may also have a thickness of about 9.5
mils. Alternatively, the reinforcement material 19 may be a woven
material having a thickness within the range of from about 5 mils
to about 15 mils. Additionally, the reinforcement material 19 may
be a woven material having a thickness within the range of from
about 3 mils to about 20 mils. The reinforcement material 19 may
also have having any other desired thickness.
[0071] The embodiment of the woven reinforcement material 19
illustrated in FIGS. 2 and 3 may further have an air permeability
of about 210 cm.sup.3/s/cm.sup.2, measured, for example, in
accordance with ASTM D737. Alternatively, the reinforcement
material 19 may be a woven material having an air permeability
within the range of from about 160 cm.sup.3/s/cm.sup.2 to about 260
cm.sup.3/s/cm.sup.2. Additionally, the reinforcement material 19
may be a woven material having an air permeability within the range
of from about 85 cm.sup.3/s/cm.sup.2 to about 335
cm.sup.3/s/cm.sup.2.
[0072] The embodiment of the woven reinforcement material 19
illustrated in FIGS. 2 and 3 is formed from polyester fiber.
Alternatively, the woven reinforcement material 19 may be formed
from any other suitable material, such as nylon, KEVLAR.RTM.,
cotton, rayon, and fiberglass. It will be understood that the
properties and characteristics, such as weight, density, and air
permeability, of the polyester reinforcement material 19 described
above will vary when the reinforcement material 19 is formed from
materials other than polyester fiber. Further, polypropylene may be
used to form the woven reinforcement material 19 if either the
reinforcement material 19 and/or the first asphalt-coated sheet 18
are cooled so that the reinforcement material 19 does not melt or
shrink when it contacts the first asphalt-coated sheet. It will be
understood that the embodiments of the woven reinforcement material
described herein may have any desired weave pattern.
[0073] It will be understood that the reinforcement material 19 may
be formed as a non-woven mat. In a first embodiment of a non-woven
mat, the non-woven mat may comprise about 10 percent glass fiber
and about 90 percent bi-component polymer fiber, or a glass to
bi-component fiber ratio of 10:90. One example of a suitable
bi-component fiber is a fiber having a polyethylene (PE) outer
sheath and a polyethylene terephthalate (PET) core, wherein the
bi-component fibers have a 50:50 by weight sheath to core ratio. It
has been shown that the glass fiber in the reinforcement material
19 helps to ensure dimensional stability of the reinforcement
material 19 when it is cured and when it is applied to a
shingle.
[0074] It will be understood that non-woven mats having glass to
bi-component fiber ratios other than 10:90 may also meet or exceed
the desired bond strengths over a range of temperatures. For
example, non-woven mats having glass to bi-component fiber ratios
within the range of from about 5:95 to about 25:75 may also be
used.
[0075] It has been shown that a non-woven mat comprising about 10
percent glass fiber and about 90 percent bi-component fiber with a
50:50 PE sheath to PET core ratio does not require a binder, as the
PE of the outer sheath melts in the curing oven and bonds the
glass, and polymer fibers together. The embodiments of the
non-woven mats disclosed herein and comprising about 10 percent
glass fiber and about 90 percent bi-component fiber were cured in
an oven having a temperature of about 350 degrees F. It will be
understood that if desired, a coupling agent or bond promoter may
be applied to the fibers within the non-woven mat to enhance bond
strength between the glass, and polymer fibers.
[0076] To determine bond strength, five shingles were tested after
the reinforcement material; i.e., the non-woven and woven mats,
were sealed to the shingles per ASTM 6381. The shingles tested
included: (1) control shingles formed with the woven reinforcement
material 19, as described above; (2) shingles with a non-woven mats
having bi-component fiber with a 50:50 PE sheath to PET core ratio
and a basis weight of about 0.85 lbs/csf; (3) shingles with a
non-woven mats having bi-component fiber with a 50:50 PE sheath to
PET core ratio and a basis weight of about 1.0 lbs/csf; (4)
shingles with non-woven mats having bi-component fiber with a 25:75
PE sheath to PET core ratio and a basis weight of about 0.85
lbs/csf; and (4) shingles with non-woven mats having bi-component
fiber with a 25:75 PE sheath to PET core ratio and a basis weight
of about 1.0 lbs/csf. The tests were conducted at three different
temperatures: 72 degrees F., 40 degrees F., and 0 degrees F. As
used herein, the temperatures at which the tests were conducted are
referred to as pulling temperatures.
[0077] At a pulling temperature of about 72 degrees F., both the
shingles with the non-woven mats having bi-component fiber with a
50:50 PE sheath to PET core ratio and basis weights of about 0.85
lbs/csf and about 1.0 lbs/csf, and the shingles with woven mats
achieved or were very close to the desired bond strength of about
25 lbs. The shingles with the non-woven mats having bi-component
fiber with a 25:75 PE sheath to PET core ratio and a basis weights
of about 0.85 lbs/csf and 1.0 lbs/csf did not achieve the desired
bond strength of about 25 lbs.
[0078] At a pulling temperature of 40 degrees F., both the shingles
with the non-woven mats having bi-component fiber with a 50:50 PE
sheath to PET core ratio and basis weights of about 0.85 lbs/csf
and about 1.0 lbs/csf, and the shingles with woven mats achieved or
were very close to the desired bond strength of about 15 lbs. The
shingles with non-woven mats having bi-component fiber with a 25:75
PE sheath to PET core ratio and a basis weights of about 0.85
lbs/csf and about 1.0 lbs/csf did not achieve the desired bond
strength of about 15 lbs.
[0079] At a pulling temperature of 0 degrees F., both the shingles
with the non-woven mats having bi-component fiber with a 50:50 PE
sheath to PET core ratio and basis weights of about 0.85 lbs/csf
and about 1.0 lbs/csf, and the shingles with woven mats exceeded
the desired bond strength of about 8 lbs. Advantageously, the 50:50
ratio mats with the basis weight of about 0.85 lbs/csf had a higher
bond strength than the 50:50 ratio mats with the basis weight of
about 1.0 lbs/csf. The shingles with non-woven mats having
bi-component fiber with a 25:75 PE sheath to PET core ratio and a
basis weights of about 0.85 lbs/csf and about 1.0 lbs/csf did not
achieve the desired bond strength of about 8 lbs.
[0080] Over a range of temperatures including 0 degrees F., 40
degrees F., and 72 degrees F., the shingles with the non-woven mats
having bi-component fiber with a 50:50 PE sheath to PET core ratio
had a higher bond strength than the shingles with non-woven mats
having bi-component fiber with a 25:75 PE sheath to PET core ratio
at both the 0.85 lbs/csf and the 1.0 lbs/csf basis weights. It is
believed that the increased bond strength is due to increased
bonding of the fibers in the non-woven mat with the larger
percentage (50 percent in the examples discussed above) of PE outer
sheath.
[0081] It will be understood that non-woven mats having sheath to
core ratios other than 50:50 may also meet or exceed the desired
bond strengths over a range of temperatures. For example, non-woven
mats having sheath to core ratios within the range of from about
40:60 to about 60:40 may meet or exceed the desired bond strengths
over a range of temperatures. It will be further understood that
these non-woven mats may have a basis weight within the range of
from about 0.5 lbs/csf to about 1.5 lbs/csf.
[0082] Advantageously, a non-woven mat having bi-component fiber as
described above is sufficiently strong and will not de-laminate
when installed on a roof. The non-woven mat having bi-component
fiber also forms a very strong bond with both the filled-asphalt of
the shingle and the tab sealant. Further, the filled-asphalt of the
shingle will not bleed through the embodiment of the non-woven mat
described above.
[0083] In the exemplary shingle 74 illustrated in FIG. 2, the
shingle 74 may have a nail pull-through value, measured in
accordance with a desired standard, such as prescribed by ASTM test
standard D3462. For example, the shingle 74 may have a nail
pull-through value that is greater than in an otherwise identical
shingle without the reinforcement material 19.
[0084] Improved nail pull-through resistance values have been
demonstrated using a modified version of the nail pull-through test
prescribed by ASTM test standard D3462, wherein the test fixture
has an opening that has been reduced from a 2.5 inch diameter to a
1.5 inch diameter. Using this modified test at a temperature of 72
degrees F., a shingle 74 having reinforcement material 19 formed
from woven polyester fabric may have a nail pull-through resistance
value within the range of from about 39 percent to about 46 percent
greater than in an otherwise identical shingle without the
reinforcement material 19.
[0085] When using the modified test at a temperature of 32 degrees
F., a shingle 74 having reinforcement material 19 formed from woven
polyester fabric may have a nail pull-through resistance value of
at least about 25 percent greater than in an otherwise identical
shingle without the reinforcement material 19. Alternatively, when
using the modified test at a temperature of 32 degrees F., a
shingle 74 having reinforcement material 19 formed from woven
polyester fabric may have a nail pull-through resistance value
within the range of from about 25 percent to about 37 percent
greater than in an otherwise identical shingle without the
reinforcement material 19.
[0086] Improved nail blow through values have been demonstrated in
shingles 74 relative to otherwise identical shingles without the
reinforcement material 19. To test nail blow through, a shingle 74
was placed on oriented strand board and a nail was driven into the
shingle 74 using an air gun at 130 psi to simulate installation on
the roof, and to replicate any nail blow through damage that may
occur to the shingle 74 during installation with an air gun at 130
psi. The test was conducted at room temperature or at about 72
degrees F. After the nail was driven into the shingle 74, the
shingle 74 was turned upside down, the nail was driven back out of
the shingle 74, and any wood present was removed from the shingle
74 and nail hole. A second nail was inserted in the hole formed by
the first nail and the shingle 74 was tested for nail pull through
resistance using the modified test described above. Using this
method, a shingle 74 having reinforcement material 19 formed from
woven polyester fabric may have a nail pull-through resistance
value within the range of from about 13 percent to about 42 percent
greater than in an otherwise identical shingle without the
reinforcement material 19.
[0087] Because there may be substantially no granules in the
portion of the overlay sheet 68 covered by reinforcement material
19, the weight of the laminated shingle 74 may be reduced relative
to an otherwise identical shingle without the reinforcement
material 19. For example, weight of the exemplary laminated shingle
74 illustrated in FIG. 2, may be reduced within the range of from
about four percent to about six percent relative to the weight of
an otherwise identical shingle having no such reinforcement
material 19. The material and transportation costs may also be
reduced.
[0088] As described above and shown in FIG. 1, the continuous strip
of reinforcement material 19 may be payed out from a roll 20 and
adhered to the first asphalt coated sheet 18. Once adhered to the
first asphalt coated sheet 18, the reinforcement material 19
defines the reinforced nail zone 98.
[0089] As shown in FIG. 7, the laminated shingle 74 includes
reinforcement material 200, described in detail below. The
reinforcement material has a first broad face 200A engaging the
headlap portion and a second broad face 200B opposite the first
broad face. As described above, the reinforcement material 200 of
the nail zone 98 may be used as the bonding substrate area or
bonding surface for tab sealant 96 bonded to the underside of the
tabs of the overlay sheet of a laminated shingle 74 in an
overlapping course C of installed laminated shingles 74, as shown
in FIG. 7.
[0090] It is desired that the bonding substrate 98 and the tab
sealant 96 bond quickly and permanently with one another. Typical
film, such as the smooth PET film described above, typically more
quickly form a bond with the tab sealant 96 than a fabric formed
from similar material, but the film will not form mechanical bonds
necessary to achieve strong de-bonding loads at relatively low
temperatures, such as temperatures below about 40 degrees F. where
the viscoelasticity of the tab sealant 96 is degraded.
[0091] It has been found that improved bonding and improved low
temperature de-bonding loads can be achieved with modified
reinforcement material. FIGS. 8 through 12 illustrate various
embodiments of reinforcement material, such as the reinforcement
material 19, wherein the reinforcement material has been modified
to include outwardly extending attachment members. Referring to
FIG. 8, a second embodiment of the reinforcement material is shown
at 200. The reinforcement material 200 has yarns or fibers that
have been crimped, such as the yarn 218 shown in FIG. 12, and/or
texturized to provide an irregular shape and/or a modified surface
texture to the fibers in the reinforcement material 200. The fibers
may be crimped with a crimper, and/or texurized with roller having
a knurled surface. Alternatively, the fibers may be crimped and
texurized with other devices and methods, such as with high
pressure air jets, as disclosed in commonly assigned U.S. Pat. No.
4,058,968 to Benson, or a false twist texturizing process, with or
without air jets as disclosed in U.S. Pat. No. 4,559,772.
[0092] Reinforcement material 200 formed with fibers that have been
crimped as described above have an increased number of interstitial
voids between individual fibers. Reinforcement material 200 formed
with fibers that have been texturized as described above include
outwardly extending attachment members or individual fibers that
have broken ends 202 and/or loops of fiber 204 extending outward of
the plane defining the surface of the reinforcement material 200.
These broken ends 202 and loops of fiber 204 penetrate the tab
sealant 96 and provide additional surfaces for mechanically bonding
the reinforcement material 200 to the tab sealant 96 of an
overlapping roofing shingle when installed on a roof. The
reinforcement material 200 thereby creates a strong bond with the
tab sealant 96, the bond having strong de-bonding loads at low
temperatures.
[0093] Alternatively, individual yarns may be formed from
non-continuous fibers that are twisted together. The ends of the
non-continuous fibers extend outwardly of the outer surface of the
yarn and the reinforcement material 200, as shown at 202 in FIG. 8,
and also provide additional surfaces for mechanically bonding the
reinforcement material 200 to the tab sealant 96. These yarns may
be woven into the reinforcement material 19 in either or both of
the warp and the cross-machine directions. Non-woven webs may also
be formed with these fabrics.
[0094] Referring to FIG. 9, a third embodiment of the reinforcement
material is shown at 206. The reinforcement material 206 may be
substantially identical to the reinforcement material 19 and
includes hooks 208, such as the hooks in a hook and loop fastener
system. In the illustrated embodiment, the hooks are in the shape
of an inverted J. Alternatively, the hooks 208 may have any other
desired shape.
[0095] Referring to FIG. 10, a fourth embodiment of the
reinforcement material is shown at 210. The reinforcement material
210 may be substantially identical to the reinforcement material 19
and includes loops 212, such as the loops in a hook and loop
fastener system. Alternatively, the hooks 208 and/or the loops 210
may extend outwardly from a tape, such as the PET film described
above.
[0096] Referring to FIG. 11, a fifth embodiment of the
reinforcement material is shown at 214. As shown in FIG. 11,
individual yarns or fibers 216 may be inserted through the
reinforcement material 214 such that ends of the fibers 216 extend
outwardly of the outer surface of the reinforcement material 214.
The fibers 216 may then penetrate the surface of the tab sealant
96, thus providing additional surfaces for mechanically bonding the
reinforcement material 214 to the tab sealant 96. Additionally, the
fibers 216 may also penetrate the surface of the asphalt coating
17, thus ensuring encapsulation of the fibers 216. The fibers 216
may be inserted through the reinforcement material 214 by any
desired means, such as with a needle punch.
[0097] Alternatively, the reinforcement material 214 may be surface
treated or coated with the sealant, oil, or a low-melting
temperature wax that is compatible with asphalt. When the sealant,
oil, or a low-melting temperature wax contacts the tab sealant 96,
it will blend with the tab sealant 96 and lower the viscosity of
the tab sealant 96 where it contacts the reinforcement material
214, allowing the tab sealant 96 to wet faster.
[0098] As shown in FIG. 13, typical laminated roofing shingles 300
are stacked in a bundle 302. Only a pair of such shingles 300 are
illustrated in FIG. 13, with every other shingle 300 inverted and
turned 180 degrees. It will be understood, however, that the
shingles 300 may be stacked such that every other of such shingles
300 are either inverted or turned 180 degrees, or both. This
stacking method minimizes uneven build in the bundle 302 caused by
the difference in thickness between the area of the shingle 300
that includes the underlay sheet 306 and the area that does not
include the underlay sheet 306. A problem may occur, however, along
a central area 308 of the bundle 302 because central areas 310 of
the shingles 300 are double-layered, whereas the cutout portions
312 of the shingles 300 adjacent the central areas 310 are
single-layered. The difference in thickness causes a ridge or hump
314 along the central area 308 of the bundle 302 that becomes
progressively higher as the number of shingles 300 in the bundle
302 increases.
[0099] FIG. 14 is a schematic sectional view of a representative
pair of stacked shingles 74 manufactured according to the present
invention. As shown in FIG. 14, the laminated roofing shingles 74
are stacked such that every other of the shingles 74 is inverted
and turned 180 degrees relative to an adjacent one of the shingles
74 to define a bundle 220. It will be understood however, that the
shingles 74 may be stacked such that every other of such shingles
74 are either inverted or turned 180 degrees, or both. The bundle
220 includes a central area 222. In the illustrated embodiment, the
central area 222 includes the portion of the overlay sheet 68
having the reinforcement material 19 of each shingle 74, and
includes the portion of each laminated roofing shingle 74 wherein
the shingle 74 is double-layered. In contrast to the shingles 300
shown in FIG. 13, when the laminated shingles 74 of the invention
are stacked, the areas of the adjacent shingles 74 having no
granules, such as the areas covered by the reinforcement material
19, cooperate to advantageously reduce humping in the central area
222 of the bundle of stacked shingles 74.
[0100] Referring to FIG. 15, the reinforcement material 400 of the
laminated shingle 274 may be formed from materials having a
thickness which causes the second broad face 400B of the
reinforcement material 400 to extend outwardly of a broad face 274B
(upwardly facing face of the overlay sheet 68 when viewing FIG. 15)
of the laminated shingle 274. These materials may compress when the
laminated shingles 274 are stacked in a bundle, such as shown at
220 in FIG. 14. When the laminated shingles 274 are removed from a
bundle and installed on a roof, the compressed reinforcement
material 400 will expand or recover to substantially its original
thickness to better bond with the tab sealant 96 of a laminated
shingle 274 in an overlapping course of installed laminated
shingles 274. For example, the reinforcement material 400 may
recover to a thickness of within the range of from about 75 percent
to about 100 percent of its original thickness. Alternatively, the
reinforcement material 400 may recover to a thickness of within the
range of from about 50 percent to about 75 percent of its original
thickness.
[0101] The reinforcement material 400 may be formed from
compressible fabric, wherein the fabric caliper or thickness of the
yarns within the compressed reinforcement material 400 will
increase or expand to better bond with the tab sealant 96 of a
laminated shingle 274 in an overlapping course of installed
laminated shingles 274. Examples of suitable compressible materials
include foamed rubbers such as EPDM Styrene Butadiene Rubber (SBR)
foam, polyurethane, texturized fabrics.
[0102] Alternatively, the reinforcement materials 200, 206, 210,
and 214 discussed above and illustrated in FIGS. 8 through 11, in
which a portion or component of the reinforcement material, such as
the hooks 208 and the loops 212, extends outwardly of the of the
broad face 74B of the laminated shingle 74. When a plurality of the
laminated shingles 74 are stacked in a bundle, the portions, such
as the hooks 208 and the loops 212, will bend, fold, or flatten.
When the laminated shingles 74 are removed from the bundle 220 and
installed on a roof, the outwardly extending portions have a
property wherein they will recover and again extend outwardly of
the broad face 74B of the laminated shingle 74. Thus, as described
in detail above, the outwardly extending portions may penetrate the
tab sealant 96 and provide additional surfaces for mechanically
bonding the reinforcement material 200, 206, 210, and 214 to the
tab sealant 96 of an overlapping roofing shingle when installed on
a roof. The reinforcement material 200, 206, 210, and 214 thereby
creates a strong bond with the tab sealant 96, the bond having
strong de-bonding loads at low temperatures.
[0103] 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.
[0104] 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.
* * * * *